The Rail Vikas Nigam Limited (RVNL) India, a public sector enterprise set up as a wholly owned government company, is developing various railway projects in the Himalayan corridors. In this project, the construction of tunnels T11, T12 and T13, bridges and formation work from chainage 32 + 100 to 39 + 900, including slope protection works, earthwork in cutting and filling, development of the station, and allied works in connection with Bhanupali–Bilaspur–Beri New Railway Line in district Bilaspur of Himachal Pradesh State, India. The paper describes the challenges faced in tunnelling in the lower Himalayas which is difficult due to its variable rock type and low cover. Tunnelling in this rock mass results in constant changes of in-situ stress state due to water conditions and very loose material resulting in landslides at valley regions, property damage, loss of life and high cost. This study assesses the primary support system of the Bhanupali–Bilaspur–Beri package-4 railway tunnel project by the Convergence-Confinement method. A flexible tunnel support design and optimisation are used after continuously assessing Rock Mass Rating and ground type. All tunnel support systems were analytically determined using the Cv–Cf method. The results of elastic and plastic deformation (Hoek–Brown failure criterion) of support systems are compared to the actual critical internal pressure which shows that the recommended support systems can stabilise the underground excavations.