Mumbai–Pune commuters will soon bypass the congested ghat section as the Rs 6,695 crore missing link on the expressway nears completion. Featuring one of India’s tallest bridges and some of the world’s widest tunnels, the project is expected to open by December, cutting travel time by up to 25 minutes—especially during monsoons, when landslides and traffic snarls are frequent.
Work on the transformative expressway project began in 2017 to tackle bottlenecks and unpredictable delays in the Lonavla–Khandala ghat section. With twin tunnels measuring 1.75 km and 8.92 km and 23 metres wide, and a 170-metre-high cable-stayed bridge, the project is a major engineering feat. The tunnels will connect every 300 metres for emergency support, while the bridge—equal in height to a 45-storey building—will span deep valleys below, bypassing the hazardous slopes and landslide-prone zones that have long plagued the route.
The missing link, stretching from the Khopoli exit to the Sinhgad Institute in Lonavla, will reduce the road distance from 19 km to 13 km. The section of National Highway 4 and the Mumbai–Pune Expressway that currently handles this stretch together often witnesses heavy traffic jams, worsened during monsoons. Vehicles are known to speed excessively in compensation, contributing to accidents. Officials believe the new route will help improve traffic flow, lower accident risk, and minimise pollution from idling vehicles. The expressway will also be widened at the Pune end of the Khalapur toll plaza to allow seamless integration with the upgraded section.
Authorities at the Maharashtra State Road Development Corporation (MSRDC) are coordinating with engineering experts to ensure the project incorporates sustainable infrastructure, including tunnel ventilation systems and preventive mesh to block debris. The use of advanced design and planning is not only set to improve traffic movement but also enhance climate resilience by mitigating disruption due to seasonal weather conditions. Civic engineers stress that the final few months of construction will focus on completing the bridge and ensuring safe, uninterrupted access across the tunnels—designed to handle high traffic loads without compromising safety.
Once operational, the missing link will transform the way Mumbai and Pune connect—supporting economic activity, improving logistics, and enhancing everyday commuter convenience. The city-to-city corridor, a critical regional artery, is also set to demonstrate how large-scale infrastructure can be delivered with a balance of engineering innovation, safety, and climate-aware planning. As Maharashtra pushes forward with sustainable urban mobility, this project marks a significant step toward future-ready infrastructure with long-term public value.
