Lts-Cvg-P01-16-0005-A4 Daar PDF

L&T-STEC JV MUMBAI
Mumbai Metro Line 3

Package No: UGC 01
14/03/2017
Reference number LTS-CVG-P01-16-0005-A4
DURABILITY APPROACH & ASSESSMENT REPORT FOR

CUT & COVER INCLUDING TUNNEL
L&T-STEC JV MUMBAI
Mumbai Metro Line 3
Package No : UGC 01
MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ)

UGC001
DURABILITY APPROACH & ASSESSMENT REPORT FOR CUT & COVER INCLUDING
TUNNEL
IDENTIFICATION TABLE
Client/Project owner MUMBAI METRO RAIL CORPORATION LTD.
Project MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

Durability Approach & Assessment Report for Cut & Cover including
Study
Tunnel
Type of document Report
Date 14/03/2017
LTS-CVG-P01-16-0005-A4 Durability Approach & Assessment Report
File name
for Cut & Cover including Tunnel
Framework Technical Report
Reference number LTS-CVG-P01-16-0005-A4
Confidentiality External
Language English
Number of pages 32
APPROVAL
REVISION Name Position Date Signature Modifications
Production MGO TL 10/01/2017
Check AAP DM 10/01/2017

A1
Establishment
of liability for NGU PL 10/01/2017
the entity

A2
Establishment
the entity
MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

Durability Approach & Assessment Report for Cut & Cover including Tunnel LTS-CVG-P01-16-0005-A4
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L&T-STEC JV MUMBAI
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A3
Establishment
the entity
A4 Check AAP DM 14/03/2017
Establishment
the entity

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TABLE OF CONTENTS
1. GENERAL INTRODUCTION 6
1.1 UNDERGROUND STATIONS STRUCTURES AND TUNNEL STRUCTURES 6
1.2 ENVIRONMENTAL CHARACTERISTICS 7
2. EXPOSURE CONDITIONS 7
2.1 OUTDOOR ATMOSPHERIC EXPOSURE 7
2.2 UNDERGROUND EXPOSURE 8
2.3 EXPOSURE AT GRADE LEVEL 8
2.4 INDOOR ATMOSPHERIC EXPOSURE 9
2.5 STRAY CURRENT EXPOSURE 9
2.5.1 STRAY CURRENT FROM METRO SYSTEMS 9
2.5.2 STRAY CURRENT FROM CATHODIC PROTECTION SYSTEMS 9
3. CONSTRUCTION CHALLENGES 10
3.1 ENVIRONMENT 10
3.2 WORKMANSHIP 10
3.3 MATERIALS 10
3.4 FORMWORK 10
3.5 CONCRETE PRODUCTION 10
3.6 CURING 11
4. DURABILITY RISKS FOR CONCRETE STRUCTURES / POTENTIAL DETERIORATION

MECHANISMS 11
4.1 REINFORCEMENT CORROSION 11
4.1.1 GENERAL 11
4.1.2 CHLORIDE ATTACK 12
4.1.3 CARBONATION 13
4.1.4 IMPACT OF GROUND WATER 14
4.1.5 EFFECT OF TEMPERATURE / RELATIVE HUMIDITY 14
4.1.6 CORROSION IN OXYGENATED ENVIRONMENTS 15
4.1.7 CORROSION IN DE-OXYGENATED ENVIRONMENTS 15
4.1.8 DIFFERENTIAL AERATION EFFECTS 15
4.1.9 STRAY CURRENT CORROSION 15
4.2 CONCRETE DEGRADATION 16
4.2.1 SULPHATE ATTACK 16
4.2.2 CHEMICAL ATTACK 17
4.2.3 ALKALI-AGGREGATE REACTION 17
4.2.4 PHYSICAL DETERIORATION OF CONCRETE 17

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4.3 SUMMARY 19
5. OVERALL DURABILITY ASSESSMENT APPROACH 19

5.1 DESIGN STRATEGY 19
5.2 PROPOSED DETERIORATION AND CONCRETE CONSTRUCTION MITIGATION MEASURES 19
5.2.1 CONCRETE MIX DESIGN ELEMENTS 19
5.2.2 CONCRETE CONSTRUCTION MITIGATION MEASURES 23
6. RECOMMENDATIONS FOR UNDERGROUND STRUCTURES 26

6.1 PROVISIONS AND CODAL REFERENCE 26
6.2 EXPOSURE CLASS, GRADE OF CONCRETE, W/C RATIO AND COVER TO REINFORCEMENT 27
6.3 WORK METHOD STATEMENTS 30
6.4 ADDITIONAL SPECIAL RECOMMENDATION 31
7. REFERENCES 32

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1. GENERAL INTRODUCTION
The following section considers the Employers requirements regarding durability and design life for
the Mumbai Metro Line 3. It describes the specific border conditions, design approach and results for
preliminary concrete mix compositions for the cast-in-place concrete station structures and for both
precast concrete segments and cast-in-place tunnels final lining, together with some additional
mitigation measures to be considered in the design and construction phase.
The environmental conditions in the project area represent a significant challenge for ensuring
durable concrete structures, owing to the combination of high ambient temperature, high relative
humidity, possible high levels of chlorides and sulphates in ground waters (neighborhood of the sea),
marine aerosols and highly polluted water in Nallah. Such environmental conditions, particularly
during summer months, create particular requirements relating to the manufacture, placement,
compaction and curing of concrete structures. Other deterioration mechanisms (ASR, Carbonation)
need to be considered, but are not likely to drive the design or detailing decisions.
The Employers Specification in the tender documents for the Line 3 requires a service life of 120 years,
specified in Part 2, Section VII, Sub-division 2, paragraph 2.4.2.
Employers requirements Part 2, section VII, Sub-division 2, paragraph 2.6 specify the grade of
concrete to be used, the minimum request for fire resistance period and the cracking acceptable
limitations for underground structures assumed to be in severe environmental exposure.
L&T STEC JV acknowledge that:
Minimum grade of concrete for underground structures shall be M35;

Minimum grade of concrete for structural elements that might come in contact with Nallah
water shall be M45;
Fire resistance period shall be of 4 hours for underground structures and comply with
minimum elements size and minimum concrete cover and crack width criteria requests as
per paragraphs 2.6.2 and 2.6.3;
All structural concrete element shall comply with paragraph 2.6.3 concrete cover and crack
width criteria;
Fire resistance period shall be of 2 hours and environmental exposure condition shall be
severe for all underground ancillary structures , as per paragraph 2.6.4;
Walls and slabs more than 250mm thick shall be designed with anti-crack reinforcement as
per paragraph 2.6.5.
The following paragraphs intend to supplement the measures already provided in the contract,
particularly as regards the concrete production, placing and curing, to guarantee the requested service
life of 120 years.
1.1 Underground stations structures and tunnel structures

The present summary addresses durability related design issues of the single shell segmental lining
and cast in situ lining of the bored tunnel as well as the underground stations structures. The overall
aim is to identify the requirements and define suitable measures for the design and construction that
will secure the stated design life of 120 years. The requirements for concrete structures involve an

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integrated process of adopting a suitable design, use of durable materials and ensuring that work is
carried out to a very high standard.
1.2 Environmental characteristics

