Advancing Tunneling

in India
Challenges, priorities and
potential solutions
September 2024
FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 2
Contents
Foreword from FICCI ................................................................................................................................................5
Foreword from CRISIL ..............................................................................................................................................6
Introduction ...............................................................................................................................................................7
Enabling growth, bolstering defence capability and enabling energy security ........................................................8
Tunnel infrastructure in India ................................................................................................................................ 10
Major tunnels in India ............................................................................................................................................. 11
Challenges in tunnelling ....................................................................................................................................... 12
Risk allocation in contracts ................................................................................................................................... 14
Workers’ safety ..................................................................................................................................................... 14
Geological uncertainties ........................................................................................................................................ 15
Tunneling in urban areas ...................................................................................................................................... 16
Construction resources ......................................................................................................................................... 16
Priorities for advancing tunneling in India .......................................................................................................... 18
Effective contract design and administration ........................................................................................................ 18
Safeguarding health and safety ............................................................................................................................ 19
Precise technical appraisals ................................................................................................................................. 20
Encouraging skill enhancement ............................................................................................................................ 20
Emerging trends .................................................................................................................................................... 22
Green tunneling .................................................................................................................................................... 22
Sustainable materials and methods ...................................................................................................................... 23
Leveraging IT in operations and maintenance ...................................................................................................... 24
Advancements in tunneling equipment ................................................................................................................. 25
Case study .............................................................................................................................................................. 27
Mumbai Coastal Road Project – India’s first undersea tunnel .............................................................................. 27
Fehmarn Belt fixed link – Europe’s immersed tunnel ........................................................................................... 29
Suggestions/way forward ..................................................................................................................................... 31
Harmonising DPR contracts and construction contracts ...................................................................................... 31
Embedding safety during bidding ......................................................................................................................... 31
Creating a GIS-based National Digital Geotech Library ....................................................................................... 32
Considering Production Linked Incentive (PLI) scheme for imported items ......................................................... 32
Opting for AI-enabled camera-based tunnel face mapping .................................................................................. 33

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 3

Acronyms and abbreviations
AACM Alkali-Activated Cementitious Material KRC Konkan Rail Corporation

AEM Airborne Electromagnetic MCGM Municipal Corporation of Greater Mumbai

AI Artificial Intelligence MoRT&H Ministry of Road Transport and Highways

BMC Brihanmumbai Municipal Corporation MoSPI Ministry of Statistics and Program Implementation

BRO Border Roads Organization MoU Memorandum of Understanding

Centre of Excellence for Tunneling and

CETUSE NATM New Austrian Tunneling Method
Underground Space Engineering

CSMT Chhatrapati Shivaji Maharaj Terminus NGI Norwegian Geotechnical Institute

DBM Drill-and-Blast Method NHAI National Highways Authority of India

Dedicated Freight Corridor Corporation of National Highways and Infrastructure Development

DFCCIL NHIDCL
India Limited Corporation Limited

DMRC Delhi Metro Rail Corporation NHSRCL National High Speed Rail Corporation Limited

DPR Detailed project Report NTPC National Thermal Power Corporation

EPB Earth pressure balance SCMs Supplementary cementitious materials

Fédération Internationale des Ingénieurs-

FIDIC SDGs Sustainable Development Goals
Conseils

GBR Geotechnical Baseline Report SFRC Steel fiber-reinforced concrete

GGBS Ground-granulated blast furnace slag SRCC Sahar Road Crossover Cavern

GSI Geological Survey of India TBM Tunnel boring machines

HRT Head Race Tunnel TEA Tunneling Excellence Academy

Indian Institute of Technology (BHU),

IIT BHU TEM Tunnel excavation material
Varanasi
Indian Strategic Petroleum Reserves
ISPRL TRT Tail race tunnel
Limited
International Workshop on Renewable
IWRED USBRL Udhampur-Srinagar-Baramulla Rail Link
Energy and Development

KMRC Kolkata Metro Rail Corporation

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 4

Foreword from FICCI
I am pleased to present the FICCI-CRISIL Knowledge Report on ‘Advancing
Tunneling in India: Priorities and Potential Solutions’, unveiled at the 2nd
edition of TUNNELING INDIA 2024, organized by the Federation of Indian
Chambers of Commerce and Industry (FICCI).

In recent years, tunnels construction in India has seen remarkable growth, driven
by developments across key infrastructure segments, such as metros, railways,
roads, hydropower, and water supply. Advancements in tunneling techniques
Mr. S Paramasivan and underground-space engineering are improving the speed and efficiency of
tunnels construction. However, there remains substantial room for further
Co-Chairman, FICCI Committee progress. Significant engineering challenges, particularly in regions, such as
on Transport Infrastructure and Himalayas, must be addressed to ensure safety, financial viability, and
Managing Director, sustainability of tunneling projects. This underscores the need for continued
Afcons Infrastructure innovation in tunnel construction in India.

The outlook for India’s tunneling industry is promising. A robust pipeline of new
and ongoing projects, developing extensive connectivity infrastructure, presents
significant business and employment opportunities for industry partners across
the tunneling value chain, including construction, consulting, technology, and
equipment and material supply. Conducive policies and programs by the
Government of India, along with the enhanced focus on the PM Gati Shakti
National Master Plan, are bolstering our infrastructure development capabilities
and providing a fillip to the tunneling sector as well.

Advancements in tunneling technology and construction methods can enhance

the efficiency of government investments. Innovations like green tunneling and
IT-driven operation and maintenance are currently leading the way, reflecting
India’s commitment to sustainable practices and advanced technologies in
infrastructure.

The FICCI-CRISIL Knowledge Report delves into India’s tunneling landscape,

offering a comprehensive analysis of emerging trends, key opportunities,
challenges, technological innovations, sustainability considerations, and a
roadmap for future progress. The report also features case studies on successful
tunneling projects, providing valuable insights into effective project management
practices.

We hope you find this report informative and valuable. Your feedback and
suggestions are highly welcomed.

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India ” 5

Foreword from CRISIL
India has mounted a raft of initiatives to bridge its infrastructure gap and lift
growth to the next level. Tunnels, which play a pivotal role in connecting remote
areas, driving economic growth and facilitating strategic border development,
are one such initiative. The challenges and increased costs associated with land
acquisition, particularly since the amendments to the Land Acquisition Act, 2013,
came into effect, are increasingly rendering sub-surface construction attractive
to avoid the hassles related to Right of Way (RoW) acquisition. Land acquisition
costs have skyrocketed in last few years, with the NHAI reportedly spending a
Mr. Jagannarayan Padmanabhan substantial INR 1.6 lakh crore between fiscals 2019 and 2024, compared with
Senior Director and Global Head - INR 81,000 crore from fiscals 2015 to 2018.
Transport, Logistics & Mobility,
CRISIL Limited On the eve of FICCI’s 2nd edition of TUNNELING INDIA, our report ‘Advancing
Tunneling in India: Priorities and Potential Solutions’ highlights the
importance of tunneling within India's infrastructure strategy and examines the
project challenges faced in this domain – mainly the crippling time and cost
overruns because of geotechnical uncertainties; delays and litigations due to
inefficient risk-sharing in contracts; import dependencies for specialised
equipment; shortage of skilled labour; and environmental and social concerns.
As recent incidents, such as the Silkyara tunnel collapse in November last year,
have highlighted, a drive towards improved health and safety standards for
workers is also a conscious need at par with other success factors.

This report provides certain recommendations to address these challenges for

enabling timely completion within set budgets, while reducing the avenues for
friction among project stakeholders. Aligning Indian contracts with FIDIC’s
Mr. Phani Prasad Mandalaparthy
Conditions of Contract for Underground Works, 2019, utilizing advanced
Associate Director - geotechnical investigation techniques and ensuring a comprehensive review
Transport, Logistics & Mobility, and vetting of reports by expert authorities. It also emphasizes the need for
CRISIL Limited enhanced skills through specialized academies and knowledge-sharing
platforms and a renewed focus on worker health and safety through stringent
regulations and digital technology integration. The report further explores
emerging trends, such as green tunneling practices that prioritise sustainability
using sustainable materials, such as low-carbon concrete, and practices
including muck (excavation waste) reuse, integration of advanced technologies,
such as digital twins, remote-monitoring systems, and AI-enabled computer
vision-based equipment for classification of excavated rock by face mapping.

