Larsen and Toubro (L&T) has made history with the Rishikesh-Karanprayag Rail Link project. On June 29, the construction giant set a new world record for tunnel construction using a single-shield hard rock tunnel boring machine (TBM). The achievement came a day ahead of schedule, marking a major milestone for India’s infrastructure development.
The TBM, aptly named Shiv, excavated an impressive 790 meters in just 31 days. S V Desai, Whole Time Director at L&T, confirmed the feat, highlighting the efficiency and precision of the team. “This is the first time anywhere in the world that a single-shield hard rock TBM has been used with such remarkable results,” he said.
This 13.09 km tunnel is part of a pair running parallel to each other. The first tunnel, spanning 14.57 km and named Shakti, was completed earlier in April 2025. Together, these twin tunnels between Devprayag and Janasu form India’s longest transportation tunnels. They are a crucial component of the 125 km Rishikesh-Karanprayag Broad Gauge Rail Link Project in Uttarakhand, expected to be operational by December 2026.
Rakesh Arora, Project Director, shared insights into the construction process. While 70% of the tunneling work (21 km) was done using TBMs, the remaining 30% (9 km) relied on the drill and blast method, also known as the New Australian Tunneling Method (NATM). On average, the team achieved over 400 meters of tunneling per month with TBMs and 70 meters with NATM.
The project wasn’t without its challenges. Geological hurdles like loose rock, shear zones, and high water ingress were constant obstacles. Adverse working conditions, including high temperatures and humidity in the long tunnels, made the task even more demanding. Despite these difficulties, the team pushed forward, completing the work ahead of schedule.
Logistics played a critical role in the project’s success. Transporting the massive TBMs from ports to the site, assembling them, and managing muck removal required meticulous planning. Senior officials praised the unprecedented logistics management that made this record-breaking achievement possible.
Suresh Kumar, Head of Hydel and Tunnels Business at L&T, acknowledged the efforts of the entire team. Rakesh Arora also reflected on the journey, remembering the early days in February 2021 when the project began from scratch. Mobilizing resources, setting up infrastructure, and launching the TBMs were all monumental tasks that the team executed flawlessly.
Collaboration with Rail Vikas Nigam Limited (RVNL) was another key factor in the project’s success. The vision and support from RVNL ensured that the team had the backing they needed to overcome challenges and deliver outstanding results.
With this record-breaking achievement, L&T has not only set a new benchmark in tunnel construction but has also paved the way for future infrastructure projects in India. The Rishikesh-Karanprayag Rail Link is set to transform connectivity in Uttarakhand, making travel faster and more efficient for thousands of passengers.