2. News / Mumbai Coastal Road Project completes all Mono Pile foundations

Mumbai Coastal Road Project completes all Mono Pile foundations

December 26, 2023: Continuing HCC’s historical tradition of doing the Firsts in India whilst embracing new technologies, Mumbai Coastal Road Project (MCRP) Package-2 is proud to announce successful completion of Mono Pile foundations with varying diameters of 2.5 m, 3.0 m and 3.5 m for bridges and interchanges. This is the first large scale, large dia (> 2.5 m diameter) done in Indian heavy civil engineering industry till date.

Solution adopted post award in MCRP is the most aesthetic, cost effective and causing least disturbance to the ocean flora and fauna. MCRP was tendered with top of the pilecap being 500 mm below the seabed level. This meant taking significant exposure to marine conditions, building suitable cofferdams, undertaking excavation upto 7.5 m below the seabed level. Right at the bid stage this risk was identified, and it was agreed that alternate foundation system would be a proper mitigation strategy.

The persistent follow up of HCC-HDC JV resulted into formation of Expert Committee to consider Mono Pile adoption consisting Professors of IIT, Consultants like AECOM, Egis, LBG. To instil confidence in expert committee members and clients, filed study tours were organised to developed countries where such foundation system for bridges have been adopted. After due assessment, the committee forwarded positive recommendation for adoption of Mono Pile and received expeditious approval from BMC.

The process of commencement of execution was not smooth though. Conditions imposed by IIT for deployment of experts as detail designer, reviewer and recommending agency took long time for deployment, as there were very few projects having carried Mono Piles even in developed countries. Further, the required large diameter drilling equipment were not abundance and we had to approach Netherlands for supply of these equipment.

The Hard rock at bed level would not allow for liner driving and thus required Torque couldn’t have been generated with conventional system of RCD. The penetration rates in initial stages were 60-80 mm per hour. This needed brainstorming among experts, and they came out with solution of adding dead weight by use of lead inside RCD’s BHA which will result into necessary thrust on bits without application of torque through liner attachment. Some of the changes made led to site achieving a penetration rate of ~200 mm per hour. Charging preparation for concrete, reinforcement and handling for huge weights were additional challenges. All these challenges were duly discussed in parallel to design phase and firm method statement was finalised. Handling of large Jack up Platforms, Cranes working in tandem for various works, sea transport of material, manpower movement in open sea conditions with changing weather and wave pattern was a challenge successfully negotiated by the team.

The load test of more than 16,000 MT in vertical and 1,100 MT in horizontal direction is the highest load test carried out so far in India for any pile. Separate piles were cast for test pile having similar bore hole data as that of intended pile locations. The tests were successful and gave sufficient boost on confidence level of execution team.

The hard work and passion of project team has resulted into completion of the entire scope of 79 piles on 26.12.2023, with many feathers in HCC’s cap for:

  • First Mono Pile in foundations for Bridges in India
  • Largest Diameter executed so far for Bridges in India
  • Highest vertical and Horizontal load test for piles in India

Several dignitaries from NHAI, Ministry of Railways, National High Speed Rail Corporation, Konkan Railways, PWD, BMC, MMRDA, AP Port trust, various consultants and colleges across globe have visited the coastal road project to understand the Mono Pile founding system and its successful usage. Contributions made by Design, Planning and Execution teams at HO and Project site has led to this achievement. The successful completion of Mono Piles, once again demonstrates the indomitable spirit of HCC, delivering most challenging projects with best-in-class technology and quality.

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