Revolution: Western Railway Builds India’s First Steel Underpass at Udhna Station

SURAT: A historic chapter in Indian railway engineering is being written at Udhna railway station in Surat, where Western Railway has started work on the country’s first steel arch technology-based underpass. The ambitious project aims to complete a construction task that normally takes months within just six hours of railway block.

The Mumbai division of Western Railway, in collaboration with infrastructure giant Larsen & Toubro (L&T), has taken up this innovative pedestrian subway project to improve passenger safety and eliminate unsafe railway track crossings.

“This is not just a construction project but a major technological breakthrough. The work will demonstrate how modern engineering can reduce disruption to railway operations,” said Western Railway officials.

The biggest feature of the project is the use of a pre-fabricated steel tunnel. During the scheduled block period, a section of the railway track will be removed, a pit will be prepared using advanced machinery and the ready-made steel tunnel will be installed directly with the help of cranes.

Western Railway Mumbai Division DRM Pankaj Singh explained that traditional underpass construction methods, including the ‘cut and cover’ method and box pushing technology, require lengthy preparation and can impact train movement for months.

“Earlier methods required extensive excavation and track protection arrangements. With this new technology, we will remove around 10 metres of track and install the pre-built steel tunnel within hours,” Singh said.

The steel arch subway has been developed through joint research and engineering efforts by Indian Railways and L&T. The structure uses 6 mm special-grade steel plates and has been protected with a four-layer anti-corrosive coating to ensure durability for decades.

Engineers faced major challenges at Udhna station due to its heavy rail traffic and complex underground infrastructure. The station handles trains towards Jalgaon, Bhusawal and eastern parts of India, making the execution of such an experiment highly challenging.

Thousands of power cables, signalling wires and communication networks run beneath the station area. Any damage could disrupt railway operations on the busy Mumbai-Surat route. The L&T team carried out detailed planning and scientific protection measures to safeguard these systems.

The project is being executed on Line No. 6 towards Jalgaon, with railway authorities allowing only a six-hour traffic block from noon to 6 pm.

The new underpass is expected to provide safer movement for thousands of passengers, workers and local residents. It is also part of Indian Railways’ broader plan to prevent accidents caused by illegal track crossings.

With this project, Western Railway aims to set a new benchmark in railway infrastructure development and introduce faster, safer construction techniques across the country.