Project Report: Mumbai Metro

MUMBAI METRO RAIL CORPORATION (MMRC)

PROJECT TRAINING 2020

FINAL COMPREHENSIVEREPORT (FCR)

MUMBAIMETROLINE-03,UNDERGROUND CONSTRUCTION PACKAGE-02

COLABA-BANDRA-SEEPZ

SUBMITTED BY : BHUMIKA RAJ (UC5316)

GUIDED BY: PROF.: RESHMA SHAH

TEACHING ASSISTANT : MAYURIKA

BACHELORS IN CONSTRUCTION TECHNOLOGY

Certificate of Approval

This is to certify that Miss Bhumika Raj, Code No. UC5316, undertaking Project Training course offered in Spring Semester, academic year 2019-20 has satisfactorily completed training on site Mumbai Metro Line 3 UGC02, Mumbai and submitted final comprehensive report that broadly satisfies the training requirements.

Signature of Faculty:

Name of Faculty Incharge: Prof. Reshma Shah

Date:

T +91 7926302470

DECLARATION

I hereby declare that the project training report submitted to the Faculty of Technology, CEPT University is a record of an original work carried out by me on project training site Mumbai Metro Line-03, UGC 02 at Mumbai Maharashra. further declare that the material obtained from other sources has been duly acknowledged in the Report. I shall be solely responsible for any plagiarism or other irregularities, if found in the report.

Signature of student:-

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ACKNOWLEDGEMENT

I would like to express my deepest gratitude to my reporting officer, Mr. Abhijeet Chaudhary (Asst. General Manager, MMRC), whose contribution in stimulating suggestions and encouragement, helped me to coordinate my project especially in curating this report.

Also I would like to extend my thanks to Mr. Mukul Borah (R.E. MAPLE) who helped me to complete my report as well as took their precious time to explain and guide me. A special thanks goes to Mr. Avinash who patiently provided with all the information. Finally, many thanks go to the Chief Project Manager, Mr. Ravi Ranjan Kumar; Deputy General Manager, Mr. S. G. Dalvi; and Deputy Engineers, Mr. Rohan Shiral and Mr. Ranjit Deore whose have invested their full effort in guiding me in achieving the goal.

I appreciate the guidance given by my faculty Prof. Reshma Shah as well as the our Teaching assistant Mayurika as their continuous monitoring and feedbacks during the internship period helped me in overcoming my setbacks.

Bhumika Raj UC5316

CEPT University, Ahemdabad

This subject called Project Training Report has been made in requirement of BCT [Bachelor’s in Construction technology] in Civil-Construction from Faculty of Technology, CEPT University, Ahmedabad; in the 8th Semester of this course. It is a 10 semester course in which along with theoretical study, equal emphasis is laid on practical study and experience.

Project Training was a 16 week long intensive training program where emphasis was laid on study of Construction Technology, including method of construction, use of equipmentplants, productivity and related management aspects. The structure of training was for me to take up major constructions activity unique to the project and study them in detail, dedicating minimum three weeks of time to each report. It has total 5 reports ( 1 Preliminary Site Report (PSR) + 4 Construction Activity Report (CAR). Effort has been made to cover all the major aspect of construction, including planning and management for each of the construction activity studied which is Part one.

Also due to Covid-19 few days were left for training so 4 tasks were allotted to us including a sketch up model to work from hom which is Part two.

This Project Training has been a great learning experience towards understanding the functioning of such a huge Project with involvement of multiple agencies and the challenges in coordination, planning and execution.

Time Sheet

Project Training | Faculty Of Technology |Spring 20

PART 1 CHAPTER 1: INTRODUCTION TO PROJECT

2 METRO PROJECT IN A NUTSHELL

The Aqua Line of the Mumbai Metro, also known as Line 3 or the Colaba–Bandra-SEEPZ line, is a part of the metro system for the city of Mumbai, India of which construction has been initiated. When completed, the 33.5-km long line will be the first underground metro line in Mumbai

Though 2,150 trains hurtle through the city, carrying millions of Mumbaikars to their destinations but for the 75 lakh odd commuters, every day brings with it the challenge of searching for foot-space in a train that cannot hold a pebble more. Time has truly come for ‘the lifeline’ of Mumbai to now change to Metro –a grade separated rail based Mass Rapid Transit System

Mumbai Metro Line - 3 (MML - 3) is one of such key projects to improve the transportation scenario in the financial capital of India i.e. Mumbai. MML-3 project - a 33.5Km. long corridor running along Colaba-Bandra-SEEPZ, envisages to decongest the traffic situation in Greater Mumbai. Mumbai Metro Rail Corporation Limited (MMRC) is the nodal agency responsible for the implementation of Mumbai Metro Line–3(MML-3) project. It has been constituted as a JV of the Govt. of India(GOI) and the Government of Maharashtra(GOM) on 50:50 sharing basis.

