Urban area above, controlled blasting continues below:Bhaskar reaches state’s largest railway tunnel beneath a bustling city; train services to start within four months

The Tihi–Pithampur tunnel, the most crucial and challenging stretch of the Indore–Dahod new rail line project, has entered its final construction phase after eight years of work. Concrete work inside the tunnel has been completed, the first consignment of tracks has begun arriving, and track-laying has started in some sections. The project faced major delays five years ago due to the COVID-19 pandemic, as well as persistent water seepage from the hills and the threat of venomous snakes. Overcoming these challenges, railway and project officials now claim the tunnel work will be completed and train services extended up to Dhar within the next four months. This tunnel is not just an engineering structure but a milestone for industrial growth and passenger convenience in the Malwa region. The Bhaskar team entered the tunnel and spent eight hours with engineers and workers, gaining insight into the challenges that led to the completion of this long-awaited project. Read the full report. Mud and darkness in tunnel, jeep’s wheels stopped Accompanied by four railway and project company officials, we reached Portal-1, the tunnel entrance. Before entry, we were provided safety shoes, helmets and reflective jackets, as officials said work was ongoing inside and entry without safety gear was prohibited. Vehicles were not allowed as they could get stuck in the mud. We entered the tunnel in two company jeeps, where workers were seen operating under dim tube lights. After moving barely 200 metres, the driver stopped, citing excessive mud ahead that even heavy machines could not cross. We then proceeded on foot. Stepping down revealed the importance of safety shoes, as our legs sank into debris and mud up to below the knees. Amid pitch darkness, sticky mud, and the constant risk of slipping, we continued our journey inside the tunnel. The state’s first ‘Dry Tunnel’
Walking on this difficult path, Project Manager Brajesh told us about the biggest feature of the tunnel. He said, This is going to be the state’s first dry tunnel. To deal with the water seeping from the mountain, a high-tech water drainage system has been prepared. A special ‘membrane’ has been installed between the thick concrete walls and the mountain. The water seeping from the mountain collects in this membrane and reaches chambers built every 50 meters, from where it is drained out of the tunnel through large pipes. Work-accelerating ‘Edit Point’ and future security
The officials then took us in their vehicle to a central structure above the tunnel, technically known as an ‘Edit Point’. The Project Manager explained that to speed up construction, a massive pit about 30 metres deep and 60 metres long was dug at the centre of the tunnel. This allowed excavation and construction to be carried out simultaneously from both ends and from the middle. Concrete was supplied inside through large pipes from above, saving significant time. Brajesh said, After the tunnel is built, this adit point will become an important safety center. A three-story emergency lift and stairs will be built here. Large jet fans will be installed for ventilation. In any emergency, passengers and staff will be able to be safely evacuated from here. A grid to supply electricity to the railway line has also been completed nearby. Ballastless track and final stage work Mountain of challenges: Blasting, water, and poisonous snakes For ABCI company, which is constructing the 3-km-long tunnel, the journey has been extremely challenging. Project Manager Brajesh said the biggest hurdle was controlled blasting, as Pithampur city lies directly above the tunnel, and care had to be taken to ensure no houses were damaged, using modern technology. Water posed the next major problem, with rainwater flooding the tunnel and halting work for two to three months at a time. Although heavy pumps were used to drain the water, some earlier concrete work was damaged and had to be broken and removed. Workers also encountered venomous Russell’s viper snakes on several occasions, which were safely captured and released into the forest. Additionally, the COVID-19 pandemic in 2020 significantly slowed the project’s progress.