Final Report VII PDF

GUJARAT TECHNOLOGICAL UNIVERSITY
Chandkheda, Ahmedabad.
Project Report On:

CASE STUDY OF AHMEDABAD METRO RAIL PROJECT
SR. NO. NAME ENROLLMENT NO.

1) JOSHI DEVDAT 161283106006
2) PATEL RAVI 161283106019
3) SAVALIYA DIVYESH 161283106022
Guided by: -
ASST. PROF. PARTH A PATEL
Semester – VII (B.E CIVIL ENGINEERING)
APOLLO INSTITUTE OF ENGINEERING
(ANASAN, AHMEDABAD)
2018-19
1|CASE STUDY OF AHMEDABAD METRO RAIL PROJECT (MEGA)

APOLLO INSTITUTE OF EGINEERING
CERTIFICATE
This is to certify that the dissertation entitled CASE STUDY OF

AHMEDABAD METRO RAIL PROJECT (MEGA) has been carried out
by JOSHI DEVDAT, PATEL RAVI, SAVALIYA DIVYESH under my guidance
and fulfillment of the degree of Bachelor of Engineering in Civil Branch (7th
Semester) of Gujarat Technological University, Ahmadabad during the academic
year 2018-19.
Guides:-
Asst.Prof. PARTH A PATEL
Sign Of Guide. Sign.Of External Examinar. Sign Of Head Of Department

CONTENTS
ACKNOWLEDGEMENT .............................................................................................................. 8
ABSTRACT……………………………………………………………………………………….9
LIST OF FIGURE……………………………………………………………………….………10
LIST OF TABLE……………………………………………………...……………………...….12
CHAPTER.1INTRODUCTION TO PROJECT ………………………………..………………14

1.1 GENERAL: …………………………………………………………………………………14
1.2 ROUTE LENGTH: …………………………………………………………………………15
1.3 NUMBER OF STATION: ……………………………………………………………….…16
1.4 MAINTENANCE FACILITIES: …………………………………………………………..16
1.5 COST OF PROJECT……………………………………………………………………..…16
1.6 SPEED: …………………………………………………………………………………..…16
1.7 INTERCHANGE STATION: ………………………………………………………………17
1.8 CONSTRUCTION CONTRACT DETAIL: ………………………………………………..17
CHAPTER.2 SALIENT FEATURES…………………………………………………………..18

2.1 GENERAL…………………………………………………………………………………..18
2.2 COMPANY PROFILE: …………………………………………………………………….18
2.3 PROJECT DETAILS: ………………………………………………………………………18
2.4 LOCATION: …………………………………………………………………………..……19
2.5 DETIALS OF THE AGENCIES INVOLVED: ……………………………………………20
2.6 SITE LAYOUT: ……………………………………………………………………………20
2.7 ORGANIZATION CHART: …………………………………………………………….…21
2.8 TOTAL SCOPE OF WORK: ………………………………………………………………21
2.9 WORK BREAKDOWN STRUCTURE: ………………………………………………..…22

2.10 INFRASTRUCTURE FACILITIES: ………………………………………………….…22
2.11 GRADE OF CONCRETE FOR VARIOUS ELEMENTS………………………….……24
2.12 EQUIPMENT DETAILS: ………………………………………………………….……24
2.12.1 IN LABORTARY: ......... ……………………………………………………………...24
2.12.2 ON SITE: ........................................................................................................................25
2.12.3 SHUTTER VIBRATOR .................................................................................................26
2.12.4 MOBILE HYDRA ..........................................................................................................26
2.12.5 BOOM PLACER..............................................................................................................27
2.12.6 BAR BENDING MACHINE ......................................................................................... 28
2.12.7 BAR CUTTING MACHINE ......................................................................................... 28
2.12.8 NEEDLE VIBRATOR .................................................................................................. 29
CHAPTER.3 PILE .................................................................................................................... 30

3.1 GENERAL: ......................................................................................................................... 30
3.2 ACTIVITY DETAIL: …….................................................................................................30

3.3 TERMINOLOGY: ............................................................................................................. 30
3.4 MATERIAL DETAIL: ...................................................................................................... 31
3.5 MIX DESIGN: ....................................................................................................................31
3.6 EQUIPMENTS/MACHINERIES& TOOLS DETAILS:...................................................32
3.6.1 EQUIPMENT / MACHINERIES USED FOR PILE ON SITE: ................................... 32
3.6.2 TOOLS USED FOR PILE ON SITE: ............................................................................ 32
3.7 WORK BREAKDOWN: ...................................................................................................34
3.8 GENERAL DETAIL OF PILE:........................................................................................ 35
3.8.1 PILE CONFIGURATION: .............................................................................................35
3.9 CONSTRUCTION METHODOLOGY: ...........................................................................35
3.10 BAR BENDING SCHEDULE: ...................................................................................... 40
3.11 IS CODE RECOMMENDATION: ................................................................................ 41
CHAPTER.4 PILE CAP .........................................................................................................42

4.1 GENERAL: ....................................................................................................................... 42
4.2 ACTIVITY DETAIL: ......................................................................................................42
4.3 PILE CAP DETAILS: ......................................................................................................42
4.4 GENERAL DETAIL OF PILE CAP: ............................................................................. 43
4.5 MIX DESIGN: ................................................................................................................ 43
4.6 WORK BREAK DOWN STRUCTURE:........................................................................ 43
4.7 CONSTRUCTION METHODOLOGY: .......................................................................... 44
CHAPTER.5 PIER …………................................................................................................ 49

5.1 GENERAL: ...................................................................................................................... 49
5.2 ACTIVITY DETAILS: ......................................................................................................49
5.3 PIER DETAIL: ................................................................................................................. 50
5.4 MIX DESIGN: .................................................................................................................. 50
5.5 WORK BREAK DOWN STRUCTURE:…...................................................................... 51
5.6 CONSTRUCTION METHODOLOGY: .......................................................................... 51
CHAPTER.6 PARAPET ........................................................................................................ 55

6.1 GENERAL: ...................................................................................................................... 55
6.2 ACTIVITY DETAIL: ...................................................................................................... 55
6.3 MIX DESIGN: ..................................................................................................................55
6.4 CONSTRUCTION METHODOLOGY: ..........................................................................55
CHAPTER.7 SEGMENT ......................................................................................................61.

7.1 GENERAL....................................................................................................................... 61
7.2 CASTING YARD DETAIL: .......................................................................................... 61
7.3 SEGMENT DETAIL: ..................................................................................................... 61
7.4 BATCHING PLANT ..................................................................................................... 62
7.5 ADVANTAGES OF SEGMENTAL CONSTRUCTION: .............................................62
7.6 SUPER STRUCTURE DETAIL:.....................................................................................63
7.7 CONSTRUCTION METHODOLOGY: .......................................................64
7.8 MIX DESIGN: ................................................................................................................ 71

7.9 VOLUME OF CONCRETE IN SEGMENT: ....................................................................71
7.10 QUANTITY OF STEEL IN DIFFERENT SEGMENTS: ................................................71
7.11 BAR BENDING SCHEDULE: .........................................................................................72
CHAPTER.8 QUALITY ASSURENCE AND CONTROL ...................................................74.

8.1 GENERAL: .......................................................................................................................74
8.2 AGGREGATE: .................................................................................................................74
CHAPTER.9 SAFETY PROGRAMME.................................................................................77

9.1 PURPOSE: ........................................................................................................................77
9.2 OBJECTIVES: ..................................................................................................................77
9.3 PERSONNEL PROTECTIVE EQUIPMENTS (PPE): ....................................................78.
9.4 HEALTH MANAGEMENT AND MEDICAL FACILITY: ............................................79.
CHAPTER.10 CONCULUSION ............................................................................................80

ACKNOWLEDGEMENTS
It is and will always be an obvious implication that no proceedings of any

particular training can be carried out or executed successfully and efficiently
without sharing the meticulous ideas, technical expertise and various other
innovative thoughts put forward by the technical as well as the non-technical
veterans.
In this particular regard we would firstly like to express our utmost gratitude
to our respected faculties for sharing their vast knowledge and intellect with us all
throughout, their indelible time alongside with their personal memoranda in each
and every step in the approach of the internship.
This project would never have been headed if it wasn’t for the straight
forward sight of our Head of Department and our respective Guide Dr. P V Patel
who has supported us in all ways possible to reach as far as we are today giving
every detailed input in every step we took towards our internship. Also the
continuous supported by Planning manager Mr. kuldeep brambhatt who has
encouraged and led us the way who has been a very big support in helping us get
exposed to the actual world of Civil Engineering and the insight of Metro projects.
Lastly I would like to thank all of our team members for their hard work and
their positive approach towards this particular course of Practical Training. This
innovative way of having us reluctant has made us realize the value of working
together as a team and the whole training brought us together to appreciate the value
of relations and also the mutual respect towards each other.

