A metro corridor once planned as a limited Thane–Bhiwandi link has now evolved into a longer, more complex network that could significantly change how people travel across the Mumbai Metropolitan Region.
The revised Metro Line 5, along with its extension Line 5A, stretches from Kapurbawdi in Thane through Bhiwandi to Kalyan and Ulhasnagar bringing mass rapid transit to areas that have long depended on overcrowded suburban trains and road transport.
While the project was first approved in 2017, only its initial phase moved forward. The latest redesign not only revives stalled sections but also reworks the alignment to overcome earlier on-ground challenges.
The ₹18,130.55-crore project was approved on Wednesday at a meeting of the state’s infrastructure development committee chaired by Chief Minister Devendra Fadnavis.
How the alignment has changed
The biggest shift lies in the Bhiwandi–Kalyan stretch, which had been stuck for years due to land constraints and concerns over traffic disruption.
Originally planned as an elevated corridor, a key section between Dhamankar Naka and Temghar has now been moved underground. The earlier plan would have required demolishing the Bhiwandi Bypass Flyover, an intervention likely to trigger severe congestion in one of the region’s busiest belts.
By taking the line underground here, planners have avoided large-scale demolition while making the project more viable in a densely built urban zone.
Another engineering change is the introduction of a double-decker structure between Ranjanoli Junction and Durgadi, where a flyover and metro line will run on the same corridor—optimising space in a constrained stretch.
The alignment has also been rationalised at Kalyan, with the proposed APMC station dropped and integrated instead into another upcoming corridor, improving network efficiency.
A corridor that has grown in scope
What began as a 24.9-km line with 17 stations has now expanded into a 34.2-km network.
A major addition is Line 5A, a new extension from Durgadi that splits towards Kalyan Junction and Ulhasnagar. This does two things: it links the metro directly with the Central Railway at Kalyan and extends connectivity to Ulhasnagar— an area currently outside the metro map.
The Ulhasnagar spur also sets the stage for a future extension towards Ambernath and Badlapur.
What it means for commuters
For residents of Bhiwandi, Kalyan and nearby areas, the project could bring the first real alternative to existing transport bottlenecks.
At present, large parts of this belt especially Bhiwandi and Kongaon lack any mass rapid transit system, forcing commuters to rely on crowded trains or long road journeys. The metro is expected to ease this pressure by providing a parallel, more predictable travel option.
The corridor will also integrate with other key lines connecting to Metro Line 4 at Thane, intersecting the Central Railway, and linking with the upcoming Metro Line 12 at Kalyan allowing smoother interchanges across the network.
With the Thane–Bhiwandi stretch nearing completion and expected to open by the end of 2026, the first phase of this improved connectivity may arrive soon. The remaining sections will take longer, but together they are expected to reshape how people move across the eastern suburbs.
“There is a clear benefit in bringing metro connectivity to areas that currently have none,” said Aakash Bhavsar, an infrastructure analyst. “But at Kalyan, the integration with the railway station may involve longer walking distances. A more seamless connection would have made daily commuting easier.”
Metro line 5: then vs now
Earlier Plan (2017)
Route: Kapurbawdi (Thane) – Bhiwandi – Kalyan
Length: 24.9 km
Stations: 17
Cost: ₹8,416 crore
Timeline-
Approval: 2017
Work began (Phase 1): 2019
Revised proposal: 2026
Revised Plan (Line 5 + 5A)
Route: Kapurbawdi – Bhiwandi – Kalyan – Ulhasnagar
Length: 34.2 km
Stations: 19
Cost: ₹18,130 crore
Target completion: 2031
Phase-wise Breakdown
Phase 1: Thane – Bhiwandi (Near completion)
Length: 11.9 km
Stations: 6 (all elevated)
Stations list: Balkum, Kasheli, Kalher, Purna, Anjur Phata, Dhamankar Naka
Cost: ₹6,741 crore
Progress: 96% complete
Opening: End-2026 (expected)
Phase 2: Bhiwandi – Kalyan (Redesigned)
Length: 10.48 km
Stations: 6 (including 1 underground)
Stations list: Bhiwandi, Temghar, Rajnauli, Gove Gaon, Kongaon East, Kongaon West
Cost: ₹7,326 crore
Timeline: Around 5 years
Key changes
Part of stretch made underground to avoid demolition of Bhiwandi bypass flyover
Double-decker metro and flyover planned between Ranjnoli and Durgadi
Status: Work yet to begin
Phase 3: Line 5A (New extension)
Route: Durgadi – Kalyan – Ulhasnagar
Length: 11.83 km (Main: 6.56 km | Spur: 5.27 km)
Stations: 7
Cost: ₹4,063 crore
Timeline: Around 3.5 years
Key links
Kalyan Junction (Central Railway + Metro Line 12)
Vitthalwadi (Central Railway)
Future extension towards Ambernath–Badlapur
Status: Yet to begin
The project is ₹18,130.55 crore, expanded to 34.2 km connecting Thane to Ulhasnagar. (Source: Express Archives) 
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