Mumbai-Pune Expressway project, which includes Asia’s widest tunnels and 180-metre-tall bridge, likely to be ready in three months; it will be toll-free.
The missing link’s cable-stayed bridge, which hangs 100 metres above Tiger valley. PICS/By Special Arrangement
Motorists commuting between Mumbai and Pune can expect significant relief by May as the long-awaited Mumbai-Pune Expressway missing link nears completion. Once operational, the new stretch, which is being developed by Maharashtra State Road Development Corporation (MSRDC), will bypass the accident-prone ghat section, easing congestion and reducing travel time by approximately 30 minutes, offering a faster and smoother journey for commuters. It will be toll-free.
The recent traffic jam on the expressway became a major talking point, with many commuters criticising the authorities over the prolonged delay in clearing the congestion. The project comprises two tunnels, measuring 1.68 km and 8.87 km in length, and 23 metres in width — among the widest in the world — constructed by Navayuga Engineering Company. Additionally, two cable-stayed bridges, measuring 650 and 950 metres, were built by Afcons Infrastructure.
Special tech used
>> Models of the cable bridge tested in foreign countries
>> Water mist system in tunnels
>> Fire hydrant system
>> Supervisory Control and Data Acquisition software
>> Intelligent traffic management systems
>> SOS and emergency system
>> Surveillance cameras
>> Fire detector, linear heat detection system
>> Voice evacuation system in tunnels
>> Ventilation system in tunnels
>> Use of Doka formwork system for 180-m pylon construction
>> A cantilever form traveller for deck slab construction
>> Ultra-high-performance fibre-reinforced concrete girders
>> Epoxy asphalt modified concrete works
Official Speak
An MSRDC official
‘Work is underway to connect the two segments of the cable-stayed bridge. This is likely to be completed in the coming weeks. Once that is done, finishing works and road construction will commence. The entire stretch is expected to be completed by April or May, after which it will be opened to the public’
Benefits
>> Saves time and energy; improves safety for commuters
>> Smooth travel for commuters due to flat gradient
>> Seamless traffic flow
>> Prevents bottlenecks at toll plaza
>> No access for tankers and trucks carrying inflammable materials or gas
Challenges faced during project execution
Tunnel
Muck removal and disposal from excavated tunnels
Supplying oxygen to those working in tunnels
Mitigation of work in different rock conditions
Lonavala lake blasting work
Viaduct
>> Hilly terrain >> Wind pressure
>> Heavy rainfall in Khandala forest areas
>> Extensive blasting of rocks near live road
Deadlines missed
Before January 2026, MSRDC had announced multiple timelines for project completion
The initial target month for project completion was March 2024
Subsequently, January 2025 was projected
It was then advanced to March 2025
This was revised to September 2025
Later, the target completion month was pegged at December 2025
Time overun reasons
>> Special tests for the design of the bridge and main components were only conducted abroad, and slots were not available during the pandemic
>> Permits and forest clearance
>> Heavy rainfall in Khandala
13.3 km
Length of Mumbai-Pune Expressway stretch between Khopoli exit and Kusgaon
19 km
Distance between Lonavala and Khopoli exit
1.68 km
Length of tunnel I
8.87 km
Length of tunnel II
23.50 m
Width of each tunnel
1.6 km
Combined length of both viaducts
184 m
Height of tallest pylon of cable-stayed bridge
6 km
Distance shaved off thanks to stretch
30 min
Time saved by avoiding ghat section
180 m
Depth at which tunnel passes below Lonavala lake
5.86 km
Length of expressway being widened as part of project
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