ABSTRACT
Site training provides a better exposure to the students & it proves to be much
effective as far as application of the theory is concerned. The practical training
provides a professional environment to the student to get ready for the Industry.
The training was undertaken at Ranjit Buildcon ltd.
The work consists of construction of elevated viaduct from Ranip to Motera. The
project was intended to provide a mass transport system in the city and to relieve
peoples from the Traffic & pollution problems. The report covers all the activities
starting from substructure to super structure. The work was quite different from
the normal construction work as it was a special project launched by Govt. by
forming a special purpose vehicle called MEGA.
Execution work not only needs technical knowledge but also requires
managing skills to manage material, time, labour & other resources. So, in this
report an emphasis has been given to Time cycle analysis as well as Productivity
of labour. Importance of safety & quality has been understood to a great extent.

List of Figures
FIGURE 1. 1 ALIGNMENT DRAWING …………………………………………………………..…….…..15
FIGURE 2. 1 LOCATION OF AHMEDABAD ...................................................... 19
FIGURE 2. 2 RBL CASTING YARD ................................................................ 19
FIGURE 2. 3 LAYOUT PLAN OF CASTING YARD .............................................. 20
FIGURE 2. 4 ORGANIZATION CHART ........................................................... 21
FIGURE 2. 5 WORK BREAKDOWN STRUCTURE .............................................. 22
FIGURE 2. 6 SHUTTER VIBRATOR ............................................................... 26
FIGURE 2. 7 MOBILE HYDRA ...................................................................... 27
FIGURE 2. 8 BOOM PLACER ....................................................................... 27
FIGURE 2. 9 BAR BENDING MACHINE ......................................................... 28
FIGURE 2. 10 BAR CUTTING MACHINE ........................................................ 28
FIGURE 2. 11 NEEDLE VIBRATOR ................................................................ 29
FIGURE 3. 1 TREMIE PIPE .......................................................................... 32
FIGURE 3. 2 BUCKET AUGER ...................................................................... 33
FIGURE 3. 3 HOPPER ................................................................................. 33
FIGURE 3. 5 CASING ................................................................................. 34
FIGURE 3. 6 PILE P417 CONFIGURATION ...................................................... 35
FIGURE 3. 10 CAGE PREPARATION ............................................................... 37
FIGURE 3. 17 BAR BENDING SCHEDULE........................................................ 40
FIGURE 4. 1 SEQUENCE OF REINF................................................................ 45
FIGURE 4. 2 SHUTTERING DRAWING ........................................................ 46

FIGURE 4. 3 REINFORCEMENT DETAIL ...................................................... 48
FIGURE 5. 1 REINFORCEMENT DETAIL OF PIER PILE ................................... 54
FIGURE 6. 1 PREPRATION OF CAGE .......................................................... 56
10 | C A S E S T U D Y O F A H M E D A B A D M E T R O R A I L P R O J E C T ( M E G A )
FIGURE 6. 2 MOULD FOR PRAPET ............................................................. 56
FIGURE 6. 3 REINFORCEMENT DETAILING OF PRECAST STACKING PANEL ...... 59
FIGURE 6. 4 PRECAST STACKING DETAILS FOR STANDARD SPAN ...............60
FIGURE 7. 1 ELEVATION OF SPAN ............................................................ 63
FIGURE 7. 2 SHUTTERING DETAIL OF SEGMENT ......................................... 65
FIGURE 7. 3 REINFORCEMENT DETAIL OF SEGMENT ................................... 66
FIGURE 7. 4 DETAIL OF CABLE OF SUPER STRUCTURE ................................ 68
FIGURE 7. 5 LIFTING OF SEGMENT .......................................................... 70
FIGURE 7. 8 BAR BINDING SCHEDULE ...................................................... 73
FIGURE10.1 PPE MODEL .............................................................................. 94
List of Table
TABLE 1. 1 ROUTE LENGTH OF DIFFERENT SECTIONS ..................................... 15
TABLE 1. 2 NUMBER OF STATION.................................................................. 16
TABLE 1. 3 CAPITAL AND TOTAL COST........................................................16

TABLE 1. 4 INTERCHANGE STATIONS ......................................................... 17
TABLE 1. 5 CONTRACT AWARDED FOR VARIOUS SECTION ............................. 17
TABLE 2. 1 SCOPE OF WORK .....................................................................21
TABLE 2. 2 GRADE OF CONCRETE FOR VARIOUS ELEMENTS ......................... 24
TABLE 2. 3 LABORTARY EQUIPMENT ......................................................... 24
TABLE 2. 4 SITE EQUIPMENT ................................................................... 25
TABLE 3. 1 MATERIAL SPECIFICATION ...................................................... 31
TABLE 3. 2 MIX DESIGN ......................................................................... 31
TABLE 3. 3 EQUIPMENT FOR PILE ............................................................ 32
TABLE 3. 4 IS CODE RECOMMENDATION ................................................. 41
TABLE 4. 1 PILE CAP DETAIL ................................................................... 43
TABLE 4. 2 MIX DESIGN ......................................................................... 43
ABLE 5. 1 PIER DETAIL ......................................................................... 49
TABLE 5. 2 MIX DESIGN ......................................................................... 50
TABLE 6. 1 MIX DESIGN .............................................................................. 55
TABLE 7. 1 SEGMENT ID AND LENGTH .......................................................... 71

TABLE 7. 2 MIX DESIGN .............................................................................. 71
TABLE 7. 3 VOLUME OF SEGMENT ................................................................ 71
TABLE 8. 1 RESULT OF SAND ...................................................................... 75

TABLE 8. 2 RESULT OF 10MM AGGREGATE .................................................... 75
TABLE 8. 3 RSESULT OF 20MM AGGREGATE .................................................. 76
TABLE 8. 4 RESULTS FOR COMPRESSIVESTRENGTH TEST ................................ 76
CHAPTER.1 INTRODUCTION TO PROJECT
1.1 GENERAL:-
The historic city of Ahmedabad is amongst the major metropolitan cities in India.
With the increasing opportunities for trade &commerce & as a center for higher
education, the population of the city is already touching 6 million & this heavy
growth continues, so the need of strengthening the transport infrastructure has
increased.
The Gujarat Infrastructure Development Board carried out the study for urban
transport between Gandhinagar & Ahmedabad. The Special purpose vehicle called
Metro-Link Express for Gandhinagar& Ahmedabad (MEGA) Company Ltd, was
established by Government of Gujarat on 4 February 2010.
Vision & Mission

“To provide safe, fast & ecofriendly rail based mass transit services to the public at
affordable rates while simultaneously catalyzing dense & urban growth”.
1.2 ROUTE LENGTH:
TABLE 1. 1 ROUTE LENGTH OF DIFFERENT SECTIONS

ELEVATED
TOTAL LENGTH UNDERGROUND LENGTH (KM)
CORRIDORS
(KM) LENGTH (KM)
East-West corridor 19.435 6.335 13.100

North- South corridor 18.439 - 18.439
Total 37.928 6.335 31.593
FIGURE 1. 1 ALIGNMENT DRAWING
1.3 NUMBER OF STATION:
TABLE 1. 2 NUMBER OF STATION
SR. NO CORRIDOR NAME UG ELEVATED TOTAL

1 East West Corridor 4 13 17
2 North-South Corridor - 15 15
3 Total 4 28 32
1.4 MAINTENANCE FACILITIES

Depot at Gyaspur (For N/S corridor)
Depot at Appral park (For E/W corridor)
1.5 COST OF PROJECT:

TABLE 1. 3 CAPITAL AND TOTAL COST
NAME OF THE CAPITAL TAXES & DUTIES TOTAL

SR. NO
CORRIDOR COST (RS. CRORE) (RS. CRORE)
1 East-West corridor 4951 86 5815
2 North-south corridor 3436 584 4020
3 Total 8387 1448 9835
1.6 SPEED:
Design Speed 80 km/hr.

