Harsh Himalayan geology, minus 30°C temperatures posed biggest challenge: Design Director MEIL

Minamarg, Jun 9: The final breakthrough of the Zojila Tunnel marks the culmination of years of engineering efforts undertaken in one of the most hostile and geologically challenging terrains of the country.

Talking to Greater Kashmir on the sidelines of the breakthrough event on Tuesday, the Hyderabad-based Design Director Muhammad Rafi said the construction team had to overcome formidable challenges posed by the Himalayan geology, seismic vulnerabilities, extreme weather conditions, and constantly changing rock formations during the execution of the ambitious project.

“The biggest challenge was working in this type of geology and under such extreme temperatures. This is Himalayan geology where rock conditions keep changing, forcing us to repeatedly reassess and redesign the support systems,” he said.

The Zojila Tunnel, which will provide all-weather connectivity between Kashmir and Ladakh, is considered one of India’s most important infrastructure projects because of its strategic and economic significance.

Describing the tunnel as “an important project for the nation,” Rafi said the engineering team remained committed despite numerous obstacles encountered during the last 5 years.

“There were several design modifications. The tunnel design underwent changes four to five times as geological conditions evolved during excavation,” he said. “In a project like this, designs cannot remain frozen because the ground realities keep changing.”

Rafi said the project was executed in a highly-sensitive seismic zone, requiring engineers to factor in earthquake risks while preparing the structural design.

“We had to continuously monitor rock behaviour and revise support systems accordingly. Every design decision had to account for the seismic nature of the region,” he said.

Apart from the main tunnel excavation, Rafi said the construction of avalanche protection structures along different sections of the project also posed significant engineering challenges.

The extreme winter conditions at Zojila Pass, where temperatures can plunge to minus 30 degrees Celsius, further complicated construction activities.

Despite heavy snowfall and prolonged winter closures in the region, the project team ensured uninterrupted work by undertaking extensive pre-planning and stockpiling construction material well in advance.

“We used to stock material for nearly six months before winter. Once inside the tunnel, the working conditions are different from the outside environment, allowing construction activities to continue even during severe weather conditions,” he said.

About Tuesday’s breakthrough blast, Rafi said the exercise was aimed at achieving “daylighting”, a stage where excavation from both ends of the tunnel becomes visually connected.

“After today’s blast, the tunnel alignment appears continuous, though some work remains. It establishes through connectivity for further execution activities,” he said.

However, Rafi clarified that substantial work was “still pending before the tunnel can be opened for traffic.”

“The main lining, electromechanical systems, ventilation infrastructure, and other equipment installations are yet to be completed. It will take at least one-and-a-half years before the tunnel becomes fully operational,” he said.

Talking about the strategic importance of the tunnel, Rafi said it would provide immense benefits to the armed forces and civilian commuters by ensuring uninterrupted movement throughout the year.

“Currently, traffic often faces disruptions due to snow accumulation and harsh weather conditions. Once operational, this will provide all-weather connectivity and ensure movement without interruption. Its strategic importance is immense,” he said.

Meanwhile, MEIL executive Suchika Joshi, who has been associated with the project through years of construction, said the breakthrough represents the culmination of relentless effort under extreme conditions.

“Every second was a challenge,” Joshi said.

She recalled working through harsh winters, heavy snowfall, and sub-zero temperatures that often dropped below minus 30 degrees Celsius.

She said the project demanded extraordinary commitment from engineers, designers, workers, and management teams.

“I don’t think our engineers, directors, and design teams slept properly when this project started. What you see today is the result of countless sleepless nights,” Joshi said.

She said difficult terrain, unpredictable weather, and repeated machinery-related challenges forced teams to constantly adapt their plans and methods.

“Sometimes there were things that nobody knew would emerge. Only time revealed those challenges, and the company had to respond to them,” Joshi said.

She credited the project’s progress to coordination between MEIL, the NHIDCL, consultants, and government agencies.

Beyond its engineering significance, Joshi said the tunnel was expected to transform connectivity to Ladakh, which remains cut off by heavy snowfall for several months every year.

“This is not just a tunnel. It is important for the country’s security, for the Army, and for the people of Ladakh who often remain disconnected during winter,” she said.

Although the breakthrough allows excavation from both ends to meet, the tunnel is not yet ready for public traffic.

Officials said extensive finishing work, including concrete lining and installation of operational systems, must be completed before the tunnel can be opened.

“We are trying to deliver it to the nation as soon as possible,” Joshi said.

She said that the progress would continue.