Case Study on Project Planning for Fast Paced

construction of Tori – Shivpur new BG Railway line

(44.40 km in 2 years’ effective time)
By
Sitesh Kumar Singh
Chief Engineer (Construction)/Patna
&
Lakhan Lal Meena
Dy. Chief Engineer (Construction)/Hazaribagh

East Central Railway

Construction Department
 Brief History

Tori-Shivpur project was initially sanctioned in 2005-

06 with 44.40 Route kms at a cost of Rs.291 crs.

In 2011, CCL revised their requirement & desired 3

lines for 170 Million Tonnes per Year of coal. Work
was converted as Deposit work of CCL at Rs.2192 crs
(DE sanctioned in Aug’17).
For completion of the project, there was need for
faster construction of work as it was delayed due to
Forestry Clearance, Change in alignment, decision for
single/double/multiple line
2
3
 Objective & Motivation

Ensure QUALITY construction for

Ensure quality Economy & Speedy
safety construction
formation & bridges with
• Well defined
QAP • Deposit work • Finalization of
reasonably FAST pace and
• Fabrication at • Common goal tender, overcome unforeseen
site of Rly & Coal drawings etc
• Modern testing ministry • Earth Moving PROBLEMS in the field
lab • National Equipment
• 24x7 Police project (PMO • Launching by
camp monitored) road crane

Challenges
Remedial
measures

Analysis
Positive contribution
Problems faced
4
 Scope of work

SN Description Quantity
1 Earthwork incldg. 224 lakh cum
Rock cutting
2 Concreting 2 lakh cum
3 Minor bridges 76 nos
4 Major bridges 13 nos
5 Road over bridges 13 nos
6 Road under bridges 13 nos
7 Station buildings 7 nos (3 stations
with yards with long haul loops)
8 Land acquisition 1186 acres (293
acres Forest land)
9 Signalling works Involved
10 Electrical works Involved

5
 Constraints faced
Land acquisition

Forestry clearance

Demand for additional ROB during progress of work

Law & Order (Area is affected by LWE)*

Frequent bandhs

Failure of contracts

*On 04.07.17 evening, Shri Madhu Samajdar, SE/Con/Works was found

missing from work site. A FIR was lodged with PS Balumath. His body was
recovered from a water-logged ditch on 06.07.17 at 16 hrs. by police.
6
 Alignment Plan & Milestones
JULY-18

MAY-18

APRIL-18
FEB-18
AMRAPALI MINES

MAGADH MINES

LEGENDS
Station

Major bridge

SURFACE ROB
CONNECTION
TO GOMOH / RANCHI

ROR 7
TO GARHWA TO RANCHI
Methodology adopted for Fast Paced Construction
Quick Survey, Alignment and Land Acquisition
process

Timely preparation of L-section, all GADs,

designs, drawings
Planning

Timely processing of tender with required

eligibility criteria (Non JV with reduced DOC)

Location of concrete batching plant

Use of Modern facilities in camp office

8
Methodology adopted for Fast Paced Construction
Sequencing of parallel activities

Use of Batching plant & TM

Use of advanced earth moving machines

Execution

Use of Concrete Boom placer

Use of Slip form shuttering

Use of Road cranes

Use of Pre-bent Reinforcement Bars & cage

9
 Use of Advanced Earth Moving Equipment
• 40 nos of 400/380/300/220 capacity excavators
(Poclains), 4 nos of Graders,100 nos of Hyvas, 10 nos
of Vibro rollers, 10 nos of Dozers, 20 nos Wagon &
Tractor drills etc.
• Use of Slip Form Shuttering & Concrete boom
placer

• Use of Road crane & Hydra for launching of Major

bridge & ROB girders
Methodology adopted for Fast Paced Construction

Regular meetings with State Govt.

authorities: CS/Secy/DC

Regular reporting on group

Monitoring

Aerial survey by

at major bridge sites

Regular visits by higher officials

11
 Innovations

Tractorofwith
UseJCB Hydra
beingfor
Trolley being
shifting
usedof as
Panel
Special Slings
used as BOBYN
rails
BRM
attached
Use oftoTruck Front wheel
Hydra for
for ballast lifted
Sleeper/Rail
unloading in
Use of Hydra for dismantling & laying of Switch (T-28)
handling track
(UTV)
12
Problems faced and remedial measures

New temporary
roads were built

No approach road

Weather pattern studied &

activities planned
accordingly. Morning
forecast of locals helped.

