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PROJECT TRAINING REPORT PROJECT TRAINING -2014 PROJECT- DMRC CC-30 Design and Construction of Twin Tunnel between Shalimar bagh and Netaji Subhash Place station by shield TBM, Twin Box Tunnel and Underground Ramp on Shakarpur site of Netaji Subhash Place station and two station namely Shalimar Bagh (Underground) and Netaji Subhash Place(semi Underground) including Architectural finishing of these two stations on Mukundpur–Yamuna Vihar corridor(Line- 7)of phase III of Delhi Metro. Contractor-HINDUSTAN CONSTRUCTION COMPANY (HCC) Topic: TUNNELING, BASE SLAB AND WALL CONSTRUCTION Training site-SHALIMAR BAGH STATION (UNDERGROUND) `

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PROJECT TRAINING REPORT PROJECT TRAINING -2014

PROJECT- DMRC CC-30

Design and Construction of Twin Tunnel between Shalimar bagh and Netaji Subhash Place station by shield TBM, Twin Box Tunnel and Underground Ramp on Shakarpur site of Netaji Subhash Place station and two station namely Shalimar Bagh (Underground) and Netaji Subhash Place(semi Underground) including Architectural finishing of these two stations on Mukundpur–Yamuna Vihar corridor(Line-7)of phase III of Delhi Metro.

Contractor-HINDUSTAN CONSTRUCTION COMPANY (HCC)

Topic: TUNNELING, BASE SLAB AND WALL CONSTRUCTION

Training site-SHALIMAR BAGH STATION (UNDERGROUND)

`

Submitted By:-

Prabhjot chawla

ACKNOWLEDGEMENT I prabhjot chawla highly indebted to Mr. Brijveer singh(Site in charge),Mr.Praveen kumar(Site engg.),Mr Aamir Haider (Site engg.) of Hindustan Construction Company (HCC) for their guidance and constant supervision as well as for

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providing necessary information regarding the project and also for their support in completing the Hindustan Construction Company (HCC) project.

I would like to express my gratitude towards members of Hindustan Construction Company (HCC) Company for their kind co-operation and encouragement which help me in completion of this project.

I also extend my heartfelt thanks to my family and well wishers.

CONTENTS:-

1. Details of project.

2. Safety considerations of project.

3. Base Slab construction:

(a).Laying of PCC.

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(b).Provision of reinforcement.

(C).Checking the reinforcement.

(d).Provision of survey points.

(e).Concreting of slab.

4. Construction of Walls:-

(a).Provision of reinforcement.

(b).Checking of reinforcement.

(c).Shuttering of wall.

(d).Concreting of wall.

5. Construction of Tunnels:-

(a).Tunnel Boring Machine(TBM).

(b).Parts and Working of TBM.

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1. Details of Project:-

This Project is DMRC CC-30 Project which includes Design

and construction of Twin Tunnels between Shalimar Bagh

and Netaji Subhash Place and construction of underground

Shalimar Bagh Metro Station.

This underground metro station construction is going at

Shalimar bagh Location. This location is heavily populated

all major construction (Fly over, Ring Road) is going at this

location. This project is named by DMRC as DMRC CC-30

The underground Shalimar Bagh Metro station has a length of 225m and width of 26m and has an extra widened portion of 39m and has excavated upto the depth of 19.5m below the ground surface. The station is excavated in the intervals of 4m depth and then a system of wales and struts are provided to support the walls of excavation. This system of wales and struts are provided after each successive excavation of 4m.Each strut has been provided with pressure gauges to measure the pressure coming on the struts from the sides of excavation. The Wales are supported on the soldier piles which are provided along the walls of excavation and wooden laggings are provide between the soldier piles to avoid the falling of soil from

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the sides. The whole station has been divided in 23 Grids from grid 1 to 23 along the length and from A to G grid along its width. These Grids may or may not have same length or width. The concrete piles are provides on two opposite walls of the station along the length through which the tunnels comes out. Out of the two tunnels one tunnel of length 1.3km starting from Netaji Subhash Place has completed and reached the Shalimar Bagh station and second tunnel has reached upto half of its length and will reach the station in 2-3 months. The base slab and the walls at the base level of the station are under construction.

