A detailed presentation on the construction of underground Metro

StationSukhdarshan

Under the guidance of

Mr Tanuj Chopra

L&T SUCG JV DELHI DMRC CC-27 PROJECT

CONTENT

Introduction to Project CC-27

Tendering For the Project

Bore Hole Results

Vasant Vihar structure lay out

Bottom-Up Construction

Excavation/Soil stabilization

Concreting Operation& Repair

Waterproofing of Structure

Project Name-Design and construction of tunnel & underground metro stations from JanakpuriWest to Botanical Garden(CC-27)

Key Details COST OF PROJECT(App) INR 1435 CRORES

COMPLETION PERIOD(Expected) 42 MONTHS

TENDER SECURITY AMOUNT INR 14.35 CRORES

TENDERING AGENCY DMRC

TENDER GIVEN TO L&T-SUCG-JV

Quoted Price & Final Price 1265 CRORES

Proposed Route Map for CC-27

Tendering For the Project

Tender document is further divided into volumes that define the scope and procedure for various activities related to project. The CC-27 Tender Document was further divided into 9 volumes

Volume 1- Instructions for tenderer and form of tender.

Volume 2-General conditions and special conditions for contract

Volume 3-Emplyers Requirement about Functional, Design &

construction.

Volume 4-Outline Design Specifications

Volume 5-Outline Construction Specifications

Volume 6-Tender Drawings

Volume 7-Bill of Quantities

Volume 8-Vonditions on Safety, Health & Environment

Volume 9-Reference Document(Geotechnical report)

Eligibility Criteria for bidding

Work Experience

Financial Standings

a) Liquidity

b) Profitability

c) Net Worth

d) Annual Turnover

Bid Capacity Criteria

Minimum Key staff Requirement

AWARDING OF TENDER

• The most basic criteria for awarding the tender is as follows but not limited to it

“The employer awards the contract to the tenderer whose tender has been determined to be substantially responsive and compliant to the requirements contained in the tender document & who has offered the lowest evaluated tender price”

MY CONCLUSION

TENDER

A-Z Everything on site …..is done according to the tender document.

Bore Hole Data

-Before starting construction Geotechnical data was collected from various locations along the proposed route to know about soil characteristics.

-Bore Holes were made along the proposed route up to a depth of 30m below the existing ground level.

Next Image shows the Soil Strata available at various sections of the project.

BORE HOLE

61

BORE HOLE

35

Based on the samples obtained from the bore holes following tests were conducted on the samples-

Following tests were then performed on the collected samples-

• Sieve analysis.

• Hydrometer testing

• Moisture content

• Specific gravity

• Dry Density

• Atterbergs limit

• Triaxial shear test(uu, cu, cd)

• Consolidation test

• Direct Shear Test

• Chemical analysis of both soil and water samples

The collected rock core samples(VASANT VIHAR SITE) were taken and the following tests were conducted on them-

• Density test

• Water absorption& porosity

• Hardness

• Ucs

• Point load index

• Vasant Vihar-Hard Rock strata (Bottom-Up construction approach)

• Hauz Khas - Soft Soil strata(Top-Bottom construction approach)

Vasant Vihar Station

TOP VIEW – VASANT VIHAR

METHOD OF CONSTRUCTION- BOTTOM UP CONSTRUCTION

EAST SIDEWEST SIDE

VASANT VIHAR PLAN

1

2

3

4

D

S.NO DESCRIPTION UNIT SCOPE

1 STATION LENGTH M 265

2 WIDTH(BOX) M 21.57

3 Launching Shafts Num 2

4 Entery/Exit Num 4

East Side

West Side

ROOF SLAB

CONCOURSE SLAB

BASE SLAB

1

2

3

4

5

6

78

1 BLOCK WORK

2 UPE(UNDER PLATFORM EXHAUST)

3 OTE(OVER TRACK EXHAUST)

4 PLATFORM SLAB

5 FRESH AIR DUCT(ROOF SLAB)

6 SCUPPER DRAIN(BEHIND BW)

7 FALSE CEILING BELOW CONCOURSE

8 COLUMN

9 RETAINING WALL

CROSS SECTIONAL VIEW VASANT VIHAR

9

BLOCK WORK INFRONT OF RETAINING WALL Dimension of Block– 400*200*200Mortar-Cement sand mortar with ratio 1:4Block Strength- 7.5 N/mm2 MIX –M15Thickness of the bond-10mmJoint Type-Basic English Bond(1 block thick)