As determined and presented in our Geotechnical Report, the subsurface profiles at the stations and
along the tunnel sections are similar, with made ground overlying weathered to sound basalts, breccia
and tuff. Thus, all stations as well as the complete tunnel sections will be located below the
groundwater surface. Water pressures on the base of the stations (based on the elevation of the
stations and the groundwater at the surface) are expected to be 2~3 bars at the deepest levels.
Tunnels will have to withstand a max water pressure as per following table.
Package Stations Tunnel
UGC001 2.8 bars 2.7 bars
Table 1 : Maximum water pressure expected for each package
Average hydraulic permeability of soils range from 10-6 to 10-7 m/s & average hydraulic permeability
of rocks range from 10-6 to 10-8 m/s. These values are secondary and the rock mass discontinuities will
primarily govern permeability
When stations are closed to buildings, excavation will be supported by impermeable temporary
structures such as secant piles or D-walls, without dewatering on active side, to avoid damaging
settlements.
We assume that rock mass is quite impermeable. For long term conditions the design keep into
consideration water pressure on the full height of the structures.
The tunneling works will be carried out within full water pressure, except at the interfaces to the
stations structures.
2. EXPOSURE CONDITIONS
As wrote in the design specifications the exposure conditions in the Mumbai Metro Line 3 area
represent a very aggressive environment for concrete constructions.
However, depending on the specific location / orientation of a structural element we foresee that
specific risks will vary as outlined in the following sections.
2.1 Outdoor atmospheric exposure

Concrete structures subject to outdoor atmospheric exposure are at risk from:
Carbonation owing to reaction of atmospheric carbon dioxide with alkali components in the
concrete.
Chloride attack owing to marine aerosols.

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High humidity providing sufficient moisture for corrosion to proceed and providing a path for
chloride ingress into the concrete.
High temperature which accelerates corrosion and concrete degradation processes.
Corrosion control is normally ensured by a combination of a selection of high quality concrete, crack
width limitation, control of concrete placement and curing, and application of sufficient concrete
cover.
2.2 Underground exposure

Concrete structures, which are buried in the ground, are at risk from:
Sulphate and chemical attack of the concrete, Chloride ingress from saline soils / ground waters
resulting in corrosion of embedded steel. Where the concrete is fully immersed in the groundwater,
chloride ingress will occur (owing to diffusion); however, the extent of corrosion will be limited by the
lack of oxygen. Corrosion will cease once the available oxygen has been consumed by the corrosion
reaction.
According test results of Nallahs water analysis to be done in case of contract awarding, we may take
into account corrosion due to nitrates ( corrosivity depending on hygrometry and ambient
temperature) and the hydrogen sulfide emissions caused by sulfate-reducing bacteria that can corrode
metallic materials and concretes.
Corrosion control is normally ensured as described above. With state-of-the-art high quality concrete
technology it is generally possible to provide a 120-year design life warranty for exposure conditions
in Mumbai; additional measures merely represent supplementary protection.
2.3 Exposure at grade level

Where concrete structures intersect the ground (for example foundations, columns, piles, wall
footings) they are at further risk owing to saline water ingress as a result of wicking and evaporation
of groundwater, resulting in concentration of salts, which then lead to corrosion of reinforcing steel.
Such damage is normally limited to 1m to +0.5m of grade level.
Similar situations can occur for tunnel elements where groundwater can be drawn into the structure
by evaporation on the inside face. A separate, but related, mechanism that also increases the rate of
chloride ingress, relates to wet / dry cycling owing to seasonal changes in ground water levels. When
the ground water levels increase, saline water is directly absorbed into the concrete that had
previously not been submerged. When the ground water level decreases this water is drawn out of
the concrete leaving some of the dissolved salts behind. The continuation of this cycle has the effect
of concentrating the salt levels in the concrete leading to a higher rate of ingress than for the fully
submerged concrete lower down.
Predicting the resulting acceleration factor of these two separate, but linked, effects over the life of
the structure is practically impossible owing to the number of variables involved and the uncertainty
in them. Corrosion control is therefore normally ensured by a combination of measures as described
above.

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2.4 Indoor atmospheric exposure

Indoor elements, such as building walls, underground station walls and slabs, are at least risk from
corrosion. This is because the main sources of problems - saline ground water, soils and marine
aerosols - are not present, and temperatures will normally be controlled to design levels.
The only significant risk is that of carbonation, which at the lower relative humidity will be expected
to occur at a higher rate than for outdoor conditions.
Corrosion control is normally ensured by use of high quality concrete, control of concrete placement,
sufficient concrete cover and curing.
2.5 Stray current exposure

Rail systems with DC power systems are recognised as a primary source of stray current. Other
possible sources are cathodic protection schemes, high voltage DC cable links, and other DC powered
equipment such as cranes. The stray current damage arising from interaction with such systems is a
cumulative effect that is a function of the current density current per unit surface area and the
duration over which it occurs. In addition to these possible long term threats to the Mumbai Metro
system, other short term and more intermittent sources of stray current such as electric arc welding
operations may also be present at times over the life of the system.
The reinforcement steel in concrete structures generally provides a low resistance preferential path
for stray current flow; although the exact path of the stray current can be complex and will frequently
involve discharge from the structure into the ground. It is at the point of current discharge that stray
current corrosion will occur.
Current transfer from one mesh of reinforcement to another, or even from one reinforcement to an
adjacent one, can also take place through the concrete. Where current leaves the reinforcement and
enters the concrete, corrosion will occur.
2.5.1 Stray current from metro systems
While stray current cannot be eliminated, the metro system is designed to minimize and control the
flow of stray current and thus control the risk to the concrete structures. This is a separate design
issue.
The stray current flow from and to the metro system will be time and location variant as a function of
train movement across the system and timetable variations through the operational life. This variance
helps to mitigate the issue by distributing the current over a very large surface area, thus reducing the
current density.
2.5.2 Stray current from cathodic protection systems
There are a number of cathodic protection systems in operation for the protection of reinforced
concrete and other metallic infrastructure. All of these schemes will have associated stray current;
however, the impact of this to the Mumbai Metro structures will depend upon their system design
and system proximity to the metro.

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3. CONSTRUCTION CHALLENGES
Some of the main difficulties and challenges of construction in the Mumbai region include the severe
working environment, nature of surface soil and groundwater and availability of good building
materials and skilled workers. These are detailed further in the following sections.
3.1 Environment
The high temperature and humidity in Mumbai, particularly during the long summer season, render
work conditions difficult and possibly dangerous and as a result can lead to loss of efficiency and
attention to detail. Other factors, which need to be considered, are listed below:
The high temperature and solar radiation can result in very high surface temperatures
The rate of water evaporation during the day makes effective curing difficult
The condensation rate at night can result in contamination of building materials and exposed
steel
The daily and seasonal temperature variations can lead to substantial thermal movement in
the concrete structures and have to be taken into account in the design and concrete
production
3.2 Workmanship
Work will only be undertaken as per Employers requirement. And also all the testing and inspection
will be recorded in accordance with employers requirement.
3.3 Materials
The need for controls on source materials is recognized by the Technical Specifications for the project.
The availability of suitable quality materials and the use of materials from a variety of sources with
differences in quality and specification has been one of the main factors contributing to lack of
durability in the past.
The water that is used in all aspects of the works also plays an important role in ensuring the concrete
is free from contamination and it therefore needs to be free from any contamination.
3.4 Formwork
Formwork gives the concrete its ultimate shape and finish, so it must be sufficiently rigid and able to
withstand the effects of pressure, temperature and humidity on the materials used. The type and
design of formwork, method of placing and compacting the concrete, the quality of supervision and
the experience of the workforce can all affect the resulting finish and also the durability of the surface.
3.5 Concrete production

