Pune Metro Elevated P1C 05 Reach-3 Training

PROJECT TRAINING
(SPRING SEMESTER 2020)
PUNE METRO ELEVATED P1C 05 REACH-3
Pune Metro project has been undertaken by MAHA Metro, a
SPV (Special Purpose Vehicle) of Government of India and
Government of Maharashtra. The project intends to develop
world class stations and surrounding areas to showcase the
rich cultural heritage, journey of various social reformation
that started from the city.
GUIDED BY:
Prof. Devanshu Pandit
Prof. Bhargav Tewar
Prof. Reshma Shah
Prof. Paresh Shah
Prof. Abhi Zaveri
Prof. Ganesh Devkar
SITE ADDRESS
Site office: J. Kumar infraprojects ltd, Irrigation colony, Nr. Yerwada post office, Opp.
Ishanya mall, Badami chawk, Yerwada, Pune, Maharashtra (411006)
Casting Yard: J. Kumar Infraprojects Ltd., Mahalaxmi Lawns, Nagar Road, Near Kharadi
Bypass, Opp. Lohgaon-Wagholi Octroi Naka, Pune, Maharashtra (411047)
Site: Stretch Between: Civil & Criminal Court, Shivajinagar to Ramwadi Via Kalyani Nagar.
EFFORTS BY:
JHANVI CHAUHAN
UC2416

OBJECTIVE OF THE PROJECT
• Pune Metro is a mass rapid transport system (MRTS) under
construction in Pune, Maharashtra, India.
• The metro network will have a total length of 54.5km when
fully operational in 2022.
• Pune is an industrial city that has witnessed growth in the
areas of corporate and industrial infrastructure over the last
decade. The existing roads in the city currently carry 8,000
commuters an hour in each direction on an average.
• The city experiences high traffic during peak hours that
leads to congestion and long hours of traffic jams along
with increased pollution. The Pune Metro aims to provide a
solution to the above issues by offering a safe and eco-
friendly journey with a 50% reduction in travel time.
• The Pune Metro rail comprises three corridors.
Construction of the first two phases is currently underway,
while the third phase was approved for construction by the
government of Maharashtra in October 2018.
OVERVIEW

Design and construction of elevated viaduct of length 7.578
km from CH: 6688 to CH: 6817 and CH: 6896 to CH: 14346
between civil court and Ramwadi.
AND
Construction of elevated Viaduct on BOQ basis of length
0.079 km from CH: 6817 to CH: 6896 Near Sangam Bridge.
SCOPE OF WORK

PRELIMINARY SITE
INTRODUCTION
PUNE
METRO
ELEVATED
PIC 05
REACH-3
TYPE OF CONTRACT: Lump Sum and
BOQ
CONTRACT VALUE: INR 388,58,55,150/-
DATE OF STARTING OF PROJECT:
2nd AUGUST 2018
TIME TO COMPLETE THE PROJECT:
110 weeks from 02nd August 2018
(10th September, 2020)
CONSULTANTS:
GC: SYSTRA-AECOM-EGIS-RITES
Contractor’s DDC:Spectrum
Techno Consultants Pvt. Ltd.
LOCATION: PUNE, MAHARASHTRA
OWNER AND EMPLOYER:
Maharashtra Metro Rail Corporation
ltd. Maha-Metro)
CONTRACTOR: J.KUMAR
INFRAPROJECTS LTD.

CONTRACTUAL DATA
PUNE
METRO
ELEVATED
PIC 05
REACH-3
PLANT AND MACHINERY ADVANCE:
5% Of fixed Lump Sum price quoted
in Schedule A charged @ 12% per
annum compounded quarterly.
THIRD PARTY INSURANCE: National
Insurance Company Limited
LIQUIDATED DAMAGE: 10% of
Original contract Value
PERFORMANCE SECURITY: INR
38,85,85,515
DEFECT LIABILITY PERIOD:
52 weeks after date of issue of the
latest Taking over Certificate for the
whole of the works.
MOBILIZATION ADVANCE: 10% of
Original contract Value

132
58
64
98
485
324
SCOPE OF WORK INVOLVED WITH
Piles
Foundation
Piers
Pier caps
Segments casted at casting yard
Segments erected on site
WORK DONE WHEN STARTED MY TRAINING
WORK DONE WHEN ENDED MY TRAINING
STATUS OF SITE

DESIGN STUDY
SEGMENTS
• The segments
are laid upon the
bearings which
rest on the
pedestal.
• This joinery is
important to be
precise.
• The bearings
and pedestal are
casted together
after casting of
pier cap.
PIERS
Piers are of two
types:
• Circular- in river
beds
• Cuboidal –on
roads
LAUNCHING GIRDER
At the erection,
location the
segments are lifted
to the required
elevation using
winch and are
moved to position
using segment
trolleys on
Launching Girders.
CPC AND PPC
The Difference
between
components in
station and viaduct
is that CPC and PPC
are present in only
stations.
CPC – Concourse
pier arm
PPC- Platform pier
arm
FOUNDATION
While some piers
have open
foundation where
as others have
piles depending
on the soil strata.