CONCOURSE SLAB

ROOF SLAB

BLOCK WORK IN FRONT OF RETAINING WALL

RETAINING WALL

INITIAL LAYER OF BLOCK WORK

BLOCK WORK FOR ROOMS

ARCHITECTURAL ROOM PLAN(CONCOURSE SLAB)

EXAMPLE

U23-SAFETY ROOMU64-ELECTRICAL APPLIANCE REPAIRU26-WAITING ROOM

UPE(UNDER PLATFORM EXHAUST)

BASE SLAB

UPE CUTOUT

PLATFORM SLAB

UNDER PLATFROMEXHAUST

(UNDER PLATFROM EXHAUST ) are basically cut outs provided below the platform slab

OTE(Over Track Exhaust)

COOLING MECHANISM OF OTE

OTE LIFTING

FRESH AIR DUCTS

Ventilation systems provided below the roof slab for a constant supply of fresh air.

ROOF SLAB

SCUPPER DRAIN(BEHIND BLOCK WORK) Water proofing material (Brush Bond Rfx)

Scupper Drain Behind Block Work

DIMENSION- .37m X .3mPCC M15Brush bond Rfx Coating for waterproofing of thickness 1mm

Structural Drawing Scupper Drain

False Ceiling

Factors that determine the construction approach are

• Soil Profile- As suggested by the geotechnical investigation.

• Site Location-Weather the site is located in an isolated environment or urban dwellings.

• Cost Incurred -Depends

• Surrounding Environment-Weather the Surrounding environment consists of existing

structures and road networks.

• Time Constrain-The total time available for completion of project.

• Availability of Material-The availability of material for filling and construction Activities

to be carried out

Vasant Vihar Station

Area-33,706 sqm

Hauz Khas Station

Area- 15,533.69sqm

Bottom Up construction Method(VASANT VIHAR)Bottom up construction involves

Excavation & Soil Stabilization

Construction of Base slab, Concourse slab & Roof slab

Construction of Columns and Retaining wall.

Waterproofing of structure

Filling Operations

Excavation

• Excavation on site was carried out according to IS 3764:1992.• Excavation can be done in many ways depending on the soil profile in our

case it was done using Breakers and Excavators. • Excavation Volume= 18*265*26=124020 cum(Lump sum)

Machinery used in excavation

EXCAVATORS

Hydraulic 220 Excavator

Hydraulic 210 Excavator

Hydraulic 215 Excavator

BREAKERS

Hydraulic 340 Breaker

Hydraulic 210 Breaker

HEAD ATTACHMENT FOR BREAKER

Slope/Soil Stabilization

Soldier Pilling

Shot creting

Shot Creting is done according to IS 9012:1978(reaffirmed 2002)

Mix- 1:3 To 1:5 is used depending upon surface . W/c is kept at .30-.35

Plasticizer -6% wt of cement( Glenium sky 777)

Operating temp- 5deg to 30deg Celsius

Mesh Dia- 4mm

Mesh overlap length- 300mm

Min area for applying-300mm*300mm

Procedure For shotcreting 1)Clean the surface off the loose material and then clean with air compressor.

2) Apply a layer of shortcrete to the surface and wait for it to cure.

3) Apply the wire mesh on the surface and bind it to the surface using reinforcements.

4) Now apply the second layer of the shortcrete on the surface . Keep the nozzle perpendicular at a distance of 1 to 1.4 m away form surface.