Rough weather

13
Problems faced and remedial measures contd..

Local labourers
were trained

Height of work space

Dedicated Police camps

were provided

Frequent law & order problems

14
 Problems faced and remedial measures contd..

Alternate sources
were arranged

Delay in supply of detonators

Eligibility criteria in
Contract provisions
need to cater to this
aspect

Non availability of GOOD contractor locally

15
 Problems faced and remedial measures contd..
Special chemicals under
skilled supervision
arranged alongwith first
aid
Poisonous insects, snakes and bees

Some outside labourers

were kept in camps

Local festivals

Regular liasoning
with Dam authorities

Release of sudden water from Dam intermittently

16
 Few Unfortunate incidents

Death of 2
labourers
due to
falling into
well & Dead
breakage of body
Pier cap
shuttering
PF

17
Completed photographs
Completed photographs contd..
Commissioning

20
 Slipform
construction for
Major Bridges in
Western
Dedicated
Freight Corridor.
 Working
Platform and
the main
assembly
Key process
Precautions
Fast Track Modular Construction
of Pier Caps at Bridges at Yamuna
& Hindon Rivers

Hari Mohan Gupta Praveen Kumar

CGM/DFCCIL/Noida GGM/P/WC/DFCCIL
CONCEPT PLAN OF DEDICATED FREIGHT CORRIDOR NETWORK

LUDHIANA

DELHI

KOLKATA

Sanctioned projects
MUMBAI Unsanctioned projects

•High Density Corridor

VIJAYAWADA
VASCO (Golden Quadrilateral +
CHENNAI Diagonals) 16% of route
BANGLORE
Km carries 52% of
passenger & 58 % of
2
freight
DFC Alignment Rewari-Dadri
 Detail of Bridges

Location Type Span

Yamuna Important 11x48.5 m

Hindon Major 04x48.5m

RFO-8 RFO 01x48.5m

 Open Web through girder bridge – E250 + E350 combination

 Weight of 1 Girder – 156 MT

 Detail of Bridge Components

 Well foundation

 Dia of Well Abutment:

 Before transition - 13.8m (Outer), 11m (Inner)
 After transition - 13.2m (Outer), 11m (Inner)

 Dia of Well Pier:

 Before transition - 10.8m (Outer), 8.4m (Inner)
 After Transition - 10.4m (Outer), 8.4m (Inner)

 Depth of Well - 36.7m to 42.7m

 Pier Height - 4.3m to 6.3m

 Abutment Height - 7.8m

 Detail of Bridge Components (Contd.)

PIER CAP:-

Final Dimensions - 19 x 3.0 x 2.0 in Meters

Concrete: M-40, Quantity - 110 CUM
Reinforcement Weight - 35 MT
Shuttering - 124 Square Meter
 Conventional Pier Construction Technique

 Cast in Situ Type – By fixing the reinforcement exactly at pier cap

location above the casted piers at height.

 This method requires almost 45 days, as:

 It requires lifting of all individual rebar from the ground

 Involves lot of temporary structures/platform

 Need sufficient skilled workforce

 Has no. of safety challenges & risks being working at height.

 Due to above limitations/problems, innovative technique was

planned, examined & adopted.
 Innovative Pier Construction Technique

 The complete reinforcement placing & tying was done at

the ground on specially made jigs & fixtures.

 The reinforcement cage (19m long & weighing 35 MT)

was lifted and placed over the piers with 2 No’s 75MT
crawler cranes in tandem.

