India’s road network—an impressive 6.6 million km—stands as the world’s largest. Yet, within the past 12 months, the nation witnessed a staggering ₹28,000 crore worth of damage across key road assets—national highways, expressways, and flyovers.
This piece explores the reasons behind the crumbling infrastructure, the incidents themselves, the human and financial toll, and the long-term strategies required to rebuild public trust and safety.
NH‑66 Collapse at Kooriyad, Kerala: A Geotechnical Disaster
- Incident Date: May 19, 2025, at 2:30 PM IST
- Injuries: 7 reported; multiple vehicles damaged
- Primary Cause:
- Embankment built over waterlogged paddy land collapsed due to weak subsoil with high pore-water pressure
- No bitumen seal allowed seepage during pre-monsoon rain
- Official Review:
- MoRTH & NHAI initiated expert review involving geotechnical experts and IIT-backed teams
- Findings attributed failure to soil saturation, design flaws, and inadequate slope stability
- Accountability Actions:
- KNR Constructions and Highway Engineering Consultants were debarred, fined ₹20 lakh each
- Project Director suspended; Site Engineer terminated; CAG audit ordered by PAC
- Legal & Administrative Follow-up:
- Kerala HC strongly criticized delays and demanded corrective roadmap
- NHAI to reconstruct collapsed embankment using viaduct structure within six months
Renowned engineer E. Sreedharan flagged fundamental design lapses—including six-lane expansion on 45m terrain—and warned against unsafe embankments in Kerala’s unique landscape.
Expressways Faltering Amidst Ambition
Purvanchal Expressway, Uttar Pradesh
- Built at ₹22,494 crore, it is a 340 km, 6-lane stretch opened in Nov 2021
- Within months, monsoon rains opened deep sinkholes—some up to 15 ft deep—forcing emergency repairs
- State and NHAI both blamed sensationalism; social media corrections ensued
Emerging Expressway Cracks
- New corridors like Delhi–Mumbai, Mumbai–Pune, Bundelkhand, and upcoming Ganga Expressway reveal early-stage construction defects
- Most issues involve subpar water-proofing and poor earth compaction, especially during monsoon months
Urban Flyovers & ROBs under Pressure
- Ahmedabad: Five flyovers flagged; Hatkeshwar bridge to be demolished after failing core tests
- Nagpur: ₹65 crore ROB collapsed before inauguration, exposing severe quality-control lapses
- Delhi Outer Ring Road: Noise-barrier structures rusted and loosened, requiring urgent intervention
Calculating the ₹28,000 Crore Shock
| Category | Damage Estimate (₹ Crore) | Examples |
|---|---|---|
| NH & National Corridors | 4,000–5,000 | NH‑66 collapse, NH‑754K, Gurugram sinkholes |
| Expressways | 8,000–10,000 | Purvanchal holes, cracks on Mumbai, Delhi corridors |
| Urban Flyovers & ROBs | 3,000–5,000 | Ahmedabad, Nagpur, Delhi structures |
| Reworks, Repairs & Inspections | 8,000–10,000 | Reconstruction, viaduct replacements, audits |
📌 Total: ₹23,000–30,000 crore, conservatively ~₹28,000 crore.
Why Are Roads Failing at This Scale?
Flawed Design & Soil Ignorance
Projects neglected region-specific hydrology—building embankments on loamy, flood-prone land. Design consultants failed to recognize ecological constraints.
Constructed in a Hurry
Political deadlines pressured rapid completion, pushing quality control aside.
Oversight Gaps
Third-party audits and independent inspections were lacking. Engineers on record were slow or absent.
Weather Peril
Monsoon rains turned latent defects into full-blown collapses—particularly on embankments and flyovers.
Accountability Loopholes
Punishment comes only after major failures. Routine inspections rarely yield robust penalties.
