SUBMITTED BY

RAKSHA KAPOOR
CIVIL, 3rd Yr
NIT-JALANDHAR
1
L&T—SUGC JV DMRC-CC 27

Design & construction of tunnel from end of underground ramp (near

Shankar Vihar Metro Station) to Hauz Khas Metro Station &
underground ramp near Shankar Vihar Metro Station & underground
metro stations atVasant Vihar, Munirka, R K puram, IIT &Hauz Khas
On Janakpuri west- botanical garden corridor of Delhi MRTS project of
phase-3.

PROJECT GUIDE SUBMITTED BY

A.K.Sharma Raksha Kapoor
Station manager student civil, 3rd yr.
Vasant Vihar NIT JALANDHAR
2
 ACKNOWLEDGEMENT

I want to acknowledge ER. R G Saini (project manager) for showing the

trust in me and giving me the opportunity to learn in this project.
And through this I also want to share thanks with ER. A.K.Sharma under
whose guidance I have been able to learn and prepare the upcoming
project report.
Last but not the least, I want to thank all the engineers from various
department such as Mr. Prabhat (Section Incharge), Mr. Sarvanan
(Reinforcement Incharge), Mr. Gyanaprakash (Quality Incharge) who
have shown keen interest in imparting knowledge to me.

3
 INDEX
CONTENTS PAGE NO.
Larsen & Toubro 5

Shanghai urban construction group 6

DMRC 7

Metro in India 8

Scope of Works 9
Project specifications 10-11

Project layout 12

Construction methods 13

Cut and cover construction method 14

Bottom up and top down methods 15-17

Vasant vihar station(intro) 18

Methodology 19-36

Earth mat 37-41

Instrumentation and control 42-43

Tunneling 44-47

Safety and environmental management 48-49

L&T casting yard 50-54

Munirka 55

RK puram 56

Conclusion 57

4
 LARSEN & TOUBRO
L& T has contributed significantly to the successful
implementation of PHASE-I of Delhi Metro Rail Corporation
Project. As a consortium partner, L&T constructed an underground
corridor from Kashmiri Gate to central secretariat, Mandi house
underground station & the ramp on the extension of Barakhamba
Road-Dwarka corridor towards PragatiMaidan.
L&T constructed the largest Delhi Metro underground station at
Rajiv Chowk. In addition, the company executed a platform tunnel
for deepest station at Chawri Bazaar. L&T has also constructed
station at UdyogBhawan, Saket& Green Park in PHASE-II of
Delhi Metro.
SPECIALITY:
Construction of underground stations

5
SHANGHAI URBAN CONSTRUCTION GROUP

With rich experience in design and construction of metro, SUCG

has undertaken the task of laying Delhi Metro in joint venture with
L&T (due to their meagre experience in underground tunneling).

They have done remarkable job in projects like

1. the Bund Channel(Tunnel) project
2. Play Pu Road tunnel multiple tracks etc.

SPECIALITY:
Underground tunneling for laying of metro rail

6
 DMRC
(DELHI METRO RAIL CORPORATION)

The Delhi Metro Rail Corporation Ltd. (DMRC) is a state

owned company that operates the Delhi metro in the national
capital region in the metro, the DMRC is also involved in the
planning and implementation of metro rail, monorail and high
speed rail projects in India. The DMRC has equal equity
participation from the government of India and the government of
Delhi
DMRC was registered on 3 May 1995 under the Companies Act,
1956 for the implementation and subsequent operation of the Delhi
Metro. E.Sreedharan was appointed as the first managing director
of DMRC. Sreedharan handed over charge as MD of DMRC to
Mangu Singh on 31 December 2011.
The ministry of urban development (MoUD) instructed the DMRC
to set up a separate subsidiary company to provide consultancy
services. The intention was to let DMRC focus on the Delhi Metro
while the separate firm will provide consultancy services. The
decision was reportedly taken following the appointment of
DMRC as a consultant in the Kochi metro project, on the Kerala
Government's insistence. According to a MoUD official, "The
objective is to provide consultancy services without infringing in
the main functioning of Delhi Metro. The sister company of the
DMRC will also be registered under Companies Act 1956.
DMRC has made it compulsory to wear safety helmets on
construction sites. It also earns carbon credits with rainwater
harvesting at metro stations and runs an HIV/AIDS programme for
workers.

7
 METRO IN INDIA

Due to increasing population of our country and a hike in the need

for cheap and rapid transit system for short distances, it was
planned in 2009 that all Indian cities having population more
than 20 lakhs will have metro rail system. And subsequently, it
was decided to invest Rs. 200,000crore on metro rail projects in
next 10 years.
Currently, rapid transit systems have been deployed in these cities
and more are under construction or in planning in several major
cities in India.
The Kolkata metrowhich started operations in 1984 was the first
metro rail system in India followed by Chennai mass rapid transit
system, started in 1995. Delhi metro was India's first modern
metro and third metro overall, beginning operations in 2002.

