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Under the Hills: Inside the Samruddhi Mahamarg’s 7.8 km Kasara Ghat Tunnel

Discover the 7.8 km Kasara Ghat Tunnel on the Samruddhi Mahamarg - India’s longest road tunnel. Learn how it reduces travel time, boosts safety, and connects Maharashtra faster.

Pratik Kamble

12 Aug 2025 — 1 min read

7.8 km Kasara Ghat Tunnel

A Tunnel That Changes the Game

Cutting through the rugged terrain of Kasara Ghat, the 7.8 km tunnel on the Samruddhi Mahamarg is not just Maharashtra’s pride - it’s India’s longest road tunnel. For years, the steep slopes and hairpin bends of Kasara meant slow travel and traffic snarls. Now, with this modern engineering feat, what was once a 30-minute uphill struggle has turned into a smooth, breezy ride in just minutes.

Why It’s a Big Deal

Length: 7.8 km (longest road tunnel in India)
Part of: Nagpur-Mumbai Samruddhi Mahamarg (701 km access-controlled expressway)
Purpose: Reduce travel time, improve safety, and bypass steep ghat roads prone to accidents.
Location Advantage: Connects Igatpuri region to Thane/Nashik side without the old bottlenecks of NH3.

Engineering Brilliance

Built using state-of-the-art drill and blast and New Austrian Tunnelling Method (NATM), this twin-tube tunnel accommodates 3 lanes in each tube. Each tunnel has its own lighting, ventilation, fire safety systems, and escape passages for emergencies.

Ventilation: Jet fans and exhaust systems keep air quality in check.
Safety Systems: CCTV surveillance, SOS booths, and fire-fighting equipment at intervals.
Emergency Preparedness: Cross-passages every 300m for quick evacuation.

What It Means for Travellers

Time Saved: Avoids slow, winding ghat roads - saving 20-30 minutes.
Safety Boost: Reduced risk of landslides, fog accidents, and truck rollbacks on slopes.
Driving Comfort: Consistent gradient and lane width for a stress-free drive.

Eco-Friendly Angle

By bypassing the ghat road, the tunnel cuts fuel use and emissions from vehicles constantly accelerating and braking on slopes. Plus, careful excavation and slope stabilization reduced environmental impact during construction.

In a Nutshell

The Kasara Ghat Tunnel is more than just a shortcut - it’s a symbol of speed, safety, and smarter travel. As the Samruddhi Mahamarg unfolds across Maharashtra, this tunnel stands as a shining example of infrastructure built for the future.