Finally, it presents a way forward for advancing tunneling practices in India,

aiming to overcome the current constraints while embracing innovative
solutions.

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India

” 6
Introduction
The efforts have been directed towards projects
India is targeting to surpass Germany and Japan to
outlined in the National Infrastructure Pipeline (NIP),
become the world’s third-largest economy by fiscal
2027. Furthermore, with a vision to work towards Viksit which envisages an investment of INR 111 lakh crore
Bharat, or developed India, by 2047, the country aims over fiscals 2020 to 2025 across infrastructure
sectors2. As a part of this ambitious plan, the
to take its economy beyond USD 30 trillion on its
government is focusing on modernising transportation
centenary year of independence. To achieve this
networks, upgrading urban amenities and expanding
ambitious goal, the government has embarked on a
groundbreaking initiative to revamp the country’s digital infrastructure. The capital expenditure in the
infrastructure sector is expected to be INR 33-35 lakh
public goods and fill the infrastructure gap, with the
crore cumulatively in fiscals 2025 and 2026, driven by
goal of boosting economic growth, improving
power, road, and railways.3
connectivity, and enhancing the quality of life. Global
cases show that each rupee spent on infrastructure
boosts GDP by 2.5-3.5 times1.

1
RBI and National Institute of Public Finance and Policy, 2023 Image Source- Microsoft Library
2
https://www.investindia.gov.in/team-india-blogs/indias-push 3
CRISIL Yearbook
infrastructuredevelopment#:~:text=India's%20journey%20towards%20beco
ming%20a,cities%20that%20drive%20economic%20growth.

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 7

Figure 1: Capex incurred over FY23 to FY24 and projected capex during FY25- FY264

Source: CRISIL Yearbook

Railways, Regional Rapid Transit System around NCR

Enabling growth, bolstering and greenfield airports, such as the second airports for
Delhi and Mumbai (Jewar and the Navi Mumbai
defence capability and enabling
International Airport) indicate the thrust on
energy security infrastructure development in modern India. While
The emergence of engineering mega projects across these projects like others form the bulk of all capital
the country – such as the Atal Setu in Mumbai, works and represent the visible infra, a relatively
Chenab Bridge in J&K, Dhola Sadiya Bridge in Assam, small but crucial element of the sub-surface or
Eastern and Western Dedicated Freight Corridors for invisible infra is addressed through tunnels.

Hydro power Metro railway

Tunnels play a crucial role in providing essential links in all classes of surface-transport projects and are strategically
very important. These tunnels facilitate swift and unhindered military deployment, crucial for national defence.
Considering the significant importance of national defence, enhancing infrastructure in remote and high-altitude
regions has become critical to ensure that Indian military can be deployed promptly to threats and strengthen the
country’s overall defence capability by leveraging all-weather connectivity.

4
CRISIL Yearbook

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 8

 Railways Roads and highways

infrastructure development across these sub-sectors.

In addition to serving the economic and military
Instances of notable tunnel projects commissioned
purposes, the country’s energy security needs also
involve the construction of underground caverns in the past few years are:
connected through tunnels to create emergency • Sela Tunnel in Arunachal Pradesh, by NHIDCL
stockpiles for crude oil. This is being developed in (2024) – A strategically important tunnel providing
various parts of the country to safeguard against the all-weather connectivity to Tawang. It is the world's
global oil-and-gas supply chain disruption5. Such longest bi-lane tunnel at over 13,000 feet.7
strategic crude oil storage sites are located
• East-West Metro Tunnel, Kolkata, by KMRC
underground in Mangalore, Visakhapatnam and Padur
(2024) – India’s first underwater tunnel spanning a
(Udupi, Karnataka)6.
520 m stretch beneath the River Hooghly.
Given these priorities, over the past couple of
decades, India has achieved notable milestones in

Figure 2: Sela Tunnel, Arunachal Pradesh Figure 3: East-West Line Metro Tunnel, Kolkata

Source: Wikimedia Commons Source: Wikimedia Commons

• Sohna Rail Tunnel in Haryana by DFCCIL (2023)

• Coastal Road Tunnel in Mumbai by MCGM (2024)
– India’s first undersea (Arabian Sea) tunnel. The – The 1 km rail tunnel is part of the Western
twin tunnel 3.93 km long is equipped with
advanced LED technology and intelligent control
systems.8

5
https://indianexpress.com/article/india/india-others/stocking-up- 7
https://www.ndtv.com/india-news/5-facts-about-the-worlds-longest-bi-lane-
underground/ sela-tunnel-set-to-be-inaugurated-by-pm-modi-5204917
6
https://en.wikipedia.org/wiki/Strategic_Petroleum_Reserve_(India)#:~:text= 8
https://www.financialexpress.com/business/roadways-mumbais-longest-
Strategic%20crude%20oil%20storages%20are,Padur%20(Udupi%2C%20K intra-city-underground-road-opens-a-ride-through-coastal-roads-
arnataka). underground-tunnel3424501

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 9

 Dedicated Freight Corridor project. It is the world's connectivity between Srinagar and Kargil and
first electrified double-stack container tunnel.9 boost tourism in Sonamarg.

• Atal Tunnel in Himachal Pradesh, by BRO (2020) • Shinku La Tunnel in Himachal Pradesh by BRO
– The world's longest single-tube road tunnel (2025) – This 4.1 km road tunnel will be the world's
above 10,000 feet. highest tunnel, located at an altitude of 15,800
feet.10
• Dr Syama Prasad Mookerjee Tunnel in J&K by the
NHAI (2017) – The 9.28 km tunnel was Asia’s • Zoji-la Tunnel in Ladakh by NHIDCL (2026) – This
longest road tunnel at the time it was built. It is the 14.2 km, horseshoe-shaped single-tube, double-
country's first tunnel with a fully integrated tunnel lane tunnel is at 11,575 feet above the sea level
control system. and will enable uninterrupted movement from
Srinagar to Leh.
The country has also embarked on transformative
tunnel projects; some of them are presently in the • HSR Thane Creek Tunnel by NHSRCL (2028) –
construction phase - such as: The nearly 7 km undersea tunnel below the Thane
Creek (intertidal zone) will be India’s first undersea
• Z-Morh Tunnel in J&K by NHIDCL (2024) – A 6.5 rail tunnel.11
km long tunnel which will ensure all-weather

Figure 4: Z-Morh Tunnel, J&K Figure 5: Zoji-la Tunnel, Ladakh

Source: Wikimedia Commons Source: Megha Engineering & Infrastructures Ltd.

pollution, and advanced tunneling methods and

Tunnel infrastructure in India technology are being used to address key challenges.
Overall, the infrastructure sector has witnessed an
The demand for construction of tunnels has been
increase in tunneling, with significant opportunity for
rising across infrastructure sub-sectors, with reports
further growth.
indicating that hydro power, railways, roads and
highways, water supply and metro (in that order) Various methods are used for tunnel construction,
having a substantial number of new tunnels in the including conventional techniques such as drill-and-
upcoming projects. As urban agglomerations grow blast method (DBM), new Austrian tunneling method
and land availability becomes scarce, tunnel (NATM), tunnel boring machines (TBMs) and micro-
construction is becoming a necessary solution. The tunneling. Modern techniques such as sequential
trend is expected to continue, and a significant surge excavation and ground freezing are also being
in tunneling is likely in the coming years. Construction explored. Conventionally, DBM has been the preferred
of tunnels is crucial to overcome urban congestion and technique for tunneling, especially in the Himalayan

9
https://economictimes.indiatimes.com/industry/transportation/railways/world https://nhsrcl.in/en/media/press-release/nhsrcl-signs-contract-construction-
11

s-1st-electrified-double-stack-container-tunnel-near-haryana-may-be- 21-km-long-tunnel-including-indias-first-
operational-in-a-year-official/articleshow/77152789.cms?from=mdr 7#:~:text=The%2021%20km%20long%20tunnel,come%20up%20in%20the
10
https://www.hindustantimes.com/india-news/shinku-la-tunnel-work-to- %20country.
begin-by-midseptember-101715885151627.html

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 10

region, owing to its flexibility and ability to handle used for pipeline installation. In our view, tunnel
challenging geological conditions. However, it poses a development in India has a promising outlook, with a
greater risk to construction workers and requires strong pipeline of tunnel projects across various
advanced technologies to improve its effectiveness. sectors. DBM is expected to remain the dominant
TBMs, on the other hand, are suitable for congested technique for tunneling in highly variable (Himalayas)
urban areas and reduces lining costs. NATM (works strata owing to its flexibility and ability to withstand
on a design-as-you-go philosophy) is a cost-effective challenges, while TBMs are likely to remain the
method suitable for uncertain geological conditions. preferred mode for hard rocks or geological conditions
Micro-tunneling is a trenchless construction technique with lower variability.