8
 SCOPE OF WORKS

Design & Construction (Civil &

Architecture)
5 Underground Stations of Length 265M each.
 4 STATIONS – Top Down Method
*HauzKhas, IIT, RK Puram, Munirka
 1 STATION - Bottom Up Method
*Vasant Vihar
5 Tunnel Stretches
 IIT to HK - 806 m ( 4 CP*)
 IIT to RKP - 505 m ( 2 CP*)
 MUN to RKP - 1067 m ( 4 CP*)
 VV to MUN - 1241 m ( 5 CP*)
 VV to SV - 1421 m ( 5 CP*)
*CP- Cross Passage
2 Cut & Cover tunnel stretches
 Near Shankar Vihar Ramp -103m
 Near RK Puram Station -336m
1 Underground ramp of length160m

9
 PROJECT SPECIFICATIONS

CLIENT M/s delhi metro rail corporation ltd.

NATURE OF CONTRACT Lump sum- design & build contract

(civil & architecture)

CONTRACTOR L&T-SUCG JV CC27 Delhi

CONTRACT PRICE INR 1252.6 cr.

CONTRACT PERIOD 42 months

COMPLETION DATE 9th may, 2016

DESIGNER Station works: M/s Tandon consultant

pvt. Ltd.
Tunnel works: M/s Amberg

10
SCOPE OF WORKS-PHASE III OUTER RING ROAD CC27 DMRC
PROJECT (TOTAL LENGTH OF THE STRETCH = 6.75 Kms)

11
PROJECT LAYOUT

12
 CONSTRUCTION METHODS

Tunnels are dug in types of materials varying from soft clay to hard
rock. The method of tunnel construction depends on such factors
as the ground conditions, the ground water conditions, the length
and diameter of the tunnel drive, the depth of the tunnel, the
logistics of supporting the tunnel excavation, the final use and
shape of the tunnel and appropriate risk management.
There are three basic types of tunnel construction in common use:
• Cut-and-cover tunnels, constructed in a shallow
trench and then covered over.
• Bored tunnels, constructed in situ, without removing the
ground above. They are usually of circular or horseshoe
cross-section.
• Immersed tube tunnels, sunk into a body of water
and sit on, or are buried just under, its bed.

PARIS METRO CONSTRUCTION

13
CUT AND COVER CONSTRUCTION METHOD

Cut-and-cover is a simple method of construction for shallow

tunnels where a trench is excavated and roofed over with an
overhead support system strong enough to carry the load of what is
to be built above the tunnel. Two basic forms of cut-and-cover
tunneling are available.

CUT AND COVER TUNNEL

14
 BOTTOM UP METHOD TOP DOWN METHOD

STEP1: Installation of temporary STEP1:Installation of excavation support/

excavation support walls, such as soldier tunnel structural walls, such as slurry walls
pile and lagging, sheet piling, slurry walls,
tangent or secant pile walls or secant pile walls
STEP2: Dewatering within the trench if STEP2:Dewatering within the excavation
required limits if required
STEP3:Excavation to the level of the bottom
STEP3: Excavation and installation of
temporary wall support elements such as of the tunnel top slab
struts or tie backs STEP4:Construction and waterproofing of
the tunnel top slab tying it to the support
STEP4: Construction of the tunnel
structure by constructing the floors of excavation walls
STEP5:Backfilling the roof and restoring
STEP5: Compete construction of the the ground surface
walls and then the roof, apply
STEP6:Excavation of tunnel interior, bracing
waterproofing as required;
of the support of excavation walls is installed
STEP6: Backfilling to final grade and as required during excavation
restoring the ground surfa
STEP7:Construction of the tunnel floor slab
and tying it to the support of excavation walls;

15

BOTTOM UP METHOD
ADVANTAGES & DISADVANTAGES
ADVANTAGES:
• Waterproofing can be applied
to the outside surface of the
structure.
• The inside of the excavation is
easily accessible for the construction
equipment and the delivery, storage
and placement of materials.
• Drainage systems can be
installed outside the structure to
channel water or divert it away from
the structure.
DISADVANTAGES:
• Somewhat larger footprint
required for construction than
for top-down construction.
• The ground surface cannot be
restored to its final condition
until construction is complete.
• Requires temporary support or
relocation of utilities.
• May require dewatering that
could have adverse affects on
surrounding infrastructure
STEP8:Completing the interior finishes
including the secondary walls.
TOP DOWN METHOD
ADVANTAGES &DISADVANTAGES
ADVANTAGES:
• The temporary support of
excavation walls are used as the
permanent structural walls
• The structural slabs will act
as internal bracing for the support
of excavation thus reducing the amount
of tie backs required
• It requires somewhat less width
for the construction area
• It may result in lower cost for
the tunnel by the elimination of
the separate, cast-in-place concrete
walls within the excavation
DISADVANTAGES:
• Inability to install
external waterproofing outsie
the tunnel walls.
• More complicated connections for
the roof, floor and base slabs.
• Potential water leakage at the
joints between the slabs and the walls
16
17
 BOTTOM UP CONSTRUCTION
METHOD
VASANT VIHAR STATION

TOP-DOWN CONSTRUCTION
METHOD
RK PURAM STATION

18
 Vasant Vihar Station
Construction of Vasant Vihar station is done by bottom top method.
Length of the station is 267m.
TBM tunnel length is 687m. NATM/TBM length is 756m. C&C
tunnel length is 103m. Length of the ramp is 160m. There are 4
entry and exit points. The bottom top method has been adopted due
to the difficulty faced in the excavation of the earth here which
includes rock and soil both.
Machinery used here includes JCB excavator, second generation
hydra, DTH drilling machine, crane etc.