East- West corridor 33 km/hr.
North- South corridor 32 km/hr.
1.7 INTERCHANGE STATION:
TABLE 1. 4 INTERCHANGE STATIONS
METRO STATION BRTS RAIL METRO

APMC NO NO NO
JIVRAJ NO NO NO
RAJIV NAGAR NO NO NO
SHREYAS CROSSING NO NO NO
PALDI NO NO NO
GANDHIGRAM YES YES NO
USMANPURA NO NO NO
METRO VIJAY NAGAR NO NO NO
CORRIDOR
VADAJ YES NO NO
RANIP YES NO NO
SABARMATI RAIL STN NO YES NO
AEC YES NO NO
SABARMATI NO NO NO
MOTERA STADIUM NO NO NO
1.8 CONSTRUCTION CONTRACT DETAIL
TABLE 1. 5 CONTRACT AWARDED FOR VARIOUS SECTION
CONTRACT CONTRACTOR
Apparel park Depot URC Constriction
Gyaspur Depot Gannon Deunkerly-PSPO JV
Vastral Gam-Apparel park (Viaduct 6km) J Kumar Infraprojects
Vastral Gam- Apparel park ( 6 station) DRA- CICO JV
East Ramp- Kalupur (Tunnels & 2 Station 2.45 km) Afcons Infrastructure.
Gyaspar-Shreyas (Viaduct & 4 stations 4.62km) IL & FS
Shreyas- Ranip (Viaduct & 6 station
Simplex Infrastructure
8.94km)
Motera-Ranip (viaduct- 4.85km)
Motera -Ranip ( 5 station Pratibha-Ranjit JV
Thaltej 9km to West Ramp. (viaduct,
Sabarmati Bridge & 7 stations 8.21 km) Tata- CCECC JV
CHAPTER. 2 SALIENT FEATURES
2.1 GENERAL:
This chapter describes detailinformation about the agencies involved & infrastructure
facilities provided.
2.2 COMPANY PROFILE:
RBL is a public incorporated company & has done many Infrastructure Projects.
The Metro Project, Ahmedabad phase-1(North-south corridor) has been awarded to

RBLfrom Ranip to Motera from chainage 12300.2m to 17147.20m.The work consist
of Construction of elevated viaduct & Stations.
A joint venture of RBL &Pratibha for the METRO stations.

The station work comes under package 4B while the work of viaduct comes under
package 4A.
2.3 PROJECT DETAILS:
MEGA Project phase-1,
Name of the Project CONS/VDCT/PKG-4A/NS
Type of the project Infrastructure

Type of contract Item Rate contract
Type of Structure Elevated Viaduct
Route length 4.85 km Motera to Ranip (chainage
Scope of Work 12300.2m to 17147.20 m.)
Estimated cost of the work package 228 Cr
Time Frame of the Project 30 months
Date of commencement 12/1/2016
Date of completion as per current status 20/10/2020
2.4 LOCATION:
FIGURE 2. 1 LOCATION OF AHMEDABAD
FIGURE 2. 2 RBL CASTING YARD
2.5 DETIALS OF THE AGENCIES INVOLVED:
Name of the Client MEGA Company Ltd.

Name of the design consultant STUP consultant
Name of the contractor Ranjit Buildcon Ltd.
Name of general engineering consultant Systra-Rites-aeccom
Name of proof Consultant Shah consultant
2.6 CASTING YARD LAYOUT:
FIGURE 2. 3 LAYOUT PLAN OF CASTING YARD
2.7 ORGANIZATION CHART:
FIGURE 2. 4 ORGANIZATION CHART
2.8 TOTAL SCOPE OF WORK:
TABLE 2. 1 SCOPE OF WORK
ELEMENT NUMBER
S.NO
1 Pile 747
2 Pile cap 173
3 Pier 173
4 Pier cap 127
5 Portal beam 23
6 Crash barrier 173
7 Parapet 3060
8 Segment 1530
2.9 WORK BREAKDOWN STRUCTURE:
FIGURE 2. 5 WORK BREAKDOWN STRUCTURE
2.10 INFRASTRUCTURE FACILITIES:
WATER SUPPLY:
There is under ground water tank at the casting yard and 1 bore. Also, there
is recycle water tank, where the recycled water at site is stored and later used
the same water for curing of the segments on the casting yard. On site, there
is a water tank of 3900litre, which is every filled up using the tanker water,
once in a day. The bore wells will be dug as per the requirement on site.
ELECTRICITY SUPPLY:
At casting yard, the electricity is generated using the GEB, and also have 1
Diesel Generator of 125KVA, whereas, on site they are using the Diesel
generator (3 nos.) and the power house of torrent for electricity is under
work.
LABOUR COLONY:
Labour Colony is situated at the casting behind the site office. Also, the
labour are provided transportation facilities to the site and back to the casting
yard.
LABOUR WELFARE:
Regular medical check-ups are arranged for the labours.

CANTEEN:
At the casting yard, the canteen is provided for the staff and labours.
FIRST – AID:
The medical room is situated at the casting yard, where a doctor is available
24 hrs. Also, the provision of the ambulance is there for any emergency.
FIRE SAFETY:
The fire points are located at various locations on the site – At fabrication
yard, at the main store, near the project office, near the batching plant, at the
steel yard, near the transformer.
2.11 GRADE OF CONCRETE FOR VARIOUS ELEMENTS:
TABLE 2. 2 GRADE OF CONCRETE FOR VARIOUS ELEMENTS

ELEMENT GRADE OF CEMENT USED
CONCRETE
Pile M35 PPC
Pile cap M35 PPC
Pier M50 OPC
Pier cap M50 OPC
Segment M50 OPC
Portal beam M60 OPC
2.12 EQUIPMENT DETAILS:
2.12.1 IN LABORTARY:
For various tests different lab equipment’s are used for performing various tests
on aggregates, on cement, on cubes etc., which are tabled below.
TABLE 2. 3 LABORTARY EQUIPMENT

S.NO NAME OF THE EQUIPMENT USED
TEST
1 Compressive strength CTM
2 Consistency Vicat apparatus
3 Sieve analysis Sieve shaker
4 Flakiness index Flakiness index apparatus
5 Elongation index Elongation index apparatus
6 Specific gravity Pycnometer

7 Vibration Vibrating machine
8 Slump Slump cone
9 Drying Hot air oven
10 Abrasion Abrasion test apparatus
11 Setting time Vicat apparatus
12 Crushing value ACT
13 Permeability Permeability test
14 Impact value AIV
15 Curing Curing tank
16 Soundness Le-chatelier
2.12.2 ON SITE:
To perform various activities, various equipment’s are used, as tabulated below.
TABLE 2. 4 SITE EQUIPMENT

EQUIPMENT NOS. MANUFACTURER MODEL SPECIFICATIONS
Batching plant 2 - - Capacity=30m3
Boom placer 1 Schwingstetter S36x Boom length = 80
feet
Hydraulic
2 Mait NA 46 T
piling rig
2 Case 77oss NA
Excavator cum
DIGMA
backhole 1 ESCORTS NA
X
Transit mixer 7 Schwingstetter NA Capacity=7m3
1 Ashok leyland U-4019tt NA
Trailer TATA
1 TATA NA
4923C
Mobile hydra
2 Escorts Trx 1550 Capacity upto 14t
crane
Mobile crane 1 Bucyrus erie NA Capacity= 40t
Case
Loader 2 Case NA
770ci
2 10t (SWL)
Gantry NA NA
2 58T(SWL)
Diesel 125kva(2no),
4 Ashok leyland NA 82.5kva(2no)
generator
Bar bending 1 Universal Ubm 42 42mm
machine 4 SPARTAN SCM 42 42mm
Bar cutting 1 Universal Ubm 42 42mm
machine 4 SPARTAN SCM 42 42mm
Needle vibrator 8 Wicker neuson NA 40mm,60mm
Shutter 4 Wicker neuson AR54 6000rpm
vibrator
2.12.3 SHUTTER VIBRATOR
Vibrations:6000rpm
Centrifugal force max.: 14.23kN
Rated voltage 3.250V
LWH: 245150186mm
Standard centrifugal force: 8.22 kN
FIGURE 2. 6 SHUTTER VIBRATOR
2.12.4 MOBILE HYDRA
They are designed to easily transport to a site and use with different types of
load and cargo with little or no setup or assembly. It is used for handling and
placing shutter, barricading boards, etc. Other higher capacity crane is used for
lifting pile head and for other heavy lifting like pier cap reinforcement cage.
SPECIFICATIONS:
Fuel tank capacity: 45 liter
Boom: lifting angle- 2 deg. to 60 deg.
Telescoping: heavy duty, three-part box type hydraulically operated
Operating weight: 15315 kg
Overall dimension: 9725 mm length, 2450 mm width, 3215 mm height
Speed: maximum 40 kmph
Turning radius: 7.2 m
FIGURE 2. 7 MOBILE HYDRA
2.12.5 BOOM PLACER

