MUMBAI METRO RAIL PROJECT .

National Institute Of Construction Management And Research

2

CONTENTS

Introduction.

Project Details.

Study Of Tender Documents.

Time And Motion Study.

Construction And Methodology.

Resource Utilization.

4

Introduction

Present Traffic Scenario:-

1. Rail- 48% , Bus- 44% & Private Vehicles - 8%.

2. Inadequate road network.

3. Suburban rail traffic increased by 6 times while the capacity increased by

only 2.3 times.

4. 4500 passengers travel per train against the carrying capacity of 1750 resulting

an unbearable overcrowding

5. Vehicular growth Increased from 61,000 to over 1.02 Million in the last four

decades.

N E E D

Existing suburban systems under extreme pressure Existing bus system’s role limited to providing feeder services to

railways. Bus system alone cannot meet the future demand Constraints to expand the existing road network capacity The Road & Rail improvements not adequate for future demand Many pockets in Island city and suburbs not served by rail based

mass system. Environmental deterioration due to growth in road traffic

W H Y

• it has high-capacity • ...it is fast • ...it is environment-friendly • ...it is financially viable and economical • ...and is attractive to the commuters

A D V A N T A G E S

Carries same amount of traffic as 6 lane bus or 26 lane Private cars (Either way).

Reliable, Comfortable and Safe Reduces time by 50-75% as compared to road No Air pollution and less noise levels Energy efficient; Consumes 1/5th Energy per road

passenger km. Occupies no road space if underground and only about 2m

width of road if elevated

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Mumbai Metro Rail Master Plan:-

Phase I (2006 – 2011) Versova-Andheri-Ghatkopar - 11.07Km

Colaba-Bandra-Charkop - 38.24Km

Bandra-Kurla-Mankhurd - 13.27Km

Total - 62.68 Km 

Phase II (2011 – 2016) Charkop-Dahisar - 7.5Km

Ghatkopat-Mulund - 12.4Km

 

Phase III(2016 – 2021) BKC – Kanjur Marg via Airport - 19.5Km

Andheri (E)-Dahisar (E) - 18Km

Hutatma Chowk-Ghatkopar - 21.8Km

Sewri-Prabhadevi - 3.5Km

Total Length - 146.5Km  

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SIGNIFICANCE (V-A-G)

Provides East-West rail based connectivity to Central and Western suburbs.

Facilitates smooth and efficient interchange between suburban rail system and MRT System at Andheri and Ghatkopar stations.

Reduces the journey time from 71 minutes to 21 minutes, between Versova and Ghatkopar .

Provides rail based access to the MIDC, SEEPZ and commercial developments .

12

13

CAR DEPOT

VERSOVA CAR DEPOT (AREA 13.8 HA)

Stabling

Routine maintenance

Periodic maintenance

Workshop

Offices and storage

TECHNICAL DETAILS

Cab signaling with Automatic Train Protection.

Traction - 25 Kv Ac OHE Rolling Stock with all advanced features Train control With Driver Ticketing system - Automatic Collection Train Composition – Four/Six Coaches No. of Classes - Single Class

TECHNICAL DETAILS

Environment - Air Conditioned Max. Speed - 80 kmph Average Speed - 33 kmph Acceleration - 1.0 m/sec2 Deceleration - 1.2 m/sec2. Frequency (2009)- 4 min ,(2031)- 3 min. Carrying Capacity/rake -1500 Pax. System Capacity – 60,000 pphd Total Journey Time 21 min Approx

TECHNICAL DETAILS

Gauge (Nominal) 1435mm Route Length (Elevated 31.87 Km

between  dead ends) Number of stations Elevated 27 Nos. Rolling Stock

3.20 m wide & 22mts length modern rolling stock with   stainless steel body Axle load 15 t Seating arrangement Longitudinal Capacity of 4 coach unit 1178 Passenger

PASSENGER SECURITY AND INFORMATION SYSTEM

The passenger security and information system would manage the MRTS passenger related functions.

OPERATION CONTROL CENTRE (OCC)

To supervise the passenger areas and trains,

To provide visual information to passengers and at stations.

To provide one way communication from Operation Control Centre to the passengers at stations through Public Announcement (PA) system. CLOSED CIRCUIT TELEVISION (CCTV)

System monitoring the stations and emergency call points on the stations. DYNAMIC VISUAL DISPLAYS AND LOUDSPEAKERS.

