Dr.

Babasaheb Ambedkar
Technological University, Lonere
Mahatma Basweshwar Education Society's
M.S. BIDVE ENGG. COLLEGE, LATUR

An Internship Report On
“PUNE METRO RAIL PROJECT”

Guided by Prof. Mrs. S.G. Deshpande

Submitted by
Mayur Patil
Ajay Biradar
Yash Dhage

(B.Tech Civil)

DEPARTMENT OF CIVIL ENGINEERING

For the academic year 2020-21 as per prescribed in the curriculum
of D BATU LONERE.
 CERTIFICATE
This is to certify that Mayur Patil, Ajay Biradar and Yash Dhage of final year
B.TECH Civil Engineering have successfully completed the internship program
at J. KUMAR INFRAPROJECTS LTD.

“PUNE METRO RAIL PROJECT”

Prof. Mrs S.G. DESHPANDE

Guide HOD
(Department of civil engineering)

Principal
(M.S. Bidve Engineering College, Latur )
INTERSHIP CERTIFICATE
Mayur Patil
INTERNSHIP CERTIFICATE
Ajay Biradar
INTERNSHIP CERTIFICATE
Yash Dhage
 INDEX

1. Acknowledgment

2. Declaration

3. Synopsis

4. Summary

5. Introduction

6. Casting of segment

7. Load testing of pile

8. Pile integrity test

9. Open foundation

10.Piling in rock with rotary

11.Bored cast situ

12.Construction of pile cap

13.Quality control

14.Conclusion
 ACKNOWLEDGEMENT

This Internship program titled "REPORT ON PUNE METRO RAIL

PROJECT " is completed as a part of academic curriculum.

We are really thankful to our course guide, Head of Civil Engineering

department of our Institute, M.S. BIDVE ENGINEERING COLLEGE LATUR.
For this invaluable guidance and assistance, without which the accomplishment
of the task would never been possible.

We also grateful to Mr. Pranav Zambare Sir, for giving this opportunity to
explore into the real world and realized the interrelation without which Intership
program can never be accomplished. We also thank the team members at Pune
Rail Metro Project for their valuable guidance and support at every step of
Internship program.

We are also thankful to our parents, friends and all staff of Civil Engineering
Department for providing us relevant information and necessary clarification, and
valuable supports.
 DECLARATION

I hereby declare that the project entitled CONSTRUCTION OF PUNE METRO

RAIL PROJECT is an authentic record of my own work carried out at J.Kumar

Infraprojects Ltd. as per the requirement of project semester for the award of

degree of B.Tech (Civil Engineering), M.S. Bidve Engineering College, Latur,

under the guidance of Mr. Pranav Zambre and Prof. Mrs S.G. Deshpande,

during March to June 2021.

 SYNOPSIS

Pune Metro is a metro rail based rapid transit system under construction to serve
the city of Pune, India. As of December 2019, the system comprises 3 lines with
a total length of 54.58 km. The 16.59 km Line 1 PCMC Bhavan – Swargate will
be elevated between PCMC Bhavan to Range Hills, from where it will run
underground. Line 2 will run from Vanaz to Ramwadi covering a distance of
14.66 km on an elevated viaduct. Lines 1 and 2 are expected to be operational in
2021. The 23.33-km elevated Line 3 will run from the Rajiv Gandhi Infotech
Park in Hinjawadi via Balewadi to Civil Court. All three lines will align at the
Civil Court interchange station.
As of December 2019, the foundation stone for Lines 1,2,3 are laid by Prime
Minister of India. The first two lines with a combined length of 31.25 km and
are being implemented by the Maharashtra Metro Rail Corporation Limited
(MahaMetro), a 50:50 Joint Venture of the State and Central Governments. Line
3 will be implemented by the Pune Metropolitan Region Development
Authority (PMRDA) and the Joint Venture between Tata Realty and Siemens
on a Public–Private Partnership basis. On 18 December 2018, PM Modi laid the
foundation stone for Line 3. Construction on Line 3 was started in January
2020.
 INTRODUCTION

Pune is well known as the ‘Queen of Deccan’ due to its scenic beauty and
rich natural resources. Besides, it is famous for its religious and historical
places. Pune city is known in the world map because of its educational,
research and development institutions. The district also has an importance
as an important military base. Pune is the most industrialized district in
western Maharashtra and a famous IT hub in the country. Pune exemplifies
an indigenous Marathi culture and ethos, in which education, arts & crafts
and theaters are given due prominence. Pune is the cultural capital of
Maharashtra. It is the birth place of the poet-saint Tukaram. It is the home
of great freedom fighters like Bal Gangadhar Tilak, Agarkar and Gopal
Krishna Gokhale. Jayant Narlikar, the famous contemporary scientist is
from Pune. Location Pune district is located between 170 54’ and 100 24’
North Latitude and 73019 and 750 10’ East Longitude. The district is
bound by Ahmadnagar district on the north-east, Solapur district on the
south-east, Satara district on south, Raigad district on the west and Thane
district on the north-west. Pune district forms a part of the tropical
monsoon land and therefore shows a significant seasonal variation in
temperature as well as rainfall conditions. Climate of the western region
of Pune is cool whereas the eastern part is hot and dry.

Road Network
Pune district is well connected with the state capital and surrounding
headquarters through road and rail linkages. The road network consists of
Express Highways. National Highways, State Highways and Major
District Roads.

The district has total length of 13,642 km of roads. Following National

Highways pass through the district : 1. National Highway No. 4 (Mumbai-
Bangalore) 2. National Highway No. 9 (Pune-Solapur-Hyderabad) 3.
National Highway No. 50 (Pune-Nashik)
 Rail Network
The district has a total rail network of 311 km. Pune and Daund are the
two major junction stations. Following are the three main railway routes
pass through the district: 1. Mumbai-Pune-Solapur 2. Pune-Miraj 3.
Daund-Baramti. Air Route Pune is well connected through domestic
airlines with the entire country.

The airport located at Lohgaon has recently acquired status of an

international airport. Also it is proposed to develop an international air-
cargo hub near Khed Tahsil of the district

Demographic Profile The total population of the study area in 2001 was
35.6 lakhs. The decadal growth in PCMC area is almost 100% in the past
3 decades. PMC area has registered an average decadal growth of around
35% and a decline in population is observed in both the cantonments. The
population figures of study area for the base year 2011 and estimated
population for the horizon years are as under:

Traffic Demand Forecast

Based on the experience of Delhi Metro the optimistic projections are normally
not achieved and it is felt that initially the most likely rider ship may only
materialize. Hence, the all further planning for the Metro infrastructure is done
for catering the most likely projections
 NEED FOR METRO

Public Transport System is an efficient user of space and with reduced

level of air and noise pollution. As the population of a city grows, share
of public transport, whether road or rail-based, should increase.
Experience has shown that, in cities like Pune where roads do not have
adequate width and which cater to mixed traffic conditions comprising
slow and fast moving vehicles, road transport can optimally carry 8,000
persons per hour per direction (phpdt). When traffic density increases
beyond this level, average speed of vehicles comes down, journey time
increases, air population goes up and commuters are put to increased
level, of inconvenience. Thus when on a corridor, traffic density during
peak hours crosses this figure, provision of rail-based mass transport, i.e.
Metro system should be considered.

Advantages Of Metro System  Requires 1/5th energy per passenger km

compared to road-based system.  Causes no air pollution in the city. 
Causes lesser noise level  Occupies no road space, if underground and
only about 2 metres width of the road, if elevated, carries same amount
of traffic as 5 lanes of bus traffic or 12 lanes of private motor cars (either
way), if it is a light capacity system.  Is more reliable, comfortable and
safer than road based system  Reduces journey time by anything
between 50% and 75% depending on road conditions
 CASTING OF SEGMENTS
CONTENTS
1. Introduction
2. Definitions
3. Responsibilities and authorities
4. References
5. List of moulds and equipments
6. Sequence of casting
a. Sequence of casting for Typical segments
b. Sequence of casting for Pier segments
7. Time cycle for casting
8. Reinforcement work
a. Rebar jig
b. Rebar cage
9. Cover blocks
10. Concreting
11. Debonding agent

12. Embedded items

13. Geometry controls
14. Marking of segments
15. Curing of segments
16. Strength requirements
17. De-Shuttering of segments
18. Lifting of segments
19. Post pour inspection
20. Sandblasting
21. Handling and Stacking of units
22. Casting of curved span
22. Safety, health and environment
 1. INTRODUCTION

Casting Yard
A casting yard is a very important place where concrete segments are casted in a controlled
environment and shifted to their stack yard after being cured for the specific period before
shifting them to the working site once they gain their required strength.
In casting yard we have seen all the detailing including bar bending machine, Reinforcement
cage formation, Steam curing, moulding, concreting, removing formwork, stacking of rings,
Quality control lab, safety precautions, detailed drawings, etc.
Casting yard is located at wagholi (plan closed) where complete set is made to take up
precast segments casting works. The facilites provided here are as given below.
Casting yard is divided into four parts i.e Bay1,Bay2,Bay3 and steel yard.

1. Casting Bed
a. Long Line casting beds for straight span upto 34m
Moulds for casting of segment
o Mould for casting of pier segment – EJ1-EJ2
o Mould for casting of intermediate varying segments- S1 and S10
o Mould for casting of intermediate typical segments- S2-S9
o Pier Segment Beds- 7Nos
o Rebar Tying Area
o Batching Plant
o Rebar Fabrication and storage Yard
o Segments Stacking Yard
o Storage of Aggregate, Cement, Pre-stressing Materials, general civil and mechanical
items
o QC Laboratory with Water Storage curing tank
o Office blocks, Generator shed, Access road
o Survey Towers & Pedestals for general inspection / sleeve checking of segments
o Gantry Crane 125 T capacities (1 Nos), 75T capacities (3 Nos) and 15 T capacities (3
Nos)
o Curing Area for completed segments
 INFORMATION ABOUT CASTING YARD

SR.NO. ASSETS BAY 1 BAY 2 BAY 3

1 75 TON GANTRY 2 1 N/A
2 15 TON GANTRY 1 1 1
3 125 TON GANTRY N/A N/A 1
4 LONG LINE STRAIGHT (34M) 1 N/A 1
5 LONG LINE CURVE (34M) 3 N/A N/A
6 SHORT LINE 4 4 N/A
7 LONG LINE OUTER SET 10 6 N/A
8 SHORT LINE OUTER SET 4 4 N/A
9 CPC BED N/A N/A 4
10 PPC BED N/A N/A 4
11 CPC SHUTTER SET N/A N/A 2
12 PPC SHUTTER SET N/A N/A 2
13 SEGMENT JIG 11 8 0
14 CPC STOOL N/A N/A 3
15 PPC JIG N/A N/A 4
16 SURVEY TOWERS 4 4 2
17 STACKING CAPACITY 490 490 144
 CASTING OF SEGMENT

\
 List Of Moulds And Equipments In Casting Yard

Sr No. Description Type Capacity Nos.

