135-Year-Old Bridge Over Mithi River Replaced, Marking End Of Cast Iron Era In Indian Railways

Western Railway completed the reconstruction of the last remaining railway bridge built on cast iron (CI) pile foundations—Bridge No. 20 over the Mithi River between Mahim and Bandra stations in Mumbai on Sunday. The 135-year-old bridge, originally constructed in 1888, marks the end of an era in railway infrastructure and the beginning of a safer and more resilient network.

This was the last remaining CI pile bridge on the Indian Railways. The Cast Iron Pile Bridge was replaced with a robust reinforced cement concrete foundation. According to WR, this critical infrastructure upgrade was carried out in two meticulously planned phases, with the final phase completed on Sunday, April 13, 2025.

The CI pile, also referred to as a screw pile, had served its purpose for over a century. However, due to its inherent structural limitations—most notably, the risk of sudden collapse without prior warning—Railway Board had adopted a policy decision to replace all such foundations across the network.“The reconstruction enhances safety for running trains, especially in the densely used Mumbai suburban section,” a senior Western Railway official stated.

“CI pile foundations are outdated and potentially dangerous. Replacing them with reinforced cement concrete foundations significantly reduces the risk of structural failure.”The reconstruction work was first sanctioned for the south-end abutment and began in December 2024. The first phase, involving major technical efforts like de-launching existing steel girders and shifting OHE (overhead equipment) wires on four suburban lines, was completed on January 26, 2025.

The project required delicate handling to ensure minimal disruption to Mumbai’s high-frequency local train services."The biggest challenge was executing the work without affecting suburban traffic," the official added. "There was no direct approach to the bridge site, so we had to use stabling lines to move machinery and materials. Most operations were carried out during night blocks to minimize commuter inconvenience."

The final phase, successfully completed in two mega night blocks on April 11–13, involved dismantling the CI pile-based abutments, rebuilding them with modern materials, and reinstalling girders along with electrical and signaling equipment.

The operation utilized heavy machinery including a 700MT crane, JCBs, tamping machines, tower wagons, and over 150 personnel. Another major challenge was constructing coffer dams on both east and west sides of the Mithi River, which experiences bi-directional tidal flow from the coastal region.

Awarded under EPC (Engineering, Procurement and Construction) mode in March 2023, the project has now been completed well before the onset of the monsoon, as committed by Western Railway."With this reconstruction, Indian Railways has officially eliminated all remaining cast iron pile bridges from its network, setting a new benchmark for safety and reliability in railway infrastructure" said an official of WR.

When asked about the imidiate benefits to commuters, an official stated that the new system will also help trains handle jerks more effectively. This means that after the bridge is rebuilt, passengers will experience fewer jolts while crossing it, resulting in a smoother and more comfortable journey.

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