Major tunnels in India

Note: The year mentioned is the year of completion or the expected year of completion

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 11

Challenges in tunnelling
months on average, beyond their original completion
Tunnel construction projects continue to face
significant challenges, leading to cost and time dates12. The COR and TOR situation is particularly
acute for projects involving tunnels as a key
overruns because of various difficult situations arising
component. CRISIL’s analysis of the data from the
during tunneling, particularly in the construction
MoSPI report identified 64 such projects across roads,
phase. This chapter delves into those primary
challenges and provides a deeper look into how they railways, urban development and power sectors. The
analysis revealed that these projects are experiencing
impact tunneling.
higher CORs averaging 25%, compared with 20% for
Brief on cost and time overruns other projects. Such projects are also facing severe
TOR, with an average delay of 26 months compared
It is widely acknowledged that cost and time overruns with 14 months for other projects. In addition to the
have been a persistent concern in infrastructure above COR and TOR concerns, there is also a risk of
development in India. As per Flash Report on Central environmental degradation, particularly in hilly areas
Sector Infrastructure Projects published by the where seismic activities can increase the risk of
Ministry of Statistics and Programme Implementation landslides and gradual settling or sudden sinking of
(MoSPI), as of May 2024, out of 1,817 ongoing the earth's surface. The quantification of adverse
projects spanning 21 sectors, 458 are grappling with environmental impacts over a tunnel’s lifecycle would
cost overrun (COR^) of approximately 21% above their also need to be considered when project appraisals
original estimates. Additionally, 554 projects are and project viability are worked out.
experiencing time overruns (TOR) of approximately 35

^
Cost Overrun (COR) = (Total Anticipated Cost – Total Original Cost) *100/ 12
http://www.cspm.gov.in/english/fr_part/2024-25/May/Part-1.pdf
(Total Original Cost)

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 12

Figure 6 Cost and Time Overrun Comparison
Cost overrun (%) Time overrun (months)
109%
60
91% 56

26

25% 14
20%
24
19
15 16
12 14
10% 8% 11%13%
5% 3%

Roads Railways Urban Power Roads Railways Urban Power

Development Development
Projects with Tunnels Other Projects Projects with Tunnels Other Projects

Dashed lines indicate average overrun across sectors.

Source: CRISIL Research

Grouping of tunneling challenges

Ambiguity in contracting practices, lack of skilled manpower, safety and risk issues, and geographical complexities
are some of the major hurdles that hinder the progress of tunnel construction in India. Inadequate investigations and
deficiencies in contract documents and contracting practices also lead to contractual delays and disputes. These
challenges highlight the need for more effective planning, investigation and execution strategies to ensure successful
project outcomes.

Challenges in
tunneling

Mitigating
Risk allocation Geological Tunneling in Construction
Workers' safety environmental,
in contracts uncertainties urban areas resources
social impacts

Objective rock Differing rock Availability of

classifications strata skilled labour

Value Equipment
Weathering and
engineering import
fracture
initiatives dependencies

Approach for
unforseaable Rock stress
conditions

Water ingress

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 13

 risk profiles different from those initially agreed
Risk allocation in contracts upon. If the VE process is not carefully managed
and documented, there may be challenges in
One of the major challenges in tunnel
ensuring that all parties understand and comply
projects is the skew in contract terms and with the new approaches, leading to potential
practices towards the authorities, leading to disputes delays or disputes.
and delays. Tunnel contracts (under hybrid annuity,
3. Approach for unforeseeable conditions –
engineering, procurement and construction or item-
Tunnel projects are prone to encountering
rate models) often fail to clearly outline roles,
unforeseeable conditions, such as unexpected
responsibilities and risk allocation among parties
water inflows, gas pockets or unstable ground.
during the execution phase. In some instances, the
Allocating risks associated with these conditions is
contract documents do not clearly articulate how the
complex. Contracts typically include clauses for
contractor’s claims should be treated. Neither do they
unforeseeable conditions, but defining what is
elaborate the methodology for calculating rates for
“unforeseeable” can be contentious. Disputes
extra work or design changes. Whenever contract may arise over whether a condition could have
administration based on the existing one-sided been predicted or whether the risk should be
contract design deteriorates, dispute resolution shared. If the allocation of risk is not clear, it can
procedures are invoked. Contracts in India include lead to prolonged disputes or even litigation,
dispute resolution clauses, and the procedures and further delaying the project.
timelines are often prolonged for years. This, too, is a
major issue in tunnel projects, resulting in an Workers’ safety
immediate impact on the contractor’s cash flows and
ultimate effect on project timelines and budgets. A few Workers' safety poses significant
challenges associated with contracts in tunneling challenges in the infrastructure
projects are listed below: construction stage. More so in tunnel construction,
which faces multiple risks, including the possibility of
1. Objective rock classifications – A collapse or cave-in owing to unstable soil, water
comprehensive site investigation is vital for pressure, or seismic activity; fires or explosions from
understanding the sub-surface conditions and flammable gases, dust or explosives; flooding from
determining appropriate support systems. groundwater infiltration or heavy rainfall; and exposure
Misclassification of rock classes or to toxic substances such as chemicals. Inadequate
oversimplification of proposed support systems in ventilation can also lead to buildup of hazardous
the detailed project report (DPR) can lead to gases, dust and fumes, which also endangers
expensive geological variations (elaborated later
workers' health.
in this report) realized during excavation.
2. Value engineering initiatives – Value The recent collapse of the Silkyara Bend–Barkot
engineering (VE) aims to improve project value by tunnel brought to the fore the importance of workers’
optimising cost, while ensuring quality and safety. The incident, which trapped 41 construction
performance. VE changes may not be clearly workers, underscores the severity of the risks inherent
aligned with the original contract, causing in tunnel construction, particularly in geologically
disagreements on sharing the savings effected, complex locations such as the Himalayas.
especially if the proposed VE measures lead to

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 14

Figure 3 Rescue Operations post Silkyara Tunnel Collapse

Source: Wikimedia Commons

As per news articles on the post-evacuation i. Proper identification of the rock quality being
investigations, safety provisions, like escape shafts encountered and
that are desirable for tunnel construction over such ii. Timely implementation of effective rock
fault lines, were found to be missing. This emphasises support measures
the need for better safety guidelines and stringent
adherence13. The incident has highlighted the Accurate assessment, analysis and interpretation of
importance of comprehensive safety measures that the quality of the rock mass is crucial to overcoming
must be implemented and enforced from the planning geological uncertainties, as oversight can lead to cost
stage to construction and beyond. overruns and safety risks. This is also crucial for
completing tunneling projects efficiently and safely 14.
The Silkyara tunnel incident on November 12, 2023,
Geological uncertainties
was an example for rock mass quality uncertainty, the
Geological uncertainties remain one of tunnel’s alignment along shear zones; these are zones
the most formidable challenges in formed by highly deformed and poor quality rock
tunneling, often presenting unforeseen incidences, masses that may collapse if not secured well during
leading to overruns and safety hazards. Geological construction15. In the case of the Silkyara tunnel
conditions beneath the surface can be highly variable incident, owing to insufficient preparation, the tunnel
and unpredictable. Major geological issues that arise collapsed, and a large volume of sediment and
during tunnel construction are: boulders blocked the tunnel entrance, trapping 41
workers.
1. Rock Classifications: All case studies with
regard to tunnel projects undertaken over the 2. Weathering and fracturing: In tunnel
decades in India conclude that the success or construction, weathering (fragmentation of rocks)
failure of a tunneling project hinges on two critical because of exposure to water, temperature,
factors: humidity or other environmental factors can
weaken the rock mass, making its more
susceptible to instability and failure. Fracturing

