India's Rs 1.08-trillion bullet train project is setting new benchmarks

A raft of cutting-edge technologies is being used to speed up project completion

India’s Rs 1.08-trillion bullet train project, whose first trial run — between Surat and Bilimora in Gujarat — is due in August 2026, is setting new benchmarks during construction through the use of cutting-edge technologies, from augmented reality (AR) and virtual reality (VR) to internet of things (IoT)-related machinery, and monitoring with light detection and ranging (LiDAR) and drones.

Executed by the state-run National High Speed Rail Corporation (NHSRCL), the project is based on Japan’s Shinkansen technology and the train will be embedded with the digital Shinkansen automatic train control system, with a special braking mechanism to prevent collision and overshooting of stations. 
 

Engineering major Larsen and Toubro (L&T), which won multiple bids for the project, including the country’s largest-ever government-funded civil contract of nearly Rs 25,000 crore for the design and construction of the 237-km Gujarat segment, is leading the technology revolution in the construction phase.
 

The first bullet train route will be Ahmedabad-Mumbai, and a top speed of 320 km per hour will ensure the 508-km distance is covered in three hours. The route covers Maharashtra (155.76 km), the Union Territory of Dadra and Nagar Haveli (4.3 km), and Gujarat (348.04 km), with 12 stations along the corridor.
 

The Mumbai-Ahmedabad High Speed Rail (MAHSR) project has achieved over 33 per cent physical progress in Gujarat and 14 per cent in Maharashtra. According to government data, of the 352-km elevated viaduct, about 257 km of piling, 180 km of foundation, 155 km of piers and 37 km of girder launching have been completed in Gujarat and Dadra and Nagar Haveli.
 

Unique technique

A unique construction technique will be used in India for the first time — Shinso piles. These will be deployed in areas where the alignment runs next to existing rail tracks, where the foundation cannot be very wide and heavy machinery cannot be used. More than 100 Shinso piles are expected to be constructed along the corridor.

The MAHSR project’s progress is being monitored through drones and LiDAR — a first in India — because of their high accuracy. “This technique uses a combination of laser data, GPS data, flight parameters and actual photos to give accurate survey data. This data is then used in designing the alignment of the high-speed rail corridor”, says an NHSRCL official.

L&T is using radio frequency identification (RFID), which provides an analytical report on the consumption pattern of different assets on-site. Apart from enabling objective data-driven decisions, the use of RFID also helps reduce pilferage.
 

To expedite construction of the viaduct, NHSRCL has opted for full-span girders (each 40 metres long), which can be erected seven times faster than segmental girders. Full-span launching equipment used by L&T — the straddle carrier and the girder transporter — have been designed and manufactured in India for the first time.
 

“To transport heavy machinery, we use special equipment such as straddle carriers and girder transporters. The straddle carrier has 80 tyres and the girder transporter 216 tyres. It saves eight to 10 man-hours daily in monitoring the tyre pressure of special equipment. It will save 8,000-10,000 man-hours overall. It avoids the risk of tyre failures on the viaduct while carrying 1,100-tonne segments, augmenting safety standards significantly”, says a source. 
 

Data analytics models
 

With the data generated from IoT devices of plant and machinery covering over 500 machines, data analytics models help in optimal utilisation of the assets deployed by L&T. “The operation of the assets is being continuously monitored, and any asset that is lying idle, or not being used as per standard, is removed from the site, saving unnecessary hiring and maintenance costs. IoT-isation has also helped in the reduction of diesel consumption,” the source adds.
 

The company is also using building information modelling (BIM) right from conceptual presentation to detailed architecture, quantification, service integration, building monitoring, post-construction and other performance-enhancing applications. BIM’s integrated process enables exploration of a project’s key characteristics — both physical and functional — digitally, even before it is built. BIM is used to plan and monitor the construction of bridges and stations.

Furthermore, worker safety and productivity are monitored through CCTV-enabled image analytics. This enables quick detection of violations such as the absence of safety jackets, helmets, face-shields, and safety shoes. Supervisors are immediately notified so that necessary corrective action can be taken. Image and video analytics are also used to assess worker productivity and adherence to procedures, quality standards and schedules. 
 

L&T also uses an AR-based application to make workers aware of safety procedures. Moreover, VR-based systems are being developed to train them to work in different conditions. In addition, an application called Torq is used to monitor and rectify any quality-related issue at work sites. 
 

According to the NHSRCL, 99.17 per cent of the land for the project has been acquired — 98.91 per cent in Gujarat, 100 per cent in Dadra and Nagar Haveli, and 99.75 per cent in Maharashtra. Implementation was affected by a delay in land acquisition in Maharashtra and consequent delays in the finalisation of contracts, as well as by the Covid-19 pandemic.
 

The final anticipated costs and timeline, says NHSRCL, can be assessed only after the completion of land acquisition and the finalisation of all contracts and associated timelines. However, the use of new-age technologies is expected to fast-track the project and help it meet all timelines.