The Maharashtra State Road Development Corporation (MSRDC) has initiated work on a detailed project report to upgrade the old Pune-Mumbai Highway from four lanes to six after the Pune-Mumbai Expressway was widened to 10 lanes. The move follows growing traffic demand on the older alignment and forms part of broader efforts to improve regional connectivity. The DPR will define the precise scope, alignment and design parameters for the upgrade.

The project is estimated to cost between Rs 50 billion (Rs 50 bn) and Rs 60 billion (Rs 60 bn), with the investment proposed to be recovered through toll revenue. As a result, the existing toll collection period, currently permitted until 2035, may be extended by 10 to 15 years. Authorities expect the financial model to be refined once the DPR yields detailed traffic and revenue projections.

Proposed works are likely to include new road links and alignment improvements to enhance traffic flow and reduce travel time, particularly through the Lonavla and Khandala ghat sections. The existing four-lane carriageway will be expanded to six lanes, with alignment modifications undertaken wherever necessary to address terrain constraints. MSRDC has appointed a consultant to prepare the DPR and a senior superintendent engineer said the exact scope and design will be finalised after completion of the report.

The old Pune-Mumbai Highway carries historical significance, having been developed during the British era to link Mumbai with the Deccan Plateau via Bor Ghat and later designated National Highway four before the Yashwantrao Chavan Pune-Mumbai Expressway opened. It was redesignated as part of National Highway 48 in 2010 and stretches approximately 150 to 156 km. The road was initially a two-lane highway before being widened to four lanes to accommodate growing traffic volumes and MSRDC currently remains responsible for its maintenance. The proposed six-laning is intended to improve connectivity between Pune and Mumbai while addressing increasing traffic demand.