13
https://economictimes.indiatimes.com/news/india/uttarakhand-tunnel- 14
https://constructiontimes.co.in/underground-space-tunnelling-challenges-
collapse-escape-passage-mentioned-in-tunnel-plan-but-panel-finds-it-is-not- technology#:~:text=The%20complexity%20is%20represented%20mainly,an
there/articleshow/1s05482722.cms?from=mdr d%20(d)%20groundwater%20effect.
15
https://scroll.in/article/1063331/uttarakhand-more-tunnelling-disasters-in-
store-as-norms-are-disregarded-amid-infrastructure-push

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 15

 refers to the formation of cracks in rocks on settlement and vibrations, putting nearby structures at
account of tectonic forces, concentration of stress risk. The presence of utilities such as water mains and
or other geological processes. Fractures can gas lines require careful navigation or relocation, while
provide pathways for water to flow, leading to limited space for construction staging and equipment
erosion, and can also reduce the strength and storage adds to the complexity. These factors
stability of the rock mass. During tunneling of the necessitate precise excavation techniques,
10.96-km-long Pir Panjal tunnel, which is part of continuous monitoring and innovative solutions to
the Udhampur-Srinagar-Baramulla Rail Link ensure the safety and success of a project. In
project, there was heavy seepage at the starting September 2019, two buildings collapsed, and several
end of the tunnel, leading to a face collapse and
others developed cracks because of tunneling work of
formation of a cavity16.
the East-West metro line project in Kolkata, thereby
3. Rock stress: It refers to natural or induced delaying the project. In May 2022, on account of a
stresses that exist within the rock mass similar issue, over 150 residents had to be moved out
surrounding a tunnel. These stresses can cause for safety reasons18.
deformation, cracking and failure of the rock,
which can lead to tunnel instability, collapse or During the construction of Mumbai Metro Line 3,
other safety issues. These stresses are generated specifically at the Hutatma Chowk Station on the
because of the excavation or construction UGC01 stretch between Cuffe Parade and CSMT
process, e.g., stress caused by the removal of stations, these challenges were acutely felt. The
rock material or the weight of the overlying rock. station was constructed beneath old and heritage
In 2015, a part of the NHAI’s under-construction buildings on narrow roads, which limited the use of
Deu-Khotinal tunnel along the Kiratpur-Manali traditional cut-and-cover methods. Instead, a
highway collapsed in Mandi district following the combination of cut-and-cover and a conventionally
formation of cracks on the surface of tunnel due to driven tunnel was employed. The hard basalt rock
stress. required blasting for excavation, raising concerns
4. Water ingress: Water ingress is a significant about vibration and its potential impact on the
challenge in tunneling, particularly when surrounding structures. Controlled blasting techniques
excavating below the water table or near water were implemented, with trial blasts and careful division
bodies. High water pressure can lead to flooding, of the tunnel face to limit the vibrations. This approach
creating hazardous working conditions and successfully minimised the risk to the buildings,
hampering construction progress. During the allowing the project to progress without compromising
construction of Mumbai Metro Line 3, high water on safety19.
pressure was unexpectedly encountered while
tunneling beneath Andheri-Kurla Road filling the Construction resources
tunnel with muck and severely affecting progress.
Notably, no similar issues were observed during Securing and managing construction
the downline tunneling17, highlighting the resources, including skilled labour and specialised
uncertainties in underground tunneling. equipment, is critical to the success of tunneling
projects. The availability, quality and cost of these
Tunneling in urban areas resources can significantly impact project timelines
and budgets.
Tunneling in urban areas presents
significant challenges due to the proximity 1. Availability of skilled labour: EPC players in
of buildings and the dense network of underground India report that the availability of skilled labour is
utilities. Excavation can cause ground movement, a challenge across the infrastructure sector.

16
https://www.cecr.in/underground-construction-1/conventional-tunnelling- bowbazar/1189845/#:~:text=In%20September%202019%2C%20two%20buil
challenges-in-the-himalayas-a-case-study dings,moved%20out%20for%20safety%20reasons.
17
https://www.ej-eng.org/index.php/ejeng/article/view/1634 19
https://www.taylorfrancis.com/chapters/oa-edit/10.1201/9781003348030-
18
https://theprint.in/india/governance/after-kolkata-metro-work-causes- 190/challenges-faced-conventional-tunneling-urban-environment-mumbai-
cracks-panel-wants-to-raze-45-british-era-homes-in- metro-line-3-singh-raju-gupta

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 16

 Recently, Larsen & Toubro (L&T) reported a deficit
2. Import dependency for specialised equipment:
of ~25,000 workers in engineering and
Advanced tunneling machinery and technology
construction roles20. As per a MoSPI report on
are critical for efficient and safe tunneling
central sector infrastructure projects, manpower
operations. India is one of the largest importers of
shortage was one of the major reasons for project
specialised tunneling machineries, including
time and cost overruns21. This issue is particularly
TBMs and trench cutters22. This reliance presents
pronounced in tunneling, where the need for
several challenges, including procurement delays
specialised skills is even more critical. Tunneling
due to lengthy procurement processes, customs
projects require expertise in handling
clearance, and logistical issues. Additionally,
sophisticated machinery. This shortage
dependence on international suppliers makes
complicates project execution and impacts overall
projects vulnerable to global supply chain
efficiency.
disruptions. Also, importing advanced tunneling
equipment incurs substantial costs, including
import duty, and shipping and handling fees.
These challenges can significantly affect project
schedules and budgets, underscoring the
importance of effective resource management in
tunneling projects.

20
https://www.moneycontrol.com/news/business/skilled-labour-shortage- 22
https://www.volza.com/p/hsn-code-84303120/import/
challenges-indias-infra-ambitions-12757413.html
21
http://www.cspm.gov.in/english/fr_part/2024-25/May/Part-1.pdf

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 17

Priorities for advancing tunneling in India
help the stakeholders train and transition into. An
As the tunneling sector in India grapples with a range
expert committee consisting of design experts,
of challenges, from geological uncertainties to labour
shortages and safety concerns, it is imperative to geologists and researchers can be formed to
ideate and devise a new system suitable to Indian
establish clear priorities to effectively address these
geology and which can overcome the deficiencies
issues.
of the traditional classification system.
Advancing tunneling practices require a focused
approach that not only mitigates existing challenges 3. Sharing a geotechnical baseline report
but also fosters innovation and sustainability in the A geotechnical baseline report (GBR) is a
sector. By prioritising effective contract management, document shared during the bidding stage, which
and employing rigorous health and safety protocols, outlines the expected geotechnical conditions for
precise technical appraisals and skill enhancement, a construction project. It provides a measurable
the industry can overcome its current limitations and description of the ground and groundwater
pave the way for more efficient and resilient tunneling conditions, including geotechnical properties,
projects. serving as a basis for contract tendering and
construction. The GBR defines risks to be
Indeed, these priorities directly respond to the
included in the contract price and allocates the risk
challenges identified, laying the foundation for a more
between the contractor and client, helping in
robust and capable tunneling infrastructure in India.
better risk allocation and reducing disputes; during
construction, it is used to evaluate compensation
Effective contract design and for unexpected conditions. The practice of sharing
administration a GBR is presently adopted in the NHAI and
NHIDCL concessions and contracts since late
Contract management in tunnel projects is critical,
2010s/early 2020s and this practice is
given the complex and high-risk nature of these
recommended to be adopted by the authorities in
projects. In India, specific priorities must be
other sectors as well.
considered to ensure successful project delivery while
effectively managing risks. 4. Align Indian contracts with FIDIC’s Emerald
Book
1. Balanced risk allocation
FIDIC’s Conditions of Contract for Underground
Indian contracts often have inadequate or skewed
Works (informally referred to as Emerald Book),
risk allocation. Risks like geological variations,
2019 together with its subsequent amendments is
geological surprises and design challenges are
specifically designed for tunneling and
not clearly allocated, leading to disputes and cost
underground works, offering a well-structured
overruns. Contracts should clearly define risk-
approach to manage inherent risks. Integrating it
sharing mechanisms. This includes using risk
into the Indian contracts may address many of the
matrices, contingency allowances and predefined
existing deficiencies.
procedures for unforeseen circumstances.
• The book emphasises a balanced risk-sharing
2. Adopting newer rock classification systems
approach, particularly for subsurface conditions. It
This would result in devising and adopting includes provisions for the use of a GBR and
modern, research-backed rock classification allows for remeasurement and reclassification
systems which go beyond the traditional RQD or based on actual conditions encountered.
RMR systems and occasional expert reviews to