AIM : CONNECTING THE UNCONNECTED

FIGURE 1: MAP SHOWING ALL STATIONS

METRO

Since the beginning of rapid transit systems 154 years ago in London’s Metro Railway, metro rail systems have advanced to most recent and updated technologies that took place in past 30 years. Almost a quarter of world’s 150 metro cities have at least one line operating in fully automated mode. Automation in metro is significantly seen in Europe, Middle East and China

2.2 BENEFITS OF THE PROJECT

Environmental benefits :There is expected to be reduction in air pollution, and improvement in air quality. MML-3 is committed to preserve the environment. As commuters would start to prefer the comforts of metro over other conventional transport options.

Travel with comfort: Today suburban trains are overcrowded, carrying 5000 passengers against design capacity of 1750. Metro 3 is expected to reduce the load by nearly 15%. Since the entire train will be air-conditioned, commuters will be saved from noise/dust pollution and will be able travel with better comfort

Revisiting History : The present travel time of 100 minutes from Cuffe Parade to Airport will come down to only 50 minutes due to MML-3

Economic Benefits: MML- would be uniquely positioned to attract more business investments and is also expected to result in employment generation during and after constructiom

2.1 AUTOMATED

(reference Mumbai metro magazine vol. 3)

FIGURE 2: AUTOMATED METRO DETAILS

MUMBAI METRO LINE 3 –

PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

2.3 ORGANISATION CHART

MMRC ( EMPLOYER)

MAPLE (GENERAL CONSULTANTS)

PACKAGE 1&7 (L&T) ANS SHANGHAI TUNNEL ENGINEERING CO.

PACKAGE 2 HCC AND MOSCOW MOSMETROSTROY

PACKAGE 3 DOGUS AND SOMA

PACKAGE 4 CONTINENTAL ENGCORP.,ITD CEMENTATION AND TATA PROJECTS

PACKAGE5 &6

J KUMAR INDRA PROJECTS AND CHINA RAILWAY RUNNEL GROUP

CST STATION CHATTRAPATI SHIVAJI TERMINUS

KALBADEVI STATION

GIRGAON STATION

GRANT ROAD STATION

Note MAPLE is a consortium of 4 different companies :AECOM-LEAD, PAEDCO,LOUIS BERGER,EGIS FURTHER DIVIDED INTO :L1-FOREIGNER HIGHEST DIVISION L2-FOREIGNER L3-IDIANS AND FOREIGNERS L4-L5-INDIANS

2.4 Roles and responsibilities

AUTHORITY NAME

MUMBAI METRO RAIL CORPORATION

RESPONSIBILITY

Over all supervision of metro station works and tunnel Dealing with different departments like traffic,BMC for completion of project

GENERAL CONSULTANTS

CONTRACTORS

Supervision of over all metro construction ,providing drawing and weekly progress report to client

Excecuting the metro work as per terms and conditions of client

Kasturbhai Lalbhai Campus University Road, Navrangpura

Ahmedabad – 380009, Gujarat

T +91 7926302470

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STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

2.5 DETAILS OF THE PROJECT

NAME – Package 2, Line 3 (underground), Mumbai Metro

OBJECTIVE – To construct two parallel underground tunnels by using TBM (Tunnel Boring Machine) for Mumbai metro line 3 including four stations – CST Metro, Kalbadevi, Girgaum and Grant Road.

SITE OFFICE ADDRESS – Gate 3, Azad Maidan, Nr. Metro Cinema, Mumbai – 400001, Maharashtra

SCOPE OF WORK – Design and construction of Underground Stations namely CST Metro, Kalbadevi, Girgaum and Grant Road and Twin Tunnel between CST and Mumbai Central – Up Line (from Ch. 3770.58 m to Ch. 7842.62 m) and Down Line (from Ch. 3801.05 to Ch. 7860.22 m) by TBM including Scope of works comprising of Civil, Architectural, E&M works as defined in agreements.

PROJECT TYPE – EPC (Engineering, procurement and construction) Contact. EPC Contractor is responsible for all activities engineering, procurement and construction and hand – overs the project to the owner.

LENGTH OF PROJECT:CST METRO STATION – 255 m ,KALBADEVI STATION – 208 m,GIRGAUM STATION – 292 m,GRANT ROAD STATION – 202 m.NORTH BOUND (Downline) TUNNEL LENGTH – 3115 m SOUTH BOUND (Upline) TUNNEL LENGTH – 3102 m TOTAL LENGTH OF TUNNELS – 6217 m

CLIENT – MMRC (Mumbai Metro Rail Corporation Limited)

CONTRACTOR – HCC – MMS JV ( Joint Venturebetween Hindustan Construction Company and Mosmetrostroy). (HCC – 74% and MMS 26%)

 Start date – 18th july, 2016

 Project completion date – 10th january, 2021

 Duration of project (as per contract) – 1638 days

 Tender project cost – rs. 2115.3 crores

 Muck disposal site – mhape midc and ambernath

 Mean sea level -25

 Track gauge- Standard Gauge (1435 m)