The construction techniques adopted for projects in the Mumbai area have to be suitable for the
conditions. If needed it is now common practice to use ice in the mixing water and nitrogen cooling of
the cement to keep the temperature of the concrete low and to avoid problems associated with
temperature gradients. However, this has to be done in a controlled and well-calculated manner. The

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following factors have to be addressed in detail to ensure correct and satisfactory concrete
production:
Workability at placement
Workability retention
Environmental conditions
Transport time
Placement time
Concrete temperature
Absorption and evaporation effects
Retardation requirements
High early strength requirements for precast etc
Special finishes
3.6 Curing
Adequate curing of concrete is, arguably, the most critical of all construction operations with regard
to the durability of concrete. All the benefits of concrete specification of materials and high standards
of mix design and construction practice can be lost if curing is not properly carried out.
The use of low water/cement (w/c) ratios and mineral additions in the mixes adds an extra
requirement for good curing to minimize shrinkage cracking.
4. DURABILITY RISKS FOR CONCRETE STRUCTURES / POTENTIAL

DETERIORATION MECHANISMS
Durability issues for concrete structures relate to both direct attack / degradation of the concrete and
corrosion of embedded steel. Both types of damage can be a major problem worldwide.
The extent to which a concrete structure is at risk to either form of degradation is dependent on many
factors including the specific local environment, concrete mix, method of placement, etc. All the
different forms of attack relevant to the Mumbai Metro Line 3 project are outlined below.
4.1 Reinforcement corrosion

4.1.1 General
Sound non-contaminated concrete forms a highly alkaline protective environment for embedded steel
components, including the reinforcing steel. However, the protective conditions can be lost leading to
corrosion, which whilst relatively slow (typical corrosion rates for carbon steel in concrete range from
1 to 100 m/yr) can soon form a sufficiently thick oxide film which places a bursting force on the cover
concrete to cause cracking, delamination and eventual spalling.
The protective conditions for steel in an alkaline solution are owing to the formation of a very stable,
thin film of iron oxide formed on its surface, thus preventing further corrosion. This condition is
termed 'passivity' and the iron oxide film is referred to as the 'passive film'. Reinforcing steel becomes
passive as a result of the alkaline conditions within the concrete. This alkalinity arises from two
sources:
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Calcium hydroxide which is formed when the main cement constituents hydrate
Alkali metal hydroxides which are formed from the small amounts of sodium and potassium
oxides present in the cement
Corrosion of steel embedded in concrete will only occur if the concrete is affected by corrosive species
(ie chlorides and carbon dioxide) that break down the passive film. No concrete is entirely impervious
and if there are corrosive species in the surrounding environment they will eventually reach the steel,
allowing corrosion to start, provided there is sufficient oxygen present. There are three distinct phases
in the development of corrosion damage.
An induction period before corrosion starts
In an impermeable concrete the induction period can be many years. However, corrosion can
occur at an early stage when either the concrete is contaminated with corrosive species at the
time of construction, or if the concrete is highly permeable.
Early corrosion of the reinforcement
Once corrosion starts, the rate of corrosion will depend on several factors. These include
concrete resistivity, moisture content and the availability of oxygen. In general, a permeable
concrete, in a corrosive environment, results in loss of passivity (depassivation) and high
corrosion rates.
Cracking, delamination and spalling of the concrete cover
Depending on the form of corrosion, cracking, delamination and spalling may occur after only
a slight reduction in bar thickness. This is because the resultant corrosion products occupy
large volumes that may be several times the original steel volume. Alternatively, external signs
of corrosion may be delayed until severe local loss of bar section has occurred. Damage to the
concrete cover may increase or decrease the rate of corrosion of the reinforcement,
depending on the external environment. For example, when chloride contaminated concrete
falls away and exposes reinforcement to a dry atmosphere, the corrosion rate may decrease,
but exposure to a damp environment where chloride contaminated sand may accumulate
would increase the rate.
It should be noted that under certain conditions, (limited oxygen, high chloride), steel in concrete can
corrode to a form of corrosion product ('black rust') that has a volume similar to the original steel. In
these circumstances there may be no visible signs of deterioration on the surface of the concrete.
Any depassivation of steel in concrete which leads to serious corrosion is usually owing to either
carbonation or the effect of chlorides. There are usually significant differences in the form and effects
of the subsequent corrosion between these two major causes of depassivation.
4.1.2 Chloride attack
Chloride attack occurs when chloride ions reach the steel reinforcement and break down the
protective oxide layer on the steel. Chloride ions therefore depassivate the steel and cause the
development of local corrosion cells.

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Chloride ions present at the interface of steel and concrete are not consumed in the reactions, but
may be considered as acting like catalysts by promoting a continuing corrosion process. The
interrelation between the chloride ions, the concrete, relative humidity and extent of carbonation is
complex. Hence it is seen that it is not possible to define an absolute 'critical chloride concentration'
below which corrosion will not occur.
However, a comprehensive review of the literature on this topic will be applied. According to state of
the art literature, the threshold values range anywhere from 0.17 to 2.5% chloride (expressed as total
chloride by mass of cementitious material).
Normal working criteria for critical chloride levels for concrete is 0.6 kg/m concrete as per I.S. 456.
Chlorides can enter the concrete at the time of construction, by use of contaminated or marine
aggregates or seawater in the mix, and after construction from exposure to seawater, saline ground
water, salt laden aerosols or as salt laden dust / sand particles. Ordinary Portland cements, with a
tricalcium aluminate (C3A) content of greater than 5% can react with chlorides that are present in the
mix to form insoluble chloro-aluminates. Sulphate resistant cements, which are low in C3A do not
combine with chlorides and hence are less tolerant.
Chloride ingress can be due to simple diffusion, capillary risk, water movement through the concrete
or by evaporation / concentration effects. The rate of chloride ingress is dependent on the
concentration in the environment and the quality of the concrete, which itself is dependent on:
Water cement ratio

