Project Overview

The Mumbai–Pune Expressway Missing Link was inaugurated on 1 May 2026 by the Maharashtra Chief Minister Devendra Fadnavis. It is a 13.3 km eight-lane greenfield bypass that eliminates the most dangerous and congested section of India's first access-controlled expressway, the Yashwantrao Chavan Expressway, after a 23-year wait.

The corridor runs through the Sahyadri mountain range between Khopoli (Raigad district) and Kusgaon (Pune district), via two record-breaking twin tunnels and India's tallest road-cable-stayed bridge, bypassing the notorious Khandala Ghat hairpin section entirely.

The project is developed and funded by Maharashtra State Road Development Corporation (MSRDC) on an EPC basis. Two contractors executed the two packages in parallel: Navayuga Engineering Company Limited (Package I - tunnels) and Afcons Infrastructure Limited (Package II - viaducts and capacity augmentation).

The project sets two Guinness World Records. The longer tunnel, at 8.92 km length and 22.33 meters internal width, is the widest underground road tunnel in the world. The 650-meter cable-stayed bridge over Tiger Valley, rising on 182-metre pylons, is the tallest road cable-stayed bridge in India.

The bypass reduces travel time on the Mumbai–Pune corridor by 25–30 minutes and cuts 6 km off the distance on the ghat section. The new alignment permits speeds of up to 120 kmph throughout its length. 

CM Fadnavis estimated the project would catalyze INR 70,000 crore in economic activity over its lifetime, driven by faster freight movement on one of India's densest interurban corridors, the near-elimination of ghat-section accident risk, and the unlocking of residential, logistics, and warehousing development along Karjat, Neral, Khopoli, and Lonavala. 

Technical Details

Project Background

The Yashwantrao Chavan Expressway, India's first six-lane concrete access-controlled expressway, was commissioned in 2002 over a 94.5 km alignment from Kalamboli in Navi Mumbai to Kiwale in Pune. 

RITES had identified an alternate alignment for this ghat section as early as 1995, in a feasibility study conducted before the expressway was even built. The alternate route was set aside during construction, and the ghat section was built as originally designed.

MSRDC revived the alternate alignment proposal and appointed a Technical Advisory Committee to review a new Detailed Project Report. The Technical Advisory Committee approved the alignment and design. On 13 June 2017, the Maharashtra Cabinet Sub-Committee on Infrastructure approved the project for execution on an EPC basis at an estimated cost of INR 4,797.57 crore (based on the Schedule of Rates for 2015–16).

The Geodata–LB Consortium was appointed as General Consultant on 26 December 2017. Letters of Acceptance were issued to Navayuga Engineering (Package I - tunnels) and Afcons Infrastructure (Package II - viaducts and capacity augmentation) on 30 August 2018. Construction commenced in February–March 2019 with a 36-month completion period, targeting March 2022. 

Due to multiple factors, the project was extended by approximately four years. Multiple revised completion deadlines were announced and missed: March 2024, January 2025, March 2025, September 2025, and December 2025.

MSRDC finally inaugurated the Mumbai Pune Missing Link Expressway on 1 May 2026 (Maharashtra Day). The ceremony at Khalapur, attended by CM Devendra Fadnavis and both Deputy Chief Ministers, included the formal presentation of the Guinness World Records certificate and a ceremonial inaugural drive by CM Devendra Fadnavis and DCM Shinde through the new tunnel. 

Mumbai Pune Missing Link Start Date

The Mumbai-Pune Expressway "Missing Link" project was officially inaugurated on May 1, 2026, coinciding with Maharashtra Day. While the formal inauguration took place on that date, the route became available to the public for motor vehicle use starting the morning of May 2, 2026. 

The project is expected to reduce the total travel distance by approximately 5.7 to 6 km and cut travel time between the two cities by 25 to 30 minutes.

Stakeholders Details

Mumbai Pune Missing Link Route

The Mumbai Pune Expressway “Missing Link” runs parallel to the existing Khandala Ghat stretch. It starts diverging from the main expressway at the Khopoli exit, near the Khalapur Toll. Then it connects to the new alignment, rejoining the expressway at Kusgaon/Sinhgad Institute near Lonavala.