Official Response & Reparative Measures
- Bans & Fines: Debarment of KNRCL and Consultants; fine levied; rehabilitation mandated under expert supervision
- Expert Task Forces: IITs, geotechnicians, and GSI scientists investigating failure spots
- Legal Pressure: Kerala HC demanded progress reports and adherence to scientific rebuilding
- Revised Guidelines: NHAI drafting fresh erosion-control and slope-stabilization standards
- Smart Tech & Monitoring: Pilot remote-sensing, IoT sensors, and early warning systems planned across new highway sections
The Human & Economic Toll
- Safety Risks: Road collapses injured individuals and paralysed transit routes—for instance, NH‑66 led to blocked travel across Kerala during pre-monsoon rains.
- Economic Loss: Disrupted freight corridors and commuter paths lead to loss of productivity, logistics costs, and market delays.
- Public Distrust: Repeated failures erode faith in government-built infrastructure and increase political backlash.
Rebuilding India’s Road Credibility
- Site-Specific Design: Acknowledge local soil & hydrology; design reduced lanes or opt for viaducts where needed.
- Rigorous Digital Monitoring: Implement IoT-based stress sensors and predictive analytics on all major builds.
- Real-Time Public Reporting: Encourage crowdsourced defect reporting apps with prompt response mechanisms.
- Stricter Enforcement: Enact automatic debarment and financial liability for failures linked to design or construction errors.
- Third-Party Oversight: Require IIT-approved auditors to monitor every stage—from DPR to final layer.
- Climate-Responsive Engineering: Integrate flood, seepage, and slope modeling in all projects, especially in monsoon-prone regions.
FAQs
1. Are all these failures due to monsoon?
While monsoon acted as a catalyst, the root lies in weak design and construction—weather only exposed the flaws.
2. Who bears final responsibility?
Design consultants, contractors, and overseeing NHAI or PWD officials—all share responsibility; however, punitive action typically targets flagrant cases.
3. Why not build roads as concrete by default?
Concrete is durable but expensive. Many projects use flexible pavement to manage costs. However, neglecting proper sealing invites seepage-related damage.
4. Is any region safer?
Arid and flat zones face fewer soil/seepage issues, but accidents still occur due to poor compaction or planning. No region is exempt from quality risks.
5. What about newly constructed bridges?
They too develop early cracks. Some, like the Nagpur ROB, collapsed before use—highlighting that bridges are not immune to systemic lapses.
6. Could smart highways avert these?
Partially—sensor systems can catch subsidence early, but they can't fix fundamental design issues or construction shortcuts.
7. Will legal bans stop future issues?
Debarment acts as a deterrent, but systemic reform is necessary to enforce design fidelity and inspection protocols consistently.
8. How quickly can these fixes happen?
Some viaducts and audits are underway (e.g., NH‑66 rebuild in six months); widespread structural stabilization may take 1–2 years.
9. Can citizens play a role?
Yes—via public reporting apps, RTI filings, and vigilance. But official channels must remain responsive.
10. Will costs exceed ₹28,000 crore?
Likely. As monsoon progresses, hidden faults may surface; emergency repairs, rerouting, and audits could push total closer to ₹35,000 crore.
Tabular Summary
| Area Affected | Nature of Failure | Estimated Cost | Remedial Action |
|---|---|---|---|
| NH‑66 (Kerala) | Embankment collapse; soil failure | ₹1,500 crore | Viaduct construction; redesign; ₹20 lakh fines |
| NH Corridors | Pavement failures, sinkholes (Gujarat) | ₹2,500 crore | Suspensions; audits |
| Expressways | Massive potholes; structural cracks | ₹10,000 crore | Earthworks redo; drainage retrofit |
| Urban Flyovers | Slab cracks, instability, noise-barrier failure | ₹4,000 crore | Demolitions, repair projects |
| Rework & Inspections | DPR revisions; audits; reconstruction | ₹10,000 crore | Policy updates; technology upgrades |
Conclusion
India's ₹28,000 crore road crisis is not a mere statistical anomaly—it’s a clear indicator of structural negligence. Design shortcuts, inadequate oversight, environmental ignorance, and accountability gaps created perfect storm conditions. While agencies and experts are responding—through fines, redrawn plans, viaduct projects, and technological upgrades—restoring public trust will require systemic change at every phase of infrastructure development.
Report by Toofan Express