 The reinforcement cage was lifted through specially

designed lifter and with various unique lifting gears as
per the approved lift plan.
Simultaneously Jig & Rebar Fixing
Fixing of Macalloy bar and Universal Beam Assembly
 Lifting Arrangement
A lifting hook arrangement was attached with the rebar cage.
Lifting arrangement and Operation

.
Balance reinforcement fixing and shuttering .
Concreting of Pier Cap

.
 ADVANTAGES

Work at Height risk eliminated Temporary Structures/ Platform avoided

Easy to handle rebar at ground Time Saving

Simultaneous works on shuttering & rebar Resource saving

 TIMELINE CYCLE
Completion in 8 days
Simultaneously jig and Balance reinforcement
rebar fixing fixing and shuttering

3RD DAY 4TH DAY 5TH DAY 7TH DAY 8TH DAY

Fixing of Macalloy
Lifting arrangement Concreting of Pier
bar and Universal
and Operation Cap
Beam Assembly
CONVENTIONAL METHOD
6 days 5 days 6 days 17 days 1 day
6 days

•Making of •Placing of •Placing of •Concreting

•Ground Working Bottom Side
Preparation Platform on Shutter & Shutter &
& Staging staging Alignment •Fixing of alignment,
all around Rebars at Inspection
the Pier Cap Pier Cap with Client 41 days
location Location

MODULAR METHOD

5 days 1 day 3 days 1 day 1 day

•Fixing of •Inspection •Concreting 11 days

Beam B1 •Fixing of •Fixing of With Client
& B2 with Lifter Balance
Mcalloy Assembly Reinforcem
bars. & Lifting ent &
Fixing of & placing Placing of
all rebars in of rebar side shutter
Jigs to cage above
make the Pier,
complete
Cage 30 days saved per Pier
Cap
 Reduction of Excessive Formwork
CONVENTIONAL MODULAR
THANK YOU
Construction of Single Barrel Limited Height Subway
by
“Box Pulling Technique“

- Ved Parkash Dudeja

 Background and Necessity of New Technique
• Elimination of Level Crossings taken up in mission mode by
IR

• Thousands of Level Crossings eliminated by Road Over and

Under Bridges (ROB/RUB) and Limited Height Subways
(LHS) in last 4-5 years.

• Still about 22000 Level Crossings left - being eliminated in a

phased manner.

• Traditionally, LCs replaced with LHS by launching precast

segments by cranes – “Cut and Cover Method”
 Problems with “Cut and Cover” Method

• Alignment issues of the segments - longitudinal, vertical

and lateral

• Involvement of heavy duty cranes usually 2 cranes of 300

MT capacity and a standby crane.

• Sealing of joints for water proofing – effectiveness issues.

• Block bursting due to slippage of earth during and after

placement of precast RCC base slabs

• OHE shifting involved

 Innovative “Box Pulling Technique”

• Developed by Northern Railway

• Box Pulling using Double Acting Prestressing Jacks in

Single Line sections

• First four experiments with RCC Single Segment (3m x

2.75m – 10.5m long), weighing 125 tonnes.

• Fifth experiment with 4m x 3m – 10.5m long single

barrel, weighing 170 tonnes
 Equipments Used

• Two Double Acting Prestressing Jacks plus one spare

jack (200 MT capacity with total 600 mm stroke length)

• One Mild Steel Spreader Beam – Box type

• Three Mild Steel Buffer Beams

• Two Poclains plus one standby

• Two Hydra cranes for handling track panel

 Steps Involved
• Before Block:
• Design of Retaining Wall Foundation-cum-Casting Bed
alongwith Deadman Anchor, Spreader beam, Buffer
Beams etc.
• Construction of Retaining Wall Foundation-cum-Casting
Bed alongwith Deadman Anchor.
• Casting of Complete Single RCC Box Barrel over the
Casting Bed
• Fabrication of Spreader Beam and Buffer Beams
including connections
• Fixing of Double Acting Prestressing Jacks and strands
• Preparatory Arrangements Related to Track.
General Arrangement
Spreader and Buffer Beams Arrangement
General Arrangement
 Steps Involved
• Before Block:
• Design of Retaining Wall Foundation-cum-Casting Bed
alongwith Deadman Anchor, Spreader beam, Buffer
Beams etc.
• Construction of Retaining Wall Foundation-cum-Casting
Bed alongwith Deadman Anchor.
• Casting of Complete Single RCC Box Barrel over the
Casting Bed
• Fabrication of Spreader Beam and Buffer Beams
including connections
• Fixing of Double Acting Prestressing Jacks and strands
• Preparatory Arrangements Related to Track.
 Steps Involved
• During Block:

• Removal of track and excavation of earth

• Pulling of Box by Double Acting Prestressing Jacks – Started 30

minutes after starting excavation and continued simultaneously
with excavation

• Total 12 metre pushing completed in about 2.5 to 3 hours.