225m

26m

39m

PLAN OF STATION

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DIFFRENT PICTURES OF CONSTRUCTION SITE

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PLANNING AND SCHEDULING OF PROJECT

The scheduling of the project is designed in such a way that it can be completed in a scheduled time .The schedule of Shalimar bagh station is given under this figure:-

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The above figure shows the scheduling of the project

In this chart given on the right side gives all the details regarding the project it includes all scientific and egg. Details of project for e.g. its beginning, submission of survey report, TBM details etc.

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KD14 Completion of 2nd TVF room in both the stations

KD15 Completion of TER,SCR,SER,UPS,GSM,CDMA and other operational in both stations

KD16 Completion of under croft ,cable duct cable &other service gallery in both the stations

KD17 Completion of first EFO,TOM and AFC in both the stations

KD18 Completion of civil structures fit for installation of lift and escalator from platform to concourse

KD19 Completion of second EFO,TOM and AFC in both the stations

Key date DescriptionKD1 Submission of detailed work programme with all activity for entire work

KD2 Submission of copy of agreement/LOA/purchase order of TBM

KD3 Final submission of work programme incorporating all the comments of engineer

KD4 Preliminary design submission and preliminary report of structures 30m on either side

KD5 Submission of definitive design and final report of structures of 30m on either side

KD6 Start of initial drive of TBM for 1st tunnel

KD7 Start of initial drive of TBM for 2nd tunnel

KD8 Completion of station structures fit for installation of 1st lift and 1st escalator from concourse to ground

KD9 Completion of 1st ECS in both station

KD10 Completion of track way basic structure ,access track way , including cross passage

KD11 Completion of 2nd ECS room in both stations

KD12 Completion of 1st TVF room in both the stations

KD13 Completion of 1st and 2nd ASS room in both the stations

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2. Safety Importance in Project:-

Ensuring the safety of workers during the construction works is the first priority in the execution of the construction project. Without ensuring the safety of the workers major accidents can occur during construction and the work can never be executed properly.

Causes of Accidents:-

1. Lack of Supervision.

2. Inattention of workers during work.

3. Improper or no use of PPE’S (Personal Protection Equipments) by workers.

4. Lack of information of the hazards related to the work.

5. Working on heights without using safety belts.

There are so many other reasons which can lead to fatal accidents and danger of life to the workers.

The safety of the workers is ensured by the Safety Department which always keeps an eye on the activities which includes the hazards and provides proper safety measures for carrying out the activities.

For safety of workers PPE’S (Personal Protection Equipments) are provided to the workers by safety

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department which includes safety Helmet, Shoes, Reflective Jacket, and Gloves etc.

Corrective Preventive Actions:-

1. Safe means of access and egress to be provided upto the work location.

2. Strict supervision shall be ensured for erectile activities.

3. Tool Box Talk (TBT) to be conducted before starting the job.

4. The job shall be carried out as per the agreed methodology which shall include safe access, safety precautionary measures to be taken during execution.

5. Hazard Identification Risk Assessment & Control Measures of each activity shall be discussed with the workmen through 3Q meetings & Tool Box Talks.

According to Health & Safety Department

“Better be safe than sorry afterwards”

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3. Base Slab Construction:-

The base slab of the station is under construction and a large portion of the slab has been constructed. The various steps involved in the construction of base slab are as follows:-

(a). Laying of PCC:-

After the complete excavation of the station upto the bottom, a layer of PCC (Plain Cement Concrete) of 75mm thickness was laid on the bottom soil surface on the whole station before starting the actual construction of the base slab. The main purposes of laying PCC before construction of slab are as follows:-

1. It provides a non-porous, smooth and levelled base against the undulated soil surface for laying the reinforcement of the base slab.