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 18

• The book allows for flexibility in design and Recognising the importance of safety, the NHAI has
construction, with a focus on adapting to established a dedicated design division to review the
unforeseen conditions. This reduces the likelihood design and construction of tunnels and other
of disputes related to scope changes. specialised structures 24. Additionally, in September
2023, the NHAI signed a memorandum of
• Under a new sub-clause 1.16, the contractor is
required to maintain a contract risk register and understanding with the Delhi Metro Rail Corporation
prepare and maintain a contract risk management (DMRC) and another in November 2023 with the
plan. Konkan Railway Corporation (KRC) 25. These
agreements enable expert review of the planning,
• A technical consultant or subject matter expert design and construction phases, as well as conducting
shall be appointed by the employer or owner to
of safety audits and remedial suggestions.
discuss and foresee technical uncertainties evolve
during the execution. Also, following the Silkyara tunnel collapse, the NHAI
• A hybrid pricing mechanism, i.e. on a conducted safety audits of ongoing tunnel projects 26.
measurement basis as per actual work carried out However, the reactive approach might not be
for excavation and lining works, and lumpsum sufficient. Ensuring workers' safety in tunnel
amount for all other works; and a mechanism for construction requires a proactive stance, with
adjusting the Time for Completion depending on systematic risk assessment, stringent safety protocols
actual ground/physical conditions encountered 23 and continuous monitoring throughout the
construction process.
5. Standard operating procedure (SOP) for
geological variations and financial impacts: Beyond traditional safety measures, tunnel projects
For contracts where the approach to evaluating must be supplemented with advanced technologies to
and approving financial impacts, and pre- ensure a safe working environment. Digital solutions
determined cost matrices to adjust for differing and advanced instrumentation are pivotal in
rock classes are not available, an SOP is enhancing safety as these enable real-time monitoring
recommended on the lines of NHAI’s SOP issued and early detection of potential hazards. Internet of
in July 2024 to identify and streamline the financial things (IoT)-enabled sensors continuously track
impacts of variations in rock classes encountered. environmental conditions, such as gas levels,
Such SOPs if adopted across sectors can ensure temperature and structural integrity, within the tunnel.
timely provisional and final approvals, thereby These systems provide instant alerts if conditions
resulting in timely payments to the contractors and deviate from safe thresholds, allowing for immediate
ensuring adequate cash flow is maintained. intervention to prevent accidents. Advanced tools,
such as LiDAR surveys and seismic sensors, further
Safeguarding health and safety enhance safety by detecting anomalies in the tunnel
structure and surrounding geology. These tools can
Ensuring the health and safety of workers in tunneling identify issues such as ground movement or water
projects is critical due to the complex and hazardous ingress before these become critical, enabling timely
nature of underground construction. A comprehensive corrective action.
approach is necessary at all stages of the project, from
planning and design to construction and during
operation. This includes strict adherence to safety
protocols, regular training, use of protective equipment
and conducting frequent safety audits.

23
https://www.hfw.com/insights/fidic-emerald-book-first-impressions-july- https://pib.gov.in/PressReleaseIframePage.aspx?PRID=2004006#:~:text=
26

2019/ NHAI%20has%20conducted%20preliminary%20safety,Jammu%20and%20
24
Press ReleaseI:Press information Bureau (pib.gov.in) Kashmir%20and%20Delhi.
25
https://nhai.gov.in/nhai/sites/default/files/2023-11/Press_Release-
Tunnel_Audit.pdf

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 19

By integrating digital and advanced tools into tunneling intrusive methods such as horizontal directional
projects, the industry can shift from a reactive to a coring, providing direct samples from the ground
proactive approach in safety management. This not for detailed analysis. These investigations should
only reduces the likelihood of accidents but also be mandatory and exhaustive to ensure that all
ensures that the workforce is better protected, and potential risks are identified and addressed at the
projects are more resilient against unforeseen planning stage. An MoU signed between India and
challenges. Norway in 2018 is a step in this direction. This
agreement between the NHIDCL and the
Norwegian Geotechnical Institute promotes non-
Precise technical appraisals
intrusive remote sensing techniques, such as
Technical appraisals are the cornerstone of any AEM surveys, in India, thereby significantly
tunneling project, providing critical insights into the enhancing geological investigation capabilities 28.
geological, environmental and engineering challenges 2. Validation through collaboration: Engaging
that must be addressed. These appraisals form the industry experts for the review and validation of
basis that guides the entire construction process. DPRs ensures the accuracy and completeness of
geological and technical assessments.
Accurate and thorough technical appraisals are
Institutional partnerships with specialised
essential because these ensure that all potential risks
organisations offer additional expertise and
are identified and managed from the outset, helping to
validation.
avoid costly delays, budget overruns and safety
hazards. However, inaccuracies in these reports, often Examples of such collaborative efforts include an
due to insufficient geological investigations and lack of MoU signed between the NHAI and the Geological
technological integration, have led to significant Survey of India (GSI) in January 2024 that
challenges in several past projects. advocates for site-specific geotechnical
consultancy and assists in vetting the DPRs 29.
For instance, in the Tapovan Vishnugad Hydro Power This collaboration enhances the quality and
Project (Joshimath tunnel) of NTPC in Uttarakhand, reliability of geotechnical assessments, including
comprising a 12.1-km-long headrace tunnel, there geological mapping and slope stability studies,
were significant cost and time overruns due to contributing to more robust and efficient tunnel
discrepancies between the geological details provided project planning and execution.
in the contract and the actual conditions encountered
during construction. These issues arose from Encouraging skill enhancement
insufficient geological investigation that did not meet
the recommended guidelines, resulting in the DPR The growing complexity of tunneling projects demands
failing to accurately account for the geological a skilled and knowledgeable workforce. Training and
conditions27. skill enhancement not only improves technical
expertise of the workforce but also leads to the
To avoid such issues and enhance the precision of adoption of the latest technologies and best practices,
technical appraisal in tunneling, it is essential to carry thereby boosting industry growth and project outcome.
out:
Training programmes should focus on modern
1. Comprehensive geological investigations: tunneling techniques, safety protocols and the use of
Accurate understanding of the geology is crucial advanced machinery. These programmes should be
to anticipate and mitigate risks such as collapses, tailored to suit various roles, from engineers to on-site
water ingress, etc. This requires thorough workers. Continuous learning opportunities, such as
surveys, i.e. advanced airborne electromagnetic
workshops and seminars, keep the workforce updated
(AEM) surveys, for subsurface investigation with
on new developments and innovations in tunneling.

27
https://mospi.gov.in/sites/default/files/Kpmg1.pdf 29
https://pib.gov.in/PressReleaseIframePage.aspx?PRID=2000912
28
https://pib.gov.in/Pressreleaseshare.aspx?PRID=1566767

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 20

Exchange of knowledge, experiences, challenges and Here are a couple of examples: the Delhi Metro Rail
solutions by industry professionals on different forums Corporation’s collaboration with IIT BHU to establish
can lead to the development of best practices that the Centre of Excellence for Tunneling & Underground
improve efficiency and safety in tunneling projects. Space Engineering (CETUSE) at the Delhi Metro Rail
Partnering with universities, technical institutes and Academy focuses on training and skill development to
industry leaders further supports skill enhancement. address the shortage of skilled resources 30. L&T’s
Tunneling Excellence Academy provides training in
tunnel design, construction and management for its
workforce.

https://kiosk.delhimetrorail.com/pages/en/pressrelease_details/centre-of-
30

excellence-for-tunnelling-underground-sp

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 21

Emerging trends
2018)31, tunnel construction requires minimising traffic
The tunneling industry is evolving quickly, setting new
evacuation, groundwater loss, ground deformation
benchmarks in sustainability and efficiency. Green
tunneling, the use of sustainable materials, and the and impact on surrounding buildings. It is essential to
exercise green tunnel construction to maintain the
recycling of construction waste have become central
safety of vehicles and people in the tunnels, to save
to reducing environmental impact. Additionally, the
energy and to minimise the impact on the
integration of cutting-edge technology and continuous
innovations in tunneling equipment are transforming environment. Green tunnel refers to an underground
how tunnels are designed and constructed. This structure that harmoniously coexists with nature and
the city. It provides people with an unobstructed,
chapter explores these developments.
efficient, convenient and comfortable travel
environment. A green tunnel effectively saves
Green tunneling
resources, protects the environment and reduces
In recent years, the spotlight has turned on energy pollution through its life cycle. Its development
saving and the increased use of renewable as key includes five major aspects:
strategies to achieve the United Nations’ Sustainable
Development Goals (SDGs) outlined in the 2030 1. Prefabricated construction technology
Agenda for Sustainable Development. According to 2. Noise control technology
the report published by International Workshop on
3. Lighting energy saving technology
Renewable Energy and Development (IWRED