3D MODEL
ISOMETRIC VIEW OF STATION
SEGMENT STRUCTURE
JOINERY OF SEGMENTS AND SEGMENT OVER PEDESTAL
OPEN FOUNDATION
PILE FOUNDATION

3D MODEL
TOP VIEW OF VIADUCT
TOP VIEW OF VIADUCT
SEGMENT DETAIL

STEP 1:
Permits
STEP 2:
Survey Work
STEP 3:
Geotechnical
Investigation
STEP 4:
Factual
Interpretation
Report
STEP 8:
Utility
Identification
and Diversion
STEP 7:
Traffic
Management
STEP 10:
Casting Yard
work and on
site work is
simultaneous
STEP 9:
Site
Clearance
STEP 5:
Geotechnical
Investigation
Reports
STEP 6:
Design and
Drawing
CONSTRUCTION
METHODOLOGY

CONSTRUCTION
ELEMENTS
Precast box
segments
Bearing & shear
key installation
Pier cap
Pier
Crash barrier
Pile Cap
Group of Piles
SEQUENCE OF PILING
OVERALL STRUCTURE
METRO SYSTEM
SUB-STRUCTURE
OPEN FOUNDATION PILE
PILE CAP
SUPER-STRUCTURE
STATION
PIER
CONCOURSE PIER ARM
PIER CAP
STATION PIER ARM
GIRDERS
SLAB
VIADUCT
PIER
PIER CAP
SEGMENT
PEDESTAL
SEISMIC ARRESTOR
PIER PROTECTION
ROLLING STOCK (RAILS)
SEGMENT
ELASTOMETRIC BEARINGS
PEDESTAL
PIER CAP
PIER
PILE CAP
PILE
SOIL
TRAPEZOIDAL FOOTING
SOIL

WORK BREAKDOWN
STRUCTURE

CLIENT ORGANISATION
CHART

CONTRACTOR
ORGANISATION CHART

PROJECT MANAGER
• Overall scope of work.
• Coordination of
personnel and
equipment to ensure
continuous program of
works during the
execution..
SITE MANAGER
• Ensuring that the works are carried out in
accordance with approved permits.
•Liaising with Client's approved
representative during the operations or
mitigation works.
.
SITE ENGINEER
• Ensuring that all required
as built data is recorded.
•To calculate the relevant
field calculations as
required during execution
and recording the same.
SURVEYOR
•Shall report to Site
Manager e Shall give
location of pile/s at site as
per approved schemes.as
for format QA/QC ENGINEER
•Ensuring that all required tests are out and
the respective records are maintained.
•Reporting the results to QA/QC Head.
SAFETY MANAGER
•Responsible for
verification/ Inspection of
all the activities in
accordance with the Safety
•Manual/Risk assessment.
RESPONSIBILITIES

SUBCONTRACTOR NAME SUBCONTRACTOR WORK
Zenith Consultants Survey work
Spectrum Techno Consultants Pvt. Ltd. Design and drawing
Zed Geotechnics and Const. (Mumbai) Geotechnical work
Shree Samarth Geotechnics Geotechnical work
Sara Engineers Bus Shelter work
Troops Facility Service Security service
Ado Additives Technologies Ltd. (ATPL) For admixtures
Composite Combine Technocrats Pvt. Ltd. Proof checking
Dr. J.M. Mulay Consulting Engineers Pvt. Ltd.
Structural designing, Project Management, Project planning,
Quality assurance
Expert Agency For SHE Services
National Accreditation Board Testing and Calibration Laboratories
Design Enterprises Vinyl Stickers Printing
Global Lab Testing and Calibration of lab equipment
Green Engineers and Consultant Pvt. Ltd. SHE services (Environment Monitoring)
Amol Construction Soil investigation work
Geo Dynamics Pile Testing
Maruti Steel Fab Shuttering and Formwork
Technocraft Industries (India) Ltd. Shuttering fabrication work
M/S Pranav Construction Systems Pvt. Ltd. Shuttering fabrication work
Xetex Industries Pvt. Ltd. Fibre
Xetex Industries Pvt. Ltd. Micro Silica
AGENCIES INVOLVED

JOB LAYOUT OF CASTING YARD
LIST OF OTHER DRAWINGS
SR. NO. DRAWING TOTAL
SCOPE
(TENTATIVE)
APPROVED
NUMBER
OF PLANS
1 GT Report 215 53
2 Viaduct Pile 155 Station
Open
foundatio
n
Viaduct
Pile Cap 155 0
Pier 155 0
Pier Cap 150 46
Cantilever
Pier cap
5
Extended
Pier cap
4
3 Station Pile 60 Viaduct
Open
foundatio
n
Station
Pile Cap 60 0
Pier 60 0
4 Test Pile 8 6

LABOUR DETAILS
PLANNED (AVG.) ACTUAL (AVG.)
VIADUCT
CASTING
YARD
240
70
310
SKILLED UNSKILLED TOTAL
295
64
359
390
185
575
334
197
531

EQUIPMENT DETAILS
Piling Equipment
Hydraulic Rig
Batching plant Concrete Pump Boom Placer
Cranes (Casting
yard)
Cranes
(Launching)
Gantry (casting
yard)
Minimum number
of pre-casting
beds (typical)
Launching girders Transit Mixers Trailers
REQUIRED (as per contract) 4 2 5 2 3 12 4 8 4 12 8
ACTUAL (on site) 5 2 4 2 4 4 6 8 4 11 5
0
2
4
6
8
10
12
14
NUMBER
OF
EQUIPMENTS
EQUIPMENT
REQUIRED (as per contract) ACTUAL (on site)
BATCHING PLANT MIX-DESIGN
Cement
(Kg/m3)
GGBS
(Kg/m3)
20mm AGG.
(Kg/m3)
4.5mm AGG.
(Kg/m3)
12.5mm
AGG.
(Kg/m3)
Crush Sand
(Kg/m3)
Micro Silica
(Kg/m3)
w/c ratio
M15 165 165 ˗ ˗ ˗ ˗ ˗ ˗
M20 200 150 625 400 ˗ 900 ˗ 0.5
M35 264 176 600 ˗ 450 960 ˗ 0.41
M50 450 ˗ 720 ˗ 500 870 ˗ 0.29
M60 400 120 500 550 ˗ 830 25 0.27

