The National High-Speed Rail Corporation Limited (NHSRCL) has successfully launched the first 40-meter Full Span Pre-Stressed Concrete (PSC) Box Girder in Maharashtra for the MAHSR Bullet Train corridor. This breakthrough at Sakhare Village marks rapid progress in the state’s 156 km alignment, ensuring faster, efficient viaduct construction.
Introduction:
In a significant development towards infrastructure in the Mumbai-Ahmedabad Bullet Train corridor, the National High-Speed Rail Corporation Limited (NHSRCL) successfully launched the first Full Span Pre-Stressed Concrete (PSC) Box Girder in the Maharashtra section by full span launching gantry (FSLG). This major development took place at Sakhare Village, Dahanu, and marks a significant leap in the construction of India’s first high-speed rail project.
Scope of the Maharashtra Section:
The Maharashtra portion of the corridor spans 156 km, including 135 km of elevated viaduct between Shilphata and Zaroli (Maharashtra-Gujarat border). This section will require 2,575 full-span girders, each measuring 40 meters and weighing around 970 metric tonnes. In addition, the alignment includes:
- 17 km constructed with segmental girders
- 2.3 km of steel bridges
- 7 mountain tunnels totaling 6 km
- 3 elevated stations (Thane, Virar, and Boisar)
To support this work, 13 casting yards are planned along the alignment, with 5 already operational.
Why Full Span Girders Matter:
Each full-span PSC box girder is cast as a monolithic unit using 390 cubic meters of concrete and 42 metric tonnes of steel, making it the heaviest in India’s construction history. These girders are launched using advanced heavy machinery like Straddle Carriers, Girder Transporters, and Launching Gantries.
Full-span construction offers immense benefits:
- Enables progress up to 10 times faster than segmental girder methods
- Ensures higher precision and durability with fewer joints
- Facilitates mass production and pre-stacking in casting yards
This technology has already been proven in Gujarat, where 319 km of viaduct has been completed since 2021.
Progress in Maharashtra:
As of 5th September 2025, Maharashtra’s bullet train construction shows visible momentum:
- Station works: First slabs cast at Virar and Boisar, with rapid progress at Thane.
- Piers: Approximately 48 km worth of piers have been completed.
- Tunnels: Out of 6 km of mountain tunnels in Palghar, 2.1 km of headings have been achieved.
- Bridges: Work underway on Vaitarna, Ulhas, and Jagani river bridges.
- Underground stretch: A 21 km long tunnel, including a 7 km undersea tunnel at Thane Creek, is progressing. About 4.65 km of tunnel heading has been completed.
- Bandra-Kurla Complex station: Excavation is 83% complete, and base slab casting has commenced 100 feet below ground.
Broader Impact:
The beginning of full-span girder launching in Maharashtra is a turning point in the path of achieving advanced high-speed rail infrastructure. It ensures construction speed, safety, and quality for India’s flagship high-speed rail project. With stations, tunnels, and bridges advancing in parallel, the project showcases India’s growing capability in adopting advanced construction technologies.
Conclusion:
The NHSRCL achieved a significant milestone with the launch of Maharashtra’s first full-span PSC girder, marking a rapid progress in the Mumbai-Ahmedabad Bullet Train project. With viaducts, tunnels, bridges, and stations being built, India’s goal of introducing high-speed rail is getting closer to reality. The development highlights engineering precision and reinforces regional connectivity between Mumbai and Ahmedabad.
Source: NHSRCL – Press Release | Image Credit: NHSRCL
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