Long line Casting Intermediate
1 - 1
bed for straight span segments
Long line Casting Intermediate
2 - 6
bed for curved span segments
3 Casting bed Pier segments - 8
4 Casting moulds EJ1-EJ2 - 7
5 Gantry Crane EOT 75T 3
6 Gantry Crane EOT 15T 3
7 Gantry Crane EOT 125T 1
8 Shutter Vibrators - - 16
Internal 40mm 4
9 Needle Vibrators
60mm 9
10 Transit Mixers - - 4
Concrete Placer
11 Boom/ Concrete - - 1/2
Stationary Pump
12 Curing Pump - - 5
30cum/hour 1
13 Batching Plant -
60cum/hour 1

 There are three types of moulds for casting of segment

a. Pier Segment Mould- EJ1-EJ2
b. Intermediate Varying Segment Mould for segment- S1 and S11
c. Intermediate Typical Segment Mould for segment- S2-S10
d. Each mould comprises 3 major components- Outer Shutter,
Bottom Shutter and Core Shutter. Bottom Shuttering is
supported on casting bed pedestals. Outer shutters supported on
bottom bed assembly. Core shutter is supported on the movable
Rail.
Gantry Girder 15T Capacity

Gantry Girder 125T Capacity

Gantry Girder 75T Capacity

Needle Vibrator
Reinforcement Bar Jig

External form work

Definitions

Jig : Refers to the steel cage fabrication frame that is required for the fabrication of
geometrically and dimensionally accurate steel cages. Separate jigs for EJ-segment/varying
segments S1-S10 segments are fabricated in required no’s to prepare the reinforcement cages
in advance so as to expedite the work
Pier Segments: Two pier segments for both ends of a given span of segments. This segment
is cast as the Wet Cast Segment against the bulkhead on both sides.
Wet Cast Segment (W/C): The segment being cast within the casting mould. One face is
formed using a bulkhead with anchor cone fixed to it and the other face is formed using
bulkhead with shear keys.
Match Cast Segment (M/C): Used to form one bulkhead face (match cast face) of the Wet
Cast Segment. The match cast face (face against the W/C segment) must be coated with a
suitable bond breaker so that the joint at the interface between the M/C and W/C segments
separates cleanly at stripping with no spalling of either face.
Anchor Head: Hardware which holds the wedges of a multi-strand tendon and transfers
tendon force to the bearing plate.
Bearing Plate: Hardware that transfer the tendon force into the structure.
Wedge: A conically shaped device that anchors the strand in the anchor head.
Duct: Material forming a conduit to accommodate post tensioning tendon installation. It is
made of HDPE.
Responsibilities And Authorities:
The Construction Manager: is responsible for coordinating construction operations related
to the elevated corridor including the start-up and production of the casting Yard ,
Substructure , Erection and post tensioning areas. He is the final responsible individual for
safety, quality and production of the project within the scope of work of J KUMAR
INFRAPROJECTS LTD
The Precast Yard Manager: is responsible for the day to day management of all work
performed at the casting yard.
The Quality Assurance Manager: in coordination with the Precast Yard Manager is
responsible for initiating Work Methods and Inspections and Tests Plans covering all
construction aspects of the project.
The Field QC Engineers
The Safety Coordinator
The Environmental Coordinator
The Manager of Survey
The Survey Crews
The Shift-in-Charge(SIF)
References:
1. Contract/Tender Documents -Technical Specifications
2. Good For Construction Drawing
3. MORTH Specification
4. IS 456 : 2000 – Plain & Reinforced concrete
5. IS 1786 : 2008 High strength deformed steel bars & wires for concrete reinforcement
6. IS 9417 : 1989 Recommendation for welding cold worked bars for reinforced
concrete construction
7. Bar Bending Schedule
8. Project Quality Plan
9. Safety , Health & Environment Plan .
Sequence Of Casting:
A. Sequence Of Casting for Typical Segment :
The Pier segements were cast first on independent bed and brought to the long line
casting bed to form the match cast segments for casting the adjacent segments (S2 or
S9).
The sequence of casting for Typical Segments in long line bed as follows:

a) Preparation of segment reinforcement cage (incl. Cutting,bending and fixing

of reinforcement. )
b) Aligning of the soffit formwork for straight span or curved span of required
radius of curvature and placing of outer formwork with bed.

Casting Of Pier Segment

Pier Segment

c) Fixing the gap plates at the joints between the soffit forms.
d) Placing the pier segments.
e) Application of curing compound at match face of pier segment for casting
intermediate segments (i.e. S2 to S9).
f) Applying shuttering oil over the shuttering.
 g) Lowering and positioning of the reinforcement cage. Lifting of reinforcement
cage by means of Spredor beam and placing it to the aligned Bed.
h) Installation of sheathing pipe.
i) Profiling the sheathing pipe as per co-ordinates (X,Y,Z axis). For post-
tensioning.
j) Bringing the formwork traveller and locking it in a position.
k) Closing of an external and internal formwork and placing of Parapet
formwork.
l) Installation of all inserts, Lifting holes, temporary stressing arrangements etc.
m) Concrete Pouring ( Casting of Segment)
n) Allow setting of concrete.
o) De-shuttering the bulkhead, external and internal formwork
p) Moving the formwork traveller to the next segment.
q) Curing of segment.
r) Casting of next segment.
s) Lifting of segment and shifting it to the stacking yard.
t) Dispatch of segment to site for Erection.

2. Sequence of Casting for Pier Segments:

a) Aligning and levelling of soffit formwork for the Pier segment.
b) Aligning the first Bulkhead in position (Anchorage Side).
c) Fixing the guide cones on bulkhead.
d) Application of shuttering Oil.
e) Placing of Reinforcement Cage.
f) Installation of sheathing Pipes.

Sequence of Casting for Pier Segments:

g) Closing the external formworks of pier segment.
h) Installation of inserts for lifting holes etc. and installation of drainage pipes.
i) Aligning the 2nd Bulkhead in position (S2 or S10 side).
j) Providing internal formworks.
k) Casting of the Segment.
l) Allow setting of concrete.
m) De-shuttering the formwork.
n) Curing of Pier Segment.
Internal Formwork Trolley
Time Cycle For Casting:
Both the pier segments of a span shall be cast simultaneously in advance. The casting of
further segments may advance on long line bed. The Time cycles for casting of intermediate
segments on Long Line bed and pier segment on separate bed are presented in table-1 and
table-2.
 Time Cycle for Casting of Pier Segment EJ on Pier
Segment Bed

SL.No Activity Time(hours) CUMMULATIVE(hrs)

1 Clean of the bed 0.5 0.5
2 Down Stand Alignment, Levelling, 4.0 4.5
Grouting & Inspection

3 Fix the external formwork (outer 1.5 6.0

shutter) including cleaning and
application of shuttering oil

4 Fix the anchorages to the end block 2.0 8.0

shutter

5 Lower the rebar cage and place it over 1.0 9.0

casting bed using 10T Gantry

6 Attach the sheathing pipe to the 1.0 11.0

trumpet/profile and fix it.

7 Inspection by client 1.0 11.0

8 Fix and shutter towards span side and 1.0 12.0
close the formwork including fixing of
internal shuttering to both side and
stoppers

9 Provide inserts, holes etc. for lifting & 1.0 13.0

temporary pre-stressing

10 Fix end stopper/bulk head shutter 1.0 14.0

11 Inspection and approval from client for 1.0 15.0
concreting

12 Concreting of the segment 2.0 17.0

13 Setting Time for concrete and waiting 12.0 29.0
period for demoulding

14 Demoulding of the segment 1.5 30.5

15 Waiting period for Lifting Segment 34.5 65.0
Total Hrs 65.0 65.0
 Time Cycle for Casting of Typical/Intermediate
Segments:

SL. ACTIVITY TIME CUMU-

NO IN (Hrs) LATIVE (Hrs)

1 De-moulding of previous segment including collapse of 1.0 1.0

internal shuttering and loosening of outer shutter with the
help of various turnbuckles provided in the shuttering
frames (outer/inner shutter).

2 Clean the bed for the next segment 1.0 2.0

3 Shifting of mould to next location i.e. sliding/ shifting of 1.5 3.5

the outer and inner shutter to next segment location and
cleaning and application of shuttering oil
4 Apply de-bonding agent 1.0 4.5

5 Place of the rebar cage with the help of 10T Gantry 1.0 5.5

6 Fixing of sheathing pipe including its connection to match 1.5 7.0

cast the segment.

7 Inspection by client 1.0 8.0

8 Move the internal shutter and fix the same butting against 1.5 9.5
match cast segment

9 Provide inserts, holes etc. for lifting and temporary pre- 1.0 10.5
stressing purpose

10 Fix end stopper/bulk head 1.0 11.5

11 Inspection and Approval from client for concreting 1.0 12.5

12 Concreting of the segment 4.0 16.5

13 Setting time for concrete 12.0 28.5

14 De-moulding of segment 2.0 30.5

TOTAL HOURS 30.5 30.5

REINFORCEMENT WORK:

 Reinforcement Cutting and bending done by cutting bending machine with skilled and
experienced worker, By taking reference from the approved BBS.
 After that fixing of the reinforcement done by skilled workers in the segment shape
JIG
 After fixing of reinforcement the cage is checked by client and after taking permission
from client we proceed for the next step.

a) Rebar Jig: 10 Rebar Jigs for intermediate segments and 4 Rebar Jigs for pier
segments shall be provided with 35 mm clear concrete cover for Web and 25 mm
for Deck & soffit from sides of concrete surface. Each casting bed/mould shall
have a dedicated jig for installation of its rebar cage.

Rebar Jig

b) Reinforcement Bar Cage: As per approved BBS, the reinforcement bars were cut
and bent by using bending machine at the centralized reinforcement yard adjacent
to the casting bed.
 Bar Bending and Cutting Machine

o The bent bars were shifted to the respective rebar cage jigs where they
were tied by using GI binding wire according to the approved drawings.
o Prior to preparation of rebar cage , the bar bending schedule is prepared as
per GFC drawings issued for each span geometry considering the span
geometry into account of pier segment (which shall be remain same for
curved/straight span), varying segment and typical segment.
o Rebars shall be checked for corrosion, contaminants , surface cracks ,
damage .
o The corrugated HDPE sheathing ducts shall be fixed inside the rebar cage
at the required location as detailed in approved tendon profile drawings -
and held in position using hooks within tolerance.
o Using Gantry Crane, the cage shall be lifted with a structural frame
holding the cage in a manner to prevent any distortion while lifting and
placing it in position inside the casting mould.
o Re-check the HDPE Sheathing ducts position and profile tp ensure that
they are not disturbed during placing in the mould.
o The circular cross section of the HDPE pipe shall be maintained at
bulkhead and Match cast end location before and after the concreting.
COVER BLOCKS:
o Cover blocks are provided to maintain 35mm in web portion & 25mm for deck &
soffit slab clear cover to the reinforcement as per the drawings.
o Approved Cover Blocks shall be used.
o The strength of the cover block will be equal to or more than the member in
which they are being used.

o The Cover Blocks were cast from the same grade of concrete as used in segment.
The shape of the cover blocks was semi circular to ensure the clear cover as per
the drawing. These were cast and curved in advance to ensure that the cover
blocks do not crush under the rebar cage weight while placing the cage in the
Machine

Cover blocks

CONCRETING:
o After formwork completed we need to take approval for concrete Pouring.
o Concrete to be done with static Pump or Placer boom.
o During Concreting we need to check the proper arrangement of Shutter, needle
vibrators & All Tools & Tackles Required for concreting.