Vertical reach: 35.30 m
Horizontal reach: 31.30m
Pump battery:P2023-110/75
Maximum concrete pressure: 85bar
Maximum output: 96m3/hr
FIGURE 2. 8 BOOM PLACER
2.12.6 BAR BENDING MACHINE
Power: 3kW
Weight: 365kg
Electricity supply: 410Volts,50Hz
LWH: 810760860mm
Capacity:42mm
FIGURE 2. 9 BAR BENDING MACHINE
2.12.7 BAR CUTTING MACHINE
Power: 3kW
Weight: 510kg
Electricity supply: 410Volts,50Hz
Capacity:42Mm
FIGURE 2. 10 BAR CUTTING MACHINE

2.12.8 NEEDLE VIBRATOR
The frequency of vibration varies up-to 15000 rpm

Desirable minimum: 3000-6000 rpm
Normal radius of action: 0.50-1.0 m
Period of vibration: 30 seconds to 2 minute.
FIGURE 2. 11 NEEDLE VIBRATOR
CHAPTER. 3 PILE
3.1 GENERAL:
This chapter describes the important aspects & construction procedure of RCC
bored cast in-situ pile which includes layout work, Boring, Casing lowering,
Reinforcement Cage preparation and Cage lowering along with their IS Code
provision.
Pile: A pile is a vertical structural element of a deep foundation.
3.2 ACTIVITY DETAIL:

Name of the activity: Construction of Bored Cast in-situ Pile
According to the contract the foundation of the viaduct is supposed to be pile
foundation. Pile group consist of 4, 5 or 6 number of pile. Piling is done using a
hydraulic rotary piling rig machine. Polymer is used for soil stability while boring.
Formation of Reinforcement cage is carried out in the casting yard and then
transported to the site. Concreting is done by transit mixer. The depth of the pile
varies from 22m to 36m. The diameter of pile is 1.2m for viaduct & 1.5m for
stations.
3.3 TERMINOLOGY:
BORED CAST IN-SITU PILE:
A pile is formed by boring a hole in the ground by percussion or rotary
method with the use of temporary or permanent casing or drilling mud &
subsequently filling the hole with the reinforced concrete.
CUT-OFF-LEVEL:
It is the level where a pile is cutoff to support the pile-cap or beams or any other
structural components at that level.
DIAMETER OF PILE:
Piles of 600mm or less in diameter are commonly known as small diameter
piles while piles greater than 600mm are called large diameter piles.
“Minimum pile diameter shall be 450mm” as per IS: 2911 (Part
1/Sec2:2010)
PILE SPACING:
The spacing of the piles means the center to center distance between the adjacent
piles.
3.4 MATERIAL DETAIL:
TABLE 3. 1 MATERIAL SPECIFICATION
MATERIAL SPECIFICATION
Cement PPC
Reinforcement (Fe 500D) 12,16,20,25,32mm TMT
Bars
Binding wire Galvanized iron
Polymer (POLYCOL 60 Eco-drill
LS)
Anti-corrosion agent Clean-flo
Sand Zone
Admixture BASF Glenium Sky
8583
Aggregate 10mm & 20mm
Grade of concrete M 35
TABLE 3. 2 MIX DESIGN
3.5 DESIGN:
W/C 20MM 10MM

CEMENT WATER AGGREGATE AGGREGATE SAND ADMIXTURE
RATIO
0.36 400 kg 152 kg 637 kg 518 kg 810kg 3.4 kg
3.6 EQUIPMENTS/MACHINERIES& TOOLS DETAILS:
TABLE 3. 3 EQUIPMENT FOR PILE

SR. NO NAME MODEL NAME /BRAND SPECIFICATIONS
MaximumTorque:233
(kNm)
Maximum diameter: 1600
1. Pile Rig Machine MAIT/HR 180
mm
Maximum depth: 60m
Weight: 57-60 ton
2. Mobile hydra Escorts Trx1550 Capacity: 14ft
3. Diesel generator Ashok Leyland 125kva(2no), 82.5kva(2no)
4. Transit mixer Schwing setter Capacity: 7m3
5. Dumper Ashok Leyland Capacity: 8.5 m3
8. Total station TOPCON Magnification 30x
Capacity 1800kg
9. Backhoe loader JCB 3DX
Depth 5.05m
3.6.2 TOOLS USED FOR PILE ON SITE:
3.6.2.1 TREMIE PIPE:
Used for concreting

Diameter: 30cm
Available in sizes : 4m, 2.18m, 3.30m
FIGURE 3. 1 TREMIE PIPE
3.6.2.2 SPIRAL AUGER:
Diameter:1.180m
One lift: 0.35m3 excavate
3.6.2.3 BUCKET AUGER:
Used for soft soil

Productivity 0.452m3in one lift.
FIGURE 3. 2 BUCKET AUGER
3.6.2.4 HOPPER:
Used for concreting

Conical shape
FIGURE 3. 3 HOPPER
3.6.2.5 CASING:
It is inserted in the bore hole after 3.5 to 5m of boring is completed.

Height 4.5m.
Diameter 1.2m
FIGURE 3. 4 CASING
3.7 WORK BREAKDOWN:
1. Setting Out
2. Boring with Auger
3. Casing lowering
4. Reinforcement Cage lowering
5. Tremie lowering
6. Concreteing
7. Removal of casing
3.7 GENERAL DETAIL OF PILE:
Pile under study: P417/05 Pier under study: P417

Number of piles: 05
Diameter: 1200mm Length: 30.0
Grade of concrete: M 35 Existing ground level: 50.309m
Pile cutoff level: 48.059m Foundation level: 18.009m
Equipment used: Pile rig machine ID: P-pile
417---- Pier number 05------Pile number
3.8.1 PILE CONFIGURATION:
FIGURE 3. 5 PILE P417 CONFIGURATION
3.9 CONSTRUCTION METHODOLOGY:
SURVEY AND LINE OUT:
Center point of the piles are marked by the surveyor using total station with
the help of temporary benchmark.
RL of the road was taken as the TBM.

A small reinforcement bar is inserted at that location & yellow color paint is
applied on it.
Location is marked by entering Northing & easting in TS which is mentioned

in the Working pile drawing.
Two points are marked by the surveyor at a distance of 2m from the center
of the pile (as shown in the figure 3.7 below) which serve as a reference to
check the accuracy of the pile after casing lowering.
BORING:
Boring is done using MAIT HR 180 rotary rig machine.

Auger is used for boring initially up to 5m. At first the centre tooth
below the auger is placed above the marked point of pile & boring is
started.
After a certain depth of boring, the alignment is checked by

measuring the distance from the marked reference point (shown in
figure 3.8).
DRIVING OF TEMPORARY CASING:
After 5m of boring is done M.S Liner is installed for the stability of soil.
Again a check is done from the marked reference point (as shown in figure
3.9).
After casing is placed in its position it is inserted by tamping and by giving

impact by the teeth of the auger.
While inserting the casing, verticality is checked using spirit level.

Spirit level has magnet which directly get attached to the steel casing.
Casing is kept 400mm higher than the existing ground level.

Constant supply of polymer fluid is started in to the pile for side stabilization
of soil while boring.
Polymer is in the powder form & 5kg is mixed with 100lit of water.
The level of the polymer fluid in bore, shall be maintained 1.5m above the
bottom of the casing.
Below 5m boring is done using a bucket because of muddy soil.

Depth of pile is checked by lowering a chain after completion of boring.
REINFORCEMENT CAGE LOWERING:
Reinforcement cage is prepared at the casting yard including cutting,

bending & binding as shown in figure 3.10.
A cover of 75mm is placed at the distance of 2m each and staggered.
The reinforcement cage is prepared in 3parts top, middle & bottom.

The cage is lifted and lowered in the bore with the help of winch in the pile
rig (as shown in figure 3.11).
The cage is lapped with the other cage, welding is done & spirals are
provided in the lap region.
Similarly the whole cage is welded and lowered down as shown in figure
FIGURE 3. 6 CAGE PREPARATION
FIGURE 3. 7 CAGE LIFTING
FIGURE 3. 9 CAGE LOWERING
CONCRETING:
Before starting of the concreting hook length is provided to hold the

reinforcement cage.
Tremie stand is placed for the installation of tremie pipe as shown in figure
3.13.
Number of tremie pipe are inserted as per the depth of bore and hopper is
kept at the top.
A sump is made nearby so that when concrete is poured into bore hole, the
polymer comes out and it can be recycled
Concrete from RMC plant is transported to the site in Transit mixer.