MATERIAL DETAILS
SR. NO MATERIAL BRAND/VENDER RATES
1 OPC Cement Ultratech OPC 240/Bag
2 Steel JSW, TATA
8mm: 42/Kg; 10mm: 40.71/Kg;
12mm-32mm: 40.12/Kg
3 GGBS JSW 3/Kg
5 Batching Plant Aggregates (Wagholi) 2200/Brass + GST
6 Cover Block Mentone Concrete Pvt. Ltd and Astra
50mm (square): 2.2/Pc.;
25mm(square): 0.8/Pc.;
35mm(square): 1.1/Pc;
40mm(circle):4.06; 75mm
(Square): 5.4/Pc;
75mm(circle): 9.3/Pc;
35mm(circle): 3.19/Pc
8
Anchor Cone, Anchor Wedge, Anchor Head,
Dynamic Prestress Pvt Ltd
Anchor Cone(12DP15): 1239/Pc;
Anchor Head(12DP15): 914/Pc.;
Anchor Head(19DP15): 1171/Pc;
Anchor Wedge(15.2mm): 80/Pc
9 Curing Compound Apple Chemie 76/L
10 Shuttering Oil Image Marketers of Shuttering Oil 103/L

MATERIAL SOURCES AND
LAB DETAILS
SR. NO. MATERIAL SOURCE
1 Cement OPC 53 grade Solapur
2 Sand Talegaon
3 Aggregates Talegaon
4 Add. Mix. 1 Raighad
5 Add. Mix. 2 Raighad
6 Micro Silica Mumbai
7 GGBS Raighad
8 Reinforcement couplers Local
9 Reinforcement steel Mumbai, Pune, Nagpur
10 Other Fabricated steel Local
11 Formwork Mumbai
12 PVC items Mumbai, Pune
LABORATORY DETAILS
LIST OF TESTS PERFORMED AT LABORATORY
• Concrete Permeability test
• Flakiness Index test
• Elongation Index test
• Gradation for CA and FA
• 75-micron test for FA
• Moisture Content
• Aggregate Impact Value test
• Concrete Trial mixes
• Specific gravity and water absorption
• Concrete flow table test
• Slump Cone test
• Cube test (glue, grouting, concrete cube)
• Grouting test
• Crushing Value test
MATERIAL SOURCES

30-Aug-18 13-Oct-18 28-Feb-19 25-Oct-19 02-May-19 05-Sep-19 02-May-19 27-Jun-18 05-Dec-19 10-Sep-20
Submission of
detailed
baseline
programme &
establishing
site office
Casting of 1st
working
pile/footing
Completion of
• 02 no's of casting beds.
• Erection &
commissioning of 04
no's of gantries.
• Erection of complete
from work for 02 no's
segment at casting
beds
Submission of detailed design
parameters, design basis report
and list of GFC's and Commissiong
of 1st Batching plant in casting yard
(production of 1st batch of
concrete)
Casting of all
segments for
one span
Completion of
Launching of
all segment for
two spans
using
launching
girder
Mangalwar Peth station (13
Nov 2019 - 29 Jan 2020)
Pune Railway station (5
Nov 2019 - 3 Feb 2020)
Starting of
Kalyaninagar Station
and Ramwadi Station
Completion of viaduct for
all station
Completion of
construction of viaduct of
2km (in single stretch) and
access of the same for
laying of track
Completion of
construction of entire
length of viaduct and
access of the same
Completion of entire
work including
omega seal, cover
plate for manhole
and Macleay bars etc.
IMPORTANT DATES

CONSTRUCTION OF PIER
AND PIER CAP
PIER
Pier is a super-structural element located between the Horizontal spans and foundations. It is
similar to column, however from structural point of view a column is a member that resists the
lateral force mainly by flexure action whereas a pier is a member that resists the lateral force
mainly by a shear mechanism.
Pier can be classified –
• One is by its structural connectivity to the superstructure: monolithic or cantilevered.
• Another is by its sectional shape: solid or hollow; round, octagonal, hexagonal, or rectangular.
• Another by its framing configuration: single or multiple column bent; hammerhead or pier wall.
Pier can be classified –
One is by its structural connectivity to the superstructure: monolithic or cantilevered.
Another is by its sectional shape: solid or hollow; round, octagonal, hexagonal, or rectangular.
Another by its framing configuration: single or multiple column bent; hammerhead or pier wall.
There are three types of pier in Pune Metro:
➢ Simple Hammerhead Pier
➢ Cantilever Hammerhead Pier
➢ Circular Portal Pier
PIER CAP
Pier Cap / Headstock is the component which transfers loads from the superstructure to the
piers. Pier cap provide sufficient seating for the Bridge girders and disperse the loads from the
bearings to the Piers. PUNE METRO ELEVATED P1C 05 REACH-3

