Maharashtra CM Devendra Fadnavis launched TBM ‘Nayak’, India’s largest hard rock tunnel boring machine, for the MMRDA’s Thane-Borivali twin tunnel project. The 11.84-km corridor will cut travel time between Thane and Borivali from 60-90 minutes to just 15 minutes
‘Nayak’ is one of India’s largest single-shield hard rock TBMs with a 13.34-metre cutterhead diameter. Pic/MMRDA
In a major infrastructure push, the Maharashtra government launched the tunnel boring machine (TBM) ‘Nayak’ for the Mumbai Metropolitan Region Development Authority’s (MMRDA) flagship Thane–Borivali Twin Tunnel Project. The ceremony was attended by Maharashtra Chief Minister (CM) Devendra Fadnavis, Deputy CMs Eknath Shinde and Sunetra Pawar, along with senior government and Mumbai Metropolitan Region Development Authority (MMRDA) officials.
MEIL Managing Director Krishna Reddy, Director Subbaiah, and MMRDA Commissioner Sanjay Mukherjee were also present during the commissioning of ‘Nayak for the commencement of large-scale tunnelling of the transformative infrastructure project.
The Thane–Borivali Twin Tunnel is a strategic initiative aimed at improving east–west connectivity across MMR. Stretching 11.84 km, the project includes 10.25 km of twin tunnels and 1.59 km of approach roads, linking Ghodbunder Road in Thane with the Western Express Highway in Borivali. Once operational, the travel time on this corridor is expected to drop from the current 60–90 minutes to around 15 minutes, providing a faster and more efficient commute for thousands of daily travellers.
Advanced technology and safety
The project features four state-of-the-art TBMs, including one of India’s largest single-shield hard rock machines, with a 13.34-metre cutter head diameter, 86 metres in length, and weighing approximately 2,500 tonnes. The TBMs will excavate tunnels at depths of up to 23 metres, including sections beneath the Sanjay Gandhi National Park, ensuring minimal surface disruption and environmental impact.
Each tunnel will have two traffic lanes and one emergency lane, with cross-passages every 300 metres for safety. The project incorporates advanced safety systems, including mechanical ventilation, firefighting infrastructure, smoke detection, and retro-reflective LED signage, aligned with international NFPA 502 standards.
The Thane–Borivali Twin Tunnel is divided into two civil packages: the Borivali section covers 5.75 km of tunnelling and underpasses, while the Thane section spans 6.09 km, including tunnels, a viaduct, and a toll plaza. The Hill–TCE Joint Venture is responsible for project design and consultancy. As of 31 August 2025, the project has achieved over 8 per cent physical progress, with further acceleration expected following the TBM launch.
Impact on Mumbai commuters and environment
The corridor is expected to ease congestion on Ghodbunder Road, which currently handles 1–1.2 lakh passenger car units daily, while reducing vehicular emissions and noise pollution. By 2029, the tunnel is projected to serve around 80,000 vehicles daily, shortening travel distance by 11–15 km, and supporting sustainable urban development.
With TBM ‘Nayak’ now ready to begin excavation, MEIL has reaffirmed its commitment to delivering world-class infrastructure through innovation, sustainability, and engineering excellence, continuing its role in shaping the future of urban mobility in India.
Thane–Borivali Twin Tunnel – Key project features
Total project length: 11.84 km
Twin tunnel length: 10.25 km
Approach roads: 1.59 km
Tunnel configuration: 2 traffic lanes + 1 emergency lane per tunnel
Cross-passages: Every 300 metres
TBM specifications: 13.34 m diameter, ~2,500 tonnes
Maximum tunnelling depth: ~23 metres
Environmentally sensitive sections: Beneath Sanjay Gandhi National Park
Safety systems: Mechanical ventilation, firefighting, smoke detection
Signage: LED and retro-reflective, compliant with international standards
Travel time reduction: 60–90 minutes to ~15 minutes
Traffic decongestion: Ghodbunder Road, reduced emissions
Projected traffic by 2029: ~80,000 vehicles per day
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