Concrete is placed through tremie pipe.
Tremie should be kept 250mm above the bottom of the bore hole.
Hook length is equal to 1.04m
Hook length from CTL= CTL- COL-WL=1.268
As the concrete level rises, the tremie at the top is removed taking care that
1m to 1.5m of tremie should always be embedded in the concrete.
Slump test and cube casting are carried out on site before concreting.
Total 5 transit mixer each of 6m3 are required.

Concreting is done above the cutoff level upto a height of 1m approximately.
3.10 BAR BENDING SCHEDULE:
FIGURE 3. 8 BAR BENDING SCHEDULE

3.11 IS CODE RECOMMENDATION:
TABLE 3. 4 IS CODE RECOMMENDATION
SR. NO DESCRIPTION IS CODE ON SITE

Clear Cover Clear cover to the main Clear cover of
1. reinforcement shall not be < 75mm was provided
50mm
Lateral Reinforcement Spiral or links Spiral
2. Minimum diameter 8mm & Diameter:12mm
spacing </ 150mm Spacing: 150mm
Stiffner ring Stiffner ring preferably be of Stiffner ring of

16mm diameter at every 1.5m 16mm diameter with
3.
c/c. 1.5m c/c.
Vertical bar Minimum 6 nos. of vertical bar 18 nos. provided

Minimum Diameter: 12mm Diameter: 20mm
4.
Overhang of pile cap Clear overhang of the pile cap Provided overhang
beyond the outer most pile was 250mm.
0.250
shall be minimum of 150mm.
5.
6. Slump 150 to 180mm 150-170mm

7. Minimum Grade M 25 M 35
8. Minimum cement content 400 kg/m3 400 kg/m3
Pile Cap is cast over 75mm PCC 100mm thick
9. Levelling Course
thick levelling course.
When cutoff level is less than 2.5m Concrete shall be cast to a 1 m above the cutoff
10. minimum of 600mm above level
below ground level the cutoff level
Pile above 600mm diameter Diameter of tremie
11. Tremie Diameter shall use tremie of diameter used was 250mm.
200mm
CHAPTER.4 PILE CAP
4.1 GENERAL:
This chapter describes the important aspects and construction of pile cap. The main
objective of constructing the pile cap is to distribute the load of pier to the
underlying piles. The entire process for the construction includes Excavation,
levelling & PCC, chipping of pile, straightening of pile reinforcement,
reinforcement cage preparation, shuttering work & concreting.
Pile Cap: It is a thick concrete mat that rest on the concrete or timber piles to provide a
suitable stable foundation.
Name of the activity: Construction of pile cap

A pile cap is constructed above 4, 5 or 6 group of piles. Excavation is done through
mechanical means. Cutting & bending of bars are done in the steel yard.
Concreting is done by transit mixer.
4.3 PILE CAP DETAILS:
Scope: 173 nos.
Pile cap under study: P417
Shape: Square & Rectangle
Pile Cap consist of 4, 5 and 6 numbers of pile forming a pile group.
Soil strata: sandy soil
Size: 6.6×6.6 m
Depth: 1.8 m
Grade: M35
4.4 GENERAL DETAIL OF PILE CAP:
TABLE 4. 1 PILE CAP DETAIL
GROUND PILE PILE CAP DEPTH OF

PILE NO. LEVEL CUTOFF TOP LEVEL PILE (m)
(m) LEVEL (m) (m)
P417 50.309 48.009 49.759 30
P416 51.662 49.362 47.612 32
4.5 MIX DESIGN:
MATERIAL M35 (OPC) M20(PPC)

w/c ratio 0.36 0.37
Cement 416kg 400kg
Water 150kg 148kg
20mm aggregate 638kg 650kg
10mm aggregate 425kg 436kg
Sand 857kg 880kg
Admixture (BASF Glenium Sky 2.91kg 2.5kg
8583)
4.6 WORK BREAK DOWN STRUCTURE:
1. Survey
2. Excavation
3. Levelling course
4. Chipping of piles
5. Reinforcement age
6. Shuttering
7. Concreting
8. Deshuttering
SURVEY:
Before commencing the excavation, the pile cap layout shall be marked on the
ground with reference to the control points.
After excavation is completed, bottom level is to be checked w.r.t to drawings.
The shift of the pile if any should be recorded.

If the deviation of the pile is more than 75mm then corrective measures as
mentioned in the specifications should be adopted.
EXCAVATION:
The Excavation shall be done mechanically by Excavator.

For the placing of reinforcement & erection of formwork 1m more excavation than
the size of the pile cap (6.7×6.7m) is done.
The last 200mm excavation should be carried out manually levelling & course is to
be laid within 36 hours after completing excavation of last 200mm depth.
The excavated material shall be dumped to the nearby dumping yard.
LEVELLING COURSE:
After levelling the bottom, the pit shall be watered to keep the soil moist.
PCC of M 20 mix shall be carried out of 100mm thickness.
Generally PCC was done 1m more than the size of pile cap to facilitate the erection
of formwork.
PCC is transported to the site from the batching plant.

The concreting was carried out by the chute attached to the transit mixer
and it shall be spread manually to the minimum specified thickness.
CHIPPPING OF PILES:
After the excavation the pile should be chipped to the cutoff level by using
Pneumatic jack hammer.
The top of the pile after chipping is cleaned.

The projecting bars of the pile should be straightened.
REINFORCEMENT CAGE:
Fabrication of the reinforcement shall be done as per the approved BBS in the Steel
Yard which includes cutting & bending of rebars.
Fixing of rebar in its position as per the drawing.

The sequence is shown in the figure 4.1 below.
After pile-cap reinforcement cage is ready, the pier verticals and the crash barrier
bars placed in position and tied.
Earthing bars of 25mm are provided throughout from pile cap to pier.
These bars are kept diagonally and are connected by earthing plate of 50×8mm.
Shuttering work is carried out after the reinforcement is approved by MEGA/GEC.
FIGURE 4. 1 SEQUENCE OF REINF.
SHUTTERING:
Shuttering oil shall be applies to ensure easy removal of formwork and for proper
finishing.
Steel plates are used as shutter plate, channels and U- Jack are also used to maintain
the shutter in its position.
Foam sheet were used to prevent the leakage of the slurry.
FIGURE 4. 2 SHUTTERING DRAWING
CONCRETING:
The concrete of approved design shall be transported from the batching plant to the
site by transit mixer.
Concrete slump should be checked before pouring & it should be 75mm to 100mm.
The concrete is placed directly by the chute from the transit mixer.
Concrete is vibrated using 60mm diameter needle vibrator.
Concrete cubes are casted for testing its compressive strength.
DESHUTTERING:
Deshuttering of the pilecap is to be done after 24 hours.
CURING & BACKFILLING:
Curing is done by ponding method.

Bunds of cement mortar of lean mix are built after the final setting of concrete &
these bunds are filled with water.
Hessian cloth shall be used for curing the sides of the pilecap which is kept wet by
sprinkling water.
Backfilling is done by the excavated material in layers of 200mm.
FIGURE 4. 3 REINFORCEMENT DETAIL
CHAPTER.5 PIER
5.1 GENERAL:
This chapter includes the construction aspect of Pier. The main objective of
constructing the pier is to support the elements above it. The entire process for the
construction reinforcement cage preparation, shuttering work & concreting.
Pier: It is a vertical load bearing member.
5.2 ACTIVITY DETAILS:

Pier shape: circular and oblong Pier
Sizes: Circular Pier 1800 mm dia.
Circular Pier – 2000 mm dia
Oblong Pier – 1800 mm × 2400

mm
Oblong Pier – 2200 mm × 3000

mm
Grade of Concrete Used:
For Normal Pier – M50

For Portal Pier – M60
Type of Cement Used: OPC
Cover In Pier: 50 mm
Pier Identification:
For Normal Pier (P 417)

Pier Type (normal Pier)
5.3 PIER DETAIL:
Scope: 173 number

Pier under study: P417 & P412
P stands for Pier
417 was oblong and 412 was circular
Pier type: oblong & circular
Location: Keshavnagar near chimanbhai bridge
TABLE 5. 1 PIER DETAIL
Rail level Ground Pier quantity

Pier Pier size
(RL) Pier height (m) level per cum
number (m)
(RL)
P412 62.796 6.426 52.0 1.800 2.543
P417 66.375 11.696 50.309 1.8×2.4 3.623
5.4 MIX DESIGN:
Grade of concrete M50

w/c ratio 0.29
Cement 460kg
Water 133kg
20mm aggregate 589kg
Sand 718kg
Admixture (BASF Glenium Sky 4.6kg
8583)
5.5 WORK BREAK DOWN STRUCTURE:
1. Survey
2. Reinforcement
3. Casting of starter
4. Arrangement of mould
5. Concreting
6. Deshuttering
7. Curing
SURVEY:
The pier coordinates are transferred to the top of the footing using total station based
on the drawing provided.
The outer lines of the pier and the center shall be marked with the paint.
The placement of the main starter bars are checked properly, in terms of its quantity,
diameter, position and verticality.
Preparation of the Construction Joints and Staging

The waste materials from the surface shall be removed and cleaned using the jet of
water.
The staging is fixed up to the required height, to which the reinforcement is to be

fixed. For staging, the base jack is placed at the bottom.
The cup-lock system is used for staging.
REINFORCEMENT:
Vertical bars of the pier are already tied with the pile cap before concreting of the
pile cap and spacer bars areinserted.
After the construction of pile cap, temporary cup lock staging is provided for tying
the stirrups of pier.
The cutting and bending of the stirrups is done at the steel yard and then transported
to the site.
The stirrups are inserted from the top and tied from bottom to top according to the
spacing provided in the reinforcement schedule.
Cover blocks of 50mm are inserted on all sides at few intervals.