SATELLITE VIEW OF VASANT VIHAR STATION

19
 METHODOLOGY
The methodology of bottom up construction is explained in the
steps below:
1. rock excavation
2. installation of removable rock anchor
3. soldier pile installation
4. shotcreting

ROCK EXCAVATION

ROCK EXCAVATION AT VASANT VIHAR STATION

Rock excavation describes details of excavation for launching

shaft, station box and entrances at Vasant Vihar station. The cut
and cover tunnel excavation used here is:
(A) Excavation and installation of rock bolt.
20
 • Obtaining permit to dig first rock bolt level with rock
breaker working at surface, excavate down to first rock bolt
level.
• Mark locations of bracket on soldier piles and excavate
wedges at bracket locations.
• Install (weld) pre-fabricated steel brackets to soldier piles.
Surveyor will locate level of bracket accurately using survey
instrument. Ensure elevation of bracket exactly at soldier
pile ends.
(B) Excavation and installation of second rock bolt level
• obtain permit to dig to 2nd street level & excavate further
down to 2nd rock bolt level with breaker working from
inside excavation area.
• excavate further at central part with mini breaker inside the
excavation area. The beams on side walls will be wide
enough to provide adequate passive resistance at soldier
pile walls.
• Excavated material will be lifted in a steel bucket using a
50 ton crane.
(C) Excavation and installation of third to eighth rock anchor

21
 INSTALLATIONOF REMOVABLE
ROCK ANCHOR

ROCK ANCHOR

A retaining wall system with soldier pile and rock anchor is

created at different levels to support intended excavations.
After this, excavation shall be carried out to about 0.5m below
the proposed anchor level.
A stable and a good working platform shall be prepared to have
a safe platform for movement of heavy equipment (eg: hydraulic
anchor drilling rig)
Steps involved in installing anchors-
1. Drilling process
(1) Drilling is carried out by typically a machine typically
inclined at 20°±5° to the horizontal as required. Using suitable
anchor drilling rig with appropriate drill tools to drill a hole of
about 6” diameter(152mm) to the desired length of about 7m-13m.
(2) Full length casing is ensured during drilling process with due
consideration to the collapsible in-situ soils, in order to stabilise the
boreholes. However, casing is not required when drilling through rock
mass as it is not a collapsible medium.
(3) During, drilling, sequence of strata in ground needs to be
observed carefully. It must be ensured that fixed/bond length of the

22
anchor doesn’t fall under a soil stratum that is significantly different
from that of idealized soil strata considered during design stage.
(4) Once final depth of borehole is reached, it is flushed out using
air/water and drill tools are removed.
2. Anchor installation and grouting
(1) High tensile steel strands shall be used (conforming to IS:
14268-1995) to fabricate the anchors (retrievable), to achieve the
desired structural capacities. Pre-fabricated anchor shall be tied
together with HDPE grout pipes for grouting process (secondary
grouting).
(2) Anchor strands are covered by HDPE insulation along the
anchor length.
(3) Along fixed length of anchor, spacers &centralizers are fixed as
per accordance with recommendation of system manufacturers to
achieve centering of tendons within borehole. Anchor assembly shall
be carried out either at site / fabrication yard.
(4) A shrink free grout mixture is used as a grout material
(water/cement ratio=0.35-0.4)
(5) Approved OPC grade 53 shall be used as admixtures (eg: cebex
100 be used)
(6) Pre-fabricated anchor assembly is then inserted into borehole &
grout is injected either through HDPE grout pipe or gravity flow from
top of borehole (primary grouting) using grout station (consisting of a
colloidal mixture, agitator & a high pressure pump).
(7) During this, casing is withdrawn & gap formed is filled up with
grout.
(8) Following primary grout process secondary grouting is done under
high grout pressures through pre-installed HDPE grout to ensure
fracturing of primary grout to form effective bonding with surrounding
soil.
(9) volume of grout depends upon localized ground conditions

Grout material include:

1. water (clean)
2. cement OPC grade 53
3. admixture (cebex 100 or equivalent
Grout properties are as follows:
23
 1. water/cement=0.35-0.4
2. Admixture cebex 100 is added at a dosage of 225 Gms /
50 kg of cement bag.
3. Grout mixture temperature should be maintained at 25°C.

INSTALLATION OF BRACKETS AND WALLERS

Brackets for each location shall be measured & fabricated at site

for fixing to soldier piles. Wallers shall be installed as H-piles &
welded completely as specified. Waller beam will be fabricated in
ground & lowered & fixed in position as per working drawing.
Gap between waler pile & soldier pile wall will be filled with
concrete. Bearing plate shall be installed prior to stressing.

PRE-STRESSING
1. Grouted anchors are allowed to cure for minimum period of
7-10 days, before anchor strands are subjected to pre-stressing.
Stressing operation must not commence until grout attained
required crushing strength of at least 17MPa.
2. Each anchor is pre-stressed (i.e. 100% frequency) to access
performance for designed load carrying capacities. The anchor
strands are then pre-stressed using multi-strand hydraulic jack of
required capacity in stages to a final test load of 1.1 times working

24
load
3. Initial load increment would be about 10% working load &
successive would be 10, 50 & 100 % of working load.
Observe deformations in strand with help of dial gauge for a
minute for every load increment.
4. At ultimate test load i.e. 110% of working load deformations
are observed for 15 minutes & elongation of strand noted between
third and fifteenth minute.

