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Driver fatigue and brake failure behind Mumbai-Pune Expressway crash

Updated on: 28 July,2025 07:20 AM IST  |  Mumbai
Amarjeet Singh | mailbag@mid-day.com

During probe, trailer driver tells cops he suddenly got a severe headache and lost control of vehicle, leading to deadly pile-up

Driver fatigue and brake failure behind Mumbai-Pune Expressway crash

The trailer that was involved in the accident. PIC/BY SPECIAL ARRANGEMENT

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A day after the horrific pile-up on the Mumbai-Pune Expressway that killed one, injured 17 people and left several vehicles completely wrecked, new findings have highlighted a familiar set of dangers — brake failure, driver fatigue, and poor gear control in the Khandala ghat section.

The trailer driver, Rajesh Kumar Patel, 29, who is now in custody at Khopoli police station, told police officials that he experienced severe giddiness and a pounding headache moments before losing control of the vehicle. “Mujhe chakkar aa raha tha, sir mein dard ho raha tha… gaadi rok nahi paaya (I was feeling dizzy, my head was hurting… I couldn’t stop the vehicle).” he reportedly said during interrogation.


Swapnil Patil, assistant police inspector, highway police, said initial findings confirm that the trailer’s brake system failed, causing the heavy vehicle to swerve left and ram approximately 25 vehicles before finally halting. The driver was not under the influence of alcohol or any other drugs, but the police are investigating potential mechanical lapses and human negligence.



The trailer that was involved in the accident; (right) a Mercedes car damaged in the pile-up
The trailer that was involved in the accident; (right) a Mercedes car damaged in the pile-up

“He could not engage a lower gear in time, which worsened the situation,” an official added. At MGM Hospital in Kamothe, where all 17 victims were rushed post-crash, Medical Superintendent Dr Kuldeep Salgotra, said, “Out of 17, five are ready for discharge, two patients remain critical and on ventilators, and the remaining are stable.” One of the critically injured is a woman whose family requested she be shifted to Pune for treatment, but the hospital had to decline the transfer due to her extremely unstable condition.

Highway authorities have also shed light on a dangerous habit among some drivers. “When vehicles descend from Lonavala and reach the Khandala ghat, many shift to neutral gear to save fuel or reduce engine load. Despite warning signboards, rumble strips, and gear control advisories, some ignore safety protocols,” said a senior highway official.

He added that a similar incident occurred in March, when a heavy vehicle thudded into two cars after a brake failure on the same stretch. “Running on neutral, poor gear control, and brake failure is a deadly combination,” he warned. A police investigation is underway, and transport safety experts have once again demanded stricter enforcement of highway driving protocols, especially for heavy commercial vehicles.

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