• In the 5th experiment, an average pulling speed of 5 metre per hour

was achieved.

• Backfilling of earth, track linking, ballasting and packing

• Entire operation completed in 4-1/2 hours

 Important Features and Future Scope
• Technically Superior Scheme – No joints, no
alignment issues
• Maximum friction factor - 0.56 to 0.7
• 3mx2.75m size Box (total weight = 125tonnes)
needed a maximum pull force of 70 tonnes and
a 4mx3m size box (total weight = 170 tonnes)
needed a maximum pull force of 117 tonnes.
• No Involvement of Heavy Cranes
• No Interference with OHE
• Less Block Duration
 Important Features and Future Scope
• Box Pulling Technique is ideally suited for
constructing Limited Height Subways on single
line sections where barrel length is about 10.5
metre.
• Larger boxes can also be pulled using this
technique by providing suitable arrangement
like stainless steel plate between base slab of
box and casting bed to reduce friction.
Animation
Thanks
As per the directions from Railway Board during October-2017 all the Un
Manned Level Crossings are to be eliminated by October-2018.
Accordingly, SCR has planned for a target of removing 180 Unmanned Level
Crossings by constructing RUBs/LHSs.
To achieve fast pace of construction of RUBs by cut and cover method using
RH Girder a few Innovative Approaches/Methods adopted in South Central
Railway to overcome the following challenges encountered.
Major Challenges Encountered during construction of RUBs:
 Reducing Traffic Block Time Period.
 Non-Availability of Natural Drainage for RUBs Construction.
 Water Logging Problems in RUBs.
Innovative Methods Adopted:
 Reducing Traffic Block Time Period:
Adoption of Two Spells of Traffic Blocks, each of 2hrs instead of a single block of 6 hrs.
 Non-Availability of Natural Drainage for RUBs Construction:
Ground Water Recharge Techniques using Geo-Physical Survey have been adopted.
 Water Logging Problems in RUBs:
An arrangement of two vent ways has been adopted with a level difference between the
roads of these vents for uninterrupted vehicular traffic during water logging.
• Elimination of Unmanned LCs by providing Subways/RUBs
using Cut & Cover method requires a minimum of 06 hours
traffic block for excavation and insertion of RCC box
segments.
• Getting a traffic block of 6 hours for providing
Subways/RUBs at 180Nos LC locations from Oct’2017 to
Oct’2018 i.e. in 12 months (which includes one monsoon
period) is very critical and a challenging task.
• Hence S.C.R planned to adopt two spells of traffic blocks
each of 02 hours by using RH girder in cut and cover
method.
• Further to bring the traffic block in control, i.e., to reduce the
time of block, an innovative approach has been adopted by
this Railway.
Insertion of RH Girder:
• The precast box segments
for RUBs are to be launched
under the track by 03 Nos
of Cranes (Capacity of
200MT) by lifting the track
panel.

 RH Girder will be placed

on crib staging with
sleeper matting (@ top
and bottom) at either
ends duly excavating the
earth up to required
depth.
 The manual Manual Assembling of Cribs
assembling of
cribs staging.
 Which require
1 hr. of block
period.
This above activity has been innovatively replaced as under
 By assembling entire crib Entire Cribs
Staging as a
staging as a single unit. By single unit
clamping with angular Click on the
Image For
frame all the top and Video Clip

bottom sleeper matting.

 Which requires only 15
mins to place in position
 Click on the Image
For Video Clip

 After placing the crib staging in

position, one more innovative
approach has been done by placing
sand bags in the gap between the
excavated face of the embankment
and crib staging duly placing the G.I.
Sheeting for support.
 This arrangement of filling the sand
bags has provided the consolidated
earth filling in the approach portion.
This reduced the time for compacting
the filled up soil and thus further
added in reducing traffic block time.
 The second spell of
traffic block will be Click on the
taken after excavating Image For
Video Clip

the earth work below

the girder up to
required depth and
placing all the base
slabs and the box
segments except under
girder location.
 Base slabs and all boxes
were inserted on either
side of RH girder
without disturbing RH
girder.