SITE LAYOUT FOR PIER

SITE LAYOUT FOR
PIER-CAP

LOCATION OF ACTIVITY
OBSERVED
PIER PIER CAP

ACTIVITY INTRODUCTION
(PIER)
Element observed P301 Pier
Location of element Bund Garden, Pune
Activities observed Formwork, Reinforcement, Concreting
Pier Chainage CH:10240.000m
Foundation type Pile Foundation
Scope of work observed The construction of pier shall be executed
with specially manufactured steel formwork
system.
Dimension of Pier Dia. Of pier = 2.8m
Area of Activity observed 6m*7m
Materials used Concrete, TMT reinforcement bars, curing
compound, Concrete Cover block, GI Binding
wire, MS Shutter plates, Cup locks, Ledgers,
Verticals, Nuts and Bolts
Equipment used Batching Plant, Transit Mixers, Boom Placer,
Welding Generator, Concrete Vibrators, Crane,
Curing Tank
Grade of Reinforcement bars Fe500D
Grade of Concrete used M60
JOB LAYOUT

ACTIVITY INTRODUCTION
(PIER CAP)
Element observed P308 pier cap
Location of element Bund Garden, Pune
Activities observed Formwork, Reinforcement, Concreting
Pier Chainage CH:10465.000m
Foundation type Open Foundation
Scope of work observed The construction of pier cap shall be executed with
specially manufactured steel formwork system.
Dimensions of Pier Cap 3.85m×3.3m×0.8m
Area of Activity observed 3.85m×3.3m
Materials used Concrete, TMT reinforcement bars, Curing
compound, Concrete Cover block, GI Binding wire,
MS Shutter plates, Cup locks, Ledgers, Verticals,
Nuts and Bolts
Equipment used Batching Plant, Transit Mixers, Boom Placer,
Welding Generator, Concrete Vibrators, Crane,
Curing Tank
Grade of Reinforcement bars Fe500D
Grade of Concrete used M60
Type of formwork used Steel shutter plates
JOB LAYOUT

DIMENSIONS OF
PIER CAP

STRUCTURAL
DETAILS OF
PIER CAP

ACTIVITY WORK
BREAKDOWN AND
ORGANISATION CHART
MAHA
METRO
J.KUMAR
PIER
REINFORCEMENT
FIXING OF DRAIN PIPE
STAGING
FORMWORK
CONCRETING
DESHUTTERING
CURING
PIER
CAP
REINFORCEMENT
FORMWORK
CURING
DESHUTTERING
CURING
PROJECT
MANAGER
(MR. SAI
PRAKASH)
HEAD QA/QC
Mr. Mangesh
Gholap
QC ENGINEER
Ojaswee Ashok
CHIEF SHE
MANAGER
Mr. Rakesh
Kumar
SAFETY
OFFICER
Mr. Pradip
Mohanty
SURVEYOR
Mr. Rajendra
Shinde
DPM FOR SITE
Mr. Pawan
SITE
ENGINEER
Mr. Sarad
SUPERVISOR
Mr. Shashwat
TRAINEE
JHANVI
CHAUHAN
WORK BREAKDOWN ORGANISATION CHART

Rolling stock-
Rails
Segment
Elastomeric
Bearings
Pedestal Pier Cap Pier Pile Cap PCC Piles Earth
LOAD TRANSFER
MECHANISM

SCAFFOLDING DETAILS
AND OTHER JOINERY
DETAILS

FORMWORK ARRANGEMENT

FAILURE OBSERVED
Management
Objectives
MATERIALS
Tasks
Resources
Location – P224
Element – Pier (During Reinforcement)
Reason – Piers are usually constructed by dividing it into
different heights or say lifts.
The reason behind doing concreting in lifts:
• If shuttering is done for the entire structure, the self-
weight of shutter will increase and chances of
accidents will increase
• Needle Vibrating can’t be checked from a large
height.
• Boom breakdown can happen.
• It can be casted as on element in river but that should
be done with more care.
This pier was reinforced for the complete height.

PROCEDURE SEQUENCE
FOR PIER CAP

ULTRASONIC PULSE
VELOCITY TEST
Management
Objectives
MATERIALS Schedules
Tasks
Resources
An ultrasonic pulse velocity (UPV) test is an in-situ, nondestructive test to check the quality
of concrete and natural rocks. In this test, the strength and quality of concrete or rock is assessed by
measuring the velocity of an ultrasonic pulse passing through a concrete structure or natural rock
formation.
This test is conducted by passing a pulse of ultrasonic through concrete to be tested and measuring
the time taken by pulse to get through the structure. Higher velocities indicate good quality and
continuity of the material, while slower velocities may indicate concrete with many cracks or voids.

EQUIPMENT AND
MATERIAL DETAILS
Management
Objectives
MATERIALS Schedules
Tasks
Resources
SR.NO DESCRIPTION CAPACITY
1 Batching Plant 30 cum/hr
2 Transit Mixers 9/6 cum
3 Boom Placer
(6.0 length Hose pipe)
70 cum/hr
4. Welding Generator 400 Amps
5. Concrete Vibrators
6 Concrete Needles Shaft 60/ 40 mm dia.
8. Crane 10 ton
9 Pump for Curing
10. Curing Tank 5000 lit
Grade of Concrete: M60
TMT reinforcement bars: Fe500
Curing compound: Apple Chemie
Concrete Cover block: 75mm
GI Binding wire: 18 gauge