Cement content
Placement / compaction
Degree / quality of curing
Concrete admixtures / cement replacements
The rate of ingress for a particular concrete essentially follows a root-time law, in that the
concentration is inversely proportional to depth and the square root of the exposure time. Hence a
doubling (factor of 2x increase) of the concrete cover will result in a quadrupling (a factor of 4x
increase) in the period before critical chloride concentration is reached.
4.1.3 Carbonation
Carbonation of concrete is the reaction of alkali components in the concrete, calcium hydroxide, with
atmospheric carbon dioxide or other acidic gases and moisture to form calcium carbonate. The result
of this carbonation is to decrease the pH value of the concrete from typically high alkaline pH values
of 12 to 13 to a pH of between 7 and 9. Under these carbonated conditions, the passivating oxide films
on steel are no longer stable and therefore no longer provide protection. The loss of alkalinity is
progressive with time and the onset of corrosion occurs when the carbonation front reaches the
reinforcing steel.
The rate of carbonation is a function of concrete permeability, its cement content, its moisture content
and the humidity of the surrounding environment. Carbonation occurs most rapidly at around 60% -
70% relative humidity (RH) and hardly occurs in permanently very dry concrete or in permanently wet
concrete. In temperate climates, the carbonation rate is typically 10 to 15 mm over 40 years for good
quality concrete. Again the rate of carbonation follows a root-time law, so that doubling the depth of
cover increases the time before corrosion starts by a factor of 4x.
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4.1.4 Impact of ground water
Concrete buried in the ground is often naturally protected from the more extreme environmental
effects such as short-term fluctuations of temperature.
Ground conditions can vary from wet clay with virtually no oxygen present to dry, well aerated sandy
soils. Position in relation to the water-table is important, since water-saturated soils are also usually
low in oxygen content.
Upward leaching and evaporation of water from exposed surfaces of sections of buried structures
(such as foundation footings and columns) can result in very high concentrations of salts such as
sulphates and chlorides at, or near, grade level. This may cause sulphate attack of susceptible
concretes and, in the case of chlorides, can initiate reinforcement corrosion. Such damage is normally
restricted within 1 to +0.5 m of grade level. Similar problems can occur with tunnel walls (either
tunnel lines in bored tunnels or diaphragm walls in cut and cover tunnels and structures), with salt
build up on the inside face as well as the external face of the element.
One aspect that is particularly important is the possible damage to concrete caused by fluctuation
levels in the ground water table level. In urban environments the ground water table levels are often
artificially raised from their original, natural, state by intense irrigation after completion of the
construction work, especially for stations near parks. Foundations, column footings and other
concrete components which were expected to have remained essentially dry and above the ground
water table levels may, and in many cases have, become heavily contaminated by possible highly
saline ground waters.
Whilst there are some attempts to reverse this trend and reduce the level of the ground water table,
it should be noted that this may adversely affect concrete that has been contaminated by exposure to
saline ground water since the chloride ion concentrations at the reinforcement may be above the
critical threshold levels and oxygen will become increasingly available as the concrete dries out.
Possible corrosion of the reinforcement after reduction in water levels, where there was no prior
corrosion owing to lack of oxygen should be considered.
4.1.5 Effect of temperature / relative humidity
Temperature affects corrosion of steel in concrete in several ways; for Mumbai region the effects are
generally all detrimental, owing to the high ambient temperatures and can:
Lead to rapid loss of water from the mix resulting in a porous, less durable concrete
Increase the rate of diffusion of aggressive species through the concrete
Increase the rate of corrosion reaction once corrosion starts
The relative humidity effects on corrosion in concrete are summarised below:
At very low relative humidity (<50% RH) there is insufficient moisture in the concrete for
corrosion to proceed
At very high relative humidity (>90% RH) the rate of carbonation is significantly reduced
extending the initiation period
At 100% RH (ie fully immersed) the pores in the concrete become saturated restricting the
transport of oxygen to the steel surface, which effectively stifles any corrosion reaction

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At relative humidity of 75% to 90% RH there is sufficient moisture and oxygen for corrosion to
proceed
4.1.6 Corrosion in oxygenated environments
Where fully oxygenated conditions exist, for example in atmospherically exposed concrete (eg
elevated sections, support columns, non-buried structural concrete in stations etc), the corrosion
process is controlled by the quality of the concrete, the internal PH, concrete resistivity and chloride
level at the reinforcement.
The corrosion will generally be uniform across the reinforcement and will result in formation of
voluminous hydrated oxides. Which will, in time, cause cracking and spalling of the concrete cover.
4.1.7 Corrosion in de-oxygenated environments
Where de-oxygenated conditions exist, for example in fully immersed marine structures or buried
structures below the water table, the corrosion becomes controlled by the availability of oxygen. In
fully saturated conditions the corrosion rate can quickly stifle and become insignificant.
4.1.8 Differential aeration effects
Where a structural element is exposed to differential aeration (for example in segmented tunnel walls,
portions of diaphragm walls in stations exposed to soil on one side and open on the other), then a
form of galvanic corrosion can occur. Here the area which has free access to air (and oxygen) will
become the cathode and the de-aerated site will become the anode.
In these cases the metal loss can be accelerated and, because of the absence of oxygen at the
corroding site so called black-rust corrosion takes place. Here the corrosion products are not more
voluminous than the steel they replace and do not lead to cracking or spalling of the cover concrete.
The corrosion becomes very localised with large size pits. Where there is excess water present in the
pits it can hydrolyse forming acidic conditions, which further accelerate the metal loss.
4.1.9 Stray current corrosion
Stray current can be viewed as an accelerating factor that provides an external driving force for
normal corrosion reactions in much the same way as differential aeration effects. The impact and
morphology of the corrosion is similarly a function of oxygen availability as described above. As an
external accelerant, stray current may be present for the life of the structure. As it is driven by the
potential gradient produced between the stray current source and the stray current return point, the
behaviour over time will be a function of the relative electrical resistance of the individual components
and how these change as corrosion progresses.
With good stray current control, the worst case risks will be to the oxygen-facing parts of a structure
where the voluminous nature of the stray current corrosion product causes early cracking of the
concrete cover and thus defeats the durability protection. The absolute magnitude of current required
to give stray current corrosion problems on any individual component can be very low, but the very
large surface area of reinforcement steel that may be affected mitigates this and it is the current
density in terms of amps per square metre of steel that is important. Calculation of metal loss arising
from stray current leakage is determined from Faradays laws, and leads to the result that already a

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continuous stray current of very low density will be sufficient to cause cracking over 120 years under
worst case conditions.
4.2 Concrete degradation

Concrete degradation covers both chemical attack of the concrete from sulphates, acidic conditions
and alkali-aggregate reaction and mechanical damage. The considerations concerning the durability
of the reinforced concrete elements in this report are based on the following:
It is assumed that the station boxes and the tunnel lining are situated in a constantly water-
saturated environment
It is assumed that the concentrations of chlorides and sulphates in the groundwater will not
change significantly over the intended target service life of t = 120 years
It is assumed that the ground water exchange rate is high so that there is sufficient chloride
and sulphate supply for the considered deterioration mechanisms to take place.
If the exchange rate is low, this will lead to a reduction of the severity of the environmental conditions.
In this case it might be possible to reduce the requirements for the resistance parameters of the
underground elements formulated in this report. However, as long as there is no reliable information
on the water exchange rate it is believed that this approach is the conservative approach and is the
only reasonable approach.
The main chemical attack mechanisms are summarized below:
4.2.1 Sulphate attack
Sulphate attack of hardened concrete is caused by the reaction of sulphates with calcium hydroxide
and tricalcium aluminium hydrate, both of which are found in concrete. The products of these
reactions, gypsum and calcium sulphoaluminate (ettringite) both have greater volumes than the
compounds from which they are formed. It is this expansion that disrupts the hardened concrete,
often resulting in spalling and cracking.
Seawater contains sulphates and therefore could be expected to cause sulphate attack. However, the
presence of chlorides in seawater increases the solubility of the reaction products, gypsum and
ettringite, and these are normally dissolved in the pore water solution before they cause damage to
the concrete. Recommendations for resisting sulphate attack are given in Indian Standards (or in
various Codes of Practice, including EN 206 and BS 8500-1).
The JV will proceed to groundwater analysis to determine sulphate contents in the groundwater of
the Mumbai Metro.
The speed of sulphate attack depends on the sulphate content and the water exchange rate of the
ground water, the amount of reactive aluminates in the cement matrix (chemical resistance) and the
pore volume of the cement matrix (physical resistance).
A purely physical mechanism, commonly referred to as physical salt attack or salt weather, can also
cause concrete degradation as a result of sulphate salts present in the soil being wicked up to the
surface and then evaporating just above the ground level. This causes salt crystallization and scaling
of the concrete at the surface.

