So, the MMRDA planned to build a comprehensive link between the two cities so to handle more traffic and make travel more easier, faster, safer and hassle-free.

The firm's report, based on extensive studies conducted over 18 months, was handed over to the Ministry of Road Transport and Highways (MoRTH) on 19 December 1963.

The project underwent two failed rounds of tendering under the MSRDC, and was stuck for nearly two years (between 2009 and 2011), before the state government decided to hand over the mandate to MMRDA.

After the MMRDA was tasked with executing the MTHL, the MSRDC took up the expansion of the Vashi Bridge by adding six more lanes to ease congestion at the entrance to Navi Mumbai.

The Maharashtra State Road Development Corporation (MSRDC) had obtained clearance for the project in March 2005, but the certificate was valid only for 5 years and lapsed due to the delays in the bidding process.

Some of the conditions were that the MMRDA had to put up noise barriers, replant five times the number of mangroves destroyed, not carry out dredging or reclamation, use construction equipment with exhaust silencers and work in consultation with the Bombay Natural History Society to minimize the impact on migratory birds.

They also claim that the sea link would damage a huge mudflat and mangrove tract towards Sewri and Nhava Sheva, which is a habitat for migratory birds like flamingos.

[42][43] On 8 January 2012, the then Minister of Shipping and MP from South Mumbai, Milind Murli Deora, told reporters that JNPT would issue a No Objection Certificate (NOC) to the state government to go ahead with the project.

[48][49] IRB-Hyundai announced their withdrawal from the bidding process, on 31 July 2013, citing "the government's apathy and unfriendly attitude towards investors wanting to develop capital-intensive infrastructure projects".

[52] Under the public private partnership (PPP) basis that the project was proposed to be implemented in,[53] the state government would also contribute the same amount as the centre, while the remaining 60% would have been borne by the developer who won the bid.

In January 2014, Ashwini Bhide, the then MMRDA additional metropolitan commissioner, told The Indian Express that the state government had sent a formal proposal to the DEA for its approval to get funds from JICA.

On 17 April 2015, the Minister of Road Transport and Highways, Nitin Gadkari, stated that he favoured the construction of a submarine tunnel instead of a sea link.

Madan, the then Metropolitan Commissioner of the MMRDA, stated that the general consultants appointed for the MTHL project would engage in various activities, such as to help MMRDA organise pre-bid meetings, examine bid documents, secure various permissions from government, semi-government, examine concept designs, monitor construction of the project and ensure quality of the work among other things.

An MMRDA official stated that a detailed study has revealed that laying the foundation for the bridge with provisions for two metro lines would hike costs, instead of saving expenses.

[109] In September 2021, the MMRDA stated that regardless of the decision on metro lines, the agency would dedicate two lanes on the MTHL for a bus rapid transit system.

The MMRDA chose to use steel spans in these sections to eliminate the need to construct pillars to support the bridge, which would hinder the movement of ships in the area.

The parts for the orthotropic decks were manufactured in Japan, Myanmar, Taiwan, and Vietnam and shipped to Karanja Port in Uran for assembly.

[122] The Reverse Circulation Drilling (RCD) construction technique was also utilized for the first time in India, in order to reduce disturbance to migratory birds.

The MMRDA originally planned to install a 5 ft-tall wall as the crash barrier, but decided against it to avoid blocking the views from the sea link.

[146] The first of five composite steel girder spans, weighing 130 MT and 40 metres long, linking the MTHL with the Eastern Freeway at Sewri was installed on 20 February 2023.

[149] On 25 June 2023, an MMRDA official stated that no construction work would be carried out on the portion of the bridge over the sea during the monsoon season for safety reasons.

The bridge is constructed using corrosion-resistant materials to withstand weather variations, high wind speeds and tides, along with natural phenomena like earthquakes and cyclones.

The 70 spans of Orthotropic Steel Decks (OSDs) with lengths ranging from 65 to 180 metres and weighing up to 2,800 metric tons were erected across the Thane Creek using Japanese technology.

In addition, a Comprehensive Surveillance System (CSS) utilizes a network of high-definition CCTV cameras strategically placed along the entire route.

The carbon footprint from vehicular emissions will also significantly reduce by a few hundred thousand tons, as vehicles will be crossing the bridge at a maximum speed limit of 100 km/h (62 mph).

To solve the issue, engineers have installed 1,212 special light poles that will illuminate only the carriageways, without any luminous spill onto the sea, thus positively affecting the marine life.

[178] MMRDA officials stated that they expected the cost to reduce by 6% as a result of the Union Government's decision to lower the goods and services tax (GST) for construction work from 18% to 12%.

[181] The MMRDA has constructed a 1.5 km long cloverleaf interchange on a 27-acre plot, leased from the Mumbai Port Trust, located east of Sewri railway station.

Simplex Infrastructures Ltd. quoted the lowest bid (nearly 16–17% below the estimated cost of the project), followed by Larsen & Toubro (14% below the reserve price).

[197] The Shivajinagar interchange connects the MTHL with the Navi Mumbai International Airport, Jawaharlal Nehru Port, and local roads.