Dr. Rakesh Kumar Khali. Vice President- Operations (Tunnel & UG Works), G R Infraprojects Limited, and Prof Dr Sandeep Potnis, Professor and Head - Tunnel Engineering Program, MITWPU, highlight the issues and challenges faced during transportation and installation of a TBM and the universal geological surprises faced by the working team during the construction of head race tunnel of Vishnugad-Pipalkoti HE project after starting the boring and the remedial measures adopted. They also discuss the analysis and design of the large sized Adit bored in the extremely poor rock conditions and the innovative measures undertaken for its construction.