A major traffic gridlock hit the Mumbai-Pune Expressway after a tanker carrying highly inflammable propylene gas overturned near the Khandala Ghat section on Tuesday evening. Gas leakage from the damaged tanker forced authorities to shut down the Mumbai-bound carriageway and adopt extreme safety measures to avert a possible explosion
Massive congestion on the Mumbai-Pune Expressway after a gas tanker overturned in the Khandala Ghat section on Wednesday. Pics/PTI
A massive traffic gridlock was reported on the Mumbai-Pune Expressway on Tuesday and Wednesday after a tanker carrying propylene gas — a highly inflammable industrial chemical — overturned near the Khandala Ghat section close to the Adoshi Tunnel on Tuesday at 5 pm. The accident led to a complete shutdown of traffic on the Mumbai-bound carriageway as authorities rushed to prevent a possible explosion following a gas leak from the damaged tanker.
The leakage posed a serious safety threat, forcing emergency agencies to adopt an extremely cautious approach in dealing with the incident. Traffic on both the expressway and the old Mumbai-Pune highway remained severely affected for several hours, leaving thousands of commuters stranded. Traffic movement within Pune and Mumbai city areas was also impacted due to the prolonged congestion.
What happened
Chemical expert Dhananjay Aatmaram Gidh, who has handled over 400 similar gas leakage incidents, told mid-day that the situation required extreme caution. “When I received the call about the leakage, I was in Manchar. The tanker walls had been damaged, and our first priority was to secure them. Along with other officials, we ensured the damaged portions were stabilised. Two tankers were brought in to decant the leaked gas, while a third tanker was on the way,” he said, adding that this was the status as of 4.30 pm on Wednesday.
Vehicles stuck in a traffic jam on the Mumbai-Pune Expressway after a gas tanker overturned in the Khandala Ghat section. Pics/PTI
Gidh explained that propylene is as flammable as, and in some conditions more hazardous than, LPG, particularly when leaked under pressure in open or confined spaces. Due to the volatile nature of the gas and structural damage to the tanker, the decanting process had to be carried out slowly, significantly delaying road clearance.
“Once the decanting process is completed, the overturned tanker will be removed and traffic restored. However, the operation may continue till late night,” he said. Experts present at the site added that intense afternoon heat further complicated operations, forcing teams to temporarily halt work as an added safety measure due to the high risk of ignition.
Traffic advisory and diversions
Meanwhile, the traffic department issued an urgent advisory through its social media handles, warning commuters to avoid the Mumbai-Pune corridor. Due to the gas tanker accident and an ongoing leak near the Adoshi Tunnel, traffic on both the Mumbai-Pune Expressway and the old highway (NH-48) was severely disrupted. Commuters were advised to avoid the Lonavala-Khandala ghat section.
Alternative routes included:
>> Tamhini Ghat
>> Malshej Ghat
>> Bhimashankar-Manchar route
Inconvenience at its peak
The accident resulted in more than 23 hours of traffic congestion, turning a safety shutdown into a prolonged human ordeal. Thousands of commuters, including families, elderly passengers, children and working professionals, were stranded for up to 15 hours without access to basic facilities such as toilets, drinking water or food. For many, the crisis went beyond delay to distress and dignity.
Police personnel halt heavy vehicles on the expressway
“There were no toilets and no place to even step out safely. Managing infants inside a parked car for hours was exhausting. Milk ran out, diapers became an issue, and children kept crying through the night. This was not something anyone could have prepared for,” said a commuter stuck in traffic.
Several others reported rationing water, skipping meals and sitting inside vehicles for hours without proper ventilation. Elderly passengers complained of body pain, dehydration and anxiety, while parents struggled to calm restless children. Jalindar Kale, a business consultant travelling to Mumbai for an important meeting, said the gridlock had cost him an entire workday. “I tried attending my meeting from the car, but the poor network and constant noise made it impossible. After eight hours, I had no option but to inform my office that I would not make it,” he said.
Official response
Highway Police Superintendent Tanaji Chikhale said traffic congestion stretched up to the Khalapur toll plaza on the Mumbai side and nearly 10 to 12 km towards Pune.
“The intensity of the gas leakage increased, forcing us to completely close the Mumbai-bound lane as a precaution. Motorists faced delays until the situation was brought under control,” he said, reiterating the advisory to use alternate routes.
As containment operations continued through Wednesday, the incident exposed a critical gap in highway disaster management, particularly the absence of emergency facilities for stranded motorists on one of Maharashtra’s busiest transport corridors.
Operator statement
An official spokesperson of IRB MP Expressway Pvt Ltd said the tanker was carrying extremely flammable propylene gas, which leaked after the accident, necessitating stringent safety measures. “The IRB team has been present at the site along with authorities concerned and is continuously monitoring the situation. We are working to restore normalcy at the earliest after receiving clearance. Given the severity of the incident, the practical challenges involved in handling such emergencies must be understood,” the statement said.
Commuter Speak
Kunal Pradhan, chief business officer at TechJar Technologies Pvt Ltd, said, “I was travelling from Pune to Mumbai on Tuesday evening and saw the overturned tanker around 5 pm. I narrowly escaped getting stuck. However, after my meeting, I had to return, and by Wednesday evening, the situation had worsened.” Another commuter, Ritika Patel, said, “I work in Mumbai and live in Pune. I was travelling home for a family function, but the experience was horrible. Children were crying, elderly people were suffering, and some passengers were clearly unwell.”
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