The MUMBAI-PUNE EXPRESSWAY was totally inoperable on Tuesday (from 3rd February at approx 5 pm) because a tanker carrying highly inflammable Propylene gas was overturned on the Bhoir Ghat section just before Khandala on this expressway. The tanker developed a leak at three places, and to safeguard people’s lives, traffic was halted in both directions, leading to a traffic jam for kilometres on both sides.
It almost took 32 hours before the authorities could open to and fro sections of the expressway for vehicular traffic.
A complex operation had to be carried out to secure the leak of highly inflammable propylene gas.
The clearance took significant time due o the following reasons:
- Difficult Triple Leakage– The tanker which overturned near the Adoshi Tunnel in the Khandala Ghat section, was damaged at three separate points near the valve. Standard plugging methods were tried first, but they could not contain the gas leakage, and it was almost 24 hours after the toppling of the tank, which forced experts to use much slower “de-containing process-transferring the gas into three separate tankers.
- High Explosion Risk– Propylene is extremely volatile. Authorities forced strict no-movement zone to prevent any spark-even from passing vehicle’s engine-that could trigger massive explosion.
- Delayed expert Response– While local disaster teams (NDRF and SDRF) arrived quickly, specialised recovery equipment and technical teams of Bharat Petroleum faced delays. Official reports state that the nearest company recovery van was stationed far away at refinery in Kochi, Kerala, delaying the specialized response until the following morning.
- Environmental Challenges– Intense afternoon heat complicated the operations, as high temperatures increased the internal pressure of the leaking gas, forcing teams to temporarily halt work for safety.
- Congestion Cascades– The accident site’s location on a steep slope in the Ghat section made maneuvering heavy recovery cranes difficult. The resulting 25 km tailback further blocked access for emergency vehicles, creating a “ parking lot” effect.
Traffic finally began to move on the early hours of Thursday 5th February 2026, after the gas transfer was completed and the area was declared safe.
Why Such Accidents Keep Happening
The Mumbai-Pune Expressway has along history of accidents involving heavy vehicles especially tankers. Experts points to multiple contributing factors:
- Over speeding on slopes and curves.
- Driver fatigue, particularly during night or early morning hours.
- Poor enforcement of speed limits for heavy vehicles.
- Poor enforcement of lane discipline, I regularly travel on this route. Most of the times it so happens on the Ghats that all the three lanes of the road are occupied by heavy vehicles like trailers, trucks and tankers, and this hampers the movements of light vehicles.
- Mechanical failures, including brake overheating on downhill stretches.
Environmental and safety Concerns
Gas tanker accidents pose risks beyond immediate human casualties. LPG leaks can contaminate the surrounding environment, affect air quality, and endanger wildlife in nearby areas. Even a minor spark-from a vehicle or electrical equipment-can trigger an explosion. Such incidents underline the urgent need for specialized lanes, safer parking zones, and real time monitoring of hazardous cargo on high-speed corridors.
Administrative Response and Investigation
Following the incident, senior officials ordered a detailed inquiry to determine:
- Whether tanker was overloaded
- Of the driver had exceeded permitted driving hours.
- Compliance with hazardous goods transportation regulations.
- The role of road design and signage at the accident site.
Lessons and Way Forward
The accident serves as a stark reminder that the Mumbai-Pune Expressway, despite being one of India’s most modern highways, remains highly vulnerable to high-impact accidents involving hazardous materials.
Key measures urgently needed include:
- Stricter monitoring for heavy vehicles.
- Mandatory safety audits for gas tankers.
- Better driver training focused on expressway driving.
- Rapid-response hazardous material unit stationed permanently along the expressway.
- Use of GPS-based tracking and fatigue-monitoring systems.
In the end, this accident on the Mumbai-Pune Expressway could have turned into a major disaster but for timely intervention by emergency services. However, relying on luck and last-minute response is nor sustainable strategy. With traffic volumes increasing and hazardous cargo movement rising, systematic reforms are essential to prevent such incidents from recurring.
Friends, I am a regular traveler on this Expressway, as my son with his family stays in Pune, and I with my wife reside in Mumbai. It so happened that just 24 hours before this accident, I traveled from Mumbai to Pune on 2nd February afternoon. But whenever we travel Mumbai-Pune-Mumbai, our concern is always how much time we will take to clear the Ghat section which normally takes 15 to 20 minutes, but sometimes it might take hours. All this is because of uncontrolled heavy vehicle driving, which most of the times occupy all the three lanes in the Ghat section.
Anil Malik
Mumbai, India
5th February 2026