2. It helps the workers to set out the structure above in a easier way.

3. It acts as a cover to reinforced cement concrete and resists the corrosion of steel bars in footings.

4. It protects the RCC from absorbing moisture from soil which causes the corrosion of reinforcement.

5. It prevents foundation from underground seepage.

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(b).Provision of reinforcement:-

After laying down the PCC, the work of the reinforcement of slab started. The reinforcement was laid according to the reinforcement design drawings provided by the Design Department. These drawings are prepared by the designers according to design requirements of the slab and show the type, quantity and arrangement of steel bars in the reinforcement of the slab. Different drawings showing plan and cross-section of the slab reinforcement were provided which collectively provide all the information about the reinforcement. Different drawings were provided for the top and bottom face reinforcement of the slab. The reinforcement was provided strictly according to these drawings. All the bars in the reinforcement were properly tied with each other with steel wires so that no bar displaces from its position and required spacing remains maintained between the bars. Cover blocks were provided at the bottom face to provide proper

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cover to the slab at bottom. The top and bottom face reinforcements were properly tied to each other with the help of links which avoid the separation of top and bottom face reinforcements.

SLAB REINFORCEMENT

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(c). Checking of reinforcement:-

After providing the reinforcement according to the design drawings, the reinforcement was properly checked by the engineers that the steel bars were properly tied or not, proper lap length and development length was provided or not, proper cover was provided or not, proper links were provided or not to connect bottom and top face reinforcement. All the things were closely checked before the concreting so that no possibility of any mistake remained in the reinforcement.

(d). Provision of survey points:-

After slab reinforcement survey points were provided for determining the position of columns to be provided and after that column reinforcement was provided also the survey points were provided to level the concrete at the top level of the slab.

(e).Concreting of Base Slab:-

After properly checking the reinforcement the slab was allowed for concreting. M35 strength concrete was used for concreting of slab. The concrete used in the slab was prepared in the concrete plants and transported to the site

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in concrete mixer trucks, after arriving the concrete on the site the concrete was checked for the concrete tests like slump cone test and also the cube moulds were filled for checking the compressive strength of the concrete later and after that the concreting was done. The concreting was done with the help of machine called Boom Placer also known as Trailer-mounted boom concrete pump because it uses a remote controlled articulating robotic arm called boom to place concrete precisely. The concrete from the concrete mixing truck was fed into the boom placer which pumps the concrete to its place for concreting. During concreting the concrete was properly compacted with the vibrators and properly levelled. After concreting proper curing of slab was done.

BOOM PLACER

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4. Wall Construction:-

(a).Provision of reinforcement:-

As that of slab wall reinforcement was also provided according to the wall reinforcement design drawings. Different drawings including cross-section of wall reinforcement, elevation of wall reinforcement were provided according to which all the reinforcement of wall was provided. Different drawings were provided for inner face and soil face reinforcement of wall. The thickness of the walls in the whole station is 1m.Above wall construction joints the reinforcements of walls was extended above with the help of couplers or by providing proper lap length to the bars extending out from the wall construction joint. The soil face and inner face reinforcement was properly tied with the links & cover blocks were provided on both faces to provide required cover to the walls.

(b).Checking of reinforcement:-

After provision of reinforcement the wall reinforcement on soil and inner face was closely checked by the engineer that both the wall faces were properly tied with links or not, proper lap length was provided to bars or not, couplers were provided properly or not and required cover is available or not on both sides. After complete checking of

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reinforcement the reinforcement was allowed for shuttering.

Wall Reinforcement

(c).Shuttering of wall:-

After checking of reinforcement, shuttering of wall was done. Shuttering was done with the shuttering panels of size 4.88m×3m.Shuttering panels were the plane wooden boards fixed over the channel sections. For shuttering these panels were smeared with oil and stand against the wall reinforcement and aligned properly to ensure that the panels were completely vertical or not. After proper alignment, the panels were firmly supported on both sides

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of wall. After fixing the shuttering panels on both sides of the wall, tie rods were inserted into the shuttering panels from one side to other side and fixed on both sides of panels. Tie rods were provided on the lower portion of the wall to support the shuttering panels at lower portion so that panels do not displaces from the bottom portion during concreting of wall. These tie rods were covered with PVC pipes before inserting so that tie rods could be easily removed from the wall after concreting of wall. After completion of shuttering the wall was allowed for concreting.

Wall Shuttering

(d).Concreting of wall:-

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After completion and checking of the shuttering the wall was allowed for concreting.M35 grade concrete was used for concreting of wall. The concrete was prepared in the concrete plants and transported to the construction site in concrete mixer trucks and then concreting was done with the help of concrete pump called Boom Placer. The concrete in the wall was properly compacted with the vibraters. After concreting and drying of concrete proper curing of the wall was done.

