IIT-Bombay and CME Pune Successfully Develop Lightweight Modular Bunkers Using Prefabricated UHPC Blocks for Rapid Deployment

In a significant breakthrough that could redefine how India fortifies its frontline troops, researchers at the Indian Institute of Technology (IIT) Bombay have developed a revolutionary modular bunker system designed to offer superior protection against modern threats like drones, precision-guided munitions, and missile strikes.

Developed over nine years of intensive research, this initiative has emerged at a time when India’s defence preparedness is under renewed scrutiny. The recent Indo-Pak conflict, which saw drones carrying ammunition and missiles breaching Indian airspace, underscored just how vulnerable both soldiers and civilian infrastructure are to the evolving nature of warfare.

From Stone and Sandbags to Smart Concrete Engineering

Traditional bunkers—built with materials like stone, sandbags, cement, and wire mesh—have long served as permanent defensive positions. But their limitations are glaring: they’re time-consuming to build, logistically challenging to transport, and ineffective against today’s advanced firepower.

To address these gaps, a team led by Professor Manish Kumar from IIT Bombay, in collaboration with the College of Military Engineering (CME), Pune, created modular, prefabricated bunkers using ultra-high-performance concrete (UHPC). These structures were field-tested at the Mechanised Infantry Centre and School (MICS) in Ahilyanagar, under the leadership of Lt. Col Bharatbhushan More, building on foundational work initiated by Lt. Col Alok Dua.

Build-Anywhere Design: Portable, Scalable, and Battle-Tested

What makes these bunkers truly game-changing is their LEGO-like design. Each block weighs under 20 kilograms, requires no special tools or construction expertise, and can be assembled in hours—even under hostile conditions.

• Curved roof panels—a standout feature—are engineered to deflect aerial projectiles, unlike traditional flat slabs, which absorb direct hits.

• The modular structure allows bunkers to be scaled up or down depending on the threat level, by simply adding or removing interlocking blocks.

• No need for mortar or welding, allowing for rapid deployment and reusability.

These features offer a strategic edge in remote or high-risk regions where traditional construction would be either too slow or altogether impossible.

Real Combat Trials: Designed for War, Proven in the Field

During extensive trials, the modular bunkers were subjected to direct hits from real ammunition, including explosive and ballistic impacts. The results were striking:

• Curved roof elements delivered five times the resistance compared to flat concrete slabs of the same thickness.

• The shelters withstood multiple missile strikes without collapsing or compromising internal safety.

• Unlike traditional bunkers, these structures resisted spalling—the dangerous internal cracking that compromises protection—and minimized fragmentation risks to occupants.

Redefining Battlefield Infrastructure

In an era where threats can arrive silently via drones or explode on impact with laser-guided accuracy, India’s defensive infrastructure must evolve beyond sandbags and steel sheets. These modular bunkers signal a new era of agile fortification—infrastructure that moves with the troops, adapts to threats, and keeps pace with the fluid nature of modern conflict.

By fusing academic research with battlefield reality, IIT Bombay and CME Pune have delivered a solution that could save lives and enable quicker military responses in future conflicts. As the nature of warfare shifts toward speed, precision, and mobility, India’s defences must do the same.

The modular bunker system is not just a research project—it’s a blueprint for how nations can reimagine battlefield survivability in the 21st century.