In a major achievement for India’s first bullet train project, the National High-Speed Rail Corporation Limited has successfully launched a 40-metre-long prestressed concrete box girder near Sakhare village in Dahanu. Weighing nearly 970 metric tonnes, the girder is the heaviest of its kind ever installed in the country. It was cast using 390 cubic metres of concrete and 42 tonnes of steel.
This full-span girder is part of the Mumbai to Ahmedabad High-Speed Rail Corridor. The method used avoids construction joints, which improves the strength of the elevated track and speeds up construction nearly ten times faster than traditional segmental methods.
Indian-made machinery, including bridge-launching gantries, straddle carriers, and girder transporters, was used to lift and place the girder with high precision. This shows India’s increasing self-reliance in building complex rail infrastructure. The 508-kilometre bullet train corridor is about 90 percent elevated. As of May 2025, 300 kilometres of viaducts have been completed, with over 257 kilometres built using the full-span method.
This girder marks the first major installation in the Maharashtra section, following several similar launches in Gujarat since 2021. To support this, more than 13 casting yards have been set up along the route, equipped with modern concrete batching plants, steel rebar jigs, cement silos, and quality control labs.
The construction method is not only faster but also supports sustainability. It reduces emissions from machinery and labour and creates stronger structures that need less maintenance over time. These efforts align with India’s goals for eco-friendly urban and intercity transport systems.
However, challenges remain. In March 2025, a gantry skid incident near Ahmedabad disrupted nearby rail traffic. While there were no injuries and normal operations resumed within 24 hours, the event highlighted the need for strict safety standards and reliable equipment.
More full-span installations are planned, including for river bridges, tunnels, and stations. With each milestone, the bullet train project shows how India is using innovation, safety, and local expertise to build world-class high-speed rail.
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