The construction of the metro system in Pune city and new roads with major and minor bridges in the Satara district has emerged as a valuable solution to reduce traffic congestion problems. In this context, particularly focusing on the case study of Pune Metro in the city and the new road network from Dharampuri to Lonand connecting to adjacent districts. The construction process for elevated sections primarily relies on pile foundations, which are critical in supporting the bridge structure. One of the key challenges in the construction of this structure is the process of pile chipping, i.e., the removal of excess and weak concrete from the top head of piles. The study focuses on the challenges possessed by the pile chipping process and its implications for construction time and cost. The metro construction of the 23.3 km elevated viaduct involves more than 3500 piles, facing significant challenges in the pile chipping process, and high-way bridges in the design length of this road is 49.400 km involving more than 100 piles. The conventional pile-chipping process is time-consuming, impacting project timelines and increasing labor costs. In addition to the time constraints, the financial aspect is also adversely affected. This significant expenditure under-scores the necessity for a more efficient and cost-effective approach to pile chipping, minimizing this critical factor to ensure successful and cost-effective project completion. The study aims to provide valuable insight for improving construction practices and optimizing resource utilization in future metro construction and highway bridge projects by analyzing these aspects.