MUMBAI -AHMEDABAD HIGH SPEED RAIL
PROJECT PACKAGE – C4
The Mumbai- Ahmedabad High Speed Rail (MAHSR Bullet Train) project is
the first of its kind in India. With total 12 stations in the States of
Maharashtra, Gujarat and Union Territory of Dadra and Nagar Haveli, the
corridor will have a length of 508.17 Km. This will cover 155.76 kms in the
state of Maharashtra (7.04 Kms in Mumbai sub-urban, 39.66 kms in Thane
district & 109.06 kms in Palghar district), 4.3 kms in union territory of Dadra
& Nagar Haveli and 348.04 kms in the state of Gujarat. The entire stretch
is divided into 8 packages, C1 to C8. The package C4 from MAHSR km
156.600 to MAHSR 393.700 km having viaduct, bridges, maintenance
depots, tunnel, 4 station(Vapi, Bilimora, Surat, Baruch) and Surat depot.

PART OF SUB STRUCTURE
• 6.8*6.8*3.0
• 6.8*6.8*2.5
• 8.4*8.4*2.5
PILE CAP PIER PIER CAP
• 7.6*4.4*2.6
• 4*2.0
• 4*2.5
• 4*3.0

WORK METHODOLOGY FOR PILE CAP
CONSTRUCTION
Excavation and PCC :-
• The pile cap area shall be marked post survey with
reference to control points and excavation shall be carried
out as per dimension and required level.
• When machine are used for excavation, the last 300mm
depth before reaching the required level shall be excavated
manually. When excavation carried below levels, shall be
brought to level by filling with crushed stones and
compacted adequately.
• Pile chipping shall be carried out minimum after 7 days of
pile casting.
• During pile chipping projecting reinforcement shall not be
disturbed.
• The pile top shall be embedded into pile cap by 150mm or
clear cover to reinforcement.
To be
continued…

• After excavation up to required level
compaction of soil done and a layer of
100 mm crushed stone to be done.
• PCC of grade M20 shall be spread and
levelled manually to the specified
thickness.
• PCC concrete edges shall be at least
100 mm wider than that of pile cap
size to facilitate the fixing of formwork.

 Pile cap cover to
reinforcement-75mm
 Grade of concrete –M40
 Type of bar – Fe 500D
 Tensile strength- 565N/mm2
 Yield strength – 500 N/mm2
Pile cap :-
• Availability of good for Construction drawing and
approved drawing shall be used.
• The outline or the periphery of pile cap on PCC shall
be marked using suitable survey equipment.
• After fixing of pile cap rebar ,shuttering of pile cap
done. Alignment of shuttering checked and the
outline and periphery of pier marked on
reinforcement.
• No. of cover block to be provided shall generally be
about 4 piece per sq. m. for bottom surface and 2-4
piece per sq. m. for side surface.
• Concrete of grade M40 is used for casting of pile cap.
• Concrete shall be deposited in horizontal layer to a
compacted depth of not more than 300mm.
To be
continued……

To be
continued….
Pile cap bottom reinforcement
done top reinforcement in
progress
Pile cap bottom reinforcement in
progress after marking of
periphery
Pile cap top reinforcement done
and shuttering in progress

• Concrete shall be done in such way that next layer of
concrete will be laid before initial set of concrete of
previous layer to avoid cold joints.
• The maximum free fall of concrete shall be restricted
to max of 1.5 m.
• Concrete shall be thoroughly compacted. Internal
vibrators shall be inserted in orderly manner the
distance between the insertions shall be 500mm or
less.
• As per design of shutter, rate of rise of concrete for
pile cap – 0.5m/hr.
• Proper construction joint shall be maintained in
concrete for pier.
• Curing shall commence as soon as the concrete start
setting . Curing compound shall be applied for side
surface.
• De-shuttering of pile cap shall be done after 24 hours
of concreting.
• After de-shuttering post pour inspection done
immediately and defects if any shall be rectified .
To be
continue….

• Coupler to be used for pile steel reinforcement
found short in length.

Pile Cap Tolerances
• Width of foundation : (-10 to +20mm)
• Thickness of foundation : (-10 to +20mm)

 PIER
• Availability of good for Construction drawing and
approved drawing shall be used.
• Survey and setting out work of Pier shall be marked prior
to starting the construction activities.
• Starter depth suitably vary from 300 to 700 mm
depending upon the pier height.
• Proper Construction joint shall be made for casting of pier.
• Steel shutter shall have plate of thickness not be less
than 5mm.
• Pier shutter shall have 4 vertical joints and 4 vertical
segments shall be assembled to make a pier shutter.
 Grade of concrete – M40
 Clear cover for pier- 75mm
 Type of Bar- Fe 500D
To be continued……

• Foam sheet of 3mm thickness shall be used
at joints in pier shutter so that leakage of
concrete slurry shall be avoided.
• Cranes of capacity 40MT and operating
radius of 12m shall be used for lifting of
pier shutter at height.
• After erection of shuttering pier shutter
vertically shall be checked.
• Support of shutter should be rigid enough
to prevent settlement.
• Rate of rise of concrete for Pier – 2m/hr.
• The concrete temp. at time of placing shall
not exceed 40^C. To be continued….

• In case of unavoidable situation
like rains and machinery
breakdown the continuous
concreting for the pier could not
be done in a single pour. The
balance concreting of pier shall be
continued after preparation of
construction joint and after
applying approved adhesive
compound on old concrete.
• De-shuttering of pier shall be done
after 24 hours of concreting.
13
To be continued……..