Prior to concreting , proper arrangements shall be in place to anticipate any

changes in climatic conditions (rain and hot weather).

Before any ordering of concrete , the Pre-pour check list shall be signed off and
completed by QC Engineer , survey Engineer and Shift-in-charge for survey
checking , reinforcement checking , shuttering checking , pre-stressing profile ,
 fixing of bearing inserts/opening for man hole/lifting hole & temporary pre-
stressing hole and approved by client representatives.

The Sequenece of concreting was as follows :

1) Soffit slab of both the sides
2) 1/3 height of outer web-1
3) 1/3 height of outer web-2
4) 2/3 height of outer web-1
5) 2/3 height of outer web-2
6) Remaining 1/3 height of web-1
7) Remaining 1/3 height of web-2
8) Entire deck slab and finish to the required deck profile.
9) Parapet wall

Concrete of M-50 grade with a slump of 125mm to 175mm, as per the approved mix
design shall be produced at the centralized Batching plant and transported to the location
by transit mixers. The concrete shall be placed in sequence as mentioned above using
concrete pump/concrete bucket as per site requirement. Tempreature of the concrete
should be maintained at minimum as per cl. 3.9 of technical specification. Concrete
Grade as per approved GFC drawings.

Concreting
Concreting
 The concrete shall be vibrated by both shutter vibrators fitted to the web/outer shutter and
needle (internal) vibrators of 40mm and 60mm for compaction of the concrete. It will be
ensured that adequate vibration shall take place at any time.

During concrete placement , steel reinforcement will be checked to ensure it stays rigidly
in place and adequately supported. Concrete shall be protected from sun, wind and other
sources of evaporation and from other contamination.

The Engineer Shall Select random batched of concrete for examination without warning
the contractor and sampling will generally done at the point of discharge from the mixer.
Concrete sampling shall be done as per cl.3.23 of technical specification.

DEBONDING AGENT:
o For separation of match-cast from web cast segment, Concure WB from from Forsroc
(or equivalence) will be applied on the end surface of match cast segment as per
manufacturer's specification and recommendation.

EMBEDDED ITEMS:
o All embedded items such as gully drain, HDPE pipe, anchorage, Earthing
Reinforcement etc. shall have been tested and approved prior to its use and shall be
provided as indicated in the Good for Construction drawings.

FIXTURES IN THE SEGMENT:

o All other fixtures such as drainage pipes, OHE mast inserts, earthing arrangements
etc. were provide as detailed in the respective drawings. After casting the segment and
before the concrete had attained initial setting time, aluminium channels were placed
along the bridge centre line at 100mm from the bulkhead and the match cast face for
use in geometry control survey works. 2nos. of rivets were embedded flush to the top
surface of the freshly poured concrete at the top flange for levelling control purpose.

GEOMETRY CONTROL:
o A covered survey tower on one end and target pole on the opposite end of the casting
bed will be utilized for geometric and survey control purposes. 50x50mm size MS
plate shall be embedded at centre line of segment al deck slab, one at each end of the
segment after concreting After testing the segment, its centre line shall be clearly
marked on these plates.
o For casting long line, bottom Font shuttering will be arranged to the actual soffit
profile as per span geometry, thus the only control required is matching of centre line
along the crown and top levels of deck slab during subsequent casting operations.
 Survey Towers

MARKING OF SEGMENTS:
o Segments shall be marked immediately after removing the side forms with paint of
approved quality. The elements shall be marked on the outer faces of web and the ends
with the following detail, as per 06.14 7 & 11.4.2 of technical specification.

o a) Segment Number & ID.

o b) Date of casting of segment.

CURING OF SEGMENTS:
o Curing of concrete shall be done by water. Minimum wet outing will be for 7 days by
ponding water followed by moist curing by spraying water which will be maintained
up to total period of at least 21 days from the date of casting.
o Immediately after compaction and completion of any surface finishes the concrete
shall be protected from evaporation of moisture by mean of wet hessian cloth kept
socked by spraying.
 .

Curing of segments

STRENGTH REQUIREMENTS:
o Grab samples for cubes strengths shall be 15, 20 and 50 MPa for release, lifting and 28
days strengths respectively.
o 14 days grab samples shall also be taken.
o Test results shall be entered into the Concrete Test Report maintained at lab Concrete
cubes are to be tested at 14 hrs, 24hrs, 14 days and 28 days age generally.

DE-SHUTTERING OF SEGMENTS:
o Shuttering shall only be removed after sign-off from the OC Lab Engineer and the
Survey Engineer. This is to ensure that the concrete has attained the minimum 20 MPa
strength As per cl3.1.1 of IRC SP 65 2005.
o The core shutter will be collapsed using the turn-buckles and then pulled out. The
outer shutter will be released by the turn-buckles and pulled outwards.
o The frame supporting core and outer shutters are shifted to the next location by
moving them on carrier rails.
o After de shuttering, Marking of Segment as per span geometry shall be made before
lifting from the bed.
 De-shuttering of segment

LIFTING OF SEGMENTS:
o The match cast segment will be fitted with the approved lifting frame and approved PT
bars and assembly through the lifting holes provided at the time of casting of the
segment.
o After achieving 25MPA strength, segment is lifted from the shutter by the 75 ton
capacity Gantry Crane and placed at the stacking yard as shown in the drawing.
o The Lifting of segment shall be allowed only after concrete attains a min. of 25MPA
compressive strength.

Lifting of segment
POST POUR INSPECTION:
o It shall be performed immediately after removal bed and stacking at yard. Post pour
inspection of segments at stacking yard before dispatch to the site for erection.
o Segment requires through Inspection in respect of anchorage cones ducts, holes and
bearing pedestals etc which need to be cleaned before transportation to the site.
o After final concrete strength checked, Deficiencies repaired, faces are free of bond
breaker by sand blasting, and then only the segments may be transported to the
erection site.

SAND BLASTING:
o Sand Blasting of segments will be done at stacking area.
o The purpose of sand blasting is to remove the de bonding agent and clean the segment
from any laitance, dirt & foreign material etc just before it is transported to the
erection site.
o Sand blasting shall be applied gently just for without causing damage to the concrete
surface Sand blasting shot be applied using dry fine sand & compressed air through
sand blasting equipment.

HANDLING AND STACKING OF UNITS:

o After inspection and sand blasting completion, a spreader beam attached to the Gantry
crane and fastened to the lifting lugs of the segments will lift the segments.
o The segments will be shifted and stacked on stacking pedestals with Concrete
Pedestals/ wooden stools provided in the yard for its specific purpose.
o The segments will be stacked on 4-point support system as per cl. 11.4.4 of technical
specifications.

CASTING OF CURVED SPAN:

a) Casting bed for curved span:
o Casting of curved spans shall be done on long line bed.
o The width of Bed for curved span shall be 2850mm for intermediate
typical segments so that the beds for curved spans will cover 2850
mm width out of 3000mm for typical segment between ends of comer
curves on bottom side of segment soffit.
o The remaining 150 mm shall be added by inserting mild steel wedge
plates welded/ bolted to the bed and surface finished using grinders.
o The shape of these wedges will vary with the length of the span to be
cast, radius of its plan curvature and arrangement of 3,000 mm wide
straight bed between outer curve lines of the bottom surface of the
span planned for its casting.
 o A typical drawing showing the "Schematic Details of Bottom Shutter/
bed arrangement drawings for 37.00mt span where wedge plates are
to be provided are enclosed herewith for clarity.

b) Edges of segments along transverse direction:

The Curved spans can be grossly categorized in three distinct categories
o Spans Lying on fully circular alignment.
o Spans Lying partly on circular alignment and partly on transition
curve.
o Spans Lying partly on transition curve and partly on straight
alignment.
Segment EJ is cast on pier segment bed separately therefore its two
edges are always parallel to each other. The edges for intermediate
segments will not be parallel to each other in most of the cases, however
in certain circumstances they may be planned parallel to each other for
some segments of the span.

c) Governing Criteria:
o The Length of outer shutter for Typical segment is 3200mm as per
drawing no--- for 3000mm long segment.
o Therefore the planning of segment edge line should be such that the
maximum length of segment does not exceed 3100mm when cast
against already cast segments on one edge and end shutter provided
on the other edge
o so that an overlap of at least 50 mm is maintained between outer
shutter and the surface of already cast segment.

d) Geometry Control:
o Three points “A, B and C” shall be marked over the edge of the
casting bed as shown in the typical drawing attached.
o The coordinate system for the layout of the bed shall be set with the
help of Total Station (Survey Instrument) using the coordinates of
the three points already marked on the edge of the bed
o The details of bottom shutter also provides coordinates of the
segment edges along the centre line of span using which the exact
position of casting of various segments can be set out.
e) Steps
o Prepare shuttering for a particular radius by replacing wedges as per
the details of the particular span to be cast.
o Bring pier segment at its position and align with the help of
coordinates detailed out in the drawing for the particular span to be
cast
o Mark start and end points of the segments on the shuttering along
centre line by the coordinates provided
o Adjust the inner and outer shutter using the casting length shown in
the drawing
o Place the rebar cage
o Place the end shutter along the segment edge line shown in the
drawing
o Perform other check pertaining to reinforcement, pre-stressing cable
duct and other inserts
o Cast the segment
o Repeat the steps and cast all the segments starting from both end of
the span and moving towards mid span segment
o After casting of every segment check the plan dimensions and
coordinates of previously cast segments, and in case of any error
adjust the next segment compensating the previous errors and
complete the casting of entire span.
SAFETY, HEALTH AND ENVIRONMENT
o The casting yard shall be maintained and ensured that it is neat and clean at all times.
o All moving parts, tanks and high level working shall be prevented by cover, guard,
fence or handrail.
o SHE morning tool box talk shall be conducted twice a week.
o PPE shall be provided and used at all times J KUMAR INFRAPROJECTS LTD shall
provide training to all personnel.
o As per SHE manual all work areas above 1.8 m shall have safe access, platforms and
handrails.