CCTV cameras, loudspeakers, and information displays will be provided.

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Project Details

Type Of Design:- 1. SUB-STRUCTURE: Pier with pile foundation

2. SUPER-STRUCTURE: Pre-cast segmental girders

 

No. Of Piles: 1680 NOS. 1. DIA. OF PILES: 1000, 1200, 1500 mm

2. LENGTH: 12 TO 18 M

No. Of Pile Caps: 457 NOS. 1. LENGTH: 4.5 To 11.5 M

2. WITDH: 4.5 To 11.5 M

3. DEPTH: 1.8 To 2.5 M 

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NO. OF PIER: 457 NOS. 1. HEIGHT: 10 M

2. LENGTH – 2 M

3 WIDTH – 3 M

4 DIAMETER- 1.75 To 2.25 M

No. Pier Caps: 457 NOS.

 

No. Of “U” Girders: 747NOS. (PRECAST SEGMENTAL GIRDERS)

Bearing: Elastomeric Bearing.

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Project Tender Documents

Requirement To Contractor:- Passengers Per Day – 45000

Speed – 33Km/hr.

Time Interval – Less than 120sec.

Distance Of V-A-G Corridor – 11.4Km.

No. Of Stations – 12.

The total cost of the project will

be around Rs. 4,57,52,00,581.35 /-

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Contractors For Work

Package Awarded to

Civil Works – Viaduct Simplex Infrastructure Ltd

Civil Works – Stations Sew Infrastructure Ltd

Civil Works – Special Bridges Sew Infrastructure Ltd

Civil Works – Depot Earthworks Shyam Narayan & Bros

Rolling Stock CSR Nanjing, China

Signaling System Siemens

Power Supply Traction & SCADA ABB

Communication System Thales

Track work VNC Rail One

Automatic Fare Collection Indra

E&M ABB

Escalators Schindler

Lifts OTIS

Depot Machinery & Plant Awarded to various suppliers

Depot Civil Works Ahluwalia Contracts (India) Ltd.

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Funding Arrangement:-

69%

5%

26%

% Share

Reliance Energe Ltd.

Veolia Transport, SA, France

MMRDA

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Basic Details:-

The contract here is executed between MMOPL and SIMPLEX INFRASTRUCTURES

LTD.

The contract was issued to SIMPLEX INFRASTRUCTURES LTD on 28/02/2008.

Estimated value of the project by MMOPL was 457.52Cr. INR.

Bid security was to be paid off, of amount 21Cr. approximately.

The project has to be completed within the stipulated time period of 22 calendar months

or else the contractor has to pay the penalty.

The total length of Viaduct under this project is 11.343 km.

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SALIENT FEATURES

Name Of Project Construction of Viaduct VA & VB

Name Of Employer Mumbai Metro One Private Limited

Name Of Contractor Simplex Infrastructure Ltd.

Name Of Consultant PB – Systra

Name Of Designer PB – Systra

Tender Value Rs.457.52Cr

Project Value Rs.2356Cr

Type Of Contract Unit Rate Contract

Project Duration 22 Months.

Route Length - 11.07 km

Elevated Alignment- 100 %

Maximum Gradient- 4.0%

Minimum Curvature - 100 m

Minimum Ground Clearance - 5.5 m

No. Of Stations - 12

Platform Length - 135 m

Car Depot - D.N Nagar

Length Of Coach - 22 m.

Width Of Coach - 3.2 m.

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LAYOUT OF WADALA CASTING YARD

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WORK BREAKDOWN STRUCTURE

Mumbai Metro Rail Proj.(Construction of VA & VB in

V-A-G corridore)

Foundation

Open Foundatio

n

Pile Foundatio

n

Sub Structure

Pier

Anticrash Barri

er

Pier Cap

Superstructure

Bearing U-Girder

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PROJECT ORGANIZATION CHART

General ManagerMr. Ajit Singh

QA/QC Incharg

eMr. Suman

Casting Yard

Incharge

Mr. Umakant

Dube

VA-Section Incharg

eMr.

Dipak Tiku

VB Section Incharg

eMr. I. Saha

Erection Incharg

eMr. S.

Adhikari

Planning &

Billing Incharg

eMs.

Vidya Murugan

Survey Incharg

eMr.