Drainage pipe is inserted in the center.
CASTING OF STARTER:
The shuttering is carried out for the pier starter.
After, placing of the shutter, the alignment is checked, using the total station.
Then the verticality of the formwork is checked (should be in plumb, as it guides the
rest of the pier)
The starter height is up to 1000mm.
The concreting of the starter is carried out using the chute.
The surface shall be roughened, and then the surface shall be prepared as mentioned
above.
The starter shutter shall be removed, after 24hrs.
ARRANGEMENT OF MOULD:
Prefabricated steel formwork is used.

The buffing of the form plate is done and releasing agent is applied to it.
Proper lineout is done before placing the formwork.
No kicker is constructed before formwork.
First, one half of the bottom most form plate is lifted and placed above the marked
lineout.
Then the other half is placed and similarly above form plates are attached.
Then the staging tower on all four sides are placed and necessary bolting is provided.
CONCRETING:
Survey coordinates at the top of the pier are checked by the surveyor to confirm the
plumb.
Concreting is done by a boom placer and transit mixer.

First, cement slurry is passed through the boom so that the concrete does not choke
and proper pressure is achieved while concreting.
Slump of the concrete should be 140 +/-20mm is checked using the slump cone and
12 cubes are filled for cube test.
Then the concreting is done from bottom to top and vibrating is done using needle
vibrators of 60mm from the top of the pier.
DE SHUTTERING:
De shuttering of the pier formwork is done after 24 hours.
First, the scaffolding is detached then the top most plates are removed using
a hydra crane and then the bottom plates are removed.
CURING:
After de shuttering, curing compound is sprinkled and jute bags are applied all over
the pier.
Water is sprinkled on the jute bags and curing is done for 14 days.
FIGURE 5. 1 REINFORCEMENT DETAIL OF PIER PILE
CHAPTER.6 PARAPET
6.1 GENERAL:
According to the contract, precast parapets are provided above the span.
Parapets of 3 meter length are casted for the intermediate segments and that of
1.975 meter is casted for pier head segments, at the casting yard and then erected
on site using a launching girder.
Parapet: A Parapet is a barrier provided at the edge of the viaduct.
Scope: 3060nos.
Type: type 1 & type 2
Grade: M30
Type II parapet is for pier segment whereas Type I is for Intermediate segment.
Type I parapet has Mega logo on it.
6.3 MIX DESIGN:
Grade of concrete M 30
w/c ratio 0.38
Cement 400kg
Water 152kg
Sand 823kg
Admixture (BASF Glenium Sky 3.2 kg
8583)
REINFORCEMENT:
CUTTING AND BENDING OF REBAR:

The steel bars used for parapet are of10mm diameter but sometime because of lack
of stock 8mmØ bar were also used.
Cutting and Bending of bar is done simultaneously with the cage preparation.
LAYING OF REINFORCEMENT BAR:

Reinforcement cage for parapet is prepared by laying bars on the table (act as a frame
for laying bars)
– Insert plates for future electrification work is inserted.
FIGURE 6. 1 PREPRATION OF CAGE
ARRANGEMENT OF MOULD
The buffing of the mould is done and releasing agent is applied to it before laying
of reinforcement.
After the reinforcement cage is prepared the outer shutter is turned upwards and
locked.
The inner shutter plate is inserted with the help of hydra crane and necessary bolting
isdon
FIGURE 6. 2 MOULD FOR PRAPET
LIFTING OF CAGE
The prepared cage is staked nearby and is then lifted by using crane.
For lifting purpose one additional bar of 25mm diameter is tied with main bars.
PLACING OF CAGE IN MOULD

The cage is placed in the mould, after that cover of 50mm is tied.
Oiling is done thereafter for easy removal of casted element.
Shutter is lifted and placed in position by means of screws and bolts.
CONCRETING:
Foam is applied at the corners to avoid the leakage of slurry.
Temperature is checked, slump test is done and total 5 nos. of cubes are filled for
cube test.
Concreting is done directly from the transit mixer into the mould with the help of
chute of transit mixer. Concreting is started and first concreting of the parapet
portion is done.
Then the concreting of the side connecting portion and the walk way is done.
At one time 7 to 8 parapets are casted.
DE SHUTTERING:
De shuttering of the pier formwork is done after 24 hours.

First, the inner mould are removed & then side shutter are lifted by crane hydra.
FINISHING &CURING:
After the removal of mould proper finish is provided on the parapet wherever
required and if honeycombing has occurred at any place then that part is chipped
and finishing on it is done using repairing agent.
Curing of the parapets is done for 14 days from the date of casting.
Soon after the de shuttering, curing compound is applied on the surfaces.
STACKING
after de-moulding of parapet is done it is lifted using the hydra crane by

inserting siling and D-shackle in the lifting hooks and it is stacked in the
stacking area.
FIGURE 6. 3 REINFORCEMENT DETAILING OF PRECAST STACKING

PANEL
FIGURE 6. 4 PRECAST STACKING DETAILS FOR STANDARD SPAN
CHAPTER.7 SEGMENT
7.1 GENERAL:
According to the contract MEGA/CONS/VDCTPKG-4A/N-S, precast segmental

construction methodology is used at site. Spans of box girders of 2.25 meter height
are constructed in varying span lengths of 22, 25, 28, 31, 34 and 37 meter length at
the casting yard and then erected on site using a launching girder. Post-tensioning
is done after launching of the segments. Precast methodology is used over the cast
in situ method for avoiding the blockage of traffic on site. Segmental construction
is done mainly for ease of erection
7.2 CASTING YARD DETAIL:
A Casting yard is a confined place where all concrete structure like segment,
parapets are casted, stacked cured for specific period and then shifted to working
site after they gain required strength.
Plot no: 44 casting yard near shree rang city, Chandkheda, Ahmedabad.
Area: 29725 m².
7.3 SEGMENT DETAIL:
Total no. of segments: 1530 nos.

Type of Segment : Precast Hollow Box type
Location of Activity Observed : Long line bed – 2 Of curve bed
Span under study: P-463-464, 31m
No. of segments in the span : 11 Segments
Segment under study : S2D
Segment Dimension : S1 – 8.80m x 1.975m x 2.25m
S2 to S7 – 8.80m x 3.00m x 2.25m
TABLE 7. 1 SEGMENT ID AND LENGTH
Span Segment I’ds
length S1U S2U S3U S4U S5U S6U S7C S6D S5D S4D S3D S2D S1D
37 m
34 m
31m
28 m
25 m
22 m
19 m
Not included the span (to adjust the span length)
Here, ‘U’ denotes upward, ‘D’ denotes downward and ‘C’ denotes center
Pier segment length (S1U and S1D): 2m

Intermediate Segment length (S2U to S2D): 3m
7.4 BATCHING PLANT
There are two batching plants at the casting yard, each of the capacity
30cu.m per hour, and 4 silos (2 silos for OPC and other 2 for PPC), for
storing of the cement.
The concrete produced using these batching plants, is only supplied for the
concreting of the other elements such as pile, pile-cap, pier, pier-cap, etc.
7.5 ADVANTAGES OF SEGMENTAL CONSTRUCTION:
Permits reduction of construction time as the segment are casted in casting yard &
Superstructure work proceed simultaneously at the working site.
Interference to traffic is reduced.

Segments are easy to stack in the casting yard/ stacking yard in more than one layer.
Better quality control is possible.
It contributes to aesthetically pleasing structure & good finishing.
7.6 SUPER STRUCTURE DETAIL:
The superstructure of viaduct comprises of simply supported spans.