MANDATORY SAFETY MEASURES:

o Work shall be executed in competent & continuous supervision Any unauthorized
activity shall be strictly prohibited
o Lifting of reinforcement cage, casted segment shall be done in strictly prohibited
o There should be properly co-ordination and communication between teams/workmen
at all times.
o Proper housekeeping shall be maintained.
o Required inspection shall be carried out prior to start.
o Working under suspended load shall be strictly prohibited.
Drawings
Drawings
 LOAD TESTING OF PILES

Pile load test is the most direct method for determining the safe loads on piles including
its structural capacity with respect to soil in which it is installed. It is considered more
reliable on account of its being in-situ test, then the capacities computed by other methods,
such as static formulae, dynamic formulae and penetration test data.
The purpose of the test is to determine the compression capacity & Lateral Load carrying
capacity of the Preliminary test pile at the maximum working loads multiplied by the load
factor 2.5. The working load on the pile is 532 tons and the reaction system is to be
designed for a maximum compression load of 1,330 tons. Initial Vertical Test Load is
1330 T. The Lateral working Load of pile is 10 T & Initial Lateral Test Load is 25 T

 MACHINERY, TOOLS, EQUIPMENTS AND MATERIALS

 MAJOR EQUIPMENTS /TOOLS

Following major equipment/ tools shall be in the construction of a Bore-in-Situ

Pile
S. DESCRIPTION CAPACITY NO.
No.
Reaction girder assembly —
1 1
complete set.
1000T/other required
2. Hydraulic Jacks Capacity as per Site 2
condition

3. Hydraulic Pump / Power Pack 700 kg/sq.cm 1

1000 kg/sq.cm , least
4. Calibrated Pressure Gauge count 1
20 mm
5. Calibrated Dial Gauge 0.01 mm least count 4
6. Rigid Datum Bars 2
Crane 30-35 T Capacity 1
The number of equipment mentioned above may increase or decrease as per actual
site condition. Any other equipment, machinery, tools and plants etc. whenever
required to complete the scope successfully shall be deployed.

TYPES OF TESTS

1. Static Vertical Load Test

a) Setting Out:

The position of test pile location shall be set out by J. Kumar Infraprojects
Ltd. It shall be jointly checked along with client's representative, with
reference to suitable marking points fixed on location. Once the centre
point of test pile is fixed, centre points of 4 reaction piles shall be marked
on the ground as per reaction assembly drawing. Locations of centre points
of four reaction piles shall also be jointly checked along with client's
representative.

b) Test Pile:
The Test Pile shall be built up to the proper length. The construction
of test shall be built as per the approved method.

c) Pile Head Construction:

The pile head shall be prepared during the concreting of the pile. GP-
2 Material is used for Pile Head Construction. The reinforcement
including helical shall be provided up to top of pile. The pile head to
be levelled and smoothened for the even seating of the jacks.

d) Working Platform Level:

The static load of piles shall be carried out from an approved working
platform level. Concrete cubes shall be tested to check the concrete
strength before starting the pile load test. No test shall be started before
achieving the design compressive strength of concrete.
e) Loading System:
Load shall be applied using an approved reaction system.
Compression force on the pile will be applied directly to the pile
head. The reaction will be provided by reaction anchors tied to crown
system. Hydraulic jack shall be used for load application.
f) Measuring System:
Load applied by the jack shall be measured by pressure gauge. The
calibration certificates of all loading devices shall be submitted prior
to the testing.
Movement of the pile shall be measured by dial gauges fixed to datum
bean-I and having a least count of 0.01 mm. A minimum of four dial
gauges placed at 900 on the datum beam. The datum beams shall be
provided with rigid supports. The datum beam to be simply supported
at distance of 3.0 m from the test pile and any part of the reaction
system. The testing shall be carried out under the supervision of an
experienced Engineer.
g) Method of Pile Test:
The test shall be conducted as outlined below:Loading shall be
applied to the pile top increments as specified in the table below. Each
stage shall be maintained for a period till the rate of movement of the
pile is less than 0.20 mm / hr.

h) Test Load (STATIC):

Preliminary test pile
For Preliminary Test Pile- 1000mm diameter, working load of 532 tons
and tested up to 1,330 tons.

i) Measurement of Pile Movement:

The settlements are recorded with 4 numbers dial gauges with an
accuracy of 1/100 mm. The recorded load test results shall be
represented in the following ways:
  Analysis of test observations shall be carried out by plotting load
verses settlement curve on natural scale, in accordance with IS: 2911
Part-4.

 The safe load on single pile shall be obtained from load-displacement

curve and shall be least of the following:
o Two-third of the final load at which the total displacement attains a
value of 18 mm or 2% of the pile diameter whichever is less;
 Fifty percent of the final load at which the total displacement equal
10 percent of the pile diameter.

j) Results:
The test results will be presented as specification
The following graphs will be included:

 Time Load Diagram

 Load settlement Diagram
 Time settlement Diagram

k) Performance of the tests:

Load 532 MT

Area of one jack 1386.4 sq.cm

Area of two jacks 2772.8 sq.cm

 PRELIMINARY PILE TEST (STATIC) TEST PROCEDURE:
% of
Cycle Load(
Design Pressure(kg/cm2) Reading Interval
no T)
load
1 20 100.00 36.06 0, 15, 30, 45 min, 1 Hrs
40 200.00 72.13 0 , 15 , 30 , 45min ., 1 Hrs.
3 60 300.00 108.19 0 , 15 , 30 , 45min ., 1 Hrs.
4 80 400.00 144.26 0 , 15 , 30 , 45tnin ., 1 Hrs.
5 100 500.00 180.32 0 , 15 , 30 , 45min .,
6 120 600.00 216.39 0 , 15 , 30 , 45min ., 1 Hrs.
7 140 700.00 252.45 0 , 15 , 30 , 45min ., 1 Hrs.
8 160 800.00 288.52 0 , 15 , 30 , 45min ., 1 Hrs.
9 180 900.00 324.58 0 , 15 , 30 , 45min .,1 1-1rs.
10 200 1000.00 360.65 0 , 15 , 30 , 45min ., 1 Hts.
11 220 1100.00 396.71 0 , 15 , 30 , 45min ., 1 Hrs.
12 240 1200.00 4.32.78 o , 1 5 , 30 , 45min 1 Hrs
13 250 1250.00 450.81 0,15,30,45min.,1hts......24hrs.
12 240 1200.00 432.78 0 , 15,30 min.
11 220 1100.00 396.71 0 , 15,30 min.
10 200 1000.00 360.65 0 , 15,30 min.
9 180 900.00 324.58 O , 15,30 min.
8 160 800.00 288.52 0 , 15,30 min.
7 140 700.00 252.45 0 , 15,30 tnin.
6 120 600.00 216.39 0 , 15,30 min.
5 100 500.00 180.32 0 , 15,30 min.
4 80 400.00 144.26 O , 15,30 min.
3 60 300.00 108.19 o , 15,30
2 40 200.00 72.13 0 , 15,30 min.
1 20 100.00 36.06 0 , 15,30 min.
0.00 0.00 O , 15,30 min.

Note: - Next load step shall be applied only if the rate of settlement has become less than
0.2() per hour.

a) Installation of Reaction System for Static Load Test:

The reaction system for all compression preliminary test pile will be
provided by the ground anchors tied back to the crown.
b) Installation of Ground Anchors:
Ground anchors shall be installed for the static compression load test setup
in order to provide reaction to the loading system. Loads on each anchor
and its dimensioning are made as elaborated in the design. The Engineer
will be notified prior to the installation of any anchor to satisfy that the
installation the anchors will not have any detrimental effects on any
structures adjacent to the test pile.

c) Installation Procedure:
A powerful anchoring drill shall be used to install the ground anchors,
following sequence shall be adopted for the installation of the anchors.
a. Install the anchor machine at approximately the same level of the anchor
head. Adjust the swing mast to the required inclination to meet the
design/ site requirement.
b. Temporary steel casing shall be drilled through the soil with the help of
its water flush system. In order to prevent any escape of soil while
drilling, the casing shall be provided with an end plug.
Note: Extreme care shall be taken to avoid any damage of underground
structures while installing the anchor. In case of existence of any
obstructions such as pile foundations, the direction of the anchors can
be shifted to any adjustable mast if anchoring machine or the position
of the anchor itself can be relocated. The drilling system provided on
anchoring machine allows the operator to observe any obstruction.
c. After reaching the required depth, readymade anchor with grout pipe at
the middle will be inserted into the casing. The temporary casing shall be
withdrawn whilst filling the bore with primary cement grout. The grout
will carry on until the grout has replaced the water in hole. Temperature
of grout is 30 degree Celsius and grout is free flow.
 Temperature of Grout material is 300 c and the grout is a free flow.

- Cement grout rnixture (per batch) : 2 bags cement - 100 kg

55 litres water - 55 kg
W/ C ratio - 0.55
Design compressive strength of the grout at 28 days 25
N/mm2

The equipment used for grout mixture:

 Grout mixer
 Pressure Pump

1. STATIC LATERAL LOAD TEST

a) Pile Head Construction:

The pile head shall be prepared during the concreting of the pile. The
reinforcement including helical shall be provided up to top of pile. A
steel frame shall be welded to the bolts placed on the pile and the Lateral
force will be induced.

b) Loading System:
Load shall be applied using a hydraulic jack of adequate capacity,
abutting the pile horizontally and reacting against a suitable system. The
reaction will be provided by natural ground. Thrust pieces shall be
inserted on the either end of the jack to make up the gap. The Lateral
Load shall be applied on the test pile through the I beam.

c) Measuring System:
Load applied by the jack shall be measured by calibrated pressure
gauge. Deflection of the pile head shall be measured by dial gauges
fixed to datum beam and having a least count of least count of 0.01
mm. The datum bars shall be provided with rigid supports. The testing
shall be carried out under the supervision of an experienced Engineer.
Calibration certificate shall be submitted before starting the test.

d) Method of Pile Test:

After completion of all above arrangements, application of test load shall
be initiated in the following manner:
a. The load shall be applied in increments of about 20% of the safe lateral
load (exact percentage of increment of load shall be depend on ram
diameter of hydraulic jack & least count of pressure gauge).
b. The load increment to be applied in are as follows (xxmt , xxmt,. .. .all the
load increment to be added here)
c. The next increment shall be applied after the rate of displacement is near
to 0.1 mm per 30 minutes. On meeting this criterion next increment shall
be applied.
d. The final test load shall be maintained for 12 hours for observation and
displacement shall be recorded at every one hour.
e. After 12 hours of observation of test load, unloading of test load shall be
started in same stages as loading and readings are recorded for rebound.
The procedure shall be continued till the unloading of entire load

PRELIMINARY PILE TEST LATERAL TEST PROCEDURE:

C cle % of Design Load T) Pressure(kg/cm2 Reading
no load Interval
1 20 2 7.05 o 15 , 30 min
2 40 4 14.11 o, 15 , 30 min
3 60 6 21.16 o, 15 , 30 min
4 80 8 28.22 o, 15 , 30 min
5 100 10 35.27 o 15, 30 min
6 120 12 42.33 o, 15 30 min
7 140 14 49.38 o, 15 30 min
8 160 16 56.44 o 15 , 30 min
9 180 18 63.49 o, 15 , 30 min
10 200 20 70.55 o, 15 , 30 min
11 220 22 77.60 o, 15 , 30 min
12 240 24 84.66 o, 15 , 30 min
13 250 25 88.18 O,1hrs......24hrs.
12 240 24 84.66 o, 15 30 min
11 220 22 77.60 o 15, 30 min
10 200 20 70.55 o, 15 , 30 min
9 180 18 63.49 o, 15 , 30 min
8 160 16 56.44 o, 15, 30 min
7 140 14 49.38 o, 15 30 min
6 120 12 42.33 o, 15 30 min
5 100 10 35.27 o, 15 30 min
4 80 8 28.22 o, 15, 30 min
3 60 6 21.16 o, 15 , 30 min
2 40 4 14.11 o, 15 , 30 min
1 20 2 7.05 o, 15 , 30 min
o o 0.00 O, 15,30 min.
e) Test Load:
Preliminary test pile
For Preliminary Test Pile- 1000mm diameter, Lateral load of 10 tons and
tested up to 25 tons.

f) Measurement of Pile Movement:

The displacements are recorded with minimum 2 numbers dial gauges with an
accuracy of 1/100 mm, As per clause 8.4.1 of IS: 2911 (part4), safe lateral load
on the pile shall be taken as Max. Settlement at test load should not greater
than 5 mm".

g) Results:
The Test Results will be presented as per Specification
Following Graphs will be included
 Load Displacement Diagram
 Time Displacement Diagram
 PILE INTEGRITY TESTING

INTRODUCTION:
Pile Integrity Testing (PIT) is a Non-Destructive integrity test method for foundation piles.
The method evaluates continuity of the pile shaft and provides information on any potential
defects due to honeycombs, necking (cross-section reduction), potential bulbs, sudden
changes in soil stratum, concrete quality in terms of wave speed etc. It is known as “Low
Strain” method since it requires the impact of only a small hand-held hammer and the
resultant strains are of extremely low magnitude. The test procedure is standardized as per
ASTM D5882 and also forms part of various specifications and code provisions worldwide.
The number of tests shall be decided by the engineer to the project.
The testing method and interpretation requires expert interpretation and analysis. It is
desirable that the agency employed for testing proves its competence by submitting past
studies and expertise. In India, Geo Dynamics owns and operates the Pile Integrity Tester
system procured from Pile Dynamics, Inc., and has several years of experience in testing and
is considered to be a pioneer in country.

TEST EQUIPMENT:
Equipment: PIT-V Equipment manufactured by Pile Dynamics, Inc., USA compliant
with ASTM D5882

Software: PIT-W 2009 Software Standard Version

This is currently best equipment available worldwide with use in most countries across the
world and Geo Dynamics operates more than 20 such equipment in India. The equipment
includes a sensitive accelerometer and a non-instrumented hammer, in addition to the device.
The data is displayed on the field for preliminary evaluation and interpretation, and a field
printout is possible.

SITE ARRANGEMENTS:
The pile head with sound concrete shall be available for testing. For this pile head should be
chipped off up to cut off level or up to the depth where sound concrete is available. The sound
concrete level can be obtained after removal of any debris, muck etc. from the top.
The pile concrete should attain at least 75% of it required compressive strength before testing
is conducted. This can be checked with the help of 7 and 28 Days cube test results.
The pile head at the testing level shall be made reasonably flat by chipping or by chisel. In
some cases it can even be done using a grinder or carborundum stone. Ensure that concrete is
sound, hard and good. No high strength mortar or cement paste shall be applied on the pile
top to make it smooth and even.
The projecting rebar need to be bent outside for easy access within core region. Safe and
reasonable access to the pile is the responsibility of the client.
Data supplied at the time of testing shall include length of the pile from testing level, cutoff
level of the pile, pile diameter and pile reference as well as location. Soil information
available for the location or in the vicinity shall be provided and is a valuable tool for
interpretation. Additional data like pile installation records, load test results etc., shall also be
supplied on request.

TEST PROCEDURE:

The testing shall be conducted by an experienced engineer / technician after at least 75% of
the required compressive strength of concrete is achieved. The concrete at the pile top surface
must be relatively smooth with sufficient space for attachment of the motion sensing device
and hammer impact area.
The testing involves attachment of an accelerometer onto the pile top (not near its edge) with
the help of bonding material like candle wax, Vaseline etc. After attachment, the pile is
impacted with a hand held device (a hand held hammer). Typically six blows are impacted to
the hammer and an average of similar of these blows constitutes one data set.
The test involves collection of several data sets for each pile so that a reasonable inference
can be obtained for each pile. For piles having diameter 600mm and above, testing maybe
conducted on at least 3 locations, whereas minimum one location is enough for smaller
diameter piles.

DATA PROCEDURE:
The data collected using PIT equipment shall be processed using PIT-W 2009 software. Once
the hammer is impacted onto the pile a wave is generated. This wave moves down the pile
and as it moves down it gets weak. It also gets affected by surrounding soil, projecting
reinforcement etc.

To ensure that the signals are clearly visible for interpretation, data shall be processed in terms
of Magnification (MA to enhance the energy lost), reduce reflections from soil to evaluate
concrete (HI PASS Filter), and reduce reflections from reinforcement (Wavelet Filter). The
MA shall be a factor of the length of the pile and normally must be equal to the pile length.
The Magnification Delay shall be default 20% to avoid errors in interpretation .

The typical data sets for good or damaged piles shall generally be as per Figure: 1 and is also
defined in ASTM D5882.
 IMPACT TOE RESPONSE DEFECT

Fig: 1 Typical Velocity Trace for Good Pile Typical Velocity Trace for Damaged Pile

REPORT SUBMISSION:
On completion of field testing, a report shall be submitted and shall clearly describe the
following
 Uniformity of pile
 Changes in cross section qualitatively i.e. bulge or defect due to necking, etc.
 Sudden changes in soil stratum based on soil profile and graphs.
 Concrete quality in terms of wave speed. A normal range of wave speed shall be
between 3500 m/sec to 4200 m/sec

The report shall clearly indicated piles that are acceptable or questionable or rejected. The
comments shall generally be based on the following guidelines.

1. Piles with toe response and no defect apparent shall be classified as acceptable.
2. Piles with no toe response and significant reduction or defect above the pile toe shall
be rejected and replacement or any other remedial action may be considered. The test
engineer should specify the approximate location of defect in such a case.
3. Piles with a sudden major increase in resistance or impedance may not show toe
response and are termed as inconclusive and a typical such pile can be selected for
static / high strain dynamic test at the discretion of the engineer.
4. Piles that show toe response but some impedance reduction / defect maybe under-rated
/ replaced / repaired / or subjected to additional high strain dynamic or static testing at
the discretion of the engineer.

Acceptance / rejection of piles in Para: 3 and 4 above shall also be based on construction
records (concrete consumption, geotechnical data, and construction method) that will
provide valuable help in result interpretation.
 LIMITATIONS:
Certain limitations are inherent in the low strain test method. These limitations must be
understood and taken into consideration in making the final integrity evaluation .
1. The test method can generally evaluate for piles up to an L/D ratio of 45 to 50.
However, this also depends on the soil resistance that may attenuate the signals.
2. This method can normally identify the first major bulb or a major defect.
Interpretation may not be possible to evaluate multiple bulges or defects as the wave
may not travel beyond the first anomaly.
3. The method is intended to find major anomalies and defects and small defects
generally up to 10% of pile diameter may not be identified with this method.
4. Although the test system can be used to evaluate length of piles, the determination of
pile length is approximate within a range of  5 – 10% due to variation in concrete
density. This implies that the method cannot evaluate defects that could be present in
the bottom 5%-10% of the pile shaft.
5. The method is not applicable to steel piles, micro piles, jointed pre-cast piles etc.
6. The method cannot be used to derive the pile capacity.

RISK AND HAZARD ASSESSMENT:

The Low Strain Integrity Test involves a handheld equipment and small hammer. No heavy
machinery is involved in such testing and hence risk associated with such testing is
classified as negligible.
Care should be taken to avoid movement of heavy machinery around the testing area.
If excavations are deep, then precautions should be taken to avoid collapse of soil at the
time of testing.

INSPECTION PLAN:
S. No Description of sub-activity QCP QHP Check by Check by
JKIL GC/MahaMetro

Screening of workmen √ - R R
1

Inspection of hand held & √ - W R

2 portable power tools

Testing material Technical Data √ - W R

3

Tool Box Talk Report √ - W R

4
Interpretation of Results
5 √ √ W W
 OPEN FOUNDATION

1.1 MACHINERY AND EQUIPMENTS

Following equipment will be used for construction of open Foundations, As
per Requirement

SI. NO Description Type/brand Remarks

1 EX205/210 Excavator with 1 No
Breaker or Equivalent
2 Dumper 2 Nos
3 Jack Hammer 1 No
4 Air compressor 150 CFM - 1No
5 Service Crane / Hydra 1 No
6 Batching Plant Stetter (Casting Detail of RMC
Yard) or mix design shall
Approved RMC be submitted
Plant separately
7 Transit Mixer Stetter or As required
Equivalent
8 Needle Vibrator with 60mm As required
needles
9 Boom Placer/Pump As required
Survey Instrument Leica Total As required
Station with all
10 accessories
Auto level with As required
all accessories

2. MATERIALS

SI. No Description Specification Remarks

1 Cement
2 Reinforcement Steel
3 Coarse Aggregate
4 Fine Aggregate
5 Water
OPC53 grade – IS 8112/
IS 12269
Fe500D – IS 1786
Table 2 of IS 383
Table 4 of IS 383
IS 456
 6 Concrete Mix As Per Approved Mix Shall be
design submitted
separately for
approval
7 Binding Wire IS 280-1978

3. METHODLOGY

The sequence of work involved in the casting of Open Foundation is as follows.

SETTING OUT OF OPEN FOUNDATION:

 Survey shall be carried out from main grid lines and foundation points
shall be marked with iron page using total station.
 The coordinates of foundation shall be submitted to GC prior to start of
activity.
 Utility shall be identified by making of trial pits.
 If required, the utility shall be shifted to other locations by coordinating
with GC and the concerned authorities of the utility.
 The utility which are not Shifted shall be marked inside the foundation
layout using paint.
 Special precautions as indicated in this method statement shall be taken
while excavating such identified areas.
 Dimensions of excavation shall be suitably increased for placing and
removal of shutters and also for shoring arrangements.

