Mumbai-Ahmedabad High Speed Railway Corridor (MAHSR) – The First Bullet Train of India

In 2022, L&T Construction secured a contract from National High-speed Rail Corporation Limited (NHSCRL) to construct 116 Route Km of High-speed ballastless trackworks for the Mumbai-Ahmedabad high-speed rail (MAHSR) project, also known as the Bullet Train Project. This groundbreaking project will mark India’s first bullet train, revolutionizing rail travel in the country. The proposed route will run from Pune to Ahmedabad via Mumbai, covering a distance of 508 km in just 3 hours, thanks to its remarkable speed of 320 kmph. The Mumbai-Ahmedabad high-speed rail project is set to bring a new era of connectivity and efficiency to the Indian rail network. 

Japanese Shinkansen Track Technology 

One of the key highlights of the Mumbai-Ahmedabad high-speed rail project is the adoption of Japanese Shinkansen track technology. Known for its safety and efficiency, the Shinkansen system has been the backbone of Japan’s high-speed rail network for decades. By incorporating this proven track technology, India aims to ensure a smooth and reliable travel experience for passengers. This advanced track system will not only allow the bullet train to achieve its impressive speed but also provide enhanced stability and reduced maintenance requirements. 

First Full-Span Erection Method 

To construct the Mumbai-Ahmedabad high-speed rail project with unprecedented speed and scale, the first full-span erection method is being employed. This innovative method allows for the rapid construction of elevated sections of the rail line, using the latest construction techniques and equipment. Package C4, which represents 46.6% of the total length, is the longest among all the packages. It runs elevated from Zaroli Village on the Maharashtra-Gujarat border to Vadodara Station, passing through four stations at Vapi, Bilimora, Surat, and Bharuch in Gujarat. The construction of this package involves the use of an impressive 66 Lakh Cum Concrete and 8 Lakh MT reinforcement. The project also boasts the capability to lift up to 1100 MT, ensuring the efficient installation of heavy components. 

The Vital Role of Straddle Carrier 

One of the key equipment utilized in the construction of the Mumbai-Ahmedabad high-speed rail project is the Straddle Carrier. This specialized equipment is designed to handle the Full Span Precast girders, transporting them from the casting bed to the stacking yard and eventually to the Bridge Gantry for erection. The Straddle Carrier is a self-propelled gantry crane mounted on tires, boasting an impressive lifting capacity of 1,100 MT. With the ability to move at a traveling speed of 6.0m/min at full load, this equipment plays a crucial role in the smooth and efficient construction of the elevated sections of the rail line. 

Ingenious Full Span Launching Method 

Another innovative construction method employed in the Mumbai-Ahmedabad high-speed rail project is the Full Span Launching Method (FSLM). This method, faster than traditional pre-casting methods, requires specialized equipment such as the Straddle Carrier, Transporter Girder, and Launching Girder. These equipment have been designed and manufactured by L&T Kanchipuram Works (Product BU, MMH SBG) specifically for the requirements of the high-speed rail project. The FSLM method allows for the rapid installation of precast segments, ensuring the timely completion of the rail line. 

The Mumbai-Ahmedabad high-speed rail project also involves an impressive number of piles, with a total of 29,755 piles being used for the construction. Additionally, the project boasts Asia’s largest geotech lab, showcasing the commitment to quality and precision in the construction process. 

Advancements in Precast Technology 

The construction of the Mumbai-Ahmedabad high-speed rail project requires state-of-the-art facilities, and the precast factory is a testament to that. With dimensions of 150m x 75m and three precasting bays, it is one of the largest precast factories in India. The factory layout includes dedicated bays for casting noise barriers, cable ducts, and precast slabs, ensuring efficient production. Equipped with an automatic concrete supply system and various casting machines, the precast factory is capable of producing a large number of high-quality precast segments. Additionally, the factory structure is designed with high-grade E350 steel to withstand wind speeds up to 44 m/s, ensuring the safety of the workers and the integrity of the facility. 

• Innovative Concrete Supply System: A high-tech and fully automated concrete supply system is an integral part of the precast factory. This modernized system, synchronized with batching plants, allows for the efficient supply of concrete to the casting machines. The system includes a shuttle, comcaster, and track, ensuring the seamless transport and pouring of concrete. Steam curing is employed for the hardening of the segments, and the entire system is meticulously detailed and integrated by the HSR C4 CMPC team to ensure smooth operations. 

• Revolutionizing Noise Barrier Casting: The Mumbai-Ahmedabad high-speed rail project also showcases cutting-edge technology in the casting of noise barriers. L&T’s HSR C4 CMPC team has developed an indigenous machine using a battery mold concept, a first of its kind in India. This machine allows for the casting of complex-shaped noise barriers, which are an integral part of the rail line’s infrastructure. The development of a stable battery mold for complex shapes was a significant challenge, but the team at L&T has successfully overcome it. The noise barrier casting machine consists of various key components, including the Concrete Shuttle, Guide Frame, Inner Form, Side Form, End Form, Soffit Form, and Intermediate Form. With the ability to produce 12 noise barrier segments at a time and 24 segments per day, this machine plays a crucial role in the construction of the Mumbai-Ahmedabad high-speed rail project. 

The Mumbai-Ahmedabad high-speed rail project is already well underway, with the first phase expected to be operational in 2026. This project, spearheaded by Larsen & Toubro, is set to revolutionize rail travel in India. With its remarkable speed, cutting-edge technology, and innovative construction methods, the Mumbai-Ahmedabad high-speed rail project will bring a new level of connectivity and convenience to the Indian rail network. As this project progresses, it will not only transform the way people travel but also drive economic growth and development in the regions it serves. The future of rail travel in India is indeed looking bright.