 Design speed- 80 kmph,

 Scheduled speed- 30 kmph

 Capacity of 8 coach unit- 2406 passenger

T +91 7926302470

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MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

CONSULTANTS

GENERAL – MAPLE (Joint Venture - AECOM, PADECO, LBJ Inc. & Egis Rail)

DDC (Detail Design Consultant) - Ayesha

LDC (Lead Design Checker) – Amber

Detail DesignConsultant (AYESHA). They design the project

Lead DesignConsultants

If there are any mistakes, the Checker designs are again sent back to DDC (AMBERG)If everything is right, issues a Design Certificate

2.6 COST BREAK UP

HCC-MMS

They also have a design team that checks the designs

COST BREAK UP

GeneralConsultants(MA PLE) also check the designs and issues NONO (Notice of no ection) if design is right

EXECUTION

GRANT ROAD-MMCT

Girgaon Station to Grant Road Station

Kalbadevi Station to Girgaon Station

CST Station to Kalbadevi Station

grant road

Girgaon Station

PIE CHART 1: DEPICTING COST BREAK UP OF TUNNELS IN ALL STATIONS.

Kasturbhai Lalbhai Campus University Road, Navrangpura

Ahmedabad – 380009, Gujarat

T +91 7926302470

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MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

2.7 PROJECT LOCATION

LENGTH OF PROJECT

CST METRO STATION – 255 m

KALBADEVI STATION – 208 m

GIRGAUM STATION – 292 m

GRANT ROAD STATION – 202 m

Seismology: As per India times data, Mumbai lies in Seismic Zone-3, which is Moderate seismic zone. It can withstand up to 6.5 Richter scale earthquake intensity.

 All the four stations under package 2 are completely different

NORTH BOUND (Downline) TUNNEL LENGTH – 3115 m

SOUTH BOUND (Upline) TUNNEL LENGTH – 3102 m

TOTAL LENGTH OF TUNNELS – 6217 m

 The type of geological strata of all four stations is completely different.

 Cst has hard rock so its depth is less compared to other stations

 The neighbouring locality also varies,example kalbadevi is a densely populated with many heritage structures like parsi temple and many more while girgaum is located near beach and is one of the high end localities of Mumbai,CST Chattrapatati Shivaji terminus

 The depth of each station varies with quite a difference.

 With so much variation in each station, much more learning can be carried out

FIGURE 3: MAP SHOWING ALL THE STATIONS

FIGURE 5: ALIGNMENT PLAN

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02 STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

Bhumika Raj (UC5316) Semester-08

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

2.9

MMRC ORGANISATION CHART Director of Project

Mr. Subodh Gupta Mr. Ravi (Package - 2)Ranjan

Kumar

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

CLIENT ORGANISATION CHART

Deputy General Mr. S. G Dalvi. Assistant General

Mr. Abhijeet Chaudhary

Deputy Engineer Mr. Ranjit Deore

Deputy Engineer Mr. Rohan Shiral

BHUMIKA RAJ (INTERN)

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

2.10 CONSTRUCTION METHODOLOGY ADOPTED FOR THE PROJECT TEMPORARY STRUCTURES

SECONDARY PILE SHOWING REINFORCEMENT

PRIMARY PILE

OVERLAPPING IS DONE TO STOP THE WATER INGRESS

Secant piles act as retaining structures and are used to support weaker strata and to stop the water ingress. Also guide walls are not used at CST station because of the hard rock strata requires different machinery and is does not turn out to be economical.While at other metros across the country diaphragm walls are used because of the soft soil conditions.(Refer piling report pg 28)

2.11 STATIONS

Secant piling is done on the periphery of the station and construction work is carried out

Traffic decking is done and supported by king post on one side and utility diversions are provided

Cst Station :bottom up approach , off road

Kalbadevi Station : natm on the road

Girgaon Station: on the road , bottom up

Grant road Station : on the road. Bottom up

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

2.12 TUNNELS –

Two tunnels are being dug by using Tunnel Boring Machine (TBM). TBMs are named after Vaitarna river (Vaitarna 1 and 2).

Cost -60 croresThe first of these was a 6.68m diameter dual-mode hard rock TBM (T58) that will be one of two new machines deployed by the Hindustan Construction Company – Moscow Metrostroy JV to build the twin tunnels on the line’s 4.049km UGC-02 contract (Chhatrapati Shivaji Terminal Station – Mumbai Central Station), which was awarded by the Mumbai Metro Rail Corporation Ltd (MMRCL) in July 2016.

Procurement

Dual Modesingle shield (hard rock)

2.13 WHY NATM:

After design and production, TBM will be assembled and tested for factory acceptancetest before shipment from China to Mumbai

Also called (New Australian Tunelling Method)Used to widen the tunnel using explosives, used when there is space constraint or In case of widening the tunnel.NATM requires high expertise as it include drilling and blasting using explosives.(refer natm report pg no.61)

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

Figure 6: process of natm is shown in above image.