Grade of concrete M60 M60
Element Pier Pier cap
Material Quantity (in kg)
Cement OPC 53
grade
400 400
GGBS 150 150
Water 161 161
Manual sand 500 500
Micro silica 25 25
10mm 433 433
20mm 652 652
Admixture 1 5.75 5.75
Grade of concrete M60 M60
Element 1st
Lift 2nd
Lift 3rd
Lift 4th
Lift PIER CAP
Material Quantity (in kg)
Cement OPC 53 grade 2000 2000 2800 3200 800
GGBS 750 750 1050 1200 300
Water 805 805 1127 1288 322
Manual sand 2500 2500 3500 4000 1000
125 125 175 200 50
10mm 2165 2165 3031 3464 866
20mm 3260 3260 4564 5216 1304
Admixture 1 28.75 28.75 40.25 46 11.5
MIX-DESIGN SHEET

PIER-QUANTITY (THEORETICAL)
Item No. Item Description Unit Nos. L B H Quantity Total
1.00 FORMWORK
Providing & erecting formwork for Pier.
Activity includes all purpose made
formwork materials, tools, centering,
erecting, oiling, de-shuttering, cleaning,
etc. complete.
m2
246.3
a 1st lift (P 301 ) 1 Area = 52.78 52.78
b 2nd life (P 310) 1 Area = 52.78 52.78
c 3rd lift (P 309) 1 Area = 70.37 70.37
d 4th lift (P 309) 1 Area = 70.37 70.37
3.00 CONCRETE
Providing and pouring of machine
mixed, mechanically vibrated and
machine batched RCC in Pier of M60
grade using max. 20 mm size of
aggregates. Activity includes production,
transportation, laying, compacting,
levelling, curing etc. complete.
m3
160.50
a 1st lift (P 301 ) 1 - - - 31.00
b 2nd life (P 310) 1 - - - 37.00
c 3rd lift (P 309) 1 - - - 47.00
d 4th lift (P 309) 1 - - - 45.50

PIER CAP-QUANTITY THEORETICAL
1.00 FORMWORK
Providing & erecting formwork for Pier
Cap. Activity includes all purpose made
etc. complete.
m2
20.845
Bottom 1 3.85 3.3 - 12.705
Side-1 2 3.85 1 - 7.7
Side-2 2 3.3 1 - 6.6
Deduction 1 - - - 6.16
3.00 CONCRETE
machine batched RCC in Pier Capof
M60 grade using max. 20 mm size of
aggregates. Activity includes
production, transportation, laying,
compacting, levelling, curing etc.
complete.
m3
1.00 - - - 11.00 11.00

INFERENCE-
The reason behind different quantities in TMs is that when concreting work is going on in adjacent places, they order concrete
accordingly. As in if the allowable quantity of TM is 10 cu.m, they load only 9.5 cu.m to avoid wastage and not to overload the TM
and they might use 3cu.m at one place and remaining at another location.
BATCHING DETAILS
5
4
8
6
8
10
7
6
8.5
5.5
8.5
10
4
7
4
6
7.5
6
4.5
6
0
2
4
6
8
10
12
Batch 1 Batch 2 Batch 3 Batch 4 Batch 5 Batch 6 Batch 7 Batch 8 Batch 9 Batch 10 Batch 11 Batch 12 Batch 13 Batch 14 Batch 15 Batch 16 Batch 17 Batch 18 Batch 19 Batch 20
QUANTITY
OF
CONCRETE
IN
M
3
BATCH

PIER-QUANTITY (PRACTICAL)
1.00 FORMWORK
Providing & erecting formwork for Pier.
Activity includes all purpose made
etc. complete.
m2
246.3
a 1st lift (P 301 ) 1 Area = 52.78 52.78
b 2nd life (P 310) 1 Area = 52.78 52.78
c 3rd lift (P 309) 1 Area = 70.37 70.37
d 4th lift (P 309) 1 Area = 70.37 70.37
3.00 CONCRETE
machine batched RCC in Pier of M60
grade using max. 20 mm size of
m3
160.50
a 1st lift (P 301 ) 1 - - - 31.00
b 2nd life (P 310) 1 - - - 37.00
c 3rd lift (P 309) 1 - - - 47.00
d 4th lift (P 309) 1 - - - 45.50

PIER CAP-QUANTITY PRACTICAL
1.00 FORMWORK
Providing & erecting formwork for Pier
Cap. Activity includes all purpose made
etc. complete.
m2
20.845
Bottom 1 3.85 3.3 - 12.705
Side-1 2 3.85 1 - 7.7
Side-2 2 3.3 1 - 6.6
Deduction 1 - - - 6.16
3.00 CONCRETE
machine batched RCC in Pier Capof
M60 grade using max. 20 mm size of
m3
1.00 - - - 11.00 11.00

BAR BENDING SCHEDULE- PIER
1 16 22.027 352.4
R = 1213 1 14
7.918
110.9
R = 1263 1 67 8.852 593.084
R =1315 1 67 9.178 614.926
R =1319 1 113 8.835 998.4
R =1275 1 113 8.559 967.2
1 1 23.738 23.74
1966 110.9 1231.75 1057
0.395 0.617 0.889 1.580 2.000 2.469 3.858 6.320
1747 175.1 3041.19 6682
Total Length ( m )
Unit Weight ( Kg / m )
Total Weight ( Kg )
300
6000
9200
21555
22738
10d 10d
10d
10d
10d
10d
10d
10d
30d
30d
30d
30d
Sr No. Item Description Nos. Bars
/No. 8 10 12 16 18 20 25 32
REINFORCEMENT
1 24 22.027 528.6
1 24 22.027 528.6
1 16 22.027 352.4
R = 1213 1 14
7.918
110.9
Cut
length
Total length (m)
300
300
300
300
300
300
6000
6000
6000
9700
9200
9200
21555
21555
21555
30d