It effectively compresses the ghat section distance from about 19 km to 13.3 km & cuts the overall Mumbai–Pune travel distance by roughly 5.7-6 km. From Mumbai, it reaches the Khalapur–Khopoli stretch. At Khopoli, vehicles diverge from the old ghat alignment and move onto approach ramps and viaducts that connect directly into a sequence of tunnels and bridges.

The route begins with a shorter 1.75 km tunnel under the hillside facing the Tiger Valley, followed by a 650 m cable‑stayed bridge spanning the valley, with twin towers rising to 180–184 m and a main span of 305 m.

After the Tiger Valley bridge, the route descends into the second, much longer tunnel, about 8.92 km, which runs under the Lonavala Lake–Khandala area and is one of the widest road‑tunnel stretches in the world.

Once the tunnel exits on the Pune side, the Missing Link emerges near Kusgaon and the Sinhgad Institute area, where a dedicated interchange and ramps reconnect traffic back onto the main Mumbai–Pune Expressway alignment.

Mumbai Pune Missing Link Cost Details

Project Scope

The following is the project scope of the Mumbai Pune Expressway:

• Expressway Design: 8-lane access-controlled expressway with twin tunnel, viaducts, and a cable-stayed bridge over Tiger Valley.
  

• Package I (Navayuga Engineering): 1.75 km tunnel and 8.92 km tunnel (world's widest underground twin tunnel at 23m width).
  

• Package II (Afcons Infrastructure): 790m viaduct, 650m viaduct, and widening works from Khalapur to Khopoli.
  

• Development Oversight: Executed by MSRDC to mitigate ghat landslides and congestion, opened to light vehicles on May 1, 2026.

Project Timeline

Mumbai Pune Missing Link Contractors

Benefits

The following are the benefits of the project:

• National Engineering Benchmark: The two Guinness World Records, the world's widest underground road tunnel (22.33 m) and India's tallest road cable-stayed bridge (182 m pylons), represent a national engineering benchmark.
  

• Technological Achievements: Tunneling beneath Lonavala Lake to a depth of 182 m through active basalt without disturbing the lake or triggering any structural incidents was recognized as a technical achievement of the project.
  

• Reduce Traffic: MSRDC estimates that up to 70 percent of peak traffic will transfer to the new bypass, leaving the legacy ghat for slower, lighter vehicles. Overall, it reduces the chances of road accidents on the Yashwantrao Chavan Expressway.
  

• Economic Benefits: Unlocking the Khopoli–Lonavala corridor for logistics and warehousing investment is an indirect economic effect with significant long-term potential.
  

• Reduce Travel Time:  Reduces Mumbai-Pune travel by 20-30 minutes via a 13.3 km bypass, replacing the 19 km ghat section. 
  

• Economic Boost: Lowers logistics costs and supports tourism, real estate, and trade between the Mumbai and Pune economic hubs.
  

• No Extra Tolls: Maintains affordability without additional fees for users.

Conclusion

The Mumbai Pune Missing Link is a transformative project that enhances the Mumbai Pune Expressway & succeeded in bypassing the most challenging Khandala ghat section. The 13.3 km eight-lane greenfield bypass began operations on 1 May 2026, reducing travel time by 20-30 minutes. 

Furthermore, it focused on safety measures through twin tunnels and viaducts. Developed by MSRDC with contractors such as Navayuga and Afcons, it alleviates congestion, minimizes landslide risk, and sets a benchmark for infrastructure resilience without additional tolls.

By diverting traffic from the landslide-prone Khandala ghat, it significantly reduces environmental stress on the Western Ghats while incorporating modern features, such as the world's widest underground twin tunnels measuring 22.33 meters.

Overall, the project drives long-term economic gains, cutting logistics costs and reinforcing Maharashtra's role as a national transport hub. The missing link spotlights the expressway’s potential for full heavy vehicle access and integration with smart highway technologies. 

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