A 12.24 km long tunnel between Maroshi and Ruparel College is being excavated by tunnel boring machine (TBM) to improve the water supply system of Greater Mumbai, India. In this paper, attempt has been made to establish the relationship between various litho-units of Deccan traps, stability of tunnel and TBM performances during the construction of 5.83 km long tunnel between Maroshi and Vakola. The Maroshi–Vakola tunnel passes under the Mumbai Airport and crosses both runways with an overburden cover of around 70 m. The tunneling work was carried out without disturbance to the ground. The rock types encountered during excavation are fine compacted basalt, porphyritic basalt, amygdaloidal basalt, pyroclastic rocks with layers of red boles and intertrappean beds consisting of various types of shales. Relations between rock mass properties, physico-mechanical properties, TBM specifications and the corresponding TBM performance were established. A number of support systems installed in the tunnel during excavation were also discussed. The aim of this paper is to establish, with appropriate accuracy, the nature of subsurface rock mass condition and to study how it will react to or behave during underground excavation by TBM. The experiences gained from this project will increase the ability to cope with unexpected ground conditions during tunneling using TBM.