The crucial final hurdle for Mumbai’s ambitious Thane-Borivali twin tunnel project has been cleared with the impending eviction of 33 remaining residents from Magathane. This development is set to unlock the Borivali entry point, allowing for the full deployment of Tunnel Boring Machines (TBMs) and significantly accelerating the construction timeline for the vital infrastructure link.
Progress and Timeline
The Thane-Borivali Twin Tunnel project, a significant undertaking by the Mumbai Metropolitan Region Development Authority (MMRDA), aims to drastically reduce travel time between Thane and Borivali from the current 60-90 minutes to approximately 15 minutes. This 11.84-kilometre road link will pass beneath the ecologically sensitive Sanjay Gandhi National Park, eliminating the need for the current lengthy detour.
Physical progress on the project stood at 8.19% as of August 31, 2025, with financial progress at 7.89%. The project, which commenced with the laying of the foundation stone in January 2024, is now firmly in its construction phase. Tunnel Boring Machine (TBM) ‘Nayak’, a colossal machine standing over 13 metres tall, is poised to begin its excavation from the Thane site, with expectations to reach Borivali by 2028. A second machine, ‘Arjuna’, is also being prepared to dig a parallel tunnel.
The overall project, estimated to cost around ₹20,000 crore, is part of India’s largest mobility investments. The main tunnelling phase is anticipated between 2025 and 2027, with an expected completion date around 2028. While minor delays are possible in such large-scale infrastructure projects, the current pace of work suggests the 2028 target remains achievable.
Technical and Logistical Aspects
The project involves the construction of twin tunnels, each with three lanes, to facilitate two-way traffic. The total length of the tunnel is approximately 11 to 12 kilometres. Advanced Tunnel Boring Machines (TBMs) are being employed to minimize environmental impact during the excavation beneath the national park. India’s largest Single Shield TBM, with a diameter of 13.34 metres, has been lowered at the Thane portal, marking a significant milestone.
The construction is being carried out from both the Thane and Borivali sides, with approximately 5.75 km of excavation planned from the Borivali side and 6.09 km from the Thane side. The TBMs are expected to advance at an average speed of 11 metres per day, boring through the rock at depths of around 60 metres. The complex engineering challenges include navigating hard rock, uneven strata, and ensuring vibration control.
Addressing Challenges and Future Impact
One of the primary challenges has been the relocation of residents affected by the project. Out of 572 affected residents, approximately 70 were still awaiting relocation on the Borivali side, causing a delay in the full deployment of TBMs. The recent clearance of the last hurdle with the eviction of 33 residents in Magathane is expected to resolve this issue, allowing for seamless operations.
Upon completion, the Thane-Borivali Twin Tunnel is expected to transform commuting in the Mumbai Metropolitan Region. It will not only save commuters significant time but also reduce traffic congestion on the Ghodbunder Road, leading to more predictable travel times, reduced fuel consumption, and lower pollution levels. The project is anticipated to foster economic growth and improve regional connectivity, supporting Mumbai’s continued expansion and development.
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The Chenab Times News Desk