The box girder having soffit width of 3600mm accommodate two tracks situated
at 4.2m c/c.
The box girder superstructure for all the simply supported spans will be
constructed by precast prestressed segmental construction with bonded epoxy.
The standard spans c/c of simply supported constructed by precast segmental

construction technique has been proposed as 31m. The usual segment shall be 3m
in length except the diaphragm segment, which shall be 2m each.
Other span comprises of 37,34,28,25 etc are made by adding or removing usual
segment of 3m from each span.
FIGURE 7. 1 ELEVATION OF SPAN
MOULDS:
Different mould for the casting of segment is,
a) Pier Segment mould
b) Intermediate segment mould
Each mould consist of major components like bulkhead, Outer shutter, Inner
shutter, Bottom carrier.
BUFFING:
Buffing is the operation used to remove the old and hardened concrete attached to
the formwork.
Oiling is done so that it can be de shuttered easily.
PUTTY:
After the buffing operation, putty is applied to fill the gap between the joints.
On that putty a bonding tape is laid only on bottom part.
BOTTOM SHUTTERING:
Bottom shuttering is supported on steel table on the casting beds provided in the
transverse direction of casting.
Bottom shutters shall be fixed for all segments on longline casting bed except for
the pier segment which shall be cast on short bed.
SIDE SHUTTERING:
Side shuttering are mounted in the rail which are fixed during casting of the
segment by using jacks.
Each long line casting bed shall have two pairs of side shutters.
So that two intermediate segment can be casted simultaneously using matchcasting.
For pier segment along with the side shutter bulkhead are also required.
For intermediate segment having both the neighbouring segment casted, no
bulkhead ids required harden concrete itself act as a bulkhead.
For other segment having only one segment beside it, bulkhead is required on only
one side.
FIGURE 7. 2 SHUTTERING DETAIL OF SEGMENT
REINFORCEMENT CAGE:
When the buffing & oiling operation were going on cage fabrication work was also in
progress.
After putty application, the rebar cage was lifted by 10 ton gantry &coverblock are tied.
The cage is lifted & is transferred to the prepared formwork by rolling on the rails so
provided for the movement of gantry.
Before lowering the cage HDPE pipes are inserted if the segment is to be match casted.
The reinforcement cage is to be prepared on the specially prepared/ fabricated rig.
Cutting and bending of TMT bar(Fe 500) is done in the steel yard, including the
application of inhibitor solution.
When the bars are ready, after bending, they are transported to the location of jig.
Firstly the web bars are placed on the jig as per the drawing & then soffit bars are placed.
Later on the deck bars & middle bars/ deviator block bars are placed.
All the bars are tied using binding wire of 18 gauge made from galvanized iron.
FIGURE 7. 3 REINFORCEMENT DETAIL OF SEGMENT
PROFILING:
Profiling is carried out, where the HDPE pipes are inserted with dummy inside it.
The dummy pipe is inserted in order to make sure that HDPE pipe inserted does not
deform from its original shape due to pressuere of concrete.
Earthing strip is welded at its location.

The dia of the HDPE pipe is 110mm.
Coordinates X,Y& Z are given in the profiling drawing.
For the straight span X varies along the span, Y varies in the vertical direction & Z
in the transverse direction.
Whereas for the curved span X varies along the span, Y varies in transverse direction
and Z in vertical direction.
The coordinate so of these are marked using he measure tape, thread & chalk & then
10mm dia U shape bar is placed along with the tie bar then welding is done to fix in
position.
The profiling work is checked by GEC & after that inner trolley is inserted in all the
segments except S1.
All recesses will be covered with thermocol so that no slurry enter inside sheathin
FIGURE 7. 4 DETAIL OF CABLE OF SUPER STRUCTURE
CONCRETING:
Concreting is done by boom placer.

As soon as the transit mixer is being loaded, the temperature and slump is checked.
When the transit mixer (capacity 6m3) reaches the location, before unloading it to
the boom placer, the slump is again checked & 15 cubes are casted (5 cube for each
transit).
Then the concrete is pumped through the hose pipe to the soffit, followed by wed &
then deck.
Two surface vibrator on each web.

Two needle vibrator.
Slump is generally kept 150mm.
Sequence of concreting:
Soffit
Upto half height of the web (1).
Upto half height of web (2).
Remaining height of the web (1).
Deck slab including cantilever on both sides.
When the web is fully filled with concrete a hump will form which shows that more
concrete is not required in the web portion.
DESHUTTERING:
Deshuttering is done after 24 hours.

Internal trolley is removed using turnbuckle & gantry.
Bulkhead if provided is removed by gantry.
The frame supporting internal & outer shutter shall be shifted to next location by
moving on rails.
CURING:
Curing is done by sprinkling water through pipe on the side surface while for the
deck portion ponding is done & sprinkler system is provided.
In summer gunny bags are also used.
LIFTING OF SEGMENT:
Lifting is done by 58 tons gantry by using lifting frame.

When the strength achieved is 25MPa lifting is done.
FINISHING & STACKING
The surface is finished if any honey combing is observed.
FIGURE 7. 5 LIFTING OF SEGMENT
7.8 MIX DESIGN:
COARSE COARSE
FINE WATE
CEMENT W/C AGGREGA AGGREGAT ADMIXTUR
AGGREGAT R
(kg/m3) RATIO TE 20mm E 10mm 3) E (kg/m3) 3)
E (kg/m (kg/m
(kg/m3) (kg/m3)
440 0.3 628 493 846 3.96 130
7.9 VOLUME OF CONCRETE IN SEGMENT:
TABLE 7. 3 VOLUME OF SEGMENT

SEGMENT VOLUME OF CONCRETE
(m3)
S1 15.808
S2 18.850
S3 15.753
S4 15.469
S5,S6,S7 15.176
7.10 QUANTITY OF STEEL IN DIFFERENT SEGMENTS:

TABLE 7. 4 QUANTITY OF STEEL
SEGMENT STEEL (TONES)
S1 4.056
S2 3.125
S3 2.295
S4 2.269
S5,S6,S7 2.216
7.11 BAR BENDING SCHEDULE:
FIGURE 7. 6 BAR BINDING SCHEDULE
CHAPTER.8 QUALITY ASSURENCE AND CONTROL
8.1 GENERAL:
QUALITY ASSURANCE: All the planned and systematic actions

necessary to provide adequate confidence that a product of
service were satisfy given requirement for quality.
QUALITY CONTROL: The operational techniques and activities

that are used to full fill requirement for quality.
8.2 AGGREGATE:
GRADATION/ SIEVE ANALYSIS (IS 2386 PART 1)
APPARATUS:
Sieve (40mm, 20mm, 16mm, 12.5mm, 10mm, 4.75mm, 2.36mm,
1.18mm, 0.6mm, 0.3mm, 0.15mm and 0.075mm).
Balance (L.C. - 0.1 g) Sieve shaker
PROCEDURE:
Take the sieve & arrange them in decreasing order with the largest sieve on top.
If mechanical sieve shaker is used then put the ordered sieve in position & pour the
sample in the top sieve & close it with the lid.
Switch on the machine & shaking of sieve should be done for at least 5 minutes.
After sieving, record the sample weights retained on each sieve.

Calculate the cumulative weight retained. Finally determine the cumulative passing
percentage.
OBSERVATION TABLE AND CALCULATION:
SAND:
TABLE 8. 1 RESULT OF SAND
IS SIEVE WEIGHT CUMULATIVE PERCENTAGE PERCENTAGE Limit

(mm) RETAINED RETAINED REATINED PASSING
(gm)
(gm)
10 2 2 0.2 99.8 100
4.75 50 52 5.2 94.8 90-100
2.36 51 103 10.3 89.7 75-100
1.18 288 391 39.1 60.9 55-90
0.6 129 520 52 48 35-59
.3 372 892 89.2 10.8 8-30
0.15 79 971 97.1 2.9 0-10
PAN 17 988 98.8 1.2
Total % of cumulative retained = 293.1

Fineness modulus = 2.931
Zone 2
10mm AGGREGATE:
TABLE 8. 2 RESULT OF 10MM AGGREGATE
IS WEIGHT CUMULATIVE PERCENTAGE PERCENTAGE LIMIT

SIEVE
REATAINED RETAINED REATINED PASSING
(mm)
(gm)
(gm)
12.5 0 0 0 100 100
10 105 105 5.25 94.75 85-100
4.75 1836 1941 97.05 2.95 0-20
2.36 50 1991 99.55 0.45 0-5
PAN 6 1997 99.85 0
20mm AGGREGATE:
TABLE 8. 3 RSESULT OF 20MM AGGREGATE

IS WEIGHT CUMULATIVE PERCENTAGE PERCENTAGE LIMIT
SIEVE
REATAINED RETAINED REATINED PASSING
(mm)
(gm)
(gm)
40 0 0 0 100 100
20 465 465 15.5 84.5 85-100
10 2528 2993 99.76 23.33 0-25
4.75 6 2999 99.96 3.33 0-5
PAN 1 3000 100 0
DISCUSSION:
The passing of 20 & 10 mm aggregate falls in limits of zone 2 that’s why they are
termed as Zone 2 aggregate.
For the coarse aggregate grading of aggregate are done for the determination of
particle size distribution of aggregate.
Grading of aggregate is an important factor in concrete mix design.

