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Main road widening can reduce the clearance of the low-level underpass road, restricting the passage of vehicles and leading to collisions with structures. Therefore, checking the clearance of the underpass road effectively should be considered at the design stage. This paper describes a digital twin approach for checking the clearance of underpass roads in highway widening projects using online map data. The underpass road digital twin and BIM model of the newly widened road based on the existing main road digital twin are created to assist the clearance check and redesign. The proposed method presented a cost-effective clearance check for underpass roads in road widening design without field surveys and was successfully implemented in an underpass road in the UK. In future research, more digital twin methods for overpasses, bridges, tunnels, and traffic safety facilities should be employed comprehensively to assist more road widening applications. • A novel approach is presented to check the underpass road clearance in the road widening project. • A method for building road digital twins from online map data is proposed. • A systematic method for road widening based on the digital twin is proposed. • According to the clearance check, the underpass road can be redesigned to increase the insufficient clearance. [ABSTRACT FROM AUTHOR]