Expressways are the highest class of roads in the Indian road network, and approximately, 1581.4 km of expressways are operational in India. Road accidents have rose over decades and are a significant contributor towards human deaths. It is increasing yearly with the increase of road users and construction of road pavement globally. In India, more than 150,000 people are killed each year in traffic accidents and that is about 400 fatalities a day. Also, India losses 3% of its GDP to road accidents. The objective of this study is to segregate critical accident blackspots on Mumbai–Pune Expressway, to map the accident blackspots using QGIS and to generate Karl Pearson correlation coefficient and regression model between number of accidents and pavement roughness index. © 2021, Springer Nature Singapore Pte Ltd.