4. EXCAVATION OF OPEN FOUNDATION:

 Excavation shall be started only after obtaining the permit to dig from the
concerned
 Engineer In charge.
 Excavator shall be engaged for excavating the foundation layout.
 Excavation shall be done 500mm away from the location of utility
identified by trial pits. The 500mm left out location shall be excavated
manually and the utility shall be excavated manually and the utility shall
be exposed carefully and shall be protected.
 Then the utilities shall be supported suitably so as to avoid damages
 Once the utilities are supported by suitable means, Excavation shall be
again done by the excavator.
 Excavation shall be carried out until the foundation level of the open
foundation/ Pile Cap.
 Excavated earth shall be loaded in the dumpers and shall be stacked away
from the excavation.Suitable stop blocks shall be installed 500mm away
from the leading edge of excavation area to prevent the falling of loading
 vehicles while reversing. After Completion of foundation and pier up to
ground level, the same shall be used for back filling of the excavated area.
 Final dressing to required level shall be done manually. If rock is
encountered in the foundation level, low vibration jack hammers shall be
used for dressing.
 If ground water level is higher than that of the excavation level, then
dewatering of the excavated pit shall be carried out continuously using
5HP dewatering pumps. A pit shall be made at the corner of the excavation
and the water shall be pumped out such the water level shall be 300mm
below the excavation level into a sump of 0.5 m x 0.5 m that would be
prepared at slope.
 If the excavated level is deeper than the level prescribed in the drawing,
the same shall be filled up with the same mix used for PCC while laying of
PCC.
 If the earth is of sliding nature, Suitable slope shall be provided on all the
four side of excavation. If the space is limited and the earth is of highly
sliding nature, Shoring method shall be adopted.

5. LAYING OF PCC FOR OPEN FOUNDATION:

 Once the excavation is completed up to the level mentioned in the
approved drawings, the same shall be checked using auto level.
 Loose earth to be watered and compacted to receive PCC.
 Co-ordinates of PCC shall be marked using iron pegs and the sides of PCC
shall be placed using ISMC Channels.
 After fixing of ISMC channels or wooden batten, PCC level shall be
accurately marked with paint by giving levels using auto level instrument.
 PCC of grade M15 shall be placed up to the required level and shall be
suitably compacted.

6. REINFORCEMENT FABRICATION AND PLACING:

 Bar bending Schedules shall be prepared with reference to the approved
drawings and shall be submitted to GC for no objection. • Fabrication of
reinforcement shall be carried out as per the approved bar bending
schedules.
 After clearing the top level of PCC, the exact boundary points of the
foundation shall be marked using total station instrument.
 Reinforcement shall be placed in position and shall be bonded using G.I
binding Wires.
 Cover Blocks of thickness specified in the approved drawings shall be
placed in bottom and sides of the foundation.
 Laps or Couplers shall be provided wherever necessary and shall be
bonded together using binding wires. Welding of laps is not permitted in
this case. Welding if required shall be done with prior written approval.
  While placing the foundation reinforcement, Pier Reinforcement shall also
be placed and tied in Position.
 A working tower using scaffolding pipes with working platform shall be
made to support the pier reinforcement vertical. If the reinforcement of
pier is very high, the reinforcement shall be cut to a workable length and
the balance reinforcement shall be tied with alternate laps after casing of
the footing

7. SHUTTERING OF OPEN FOUNDATION:

 Steel shutters of required size shall be used for side shuttering of Open
Foundation. Before placing the sides, Shutters shall be cleaned free from
all the foreign particles. Shutters shall be straight and there shall not be any
cavities which will cause the slurry to flow out.
 Shutters shall be thoroughly applied with a coat of shuttering oil of
approved vendor to ensure the finishing of the sides and also for easy de-
Shuttering.
 Shutters shall be placed true to line and level and as per the approved
dimensions drawings. Vertically of the shutters shall also be ensured using
plump-bob.
 Top Level of foundation shall be marked with paint in the shutters. Joints
between the shutters shall be filled using fill foam and shall be bolted
properly.
 Necessary supports shall be provided behind shutters as per approved
shutters design so as to maintain the line during concrete works.

8. CONCRETING:
 Concrete mix of approved mix design shall be transported from the
batching plant using transit mixers.
 Every batch of concrete shall be checked for temperature and consistency
cubes shall be casted as per the requirement at pouring end.
 Concrete shall be placed by using concrete chutes. Care shall be taken that
there shall be no segregation of concrete while placing.
 Concrete shall be placed in layers manually or Boom placer / Concrete
pump not exceeding 300mm and shall be vibrated using mechanical
vibrators. Rate of pouring will be 20 cum of concrete per hour.
 Concrete shall be placed continuous up to top level of the open
foundation/Pile Cap.
 Top level shall be finished smooth except the area of pier layout. Suitable
construction joints shall be provided at their layout. Curing shall be started
once the concrete has attained the final setting time.
 Curing shall be carried out either by pounding method or by spreading
hessian cloth and sprinkling the water at required intervals. As an
 alternative, curing compound shall be used. The details of the same shall
be submitted separately.
 Concrete shall be placed by below of temperature 35 Celsius.
 Slump shall be maintained 150mm (+ or -25mm).

9. DE-SHUTTERING:
 After 24 hours, the de-shuttering shall be started. De-shuttering shall be
done carefully so as to avoid any damages to the edges of the pile cap
foundation/Open Foundation Concrete. If the edges of the concrete breaks
in spite of extra precautions, the de-shuttering work shall be stopped
immediately and shall be continued once the concrete edges attain
sufficient strength.
 All the shuttering materials shall be lifted and stacked properly above
ground level.
 After removal of shutters from the excavation pit, the earth excavated
earlier shall be used for backfilling of the foundation area. Backfilling
shall be done in well compacted layers.
 Protective Coating of Foundations in River bed and where ever required
shall be done with solvent based coal tar epoxy coating with AC-DUR-
CT(S) to protect it.

10. CURING:
 Open Foundation top & 4 sides shall be cured 21 days.
 Cement mortar bunds to be provided on open foundation.
 The sides shall be covered with hessian cloth & continuous water
sprinkling to be maintained till backfilling started.
 Further curing to be ensured by keeping the backfilling moist with
water/curing compound.
 All curing arrangement should be approved by Engineer prior to use.

11.QUALITY ASSURANCE:
 The tolerance for dimensions of footing shall be within the limits as
specified in IS 456-2000.
 Proper Care shall be taken to ensure the correct implementation of the
working procedures described in this method statement.
 This shall be be carried out that, sonic logging test, integrity test on the
piles has been carried out as per the frequency mentioned in the technical
specification & Contract agreement. (Test Results to be attached).
TESTING & RECORDS

The following routine test shall be carried out on the fresh concrete during
concrete work and to be carried out prior to placing of concrete.
Slump/workability test shall be carried out at the pouring location. Records
shall be kept for all batches of concrete and sampling of concrete shall be
done. The pour card / slump test report and recording of following shall be
done:

 Grade of concrete
 Concrete mix used Slump of concrete
 Temperature of concrete
 Sampling of concrete for test cube

Concrete cubes shall be cast for compressive strength tests. Frequency of

testing shall be as per IS 456-2000
Checklist
 PILING IN ROCK WITH ROTARY PILING RIG

PROCEDURE
1) PILE LOCATION
The Piles were installed at locations as per the drawing, approved by PMRP. The exact
position of the pile was established by the surveyor with the help of a total station with
respect to previously fixed reference points.

2) PRETUBE DRIVING
The Pretube is a temporary casing made of mild steel which is removed after concreting
of the pile. Its internal diameter is same as the diameter of the pile. Its function is to
ensure the boring of pile vertically, at the correct position and of the correct diameter. If
the casing is not present, the soil bucket will keep striking at the sides of the hole and the
bore will become larger than required. The temporary liner prevents loose soil from
falling into the bore. The Rig was positioned w.r.t the pile bore. Pretube was placed in
the bore hole and pushed down using the Kelly of the rotary rig and pushed till the top of
pretube was about 300mm above the surrounding ground level. A pretube of length 5m
to 6m was used. After driving of pretube the same was checked for verticality and boring
was continued.

3) BORING
 For boring of the pile rotary rig, chisel and barrel were used. Rotary rig was deployed
at the beginning in soil strata. Bentonite was used if required for boring with rotary rig.

Boring with rotary drill

  When rocky strata began boring was done with the help of winch and chisel. The rock
was broken by blows from the chisel given by dropping it again and again with the
winch. To remove the debris from the bore hole the chisel was replaced by the barrel.
The barrel had a flap at the bottom which opened up while lowering due to pressure
exerted by the bentonite. Thus the broken rock pieces entered the barrel. When the
barrel was lifted up the flap was closed and the debris was brought outside.

Chisel Barrel

 This process was continued till the required depth was reached. The depth of the bore
was checked with the help of sounding chain taking reference from the top of pretube.
The bored earth was disposed off at suitable dumping yards.

4) REINFORCEMENT CAGE
a) Fabrication: The TMT reinforcement bars were cut using cutting machines or manually
as required. The cage was fabricated as per the approved BBS. Cover blocks were provided at
a spacing of 3m c/c on all four sides of the cage to provide a clear cover of 75mm to the
helix/ring. The rebar cage was checked and approved by the engineer.
b) Lowering of cage: The approved cage was lowered into the bore in segments. Crane was
used to handle the cage segments. The first segment was held in position by a suitable bar
across the pretube and the second segment was lifted and positioned over the first segment.
The lap joint was tied with binding wire and subsequently welded to ensure that no slippage
occurs while lowering of cage. This process was repeated till all segments were lowered. The
last segment had suitable hooks to enable hanging of cage from the pretube.

5) LOWERING OF TREMIE PIPE

After lowering the cage the tremie pipe elements were assembled together and the tremie pipe
was lowered into the bore. The tremie pipe should not be less than 200mm diameter for
20mm aggregate. The joint between the hopper and tremie pipe as well as the joints in the
tremie pipe should be water tight and the tremie pipes should be thoroughly cleaned after
each use.

6) FLUSHING
The pre assembled tremie pipes were lowered in the bore hole keeping the bottom 300mm
above the founding level. Flushing of the bore was done with the help of bentonite
pump/water pump attached with tremie pipe and tremie head. Flushing was done with fresh
bentonite. The impure bentonite coming out of the bore was collected in a pond and pumped
back to the bentonite tank with the help of a vertical pump.

7) CONCRETING
The concrete required (M30) was produced as per the approved design mix at the centralized
batching plant and transported by transit mixers, ensuring a slump range of 150mm to
175mm at site. The first charge of concrete was placed inside the tremie with a suitable
charge plate at the hopper mouth. The concrete was placed taking necessary precautions to
ensure that adequate length of tremie was embedded in concrete at all times to take care of
accidental withdrawals. As the concreting progressed the tremie was dismantled. Regular
soundings were recorded during concreting. The concrete cubes were taken for testing of
compressive strength of concrete in the lab.

8) PRETUBE REMOVAL
The pretube was removed as soon as the concreting was completed with the help of crane
ensuring a required top level of concrete within the bore.
 BORED CAST-IN-SITU PILE
1. MACHINERY, TOOLS, EQUIPMENTS AND MATERIALS
Following major equipment/tools shall be in the construction of a Bore-in-Situ Pile
S. No. DESCRIPTION CAPACITY NO.
Piling Rig with all As per
1. 1
accessories requirement.
2. Temporary Liner casing pipe As per requirement
3. Crane As per actual 1
Polymer Mixing Set-up
As per
4. comprising of mixing tank 1
requirement.
and pumps
5. Excavator/JCB 0.25 cum As per requirement
6. Dumpers 4 cum As per requirement
Batching Plant/Approved
7. 30 cum/hr 1
Source by PMRP
8. Transit Mixers 6 cum As per requirement
9. Welding Generator 400 Amps 1
10. Tremie Pipe 200 Dia 25-30mt
11. Hopper 2 nos.
12 Testing Apparatus
13 Measuring cylinder As per requirement
14 Mud Balance Hydrometer As per requirement
15 Weighing balance As per requirement
16 Hot plate As per requirement
17 pH papers As per requirement
18 Sounding chain 1 No.