31
https://iopscience.iop.org/article/10.1088/1755-1315/153/5/052052/pdf

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 22

4. Ventilation technology strength development, posing challenges for
applications requiring rapid strength gain, such as
5. Digital intelligent maintenance technology
sprayed concrete. A more advanced alternative is
In June 2024, a high-speed rail project (High Speed 2 geopolymer concrete, an alkali activated
or HS2) in England announced the start of cementitious material (AACM) that can eliminate
construction at the site of its first innovative green OPC entirely. Geopolymers utilise waste materials
tunnel designed to blend high speed railway into the rich in aluminosilicates, activated by alkaline
landscape and reduce disruption of communities. solutions, to create a durable binder with lower
Chipping Warden, one of the five green tunnels being carbon emissions and improved resistance to
built under HS2, aims to reduce disruption to residents heat, fire and chemical corrosion, making it
and minimise carbon emissions. The tunnel, designed particularly suitable for tunneling. As the industry
as an M-shaped double arch, will be built using offsite seeks to reduce its environmental impact, the use
manufacturing techniques, where 5,020 concrete of low carbon and zero cement concretes in
precast segments will be slotted together to form the tunneling is expected to become increasingly
structure. This approach is expected to more than common33.
halve the amount of carbon embedded in the tunnel, 2. Glass fibre reinforced polymer (GFRP) rebars:
reducing the need for carbon-intensive concrete and GFRP rebars are composed of glass fiber and
steel. The tunnel's design and construction method will polymer resins. Compared with conventional steel
also improve safety, reduce disruption and enable the rebars, they offer a high strength-to-weight ratio,
use of zero-carbon electricity to power trains, making superior corrosion resistance and require less
it a more sustainable and efficient project 32. concrete cover, making them advantageous for
use in tunneling, especially in aggressive
Sustainable materials and methods environments or in tunnel components that
eventually need to be demolished. In tunneling
Innovative materials applications, GFRP rebars are effectively used in
reinforced concrete diaphragm walls for
To reiterate, as the tunnel construction industry
underground stations. Their ease of cutting
continues to evolve, there is a growing need to adopt
compared with steel rebars facilitates smooth
sustainable materials and practices that minimise
progress of tunnel boring machines TBMs through
environmental impact, while ensuring the durability
these structures. GFRP rebars are also
and efficiency of tunnel infrastructure.
increasingly used in precast segments for tunnel
1. Low carbon concrete – geopolymer concrete: linings.
In tunneling projects, the concrete lining for shafts 3. Steel fibre reinforced concrete (SFRC): SFRC
and tunnels is deemed to be responsible for 60- in tunnel construction offers enhanced durability,
70% of the total emissions due to the use of tensile strength and structural integrity by
Ordinary Portland cement (OPC), a major carbon integrating steel fibre into the concrete mix.
emitter. This makes it imperative to explore low Traditionally, tunnels used a double-shell lining
carbon emitting alternatives. Low carbon concrete system with a temporary sprayed concrete layer
reduces OPC content through supplementary followed by a permanent cast in-situ lining,
cementitious materials (SCMs) such as ground requiring substantial materials, time and cost.
granulated blast furnace slag (GGBS) and fly ash, However, with SFRC, the industry is shifting
potentially cutting carbon emissions significantly. towards permanent sprayed concrete linings,
The use of GGBS or fly ash is common in in-situ which eliminates the need for separate linings and
shaft linings and base slabs, enhancing resistance reduces construction time and environmental
and mitigating thermal cracking. However, high impact. SFRC provides improved durability, better
levels of GGBS can slow setting times and delay

https://www.ekfb.com/post/hs2-starts-work-on-first-pioneering-green-tunnel
32
reinforcement/pdf/articles/Underground%20028_033tun1121_rule_of_thumb
https://www.bekaert.com/content/dam/corporate/en/products/construction/c
33 _GD.pdf
oncrete-

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 23

 crack resistance and reduced material usage, demonstrating successful spoil reuse in
making it a more sustainable and efficient option34. construction37.
This approach was effectively used in the Mumbai 3. Reuse in soil conditioning: Spoil can also
Metro Line 3 project in the Sahar Road Crossover enhance soil conditioning in mechanised
Cavern (SRCC). Originally planned with a tunneling. In slurry shield tunneling, waste sand
conventional lining, the complex geometry led to from slurry operations can replace lime as a filter
the adoption of SFRC for the permanent lining, aid for dewatering waste slurry. The Yellow Tunnel
making it the first metro project in India to do so. project in Jinan City, China shows that waste
The result was a durable, efficient and sustainable sand, when used in combination with a small
construction, setting a precedent for future amount of lime, achieved dewatering results
tunneling projects in the country35. similar to using only lime, but with lower costs and
environmental impact.
Tunnel excavation material recycling
4. Reuse as refilling materials: Spoil can be used
In addition to the use of sustainable materials, to refill abandoned quarries, minimising land
recycling of waste generated during tunneling is also disturbance and reducing waste. The Katzenberg
important. Tunneling generates substantial tunnel Tunnel project in Germany repurposed over 2.3
excavation material (TEM), or spoil. Traditionally, this million cubic metre of spoil for refilling a limestone
material was disposed of in landfills, leading to quarry. Environmental assessments ensured that
environmental and financial challenges. However, the refilled material did not compromise
reusing and recycling TEM can offer significant groundwater quality, demonstrating that careful
benefits, including cost savings and reduced management of spoil can support sustainable
environmental impact. The Supreme Court judgement practices.
in July 2024 regarding the royalty levied by states on
mining emphasises the need to explore TEM as an Leveraging IT in operations and
alternative to aggregated sourced from quarries as a maintenance
cost-effective solution.
Due to the intricate and complex nature of tunneling
1. Reuse as aggregates: Recycling spoil for road projects, it is crucial to use specialised tools that can
construction reduces reliance on new materials streamline construction and operations and
and lowers emissions. For instance, the Sydney maintenance (O&M), and minimise risks, costs and
Metro Tunnel project repurposed over 500,000 environmental footprint, while adapting to the distinct
tonne of sandstone for constructing airport characteristics and challenges of each tunnel. The
infrastructure36. This approach not only minimised combination of automation and digitalisation of tunnel
waste but also reduced carbon emissions by infrastructure can enhance safety and efficiency. Few
avoiding the need for new material extraction and emerging technologies to improve the O&M efficiency
long-distance transport.
of tunnels are as follows:
2. Reuse in grouting: Grouting is essential in shield
tunneling to fill gaps and prevent issues such as 1. Digital twin technology: This technology creates
leakage and ground settlement. Conventional a digital replica of the tunnel to enable real-time
grouting materials such as cement and bentonite monitoring, predictive maintenance and
are costly and often lead to high shrinkage. By simulation of different scenarios. It identifies
incorporating spoil into grouting mixtures, projects potential issues before they occur by creating a
can reduce both waste and costs. For instance, performance twin.
the S1 Vienna project used 1.4 million cubic metre
of TEM in grouting for a 19 km tunnel section,
34
https://www.tunnel-online.info/en/artikel/high-performance-steel-fibres- 36
https://www.sydneymetro.info/article/metro-sandstone-help-build-sydneys-
offer-new-possibilities-for-permanent-sprayed-concrete-lining-4007569.html new-airport
35
https://library.ita-aites.org/wtc/2149-design-construction-of-mumbai-metro- 37
https://www.mdpi.com/2071-1050/16/12/4889
line3-sahar-road-crossover-cavern-using.html

