The Thane-Borivali Tunnel is one of Mumbai's most transformative infrastructure projects. Spearheaded by the Mumbai Metropolitan Region Development Authority (MMRDA), this six-lane, twin-tube road tunnel is being built under the Sanjay Gandhi National Park (SGNP), connecting Manpada in Thane to Ekta Nagar (Magathane) in Borivali.

Thane-Borivali Twin Tunnel, YT

At 11.84 kilometers in length, it will be the longest road tunnel in Maharashtra. As a key component of the Goregaon-Mulund Link Road (GMLR), this project will drastically reduce the current 90-minute commute to just 15-20 minutes while significantly improving traffic efficiency, reducing emissions, and supporting urban mobility.

Thane-Borivali Twin Tunnel, LinkedIn

1. Thane Portal Realignment

In June 2025, MMRDA realigned the Thane-side tunnel portal by approximately 200 to 225 meters toward the Satya Shankar boundary wall. This move was made in response to concerns from residents in Mullabaug and Sainath Nagar to avoid demolition of homes. The tunnel alignment will now remain underground longer before surfacing closer to the Ghodbunder Highway, reducing disruption in residential zones.

An elevated conveyor belt system, rising about six meters above ground, will be used to transport debris from the tunneling site to designated disposal zones. This method reduces dust and truck traffic in residential areas.

2. Resettlement and Rehabilitation Plan

On June 15, 2025, MMRDA issued a structured resettlement plan for approximately 572 affected households around Magathane and adjacent areas. Residents have been offered three options:

• One-time monetary compensation
• Permanent alternate housing (Borivali or Mira-Bhayandar)
• Rehabilitation through Slum Rehabilitation Authority (SRA) schemes, including interim accommodation

This community-focused approach has helped minimize protests and delays.

3. TBM Progress and Tunneling Milestone

The first TBM, named S-1400A, successfully passed factory acceptance in February 2025 and arrived at the site by April. Excavation began before the onset of monsoon 2025. In total, four TBMs will be deployed to bore through Mumbai's rocky terrain.

Each tunnel will have three vehicular lanes with cross-passages every 300 meters, enabling emergency evacuation and ensuring safety compliance.

4. Eco-Sensitive Execution and Safety Measures

Despite its location under an ecologically sensitive zone, the tunnel has been designed to avoid any surface-level impact on the SGNP. Environmental clearance conditions have been followed strictly:

• Tunnel depth maintained at 23 meters below ground
• No trees felled within SGNP
• Advanced Saccardo ventilation system for air circulation
• Fire detection and suppression systems
• Intelligent transport management systems and CCTV monitoring

These features align the project with international safety and sustainability standards.

Benefits of Thane-Borivali Tunnel, Moneycontrol

Working Professionals

The tunnel offers faster access between commercial hubs in the eastern and western suburbs, reducing commute fatigue and improving work-life balance.

Families and Daily Travelers

Improved connectivity will support school runs, hospital visits, and day-to-day travel with greater convenience.

Logistics and Commercial Transport

Businesses will benefit from faster and more predictable delivery routes, improving supply chain efficiency.

Emergency and Medical Services

The shorter cross-city commute will enhance response times for ambulances, fire brigades, and police forces.

Environmental Stakeholders

With no ecological disruption to SGNP and significant emission reductions, the tunnel sets a benchmark for environmentally conscious infrastructure.