2.14 Contract conditions

At package 2 –HCC –MMS (CJV) total 12 volumes are available for contracts, each cobering differnet aspects of contracts management.

TABLE 1: CONTRACT CONDITIONS

5

6

7

8

Arbitration :If both the parties don’t resolve the issue mutually it is referred to indian arbitration and reconciliation act , 1996.Total 3 arbitrators are appointed .One from each party and both one presiding arbitrator shall be appointed by both arbitrators and the decision of the arbitrator shall be final

Repayment amortisation of advance payment:The recovery of mobilisation and plant and machinery advances will be completed by the time 85% of the accepted contract amount has been paid or by the time of original completion date, which ever is earlier. The recovery of advances shall be 10% of monthly bill

Payment of materials in site:Limited to 80% of the actual value or assessed value of cement and steel.The total advance on account at a time shall be limited to 1% of contract price or average consumption of such material for 3 months or less. At any time the total outstanding advance against such materials atshite shall not exceed 1.5% of conract price

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

2.15 Miscallaneous facilities

TABLE 2: MISCALLANEOUS DETAILS

INFRASTRUCTURE FACILITIES

1 Facility: Casting Yard and then transported to all the 4 stations.

• Food is available on paid basis to all the members at site, such as Civil engineers, QC staff, GC staff, SHE staff, Sub-contractor staff and all the labourers.

2 Medical Facility: Medical tool box kit is available on every station and also at the casting yard, along with OHC (Occupational Health Center) department.

• There are hospitals nearby all stations and casting yard, in vicinity of around 1-2 kilometres.

3 Health & Hygiene condition of place:

2.16 WAGES

BMC organisation people come and make a random visit, to check the hygiene of the place, as per Govt. of Maharashtra norms

Wages of labourers (For 11 hours shift)

Skilled: ₹ 650 Semi- Skilled: ₹ 600 Unskilled: ₹ 540

Labour colony is at Byculla

TABLE 3: LABOUR DETAILS

LABOUR DETAILS (AS ON JAN ‘20)

CHAPTER 2: CONSTRUCTION AND METHODOLOGY

3 PROJECT SCEHDULE

Achieve substantial completion of station public Concourse/Mezzanine (wherever applicable) Level areas including entrances (all stations) finished to Degree 2 completion and provide access to all Interfacing Contractors

Achieve substantial completion of all bored tunnels (including cross passages and temporary TBM shaft in tunnel areas, if any) finished to Degree 1 completion and provide access to Track work and other Interfacing Contractors on entire bored tunnels ( all bored tunnel lengths)

Achieve substantial completion of all bored tunnels (including cross passages and temporary TBM shaft in tunnel areas, if any) finished to Degree 1 completion and provide access to Track work and other Interfacing Contractors on entire bored tunnels ( all bored tunnel lengths)

Achieve substantial completion of all E&M works to permit permanent power on to all stations and tunnels

all architectural finishing and signage works in all respects 1522

issuance of Taking Over Certificate (all completed to degree 4 completion)

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

Above image shows how planning is done for kalbadevi station box in microsoft project, it starts with temporary structures proceeding to north box and south box construction . activity id is assigned to each of the activity which shows the start date and end date of project. For comparison baseline start and finish dates are also shown.Float shows the days by which the activityis leading or lagging. Negative float shows activity is lagging by the no of days and positive float shows the days by which activity is leading.

LIST OF ACTIVITIES

GRANT

1. Secant Piling

2. Production of Tunnel Segments at Casting Yard

3. RCC Strut and Waler Beam construction at Level-

4. set up of Tunnel boring machine

5. Secant Piling

6. Reinforcement, formwork and concreting .

7. Steel Strut Design, Fabrication and Installation

8. shotcrete for cross passage, adits and cavern

9. Instrumentation and Monitoring

10. Rock Bolting

11. Shotcreting with Dry Mix

12. Utility Diversion and support

13. Traffic Decking

FIGURE 7: PROJECT SCHEDULING FOR KALBADEVI STATION

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

3.3 METHOD STATEMENT:

There are certain documents available at site, which indicates the sequence of construction to be followed based on certain guidelines and standards. This document is called “Method Statement”.At CJV, method statements are prepared for each activity, which is to be executed at site, station wise. This is because each station has different geological strata, and hence, different type of methodology to be adopted.

 These documents are prepared by design/ Geotech engineers, which are then reviewed by managers for the respective field and approved by project manager.

 QA manager, QC manager, construction managers (Civil and Tunnel), safety manager, project manager and deputy project manager will have its controlled copies.

 They include mechanisation of machinery, required manpower, HIRA, inspection and test plan, some standard tests to be conducted, etc. items in the method statement.It also indicates contingency plan for any risk hazard, if occurred at site, then whom to contact and which person to be notified.