Pier Tolerances
• Width of foundation : (-10 to +20mm)
• Level of top : (-20 to 0mm)
• Thickness of foundation : (-10 to +20mm)

Pier cap
• Availability of good for Construction drawing
and approved drawing shall be used.
• Reinforcement tying of pier cap done in
frame.
• Cranes of capacity 40MT and operating radius
of 12m shall be used for lifting of pier shutter
at height.
• Seismic stopper reinforcement and pedestal
reinforcement tying done after erection of zig.
• Seismic stopper size Fixed (410*410*1230)
and Movable size (360*360*930).
To be continued……….
Pier cap clear cover-50mm
Grade of concrete- M50
Type of Bar- Fe 500 D

16
PIER CAP CAGE LOWERING

To be
continued…
Pier cap cage placing done
side support formwork in
progress
Pier cap reinforcement
ready survey in progress
Applying Bonding agent on
existing surface of pier
before concreting of pier cap

• Shuttering of pier cap should be rigid to
prevent the settlement.
• Slope of pier cap top is 1 in 40.
• Survey of pier cap top should be done with
high accuracy.
• Position and verticality of anchor bolt shall be
maintained
• Bonding agent should be applied on pier
surface before concreting of pier cap.
• Concrete of pier cap shall be done by boom
placer , care shall be taken such that there is
no segregation of concrete while placing.
• De-shuttering of pier cap shall be done after
24 hours of casting.

QUALITY CONTROL POINTS
• Pile cap shuttering supports to be provided on wooden block or channel of appropriate size
and thickness to prevent the slippage of jack of support.
• Pile cap shuttering side supports should be provide in sufficient number to control the
alignment of pile cap.
• Pier/Pier cap shutter to be provided on proper base support to prevent the settlement of
shuttering.
• Pier ring to be provided at every 1 m to maintain its verticality.
• When there is delay in concrete , approved bonding material and construction joint to be
made to prevent the structure from cold joint.
To be continued…

QUALITY CONTROL POINTS
• Ensure proper clear cover in the structure , if the cover is large, extra
reinforcement to be provide to prevent the structure from cracks.
• In pier cap verticality of seismic stopper shuttering box to be maintained
and checked at the time of pouring of concrete.
• Steel should be free from rust and corrosion and stacking of steel to be
done properly at site.

Approved Materials
 Curing Compound :- CONCURE AB WHITE
 Bonding Agent :- MASTER EMACO SBR- 1:1.5 POLYMER:CEMENT
FOSROC SBR LATEX-1:1:3 N.B:WATER:CEMENT
 Repairing Materials :- Master Emaco N303 – Cosmetic Touch up to (5mm) –
water powder ratio (0.19%)
Master Emaco S488 - Honeycombing, broken edges (10-100mm) – water
powder ratio 0.14%
Deeper Honeycomb/Crack Injection- Master Inject 1315
To be
continued…..

Approved Materials
 COVER BLOCK:- ASTRA CONCRETE SPACER
MARBOCON INC.
CHARBHUJA CEMENT BRICK
 MOULD RELEASE AGENT:- KUNAL CONCHEM
MASTER FINISH RL 211

DETAILS OF DRAWING NAME FOR PILE CAP
L-R2-CP1
1st L 2nd R 3RD CP 4TH 1
RECTANGULAR PIER/
SHAPE OF PIER
LOADING CASE CAST-IN –SITU PILE
FOUNDATION
GROUND CASE 1

DETAILS OF DRAWING NAME FOR PIER
L-B-10
1ST L 2ND B 3RD 10
SHAPE OF PIER
(RECTANGULAR PIER)
TYPE OF GIRDER HEIGHT OF PIER (7-10m)

MAN POWER DETAILS
 PILE CAP :- For 1 Pile Cap
Day/Night:-12 no. Each shift
Total Days :- 5
Total Man days for Pile Cap:- 120 no.
 PIER:- For 1 Pier
Day/Night:-8no. Each shift
Total Days:- 4
Total Man days for Pier:-64 no.
 PIER CAP:- For 1 Pier Cap
Day/Night:-12 no. Each shift
Total days:- 6
Total Man days for Pier Cap:-144 no.

Quantity Details
 PILE CAP :-
DIMENSION REINFORCEMENT FORMWORK (SQ
MTR)
CONCRETE QTY
(CUM)
6.8*6.8*3 6.647 74.52 133.144
6.8*6.8*2.5 6.709 60.92 110.024
8.4*8.4*2.5 8.433 73.00 165.0

Quantity Details
 PIER :-
DIMENSION REINFORCEMENT FORMWORK (SQ
MTR)
CONCRETE QTY
(CUM)
4*2.0 6.90 – 10.180 49 40-48
4*2.5 10.130-13.03 90 53-89
4*3 16.33-19.897 135 96-135
PIER CAP :-
DIMENSION PIER SIZE REINFORCEMENT FORMWORK CONCRETE QTY
7.6*4.4*2.6 4*2 8.104 53.95 57.76
4*2.5 8.105 54.85 60.04
4*3 8.224 55.75 62.32

THANK YOU

29
Bar diameter(mm) Sleeve dimensions
O.D(mm) I.D(mm) L(mm) Weight(kg)
12 24 14 100 0.25
16 32 20 100 0.4
20 38 24 100 0.45
25 45 30 160 1.1
28 53.5 34 130 1.4
32 57 38 180 2
36 63 43 180 2.6
DETAILS OF REPAIR GRIP
COUPLER(DEXTRA)