DESTRESSING AND EXTRACTION OF ANCHOR

1. after completion of parmanent support structure &

construction when reaches approximately 0.5m below anchor
level. strands will be destressed.
2. Following completion of anchoring works for a given
section of pile wall, further excavation can be carried out.
3. Over excavation should be prevented.
4. Hydraulic jack that was used to pre stress can be reused to
pull anchor steel in order to release anchor wedges from their
socket allowing them to be removed.

DESIGN BASICS
For designing a U-loop rock anchor following are to be
evaluated:
1. number of 152mm diameter strand loops.
2. Effective bond length of each loop.
3. Total bond length from 2 loop system.

PRE-STRESSING STRANDS

25
 152mm diameter seven wire high tensile steel strand.
Design parameters are assumed.
COMPONENTS ASSUMED REMARK
PARAMETERS
Bond strength at rock or grout Ultimate bond stress= 400kN/m2 Delhi region has medium hard
interface rock

BASE SLAB (THICKNESS=900mm)

COLUMNS AT THE BASE SLAB

List of major equipments required:
 Dewatering pump
 Rebar cutting and bending machines
 Diesel generators 125kA
 Concrete pump/ boom placer
 Transit mixer
 Air compressor
 Vibrators

List of materials required:

1. Concrete M40
2. Rebar Fe 500D
3. Warter free from solid suspended matter and clean
26
 4. PVC Water stop to arrest water leakage, if any

METHODOLOGY :
1. Survey works are carried out to confirm alignment level and position of slab.
2. Excavation done to the reqd. limit.
3. PCC base to be provided for the base slab (min thickness=75mm)
4. Sump should be provided for dewatering (if reqd.)
5. Embedded service pipes to be laid within earth mat .pipes should not touch
the top & bottom bars of earth mat & will run within the base slab.
6. Reinforcement will be curtailed / spacing changed to provide an outlet to
pipes.
7. Risers should be provided on base slab
8. Formwork : shutter panel of film coated plywood (12mm thick) should be
installed. It is provided for alignment, verticality (checked with plumb bob).
9. Concrete formwork: vertical sides of beams walls , columns should be
concreted first.
10.Fabrication, transportation &and installation of rebars:
 Fabricated at fabrication yard.
 Binding wire (core diam=1.25mm) used to bind rebars.
 For no rust on rebars it should be rubbed with wire brushing and
scraping should be needed.
11. Cover to reinforcement is provided to protect from corrosion and abrasion.
Control of min. thickness of concrete is done using concrete spacers. Cover
blocks are of same mix with rough surface.
12.Concreting of base slab: waterproofing admixture (crystalline type ) is used
and mixed with concrete at batching plant itself. Concreting done by
concrete pump/ boom placer/ bucket. 5˚C< temp. of concrete <32˚C.
13.Construction joints:
 To avoid cold joints , concrete is placed in continuous layer with
thickness not more than 300mm
 Only vertical construction joints shall be provided in concrete if full
depth of concrete is achieved.
 Balance sloping potion is removed after initial set.
 No horizontal constn. Joint is allowed.

27
 Concreting should be done at such a rate that plasticity should be
achieved at same time.
14. Size of pour :
 It depends upon site condition
 Detailed pour plan by start of pour.
 Water bar used ( size =230*8mm)
 Slab joint is roughened by applying retarder agent.
15. Compaction of concrete:
 Immersion type vibrator is used.
 It is used in near vertical position.
 Penetration should be till full depth of layer of placed concrete and just
into layer below.
 Max. pour size should not be greater than 20m.
16. Vibration:
 should be continuous until expulsion of air has ceased practically.
 Segregation of ingredients should not occur.
 It should not contact reinforcements or inserts.
 Screed vibrator for surface vibration should be used.
 25NB pipes should be welded perpendicular over top layer of
reinforcement & screed vibrator is installed over it.
 Proper leveling& finishing to top layer should be done.
 Such surface compaction of green concrete prevents formatn of thermal
cracks in top layer & provides a smooth finishing.
17.Curing of concrete:
 Horizontal surface:
Wet hessian cloth is placed. And covered by polythene sheet. Hessian
cloth is kept permanently damp. After 24 hrs hessian cloth & polythene
sheet is removed & area is ponded for 7 days.
 Vertical surface: same polythene + wet hessian cloth arrangement is
applicable in this case too , kept permanently damp for 7 days until next
pour of concrete adjacent to vertical surface is placed whichever is
earlier.
 In winter thermostats are used .

28
 SCAFFOLDING
REINFORCEMENT AT PLATFORM
SLAB

PLUNGE COLUMN

REINFORCEMENT
OF BASE SLAB
PORTION ALREADY
CASTED.