BAR BENDING SCHEDULE- PIER CAP
Sr No. Item Description Nos. Bars
/No. 8 10 12 16 18 20 25 32
REINFORCEMENT
1 20 4.638 92.76
1 8 4.674 37.39
1 20 4.108 82.16
1 10 4.124 41.24
1 10 4.69 46.9
1 10 4.674 46.74
1 8 4.69 37.52
1 20 4.14 82.8
1 10 4.14 41.4
1 4 7.686 30.74
1 4 7.686 30.74
1 8 8.92 71.36
Cut
length
Total length (m)
510
510
510
510
510
510
510
510
510 510
510
510
510 510
510
510
3718
3718
3718
3718
3168
3168
3168
3168
2000
2000
2000
2000
3750
3750
3750
3750
160
630
630
630
630
630
630
510 510
3718
Top bar
Top bar
Top bar
Top bar
Top bar
Top bar
Top bar
Top bar
Bottom bar
Bottom bar
Bottom bar
Bottom bar
Bottom bar
Bottom bar
Bottom bar
Bottom bar
Bottom bar
Bottom bar
Side face bars
Side face bars
Side face bars
Side face bars
rings
rings
rings
1 8 4.69 37.52
1 20 4.14 82.8
1 10 4.14 41.4
1 4 7.686 30.74
1 4 7.686 30.74
1 8 8.92 71.36
1 6 8.04 48.24
1 26 7.92 205.9
1 16 2.78 44.48
1 8 4.006 32.05
1 6 3.456 20.74
459 359.2 82.16 92.76
0.395 0.617 0.889 1.580 2.000 2.469 3.858 6.320
408.1 567.6 202.853 357.868 0
Total Length ( m )
Unit Weight ( Kg / m )
Total Weight ( Kg )
510 510
510
510
3168
3168
2000
2000
2000
2000
3750
3750
3750
3750
3750
160
160
630
630
630
630
630
630
630
630
630
630
630
630
3200
3200
3200
740
740
740
740
740
740
128
128
128
128
128
128
128
128
3200
3200
700
700
700
700
700
700
700
700
700
700
700
700
510 510
3718
Bottom bar
Bottom bar
Bottom bar
Bottom bar
Side face bars
Side face bars
Side face bars
Side face bars
rings
rings
rings
rings
rings
rings
rings
rings
rings
rings
rings
rings
Bottom bar
Bottom bar
Bottom bar
Bottom bar

ABSTRACT SHEET - PIER
ABSTRACT SHEET
Item No Item Description Unit Qty Rate Amount
1.00 FORMWORK
1.01
Providing and erecting formwork for pier. Activity
includes all formwork materials, tools, centering,
erection, oiling, deshuttering etc. complete
m2
246.3 2182.19 537473.40
2.00 CONCRETE
2.01
Providing and laying reinforced cement concrete
with M60 grade concrete Mechanically vibrated
including laying, levelling, compacting, curing
etc. and excluding reinforcement and formwork
for pier .
m3
160.5 7856.26 1260929.73
3.00 REINFORCEMENT
3.01
Providing and laying reinforcement bars of
grade Fe500 in pier as specified in structural
drawing including cutting, bending, tying,
transport etc. complete
kg 11645.8 46.87 545838.65
2344241.78

ABSTRACT SHEET – PIER CAP
ABSTRACT SHEET
Item No Item Description Unit Qty Rate Amount
1.00 FORMWORK
1.01
Providing and erecting formwork for pier cap.
Activity includes all formwork materials, tools,
centering, erection, oiling, deshuttering etc.
complete
m2
20.845 2182.19 45487.75
2.00 CONCRETE
2.01
Providing and laying reinforced cement concrete
with M60 grade concrete Mechanically vibrated
including laying, levelling, compacting, curing etc
and excluding reinforcement and formwork for
pier cap.
m3
11 7856.3 86419.30
3.00 REINFORCEMENT
3.01
Providing and laying reinforcement bars of grade
Fe500 in pier cap as specified in structural
drawing including cutting, bending, tying,
transport etc. complete
kg 1536.4 46.87 72011.07
203918.19

LABOUR AND TIME
DETAILS
REINF
ORCE
MENT
1st lift 2nd lift 3rd lift 4th lift
Pier
cap
FORM
WORK
Pier
cap
SCAFF
OLDIN
G
Pier
cap
CONC
RETIN
G
Pier
cap
DAYS 2 6 6 6 6 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
SKILLED LABOURS 8 18 18 18 18 4 4 4 4 4 8 8 8 8 8 8 8 8 8 8
UNSKILLED LABOURS 12 12 12 12 12 14 14 14 14 14 11 11 11 11 11 11 11 11 11 11
0
2
4
6
8
10
12
14
16
18
20
NUMBER
ACTIVITY
DAYS SKILLED LABOURS UNSKILLED LABOURS
REINFOR
CEMENT
1st lift 2nd lift 3rd lift 4th lift Pier cap
FORMW
ORK
CONCRE
TING
UNSKILLED PRODUCTIVITY 2.581 3.466 2.501 2.501 2.783 0.29 0.251 0.314 0.314 0.106 0.217 0.259 0.329 0.318 0.077
SKILLED PRODUCTIVITY 3.872 2.311 1.667 1.667 1.856 1.015 0.88 1.1 1.1 0.372 0.298 0.356 0.452 0.438 0.106
0
2
4
6
8
PRODUCTIVITY
ACTIVITY
SKILLED PRODUCTIVITY UNSKILLED PRODUCTIVITY
Labor productivity is the Ratio of quantity of work done
to product of No. of labors and working hours.
NO. OF DAYS AND LABOURS REQUIRED FOR THE ACTIVITY
PRODUCTIVITY GRAPH

