Gurgaon: More than two years after a depression first appeared on the Hero Honda Chowk flyover, forcing traffic restrictions on one of the Delhi-Gurgaon Expressway's busiest stretches, repairs are finally set to move forward. The National Highways Authority of India (NHAI) has announced that it is preparing to invite bids later this month to restore and strengthen the damaged structure, a long-delayed intervention for commuters who have been navigating bottlenecks and uncertainty since the lane was barricaded.
The proposed work, estimated at Rs 22 crore, will cover repairs on both carriageways wherever needed. A specialized agency will be hired not only to restore the damaged portions but also to carry out a detailed technical assessment of the flyover to identify distressed sections and decide where strengthening or replacement is required.
“We are preparing to float a tender for restoration of the damaged portions of the flyover. The agency will also conduct a thorough technical investigation to identify distressed sections and determine where strengthening or replacement is needed,” an NHAI official said.
According to the official, the tender is likely to be floated in the next one or two weeks. Once awarded, the contractor will mobilize machinery and manpower, but work is expected to begin only after the monsoon due to heavy traffic and the need for a traffic management plan to minimize disruption.
History of Structural Issues
The 1.4 km flyover, built at a cost of Rs 197 crore and opened in July 2017, was sanctioned in August 2014 to ease congestion at Hero Honda Chowk, one of NH-8's busiest junctions. However, structural concerns surfaced soon after its inauguration.
In April 2018, a chunk of concrete fell from the flyover. In May 2019, a hole appeared on the same carriageway. Following the 2019 incident, police registered an FIR under sections 336 (act endangering life or personal safety of others) and 34 (acts done by several persons in furtherance of common intention) of the Indian Penal Code on a complaint by RTI activist Ramesh Kumar.
NHAI officials and representatives of agencies linked to the construction were named in the FIR. Samples were sent for laboratory testing, and structural experts examined the flyover. The inquiry reportedly found that substandard material had been used in parts of the project, after which an NHAI committee recommended strengthening measures.
Previous Repairs and New Damage
The flyover was shut for nearly five months from October 2019 for deck slab restoration, and again for six days in September 2022 for span load testing. Fresh trouble emerged in May 2024, when a nearly 20-metre section on the Gurgaon-Delhi carriageway developed a visible depression. NHAI barricaded the stretch and restricted movement on the damaged lane, which has remained cordoned off since then.
By December 2024, the damaged portion had worsened into a cavity with reinforcement bars exposed. In January 2025, more concrete chipped off, leaving iron rods visible and a hole in the deck.
Expert Audit and Recommendations
NHAI then asked the Central Road Research Institute (CSIR-CRRI) to audit the flyover and underpass at the junction, both built by the same agency. The audit found the flyover to be stable overall but noted that parts of the deck slab and bearings were weak and needed repairs. CRRI suggested measures such as grouting, strengthening, and partial replacement of damaged sections, which were later reviewed by NHAI's technical committee.
NHAI officials said the upcoming tender will incorporate these recommendations to ensure long-term durability. Commuters, however, remain skeptical after years of delays and repeated problems. The flyover serves thousands of vehicles daily, and any disruption during repairs will require careful planning to avoid worsening traffic congestion on the Delhi-Gurgaon Expressway.
