Bullet Train Update: NHSRCL begins casting of tunnel lining segments at Mahape, Maharashtra

The Bullet Train project marked significant progress as the casting of tunnel lining segments commenced at Mahape, Thane district, Maharashtra for the 16 km TBM portion of the 21 km underground/undersea tunnel. The facility, spanning 98,898 sqm, will produce over 76,000 segments for 7,441 rings, each ring will consist of nine curved segments and one key segment.

More Details:

The casting of tunnel lining segments begins at Mahape (Thane district, Maharashtra) by National High-Speed Rail Corporation Limited (NHSRCL) for the 16 km TBM portion of the underground/undersea tunnel for Bullet Train project in Maharashtra (Total length of the tunnel is 21 km). A specially designed facility spread across 98,898 sqm will cast more than 76,000 segments for 7,441 rings for the tunnel. Each ring comprises 9 curved segments and one key segment.

Work Under Progress:

  • A 21 km tunnel is under construction between the Bandra Kurla Complex and Shilphata for the Mumbai-Ahmedabad Bullet Train Project. Of the total length, 16 km will be excavated using three Tunnel Boring Machines (TBMs), while the remaining 5 km will be constructed using the New Austrian Tunnelling Method (NATM).
  • To construct the 16-km section with TBMs, 76,940 segments will be cast to form 7,441 rings. Special ring segments are being cast for the tunnel lining, each ring comprising nine curved segments and one key segment, with each segment being 2 mtr wide and 0.5 mtr thick.

  • High-strength M70 grade concrete is being used to ensure superior structural integrity and long-term durability. The casting and stacking yard, covering an area of 98,898 sqm (9.9 hectares) in Mahape, Thane district, Maharashtra, is currently being commissioned.
  • The yard will feature nine sets of moulds, each containing ten pieces. Four sets of these moulds are already being installed on-site.
  • The yard is equipped with various cranes, gantries, and machines to automate and mechanise the casting operations, ensuring high-quality assurance during the casting and stacking of the segments.
  • Additionally, the facility will include casting sheds, a stacking area, a batching plant, and a steam curing area.


This milestone not only signifies a crucial step forward in the Maharashtra Bullet Train project but also showcases India’s advancing capabilities in large-scale infrastructure development. The successful execution of this segment casting operation will pave the way for efficient and timely completion of the tunnel, ensuring a state-of-the-art transportation system for the region.

Source: NHSRCL – Press Release  | Images Credit: NHSRCL

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