Concrete

Optimisation of Concrete Cost for Metro Projects

Published

8 years ago

June 30, 2018

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An attempt is made to develop a systematic approach for estimating the quantity of concrete and optimisation of concrete cost based on a case study. The article will be published in two parts. The present article (Part 1) discusses about the Metro Projects in brief, construction methodology adopted, estimation of concrete quantity and associated cost. The next article (Part 2) will be discussing about the methodologies used for optimising the cost associated with production, transportation and placement of concrete.

In India, for infrastructure projects, the concrete is used as one of the essential construction materials. Appropriate selection of concrete (type/grade) and precise estimation of concrete quantity are essential to achieve optimised cost of concrete. Further, optimisation of construction cost related to concrete could also be achieved by appropriate selection of construction methodology along with equipment selection (rental/purchase/outsourcing) suitable for site conditions. various equipment are required for the production, transportation and placing of concrete. The selection and usage of these equipment are crucial for the successful completion of project work. Generally, the selected equipment shall fulfill project requirements within the timeframe.

In this regard, comprehensive analysis on selection of equipment and their usage in construction site needs to be carried out by the contractor well in advance (i.e bidding stage). If equipment planned to use in construction site is inadequate, it will be difficult to follow the schedule of fast track infrastructure project. On the other hand, to reduce the time period of construction, the plan for excess usage of equipment, may not be financially beneficial for the project. Hence, there is need to develop a systematic method for for optimising the cost of concreting by accurate estimation of concrete quantity and effective decision on selection of appropriate construction systems. The method was developed based on a case study (construction of metro project in Mumbai).

Mumbai Metro project
The master plan for metro project in Mumbai includes nine corridors covering a length of 172 km, out of which 32.50 km is proposed underground and the rest is elevated. First 11.40 km long elevated metro corridor between Versova – Andheri – Ghatkopar (Line 1) is commissioned in June 2014. Elevated corridors between Andheri (East) to Dahisar (East) – 16.475 km (Line 7), Dahisar to DN Nagar – 18.589 km (Line 2A) and underground metro between Colaba – Bandra – SEEPZ is under construction. Construction of elevated corridor between DN Nagar to Mandale (Line 2B) is about to start. After implementation of the Mumbai metro master plan, 70 lakh commuters are expected to get benefit, in turn, will reduce the traffic on roads and congestion in suburban rails.
1.1. The metro line 2A is selected as a case study for the present article. Brief scope of elevated metro project is as follows:

Viaduct: Design and construction of around 18 km elevated viaduct including viaduct and ramp for depot entry.

Stations: Design of 16 elevated stations (excluding architectural finishing and pre-engineered steel roof

structure).

Construction methodology: Construction methodology of a metro project is explained in this section. Civil construction activities includes mainly two pases, i.e., construction along the alignment and construction of precast elements at casting yard.

Construction along the alignment (route of metro line): Key construction activities along the alignment are as follows:

Barricading is provided to enclose the construction area to ensure safety and coordinated movement of vehicular and pedestrian traffic (Fig. 1).

Pile locations are accurately marked on ground by using the total station. Pilot trenches are made to check for any infringing underground utilities. If utilities are found, they are shifted for hassle free construction. To initiate the piling work, hydraulic rotary piling rig is positioned at piling location for boring of the pile (Fig. 2). While boring, temporary casing is provided up to required depth depending on the ground strata. After completion of boring, reinforcement cage is lowered. For casting of pile, the tremie pipe is lowered and concrete is poured up to required level through the tremie pipe.

After completion of group of piles for one pier, excavation of the pile cap is taken up. After laying PCC, the reinforcement cage is tied and concreting of pile cap is done.

After tying reinforcement for pier, the starter is cast. After casting the starter, balance formwork is erected for casting pier. Concrete will be placed up to bottom of pier cap using the truck mounted boom placer (Fig. 3 and Fig. 4). At the end, anti-crash barrier is cast.

Precast pier cap from casting yard is transported to the site and erected on pier by using the crane (Fig. 5 and Fig. 6).

"Stitch concrete" (Fig. 7) of pier cap (junction of pier reinforcement and pier cap reinforcement) is done by using the crane and bucket.

First stage stressing of pier cap is done. Bearing pedestals are cast using crane and bucket. For curing of bearing pedestals, curing compound can be used.

Precast "U" girder from the casting yard is transported to the site using multi-axle hydraulic trailer. The girder is placed on bearing pedestal using high capacity cranes (Fig. 8).

After erection of girders in the adjoining spans, second stage stressing of pier cap is done.

Construction of station building by combination of precast and cast in-situ concrete is done at each station location (Fig. 9).
Casting yard: Casting yard is mainly utilised for casting of the precast elements (pier caps, "U" girder, "I" girders, etc.), which are transported to the desired location along alignment for erection. Key construction activities at the casting yard are as follows:

Development of infrastructure at casting yard is very important activity. This includes the RMC plant installation, stacking of materials for RMC plant, construction of casting beds for precast piers, "U: girders and "I" girders, arrangement for stressing activity at each casting bed, stacking beds for casted precast elements and shed / gantry for handling formwork and casted precast elements (Fig. 10 and Fig. 11).

