The Mumbai Metropolitan Region Development Authority (MMRDA) has commenced the erection of precast segments for the 13.9-km Elevated Eastern Freeway Extension, marking the beginning of superstructure construction on the six-lane corridor connecting Anand Nagar in Thane with Chheda Nagar in Ghatkopar.
The first precast segment, weighing more than 90 tonnes, was launched at Pier P78 near Bhandup Pumping Station using a 115-metre-long mechanised Launching Gantry-01 (LG-01). The operation was carried out above the Eastern Express Highway while traffic continued to move below, allowing construction to progress without a major interruption to traffic.
The latest work represents a shift from foundation and pier construction to erection of the elevated corridor’s main superstructure. The launching gantry is designed to lift, position and install the heavy precast segments with minimal support at ground level, reducing the construction footprint along the busy highway.
LG-01 will progressively erect 1,632 precast segments towards Mumbai. The segments will then be assembled into complete bridge spans through longitudinal post-tensioning. A second launching gantry, LG-02, will undertake erection work from Vikhroli towards Mumbai, while a Ground Support System will be used for construction between Bhandup and Kanjurmarg towards Thane.
The elevated corridor will comprise 288 complete bridge spans, with a typical span measuring 40 metres and consisting of 16 precast segments. Individual segments can weigh up to 106 tonnes, while a complete span can weigh as much as 1,450 tonnes. The superstructure is planned with a width of 25 metres for the six-lane configuration.
Construction of the supporting infrastructure has also progressed. According to MMRDA, 81% of monopile work and 19% of group-pile work have been completed, while progress on piers stands at 51% and pier caps at 33%. Of the 3,732 precast segments planned for the project, 135 have been cast so far.
The project incorporates 2,500-mm-diameter monopiles and a single-pier arrangement, eliminating the need for conventional pile caps at the supporting locations. This design, along with mechanised segment launching, is intended to reduce the land and working space required along the existing highway while enabling construction to continue above live traffic.
The 13.9-km elevated corridor will run from Anand Nagar near Thane through Mulund, Airoli, JVLR, Kanjurmarg, Vikhroli, Mankhurd and Ghatkopar before terminating at Chheda Nagar. The alignment is designed as a 3+3 lane corridor, with provisions for entry and exit connections at key locations.
MMRDA has approved the project at a cost of ₹2,682 crore. Navayuga Engineering Company has been appointed as the contractor, while Sheladia Associates in association with SMEC International is serving as the project management consultant. The planned completion period is 48 months, including design and environmental clearance requirements and the construction period.
Once completed, the Elevated Eastern Freeway Extension is expected to improve connectivity between Thane and South Mumbai and reduce pressure on the Eastern Express Highway. MMRDA expects the corridor to bring the South Mumbai-Thane travel time down to around 20–25 minutes.