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4.2.2 Chemical attack
Concrete may be attacked by a range of chemicals. Strong acids rapidly attack the surface, but the rate
of attack of weak acids is much slower, or negligible in the case of some weak organic acids. Alkalis
can also cause deterioration. For example, strong solutions of sodium hydroxide can attack siliceous
aggregates in concrete. Attack by sulphates in solution is of particular concern and has been discussed
above.
Flowing water can attack the surface of concrete, particularly if the water contains free carbon dioxide
or if it is relatively pure, such as steam condensate or melting ice. With pure water, calcium hydroxide
can be leached out of the concrete leading to surface erosion. Water containing carbon dioxide acts
as a weak acid and destroys the cement matrix.
In all cases where the possibility of a particular chemical coming into contact with concrete is known
in advance, the risk can be assessed and the concrete protected by applying a special mixture, a
supplementary membrane or appropriate surface treatment. In the case of a structure not expected
to be exposed to chemicals, other than on an infrequent, unpredictable or accidental basis, it is not
usually practicable to protect all surfaces and damage must be minimised by prompt maintenance
procedures to remove the spillage and clean the concrete.
4.2.3 Alkali-Aggregate Reaction
The Alkali-Aggregate Reaction (AAR), also known as Alkali-Silica Reaction (ASR), is a chemical reaction
that produces expansive reaction products. This can occur in concrete, causing partial or total
disruption of even the hardest cement matrix.
The reaction can take one of three forms; alkali-silica, alkali-silicate or alkali-carbonate. In all cases,
the reaction is between the alkaline components in the concrete and the reactive component of the
aggregate. AAR is only able to proceed and cause damage if there is:
Sufficient moisture (at least 75% relative humidity)

Sufficient alkalinity
A critical amount of reactive aggregate
AAR is prevented by elimination of one or more of these three factors. The selection of an aggregate
to avoid the reactive elements is the safest approach, as moisture and alkalis can penetrate concrete
from an external source. The difficulty in achieving this is that some aggregates start to show signs of
AAR many years after construction. As well as standard tests for AAR, including petrographic
examination of thin sections; the history of use of a proposed aggregate source with the proposed
cement should also be investigated.
When the aggregate source is identified, testing should be completed to determine the reactivity and
potential for AAR to occur. It is noted that an alternative to low-alkali cement which is recommended
in area of AAR risk is for example the use of cement containing GGBS (Ground, Granulated Blast
(Furnace) Slag).
4.2.4 Physical deterioration of concrete
Deterioration of concrete can occur as a result of a number of physical phenomena. The most common
examples of this type of deterioration are given below.

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Salt scaling
Salt scaling is a surface effect and is best understood by comparing it to damage by frost, (where ice
crystals generate expansive forces in the concrete and produce tensile forces, with subsequent
cracking of the concrete, and spalling of the surface), except that in salt scaling, the disruptive effect
is the deposition and growth of salt crystals owing to the evaporation of water. The usual cause of this
problem is sodium chloride, which is present in significant quantities in the sea, ground and ground
water throughout many coastal areas. It is the growth of the salt crystals themselves that generates
the tensile stresses that can lead to cracking of the cement hydrate and spalling of the surface, as with
frost attack.
Surface erosion
Surface erosion of concrete normally occurs by either cavitation or abrasion where the concrete
surface is subjected to flowing water.
If the water is flowing sufficiently rapidly in open conduits (typically a flow greater than 12 m/s), or if
there is the possibility of low pressures occurring in closed conduits, then cavitation may occur. It is
the collapse of vapour bubbles that may be created under these conditions that damages the concrete
surface. As each bubble collapses, high velocity water enters the space occupied by the bubble, and
the resulting high pressure impulse can cause cavitation damage to the surface.
Under the conditions more commonly found in conduits, the main cause of surface erosion is the
transport of solid particles in the water stream which mechanically abrade the concrete surface as
they are carried along, and are directly responsible for the wear of the surface.
Surface abrasion can also occur because of mechanical wear by steel wheels or similar. Sand/cement,
or concrete, laid as a finish (screed) on floors are particularly susceptible.
Thermal variations
Concrete will expand when its temperature increases and contract when the temperature decreases,
unless it is prevented from doing so by a restraint. Restraint of movement may increase strain and
result in the concrete cracking.
Fire damage
Fully cured concrete suffers a reduction in strength if subjected to temperatures above c.300C; for
example, in case of a fire. Some loss of strength may be observed from c.250C and, in general, the
loss is not recoverable. The exact behavior depends on many factors including the aggregate type,
water content and whether the concrete was under load.
Impact / overload damage
Impact damage to concrete structures can take many forms; for example, from the repeated dropping
of objects onto a floor, to the damage of a building or bridge hit by a vehicle. It is not possible to
generalize on the type or form of damage, but the cause is usually easily identifiable from a visual
examination.
Damage by overloading can exhibit itself in many ways, but most commonly will result in cracking of
structural elements which are subjected to bending. This is because such elements tend to have a
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smaller margin of safety than, for example, columns. Cracks will be perpendicular to the principal
tensile stresses caused by the loading. Damage may occur at loads lower than expected owing to
deficiencies in either the design or methods of construction of the concrete structure.
Seismic loading
Concrete structures can be designed to withstand seismic events without collapsing. This is outside
the scope of this report.
4.3 Summary
In summary, in order to provide a durable concrete structure that will not prematurely suffer from
corrosion of reinforcement in the Mumbai Metro project it is important to:
Consider the risk factors for the particular structure component respect to local environment
and operating conditions
Develop a high quality concrete mix that will (when correctly placed and cured) result in a
dense, low permeability, low diffusibility concrete
Implement a design aimed to limit the development of cracks as per Employers Requirements
Ensure thickness of cover is sufficient for the environment / service conditions
Ensure concrete mix is (essentially) free from chlorides
Ensure the concrete is correctly placed and well compacted (to prevent formation of voids)
Ensure high quality curing, using water mist spray or hessian constantly soaked with water
Ensure sufficient stray current control measures are in place
5. OVERALL DURABILITY ASSESSMENT APPROACH

5.1 Design strategy
The primary approach to designing concrete structures and precast elements for durability is based
on the need to achieve a high quality and relatively impermeable concrete with a low diffusivity,
sufficient concrete cover, and paying particular attention to proper structural detailing. This approach
assumes that the concrete alone is able to assure the required service life for structures subject to the
aggressive environment by the two primary key measures - sufficient concrete cover and low
diffusivity.
The design must ensure that the steel reinforced station structures and tunnel segments can
withstand the aggressiveness of the ingress of salty groundwater over the time period of 120 years.
5.2 Proposed deterioration and concrete construction mitigation measures