 It has to followed in general terms. It has to approved from MAPLE (i.e. General Consultant) staff also, before executing the work. So, for this, RFI [Request for inspection] has to be prepared by contractor representative and submitted to GC. After getting approval, the activity can be started.

 Also, method statements get reviewed by GC and MMRC staff. After certain comments, the method statement gets revised.

3.4 4. DEGREE OF MECHANISATION JUSTIFICATION:

 As the package-02 has 4 stations and a casting yard under its scope of work, the Plants and machineries required for mechanisation of work needs to be planned and for the same, the work needs to be executed at a targeted time frame, within restricted cost budget.

 So, the plant and machinery department maintain a record in excel regarding the equipments owned or hired (from subcontractor agency) by the company.

Example, refer (Table of equipments) As there is more scope of excavation in Grant road station, greater number of back hoe loaders are available at grant road station , as compared to other stations. Also, at present time, piling going is on at Girgaon station. Hence, to carry out piling we require piling rigs Hence, greater number of piling rigs are required to carry out the activity, compared to other stations and according to the demand the mechanization is carried out at different station.

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

CHAPTER 3: CONSTRUCTION ACTIVITY REPORT

CAR 1 SECANT PILING

CAR 2 ROOF SLAB

CAR 3 CONSTRUCTION OF ADITS AND CENTRAL CAVERN

CAR 4 CONSTRUCTION OF CROSS PASSAGE

4 SECANT PILING

4.1 Scope of work:

 Setting out survey reference points for excavation.

 Preparing of polymer slurry

 Excavation of Secant pile wall

 Boring of piles

 Preparation and installation of reinforcement cage

 Constructing alternate soft piles and hard piles

 Finishing the topmost surfaces

4.2 OBSERVED ACTIVITY FLOW CHART

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

Construction Methodology:

Bottom-Up construction (Decided based on soil strata-page 15) (Refer Drawing )

Construction methodology )( refer GIR report page 1)

No of Piles for CST station: piles [Boring, Drilling, Concreting] 10

Piles studied: SP 1489 [Total = 9 piles], No of soft piles = 6, No of hard piles= 4

Pile type: end bearing piles, cast in situ.

Reinforcement :Fe500 neo steel

Concrete:M20 for primary piles ,M40 for secondary piles

TENDER DOCUMENT SPECIFICATION(Tender Documents, Part- 2, Section-VII)

Before starting excavation, the ground water table is to be lowered inside the excavation area to at least 1.0m below the excavation level for all stages of construction and shall be maintained until the backfilling is done, or station construction is completed. The secant pile wall is made of 1000mm diameter Primary Piles (to be drilled first) in M20 grade and 1000mm diameter Secondary Piles (to be drilled overlapping with constructed primary piles) in M40 grade

Major points in BS8004

The design of foundations subject to cyclic loading should consider the following:

• Degradation of ground strength (leading to ultimate limit states being exceeded at loads below those expected from verifications based on static strength) degradation of ground stiffness, leading to an accumulation of permanent foundation displacement (“ratcheting” effects); and amplification of loads or movements owing to resonance.

Non-engineered fill, such as industrial, chemical, and domestic wastes,should not be placed beneath foundations.All materials intended to be placed behind foundations should be properly investigated and classified.

The resistance of a pile foundation in rock depends markedly on the method of pile construction and the roughness of the rock socket in which the pile is located.

As observed on site:

Sr.no Description

Non-engineered fill, such as industrial, chemical, and domestic wastes,should not be placed beneath foundations

All materials intended to be placed behind foundations should be properly investigated and classified

Followed yes or no

YES

It is disposed in BMC Sewer

YES,all the quality check on materials was done

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

4.3 Organisation chart

•The approval of method statement,over all scope of work co-ordination of personnel and equipment to ensure continuous program of work,receiving daily progress report and giving to client HCC-MMS JV management and enusring prompt action to any matter highlighted

•implementation of method statement,ensuring all personnel are aware of their duties and responsibilities.

SITE ENGINEER

•emsuring in accordance with the appproved method statement and specification ,all required as built data are recorded

SITE SUPERVISOR

•ensuring that the construction is done as per method of statement and responsible for managing all machiney tools and laboursused in driving of bores for secant piles

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

: PROJET MANAGER

: STATION MANAGER

:

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Location where pile is observed

P1468,S1467,P1467,S14

66,P1466,S1465,P1465, S1464,P1464

Overlapping:130mm

From gl. 0.00 to -13m

4.4 PROCEDURE FOR PILING

No flushing is required if polymer is used as it ensures that the soil doesn’t collapse, Polymer slurry to be poured continously

Surveyor shall set out the centre of each pile as per location and approved drawing setting out trial pit for utility identification

Trial pit of 1.5 m depth shall be done to identify presence of utility line

polymer slurry preparation

1000mm dia shall be drilled, casing the casing should be inserted inside of 1000mm dia shall be inserted inside with the hammering effect of rotary drilling.verticality to be checked with Bore hole casing with plumb

reinforceme nt for secondary pile

Reinforcement bars should be cut as per BBS ,Lap joints and lifting hook of the reinforcement cage shall be welded.

installation of casing

bore holes for soft piles

Bore holes to be drilled within the casing by cutting and removing of soil by drilling equipment auger bucket attached. horizontal tolerane-25mm vertical tolerance1 in 200

Muck generated is shifted to the designated place,its initially dumped near working area then shifted.

