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The Thane-Borivali twin tunnel project has entered the execution phase with the launch of tunnel boring machine Nayak in Thane. The 11.84 km underground corridor, being developed by the Mumbai Metropolitan Region Development Authority, aims to cut travel time between the two locations to about 15 minutes. While tunnelling has started from the Thane end, work at the Borivali side is facing delays due to pending rehabilitation. The project involves complex construction beneath Sanjay Gandhi National Park and is targeted for completion by 2028.
The Thane Borivali twin tunnel project has moved into its main construction stage with the launch of the tunnel boring machine Nayak at the Thane site. The machine was flagged off by Maharashtra Chief Minister Devendra Fadnavis, marking the start of excavation work for the underground corridor. Advertisement
Installed at Tikuji-ni-Wadi in Manpada, Nayak is a large hard rock tunnel boring machine, over 13 metres in height, designed to cut through around 10 km of rock. Officials indicated that the machine is expected to progress at an average speed of nearly 10 metres per day. Based on the current schedule, it is likely to reach Borivali by 2028.
The 11.84 km project is being implemented by the Mumbai Metropolitan Region Development Authority (MMRDA) to improve east west connectivity in the Mumbai Metropolitan Region. At present, commuters travelling between Ghodbunder Road in Thane and Borivali take around 60 to 90 minutes depending on traffic. Once completed, the tunnel is expected to reduce this travel time to approximately 15 minutes.
The alignment passes beneath the Sanjay Gandhi National Park, making it a technically challenging project due to environmental sensitivity and geological conditions. The tunnel will consist of twin tubes, each planned to accommodate multiple lanes along with an emergency lane. Cross-passages will be built at regular intervals to ensure safety, along with systems for ventilation, fire safety and real-time monitoring.
Officials stated that a second tunnel boring machine, named Arjuna, is currently being assembled and will soon be deployed to construct the parallel tunnel. In total, four TBMs are planned for the project, two from each end, to speed up the excavation process. Tunnel lining work will be carried out simultaneously behind the machines to maintain structural strength and stability.
The project received approval in 2023, and groundwork, including preparatory and access-related activities, began last year. The launch of Nayak now marks the transition into full-scale tunnelling activity.
However, progress at the Borivali end remains slow. The site at Magathane is yet to be fully cleared due to incomplete rehabilitation. Out of 572 affected families, around 70 are still awaiting relocation, which has delayed the readiness of the launch shaft on that side. This has also postponed the deployment of TBMs from Borivali.
Once operational, the tunnel is expected to reduce congestion on key routes such as Ghodbunder Road and improve connectivity between Thane and the western suburbs. It is also expected to support smoother traffic movement across the region by offering a direct underground link.
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