This section briefly describes concrete deterioration mitigation measures, including mix design
elements, concrete design investigations, mix design mitigation measures, and construction
measures.
5.2.1 Concrete mix design elements
The following section details the mitigation strategies that can be employed with each component of
concrete mix design in order to achieve the required design life of 120 years.
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Portland cement
Mitigating strategies:
Shrinkages - Keep paste, water and cement in the concrete mix as low as practically possible
(desired to be below 35%)
Early Age Cracks and Heat of Hydration restrict the content of C3S and its fineness by
specification
Calcium Sulphate Attack use cements with low C3A contents, such as Type II or Type V
Portland Cement
Sodium and magnesium sulphate attacks use appropriate water-cement ratio.
ACR Use low-alkali cement, which may reduce the possibility of damage caused by alkali
carbonate reaction
Aggregates
Drying Shrinkage select a high aggregate to cement ratio, in the vicinity of 4 and 7. Do this
with a dense gradation of coarse aggregate, which reduces the amount of paste in concrete
matrix
Shrinkage and Cracking use hard, rigid coarse aggregate with fairly large size (up to 11/2 )
ASR Damage - aggregate testing and dense, relatively impervious concrete
Paste reduce paste by using spherical shape coarse aggregates. Deviation from spherical
shape requires higher paste volume to enable rotation without particle interference in the
concrete mix
Water
Water from the local mains water supply (potable water), or water from other sources
meeting the requirements of Part 2, Section VII, Sub-division 1, paragraph 1.5.1.5 will be used.
An analysis certificate of the water should be checked to ensure it complies with the project
specifications.
Water/cement ratio
General - shift the emphasis from the W/C-strength relation to the water content-durability
relation. Keep the total water content low to minimise the amount absorbed water that
evaporates out of the concrete mix,
Porosity generally speaking, low W/C ratio results in lower porosity concrete, (Reference
[10]). The use of silica fume will achieve the same goal.
Pozzolans
Pozzolans include fly ash (FA), ground granulated blast-furnace slag (GGBFS), and silica fume (SF). Used
as replacement to Portland cement, pozzolans can improve concrete performance in their service
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environments. Pozzolans may also react with other alkalis such as sodium and potassium hydroxide in
the cement paste. Because of these reactions, adding pozzolans to concrete can reduce permeability,
decrease the amount of alkalis in the paste, increase strength, and thus improve durability. The effect
on durability varies with the type of pozzolan or other cementitious material used.
Ground Granulated Blast-Furnace Slag (GGBFS)
Use GGBFS in concrete mix to reduce permeability and shrinkages

Sulphate Resistance and Permeability GGBFS is effective to mitigate sulfate attack
ASR use at least GGBFS greater than 40% by weight, as replacement to Portland cement
General Use dosage in the range of 21% to 70%, by weight, as replacement to Portland
cement
Though GGBFS has beneficial properties as cement replacement, its effectiveness is
depending upon many of its chemical compositions; therefore, the chemical composition shall
be documented before being used
Silica fume
Permeability silica fume can reduce concrete permeability

Carbonation silica fume can reduce the penetration of carbonation
Resistivity - silica fume can increase concrete resistivity
Silica Fume Dosage Approx. 4.5 to 5% may be required to achieve above objectives.
Admixtures
The most common reasons for using admixtures in concrete are to:
Increase workability without changing water content

Reduce water content without changing workability
Affect a combination of the above
Adjust setting time
Reduce segregation and/or bleeding
Improve pumpability
Accelerate the rate of strength development at early ages
Increase corrosion protection in the concrete mix
Improve potential durability and reduce permeability
Reduce the total cost of the materials used in the concrete
Admixtures are normally categorised according to their effect:
Plasticizers (water-reducing agents),

Superplasticizers
Air Entrainers
Accelerators not to be used
Retarders

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Corrosion Inhibitor such as calcium nitrite or similar chemical

Shrinkage Reducing Admixture
Many admixtures provide combinations of properties such as plasticizer / retarders or plasticizer / air
entrainers. When using admixtures, their compatibility with other concrete components, such as
pozzolans, must be understood. Therefore, the compatibility of admixtures with other mix ingredients
will be evaluated before including them in the mix design.
Corrosion use calcium nitrite or similar corrosion inhibitor to prolong the onset of corrosion.
However this may not be required in this project as other, measures are used.
Concrete mix design mitigation measures
Chloride and Sulphate mitigation measures can be used in various aspects of the concrete design, from
the mix design to the construction.
Chloride ingress mitigation measures
Corrosion of steel in concrete will not occur unless the critical chloride content at the reinforcement
surface is exceeded. When designing the concrete mix, the chloride transport properties of the
concrete can primarily be influenced by a variation of the w/c-ratio and / or the type(s) of binder.
In terms of durability, the lower the w/c ratio, the lower the potential for chloride ingress resulting in
a more durable concrete. To minimize the potential for chloride ingress the w/c ratio should be less
than 0.4.
Sulphate attack mitigation measures
With respect to concrete technology, two different approaches can be followed in order to increase
the sulfate resistance of the concrete:
Increase of the chemical resistance by reduction of reactants for the sulphate

Increase of the physical resistance by production of a very dense pore structure
The need for high quality, impermeable concrete is a prerequisite for concrete resistance to external
sulphate attack. Concrete with a low w/cm is consistently recommended, as it will have lower
permeability and thus limit the amount of sulphate ions that can diffuse into the concrete to attack it.
In addition, good workmanship and curing are essential. It is thought that air entrainment is beneficial
only in that it makes the concrete more workable, so the w/cm ratio can be reduced. It is also
commonly cited that the use of SCMs will reduce the permeability of concrete and thus improve the
concretes resistance to sulphate attack (ACI 2008). The replacement of Portland cement with GGBFS
cement also has beneficial effects toward sulphate resistance through the reduction of the tricalcium
aluminate content incurred by reducing the amount of Portland cement in the concrete.
ASR mitigation measures
The mix constituents should be checked to confirm compliance.