Tremie pipe of 250 mm dia shall be lowered in pieces and connected while lowering leaving 0.3 m above bottom level with help of rig,Concrete funnel shall be filled completely and process is carried out

Reinforcement cage to be lowered by rig /hydra.Cage shall be lowered upto required levelLifing plan is followed at site.

concreteing

muck removal

flusing concreting bore for secondary piles

No flushing is required if polymer is used as it ensures that the soil doesn’t collapse

980mm dia shall be drilled, casing the casing should be inserted inside with the hammering effect of rotary drilling.verticalit y to be checked with Bore hole casing with plumb

reinforcement

Tremie pipe of 250 mm dia shall be lowered in pieces and connected while lowering leaving 0.3 m above bottom level with help of rig,Concrete funnel shall be filled completely and process is carried out

 When reinforcement cage is ready, it shall be lifted by hydra and kept on the trailer for shifting near the piling location , also the cage should be kept on wooden runners to avoid contact with soil

 Fabricated cage should be covered in plastic when not in use for longer period

 The verticality of the casing shall be checked during the installation by plumb from two perpendicular directions .

 SOUNDING CHAIN METHOD: it used to check the measurement of depth of pile , the chain in inserted inside the pile and then removed out and its length is measured by a measure tape .

 TOLERANCE LEVEL FOR VERTICALITY : HORIZONTAL 25MM ,VERTICAL : 1 IN 200

 Reinforcement cage is prepared at WTC then brought to the site of execution.

Bhumika Raj (UC5316) Semester-08

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

4.5 PROCEDURE SKETCH FOR PILING

CASING IS INSERTED

1 Drilling is done through auger and inserting case

2 Casing is inserted and polymer slurry is poured down

3 Auger is lifted up when hard rock is obtained.

4 Assembly of tremie and hopper is arranged for concrete works

5 Finishing works and drilling is started for secondary piles

F

T

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD. Kasturbhai

MAIT 130 HR 130

M40-GRADE DRILLING IS CARRIED OUT BY AUGER

6 Drilling carried out through auger for secondary piles

7 Reinforcement cage is lowered by the rig

8 Concrete work is done in same way as done for primary piles

9 Finishing work is carried out

CASING IS REMOVED AND FINISHED IS DONE

Bhumika Raj (UC5316) Semester-08

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

4.6 BBS FOR PILE( S1467)

T

5: BBS FOR PILE

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

4.7

Inference: cement used is in the maximum quantity while flyash is used in least quantity in construction of pile

Highest depth observed is 13.5

Minimum depth obtained is 9.3

4.8 Data entry done for pile- P1489

Table 7:data entry for piles

After grade 4 is obtained , penetration is continue for more 50-60 mins to ensure the pile is embedded in the hard rock.

WEIGHT OF ONE CAGE _1.8 Metric ton( as shown in machine)

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

4.9 TIME CYCLE

Table 8: time cycle analysis for primary piles

4.10

TABLE 9: TIMECYCLE FOR SECONDRY PILES

AS PER OBSERVATION: TIME CYCLE

TABLE 10: TIME CYCLE ANALYSIS AS PER OBSERVATION ( PRIMARY PILES)

Note : GREY part shows the variation observed on

4.11 AS PER OBSERVATION

CHART TITLE

primary pile TIME TAKEN (Hrs)secondary pile

Placing of tremie

Placing of reinforcement cage

Shifting of rig

In rock

In soft rock

Inference:

Posiyioh of piling rig

Survey and setting out works

Placing of concrete RCC time taken(hours)

 P1489, DATE :16 january 2020 , P1466 DATE 20 january 2020

 Placing of Tremie in took longer time because appropriate size of tremie was not available on time.

 Placing of concrete took longer time because concrete mixer was not available at site on time

 Due to unfavourable conditions on site i.e. mud disposal positioning of rig became difficult.

