Assembly Begins For 'Nayak', First Of Four Giant TBMs For Thane-Borivali Twin Tunnel Project

Mumbai: The assembly of the first (TBM), named ‘Nayak’, has commenced at the Thane site, marking a major milestone in the upcoming Thane-Borivali Twin Tube Tunnel Project. The machine, delivered by German tunneling equipment giant Herrenknecht AG. 

Megha Engineering & Infrastructure Ltd (MEIL), the Hyderabad-based firm, is the contractor for this twin tube tunnel project. The TBM assembly process is expected to be completed within the next two months, according to a source.

About 'Nayak'

'Nayak' is the first of four TBMs that will be progressively deployed to construct this crucial underground road corridor connecting Thane and Borivali beneath the Sanjay Gandhi National Park. 

Details

1. 2 +2 lane tunnel and one emergency lane on each side 

2. Total length - 11.80 km. (Tunnel: - 10.25 km, junction: - 1.55 km)

3. At every 300m, there will be a cross connection lane.

4. The projected volume of traffic in this proposed new connectivity has been estimated to be around 50,000 PCU.

Once operational, the twin tunnels are expected to significantly reduce travel time and decongest surface traffic in the Mumbai Metropolitan Region.

The TBM ‘Nayak’ is approximately 13.2 meters in diameter, making it among the largest in use, capable of boring an expansive tunnel suitable for a major road. Engineered specifically for Mumbai’s complex and diverse geological profile, it is designed to handle a mix of hard rock, soft soil, and mixed ground conditions, a significant challenge in urban tunneling.

The cutting head of the TBM has been customized with high durability, ensuring minimal wear even when tunneling through varied materials and weathered soil. These segments are built for resilience and optimized performance, even in highly abrasive and unpredictable conditions.

The machine is outfitted with state-of-the-art navigation and real-time monitoring systems, ensuring high precision during excavation. These systems are critical in densely populated urban areas like Mumbai, where even minor deviations can pose serious risks.

To ensure minimal environmental disruption, 'Nayak' features dust suppression mechanisms and noise reduction technologies, aligning with stringent environmental norms for tunneling under sensitive zones like the Sanjay Gandhi National Park.

In addition, the TBM includes automated debris removal systems, emergency response modules, and advanced worker safety features that reduce manual intervention and enhance automation.

About Herrenknecht AG

Herrenknecht AG is a leading manufacturer of Tunnel Boring Machines (TBMs) and has a significant presence in India. Their manufacturing facility is located in Chennai, where they produce TBMs using core components sourced from their main production site in Schwanau, Germany. It has a long-standing presence in India and has been involved in major infrastructure projects such as the upcoming Versova-Dahisar Link Road, Metro rail corridors, and now the Thane-Borivali Twin Tunnel Project, which is set to be one of the most challenging and impactful.

With the TBM 'Nayak' now taking shape, the groundwork is being laid for the upcoming Thane Borivali Twin Tunnel Project. 

Presently, there is no direct connection between Thane and Borivali. The Thane Ghodbunder Road (SH-42) is a major link road connecting East West link and carries heavy commercial traffic between NH-3 and NH-8.

The distance from Thane to Borivali via Ghodbunder is 23 km. It takes about 1 to 1.5 hours to cover the distance from Thane to Borivali in the morning and evening during peak hours and at least 1 hour at other times.
The construction of a twin tube tunnel is proposed between Thane and Borivali under Sanjay Gandhi National Park, so that the journey from Thane and Borivali will be reduced by 12 Km.