These affect the concrete strength & durability.
TABLE 8. 4 RESULTS FOR COMPRESSIVESTRENGTH TEST

CUBE LOAD (KN) READINGS (MPa)
NO.
1 120 22.5
2 150.00 30.7
3 162.00 32.50
CHAPTER.9 SAFETY PROGRAMME
9.1 PURPOSE:
The purpose of this EHS Plan is to ensure that all employees of RBL are
safeguarded, as far as is reasonably practicable, from potential hazards in the
performance of their duties and all practicable measures are taken to safeguard the
environment. RBL will undertake the project of Ahmedabad Metro and will be
dedicated to making improvements in safety, health and welfare standards as well
as being determined to maintain good environmental controls during every activity
and at all-time RBL requires employees, at all levels, to support and strictly
implement the EHS Policy to which end this plan is site-specific guidance to aid in
achieving the set objectives and targets.
9.2 OBJECTIVES:
The core objectives, from the RBL. EHS Policy, when completing any task are to:
Integrating EHS plan and procedure into every operation of the independent
company.
Achieving an incident free work places and offices through proactive capturing and
corrective of maximum number of UA/UB/UC, near miss and first-aid cases
subsequent reduction of severity rate, frequency & Fatality rates.
Compliance applicable legal and other requirement.

Encouraging of preparation of HIRA & EIA across the sites and offices to have a
better proactive EHS Hazard control measures and minimize the environmental
aspect and impact
Inculcating positive EHS Culture among employees through continuous training

And awareness programme
9.3 PERSONNEL PROTECTIVE EQUIPMENTS (PPE):
All people working for RBL will be provided with necessary personnel protective
equipment’s such as helmet, safety shoes, and fluorescent jacket for all workforces,
The supervisor, of the worker requiring it, must provide additional job specific PPE
like nose mask, hand gloves, goggles, face shield, ear plug, full body double lanyard
harness, etc. In turn the employee must maintain and use the correct PPE that is
provided to him. It is the responsibility of the site staff to ensure adequate supply of
PPE for the number of workers at site.
The Supervisors, with the assistance of the EHS section, must check that all
personnel are in compliance with Policies, Procedures, Plans and relevant
regulations during all work/operations and tasks.
FIGURE 10. 1 PPE MODEL
9.4 HEALTH MANAGEMENT AND MEDICAL FACILITY:
RBL will medically examine all staff as well as workers before employment to get
base data line of employee’s physical fitness. RBL also periodically check medical
fitness of employees in special cases RBL can conduct medical camp as per
situation / demand / requirement. Project site and Labour Colony will be visited by
a qualified and experienced Doctor once a Month. Minimum required First Aid
Boxes will be provided at convenient location.
The contents of the first aid box will be as under

Hydrogen Peroxide
Antiseptic Lotion ( Dettol / Savlon)
Cotton / Gauze / Bandage
Iodine tincture / Ointment (Betadine)
Pain relief spray
CHAPTER.10 CONCULUSION
It was a profound fact that knowledge & experience both governs the ability of a
person to carry out a particular task. Some aspects of construction which are not
known at undergraduate level was learnt as a part of major project in semester.VII
Inspite of the activities are of repetitive nature but every time it has some different
problem to get solved. It was a profound fact that knowledge & experience both
governs the ability of a person to carry out a particular task. Some aspects of
construction it has some different problem to get solved.

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GUJARAT TECHNOLOGICAL UNIVERSITY

Project Report On:

SR. NO. NAME ENROLLMENT NO.

1|CASE STUDY OF AHMEDABAD METRO RAIL PROJECT (MEGA)

This is to certify that the dissertation entitled CASE STUDY OF

Asst.Prof. PARTH A PATEL

Sign Of Guide. Sign.Of External Examinar. Sign Of Head Of Department

2|CASE STUDY OF AHMEDABAD METRO RAIL PROJECT (MEGA)

CHAPTER.1INTRODUCTION TO PROJECT ………………………………..………………14

CHAPTER.2 SALIENT FEATURES…………………………………………………………..18

3|CASE STUDY OF AHMEDABAD METRO RAIL PROJECT (MEGA)

CHAPTER.3 PILE .................................................................................................................... 30

3.2 ACTIVITY DETAIL: …….................................................................................................30

CHAPTER.4 PILE CAP .........................................................................................................42

CHAPTER.5 PIER …………................................................................................................ 49

CHAPTER.6 PARAPET ........................................................................................................ 55

CHAPTER.7 SEGMENT ......................................................................................................61.

5|CASE STUDY OF AHMEDABAD METRO RAIL PROJECT (MEGA)

CHAPTER.8 QUALITY ASSURENCE AND CONTROL ...................................................74.

CHAPTER.9 SAFETY PROGRAMME.................................................................................77

CHAPTER.10 CONCULUSION ............................................................................................80

6|CASE STUDY OF AHMEDABAD METRO RAIL PROJECT (MEGA)

It is and will always be an obvious implication that no proceedings of any

8|CASE STUDY OF AHMEDABAD METRO RAIL PROJECT (MEGA)

9|CASE STUDY OF AHMEDABAD METRO RAIL PROJECT (MEGA)

FIGURE 1. 1 ALIGNMENT DRAWING …………………………………………………………..…….…..15

FIGURE 2. 1 LOCATION OF AHMEDABAD ...................................................... 19

FIGURE 2. 2 RBL CASTING YARD ................................................................ 19

FIGURE 2. 3 LAYOUT PLAN OF CASTING YARD .............................................. 20

FIGURE 2. 4 ORGANIZATION CHART ........................................................... 21

FIGURE 2. 5 WORK BREAKDOWN STRUCTURE .............................................. 22

FIGURE 2. 6 SHUTTER VIBRATOR ............................................................... 26

FIGURE 2. 7 MOBILE HYDRA ...................................................................... 27

FIGURE 2. 8 BOOM PLACER ....................................................................... 27

FIGURE 2. 9 BAR BENDING MACHINE ......................................................... 28

FIGURE 2. 10 BAR CUTTING MACHINE ........................................................ 28

FIGURE 2. 11 NEEDLE VIBRATOR ................................................................ 29

FIGURE 3. 1 TREMIE PIPE .......................................................................... 32

FIGURE 3. 2 BUCKET AUGER ...................................................................... 33

FIGURE 3. 3 HOPPER ................................................................................. 33

FIGURE 3. 5 CASING ................................................................................. 34

FIGURE 3. 6 PILE P417 CONFIGURATION ...................................................... 35

FIGURE 3. 10 CAGE PREPARATION ............................................................... 37

FIGURE 3. 17 BAR BENDING SCHEDULE........................................................ 40

FIGURE 4. 1 SEQUENCE OF REINF................................................................ 45

FIGURE 4. 2 SHUTTERING DRAWING ........................................................ 46

TABLE 1. 1 ROUTE LENGTH OF DIFFERENT SECTIONS ..................................... 15

TABLE 1. 2 NUMBER OF STATION.................................................................. 16

TABLE 1. 3 CAPITAL AND TOTAL COST........................................................16

TABLE 7. 1 SEGMENT ID AND LENGTH .......................................................... 71

TABLE 7. 3 VOLUME OF SEGMENT ................................................................ 71

TABLE 8. 1 RESULT OF SAND ...................................................................... 75

TABLE 8. 3 RSESULT OF 20MM AGGREGATE .................................................. 76

TABLE 8. 4 RESULTS FOR COMPRESSIVESTRENGTH TEST ................................ 76

Vision & Mission

TABLE 1. 1 ROUTE LENGTH OF DIFFERENT SECTIONS

East-West corridor 19.435 6.335 13.100

FIGURE 1. 1 ALIGNMENT DRAWING

TABLE 1. 2 NUMBER OF STATION

SR. NO CORRIDOR NAME UG ELEVATED TOTAL

1.4 MAINTENANCE FACILITIES

1.5 COST OF PROJECT:

NAME OF THE CAPITAL TAXES & DUTIES TOTAL