How L&T set world record for Rishikesh-Karnaprayag Rail Link using tunnel boring machine

Larsen and Toubro (L&T) set a new world record in tunnel construction using a single-shield hard rock tunnel boring machine (TBM) on June 29 for the Rishikesh-Karnaprayag Rail Link project, PTI reported.

Speaking to PTI on July 1, SV Desai, the Whole Time Director, L&T Limited said that the company has “broken the world record by achieving a maximum progress of 790 metres in a month (31 days) using Single Scheid Hard Rock TBM named Shiv”.

A first in the world for efficient TBM use, says L&T

According to L&T officials, this was the first time in the world that a single-shield hard rock TBM was “used in such an efficient manner”, the report said.

“In the last leg of the boring work in the month of May-June for the longest rail tunnel of the country, the TBM, named Shiv, excavated 790 meters in 31 days and achieved a breakthrough,” Rakesh Arora, Project Director, added.

Giving details Arora added, “While the first TBM, named Shakti, completed 10.47 km of the upline tunnel on April 16, 2025, 12 days ahead of schedule, the second TBM, Shiv, finished 10.29 km of the downline Tunnel on June 29, 2025, a day ahead of schedule. On an average, we did over 400 metres of tunnelling per month by TBMs and over 70 metres by NATM.”

The Challenges

Also speaking to PTI, Suresh Kumar, Head, Hydel and Tunnels Business, recalled several difficulties during the work such as geological challenges (loose rock/ shear zones and high ingress of water) and adverse working conditions like high temperature and humidity in long tunnels.

“Besides geographical and logistical challenges, issues such as skilled staff and workmen mobilisation and retention, quarry approval and operations while managing other stakeholders such as customers, local people and local authorities were equally cumbersome,” Kumar added said.

Rishikesh-Karnaprayag Rail Link: Twin tunnels under construction

• This 13.09-km-long tunnel is the downline one, running parallel at a 25-metre distance from the first one, a 14.57 km long upline tunnel, which achieved breakthrough earlier on April 16, 2025.
• The twin tunnels between Devprayag and Janasu in the ambitious 125-km Rishikesh-Karnaprayag Broad Gauge Rail Link Project in Uttarakhand, make India's longest transportation tunnels.
• The 30 km long each tunnels are scheduled to be operationalised in December 2026. The project also includes the main tunnels, escape tunnels, cross-passages and niches, as per L&T officials. 
• 70 per cent work (21 km) was done through TBMs, and the remaining 30 percent (9 km) was completed using drill and blast (also known as New Australian Tunnelling Method). 
• Senior officials from the construction sites narrated unprecedented logistics management in TBM transportation from port to project site, as well as assembling and shifting to launching position; segment and muck handling, and their transportation, besides multiple tunnel logistics along with several other activities.

(With inputs from PTI)