The Klang Valley Mass Rapid Transit (KVMRT) project involves the construction of an urban passenger transport system, i.e., Mass Rapid Transit (MRT) system, together with the existing urban rail network, will form the backbone of the public transport system in the Greater Kuala Lumpur/Klang Valley region in Malaysia. The first MRT line implemented is the 47 km Kajang Line, of which 9.5 km is underground tunnels with seven underground stations. Construction of the line began on 8 July 2011 and achieved the full line opening on 17 July 2017. The second MRT line-Putrajaya Line-began fully operations on 16 March 2023, stretches from Sungai Buloh to Serdang and ends at Putrajaya for a length of 57.7 km, of which 13.5 km is underground tunnels with 10 new underground stations. Like all other metro underground stations/tunnels designed as part of the urban city, the KVMRT underground construction faces challenges from a technical (engineering design and construction) as well as social (environmental and land related) point of view. Needless to say, underground construction in Klang Valley is intensified with the inherent geotechnical challenges presented by complex ground conditions ranging from hard granite, heterogeneous Kenny Hill formation and extreme karstic limestone with fully developed weathered profiles to soft recent deposits including alluvium and mine tailing that is under-consolidated in places due to past mining activities. The development of this large-scale infrastructure project has not only opened up tremendous works and new frontier for tunnelling and geotechnical engineering in Malaysia, but it also provided a wealth of information of unique geotechnical challenges/accomplishments as well as technology breakthrough and design innovation in underground engineering. This article discusses some aspects of geotechnical challenges and interesting lessons learnt as well as numerous innovations embedded into this highly complex urban underground construction project.