Recently, a viral video appeared on social media showing the 'Vande Bharat' train in orange and black livery looking very impressive as it passes through tunnels amidst dense forests and fog in the mountains. This video was shot by a drone during a trial run through the Western Ghats between Bangalore and Mangalore. Although the journey of the train surrounded by natural beauty looks magnificent, it is backed by complex engineering work and thorough safety testing by Indian Railways.
This section in the Western Ghats of Karnataka state is known as the Sakleshpur-Subrahmanya Road or Shiradi Ghat section. The length of this section is about 55 kilometers, but operating the 'Vande Bharat' here proved to be a challenging task for the railway. This route features 57 tunnels, 226 bridges, 108 sharp curves, and a height change of 1 meter for every 50 meters of horizontal distance (ascent or descent). Furthermore, a significant part of this section is prone to landslides.
Electrification of this sector began in December 2023 and was completed in December 2025. Overhead electrical equipment was installed over approximately 55 kilometers, and 5 switching stations were prepared. The total cost of this project amounted to about 93.5 crore rupees. Since some places in this section are difficult to access even for road transport, the railway had to deliver construction materials and equipment to the train during the electrical installation work. The mountainous landscape, tunnels, and the monsoon season significantly complicated the entire project, with work inside the tunnels becoming one of the most serious tasks.
Challenges of operating Vande Bharat on this route
After the completion of electrical installation work, movement of freight and passenger trains on this route was permitted; however, additional safety requirements arose for the 'Vande Bharat'. The 'Vande Bharat' is a self-propelled set, meaning it does not require a separate locomotive for traction; instead, motors and mechanisms are installed under the coaches and generate the necessary energy for movement. Nevertheless, considering the steep gradients in the Western Ghats section, engineers deemed it necessary to equip the 'Vande Bharat' with an Automatic Emergency Braking System (AEBS). Initially, existing 'Vande Bharat' sets did not have this system. The option of adding a separate locomotive to the set was considered, but the railway opted for installing AEBS. Thus, before commencing operation of the train on this difficult route, necessary changes were made to its braking and safety systems.
Testing the entire process, not just the train
The trial run of the 'Vande Bharat' on this route has already been completed. However, due to rain and difficult road conditions, the train moved at a controlled speed. Mechanical, electrical, operational, and safety services of Indian Railways continuously monitored the trial runs of the 'Vande Bharat'. Research Designs and Standards Organisation (RDSO) conducted performance evaluations of the train. During the tests, not only the operational condition of the train but also its behavior in emergency and operational situations was checked.
The final decision on starting the 'Vande Bharat' service between Bangalore and Mangalore remains with the railway. In the current test runs, one route lasted about 8.5 hours. Potential stops included stations such as Hassan, Sakleshpur, and Subrahmanya Road. The final decision regarding the route, stops, and schedule will only be made after receiving all necessary safety clearances. Previously, there were plans to extend the 'Vande Bharat' Bangalore-Mangalore line to Madgaon, but the final decision depends on the Railway Board. Currently, the railway's main focus is on ensuring the safe operation of the train on this challenging mountain section.