ALTERNATIVE TECHNIQUE
FOR CASTING OF PIER
CAP
STRENGTH SPACE FORM WASTAGE CURING
High strength
with reduced size
More utility
spaces and
Less disturbance
to public
No difficulty in
erection forms
Avoid theft and
Less
spillage/wastage
of material
Full curing- faster
in use
TECHNIQUE: PRE-CAST PIER CAPS (DIMENSIONS SAME AS THAT FOR P308

ABSTRACT SHEET – PIER CAP
30
85
450
95
45
20
45
200
70
45
70
40
675
100
250
0 100 200 300 400 500 600 700 800
Cleaning of area and jig
Transportation of reinforcement
Reinforcement (Up to reinforcement done on jig)
Bulk head removal, cleaning and fixing of guide cone
Cleaning of formwork and oiling
Tying of rope in center portion
Lifting of reinforcement and insertion in formwork
Profiling and pedestal and J-bolt fixing
Concreting
Deshuttering, Lifting, and Placing on stand
Lifting and loading on trailer
Transportation of pier cap, transportation of counter-weight
Erection of scaffolding
Erection and fixing of collar
Erection and fixing of pier cap with alignment
TIME (in min.)
ACTIVITY
TIME CYCLE FOR PRE-CAST PIER CAPS
TIME ANALYSIS
Time taken by one pier cap when
cast-in-situ= 76 Hrs.
Time taken by one pier cap when
pre-casted = 36 Hrs.
Therefore, Pre-casted pier caps are
more time efficient.
Difference in time = 40 Hrs.
Total time saved when used CFA
method = 40×265 = 10600 Hrs.

STEP 1:
Levelling the
formwork and
Application of
formwork
release agent
STEP 2:
Fabricating of
Reinforcement
at the
reinforcement
jig
STEP 3:
Lifting
reinforcement
cage from jig &
placing
STEP 4:
Closing the
Side shutters of
Pier cap
STEP 8:
Laying,
compacting &
finishing of
concrete in Pier
cap
STEP 7:
Aligning of
internal moulds
in position
STEP 10:
De- shuttering
of outer form
and Shifting of
Pier cap to
stack yard
STEP 9:
Release of
inner moulds
after about 16
hrs. of
concreting
STEP 5:
Profiling &
installation of
Sheathing Pipe
and Anchor
Cone
STEP 6:
Installation of
all Wallers to
the outer
moulds & to
top etc
CONSTRUCTION
METHODOLOGY
RATE: Here, the rate will be different for formwork while concrete and reinforcement rate will be same as quantity of concrete and
reinforcement does not change.
But also, the casting can be done speedily and the formwork can be used more no. of times.

MANAGEMENT DETAILS
MATERIAL
SAMPLING
TRAFFIC
SHE POLICIES
SAFETY,
OCCUPATIONAL
HEALTH AND
ENVIRONMENTAL
POLICY
DRUG ALCOHOL,
DRUGS & FIRE
ARM
PROHIBITION
POLICY
WORKPLACE
POLICY ON
HIV/AIDS
PREVENTION &
CONTROL FOR
WORKMEN
Diversion routes for traffic
Diversion paths for pedestrians
Capacity enhancement measures - Parking regulations, reduction
Barricades, Signage's, traffic lights and markings
Routing of construction vehicles
SAFETY
UTILITY
IDENTIFICATION
Sample that complies with the specified requirements
should not be damaged
Additional samples shall be provided for testing if in the
opinion of the engineer
The sample is not required to be retained under any
situation
Enquiries and
investigation will be
made by trial trench
to ascertain the
existence, nature,
location and size of
utilities
Valves will be
required to be
provided for all
major water utilities
before the start of
the work in any
stretch
The details of the
existing encountered
utilities shall be
recorded and
maintained
All diverted utilities
will be laid in final
location, if possible

COST ANALYSIS
EARTHWORK
32%
FORMWORK
45%
CONCRETE
23%
OPEN FOUNDATION UTILITY
TRENCHING
1%
BORING
9%
CONCRETING
25%
EXCAVATION
2%
REINFORCEMENT
63%
PILE
INFERENCE
In this foundation, work was done at a major depth and a large pit
was excavated for foundation work leaving a large area for working
space which was actually meant to protect the structure from Earth.
Hence formwork done had to be supported with a large length at
one side and hence costing goes higher for formwork followed by
Earthwork and concrete resp.
INFERENCE
The Piles are the foundation which carries load of the substructure
and transfers it to the soil hence it has to be strong enough which is
done by heavy reinforcement in piles. Therefore, reinforcement of
piles consumes large part of the costing.
Utility trenching is a small activity carried out for depth of 2.5m to
check utilities and hence it requires minimal cost.

