In a remarkable feat of engineering endurance, India’s longest railway tunnel between Devprayag and Janasu in Uttarakhand has been successfully completed, despite facing near-catastrophic challenges that once threatened to derail the entire project.
Stretching across 14.57 kilometres as part of the ambitious 125-kilometre Rishikesh-Karnaprayag Rail Link Project, the tunnel stands as a testament to human resilience, technological innovation, and the spirit of sustainable infrastructure development in some of the world’s most unforgiving terrains.
During a critical phase of construction, a major setback almost jeopardised the tunnel’s future when the tunnel boring machine (TBM) encountered an unexpected water ingress at a formidable rate of approximately 1,500 litres per minute. Deep within the mountain, nearly five kilometres into excavation, hundreds of workers were forced to battle not just the surging waters but also the terrifying prospect of a total collapse. The immediate deployment of corrective measures, including chemical and cement grouting, gradually stabilised the surrounding rock and controlled the inflow, allowing the project to proceed without casualty.
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Even as engineers wrestled with nature’s forces, the soft and squeezing Himalayan rock formations posed a constant threat, creating enormous pressure around the TBM shield. By lubricating the shield with bentonite and accelerating excavation activities, the team was able to neutralise the risk and maintain momentum. Leveraging state-of-the-art scientific methodologies such as Tunnel Seismic Prediction (TSP) and manual rock probing, engineers anticipated and adapted to varying geological conditions up to 100 metres ahead of the machine. This blend of advanced technology and on-ground human expertise underlines the success story of the Devprayag-Janasu tunnel, carving a path through one of the most volatile geological zones on the planet.
Achieving a breakthrough on April 16, the project was hailed as a milestone not just for its sheer length but also for the incredible pace at which it was accomplished. Approximately 10.49 kilometres of the tunnel were constructed using the Single Shield Hard Rock TBM, with the rest completed by conventional drill and blast methods. The project recorded an average excavation speed of 413 metres per month, positioning it among the fastest tunnel projects globally under such adverse conditions. Its successful completion adds another vital artery to India’s sustainable rail network, designed to improve connectivity across the Himalayan region while promoting low-carbon transportation solutions.
The Devprayag-Janasu tunnel’s completion underscores a broader vision of building resilient, eco-friendly, and inclusive infrastructure that respects both natural challenges and human aspirations. As India continues to invest in transformative rail projects, the story of this tunnel serves as a powerful reminder of the ingenuity and courage required to meet the nation’s future mobility needs sustainably. Against all odds, this Himalayan marvel symbolises a future where technological precision, sustainable development, and human grit work together to bridge distances in the greenest way possible.
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Indias Fastest Long Rail Tunnel Completed Safely
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