Click on the
Click on the

Video Clip
Image For
Video Clip
Image For

 On one side last

box is fixed in its
final position and
sand bags shoring
will be done in pre-
block.
 Click on the
Video Clip
Image For
Click on the Image
For Video Clip

 During block
RH girder will
be removed,
and boxes
will be
positioned
from one
side.
 Click on the Image
For Video Clip

 During second spell of block

the remaining box segments
will be launched & the track
will be linked by placing the
track panel.

 Time Saving of Traffic block in

2nd Spell:
• Normal method consumes 3hrs
and 30 mins of block period.
• with the innovative approach
of pre block activities 1 hr 30
mins of block time has been
saved. Click on the Image
For Video Clip
 Adoption of Ground water recharge techniques for draining of water in percolation
pits/sumps connected to RUBs
• At some of the RUB locations there is no feasibility of provision of natural drainage.
• Hence the drainage arrangement for these RUBs has been planned by providing percolation
pits/sump with ground water recharging systems.
• For providing the above type of arrangement at RUBs, Geo Physical Survey has been done
to identify the locations of fractured zones for leading the rain water collected in the
percolation sump/pit.
• With the subsurface lithological data obtained from the soil exploration done by Geo
Physical Survey method i.e Electrical Resistivity Test (Schlumberger method), the locations
of fractured zones of aquifers in rocky locations (which help the rain water to drain in to
underground) has been identified.
• Here the drainage arrangements have been provided with percolation sump in which bores
are drilled with 150mm diameter up to the depth of fractured zone.
 Lithological data for LC No. 28 of GNT Division

No.
Total depth of IBW of
LC Depth if fractured Lithology of
Recharge Structure (metres below fract
No zones (m) aquifers
ground level mbgl) ured
zones

3 - 15 Weathered
Recharge shaft Injection Bore Rock
28 150mbgl 3 15 - 90 Fractured Rock
Well (RSIBW)
101 - 150 Fractured Rock
 Adoption of two vent ways with level difference in RUBs to cater for
uninterrupted passage of vehicles in case of water logging.
 The probable reasons for water logging in the RUB depend upon
the location of outlet of natural drainage arrangements which are
as follows:
1)In case the outlet of the drainage has been taken to longer
length up to availability of natural drain through piping
system/open drain in which chances of chocking of the drain is
more because of longer length.
2)In case the outlet of the drainage has taken up to the nearby
bridge, where flood level (HFL) suddenly rises due to some
temporary obstruction because of dumping the debris by local
public, slipping of side slopes of stream.
3)In case the outlet of the drainage system has been taken to
percolation pit/sump, the filter media in the pit gets chocked
over a period of time which requires a periodical maintenance.
Adoption of two vent ways with level difference in RUBs to cater for
uninterrupted passage of vehicles in case of water logging.

 The stagnated water in the RUB will affect the

pedestrians, two wheelers and light four wheelers which
are having less ground clearance. Whereas bigger
vehicles like trucks, harvesting vehicles which have
more vertical clearance can pass the water stagnation
up to 0.6 metre depth.

