MEIL stated that the TBM would arrive at the project site in April, with tunneling expected to commence before the onset of the monsoon. The second TBM is scheduled to undergo its factory tests later in March, and both machines are expected to begin excavation work simultaneously by the time the monsoon arrives. The remaining two TBMs will follow, ensuring a phased approach to executing this critical infrastructure project. Once completed, the tunnels will consist of three lanes in each direction and will be constructed at a maximum depth of 23 metres below the surface.

These TBMs represent a significant advancement in tunneling technology, as each is equipped with a 13.2-metre diameter cutterhead—the largest ever deployed in Mumbai. This surpasses the 12.19-metre cutterhead used in the Mumbai Coastal Road Project’s TBM Mavala (DZ636), which successfully excavated twin tunnels between 2021 and 2023. The larger cutterheads will enhance the efficiency of excavation, helping the project meet its ambitious construction timeline while ensuring structural integrity.

The Thane-Borivali twin tunnel project is expected to be a game-changer for Mumbai’s infrastructure, as it will drastically cut travel time between the two areas. Currently, commuters using the Ghodbunder Road route often face severe congestion, with travel times extending up to an hour during peak hours. Once operational, the twin tunnels will reduce this travel time to less than 15 minutes, significantly easing traffic woes and enhancing connectivity between the eastern and western suburbs of Mumbai.

Given the complexities of tunneling beneath the ecologically sensitive Sanjay Gandhi National Park, the project is being executed with stringent environmental safeguards to minimize disruption. The adoption of single-shield hard-rock TBMs ensures precision excavation with minimal surface impact, making it a sustainable infrastructure solution for the city. As MEIL prepares to deploy the first TBM in April, this milestone marks a major step forward in the execution of one of Mumbai’s most ambitious infrastructure projects.