Mechanism for Dry- Mix shot creting

Construction of slabsBase Slabs

-M40 Grade Concrete was used-Reinforcement conforming to FE500D shall be used on site.-Water Stops –PVC water stop will be used to arrest the water leakage (at construction joints)-Binding wire used for binding reinforcement has a core dia of 1.25mm-Formwork ply 12mm thick coated with Formwork oil for easy removal of formwork-Cover blocks should be used depending on clearance that needs to be provided to the reinforcement(50mm Base slab)-Vibrator of 60mm Dia 4nos.

Mix Design of concrete M 40

MATERIAL QUANTIY(KG) TYPE

CEMENT 380 ULTRA TECH(OPC 53 GRADE)

FLYASH 80 Ashtech:IS3812(NTPC BADARPUR)

AGGREGATE(10mm) 481 Kotpulti

AGGREGATE(20mm) 666 Kotpulti

RIVER SAND 677 Yamuna Nagar

W/C RATIO .35

ADMIXTURE @ .85% 3.91 Glenium 147,Suretec(BASF)

W/P CAMPOunds@1% 4.6 MasterPel 760(BASF)

WATER 161 R.O Water at Batching Plant

Following admixture were usedMasterglenium 147 provides Extended workability Providing the ultimate high strength, especially ready.ApplicationAdd to the mixture 80% -90% of the calculated water for the concrete mix and then, with the remaining water masterglenium 147 must be added to the mixture,

Water Proofing Campound used-Masterpel 760 Provides resistance to water penetration either under

hydrostatic pressure or capillary absorption. Imparts integral water tightness to structures.ApplicationMasterPel 760 is a ready-to-use powder which is dispensed into the concrete together with the cement.

M-40 has been used for 3 slabs and retaining walls

Concreting Operations

Earth Compactor Concreting on site

Proper vibration should be provided in order to avoid cold joints

Concrete pour sequence

• After the final set has taken place wet hessian cloth shall be placed and covered by polythene sheet. The hessian cloth shall be kept permanently damp

• After 24Hours hessian cloth and the polythene sheet shall be removed and the area would be ponded with water .

• For vertical curing the hessian cloth along with polythene sheet shall secure the surface for at leasdays

before next vertical pouring begins. The hessian cloth should be damp all the time.

Concourse Slab

Concrtete-M405.25 m below roof level Thickness- 550mm

Formwork & scaffolding for Concourse slab

Reinforcement For concourse slab

Cut outs provided both on concourse and roof slab

Roof Slab

Sealing Of construction Joints on roof slab

Cut Outs of the roof Slab( Sattelite view

Design Mix M-40Thickness-1.8mRoof level

Machinery used for Concreting

Volume-6cum but loaded up to 5-5.5cum.Rotations –Depend upon distance and Mix

BOOM PLACER

Concrete Bucket Vol 1-1.2cum

CONCRETING THROUGH PIPES

Mix Design M-50MATERIAL QUANTIY(KG) TYPE

CEMENT 410 ULTRA TECH(OPC 53 GRADE)

MICRO SILICA 22 TAM CEM

AGGREGATE(10mm) 457 Kotpulti

AGGREGATE(20mm) 686 Kotpulti

RIVER SAND 765 Yamuna Nagar

W/C RATIO .37

ADMIXTURE @

.85%

2.16 Glenium sky 777

WATER 151 R.O Water at Batching Plant

M 50 was used for concreting of columns

MasterGlenium SKY 8777 -is the super plasticizer based on second generation polycarboxylic ether polymers, developed using nano-technology. The product has been primarily developed for applications in high performance ready-mix concrete to facilitate Capability of delivering high quality concrete at any

time to the job site in place.Production of concrete with low w/c ratio that meets international guidelines for consistency classes (EN 206-1) without loss of workability.