Wall casting in progress

5. Construction of Tunnels:-

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Hindustan Construction Company (HCC) has completed the first tunnel of Delhi Metro Rail Corporation’s Line 7 of phase 3.The underground tunnel between Netaji Subhash Place to Shalimar Bagh, the cc-30package of DMRC is part of 59km long Majlis Park to Shiv vihar Metro corridor of phase 3.

The tunnel boring began in October 2013 using Earth Pressure Balance Shields Tunnel Boring Machine. The TBM completed 1,247m long tunnel from Netaji Subhash Place to Shalimar Bagh consisting of 1,037 rings with diameter of 5.7m in 111 days. The average monthly boring progress achieved during the construction was 337m with installation of over 9 rings per day. The tunnel Break-Through took place in March 2014.

The tunnel crossed the elevated viaduct of currently operational Dilshad Garden-Rithala Metro corridor near Netaji Subhash Place, which was a major engineering challenge. The tunnel also crossed the flyover which is in progress currently right above the tunnel on the ring Road at Shalimar Bagh.

The 59km long Majlis Park-Shiv vihar corridor of phase 3 consists of about 14kms of underground lines. Presently five other TBM’s are working in different parts of the corridor across the city.

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The second tunnel from Netaji Subhash Place to Shalimar Bagh is under construction and is in progress at the same rate as that of the first tunnel. The tunnel has reached in its half way and will be completed in incoming 1 or 2 months.

TUNNEL CONSTRUCTION

(Right tunnel is under-construction)

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TUNNEL BORING MACHINE (TBM)

A TBM is a device or can be call a machine which is used for constructing a long tunnel under the ground surface.This machine is also called as mole .This machine can bore through anything from hardrock to sand.

SIZE(DIAMETERS)

Tunnel diameters can range from a meter to 19.25m to date.Some tunnels whose sizes are less than 1meter are done using trenchless construction.

ADVANTAGES

1.It limits the disturbances to the sorrounding ground and producing a smooth tunnel wall .

2.It reduces the cost of the lining of the tunnel and make them used suitably in heavily urbanized area.

3.Less risky to humans and very less technician and labour is required to maintain it.

DISADVANTAGES

1.This advance machine is very costly about $80 million approx.

2.It can drill about 6meter in a whole day.

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LAYOUT OF TUNNEL BORING MACHINE

Here’s the Layout of the TBM gives the complete details of the TBM a moving belt is there in which soil is excavated out. A movable trailer is there in which soil is collected.

SECTION OF TUNNEL

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PARTS AND SPECIFICATIONS OF TBM

1.SHEILD: It has a diameter of 6410mm and has length of 3275mm.it weighs 690kn.It is of EPB type. It has articulated tail skid. Gate for screw conveyor is at pressure bulkhead.

2.TAIL SKIN: It has diameter of 6400mm.It has length of 2915mm and has 8no. Of grease line. Its weight is 180kn.

3.CUTTING WHEEL: It is of scrappers bucket type. It rotates in both the direction and has diameter 6410mm.weight is 43.5kn.

4.CUTTING WHEEL DRIVE: It is of hydraulic ring drive type there are 4 hydraulic motor. Maximum torques is 4377knm.rotational speed from 0 to 12 RPM.Operating pressure 310 bar. Electrical power 640kn.Outside diameter of main bearing .weight is 275 kn. Rotary union is 1.

5.SCREW CONVEYOR: These are of screw spiral type. Diameter is 770mm.Maximum torque is 195 knm and maximum speed is 0 to 17 RPM. Weight is 180 kn.

6.CONVEYOR BELT: It has electrical drive belt, width and length are 800mm and 40mm and has speed of 2.2m/s.

7.GROUTING: GROUT batching plant produces 3m3 for each advancement of TBM.

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GROUT MIX DESIGN:-

Materials Kg/m3 For 0.25m3 batch

For 3m3 batch

Cement 300 75 900Flyash 450 112.5 1350Sand 108.57 271.4 325.71Bentonite 18 4.5 54Admixture 3.75 .9375 11.25Water 359.3 89.825 1077.9

Grout is poured into the grout car and is directly sent to the launching shaft on rail line.