29
 SUMP DETAILS

REINFORCEMENT IN SUMP SUMP

TOWER CRANE

CONCRETING WITH POURING BUCKET

30
 CONCOURSE SLAB
(THICKNESS=550mm)
List of materials required:
1. Concrete : M40
2. Rebar: Fe 500D
3. Water : free from solid suspended matter and clean
4. Water stop : to arrest water leakage if any

List of major equipments required:

 Diesel generators 125kA
 Concrete pump/ boom placer
 Transit mixer
 Air compressor
 Vibrators

Methodology:
1. Survey works are carried out to confirm alignment level and position of slab.
2. For staging heavy duty towers are ereted& fixed at positions and spacing as
drawing with bracing as required to prevent lateral tilting.
3. Arrangement provides sufficient strength support and rigidity during placing
& compacting of concrete.
4. Top tower spindle of heavy duty tower would be attached to U-head would
provide a resting platform to steel waler at 100mm back to back spacing
which would run along span of slab.
5. Over steel waler H-6 would be laid perpendicularly at 300mm c/c
6. Steel waler acts as a primary span member & timber H-beams would act as
secondary beam members .
7. Over this , plywood of 12mm thickness is fixed.
8. Slab is rested over this arrangement
9. Formwork will be placed along alignment & verticality line & level shall be
checked. Appropriate formwork at cut out portions of slab
10.Inserts if any fixed within shutter shall be fixed as design.
11.Verticality of side shutter is checked using plum bob.
12.Straight line is checked using line thread / total station.
31
13.Rebars are fabricated at factory and transported and installed at site.
14.Proper cover is provided in different sections of site.
15.Temporary column supporting concourse slab beam: composite steel
structure would be provided to give temporary support to roof slab beam. As
locations of permanent columns lie in cut out portion of station hence for
temporary support temporary column would be provided.
(i) Three sections of UV 610*229*125.1mm shall be butt welded &
fabricated as single vertical member.
(ii) Towards bottom side of fabricated column head plate of 32mm
thickness .ms plate of size 660*775mm will be welded . similarly base
plate will be welded on bottom end.
(iii) Set-up will be lowered through cut-out portion of slab above & then
positioned into place after.
16. There after concreting is done in the same way as base slab .
17.Curing is also done in the same way
 Horizontal surface:Wet hessian cloth is placed. And covered by
polythene sheet. Hessian cloth is kept permanently damp. After 24
hrs hessian cloth & polythene sheet is removed & area is ponded
for 7 days.
 Vertical surface: same polythene + wet hessian cloth arrangement
is applicable in this case too , kept permanently damp for 7 days
until next pour of concrete adjacent to vertical surface is placed
whichever is earlier.
 In winter thermostats are used
18.Cut out portions are left here due to lowering of TBM.

32
 CUT OUT LEFT FOR THE LIFT IN CONCOURSE
SLAB

CONCOURSE SLAB

BLOCK WALL BETWEEN CONCOURSE

SLAB & ROOF SLAB

33
 ROOF SLAB
(THICKNESS=1100mm)
List of materials required:
1. Concrete : M40
2. Rebar: Fe 500D
3. Water : free from solid suspended matter and clean
4. Water stop : to arrest water leakage if any

List of major equipments required:

 Diesel generators 125kA
 Concrete pump/ boom placer
 Transit mixer
 Air compressor
 Vibrators

METHODOLOGY :
1. Survey works are carried out to confirm alignment level and position of slab.
2. PCC base to be provided for the roof slab (min thickness=75mm)
3. Reinforcement will be curtailed / spacing changed to provide an outlet to
pipes.
4. Formwork : shutter panel of film coated plywood (12mm thick) should be
installed. It is provided for alignment, verticality (checked with plumb bob).
5. Concrete formwork: vertical sides of beams walls , columns should be
concreted first.
6. Fabrication, transportation &and installation of rebars:
 Fabricated at fabrication yard.
 Binding wire (core diam=1.25mm) used to bind rebars.
 For no rust on rebars it should be rubbed with wire brushing and
scraping should be needed.

34
7. Cover to reinforcement is provided to protect from corrosion and abrasion.
Control of min. thickness of concrete is done using concrete spacers. Cover
blocks are of same mix with rough surface.
8. Concreting of roof slab: waterproofing admixture (crystalline type ) is used
and mixed with concrete at batching plant itself. Concreting done by
concrete pump/ boom placer/ bucket. 5˚C< temp. of concrete <32˚C.
9. Construction joints:
 To avoid cold joints , concrete is placed in continuous layer with
thickness not more than 300mm
 Only vertical construction joints shall be provided in concrete if full
depth of concrete is achieved.
 Balance sloping potion is removed after initial set.
 No horizontal constn. Joint is allowed.
 Concreting should be done at such a rate that plasticity should be
achieved at same time.
10. Size of pour :
 It depends upon site condition
 Detailed pour plan by start of pour.
 Water bar used ( size =230*8mm)
 Slab joint is roughened by applying retarder agent.
11. Compaction of concrete:
 Immersion type vibrator is used.
 It is used in near vertical position.
 Penetration should be till full depth of layer of placed concrete and just
into layer below.
 Max. pour size should not be greater than 20m.
12. Vibration:
 should be continuous until expulsion of air has ceased practically.
 Segregation of ingredients should not occur.
 It should not contact reinforcements or inserts.
 Screed vibrator for surface vibration should be used.
 25NB pipes should be welded perpendicular over top layer of
reinforcement & screed vibrator is installed over it.
 Proper leveling& finishing to top layer should be done.
35
 Such surface compaction of green concrete prevents formatn of thermal
cracks in top layer & provides a smooth finishing.
13.Curing of concrete:
 Horizontal surface:
Wet hessian cloth is placed. And covered by polythene sheet. Hessian
cloth is kept permanently damp. After 24 hrs hessian cloth & polythene
sheet is removed & area is ponded for 7 days.
 Vertical surface: same polythene + wet hessian cloth arrangement is
applicable in this case too , kept permanently damp for 7 days until next
pour of concrete adjacent to vertical surface is placed whichever is
earlier.
 In winter thermostats are used .