TAM CEMTamCem Micro Silica is composed of silicon dioxide (5i02).Collected from silicon metal and ferrosilicon. TamCem Micro Silica will react with the Calcium Hydroxide from the cement, which will form more of the Calcium Silicate hydrate, increasing the strength of the concrete.

Concrete Repairing

BULGED CONCRETE

Bulged Concrete – Bulging in concrete takes place due to displacement of formwork.

Surface preparation: The bulged area on concrete surface shall be hacked with chisel to required line, level. All dirt, dust shall be cleaned with brush and water.

Repairing: Hacked area will be patched up with cement: sand mortar of proportion 1:4. On the completion of patch up work, the exposed area shall be thoroughly cured.

Grout Loss Exposed aggregate surface created by exit of cement slurry/grout mortar from the gaps of formwork due to excessive vibration, unsealed joint of formwork during pouring of concrete.Repair -The concrete surface is cleaned and free from dust/oil/grease etc by using broom or wire mesh by scrubbing vigorously.-After removal of loose particles surface is washed with water.-Patch-up is done at cleaned surface with non-shrink Grout conbextra GP2

It is due segregation of aggregates and mortar into the concrete. Honeycomb creates in structures due to mainly improper compaction in terms of excessive/insufficient vibration at the time of placing.

Minor Honey Combing

Major Honeycombing

Repairing Involves-The loose aggregate that are exposed shall be removed by gently tapping on it. After removal of all loose aggregate, dust, dirt etc. by wire/Soft brush then surface will be cleaned with Water. Patchup is done by using conbextraGP2/Rendroc which is mixed with cement and then the paste is applied.

Waterproofing of Structure

Chemicals used for Waterproofing

-For Priming Purpose

Master Seal M2525(Provided In two component A & B)

-Waterproofing Layer

Master Seal M800(Provided In two component A & B)

Master Seal M2525-Master Emaco 2525 is a solvent free, high-performance, versatile epoxy binder that can be used to produce a range of epoxy resin based mortars.

Used For-

Structural bonding of new to old concrete

Production of epoxy resin mortars to grout bolt holes

Steel bonding

Master Seal M800A highly elastic, solvent free, ultra-fast curing, spray applied polyurethane coating and it is used in

waterproofing applications. Master Seal M800 is a solvent free, two component substance. It is a highly reactive two component mixture used for waterproofing in tunneling and cut & cover stations

Uses-

Waterproofing compound with a setting time of 2-3seconds

Step wise Process for Waterproofing.

-SURFACE CONDITIONS

The RCC surface shall be dry before waterproofing.

Any ingress for water seepage shall be identified and treated.

Construction Joint shall be filled with high performance water stop grout of crystalline growth.

Step 1 Surface Preparation & Filling of any voids by Epoxy and Cement

-MIXING• Application of Primer Involves mixing of component A and B and application on

the surface as shown MIXING OF A & B

-Thin coat of mixed primer (RESIN + HARDNER) on the surface shall be mechanically & uniformly applied, ensuring continuous film soon after surface preparation is complete.-Moisture content in the substrate shall be less than 5 %.-The drying period of primer depends on the ambient temperature and relative humidity.

Checking moisture before application of primer.

BASF AGGREGATESBASF AGGREGATES are sprinkled over the primer layer immediately after application of the primer. Aggregates help in roughening the surface of primer for proper bonding between the primer layer and the waterproofing membrane layer.

Application of the water proofing Layer with 2 component gun

Special 2 Component gun used for applying waterproofing campound

-MasterSeal M800 is available with the Part A coloured white and the Part B colored black.

-This results in a uniform grey colour of the sprayed material thus giving the sprayer a visual control of the quality of the mixing, and machine faults become immediately obvious. If the membrane colour changes, stop spraying and check machine .

-MasterSeal M800 is normally applied at 1.5–2.0kg/SQM this corresponds to a thickness of 1.5–2.0mm.

Ponding test

Protective Covering to Waterproofing membrane

Backfilling Operations

THANK YOU!!!