2. MATERIALS

Major materials to be used in the construction of Bore – in – site concrete pile are
as follows:
• Approved Grade of Concrete as per drawing for Concrete pile.
• TMT reinforcement bars confining to IS: 1786 - 2008
•Polymer: The Poly Mud from GEO /Equivalent Brand shall be used as per
requirement
• Concrete Cover block as per approved source/as per Technical specification
requirement
GI Binding wire 18 gauge shall be used
3. METHODOLOGY

Bored Cast in Situ Pile Installation shall be performed according to the following
Sequence:
3.1 Description for Making of Survey point for Pile
The Piles were installed at locations as per the drawing approved by PMRP.
The exact position of the pile was established by the surveyor with the help
of the total station with respect to previously fixed reference points.
3.2 Setting of Piling Rig:

Initially, rig will be cantered on pile point. Base machine with rotary drill
will be positioned on firm levelled ground. The level of base-machine will
be checked with the help of spirit level on the base frame. Drilling will be
carried out using auger/bucket to a depth of approx. 2 to 3 meters. Then a
temporary MS casing of inner dia (1.2/1.0m) for about 3 to 4 m (approx)
length from the ground level will be driven to protect loose soil from falling
in the bore hole at locations where the soil is in loose state and there is a
tendency of collapse of bore hole. The temporary casing will be driven by
help of hydraulic press. After driving the casing its verticality will be
checked by plumb bob. The tolerance limit of the verticality is D/10, where
D = Dia. of Pile. The diameter of the boring tools will be 75mm less than the
diameter of the pile. Check the verticality of casing during installation by
plumbing. Before the boring passes the casing toe, the verticality of casing
until the toe shall be checked. Level at the top of steel temporary casing shall
be taken and recorded. The deviation from the true axis shall not be more
than 1.5% for vertical piles and Piles should not deviate in location by more
than 75mm when used in groups. For single or 02 piles used under columns,
deviation shall not be more than 50 to 100 mm.

3.3 Boring of Soil

Initial Boring of about 2-3 meters shall be done by using auger. The diameter
of cutting tool shall be lesser than the outside diameter of casing minus
75mm.The verticality of the hole to be drilled shall be monitored during
 installation and later checked before the reinforcement cage is lowered. The
eccentricity shall be considered jointly with the verticality.

Boring with rotary rig in soil strata

3.4 Installation of Temporary Casing

To stabilize the upper bore, a temporary steel casing of length 3-4 m shall be
installed at the bored pile location as follows:

 A 1000 mm Dia hole shall be drilled using a Hydraulic Boring machine to a depth
of about 2-3 m.
 A 4-6 m long steel casing shall then be installed in to the 2-3 m deep boreholes by
lowering the casing with rig. Verticality shall be checked and ensured during the
installation.
 The casing shall then be driven in to the ground with rotary machine until about
300 mm is left protruding above the ground. The drilling rig is then used to progress
the excavation to the bottom of the casing pipe and then polymer/ soil stabilizing
material shall be added before any further excavation is made.
 During excavation Polymer / stabilizing material shall be added continually from
the storage tank(s) such that the level of polymer / stabilising material is maintained
within 1000 mm below the top of casing pipe. Excavation depth shall be checked
using a sounding tape.
 Boring pipe

3.5 Polymer/ Soil Stabilizing Material

Polymer / Stabilizing Material shall be used to support the excavation. We
propose a polymer concentration of 0.5 kgs in 1 m3of water. Polymer slurry
will have the following properties.

Density 1.05 - 1.07 gms/cc

Viscosity 60 to 70 seconds/Qt at 300 centigrade (minimum)
Sand content <=2%
Ph value <11.5

Mixing will take place in a mixing plant for this purpose. To prevent any “Necking” of
pile viscosity of the polymer fluid will be maintained by adding Alpha bond in the bore
hole as per the SOP Geo polymer attached as “Appendix 04”.

3.6 Cleaning of Base & Completion of Boring

 Boring shall be stopped when the pile toe level has been reached. The base of
the borehole shall be cleaned carefully to remove loose, disturbed or
remoulded soil.
  The depth of the borehole must be checked within 5 minutes prior to placing of
the reinforcement cage and re-cleaning of the bore to be carried at if collapse of
soil is evident.

3.7 Fabrication & Installation of Reinforcement Cage:

3.7.1 Fabrication of Cages

 Cutting and bending of rebar shall be carried out in accordance with approved
bar bending schedule in the steel fabrication yard or on site (if sufficient space
is available) and cages fabricated.
 Tie wires shall be used to tie main bars with the links. Lapping and welding
details shall be as per approved drawing Circular concrete spacers, constructed
of the same concrete grade as the bored pile, shall be used to provide the
required concrete cover (as per approved drawings).
 Vertical distance between each layer of spacer shall be 2.5 m. Clear cover shall
be 75 mm.
 Fabrication of Cages

3.7.2 Splicing Reinforcement & Installation of Cages

 The reinforcement cages shall be lowered into the borehole by the service
crane/rig using steel slings and shackles. Lifting/supporting hook shall be
welded to main bars at the top to transfer the weight of the cage to shackles and
for supporting the cage over the temporary casing for splicing another cage on
top.
 Cages shall be spliced on site either on the fabrication bed and lowered as one
cage or above the trench. In the latter case, the lower cage shall be temporarily
supported at the top during the process of splicing.
 Splicing shall be done by means of welding and rebar rings. Finally, the
complete cage shall rest on the founding base of the borehole or be supported
from the top of the temporary casing while the correct cover to reinforcement
being assured by the concrete spacers.
 Installation of Cages
3.8 Termination Criteria:
Pile shall be terminated at the founding level as per GFC Drawing as per
directed by GC/Engineer in charge. The termination level shall be measured
&recorded

3.9 Concreting
 M35 grade concrete with slump in the range 150-175 mm shall be supplied from
batching plant, for TEST piles & ROUTINE piles respectively. All concrete delivered
shall be visually inspected and checked against delivery note before being tested and
used. Before any pouring is started, two delivery trucks should be available at site.
 Concrete shall be placed using tremie pipes. The tremie pipes (Minimum 200 mm dia.
Steel pipes) are threaded about 100 mm deep both at the lower end (threading inside)
and the upper end (threaded outside).
 Tremie pipes are joined and lowered into the hole. The end of the pipe should not be
more than 300 m above the bottom of the pile to ensure that free fall of concrete shall
not be more than 1.5 m. The embedded length of pile in concrete shall be 1.5m-1.8m.
 The concrete shall be discharged from the delivery truck to a hopper connected to the
tremie pipes. As the level of the concrete in the borehole rises, the tremies shall be
withdrawn accordingly to aid the flow of concrete. Section of the tremie pipe shall be
dismantled from the top as the pipe is withdrawn.
 During concreting, the level of concrete inside the borehole shall be monitored either
with a weighted tape or chain.
 Encasing shall be withdrawn after initial setting of concrete.
 Rate of pouring of concrete will be 12 cum/hour
 Saturation Time of Polymer will be as per Manufactural recommendation

4. INSPECTION & TEST PLAN

• Survey checks for checking the reference points for pile location.
• Checklist for Casing, driving& boring.
• Reinforcement inspection checklist for Pile.
• Prepour Inspection checklist.
• Polymer Test Record.
• Tremie Chart.
• Piling pour card. Concrete checks as per ITP.
 CONSTRUCTION OF PILE CAP
1. LIST OF EQUIPMENTS & MATERIALS:
Following equipment will be used for construction of pile caps, As per Requirement.
 Welding machines/ Welding Generator – 2 Nos.
 Batching Plant (M1 30 cum / Hour) – 1 No
 Transit mixers of 6 cum – 4Nos
 Needle vibrators – 4 Nos.
 Boom Placer/Stationary Pump -- 1 Nos
 Lighting Equipment- Flood lights – As required
 Chutes – As required

1.1 Manpower deployment will be as per ground condition.

As per actual site condition, the number of equipment mentioned above may increase or
decrease. Any other equipment, machinery Tools and plants etc. whenever required to
complete the erection successfully shall be deployed.
 Materials
Major materials to be used in the construction of pile cap are as follows
o Concrete
Approved mix design of designated grade as per drawing shall be used for casting of
Pile cap.
o Reinforcement
High Yield Strength Deformed Reinforcement bars of grade Fe 500d will conform to
IS1786:2008. Cage Fabrication & preparation to be made at steel yard at wagholi.
Lifted by approved crane, shifted by trailer to the desired location.
o Cover block
Concrete cover blocks used shall be of approved manufacturer and as per contract
agreement.
o Tying Wire
Tying wire shall be 18-gauge GI wire.
o Curing
Regular Water Curing & Membrane curing.

2. METHODLOGY
After completing of pile cap casting, backfilling shall be with back filling material.
Execution of pile shall be done in the following sequence.
 REBAR WORKS: Reinforcement bars will be fabricated/ installed as per the approved
drawings. Laps shall be provided as per the specification and positions shown in pile cap
drawings for construction and sufficient exposed lengths are obtained for pile cap. Spacers
shall be installed properly so that there is no movement during concrete works.
 TRANSPORTATIONS OF REINFORCEMENT AND PLACING AT SITE: Correct
direction of vertical reinforcement of pile cap shall be checked before transportation to avoid
any major handling at pile cap location area. Reinforcement shall be placed /unloaded in
correct position so as to ensure safe manual lifting & fixing. Length of the vertical
reinforcement.
 EXCAVATION: Once the existing road has been excavated the remaining depth of trial
pit shall be excavated using shovels, pickaxe and spades. If the soil is of sliding nature
suitable slope/benching will be provided. The trial pit shall be excavated up to required depth
as directed by the Engineer.
Extra care shall be taken while removing the soil near the utilities after excavating to a
depth of 2.5m the trail pit will be again checked manually for pipes/cables. If utility is
identified, then the pit will be excavated to required depth manually. If not, the trail pit will
be terminated as per the direction of Engineer. If any utilities encountered in the trial pit the
same shall be protected and bring to the notice of engineer. In case of accidental damage to
the utility, it should be immediately informed to the concern authorities, GC& Maha metro
and shall be made good by the contractor at its own cost.