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 24

2. Remote monitoring systems: Internet of Things Advancements in tunneling
(IoT) technology is particularly well suited for
tunnel monitoring applications as it enables the equipment
efficient handling of vast amount of digital data. By The tunneling industry has undergone significant
leveraging IoT, data can be remotely accessed, advancement, driven by the demand for more efficient,
collected and analysed in real time, reducing the cost-effective and versatile solutions. Innovations in
need for manual site visits and inspections. This is tunneling equipment have not only enhanced
critical for ensuring the structural integrity of
operational efficiency but also expanded the
tunnels.
possibilities for complex underground projects.
3. AI-based predictive maintenance: Predictive
maintenance uses advanced analytics to predict 1. Refurbished TBMs: Refurbished TBMs are a
when maintenance will be required. This sustainable and cost-effective alternative to new
technology can analyse data from sensors and machines, extending the operational lifespan of
other sources to identify patterns and detect the existing equipment. These machines are
potential problems. By predicting maintenance upgraded and customised for new projects,
needs, tunnel operators can schedule repairs and reducing capital expenditure and environmental
replacements before problems occur, minimising impact. The reuse of TBMs shortens project
downtime and reducing costs. timelines due to reduced lead times and lowers
tunneling cost. In India, a 6.61 m diameter
4. Energy-efficient systems: Modern tunnel refurbished TERRATEC EPB (earth pressure
designs incorporate energy-efficient systems, balance) TBM was deployed for the Surat Metro
such as LED lighting and ventilation controls, Rail Project39.
which reduce operational energy consumption.
Renewable energy sources, such as solar panels, 2. Non-circular TBMs: Traditional circular TBMs
can be integrated into the tunnel infrastructure to have limitations in space utilisation, particularly in
provide a sustainable power supply. The an urban environment where maximising tunnel
installation of Bajaj CitiSol tunnel lighting space is crucial. Non-circular TBMs, such as
management software at the Mumbai Coastal rectangular or horseshoe-shaped machines,
Road Tunnel is a significant step towards creating overcome these limitations by optimising tunnel
safer, more sustainable and technologically profiles to meet specific project needs. These
advanced transportation networks38. TBMs are particularly suitable for transportation
projects, as they reduce earthwork and improve
space utilisation. Notably, CREG's rectangular
TBM was employed in China’s Tianjin Metro Line
11 Project40, whereas a horseshoe shaped TBM
was utilised in the Baicheng Tunnel, Menghua
railway project in China41.
3. Autonomous and remotely operated TBMs:
The adoption of autonomous and remotely
operated TBMs represents a significant
advancement in tunneling efficiency and safety.
These systems, which use advanced sensors,
control mechanisms and IoT to harness big data,
enable remote operation and real-time monitoring.
This reduces dependence on human operators,
improves precision in complex ground conditions

38
https://www.storyboard18.com/brand-marketing/bajaj-electricals-rajesh- 40
https://www.creg-germany.com/rectangular-tbm
naik-on-mumbai-coastal-road-project-and-enhancing-urban-landscape-for- https://www.sciencedirect.com/science/article/pii/S2095809917307774#:~:t
41

future-generations-26464.htm ext=The%20rectangular%20TBM,ratio%20of%20the%20tunnel%20section.
39
https://terratec.co/terratec-tbms-launched-for-surat-metro/

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 25

 and reflects a promising trend in the industry.
4. In-tunnel variable diameter TBMs: These TBMs
MMC-Gamuda, a Malaysian infrastructure
offer unprecedented flexibility by allowing
company, developed the world’s first autonomous
diameter adjustments within a single project to
TBM (A-TBM) for the second line of Kuala
meet varying design requirements. This
Lumpur’s MRT project. This system was
innovation reduces the need for multiple machines
integrated with the existing Herrenknecht TBMs
or costly modifications, streamlining the tunneling
and was used to control steering, advance rates
process. A notable application was in the Mill
and slurry controls across 10 TBMs used in the
Creek Drainage Relief Tunnel in Dallas, Texas,
project42.
where the TBM's diameter was reduced from 11.6
metre to 9.9 metre mid-project to accommodate
changing flow requirements43.

42
https://gamuda-get.com/award-winning-autonomous-tbm-operations-2/ 43
https://www.robbinstbm.com/mill-creek-diameter-change/

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 26

Case study

Mumbai Coastal Road Project – Project overview44

India’s first undersea tunnel The Mumbai Coastal Road Project is divided into two
India's first undersea tunnel (~1 km long) is a key phases: the Coastal Road Project (South) and the
element of the Mumbai Coastal Road Project, an Coastal Road Project (North). The South section,
ambitious infrastructure initiative designed to enhance covering ~9.98 km from the Princess Street Flyover to
connectivity along Mumbai’s western coastline. the Worli end of the Bandra-Worli Sea Link, is a critical
Spanning 29.2 km from Princess Street Flyover to part of this development. The construction of this
Kandivali Junction, this project aims not only to section is divided into three packages:
improve transportation efficiency but also create
additional recreational spaces for the city’s residents.

44
https://portal.mcgm.gov.in/irj/portal/anonymous/qlprjdtlcs1

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 27

 Package Section Contractor Project cost Key features
P1 – Priyadarshini Park to Baroda M/s. Larsen & Toubro Section on reclaimed land
INR 5,290 crore
3.82 km Palace Ltd (L&T) and large interchanges

P2 – Baroda Palace to Worli end of Bridge, ramp, embankment,

M/s. HCC-HDC (JV) INR 3,211 crore
2.23 km Bandra-Worli Sea Link interchange at Worli

P4 – Princess Street Flyover to M/s. Larsen & Toubro TBM tunnel, ramps at Marine
INR 4,220 crore
3.93 km Priyadarshini Park Ltd (L&T) Drive

2. Fissures affecting annular grouting: The

This case study focuses on P4, which includes the
tunnel's proximity to high tide water levels led to
construction of the twin tunnels below the Arabian
the presence of numerous fissures connecting the
Sea.
tunnel to the sea. These fissures posed significant
Tunnel details challenges during grouting operations, as they
caused grout loss and dilution due to seawater
To preserve the heritage of the Queen’s Necklace and
salinity. To ensure effective grouting, injections
Girgaon Chowpatty and address security concerns
were made at multiple points along the TBM
near Malabar Hill, twin tunnels were constructed
shield, ensuring even distribution and proper
between Priyadarshini Park and Girgaon Chowpatty.
consolidation of the annular void.
The 2.07-km-long tunnels have an outer diameter of
12.19 metre and an inner diameter of 11 metre, 3. Monsoon flooding: Mumbai’s intense monsoon
housing a three-lane road with a width of 3.2 metre per rains created significant challenges during
lane. The tunnels, located 17-20 metre below the construction. During the first TBM drive, an
Arabian Sea, were excavated using a single shield unknown aquifer linked to the sea discharged into
the launch shaft during a period of heavy rainfall,
EPB TBM named Mavala, imported and assembled in
overwhelming the site’s drainage and pumping
Mumbai. The excavation required navigating through
systems. The tunnel was flooded up to 6 m above
complex geological formations, including breccia,
the invert level, halting TBM operations. Repairs
basalt, shale and segments under the sea, with entry
and replacement of damaged components took
and exit ramps constructed using the cut-and-cover
approximately four weeks, highlighting the need
method.
for robust contingency measures to handle such
Challenges and learnings45 extreme conditions.

1. Tunneling through reclaimed land and 4. Repurposing of reception shaft: Originally, the
sinkhole management: Early in the excavation, plan was to dismantle the TBM and transport it
a significant challenge arose when a sinkhole back to the launch shaft. However, owing to
developed after the TBM launch in a surface logistical difficulties and time constraints, an
lagoon adjacent to the tunnel alignment. This alternative approach was adopted. The completed
resulted in a large influx of slurry and boulders into tunnel was used as a passage to relocate and
the TBM’s cutting chamber, leading to frequent rotate the TBM for its second drive. This
power trips and operational delays. To address innovative solution involved moving and rotating
this, the TBM was halted and ground consolidation the TBM within a confined reception shaft,
was carried out using TAM and Packer grouting to enabling efficient continuation of the tunneling
stabilise the affected area. process46.