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5.2.2 Concrete construction mitigation measures
Concrete construction joints measures
Crack width reduce construction joint spacing between pours as practically as possible
Waterstop Interference simplify waterstop details to avoid their interferences with
reinforcing steels
Constructability instead of using keys to transfer/reset shear force at the interface between
slab and wall, use shear friction reinforcing concept where possible
The required key at wall-to-slab joint is sometimes an area of weakness in terms of crack
initiation and requires an appropriately designed structural detail to avoid cracking, such as
the use of shear friction reinforcement in lieu of key joint to resist/transfer shear force.
Waterstops, expansion joints, etc.
Crack control at joint provide waterstops and properly designed waterproofing detail around
joints
Reinforcing steel
Because chloride ions entering the concrete are a major cause of reinforcing bar corrosion, reducing
chloride permeability or providing special reinforcing bars are mitigation options for reducing the
potential for damage caused by corrosion. W/c ratios around 0.38 will provide a low value of concrete
chloride permeability. Reinforcing bar alternatives including epoxy coating, hot dipped galvanized, or
stainless steel are not considered necessary as the prevention of corrosion and enhancement of design
life will be achieved through improving the concrete quality.
Concrete cover
Increase in the thickness of concrete covering can increase the time of carbonation and chloride
ingress to reach concrete reinforcement and in turn delay carbonation- and chloride- induced
corrosion. This is one of the most straightforward adaptation options in the design of concrete
infrastructure to maintain structural durability and serviceability.
Crack control
Many of the deterioration mechanisms described in the previous sections either result in or are
accelerated by the presence of concrete cracking. Control of cracking is therefore a prime
consideration in developing a design strategy for structure durability.
Waterproofing
To mitigate encroachment of groundwater into the structures, and to minimise the opportunity for
chloride and sulphate attack, an external waterproofing membrane for the stations cut-and-cover
structures will be applied. This is a requirement for this project.
Curing
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Proper and adequate curing is essential to improve the quality of the concrete cover, the durability of
the concrete, and the strength of the concrete. Interruption or discontinuation of early curing,
whether accidental or deliberate, disrupts the process of hydration. The curing of concrete becomes
more important if the concrete contains supplementary cementitious materials (pozzolans), such as
ground granulated blast furnace slag, or silica fume, and is subjected to hot and dry environments
immediately after casting. Accordingly, many building codes and researchers have stressed the
importance of the initial seven-day curing of concrete and concrete structures.
External curing
Traditional curing methods are based on externally-applied curing compounds and are divided into
two groups:
Water curing - those that prevent moisture loss from the concrete by supplying additional
moisture
Sealed (or non-water) curing - those that prevent loss of moisture only
Examples of external curing material for concrete include: burlap, membrane curing compound, and
sheet material.
Internal curing
Curing water can also be supplied from an internal source, which is known as internal curing. It involves
introducing a component into the concrete mix that serves as a curing agent. This agent can be either
a new component (for example, an admixture or special aggregate) or a normal aggregate introduced
into the concrete mixture in a specific condition (for example, in a water-saturated state).
Internal curing, as well as external curing, can be classified into two categories:
Water curing (sometimes called water entrainment), where the curing agent acts as a water
reservoir that gradually releases water
Sealing, where the curing agent delays or prevents loss of water from the hardening concrete
Most high-strength and high-performance concretes having low w/c may have insufficient mixing
water to maintain the water-filled coarse capillaries needed to sustain cement hydration and
pozzolanic reactions. For this reason, it is generally accepted that curing methods based on adding
water (internal water supply) are more effective for this type of concrete.
Internal water curing is preferable, because internal sealing is unable to prevent self-desiccation. The
internal curing agent is a part of the system and is finely dispersed. This helps it overcome the problem
of low permeability in low W/C systems that reduce the efficiency of traditional external curing. In this
way, internal water supply can be an effective method for reducing autogenous shrinkage, since it
directly reduces self-desiccation.
Autogenous cracking provide an external source of water as soon as the hydration reactions
start and as long as the water phase is continuous within concrete. This external source of
water can be provided by appropriate water curing that starts before the full development of
hydration reactions or by including some saturated LWA in the concrete mix.

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Strength and shrinkage adhere to high quality initial seven-day curing.
Controlling heat of hydration
High concrete temperatures increase the rate of hydration, thermal stresses, the tendency for drying
shrinkage cracking, permeability, and decrease long-term concrete strengths, and durability as a result
of cracking. Controlling concrete temperature during placement will therefore improve the durability
of the concrete. A recognised approach to controlling concrete temperatures during placement is by
a construction specification limiting the maximum in-place concrete temperature during hydration.
The CJV will implement as a minimum the Employers Requirements Part 2, Section VIII, for concrete
batching and mixing, transportation, placement and finishing, and curing and protection.

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6. RECOMMENDATIONS FOR UNDERGROUND STRUCTURES

6.1 Provisions and Codal reference
The relevant Indian codes for design of Metro Structures in concrete are as mentioned below:
1) IS:456 code of practice for concrete for general Structural use
2) IRS: CBC code of practice for concrete Railway bridges
The formulation of IS:456 has been primarily based on BS:8110.
The formulation of IRS:CBC has been primarily based on BS:5400.
These BS codes now practically stand replaced by BSEN codes which are basically adaption version of
Euro code by BS. This BS EN has a latest code BS EN 206-1 on subject of concrete and its durability
aspect etc .
BS 8500- Concrete, is the complementary British standard to BS EN 206-1 and was first published in
March 2002. It provides substantial national provisions not covered in BS EN 206-1. Both documents
replaced BS 5328, Concrete, in December 2003. BS 8500 was updated in November 2006.
The standard is in two parts:
Part 1: Method of specifying and guidance for the specifier
Part 2: Specification for constituent materials and concrete
This BS 8500-1: 2006 is the latest code and as per previous history may be the basis for amendments
in future to IS:456 and IRS:CBC on concrete and its durability aspects. The fact should be noted that
neither IS:456 nor IRS:CBC clearly illustrates measures for the intended working life of structures.
However, BS 8500-1: 2006 code clearly illustrates measures for intended working life of structures as
mentioned below:
Table A.4: Durability recommendations for reinforced or prestressed elements with an
intended working life of at least 50 years
Table A.5: Durability recommendations for reinforced or prestressed elements with an
intended working life of at least 100 years
In view of the above, it is proposed that the BS 8500-1: 2006 code is very specific latest document and
should be adopted to establish the criteria to meet the intended life of 120 years for metro structures.
The specific recommendation for underground metro structures based on BS 8500-1: 2006 are
presented further: -

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6.2 Exposure class, Grade of Concrete, w/c ratio and Cover to reinforcement
Aggressive environment of Mumbai falls into category XC3 and XS2 as table A.1 of BS 8500-1 : 2006.
The table is shown below for ready reference : -

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As it is clear from above table all exterior surfaces of underground structures which are in contact with
ground falls in XS2 category and all interior surfaces of underground as well as all elevated structures
above ground falls in category of XC3. As per table A.5 of BS8500-1 : 2006 recommendations for XS2
category are more stringent as compared to XC3 category. Therefore all underground works will be
designed for recommendations as per category XS2. Table A.5 of BS8500-1 : 2006 is shown below for
ready reference : -

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As per tender document Table 2.2 of Section VII: ODS Sub-division 2: Cut and Cover Structures all
surfaces of underground structures in contact with ground should be designed with a nominal cover of 45mm.
therefore as per table A.5 of BS8500-1 : 2006 following combinations (highlighted in rectangular box
in above table) can be used
Sr. No. Minimum Grade of Maximum w/c Minimum Type of cement

concrete ratio Cement content
(kg/m3)
1 M40 0.5 340 CEM I, IIA, IIB-S,
SRPC
2 M35 0.5 340 IIB-V, IIIA
3 M30 0.5 340 IIIB, IVB-V
As per tender document minimum grade of concrete is defined as M35 therefore only first two options
from above table can be used. However for bored tunnel segment lining Minimum concrete grade is
45, however due to early demoulding strength requirement, the minimum concrete strength at 28
days will be around 50 MPa.
For type of cement refer table A.6 of BS8500-1 : 2006. The table is shown below for ready reference.

