The inauguration coincided with Maharashtra Foundation Day. The Chief Minister launched the project from the Khalapur end of the expressway and personally drove along the Lonavala-bound carriageway. Deputy Chief Minister Eknath Shinde accompanied him in the vehicle during the ceremonial drive.
The Missing Link connects Khopoli on the Mumbai side to Kusgaon near Lonavala in Pune district, effectively transforming the expressway into a fully access-controlled corridor. The project is expected to significantly ease congestion in the mountain pass section, which has long been prone to heavy traffic, particularly during weekends and public holidays.
Developed by the Maharashtra State Road Development Corporation at a cost of ₹6,700 crore, the project includes two tunnels, two viaducts, and a cable-stayed bridge constructed over Tiger Valley. It bypasses the steep and accident-prone Khandala or Bhor mountain pass section, which has historically witnessed frequent congestion and road incidents.
The Missing Link forms part of a broader 19.16-kilometre modern corridor, which also incorporates the widening of a 5.86-kilometre six-lane stretch between the Khalapur and Khopoli interchanges into an eight-lane configuration, according to official statements.
Authorities confirmed that the new alignment will reduce the Mumbai–Pune travel distance by approximately six kilometres and cut journey time by 20 to 30 minutes. Initially, access to the new stretch will be restricted to light motor vehicles and buses, while heavy goods vehicles will continue to use the existing mountain pass route due to safety considerations.
Officials clarified that no toll increase has been proposed in connection with the project, including at the Khalapur toll plaza in Raigad district.
The tunnels were constructed using the New Austrian Tunnelling Method following extensive geological studies across varying rock formations in the Sahyadri ranges. Tunnel No. 1 measures 1.58 kilometres, while Tunnel No. 2 extends 8.86 kilometres. Both tunnels are approximately 23.5 metres wide, placing them among the widest road tunnels globally. An application has been submitted to the Guinness Book of Records for official recognition.
The project also features a 650-metre viaduct that includes what officials describe as India’s tallest road cable-stayed bridge. The bridge’s pylons rise to a height of 182 metres and are supported by 240 stay cables. It underwent rigorous international testing, including wind tunnel, fatigue, and tensile assessments.
Tunnel No. 2 runs nearly 180 metres below the Lonavala lake level, making excavation and controlled blasting operations highly complex. The entire route was executed under challenging conditions marked by mountainous terrain, heavy rainfall, strong winds, and low visibility.
According to the Maharashtra State Road Development Corporation, the Missing Link is expected to significantly improve road safety by bypassing accident-prone sections, while also reducing fuel consumption. Officials estimate daily savings of approximately ₹1 crore, alongside a measurable reduction in pollution levels.
The project stands as a critical advancement in Maharashtra’s transport infrastructure, addressing long-standing safety concerns while delivering measurable economic and environmental benefits for one of India’s busiest intercity corridors.
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