DEPARTMENT OF CIVIL ENGINEERING

(GEOTECHNICAL DIVISION)
GOVERNMENT COLLEGE OF TECHNOLOGY
COIMBATORE -641013



A REPORT ON VISIT TO PILE CONSTRUCTION AT
DMRC KOCHI.
By
M.E 1
ST
YEAR GEOTECHNICAL ENGINEERING STUDENTS


ACKNOWLEDGEMENT

At the very outset, we take pleasure in thanking our honourable Principal
Dr.V.LAKSHMI PRABHA for incorporating such industrial visit as a part of
our curriculum.
We would like to render our heartfelt thanks to our Professor and Head,
Dr.T.MEENAMBAL for providing us an opportunity to visit such an
uncommon site.
Next we would like to thank our Associate Professor Dr.P.D.ARUMAIRAJ
who is always at our reach to support and guide us in all academic aspects.
And we thank our Assistant Professor Mr.V.SATHEES KUMAR for
providing us valuable information throughout the visit.
We extend our sincere thanks to Project Director Mr.P.SRIRAM and engineers
of KOCHI METRO PROJECT, KERALA for explaining clearly about the various
technical aspects involved in the pile works of the Kochi Metro and we thank
District Collector of Ernakulam M.G.RAJAMANICKAM who gave us an
inspiring and motivating speech during the visit.










INTRODUCTION
Education when adorned with experience becomes knowledge.
Knowledge empowers a man to resolve what he sees. Institution and
curriculum now a day delivers both education and experience. Someone
said seeing is believing and also feeling is more than believing.
On 27.02.2014 & 28.02.2014, we saw and felt pile coming up at
KOCHI METRO, KERALA. In the following report we share our experience
with the pile we felt at the site.

SITE SEEN DURING THE VISIT

Site 1- KOCHIN METRO YARD
Rising of ground level.
Constructing platform for the subway Box Jacking.
Site 2- KOCHI METRO PIER CONSTRUCTION
Auger Boring.
Cast in-situ pile construction.
Pile cap & pier construction
Site 3- MAKING OF PRESTRESSED GIRDERS
Prestressing of girders.
Pier cap making

LOCATION OF SITE
The site (Kochi Metro Yard) is located near Choornikkara,
Aluva, Kerala. The co-ordinates are 10.0715359 N, 76.3407343 E.


Fig.2 Box Jacking platform for the subway

FIG.1 SITE LOCATION OF
METRO YARD

CONSTRUCTION DETAILS OF KOCHI METRO YARD
The substrata consist of laterite soil with water table at the surface.
It has been proposed to fill the soil to overcome the low bearing capacity and
settlements which may be differential.
The hydraulic engineer recommended that the site should be filled by coarse
grained gravel upto 3.75 m from the initial level based on the 100 years
rainfall data and 95 % of field density must be achieved.
They had adopted underreamed piles for the piers of metro at metro yard
because frictionless soil lies under.
Standard gauge rail is to be adopted. (4 feet 8 inches).



Fig.3 PROJECT DIRECTOR & SAFETY ENGINEER EXPLAINING
THE PROJECT AND SAFETY PRECAUTIONS


Fig.4 SITE SEEING OF KOCHI METRO YARD




Fig.5 AUGER BORING FOR THE BORED IN-SITU PILE

LOCATION 2 (KOCHI METRO PILE CONSTRUCTION)

The site is located near Kalamassery , Ernakulam, Kerala. The co-
ordinates are 10.05393 N, 76.3213403E.
The points of boring are located using total station and temporary
bench marks
Auger boring was used to reach the hard strata. The auger can
excavate the soil to a depth 2m in 10 minutes.
They used cast in-situ pile of diameter 1.2 m. A group of 4 piles takes
load from the pier. While constructing the pile, they checked the
quality of work by the cross hole sonic test randomly.
We have seen the sequence of pier construction works in order:
Starting from pile, pile cap reinforcements, casting of pile cap
concrete, reinforcement details of pier and casting.
All the above mentioned works are done with sophisticated equipment
using advanced methods.





Fig.6 SITE LOCATION OF PILE AND PIER CONSTRUCTION SEEN




Fig.7 PILE DRIVING EQUIPMENTS AND WITH WORKING EXPLANATION




Fig.8 REINFORCEMENT DETAILS FOR PILE AND PIER

Fig.9 PILE CAP REINFORCEMENT





Fig.10 REINFORCEMENT DETAILS WITH EXPLANATION
LOCATION 3 (MAKING OF PRESTRESSED GIRDERS)

All the structures above the pier are prefabricated and prestressed in a
casting plant.
The pier cap, which is of Y-section is made of as a post tensioned
structure:
1. The reinforcement cage for the pier cap was made and
shuttering arrangements are given with tendons for post
tensioning in transverse direction to the rail.
2. Separate arrangements are given for shear key and connections
with both pier and U girders.
3. Concreting is done and it is allowed to achieve sufficient
strength and post tensioning is done.
4. Out of four tendons two is post tensioned at plant and
remaining two will be post tensioned after erection.






Fig.11 MAKING OF PIER CAP
The Girder, which is of U-section is made of as a pretensioned structure:

1. The maximum length to which the U Girder can be casted is 51.8m is
divided into sub sections based on construction convenience.
2. High tension steel wires are pre tensioned with in reinforcement gauge in
horizontal manner along longitudinal direction before concreting.
3. The tendons are pulled by 750mm using hydraulic jack in one end by
keeping the other end fixed.
4. The concrete used is M60 grade and after 3 to 4 days the tendons are
released slowly.







Fig.12 MAKING OF PRESTRESSED U-GIRDERS


Fig.13 REINFOCEMENT DETAILS OF PRESTRESSED U-GIRDERS

MEETING WITH COLLECTOR

Fig.14 A MEET WITH COLLECTOR



Fig.15 GROUP PHOTO WITH COLLECTOR AND L&T PROJECT MANAGER






CONCLUSION
The field visit was very much useful to us. We have learned to a great extent
about the construction procedures of pile and casting techniques of prestressed
girders.