STAIRCASE FROM THE ROOF SLAB

36
 PERMANENT CUT OUT PORTION ROOF
SLAB

TEMPORARY CUT OUT PORTION IN ROOF SLAB

SCAFFOLDING FOR COLUMN BETWEEN

CONCOURSE AND ROOF SLAB

37
 EARTH MAT
Materials required:
 Copper rod : 22.5mm diam. Copper rod installed in agrid of 1.5*1.5m
(i) Copper 99.85% (min. + silver)
(ii) Tin 0.01% (max.)
(iii) Lead 0.01% (max)
(iv) Iron 0.03% (max)
(v) Arsenic 0.05% (max)
(vi) Nickel 0.10% (max)
 Copper earth electrode: 22.5mm in diam. And 3m in length.

Equipment required :
 Oxy-acetylene torch
 Gas cylinder
 Earth tester for measuring earth resistivity and resistance

Types of earth mat:

1 Main earth mat : it is done in ASS I & II (auxiliary sub-station)
For main earth mat , from each electrode 400m^2 bare standard copper
conductor will be raised upto platform level & copper conductors are
enclosed in 50mm diam. HDPE pipe (22.5mm is used for power earth). Also at
each crossing of copper rod in an earth mat copper clamp shall be
provided & at crossing rods shall be joint by brazing.
2 Clean earth mat : it is done below S & T , SER , UPS rooms. from each
electrode 400m^2 bare standard copper conductor will be raised upto platform
level & copper conductors are enclosed in 50mm diam. HDPE pipe (13mm is used
for power earth). Also ateach crossing of copper rod in an earth mat copper clamp
shall be provided & at crossing rods shall be joint by brazing

38
FABRICATION OF EARTH MAT: earth matsections of mentioned copper rods shall
be fabricated in different sizes with provision for joining to the next section. All
rod to rod laps shall be joint with brazing.

SHIFTING OF EARTH MAT: the above mentioned earth mat shall be fabricated at
the actual site location and shall be placed one by one as per lap provisions in the
approved drawing. The earth mat shall be buried 300mm below PCC level.
The location of the earth mat in respect of the grid should be marked with the
help of civil construction section
Minimum separation between the clean earth and station earth should be 20m.

CONNECTION OF EARTH MAT SECTION: the earth mat sections shall be

connected by means of brazing joints and copper U-clamps to form the required
mat of different sizes as per the approved drawing.

INSTALLATION OF EARTHING ELECTRODES: for the installation of earth

electrodes,13 mm diameter(for clean earth mat) and 22.5mm(main earth mat for
ASS-1 and ASS-2) solid copper rods electrode 3m long is directly buried in the
required bore holes of 100mm diameter which shall be made by using augers of
suitable size. The hole will be filled with virgin soil or material with good
conductivity and the earth electrode will be buried in it. The electrodes shall be
driven in ground below the blinding concrete.

INSTALLATION OF RISERS: risers of earth shall be 185mm bars stranded copper

conductor running coaxially with HDPE pipes. From two corners of the mat riser
should run up to parallel to wall upto 450mm height above the floor of under
croft level as given in drawing. They should be joined with grid by brazing and U-
clamps is provided near the case of slab to hold the HDPE corrugated pipe in place
and also a bit higher to hold conductor in its place along the wall. Typical detail of
test links with copper lugs and U-clamps were given in drawing. The cable shall be

39
taken through 50mm diameter corrugated HDPE types. Water proof sealant
compound shall be filled after installation of cables the portion of cable exposed
shall be protected through a conduit or bend projected along the wall over screen
the conduit bend shall be sealed with fire proof material after installation of
cables.

EARTH FILLING AND COMPACTION: on completion of activities above earth filling

and compaction shall be done by civil section eg.baby roller, to achieve the
desired level.

MEASURE OF EARTH RESISTANCE VALUE: resistance of individual pits and total

grid shall be measured separately before connection of grid to pits and for the
entire system after joining. The measurement should be taken after a backfilling
and with the help of a digital earth tester accessory.

BRAZING PROCEDURE: brazing shall be done using brazing rods of reputed

makes. The parts to be brazed shall be held clean to make them free of dirt, oil or
any foreign material either by wire brush or by acetone or benzene. The faces to
be brazed shall be held in position and bind with copper binding wire. Brazing
shall be carried in flat-flow and vertical upward position. The surface to be joined
shall be bright but not too smooth to prevent the joining material from flowing
away. Flux is applied on the parts to be joined if required. The temperature of
600-650°C by heating with oxy acetylene torch. It shall be done all around and
along the length of joints. After brazing soundness of the brazed material is
checked.

40
 Baby roller used for
compaction of virgin soil for
earth mat.

Risers protruding out of the ground

through which bare copper cables
will be passed.

41
After the above process of compaction of virgin soil, clean earth mat would be
done in this area. The earth mat would require copper rods of 13mm diam. To be
placed in the grid of 1.5X1.5m size.