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Furthermore the concrete should be tested be tested for impermeability according to DIN 1048 and
ability to resist chloride ion penetration according to ASTM C-1202. Water permeability shall not be
more than 10 millimetres (at the concrete age of 28 days) and RCPT value shall not exceed 1000
coulombs at the concrete age of 28 days. These measures will ensure that the concrete will be
adequate for intended working life of 120 years.
6.3 Work method statements

Design
The contractor will work internally and with product suppliers to design cut and cover concrete
stations meeting the design life requirements. Our design process is demonstrated by our
understanding stated thus far.
A design checklist will be developed and reviewed at all stages of design and construction to
ensure that all requirements are satisfied

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All structural considerations (load factors and durability) will be applied to the concrete
structures
The following items will contribute to our durability design:
1. Concrete mix design
2. Reinforcing steel placement
3. Waterproofing / water stop placement
Construction
The manufacturing and installation of the concrete for cut and cover stations will have the following
steps:
A proposal for manufacturing and testing of concrete mock-ups will be approved by the
Employer
All concrete materials will be delivered with certification
The work of placing concrete will follow the final specifications, manufacturers
recommendations, and Employer and performance specifications for the mix designs. The
concrete mixes will be verified by the testing of trial mixes
All concrete work will follow the best practices specified for mixing, placing and consolidating
the concrete, curing, and demoulding
All concrete work will be performed with the appropriate mitigation measures for the adverse
climatic conditions (such as: hot weather, solar radiation, and/or wind)
If reusable forms are used, after stripping, the concrete forms will be washed of all dirt, oil,
grease, and debris, which could cause irregularities in the formed concrete surfaces
On site representation with experience in installation of the proposed waterstops and
waterproofing systems will be present during all installations and junction connections
Testing of the water proofing and water stop systems will be performed at intervals specified
and according to the manufacturer
Quality assurance / quality control procedures
Requirements for concrete mix design quality, construction quality, and the requirements for
workmanship will form part of our QA / QC plan. Examples of potential testing are:
Chloride mitigation testing

Resistivity testing
Determination of sulphate resistance
Concrete cover in-situ measurement
6.4 Additional Special Recommendation

The additional measures for enhancing durability of reinforced concrete structures may also be
considered as mentioned below:
Cathodic protection
Use of smaller diameter reinforcement bars
Provision of additional sacrificial reinforcement at critical locations
Provision of special reinforcement such as stainless steel at critical locations.

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7. REFERENCES
[1] Schlumberger Water Services (2012) Qatar Integrated Railway Project - Consultancy Services for
Geotechnical Investigations - Factual Report Underground Line Sections version No2.0 dated from
04/04/2012.
[2] Tender documentation and Employers Requirements for Mumbai Metro Line 3, Package UGC001.
[3] Concrete Aggregate Durability Study, Final Report 575, June 2009, Thomas Van Dam PhD, PE, David
Peshkin, PE
[4] Durability of Concrete: Molecular Transport Processes and Test Methods, Technical Report No.
544, Cement and Concrete Association, Wexham Springs, July 1981 Lawrence, C.D.
[5] CIRIA pub 577 Guide to the construction of reinforced concrete in the Arabian Peninsula, 2005
[6] Port of Miami Tunnel Project, Durability Design Report, June 2010, Roger G. Khouri
[7] Time-to-Corrosion of Reinforcing Steel in Concrete Slabs, Volume 3: Performance after 830 Daily
Salt Applications, Report to FHWA/RD-76/70, KC Clear
[8] Life-365 Service Life Prediction Model, V 2.0.1, 2009 User Manual
[9] Farny and Kerkhoff 2007, ACI 2008, Thomas et al. 2008A
[10] Superplasticizers for Durable Concrete, in: GCI 705 Course Notes Gagne, R., Aitcin, P.-C
[11] Give It a Week: 7 Days of Initial Curing, Concrete International, September 1998 Haque, M. N.
[12] Non-Shrinking Concrete, CANMET/ACI/JCI 4th International Conference on Recent Advances in

Concrete Technology, Supplementary Papers, Tokushima, Japan, June 1998 Aitcin, P-C.
[13] Novel Techniques For Concrete Curing, Concrete International, September 2005 Kovler, K. and
Ole M. Jensen, O.M.
[14] Shrinkage Cracking Can it be prevented, Concrete International, April 1998 Shah, S.P., Weiss,
W.J., and Yang, W.
[15] Micropile Design and Construction Guidelines: Implementation Manual, US Department of

Transportation - Federal Highway Administration, FHWA-SA-97-070, 2000
[16] Micro Pile Reinforcement Systems and Corrosion Protection, Con-Tech Systems Ltd, Delta BC,
Canada, Aschenbroich, H
[17] The Importance of Concrete Temperature Control During Concrete Pavement Construction in
Hot Weather Conditions, January 2002, TRB, Schindler, A.K., and McCullough, B.F

Report 14/03/2017 Page 32/32

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L&T-STEC JV MUMBAI

Mumbai Metro Line 3

Reference number LTS-CVG-P01-16-0005-A4

DURABILITY APPROACH & ASSESSMENT REPORT FOR

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ)

Project MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

Reference number LTS-CVG-P01-16-0005-A4

Production MGO TL 10/01/2017

Check AAP DM 10/01/2017

Check AAP DM 27/02/2017

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

Production MGO TL 09/03/2017

Check AAP DM 09/03/2017

Production MGO TL 14/03/2017

A4 Check AAP DM 14/03/2017

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

4. DURABILITY RISKS FOR CONCRETE STRUCTURES / POTENTIAL DETERIORATION

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

5. OVERALL DURABILITY ASSESSMENT APPROACH 19

6. RECOMMENDATIONS FOR UNDERGROUND STRUCTURES 26

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

L&T STEC JV acknowledge that:

Minimum grade of concrete for underground structures shall be M35;

1.1 Underground stations structures and tunnel structures

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

1.2 Environmental characteristics

Package Stations Tunnel

UGC001 2.8 bars 2.7 bars

Table 1 : Maximum water pressure expected for each package

2.1 Outdoor atmospheric exposure

Chloride attack owing to marine aerosols.

High temperature which accelerates corrosion and concrete degradation processes.

2.2 Underground exposure

2.3 Exposure at grade level

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

2.4 Indoor atmospheric exposure

2.5 Stray current exposure

2.5.1 Stray current from metro systems

2.5.2 Stray current from cathodic protection systems

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

3.5 Concrete production

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

4. DURABILITY RISKS FOR CONCRETE STRUCTURES / POTENTIAL

4.1 Reinforcement corrosion

An induction period before corrosion starts

Early corrosion of the reinforcement

Cracking, delamination and spalling of the concrete cover

4.1.2 Chloride attack

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

Water cement ratio

4.1.4 Impact of ground water

4.1.5 Effect of temperature / relative humidity

The relative humidity effects on corrosion in concrete are summarised below:

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

4.1.6 Corrosion in oxygenated environments

4.1.7 Corrosion in de-oxygenated environments

4.1.8 Differential aeration effects

4.1.9 Stray current corrosion

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001

4.2 Concrete degradation

The main chemical attack mechanisms are summarized below:

4.2.1 Sulphate attack

MUMBAI METRO LINE 3 (COLABA - BANDRA - SEEPZ) UGC001