PILE CAP CASTING, SURVEYING AND MARKING:

o Construction of Pile cap shall start after the construction of pile. Surveyor shall be
deployed for carrying out, setting-out and surveying work based on approved survey
stations & drawings.
o Confirm Center-line (survey Record) of pile cap marking/points are within
acceptable tolerance (+/- 25 mm)
o The Pile cap coordinates shall be transferred to the top of the pile with calibrated total
station.
o The outer lines of the pile cap and Center point shall be marked with paint.
o Check dimensional placement of main starter bars Vertical Reinforcement and
rings/helical (quantity, diameter and position) and fixed adequately.
o After completion of survey work, reinforcement shall be fixed as per BBS drawing.
o Align the framework and check the same using total station. Also check the
verticality of the formwork. The shutter shall be in plum.
o Concreting shall be done directly with placing of extra chute/Boom placer/stationary
pump with Transit Mixture.
o To control the Vehicular movement, traffic marshal, Plastic barrier and Safety cone
shall be placed.
o After completion of concreting barricades openings shall be closed with rolling half/
full height barricades.
o Curing arrangement for pile cap shall be ensured.
 Preparation of access: - Access to be prepared for movement of transit mixtures
around the pile cap as the concreting of pile cap is being done by direct pouring of
concrete from transit mixture through chutes, by compacting any loose strata around
the pile cap using suitable compacted equipment i.e roller. Area to be kept dry as far
as possible to avoid any slippery situation for movement of transit mixture.
 Concrete Placing: -
Pile cap Concreting shall be carried out as a single pour in layers. The batching plant
which is already established at site (30cum/ hr capacity) and calibrated shall be used
for production of concrete. The necessary checks on coarse aggregate and fine
aggregate shall be completed before start of concrete. All necessary formats/ reports
as per approved QA/QP shall be fulfilled. The Concrete shall be transported by transit
mixers. Each transit mixer shall be containing dispatch slip containing the details of
grade of concrete, Date, time of dispatch, Quantity dispatched, slump, temperature,
etc. (annexure 1) At the receiving end the receipt details like time of arrival at site,
temperature and no. of cubes cast as per IS 456-2000 requirement shall be noted.
Ambient temperature both at the batching plant and at the site will be maintained.
Concrete shall be well compacted using 60 mm needle vibrators. The sides and the
corners shall be compacted by using vibrating needles. The top surface of concrete
shall be properly finished with the side slopes as specified in the drawings.
 PILE CHIPPING:
The chipping shall be done with use of Pneumatic breaker. Proper care shall be taken
while chipping the loose concrete above the cut off level. The main purpose of
chipping is to make sure that there should not be any loose concrete in Pile.

Pile Chipping
 PCC:
After leveling the bottom, the pit was watered to keep the soil moist. PCC of mix
M15 was mixed at the centralized batching plant and transported to site in transit
mixers. The concrete was directly poured by chute, spread and leveled manually to
the minimum specified thickness of 75mm shown in the drawing. The PCC was cured
by sprinkling water.
 REINFORCEMENT:
a) Fabrication: For fabrication of reinforcement, BBS was prepared as per the good
for construction drawings and got approved from DMRC. The reinforcement was cut
using cutting machines or manually as required and bent at rebar yard. The cleaning
of bars was done using wire brush if required, to ensure that the bars are free from
dust & rust. The rebar were transported to location in trailer / truck or manually
depending upon the need.
b) Fixing of Rebar: The rebar was manually fixed into its position as shown in the
good for construction drawing. Cover blocks made of non-shrink grout were placed at
suitable spacing to ensure uniform cover as specified in the drawing and tied together
with binding wire.

Fabrication Fixing of Rebar

After fixing the pile cap rebar, pier rebar & crash barrier were erected. These rebar
were supported by erecting a suitable staging frame across the width of the pile cap.
The rebar cage was checked by DMRC engineers and all the rebar, chairs, spacers &
laps were jointly measured after completion of cage placing. After getting the
clearance; balance shuttering work was taken up. Pier rebar was held in position
rigidly to prevent it from buckling.

 SHUTTERING:
Required shuttering fabricated as per drawings was placed at locations as per the pile
cap dimensions shown in the good for construction drawing. Before placing the
shuttering, shuttering oil was applied on shutter face in contact with the concrete, to
ensure easy removal of shuttering & proper concrete finish. After fixing of shuttering
it was checked for its alignment, location & correctness along with rebar. For
preventing leakages from joints, rubber strip/foam strip was provided at the joints of
shuttering.
 Shuttering

 CONCRETING:
o The pump-able concrete of grade specified in the approved respective drawings
will be delivered at site using transit mixers and Conveyed by means of concrete
placing unit.
o The concrete mix received from Plant shall be verified for slump and
temperature required Cubes as per ITP shall be casted. The slump shall be -
175mm +/-25 mm.
o Then the concrete shall be pumped from transit mixer and compacted by using
needle vibrators.
o It shall be ensured that all electrical connections with vibrator, lights and other
accessories are insulated and shock proof.
o In case of work in night hrs required illumination shall be provided at work
location.
o To control the vehicular movement, traffic marshal, barrier and Safety cone shall
be placed.
o After completion of concreting barricades openings hall be closed with rolling
half/full height barricades.
o Care shall be taken not to leave weak spots around reinforcements and embedded
parts. Outer side of shutter shall be tamped and checked for the concrete in cover
Zone.
o Concrete shall be carried out in layers i.e; each layer 300mm and each
compacted before start of next layer.
 SETTING OUT:
The center line shall be marked as per approved drawings. Temporary bench marks,
transverse pillars & grid pillars shall be constructed. Grid lines & levels shall be
transferred from the approved reference pillars. The daily survey work shall be
reported in survey report form. For Pile cap, both center line as well as the Corner
points shall be properly marked so that the PCC can be done for required area only.

 CURING:
The concrete was cured by ponding method. Bunds of cement mortar of lean mix
were built after the concrete attained final strength. These bunds were filled with
water. The sides of the pile cap were covered with Hessian cloth till back filling was
started. Further curing was ensured by keeping the backfill moist with water.

Curing

Pile cap shall be cured by either of the two Procedures below.

o WET CURING
Curing shall be continuous over a minimum of 21 days period after concreting. Clean
hessian cloth shall be wrapped on exposed concrete surfaces shall be used for moist
curing. Water shall be sprayed to keep hessian cloth -interruptedly moist. Frequency
of watering shall be such that, hessian cloth shall not be allowed to get dried.
OR
o MEMBRANE CURING
Curing compound shall then be sprayed over the pier surface as per manufacturer’s
recommendation.

 MISCELLANEOUS WORKS
After backfilling the damaged roads were repaired before removing of the barricades
and the whole area was cleaned after restoration of road.
 QUALITY CONTROL
To learn and understand the importance of the Quality Assurance and Quality Control
(QAQC ) at any construction or pre-casting works in Civil Engineering.
Here , the subject being the materials being used in the pre-casting of segments used in the
Metro Rail Project in Pune.
To ensure quality and systematic execution of the PUNE METRO viaduct a Quality Manual
was prepared by GIL. This quality plan is in conformance with requirements of ISO
9001:2000. It aims at ensuring planned and timely completion of this project by avaoiding
any cost and time over runs and ensuring quality construction at all stages of the project to
the complete satisfaction of DMRC.

Quality Objectives
 Site shall try to meet customer requirements and attend to their concerns in shortest
time possible.
 Site will seek to understand the customer satisfaction level and will try to comply the
requirements.
 The site will seek to achieve the targets as per construction programme and achieve
project completion in time.
 To achieve average of 10 no. spans launching per month.
 To achieve reduction in wastage by 5%.
 To reduce accident frequency rate by 10% every year.

Codes and other references:

In case of discrepancy among standard codes of practice. Technical Specifications and
provisions in sub clauses in the Notice Inviting Tender , the order of preference will be as
below.
i. Provision in NIT
ii. Technical Specifications
iii. CPWD specifications
iv. Standard codes of practice

In case of discrepancy among standard codes of practice , the order of precedence will be IRS
, IRC , IS , BS , DIN

Critical Materials
The critical materials to be used in the project are water , cement , aggregate , admixtures ,
micro silica , reinforcement steel , structural steel , prestressing steel , sheathing strips ,
bridge bearings , expansion joints and inhibitor solution.
Test on Materials
Tests on Aggregates (as per IS 2386 and IS 383):
 Specific gravity
 Water absorption
 Gradation
 Impact Value
 Crushing Value
 Abrasion Value
 Flakiness index and Elongation index
Tests on Sand (as per IS 383, IS 460, IS 1607 and IS 2386)
 Specific gravity
 Water Absorption
 Gradation
 Silt content
 Bulking of sand
Tests on Cement:
1) Physical Tests (as per IS 4031 , IS 5513, IS 650, IS 10080)
 Fineness of Cement
 Initial and Final setting time
 Standard consistency
 Compressive strength at 3, 7 and 28 days
 Soundness by Le Chatlier’s apparatus
2) Chemical Tests
 Loss on ignition
 Magnesium content
 Sulphur Content
Tests on water (as per IS 456 and IS 3025)
 Chemical and other impurities in solution and suspension
 pH value
Tests on concrete (as per IS 456, IS 516 and IS 1199)
 Compressive strength test
 Slump test
 Permeability test
 Air content test
 Bleeding test
 Yield of concrete
 Compatibility between cement and admixture by Marsh Cone Test (IS 9103)
 Initial and final setting time by Standard Penetrometer test
Automatic weigh batching plants of ‘Shrike’ conforming to IS 4925 were provided at
centralized locations for all structural concreting work. The capacity of the mixer was 0.5
m^3 and 1 m^3. The software used for controlling the batching plant was ‘Soft Batch’ .The
amount of each component in a design mix was fed into the computer. The three gates for
sand , 10mm aggregates and 20mm aggregates opened one by one and the required quantity
entered in the mixer. The cement was stored in cement silos and there were separate tanks for
water and admixture. Everything entered the mixer automatically and got mixed by rotation
of the mixer. Then the concrete was poured into the transit mixer.
The actual weight of each component was compared by the computer with the weight fed and
graphs are plotted for the same. The deviation was also calculated and a report was generated
by the software in the end.

Batching Plant
TM Collecting Concrete and Mixer
CONCLUSION
Pune has witnessed enormous industrial growth during the last 10 years.
Rapid urbanization in the recent past has put the city’s travel infrastructure to stress.
With a large number of units have come up both in small scale as well as in
heavy & medium scale industry, etc., traffic in the city is expected to shoot up.
Being thickly populated area, Pune’s traffic needs cannot be met by only roadbased
system.
The existing urban transport system of Pune City which is road-based has
already come under stress leading to longer travel time, increased air pollution
and rise in number of road accidents. With projected increase in the population of
the city strengthening and augmenting of transport infrastructure has assumed
urgency. For this purpose provision of rail-based Metro system in the city has
been considered.
A detailed Environmental Impact Assessment Study has been carried out for the
project. As a part of this Study, comprehensive environmental baseline data was
collected, and both positive and negative impacts of the project were assessed in
detail. The project has many positive environmental impacts like reduction in
traffic congestion, saving in travel time, reduction in air and noise pollution, lesser
fuel consumption, lesser road accidents etc, with a few negative impacts (especially during
implementation phase of the project) for which Environmental
Management Plan has been suggested.
After examining the various options for execution of Pune Metro Project, it has
been recommended that the project should be got executed through a SPV on
DMRC funding pattern.