42
 INSTRUMENTATION AND CONTROL

Instrument Function
type
Piezometer Measures pore water pressure in soil

Magnetic Measures settlement or heave in foundations, fills or excavations.

Extensometer
Inclinometer Measures deflection profile in D’ Walls and its variation with time.

Borehole Measures deformation of surrounding soil during tunneling.

Extensometer
Tilt meter Measure tilt of buildings.

Building Measure settlement of building due to excavation activities.

Settlement
Points
Surface Measures settlement in adjacent ground surface/pavements etc.
settlement
points
Geodetic Measure deformation during tunneling and subway construction.
Targets
Strain gauge Measures strain in the struts to assess load on the strut.

Load Cell Measures load coming on struts.

43
 ground settlement point

Pavement settlement point

Bi-reflex point

Inclinometer Strain gauge

44
 TUNNELING

DMRC-L&T CC-27 is an underground metro project of phase III therefore, being

an underground project it demands a high standard and sound tunnel mined
approximately 25meters below the ground level. So, SUCG, the joint venture
partner is responsible for the tunneling part of this project. In the whole project 5
TBMs of different companies have been deployed for mining the tunnel.

PARTS OF TBM
CUTTERHEAD: a. it has 8 motors.
b. It has 46 cutters.
c. Types of cutters are as follows:
 Gauge cutter : weariness allowed
10mm
(present at circumference of cutter head)
 Face cutter : weariness allowed 30mm
(present at arms of cutter head)
 Twin cutter : weariness allowed 30mm
(present at the centre of cutter head)

MIDDLE SHIELD:
1. It has 16 pairs of main thrust cylinders.
2. They are used in forward movement of
TBM.
3. A segment is placed withthe help of 3 main
thrust cylinders.
4. A key is placed using 1 pair of thrust
cylinders.
45
 5. Extension of main thrust cylinder is 2.2m-
40cm
TAIL SHIELD: It has diam. 6.5m.

FUNCTIONS OF TBM
GROUTING:
a. It is done within the space of outer diam. Of
segment to the excavation diam.
b. Grouting is done with 2 types of mixes:
1. GROUT A: 300kg cement + 300kg fly ash +
25kg bentonite + 2kg retarder
2. GROUT B: 100kg sodium silicate
3. A:B= 12.5:1Volume of 1 ring: 3.18m^3
120% of 3.18m^3=4.57m^3 is used for safer side

MINING & GROUTING: They are done simultaneously.

SCREW CONVEYER: Advantage is lowers speed of muck if

cavities are building up, pressure builds up with lowered speed
and cavities start going down.

PARAMETERS OF MINING:
1. CUTTERHEAD :
a. TORQUE: 1.5-2.8kNm
b. ROTATION: 0-7rpm
(Used is 1-3rpm)

46
 2. PENETRATION: depends on soil strata
(Calculated as per mm
rotation)
3. SPEED: (calculated as mm per minute)
a. SOFT STRATA: 40mm per min
b. HARD STRATA: 15-16 mm per min
4. THRUST:
a. hard rock: 18000kN
b. soft strata: 6000kN
c. permissible: 35000kN
5. CONTACT FORCE:
a. hard rock
b. soft rock

NOTE: Thrust >contact force

NOTE:
1. HARD ROCK: 20 rings per cutter
2. SOFT STRATA: 40 rings per cutter
3. CHAMBER:
a. MAN
- Doctor
- Operator
b. MATERIAL
4 DIAMETER: Of front shield -6.6m
5. GUIDANCE SYSTEM USED: VMT
6. THEODOLITE (ADVANCED): total station (used with LASER)
7. foam+ water + bentonite are used (100l water + 2.5-3l
foam +2.5% polymer are used as conditioning plasticity)
(bentonite is used as lubricant)
47
 MUCK CART CARRYING MUCK OUT OF THE
TUNNEL

VARIOUS PARTS OF TBM

SEGMENT AND BANANA BOLTS

FOR INSTALLING THE RING
INSIDE THE TUNNEL

48
SAFETY AND ENVIRONMENTAL MANAGEMENT

There are a set of rules and regulations set by the DMRC for the safety of
the workers working at the site. It sets out the guideline on the bases of their
motto of safety of an employ is of foremost importance to the project. No
work is considered more important or more urgent than the safety of an
employ or a labour. The environment is considered equally important and
measures are taken to avoid any damage to the environment. Certain safety
and environmental management points:
 Wearing of proper helmet, Safety jacket and safety shoes.
 Proper housekeeping of all the machines and equipment.
 Any sort of misses and warning must be properly taken care of.
 Cylinder leaks should be regularly checked.
 Electric appliance should be properly used.
 Proper training of all the workers.
 Wheel wash facilities should be present at every site.

There are various types of dustbins kept at the site for proper waste disposal and
hence, proper management of environment.