45
https://www.taylorfrancis.com/chapters/oa-edit/10.1201/9781003348030- 46
https://www.taylorfrancis.com/chapters/oa-edit/10.1201/9781003348030-
276/tunneling-construction-challenges-mumbai-coastal-road-project-surana- 222/repurposing-reception-shaft-mumbai-coastal-road-project-case-study-di-
celentano-raju-swami fabio-panciera-varma-kumar-kachhy-singh-pajni

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 28

Highlights Fehmarn Belt fixed link – Europe’s
1. In August 2022, L&T announced that ‘Mavala’ set
immersed tunnel
a world record for the longest distance excavated
in a month by a single shield EPB TBM, covering The Fehmarn Belt tunnel is an 18-km long immersed
a 456.72m stretch. tunnel located 40 m beneath the Baltic Sea that
connects the Denmark and Germany. It will be the
2. The successful repurposing of the reception shaft
world’s largest immersed tunnel and includes a two-
to facilitate the TBM relaunch demonstrated the
project team's adaptability and ingenuity in track railroad and a four-track motorway. To date, it is
overcoming significant logistical challenges. the largest infrastructure project in Denmark, with a
total budget of over €7 billion.

Figure 4: Project location

Fehmarn Belt Fixed

Link

temporary refuges, although not allowed to be used by

Construction of the immersed tunnel
vehicles. As part of the Trans-European Transport
It consists of a single tube about 18 km long, 42.2 m Network, the tunnel aims to promote sustainable
wide and 8.9 m high, formed by 89 precast concrete transportation by providing a faster and more efficient
segments 217 m long. The tunnel is provided with four route for both passenger and freight traffic. This will
traffic galleries: two road galleries, 11 m wide and 5.2 lead to a reduction in CO2 emissions, alleviate
m high; and two (ballast-less) rail galleries, 6 m wide congestion on roads and railways, and encourage a
and 6 m high. It also includes a service gallery placed shift from trucks to more environmentally friendly
between the two road galleries, 2 m wide, intended for electric trains.47
the installation of pipes and cables and to be used as

Figure 5: Immersed tunnel section

Source - Meet the Challenges of the Fehmarn Belt Fixed Link by S. Pompeu-Santos

47
https://www.tec-tunnel.com/en/tunnelling-projects/fehmarnbelt-tunnel

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 29

Figure 6: On-ground section

Source - Thinkproject

The tunnel’s two-lane dual highway and dual railway will cut road and rail users’ journey time by about an hour each
way compared to the current ferry crossing. The Fehmarn Belt tunnel will also be unimpeded by poor weather,
ensuring a more reliable crossing.

Alongside the advantage of improved access to sustainable travel, the project is being constructed with great
consideration for the environment and biodiversity. The reconstruction of stone reefs and addition of stone protection
for the tunnel will create additional habitat for marine plant and animal life whilst green corridors will be created to
support insects as well as flora and fauna such as amphibians and orchids.

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 30

Suggestions/way forward
As India continues to expand its infrastructure, the role of tunneling in ensuring connectivity, economic growth and
strategic advantages becomes increasingly critical. However, a structured and comprehensive approach is necessary
to overcome the challenges faced in the current tunneling projects. The way forward involves focusing on key areas
that will enhance project execution and improve safety standards. This includes:

4. Considering a
1. Harmonising 5. Opting for AI-
2. Embedding 3. Creating a PLI scheme for
DPR RFPs and enabled camera
safety during National Digital critical tunnel
construction based tunnel face
bidding Geotech Library machinery and
contracts mapping
materials

Harmonising DPR contracts and Embedding safety during bidding

construction contracts As we move forward, a strong commitment to safety
during tunnel construction is imperative. The
• Standardising contracts across agencies such as
upcoming SOP for tunnel projects by MoRTH48
NHAI, NHIDCL and various state bodies is crucial
for tunneling projects. Harmonising contracts by represents a pivotal step in this direction. Being
leveraging best practices across agencies can developed through a collaboration between MoRTH,
ensure consistency and reduce inefficiencies NHAI, NHIDCL, DMRC, KRC and international
tunneling experts, the SOP aims to comprehensively
• A model contract document for tunnel-based address health and safety concerns in tunnel projects.
projects aligned with international best practices
such as the International Federation of Consulting • Spell-out safety during bidding: To ensure strict
Engineers’ (FIDIC's) Conditions of Contract for adherence to these safety standards, it is
Underground Works can be developed to provide essential that the safety expectations of the
a standardised, reliable framework, promoting Authority, whether related to SOP compliance, the
better risk management and minimising disputes provision of escape shafts during construction, the
use of IoT sensors for real-time monitoring during
• Similarly, establishing clear requirements for
construction or any other safety measure to be
geotechnical investigations within the Terms of
undertaken shall be clearly articulated in the bids.
Reference for DPR consultants is essential. This
This clarity will enable bidders to accurately factor
shall involve encouraging the use of the latest
the costs associated with these safety
technology as discussed in the earlier section to
requirements into their proposals, ensuring that
conduct a comprehensive test, leading to more
safety is prioritised from the outset of each project.
accurate geological assessments and reducing
the risk of unforeseen construction challenges • Master HIRA: Hazard Identification and Risk
Analysis (HIRA) – as defined in ISO 45001
‘Occupational Health and Safety Management

48
https://www.moneycontrol.com/news/business/new-standard-operating-
procedures-in-march-for-tunnel-construction-rescue-operations-
12403741.html

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 31

 System’ – is a crucial OH&S document which Considering Production Linked
involves identifying potential hazards,
understanding the mechanisms by which these Incentive (PLI) scheme for
hazards could lead to undesirable incidents and imported items
estimating the extent, magnitude and likelihood of
At present, key tunneling equipment and materials
harmful effects. Since most tunneling methods are
known and largely uniform (site-specific from TBM cutter heads, bearings, spares or gaskets
conditions aside), a master HIRA for all DBM, for segment-to-segment sealing to fire-fighting
NATM-based as well as TBM tunnel-based components, fire-proof paints for linings are largely
construction can be taken up by the government imported. Since 2020, the GoI has announced PLI
through industry experts involved in the design, schemes for 14 sectors with an outlay of INR 1.97 lakh
construction and safety to include measures from crore to enhance the country's manufacturing
learnings from recent incidents. This can be capabilities, extending the initiative to cover critical
published by the government to serve as a guide construction equipment, which would boost domestic
for all stakeholders and add to expectation setting. manufacturing and significantly enhance self-reliance
in the sector. This move would align with the
Creating a GIS-based National ‘Atmanirbhar Bharat’ vision, ensuring that the nation's
infrastructure projects are supported by locally
Digital Geotech Library
manufactured equipment, thereby strengthening the
The government can consider creating a overall growth of the Indian infrastructure sector. This
comprehensive digital geotechnical library that will also attract investment and reduce dependence on
consolidates all face mapping data and other imported machinery. The government should design
geotechnical investigation reports obtained from and launch a PLI scheme for construction equipment
tunnel projects – either completed or underway - in critical to infrastructure development, including
India. This GIS-based database can be developed to tunneling.
store and share investigation reports with borehole
logs, rock strata info and data on other physical
attributes such as cross-streams or nallahs, aquifers
or other bodies.

This digital repository will provide access to as-built

and as-encountered logs, serving as an indicative
reference point in addition to the Geotechnical
Baseline Report for tunnel bidders, consultants and
other stakeholders. As a second step, the library can
be further enriched by incorporating geotechnical data
from the ground and pile load tests can be conducted
for bridge constructions.

The Geological Survey of India (GSI) can act as the

implementing agency to facilitate this GIS database by
coordinating with the authorities from various
ministries.

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 32

Opting for AI-enabled camera- By prioritising these key areas, India can build a robust
tunneling infrastructure that aligns with the nation's
based tunnel face mapping ambitious development goals. This approach will not
In tunnel construction, the use of cameras leveraging only enhance the efficiency and safety of projects, but
machine learning (ML) and AI algorithms for tunnel also lay down a robust foundation for sustainable
face mapping marks a significant advancement in growth, ensuring that the country's tunneling projects
geotechnical practices. This computer vision-based contribute effectively to its economic, strategic and
technology enables real-time, automated analysis of social objectives.
geological conditions, improving accuracy in
identifying rock types, discontinuities and hazards. By
efficiently processing visual data, AI-driven systems
can provide predictive insights that support adaptive
excavation strategies and enhance safety. As tunnel
projects become more complex, adopting such
intelligent systems will be crucial for optimising
efficiency and minimising risks. A company based out
of Australia also offers practical kits comprising
hardware and software, which enable tunnel face
mapping using handheld cameras, making this
technology more accessible.

FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 33

Analytical Contacts

CRISIL Limited FICCI

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FICCI-CRISIL Knowledge Report: Advancing Tunneling in India 34

About FICCI
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