COST ANALYSIS
FORMWORK
1%
REINFORCEMENT
92%
CONCRETE
7%
PILE CAP
REINFORCEMENT
57%
FORMWORK
5%
CONCRETING
38%
PIER
INFERENCE
Pile cap has a complex reinforcement including a no. of link bars and
having a height of about 1.4m which asks for larger dimensions
rebars to gain strength and resist the force of the sub structure.
Hence Reinforcement activity covers larger cost section than
concrete.
Care should be taken to avoid wastage of Rebars as it will impact the
cost structure
INFERENCE
Cost of Reinforcement is high after concreting as the structure has
complex reinforcement including a large number or circular rings for
the same area as that of concreting and hence It covers larger
section.
The wastage of concrete is less as concreting is done through boom
placer which directly pours concrete in the structure.

COST ANALYSIS
REINFORCEMENT
45%
FORMWORK
23%
CONCRETE
32%
PIER CAP
INFERENCE
Formwork is done with help of steel plates which is repeated
a number of times and hence its cost consumption is less.
On the other hand, the reason of high cost of reinforcement
is because of its complex structure and to gain a tendency of
bearing high load.
Wastage of Reinforcement should be minimum to cut out
some cost.
0.2 Cost Coefficient of Labour
0.25 Cost Coefficient of Steel
0.17 Cost Coefficient of Cement
0.05 Cost Coefficient of Fuel & Lubricants
0.18 Cost Coefficient of other materials
0.15 Cost Coefficient of overhead profit
Cost
Coefficient of
Labour
Cost
Coefficient of
Steel
Cost
Coefficient of
Cement
Cost
Coefficient of
Fuel &
Lubricants
Cost
Coefficient of
other materials
Cost
Coefficient of
overhead
profit
Series1 0.2 0.25 0.17 0.05 0.18 0.15
0.2
0.25
0.17
0.05
0.18
0.15
0
0.05
0.1
0.15
0.2
0.25
0.3
COST COEFFICIENTS

CHECKLIST
CHECKS
OPEN
FOUNDATION
PILE PILE CAP PIER PIER CAP
REINFORMENT
Working drawing checked and approved YES YES YES YES YES
BBS approved YES YES YES YES YES
Bar bending and cutting satisfactory YES YES YES YES YES
Bar size correct YES YES YES YES YES
Bar spacing correct YES YES YES YES YES
Bar lap length is correct and at correct locations YES YES YES YES YES
Bar tied as specified YES YES YES YES YES
Cover to bottom and side bars is correct YES YES YES YES YES
INHIBITED CEMENT SLURRY APPLICATION
Brand of inhibited solution and cement approved YES YES YES YES YES
Material is not expired YES YES YES YES YES
Skilled manpower is used YES YES YES YES YES
Surface free from dust YES YES YES YES YES
Sufficient dipping brush is available YES YES YES YES YES
Second coat applied after desired period of first coat YES YES YES YES YES
Application satisfactory YES YES YES YES YES

CHECKLIST
FORMWORK
Formwork firmly locked to floor and protected from any
movement
YES YES YES YES YES
Formwork is thoroughly cleaned and applied good quality
shuttering oil
YES YES YES YES YES
Formwork is free from metal defects or dent YES YES YES YES YES
All joints of shutter are properly sealed with metal/putty YES YES YES YES YES
SAFETY
Safe working platform with railing has been provided YES YES YES YES YES
Ladder is placed on secure footing at safe angle and secured to
prevent slipping
YES YES YES YES YES
Scaffolding is firm YES YES YES YES YES
Electric wires kept safe and at a distance from scaffolding YES YES YES YES YES
Every employee at site is wearing a helmet YES YES YES YES YES
Operators of machinery at site are trained YES YES YES YES YES
Operators have certificate of competency YES YES YES YES YES
Driver or operator of crane is a certified trained driver YES YES YES YES YES
Safe means of access is provided for inspection purpose YES YES YES YES YES
Safety belts have been provided for operator using vibrator YES YES YES YES YES
CHECKS
OPEN
FOUNDATION

CHECKLIST
CHECKS
OPEN
FOUNDATION
PRE CONCRETE
Concrete mix design approved YES YES YES YES YES
Batching plant in order and calibration not over due YES YES YES YES YES
Sufficient manpower available for concrete pouring at site YES YES YES YES YES
POST CONCRETE
Surface finish O.K. YES YES YES YES YES
Any honeycomb found NO NO NO NO NO
Any exposed reinforcement NO NO NO NO NO
Any cracks or any edgy damages NO NO NO NO NO
Alignment, verticality, dimension and level of structural member
O.K.
YES YES YES YES YES
Proper curing done YES YES YES YES YES
CASING, DRIVING, BORING CHECKS
Pile centre and circumference for pile is marked - YES - - -
References for the pile centre are made - YES - - -
Excavation of trench before casing driving done manually - YES - - -
Verticality of casing checked - YES - - -
Sounding checked after completion of bore - YES - - -

RATIOS
Sr. No. Element Reinforcement Quantity (kg) Formwork quantity (m2)
Concrete quantity
(m3)
R:C F:C R:F
1 Open foundation 5289.161 44.8 103 51.35 0.43 118.1
2 pile 14366.5 0 82.5 174.1 0 0
3 pile cap 58087.8 69.68 79.75 728.4 0.87 833.6
4 pier 11645.8 246.3 160.5 72.56 1.53 47.28
5 pier cap 1536.4 20.84 11 139.7 1.89 73.72
INFERENCE - From these ratios we can calculate the quantity of second activity if one is known.

Thank You

Pune Metro Elevated P1C 05 Reach-3 Training

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