• Project Name: Coastal Road Project: Undersea Tunnel Construction

Project Overview

The Brihanmumbai Municipal Corporation (BMC) embarked on the Coastal Road Project in Mumbai, which required the construction of a 3.45-kilometre twin undersea tunnel starting from Priyadarshini Park and ending at Girgaum Chowpatty. Larsen & Toubro (L&T) was awarded the construction contract, involving the use of the largest Tunnel Boring Machine (TBM) ever in India, named Mavala, with an excavation diameter of 12.19 meters.

Client Challenges

Due to the ongoing COVID-19 pandemic, L&T faced significant delays in their project schedule. Their initial linear plan involved digging a 25-meter deep shaft before assembling the TBM and gantries inside. This method was not only time-consuming but also costly, requiring heavy crane solutions and extensive land preparation near the sea.

FWPL’s Involvement

Freight Wings Pvt Ltd (FWPL) was entrusted with the critical task of executing the project. The scope of work included:

  • Transportation, Skidding, and Launching: Fully assembled TBM shield (12.5 m length, 12.2 m diameter, 1500 MT) and three backup gantries (350 MT each, 26 m length, 8 m width, 9 m height).
  • Inclining, Tailing, and Positioning: Cutter head section of the TBM (350 MT, 12.5 m diameter, 3.5 m width).
  • Launch Operations: All components were to be launched into a 25-meter deep shaft.


Solution and Execution

FWPL provided an innovative solution to overcome the challenges faced by L&T, allowing for multitasking and expediting the project timeline. Key aspects of the execution included:

  1. Transportation: The assembled TBM shield (1500 MT) was transported using 4 rows of 2.4-meter wide Self Propelled Modular Transporters (SPMTs) from the assembly area to the launch ramp.
  2. Lowering: The shield was lowered into the launch ramp using FWPL’s 2500 MT capacity customized Mega lift Strand Jack system.
  3. Specialized Equipment Used:
    • 16 digitally synchronized 345 MT capacity strand jacks powered by power packs.
    • 2 power packs and 56 axle lines of SPMTs.
    • 154m heavy-duty skidding girders with skidding shoes and Teflon pads.
    • 2500 MT capacity Mega-Lift System & Tailing System & Modular Tower Lift System.


FWPL’s innovative approach and timely execution allowed L&T to complete the assembly and lowering of the TBM in record time despite strict COVID-19 restrictions. This achievement was a testament to FWPL’s expertise in heavy lifting and transportation, showcasing a true “Made in India” effort.


FWPL’s involvement in the Coastal Road Project underscores their capability to handle complex and large-scale infrastructure projects. Their ingenious solutions and precise execution not only met but exceeded client expectations, significantly contributing to the progress of the Coastal Road Project.