49
 Green dustbin is for the
disposal of organic waste

Blue
dustbin is for
the disposal of
inorganic
waste

50
 L&T CASTING YARD
(MUNDKA)

The processes carried out at the casting yard in the formation of segments of tunnel
are shown in the flow chart below:

CUTTING &
BENDING OF
REBAR
APPLICATION STEAM
OF CURING
CURING
COMPOUND

FORMATION OF
REINFORCEMENT
CAGE COMPACTION OF
TRANSFER OF
CONCRETE IN THE
SEGMENTS
FORM WORK BY
FROM CASTING
THE PUMPS PLACED
YARD TO
UNDERNEATH
STACKING
YARD
TRANSFER OF
REBAR CAGE
FROM REBAR PLACING OF
YARD TO CONCRETE IN
CASTING YARD THE HK FORM DISPATCHING
WORK OF SEGMENTS
TO THE
STATION

51
CUTTING AND BENDING OF REBAR: bending and cutting of rebar are done
to attain the required shape (length and width) of rebar cage. 8mm and 12 mm
diameter rebar along width and length, respectively of the cage are welded with
gas welding/MIG welding.3.67 m is the length if each segment.

FORMATION OF REINFORCEMENT CAGE: reinforcement cage is formed

with the rebar obtained above using gas welding/MIG welding. There is a gantry
crane of capacity 5 MT in the rebar yard to transfer the cage from one place to
another.

TRANSFER OF REBAR CAGE FROM REBAR YARD TO CASTING

YARD:
Rebar cage is transferred from the rebar yard on a trolley to the casting yard. The
reinforcement cage is carefully placed in the HK form work of segment. There are
6 types of moulds in HK form work for the casting of 5 type of segments+1 key.
The internal diameter of these segments is 5.8m. Shuttering oil eg.atmorel, is used
to lubricate the form work. All the segments(S-1 to S-6) are placed to form the ring
in the following manner:

52
PLACING OF CONCRETE IN HK FORM WORK:
M-50 concrete is poured in the form work with pouring bucket and compaction is
done after it
COMPACTION OF CONCRETE BY THE PUMPS PLACED
UNDERNEATH THE FORMWORK:
Compaction of placed concrete is done with the three pumps placed underneath the
formwork. The pumps are used to vibrate the concrete placed in the mould above.
Three vibrator pumps are used to compact for 18min. to 1 hour.
APPLICATION OF CURING COMPOUND:
A curing compound namely emcoril AC (acrylic emulsion) is applied on the
segment 2 hours after demoulding when the segment achieves a strength of
12MPa. The compound helps in retaining the moisture acquired by segment during
steam curing.
STEAM CURING:
Segments are cured with the help of steam since it is economical and judicious in
place of running and flowing water. The segments are covered and kept for 3 hours
under steam continuously. The max. temperature should be 60°C. But the
temperature maintained here was 45-50°C.
TRANSFER OF SEGMENT FROM CASTING YARD TO STACKING
YARD:
The segments are stacked in the pattern shown below after it is casted.

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TYPES OF LIFTING MACHINES USED IN YARDS:
LIFTING MACHINE NO. CAPACITY
Gantry crane 6 15ton, 30ton, 5ton
EOT crane 4 10ton
Vacuum lifter 1 3-7ton

TESTS DONE ON AGGREGRATES BY THE QUALITY DEPARTMENT:

1. Specific gravity test
2. Permeability test
3. Compression test
4. Sieve analysis (10 & 20mm & sand )
5. Water absorption test
6. Flakiness index test
7. Elongation index test
8. Impact and crushing value test

DESIGN MIX OF M-50 CONCRETE USED IN SEGMENT:

MATERIAL DESIGN MIX PER CUM WATER ABSORPTION MOISTURE CONTENT
(kg) (%) (%)
Cement 410 --- ---
Fly ash --- --- ---
River sand 765 1.40 5.35
10mm agg. 457 0.33 0
20mm agg. 686 0.87 0
Water 151 --- ---
Admixture 2.16 --- ---
Microsilica 22 --- ---
total 2493.6 2.6 5.35

54
 Formation of reinf. Cage at rebar yard

Casting and curing of segments in HK formwork in casting yard

55
 MUNIRKA
It is being constructed by “top-down” cut and cover method. It has two entry and
exit points. Station Manager is Mr. P.J Rao. Munirka station is 263 m long. Length
of TBM tunnel at this station in 1241m.
Top down method is employed here since excavation is easy due to the uniform
soil present here.
Machinery used here includes boom placer, hydraulic rig, hydraulic lift(for heavy
material).
Box pushing and TBM tunneling were there at the site.

Pictures of box pushing at munirka station

56
 R. K. PURAM
It is being constructed by “top-down” cut and cover method. R.K.Puram station is
265 m long. Length of TBM tunnel at this station in 1067m.
Top down method is employed here since excavation is easy due to the uniform
soil present here.
Machinery used here includes boom placer, hydraulic rig, hydraulic lift(for heavy
material).
Preparation for box pushing is being done with the required reinforcement and
TBM was being retrieved from here with the help of cradle beam.

Retrieval of TBM

57
 CONCLUSION
From the report it can be concluded that while L&T has
undertaken the laying of Delhi metro(one of the Asia’s
biggest projects), it also takes into consideration the safety
of the labour working in the projects. The hazardous sound
produced due to the heavy duty machines working here has
also been tried to be prevented to some extent by installing
barricades with sound insulation sheets all around the site.
The company is doing a great job by working day & night
under carefull guidance & strict supervision of a well
collaborated team of various engineers.
We can hope the phaseIII of DMRC would be a great
success as before under L&T-SUCG JV.

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