Karol Adak

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TIME AND MOTION STUDY

Pile Boring:-

Sr. No. Work Description Number of labour

Number of days Equipment/ Machinery used

1 Pavement quality concrete breaking 2 1 Diamond cutter

2 Excavation up to 2.5 m 8 2 Back hoe loader, Dumper

3 Utility checking 2 1

4 If utility found then utility shifting 2 1

5 Marking pile location 3 1/2 Auto level/ Total station

6 Initial boring with soil auger 2 2 hr Pile boring rig,

7 Temporary Pile case/linear insertion 2 1 hr Pile boring rig,

8 Soil/Rock auger boring 2 1 Pile boring rig,

9 Muck removal 2 1 Back hoe loader, Dumper

31Hydraulic Boring Rig Machine

Soil Auger

Rock Cutter

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Pile Reinforcement Work:-

Sr. No.

Work Description Number of labour

Number of days

Equipment/ Machinery

used1 Reinforcement cutting and

bending3 2 Bar bending

and Bar cutting machine

2 Reinforcement anti-corrosive treatment

3 1/2

3 Reinforcement cage preparation

4 1

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Pile Concreting:-

Sr.

No.

Work Description Number of

labour

Number of

days

Equipment/

Machinery

used

1 Reinforcement cage shifting 4 3 hr Hydraulic

crane and

truck

2 Reinforcement cage

insertion in bore hole

4 1 hr Crane

3 Pile concreting with tremie

pipe

4 1 Tremie pipe,

Transit mixer

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Pile Cut-Off Level:-

Sr. No.

Work Description Number of labour

Number of days

Equipment/ Machinery used

1 Extraction of temporary pile casing

2 1/2 Crane

2 Temporary backfilling with approved material

3 1/2

3 Cutting off pile heads (manually)

8 3 Hammer and chisel

4 Disposal of excavated material

4 1 Back hoe loader, Dumper

5 P.C.C. up to pile cut off level 4 1 Transit mixer and needle vibrator

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Pile Cap:-

Sr.

No.

Work Description Number

of

labour

Number of

days

Equipment/

Machinery

used

1 Reinforcement cutting and

bending

4 2 Bar bending &

cutting machine

2 Reinforcement anti-corrosive

treatment

3 1/2

3 Reinforcement cage preparation 6 3

4 Shuttering work for pile cap 4 2

5 Concreting of pile cap 8 1 Transit mixer

and needle

vibrator

6 Deshuttering of pile cap after 2

days

4 1

7 Curing of pile cap for 7 days 1 7

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PILE CAP REINFORCEMENT BINDING

PILE CAP SHUTTERING WORK

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Pier Starter:-

Sr.

No.

Work Description Number of

labour

Number of

days

Equipment/

Machinery used

1 Reinforcement cage

preparation

5 1

2 Shuttering work for pier

starter

4 1/2 Hydraulic crane

3 Concreting of pier starter with

the help concrete pump

4 3Hrs Transit mixer,

Needle vibrator,

Concrete pump

4 Deshuttering of pier starter

after 2 days

2 2 Hrs Hydraulic crane

5 Curing of pier starter for 7

days

1 7

38

Shuttering Of Pier Starter

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Pier CONSTRUCTION:-

Sr.

No.

Work Description Number of

labour

Number of

days

Equipment/

Machinery used

1 Reinforcement cage

preparation

8 1.5

2 Shuttering work for pier 6 1 Hydraulic crane

3 Concreting of pier with the

help concrete pump

4 1 Transit mixer,

Needle vibrator,

Concrete pump

4 Deshuttering of pier after 2

days

2 2 Hrs Hydraulic crane

5 Curing of pier starter for 7

days

1 7

40

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Anti-Crash Barrier:-

Sr.

No.

Work Description Number of

labour

Number of

days

Equipment/

Machinery used

1 Reinforcement cage

preparation

3 1

2 Shuttering work for Anti –

crash barrier

3 2Hrs Hydraulic crane

3 Concreting of Anti – crash

barrier

2 1/2 Transit mixer,

Needle vibrator

4 Deshuttering of Anti – crash

barrier after 2 days

2 2 Hrs Hydraulic crane

5 Curing of Anti – crash barrier

for 7 days

1 7

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Pier Cap:-

Activity Name No. Of

Labour

No. Of Days Equipment Or Tools

Req.

