Images Source: The Economic Times
India has achieved a landmark milestone with the completion of its longest rail tunnel, a feat attained through the relentless efforts of tunnel boring machine (TBM) operators cutting through the formidable Himalayas. This 14.57 km Janasu Tunnel lies between Devprayag and Janasu in Uttarakhand and is a key part of the Rishikesh-Karnaprayag Rail Link Project. The project has been completed ahead of schedule and marks a monumental engineering achievement in extreme mountainous terrain .
Key Highlights of the Tunnel Project
Length and Location: The Janasu Tunnel stretches 14.57 km over a single-line broad-gauge track, making it India's longest rail tunnel to date. It lies on the 125-km Rishikesh-Karnaprayag route in Uttarakhand connecting major Himalayan towns and pilgrimage sites .
TBM Technology and Operators: German-made TBMs named Shakti and Shiv were used for excavation. Operators Baljinder Singh and Ram Avtar Singh Rana led the operations despite encountering severe challenges like massive landslides blocking the tunnel path. They operated the machines with extraordinary force and shifted into 12-hour rotating shifts to keep the project on track .
Record-Breaking Progress: The team set a world record by advancing 790 meters in a single month on the downline tunnel. 70 percent of tunneling was done using TBMs while the remaining 30 percent used the New Austrian Tunnelling Method (NATM), an advanced drill-and-blast technique .
Engineering Feats in Treacherous Terrain
This tunnel project is one of the most complex and significant infrastructure undertakings undertaken by Indian Railways in recent years. The TBMs used were 140 meters long with 13.75-meter cutter heads fitted with 55 cutting discs designed for hard rock excavation. Teams worked round-the-clock stabilizing newly excavated areas to prevent collapses, essential in the brittle Himalayan geology .
A massive landslide stuck the TBM around 3.5 km deep inside the tunnel, forcing the operators to push the TBM to its full power of 130,000 kilo Newtons to clear debris and continue. The struggle lasted nearly 10 days in non-stop 12-hour shifts before the blockage was cleared, a critical moment that saved the project from potential shelving .
Strategic and Economic Importance
The Rishikesh-Karnaprayag rail project is expected to dramatically improve connectivity in the Himalayan region by reducing travel time from seven hours to two. It enhances access for pilgrimage, tourism, and military logistics and offers an all-weather safe alternative to landslide-prone hill roads. The project includes 12 stations, 16 main tunnels, and 19 big bridges across five districts in Uttarakhand .
This tunnel and others in the project collectively span some 30 km of tunneling work, integrating escape routes, cross passages, and niches, underscoring the scale and safety considerations taken .
Project Timeline and Future Outlook
The Janasu tunnel's breakthrough was announced on April 16, 2025, coinciding with the 172nd anniversary of India's first train service. The twin tunnel system’s second tube is expected to be completed by July 2025. The overall Rishikesh-Karnaprayag Rail Link aims to be operational by December 2026 under Rail Vikas Nigam Limited (RVNL) .
Larsen & Toubro (L&T), the engineering firm responsible, used cutting-edge TBM technology for the first time on a railway project in the Himalayas. This innovation has set new global tunneling standards given the challenging terrain and geological conditions .
In summary, India’s longest rail tunnel stands as a testament to human resilience, advanced engineering, and strategic foresight, significantly boosting Uttarakhand’s connectivity and economic potential.
Source: PTI, Economic Times, Millennium Post
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