The Mumbai-Pune Expressway in India is undergoing a significant upgrade with the construction of the 13.3 km “Missing Link” project. The project, led by the Maharashtra State Road Development Corporation, is being constructed by Afcons Infrastructure Ltd. The project aims to reduce travel distance by over six kilometres and travel time by approximately 30 minutes. Doka plays a pivotal role in the project, providing expertise and innovative systems for the construction of the complex cable-stayed bridge.
The bridge, which is one of the tallest in India, is designed to navigate steep slopes and hazardous sections of the existing expressway. Doka’s formwork solutions, such as the Xclimb60 Short Track and Automatic climbing formwork SKE100 plus systems, ensure rapid and safe construction progress, reducing risks for on-site crews and accelerating construction timelines. The Missing Link project is a testament to India’s ambition and engineering prowess.
The ambitious Mumbai-Pune Expressway ‘Missing Link’ project is witnessing accelerated construction progress, thanks to the integration of Doka’s advanced formwork systems. As one of India’s most significant expressway upgrades, this 13.3 km long bypass aims to decongest traffic, reduce travel time, and enhance overall road safety. A key feature of this stretch is the under-construction cable-stayed bridge, a critical engineering element that demands precision, strength, and speed—all delivered by Doka’s cutting-edge formwork solutions.
Role of Doka Formwork in Speeding Construction
Doka, a globally recognized leader in formwork technology, has supplied its SKE100 plus automatic climbing formwork and large-area Top 50 panels for the pylons and superstructure of the cable-stayed bridge. This self-climbing system enables uninterrupted work cycles without crane dependency, allowing faster and safer vertical progress even in complex terrain conditions. Doka’s involvement significantly reduces downtime between pours and ensures high-quality concrete finishes, crucial for structures exposed to heavy loads and environmental factors. (Construction).
About the Missing Link Project
The ‘Missing Link’ is being executed by MSRDC (Maharashtra State Road Development Corporation) to bypass the ghat section between Khomola and Kandla. This elevated route includes a 9.1 km long viaduct and two major tunnels, expected to cut travel time by 20-25 minutes. The cable-stayed bridge, which spans deep valleys and rugged terrain, is one of the highlights, with pylons reaching up to 180 meters high. (Mumbai-Pune Expressway).
Engineering Challenges and Innovations
Constructing such a tall bridge through mountainous regions presents challenges related to wind loads, steep slopes, and geological uncertainty. Doka’s modular formwork helps mitigate these challenges by allowing precision adjustment, minimizing risk, and enabling safe working conditions for crews at height. The integration of real-time monitoring and pre-engineered formwork solutions helps maintain alignment and reduces rework, accelerating the schedule.
Safety and Sustainability Aspects
Doka also integrates safety into its design with enclosed working platforms and automatic climbing systems that comply with stringent global safety norms. Moreover, the reusability of formwork components ensures sustainable construction by minimizing material waste. This aligns well with the Indian government’s push for green infrastructure and sustainable transport.
Project Timeline and Outlook
With the help of Doka’s systems, construction of the cable-stayed bridge is progressing ahead of schedule. The full Missing Link is expected to open by early 2026, promising smoother connectivity between Mumbai and Pune. Upon completion, it will not only reduce logistics costs and improve travel experience but also become a model for modern highway engineering in India. This collaboration between Doka and MSRDC reflects how engineering partnerships and innovation are transforming India’s transportation backbone at scale.
Q1. What is the ‘Missing Link’ project on the Mumbai-Pune Expressway?
It is a 13.3 km bypass being built to avoid the old ghat section, reduce travel time by 20–25 minutes, and improve traffic flow between Khomola and Sinha gad.
Q2. How is Doka contributing to the cable-stayed bridge construction?
Doka is providing advanced formwork systems like the SKE100 plus automatic climbing system and Top 50 panels to speed up and secure the construction process.
Q3. Why is the cable-stayed bridge important in this project?
It is one of the tallest bridge structures in India, enabling the expressway to cross a deep valley and form the backbone of the new alignment.
Q4. What are the safety features of Doka’s formwork?
Doka’s formwork includes enclosed working platforms, hydraulic climbing systems, and modular safety rails, ensuring worker safety at height.
Q5. When will the ‘Missing Link’ project be completed?
The project is expected to be completed by early 2026, according to current timelines shared by MSRDC.
