The project’s inauguration aligned with Maharashtra Foundation Day.
CM Fadnavis unveiled the Missing Link at the Khalapur (Raigad district) end of the expressway and subsequently drove along the Lonavala-bound carriageway with Deputy Chief Minister Eknath Shinde alongside him in the vehicle.
The Missing Link project links Khopoli on the Mumbai side to Kusgaon near Lonavala in Pune district and aims to make the expressway fully access-controlled, alleviating congestion in the ‘ghat’ (mountain pass) area.
Constructed by the Maharashtra State Road Development Corporation (MSRDC) at a cost of Rs 6,700 crore, the project features two tunnels, two viaducts, and a cable-stayed bridge over Tiger Valley. This route bypasses the steep and accident-prone Khandala or Bhor ‘ghat’ (mountain pass) section, which often experiences traffic jams, especially on weekends and public holidays.
The initiative is part of a modern 19.16-km corridor that includes expanding a 5.86-km six-lane segment between the Khalapur and Khopoli interchange to eight lanes, according to an MSRDC release.
Officials noted that the Missing Link will reduce the travel distance between Mumbai and Pune by approximately 6 km and decrease journey times by 20 to 30 minutes.
At the outset, only light motor vehicles and buses will be permitted on the new route, while heavy goods vehicles will continue to utilize the existing ghat path due to safety precautions.
Authorities confirmed that there are no plans for a toll increase related to the project, including at the Khalapur toll plaza in Raigad district.
The tunnels were built using the New Austrian Tunnelling Method (NATM), accompanied by detailed geological surveys across various rock formations in the Sahyadri ranges, as per the MSRDC.
Tunnel No. 1 spans 1.58 km, while Tunnel No. 2 is 8.86 km long. The tunnels measure about 23.5 meters in width and are among the widest road tunnels in the world, with officials indicating that a request has been made for Guinness Book of Records recognition.
The 650-meter viaduct boasts what officials call India’s tallest road cable-stayed bridge, featuring pylons that rise 182 meters and are supported by 240 stay cables. The bridge underwent rigorous international testing, including wind tunnel, fatigue, and tensile assessments.
Tunnel No. 2 is situated nearly 180 meters beneath the Lonavala lake level, making excavation and blasting a significant technical challenge, according to the release.
The construction faced tough mountainous conditions characterized by heavy rainfall, strong winds, and low visibility, it added.
As per the MSRDC, the project is anticipated to enhance road safety by avoiding accident-prone ghat areas and reducing fuel consumption, which could lead to daily savings of around Rs 1 crore and lower pollution levels.
The approximately 95-km-long Mumbai-Pune Expressway is recognized as India’s first access-controlled highway.