For casting of "U" girders, first cleaned bottom and outside shutters are placed in positioned and aligned properly. Thereafter, the reinforcement cage is placed in position. Inside shutters are placed after placing reinforcement and high tensile steel wires. Stressing of strands is done before casting "U" girders (Fig. 12 and Fig. 13).

Concreting of girder is done by using the placer boom. After achieving desired concrete strength, girders are shifted on the stacking beds (Fig. 14).

Casting of precast pier cap is done at the casting beds of pier cap. Truck mounted boom placer is used for placing concrete. After achieving desired concrete strength, piercaps are shifted on stacking beds (Fig. 15 and Fig. 16).
Estimation of concrete quantity
Based on the project, the required concrete quantity for viaduct and station needs to be calculated.. The estimated concrete quantity forms the base for calculating the cost of concrete and associated optimisation. Total concrete quantity at a glance for the selected project.

The cost associated with the concrete production and placement shall be estimated based on the following categories. Materials cost – depends on various grades of the concrete and the required quantity in each grade.

Plant and machineries cost – depends on the duration of project and the total concrete quantity required.

Transportation cost – depends on the location wise concrete requirement (at casting yard and/or along alignment).

Placement of concrete cost – Based on the site requirement, the concrete placement method (pumping/placer boom/bucket) needs to be planned for various concrete structures.

Details about planning and costing of above points are explained in subsequent points.

Costing of concrete

Concrete using fly ash/ground granulated blast furnace slag (GGBS) along with 53 Grade Ordinary Portland Cement (OPC) has been considered in calculation of cost.

Following are the possible technical advantages of using fly ash/GGBS along with OPC :

Diameter of viaduct pier is 1.8 m. In case of usage of only OPC, the core temperature of concrete may be higher and there are chances of thermal gradient leading to cracks within mass of concrete piers. Usage of fly ash will reduce the heat evolution during hydration, leading to reduced core temperature.

If high grade concrete is produced using only OPC, cement content in concrete increases. This may lead to shrinkage of concrete. Use of fly ash may minimise the shrinkage cracks.

In case of use of fly ash/GGBS, there will be secondary hydration which will make concrete more impermeable and greatly improve the durability of concrete structure.

Cohesive concrete can be achieved. Further, surface finish of the concrete structure can be improved.

For piles and pile caps, concrete can be produced using 53 grade OPC and GGBS.

For mass concrete, up to 70 per cent GGBS of total cementitious materials can also be used. This will be helpful in reducing core temperature of concrete. However, the limits on the percentage replacement shall be specified in the case of pumping.

Average material cost (as received from ready-mix concrete suppliers in Mumbai) for different grades of concrete required in metro construction using OPC and fly ash is given in Table 1. The fly ash is used up to 30 per cent (by mass) in concrete and the percentage replacement varies depending on the grades of concrete.

In case of GGBS usage, there will be further reduction of material cost in the range of Rs 200 to 400 per m3, depending on the grade of concrete and percentage of GGBS used.
Summary
The present article discussed about the metro projects in brief along with construction methodology of an elevated viaduct. Further, the article discussed about the method of estimation of concrete quantity and associated costs for various grades of concrete.
Acknowledgment

Mumbai metro rail projects

Schwing Stetter (India) for information on equipment required for RMC plant

AIMIL Ltd. for providing information on laboratory equipment

RMC suppliers in Mumbai for providing rates of RMC and raw materials
Authors

Mahesh Tendulkar
M.Tech Student
Construction Technology and Management
Department of Civil Engineering
Indian Institute of Technology Bombay
Powai, Mumbai – 400 076.
tendulkar_mahesh@yahoo.com
Basavaraj M B
Chief Engineer (Civil) – Metro
Mumbai Metropolitan Region Development Authority
Old Administrative Building, 6th Floor
Bandra – Kurla Complex, Bandra (East)
Mumbai – 400 051.
basavaraj.mb@mailmmrda.maharashtra.gov.in
Prakash Nanthagopalan
Assistant Professor
Construction Technology and Management
Department of Civil Engineering
Indian Institute of Technology Bombay
Powai, Mumbai – 400 076.
prakashn@civil.iitb.ac.in

Table 1 :Material cost for various grades of concrete

Concrete	Material cost/m3 (in Rs)
M15	3,800
M35	4,550
M40	4,650
M45	5,200
M55	5,600

Concrete

Ramco Cements Campaign Wins Six Kyoorius Honours

Hard Worker campaign wins Grand Prix for Eco Plaster film

Published

18 hours ago

May 29, 2026

admin

The Ramco Cements Limited’s Hard Worker campaign has achieved a major milestone at the prestigious Kyoorius Creative Awards, winning six honours including the coveted Grey Elephant Grand Prix for the Eco Plaster film. The awards were announced and presented at the Kyoorius Creative Awards Night 2026 held on 23rd May 2026 at the Jio World Convention Centre, Mumbai.