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

NAME:- BHUMIKA RAJ CODE NO:-UC5316

PROJECT TRAINING 2019-2020 ( MUMBAI METRO UGC-02)

Measurement Sheet

Providing boring for rcc cast in situ piles including withdrawl of shell, cleaning removal of earth to a distance upto 50m of dia 1000mm at CST station etc complete as directed by general consultants

TABLE 13: RATE ANALYSIS FOR REINFORCEMENT OF PILE(SECONDARY)

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

BHUMIKA RAJ

PROJECT TRAINING 2019-2020

Measurement Sheet

Providing and laying reinforcement bars of fe500 grade for secant piles as per drawings including cutting ,welding tieing with binding wires ,assembling etc and providing 40 mm cover as engineer in charge and General consultants authority etc( for 3 piles of length 13.5 m)

CODE NO:-UC5316

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

RAJ CODE NO:-UC5316

PROJECT TRAINING 2019-2020 ( MUMBAI METRO UGC-02)

Providing and laying CONCRETE OF M40 grade for secondary piles of secant piles for specified depth inlcuding transportation, pouring, casing with tremie pipe finishing etc as per the direction of engineer incharge. For 9 m3 cum A. Material

PROJECT TRAINING 2019-2020 ( MUMBAI METRO UGC-02)

Providing and laying CONCRETE OF M20 grade for primary piles of secant piles for specified depth inlcuding transportation, pouring, casing with tremie pipe finishing etc as per the direction of engineer incharge.(7.8m3)

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

4.12 ABSTRACT SHEE

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

NAME:- BHUMIKA RAJCODE NO:-UC5316

PROJECT TRAINING 2019-2020

ABSTRACT SHEET

Providing empty boring rcc cast in situ piles including withdrawl of shell, removal of earth to a distance upto 50m of dia 1000mm etc com plete as directed by engineer in charge( refer pg no.40)

Providing and laying CONCRETE OF M20 grade for primary piles of secant piles for specified depth inlcuding transportation, pouring, casing with tremie pipe finishing etc as per the direction of engineer incharge.(7.8m3)( refer pg no.41)

providing and laying reinforcement bars of fe500 grade for secant piles as per drawings including cutting ,welding tieing with binding wires ,assembling etc and providing 40 mm cover as engineer in charge and General consultants authority etc( for 3 piles of length 13.5 m)( refer pg

Providing and laying CONCRETE OF M40 grade for secondary piles of secant piles for specified depth inlcuding transportation, pouring, casing with tremie pipe finishing etc as per the direction of engineer incharge. For 9 m3( refer pg no.43)

INFERENCE : maximum cost is observed for reinforcement as the cage made for piling is dense, while concreting is also done for entire volume of pile and excavation consumes less cost as only no resources are used except rotary driller

LABOUR PRODUCTIVITY

LABOUR PRODUCTIVITY*LABOUR PRODUCTIVITY FOR 1 PILE

4.13 ACTIVITY ANALYSIS

For one primary pile

for excavation– rs1043

Cost of concreting – rs. 10709 Total cost – rs. 11752

depth of pile – 9.94• Average volume of concreting – 7.8m3

4.14

4.15

TOTAL NO OF PILES IN ANCILLARY BUILDING AREA AT CST AREA WHERE BUILDING IS OBSERVED IS:

4.16

52 PRIMARY

TOTAL COST OF EXCAVATION =54236

TOTAL COST OF CONCRETING -556868

TOTAL COST OF REINFORCEMENT –

TOTAL COST Rs. 611104

50 SECONDARY

TOTAL COST OF EXCAVATION =52150

TOTAL COST OF CONCRETING -777937

TOTAL COST OF REINFORCEMENT –rs 4821150

4.17 EQUIPMENT DETAIL

 Koden is an ultrasonic device used for measuring the depth,it’s a highy expensive machine used in large scale projects.

 It is placed above the hole from where the sensor unit is lowered down and the winch unit is placed above the hole with the help of support

 Its highly accurate so it used.

ROAD.

Bhumika Raj (UC5316) Semester-08

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

4.18 HIRA Table 16: HIRA

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

5 ROOF SLAB

•slab : reinforcement ,concrete , formwork and water proofing

5.1 SCOPE OF WORK

FORMWORK AREA:1108m2 (including bottom and sides)

CONCRETE AREA:913 m3

REINFORCEMENT: 82000kg

5.2 OBSERVED ACTIVITY FLOW CHART

MUMBAI

covered area _ grid 6 to grid 8

SECANT PILING

EXACAVATION

KING POST

STRUT ADN WALER

MAPPING

ROCK BOLTING

SHOTCRETE

CONCOURSE SLAB

ANCILLIARY

DRILLING AND BLASTING

CROSS PASSAGE

SUMP

Legend:

Ongoing activities

Observed activities Activities finished Activities yet to be started

Lalbhai Campus

Navrangpura

5.3

ORGANISATION CHART project manager exceution department station manager site engineer site supervisor

support department hse QA/QC SUrVEY

Station manager

Bhumika Raj (UC5316) Semester-08

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

ENTRY POINT 1

ENTRY POINT 3

ANCILLARY BUILDING

MUCK DISPOSAL AREA

PORTION LEFT TO BE CASTED DURING LAUNCHING SHAFT

CONSTRUCTED PORTION UPTO ROOF SLAB

OBSERVED PART

PORTION LEFT TO BE CASTED

GANTRYS ARE PLACED IN THAT SECTION TUNNEL DOWNLINE AND UPLINE 22.8

ENTRY POINT 2

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

Bhumika Raj (UC5316) Semester-08

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

5.4 JOBLAYOUT 5.5

5.6 METHODOLOGY

Wooden ply of 12 mm thickness of sizes are laid they are further given support by props and U jacks and wooden planks so all the sizes are joined together.