Reinforcement Cutting Bending 11 2 Days Bar bending & Bar

cutting machine

Reinforcement Cage Preparation 11 2 Days

Shuttering Soffit Leveling (Base) 5 1 Days

Shutter Alignment 4 1 Days

Cage Shifting Over The Shutter 3 ½ Hour Gantry

Shutter Fixing 4 1 Day

Gangway Preparation On Slab Of

Girder For Concreting

2 ½ Day

Concreting 6 3 Hours Transit Mixer, Boom

Pressure & Vibrator

Curing 1 21 Days

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REINFORCEMENT CAGEPREPARATION

PIER CAP STACKING YARD

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SHIFTING & FIXING OF PIER CAP ON PIER NECK

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Activity Name No. Of Labour No. Of Days Equipment Or

Tools Req.

Reinforcement Cutting Bending 30 2 Days Bar bending and Bar

cutting machine

Reinforcement Cage Preparation 30 3 Days

Shuttering Soffit Leveling (Base) 12 1 Days

Outer Shutter Alignment 12 1 Days

Cage Shifting Over The Shutter 4 lab.& 2 gantry opt. ½ Hour Gantry and truss to

hold cage

Inner Shutter Fixing 10 1 Day

Strand Cutting & Fixing(Threading) 20 2 Days

Slackness Removal Of Strand 5 lab. & 1 opt. 1 Hour Stressing jack

Prestressing Of Strands 3 lab. & 1 opt. 2 Hours Stressing jack

Gangway Preparation On Slab Of Girder For

Concreting

6 ½ Day

Concreting 16 lab. & 4 meson 6 Hours Transit Mixer, Boom

Pressure & Vibrator

Curing 2 21 Days

U-Shaped Girder:-

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LIFTING OF REINFORCEMENT CAGE

PRE-STRESSING OF “U” GIRDER

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CONCRETING OF “U’ GIRDER HEAVING OF CONCRETE

LIFTONG AND SHIFTING OF ‘U’ GIRDER TO STACKING YARD

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Construction Methodology Of Piling:-

50

Construction Methodology Of Pile cap

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Construction Methodology Of Pier

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Construction Methodology Of Pier Cap

Reinforcement Cutting & Bending

Anti corrosive treatment

Reinforcement Cage Preparation

Shutter Leveling(Base)

Side Shutter Alignment

Cage Shifting Over The Shutter

Fixing Pipes for post tensioning

Checking of reinforcement &

shutteringConcretingCuring on

casting bed

Deshuttering

53

Construction Methodology Of U-Shaped Girder

Reinforcement Cutting & Bending

Anti corrosive treatment

Reinforcement Cage Preparation

Shuttering Sofit Leveling(Base)

Outer Shutter Alignment

Cage Shifting Over The Shutter

Fitting Inner Shutter

Strand Cutting & Threading

Slackness removal of Strand

Pre stressing

Concreting

Deshuttering

Curing

Shifting Girder to Stacking Yard

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RESOURCE UTILIZATION

Cement Slurry

M15 M25 M35 M40 M45 M550

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

52.5 Cum155.5 Cum

246.25 Cum

1591.5 Cum

14 Cum

465.25 Cum

561 Cum

Consumption of Concrete in May-2009

Grade of Concrete

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Cement Slurry M15 M25 M35 M40 M45 M550

50

100

150

200

250

300

350

400

450

500

5 Cum

39 Cum23 Cum

485.25 Cum

71 Cum93.5 Cum

0 Cum

Consumption of Concrete in June up to 09/06/2009

Concrete in Cum

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Utilization Of Steel:-

8mm Steel 10mm Steel 12mm Steel 16mm Steel 20mm Steel 25mm Steel 32mm Steel0

10

20

30

40

50

60

70

80

5.343MT

29.252MT25.031MT

70.736MT

60.167MT

47.948MT

62.914MT

Utilization of Steel in May

Steel Utilization

57

Casting Yard JB Nagar Varsova0

100020003000400050006000700080009000

100008685

4676

6707

Manpower Utilization

Utilization of Manpower from 07/05/2009 to 06/06/2009

Utilization of Manpower

58

7/5/..

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27/5/..

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31/5/..

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2/6/..

.

4/6/..

.

6/6/..

.0

50

100

150

200

250

300

350

400

Casting YardVersovaJB Nagar

Daily Utilization of Manpower

59