Polihali Transfer Tunnel, Lesotho Highlands Water Project Phase II

A 34 km underground tunnel forming a critical link between the Polihali and Katse reservoirs, strengthening long-term water security across Southern Africa.

Client

Lesotho Highlands Development Authority (LHDA)

Project date

The Polihali Transfer Tunnel is one of the most technically complex elements of the Lesotho Highlands Water Project Phase II, yet it remains largely unseen beneath the country’s mountainous highlands.

The opportunity

Stretching approximately 34 km underground, the tunnel enables the transfer of water between the new Polihali Reservoir and the existing Katse Reservoir, reinforcing a strategic water system that supports both regional water supply and hydropower generation.

Zutari is contributing to this major infrastructure component through its role in the Metsi a Senqu-Khubelu Consultants Joint Venture, responsible for design and construction supervision. The project is being delivered by the Lesotho Highlands Development Authority on behalf of the governments of Lesotho and South Africa.

Delivering a tunnel of this scale beneath rugged, high-altitude terrain presents significant technical, logistical and environmental challenges. Geological variability, strict safety requirements and the need to protect sensitive mountain ecosystems demanded careful coordination across disciplines and stakeholders. Beyond engineering complexity, the project offered an opportunity to strengthen regional collaboration, build local technical capacity and support long-term economic development in Lesotho, while reinforcing Southern Africa’s water security system.

What we did

The Polihali Transfer Tunnel comprises a five-metre-diameter segmentally lined tunnel excavated using a hard-rock tunnel boring machine. In addition to the main tunnel, the project includes intake works and a gate shaft upstream of the 165 m high Polihali Dam, outlet works and a lake tap into the Katse Reservoir, as well as access tunnels and associated operational infrastructure.
Zutari’s role within the MSKC Joint Venture involves detailed engineering design and construction supervision, ensuring safety, quality and environmental stewardship throughout implementation.

The work requires close integration between civil, geotechnical, hydraulic and construction teams, supported by rigorous planning and monitoring processes.
The project team also addresses broader programme considerations, including environmental management, stakeholder engagement and alignment with the long-term operational requirements of the Lesotho Highlands Water Project system.
The Polihali Transfer Tunnel extends for approximately 34 km beneath Lesotho’s highlands, linking the Polihali and Katse reservoirs within the LHWP system.

The outcome

Once completed, the Polihali Transfer Tunnel will play a vital role in the long-term operation of the Lesotho Highlands Water Project Phase II. Although largely invisible on the surface, it will ensure the efficient and reliable transfer of water across the system, supporting water supply, hydropower generation and economic development across the region.

The project demonstrates how large-scale underground infrastructure can be delivered through careful coordination, technical precision and strong partnerships between clients, engineers and contractors. As construction progresses, the tunnel stands as a powerful example of the engineering innovation required to deliver infrastructure of true regional significance.


The Polihali Transfer Tunnel is one of the most technically demanding components of the project, requiring careful coordination across engineering disciplines to ensure safety, quality and long-term value.

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