Competing alongside some of the country’s leading brands and agencies, the campaign received recognition across multiple creative categories, reaffirming the power of authentic storytelling rooted in the lives of hardworking people. The Eco Plaster commercial, which highlighted the importance of water conservation through innovative construction solutions, emerged as the campaign’s biggest winner, securing most of the honours.

The campaign’s wins include:
Grey Elephant (Grand Prix) – Eco Plaster
Blue Elephant – Best Film – Eco Plaster
Blue Elephant – Best Direction – Eco Plaster
Blue Elephant – Best Music – Eco Plaster
Baby Elephant – Best Direction -Tortoise & Hare
Baby Elephant – Best Use of Humour – Eco Plaster

Established in 2014, the Kyoorius Creative Awards recognise and celebrate creative excellence across India’s advertising, marketing and communications industries. Presented by Zee Entertainment Enterprises and powered by the USA-based The Clio Awards, the awards are regarded among the country’s most respected creative honours.

Known for their ethical and neutral judging process, the Kyoorius Creative Awards evaluate work purely on merit through a non-hierarchical awards structure, without Gold, Silver or Bronze distinctions. The iconic Elephant symbolises memorable work that leaves a lasting impact on the industry.

The Hard Worker campaign by The Ramco Cements Limited was conceived around the insight that true strength and progress are built through everyday hard work. Through emotionally resonant storytelling, distinctive craft and culturally rooted narratives, the campaign connected strongly with audiences across markets. The integrated campaign was rolled out across television, digital platforms, outdoor media and extensive on-ground activations, helping strengthen the brand’s connect with consumers, engineers, masons and trade communities alike.

Commenting on the achievement, A V Dharmakrishnan, CEO of Ramco Cements, said: “Winning at the Kyoorius Creative Awards is a proud moment for all of us. The Hard Worker campaign was created as a tribute to the spirit of hardworking people who form the backbone of our industry and our nation. These recognitions reaffirm our belief that authentic, meaningful storytelling has the power to create a deep and lasting connection with people.”

Balaji K Moorthy, Executive Director – Marketing, Ramco Cements, added: “The Hard Worker campaign was built on a simple but powerful insight – that hard work deserves recognition and respect. We wanted the communication to feel rooted, emotional and culturally relevant while also pushing creative boundaries. Winning six honours, including the Grey Elephant Grand Prix, is a tremendous validation of the idea, the craft and the collaborative effort of everyone involved in the campaign.”

Concrete

GP Petroleums Q4 PAT Rises 8%

Lubricant maker reports Rs 9.3 crore profit in Q4FY26

Published

18 hours ago

May 29, 2026

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GP Petroleums reported an 8 per cent rise in PAT to Rs 9.3 crore in Q4FY26, compared to Rs 8.6 crore in Q4FY25. Revenue from operations stood at Rs 163 crore, compared to Rs 183 crore in the corresponding quarter last year.

EBITDA for Q4FY26 increased to Rs 14.7 crore from Rs 13.2 crore in Q4FY25, while EBITDA margin improved to 9 per cent from 7 per cent. The company said its performance was supported by operational efficiencies, strong customer relationships and an expanding product portfolio.

For FY26, revenue from operations rose 5 per cent to Rs 643 crore, compared to Rs 610 crore in FY25. EBITDA stood at Rs 44.7 crore, against Rs 42 crore in the previous year. PAT was Rs 26.50 crore, marginally higher than Rs 26.30 crore in FY25.

The company said FY26 PAT was impacted by a wage provision of Rs 3.25 crore, representing about 12 per cent of PAT. GP Petroleums continues to see opportunities in industrial lubricants, process oils and premium automotive lubricants, though geopolitical developments and crude-linked raw material cost volatility may pose short-to-medium-term challenges.

Concrete

Ramky Infra Order Book Crosses Rs 13,000 Crore

New order wins support resilient FY2026 performance

Published

18 hours ago

May 29, 2026

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Ramky Infrastructure reported a resilient FY2026 performance, supported by disciplined execution, cost efficiency and fresh order wins. The company secured new orders worth Rs 4,500 crore during Q4, taking its total order book above Rs 13,000 crore as of 31 March 2026.

Consolidated PAT grew 40 per cent year-on-year to Rs 283 crore in FY2026, compared to Rs 202 crore in FY2025. Standalone PAT rose 28 per cent to Rs 332 crore, while consolidated revenue from operations stood at Rs 1,846 crore. Standalone revenue from operations was Rs 1,679 crore.

During the year, the company secured orders worth Rs 6,500 crore across water, wastewater and industrial infrastructure. Key wins included a Rs 3,000 crore industrial park project from Maharashtra Industrial Development Corporation for a 1,000-hectare land parcel at Dighi Port Industrial Area, Maharashtra.

Ramky also secured a Rs 2,100 crore water and wastewater project from Hyderabad Metropolitan Water Supply and Sewerage Board for water transmission lines, and a Rs 1,400 crore EPC contract from Maharashtra Industrial Township Limited for the Dighi Port Industrial Area project.

The company generated Rs 160 crore through asset monetisation and Rs 165 crore through the stake sale of a stabilised asset, supporting equity requirements for new projects. The Board also recommended a final dividend of 10 per cent of the nominal value per share, subject to members’ approval.