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Mumbai: The National High-Speed Rail Corporation Limited (NHSRCL) launched the first full-span Pre-Stressed Concrete (PSC) Box Girder in Maharashtra for the Mumbai-Ahmedabad Bullet Train corridor on Friday . The launch took place at Sakhare Village in Dahanu, marking a major step forward in the state’s bullet train infrastructure development.

According to NHSRCL, Maharashtra section of the 508-kilometre corridor spans 156 km and features a mix of underground, elevated, and tunnel alignments. Key components include an underground station at Bandra Kurla Complex (BKC) in Mumbai, a 21-kilometre-long tunnel between BKC and Shilphata in Thane, and a 135-kilometre elevated track stretching to Zaroli village on the Maharashtra-Gujarat border.

"This elevated section will comprise 124 kilometers of viaduct, including 103 kilometers constructed using 2,575 Full Span Launching Method (FSLM) girders. An additional 17 kilometers will be built using segmental girders. The alignment also includes 2.3 kilometers of steel bridges over highways, the Dedicated Freight Corridor (DFCC), Indian Railways, and the Ulhas River. Furthermore, 1.3 kilometers of elevated structures will pass through three bullet train stations at Thane, Virar, and Boisar. The section also features 11 kilometers of additional structures, which include 6 kilometers dedicated to seven mountain tunnels and 5 kilometers of special earthworks" stated an official.

The 40-meter-long PSC Box Girder launched is a major engineering feat—each girder weighs approximately 970 metric tonnes, making it one of the heaviest in India's construction sector. Cast as a single monolithic unit using 390 cubic meters of concrete and 42 metric tonnes of steel, these girders are designed to accelerate construction timelines.

“Full-span girders are a game-changer for the bullet train corridor,” an NHSRCL official stated. “They allow construction to proceed up to 10 times faster compared to segmental girders, significantly speeding up project execution.”

To facilitate smooth and efficient launching, NHSRCL is using specialized indigenous heavy machinery, including Straddle Carriers, Bridge Launching Gantries, Girder Transporters, and Launching Gantries. A systematic supply chain has been established with girders being pre-cast and stacked in dedicated casting yards. Of the planned 13 casting yards between Shilphata and the Gujarat-Maharashtra border, five are currently operational.

The full-span girder technology has been in use since April 2021 in the Gujarat segment of the corridor, which has already seen 307 km of viaduct completed. In Maharashtra, recent milestones include the first slab castings at Virar and Boisar stations.

Mumbai-Ahmedabad Bullet Train Project: 100-Meter Long 'Make In India' Steel Bridge Launched Over DFC Tracks Near Gujarat's Bharuch

The Mumbai-Ahmedabad Bullet Train project, being developed with technical and financial support from Japan, is expected to revolutionize rail travel in India, significantly reducing travel time and introducing state-of-the-art infrastructure.

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