This eight-lane access-controlled expressway bypasses the steep 19-km Khandala Ghat section, reducing the route by 5.7 km and cutting travel time by 20-30 minutes. The new alignment is designed to ease monsoon-induced congestion and minimize landslide risks.

The project features two tunnels—1.75 km and 8.92 km long—along with two cable-stayed bridges measuring 770 meters and 645 meters. The 23.75-meter-wide underground tunnel will be the widest road tunnel in Asia, accommodating eight lanes with dedicated emergency lanes.

With an estimated cost of Rs 66 billion, this engineering marvel is set to enhance travel safety and efficiency on the Mumbai-Pune Expressway.