Project Overview

The Thane–Borivali Twin Tunnel Project is being implemented by the Mumbai Metropolitan Region Development Authority (MMRDA). This transformative infrastructure initiative involves the construction of twin tunnels beneath the Sanjay Gandhi National Park, with approach roads connecting the Western Express Highway on the Borivali side and Ghodbunder Road on the Thane side.

• Administrative Approval Date: 10th March 2023
• Administrative Approval Cost: ₹16,600.40 crore
• Total Project Cost (including IDC): ₹18,838 crore
• Date of Commencement: 19th May 2023
• Project Duration: 60 months (Expected completion by May 2028)

Currently, it takes around 1 to 1.5 hours to travel the 23 km distance between Thane and Borivali via Ghodbunder Road. Once the tunnel is operational, this journey is expected to take just 15 minutes.

Project Details

• Total Length: 11.84 km
• Tunnel Length: 10.25 km
• Connecting Roads: 1.59 km
• Tunnel Segmentation:
  • From Borivali side: 5.75 km
  • From Thane side: 6.09 km

The twin tunnels are designed with a strong focus on capacity and safety. Each tunnel will include:

• Two vehicular lanes
• One emergency lane
• Cross passages every 300 meters
• Modern safety features such as:
  • Ventilation systems
  • Fire extinguishers
  • Smoke detectors
  • Illuminated retro-reflective and LED signboards

Note: Since the tunnels pass through a protected forest area, Tunnel Boring Machines (TBMs) are being used to ensure minimal environmental impact.

Construction & Execution

• Project divided into three packages:
  • Two civil works packages (currently under execution)
  • One MEP package (for tunnel systems like ventilation, safety, etc.)
• Contractor: M/s Megha Engineering & Infrastructures Ltd. (both civil packages)
• Consultant: M/s Hill–TCE JV

Technology

To preserve the ecology of Sanjay Gandhi National Park, advanced TBMs are being used. Each machine has the following specifications:

• Cutter head diameter: 13.34 meters
• Length: 86 meters
• Weight: ~2,500 tons
• Single-shield, open-mode machine

Progress as of 30th July 2025

• Physical Progress: 7.99%
• Financial Progress: 7.37%

Benefits

• This direct Thane–Borivali tunnel link is expected to:
• • Significantly reduce traffic congestion on Ghodbunder Road
  • Cut down travel time to just 15 minutes
  • Help reduce air and noise pollution
  • Support sustainable urban development