 Until the restoration of drainage system, for facilitating

the uninterrupted movement of the pedestrian and light
vehicular traffic, it is proposed to provide an additional
vent way with lesser vertical clearance and higher road
level.
 To accommodate the harvesting agricultural vehicle and other
large vehicles through the RUBs a minimum height of 5-meter
clearance has been provided. The additional small vent box of
size 4 X3.3 meter with lesser vertical clearance of 3.3 meter has
been provided to serve the passage of light vehicular traffic.
• This method was adopted at LC No. 20 of YA-NOSM section in
Guntakal Division
 Adoption of two vent ways with different sizes at different
locations with same approach parallel to track with in the Railway
Boundaries.
 At some UMLC locations where the approach road width is very
less, the land owners along the boundary of the approach road are
objecting for excavating the earth to construct the retaining walls
and approach road ramp. The following twin box arrangement has
been adopted where the width of railway boundary is more. This
method has been adopted at LC No. 22 in YA-NOSM Section of
Guntakal Division.
THANK YOU
 ABSTRACT
1) Khurda Road is one of the blue-chip Division of Indian Railways. It
carries approx. 118 MT of freight traffic in a year.
2) Coal and iron ore are the major commodities transported from
this division. Jakhapura - Jaroli line is one among the line
3) More than 364 running staff are booked everyday to operate from
the station Jakhapura. Sufficient quarters are not available
4) Total two hours of time is being spent on round trip from Jajpur
Keonjhar Road to Jakhapura for on & off duty booking, for which
working hours and efficiency of staff is getting reduced. Trains are
being delayed for want of crew.
5) In the present phase, 12 units of Ty-III and 16 units of Ty-II staff
quarters sanctioned vide LAW BOOK No. 734B and 734A of 2017-18.
GM/ECoR/BBS instructed to complete the work by using
pre-fabricated technology for early completion.
 PROJECT DETAILS
Name of the work : Construction of 16 units
Ty-II & 12 units Ty-III
pre-fabricated quarters
at Jakhapura station.

Estimate sanctioned : 26.04.2018

Tender opened on : 31.05.2018
Letter of Acceptance issued on : 18.06.2018
Value of work : 3.99 Crore
Date of commencement of work : 20.06.2018
Date of completion of work : 22.11.2018
Duration of completion : 5 months
 SALIENT FEATURES OF BUILDING
(1) No. of stories : G+3

(2) Total no. of : 28

quarters Type II - 16
Type III - 12
(3) Area of each : 54.969 Sqm Type II
quarter 62.666 Sqm Type III

(4) Method of : Pre-fabricated

construction Building Technology
with Steel Structure
& Expanded
polystyrene wall
paneling.
 SALIENT FEATURES OF BUILDING
(5) Foundation : 211 nos of piles and 58
nos pile caps

(6) Columns : 60 nos (NPB-500 & 400)

(7) Beams : NPB-350 for main beam
NPB-250 & 200 for
secondary beam

(8) Slab : 1mm thick deck plate and

75 mm average thickness
of M20 grade concrete
 SALIENT FEATURES OF BUILDING
(9) Wall : (a) Expanded Polystrene
panel (EPS) of 150 mm
thickness with 2mm GI
wire mesh @ 50mm
spacing.
(b) Shortcreting of wall
panelings.
(10) Steps : EPS panel with
shortcreting

(11) Elevation : Architectural elevation has

been given by plastering
 SALIENT FEATURES OF BUILDING
(12) Finishing : (a) PoP false ceiling with
works aluminum frame.
(b) Vitrified tiles for room.
(c) Interior emulsion for
inside and weather-coat
for outside walls.
(d) Concealed electrical &
plumbing works
(13) Doors : Flush doors of 1050 x 2100
mm.
(14) Windows : UPVC window with iron grills.

(15) Other : (a) No trees has been cut.

important (b) Provision of rain water
features harvesting
LAYOUT
 MATERIALS & TECHNOLOGY
USED FOR CONSTRUCTION
• Innovative concept of using steel structure and factory
made EPS wall panel.
• NPB for beams and columns
• Decking sheet
• Expanded Polystyrene Panel (EPS) for walls
• Other materials for shotcreting and finishing works
SPECIFICATION OF EPS PANELS

Width – Customized as per requirement

Length – Customized as per requirement
EPS Slab Thickness – 50mm
EPS Slab Type – Plain
Mesh – 50 x 50 mm ,
Mesh wire thickness –2.0 mm, 3.0 mm
Utility Fittings – Customized as per requirement
SPECIFICATION OF DECK SHEET
SPECIFICATION OF DECK SHEET
DECKING SHEET & REINFORCEMENT LAYING
 COMPARISON
Sl No. Item Time for Time for
Traditional Prefabricated
Method Method
1 Foundation 45 days 35 days
2 Plinth 15 days 5 days
3 Column Structure 120 days 30 days
4 Roof casting 90 days 15 days
5 Wall 90 days 20 days
6 Finishing Works 90 days 45 days
Total Days 450 days 150days

Cost per sq.m Rs.16000.00 Rs. 19000.00

• Steel can be reused after dismantling of building but in traditional method, there
is no scope of recovery or reuse of materials.
Thank You