Orange Line (Mumbai Metro)

Line 5

In March 2016, the Mumbai Railway Vikas Corporation proposed building an elevated suburban rail corridor from Kurla to Bhiwandi via Thane at an estimated cost of ₹7,500 crore (US$790 million).^[1] On 19 October 2016, the Mumbai Metropolitan Region Development Authority (MMRDA), headed by Chief Minister Devendra Fadnavis, approved a plan to build 24 km metro rail line from Thane to Kalyan via Bhiwandi. The line would have 17 stations and was estimated to cost ₹8,416 crore (US$890 million). A future extension to Taloja was also proposed.^[2] The project was approved by the Maharashtra Cabinet on 24 October 2017.^[3] The detailed project report for Line 5 was prepared by a consortium of D’Appolonia and Tata Consultancy Services (TCS).^[4]

The project received Coastal Regulation Zone (CRZ) clearance from the Maharashtra Coastal Zone Management Authority (MCZMA) in June 2017. A 3.9 km stretch of Line 5 passes through CRZ areas along the Kasheli bridge crossing the Ulhas river, and also near Durgadi Fort.^[5] The MMRDA utilized a drone to carry out survey work for Line 5. The drones were fitted with 360 degrees camera that provide up to 3 millimetres (0.12 in) accuracy. The aerial survey takes less time than a regular survey, achieves greater accuracy and helps protect against false claims for compensation.^[6]

Two potential routes were proposed for Line 5's alignment. The first route passed through more densely populated areas of Thane, Bhiwandi and Kalyan, while the second route passed through their outskirts. The Bhiwandi-Nizampur City Municipal Corporation demanded that the first route be taken in order to benefit more people. The MMRDA began carrying out survey work for the line by December 2017. The same month, the MMRDA stated that it had chosen the first route as the alignment for Line 5.^[4] Survey work was interrupted due to protests by some shopkeepers and residents of Bhiwandi.^[7]

Prime Minister Narendra Modi laid the foundation stone for Line 5 in Kalyan on 18 December 2018.^[8][9] In June 2019, the MMRDA stated that it had decided to start Line 5 from Kapurbawdi station, which would serve as an interchange with Line 4. The original plan had been to build a separate station 500 metres away from the Line 4 station.^[10] Systra France, Systra MVA Consulting (India) Pvt Ltd and Consulting Engineers Group Ltd were appointed as general consultants for the project on 6 August 2019.^[11][12]

In November 2021, the MMRDA decided to construct the depot for Line 5 at Kasheli in Thane, instead of the original plan to build it at Kongaon MIDC,^[13] after local residents opposed the plan.^[14] The agency invited tenders for the construction of the depot on 20 October 2022.^[15] Ritwik Projects Pvt. Ltd. was awarded a ₹589 crore (US$62 million) contract to build the Kasheli depot in September 2023.^[16][17]

Underground section

In December 2017 following requests from the Bhiwandi-Nizampur city municipal corporation the line was altered to bypass through core areas of Thane, Kalyan, and Bhiwandi. Soon however, locals in Bhiwandi began protesting over the line going through the area.^[18] Later in 2019, MMRDA released the tenders for the line through package CA-28. However, it was later announced the package will only include the section from Kapurbawdi to Bhiwandi with the section from Bhiwandi to Kalyan APMC being placed on hold due to disagreements in alignment. In February 2020, State Urban Development Minister Eknath Shinde stated that he had requested the MMRDA to alter the alignment of Line 5 to bypass several religious sites, and also to extend the line to Shahad. MMRDA Metropolitan Commissioner R.A. Rajeev stated that the agency would finalize a new route.^[19] In March 2022, Shinde stated that a stretch of the line passing through Bhiwandi would be underground in order to avoid affecting 735 buildings.^[20] The State Urban Development Department approved building a 3 km section of Line 5 between Dhamankar Naka and Temghar underground on 6 June 2023.^[21] The underground section is estimated to increase the cost of the project by ₹1,727 crore (US$180 million).^[22]

Line 12

The MMRDA approved an extension of Line 5 from Kalyan to Dombivali and Taloja on 21 November 2018. The elevated corridor would be 20.75 km long with 17 stations and was estimated to cost ₹5,865 crore (US$620 million). The extension is called Line 12.^[23] The detailed project report for the extension was prepared by the DMRC.^[24] The extension was approved by the State Government on 23 July 2019.^[25][26]

In March 2023, the MMRDA proposed a 7.7 km extension of Line 5 from Kalyan to Ulhasnagar.^[27][28]

Tendering

Construction of the 24.9 km line was divided into two phases. The first phase is a 11.68 km section between Kapurbawadi in Thane and Dhamankar Naka in Bhiwandi. The second phase is a 11.8 km section between Bhiwandi and Kalyan, which includes a 3 km underground section between Dhamankar Naka and Temghar.^[30]

Line 5A – Thane to Bhiwandi

In January 2019 MMRDA invited bids for the construction of the line from Kapurbawdi to Bhiwandi. The package was named CA-28 and included the construction of a 12.811 km elevated viaduct, and seven elevated stations at Kapurbawdi, Balkum Naka, Kasheli, Kalher, Purna, Anjur Phata, and Dhamankar Naka. Three companies made bids for the package, which were Larsen & Turbo, NCC, and Afcons infrastructure. On January 7, 2020 MMRDA awarded a Letter Of Appointment or LOA to a Afcons Infrastructure for an approximate cost of Rs. 802 crore.^[31][11] Construction began in February 2020.^[32] The first pier cap was erected near Balkum in Thane on 22 January 2021.^[33]

One construction worker died after being electrocuted at a construction site in Thane on 25 May 2021. Police registered first information reports against the site supervisor and a crane operator charging them with "causing death by negligence".^[34] The first marine pile cap was placed on Kasheli Creek in October 2021. The metro viaduct crossing the Kasheli creek is 550 metres long, and consists of 13 piers, of which 9 are in the creek and 5 are on land.^[35] The viaduct is 15 metres above the water and has 13 spans each with a length of 42.3 metres.^[36]

In 2021, five construction workers were injured by falling iron rods at the site.^[37] The MMRDA said that 65% of the work had been completed in November 2022,^[38] and 70% in December 2022 including 64% of work on stations.^[39] Construction of the 550 metre viaduct over Kasheli Creek was completed on 22 January 2023, taking a total of 123 days. In the same month, Afcons stated that it completed 9.3 km of viaducts.^[36][40] The MMRDA stated that 79% of civil work on the first phase had been completed on 6 June 2023.^[41]