Wooden shuttering ply should be in alignment and sizes used is 1.22*2.44 for one ply sealed with tape

And foam sheets shall be provided at joint gaps to prevent leakage of slurry

Concrete of m50 grade is provided

According to pour plan the concrete pimp set up is done by using gi pipes,All the pipes are laid and concreteing is started .Prior to concrete about 0.5 to 1 cum of cement slurry shall be pumped to lubricate pipe

Needle vibrator of 3 different types were used , 40,60,80 mm are used

Aluminiumn hollow box is used curing

PRE-REQUISITE

• Surface should be clean

• Panels surface (ply) to be oiled before placement

STAGING SHUTTERING REINFORCEMENT CONCRETE CURING

Staging should be carried out as per the drawings .

Cup lock system is used .

Deshuttering is done after 24-48 hours

First base jack , verticals and u jack is errected, above that I section and RHS are errected

Wooden planks of size are laid and on the top rests wooden ply of 12 mm thickness( refer pg no 53 )

Prior to reinforcement shuttering oil should be applied

All staging should be checked

Rebar construction shall be done done at construction depot

Rebars shall be lowered to required level with help of crawler crane as per bar marking

Bottom bars are first place and after that top bars are placed

18 gauge wire is used to tie the bars and cover blocks

After completion of bottom mat chairs bars of size are provided over bottom reinforcement

Joint check to be done by gc after tying activity

Foam sheet shall be packed at joint gaps to prevent leakage of slurry(( refer pg no.54)

Hessian clotshall be placed and covered with polytehen sheet

It should be kept damp and after 24 hours area shold be pounded of water for 7 days

POST-REQUISITE

• Curing

• Surface should be clean

• Waterproofing

Moist Curing is carried out by using hessian cloth and then after 24 hours cloth and polythene sheet are removed and area shall be pounded with bund for 7 days

Clause 13.5 is code

Bhumika Raj (UC5316) Semester-08

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

F

IGURE 9: REINFORCEMENT YARD LOCATION

Bhumika Raj (UC5316) Semester-08

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad –

Bhumika Raj (UC5316) Semester-08

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad –

5.10 MATERIAL TESTING DETAILS

MATERIAL TESTING DETAILS SR

HENCE

SOUNDESS

TABLE 17: MATERIAL TESTING DETAILS

COST BREAK UP

5.11 ACTIVITY WISE COST BREAK UP

Inference:Char4 :In item wise cost break up , the highest cost is found in material followed by labour as they Constitute a major role in progress of activity.

Char 2: in total cost beak up, concrete holds 47% as the depth of slab was 1m and reinforcement holds 43 % percentage as heavy Reinforcement was used for roof slab.

TABLE 18: LABOUR PRODUCTIVITY ROOF SLAB

5.12 Labour productivity ( pour 6)

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02 STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

5.13 TIME CYCLE ANALYSIS

TABLE 19: TIME CYCLE ANALYSIS ROOF SLAB

DURATION OF ACTIVITIES(OBSERVED)

*There are 2 shifts – day and night with each shift of 12 hours including 2 hour break

Total time cycle as observed is of 31 days for one pour of roof slab at CST station

Table 20: Time cycle break up.(pour wise)

Inference: compared to the planning by contractor (HCC) Total time taken was 96 days till back filling And 76 days till water proofing.As per observation on site for pour 6 there was less time taken which is 71 days till its water proofing, because foreman were available,Machines and equipments were available on time and were efficient ,staging and fixing was carried out in full fledge due to availability Of workers on site. Rebars were transported to site on timely basis from WTC.

Kasturbhai

STAGING SHUTTERING REINFORCEMENT FIXING AND CHECKING CONCRETING OF SLAB CHART:

Column1 days as oberved time days(schedule)

CHART:

Bhumika Raj (UC5316) Semester-08 PROJECT TRAINING 2019-2020

TABLE 21: ANALYSIS FOR ENTIRE STATION LENGTH

5.14 ANALYSIS OF ROOF SLAB FOR ENTIRE STATION LENGTH ( pour 6) total grid lines 25 are there one pour covers 2.5 grid lineTotal pour to be done : 10

for one pour entire roof slab Of CST

length of entire station 250m length of 1 pour=25m so total pour to be done are 10 for entire station length

From the above data we can say that it would take 310 mandays and rs.107120140 to complete all roof slabs at CST station

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

5.15 ALTERNATIVE SUGGESTION

OBSREVATION :15% OF COST SAVING CAN BE DONE IF COUPLERS ARE USED

TABLE 22:RATE FOR COUPLERS

40 DIA REBAR MATERIAL 24653*40=986120

INCREASE IF LAPPING IS PROVIDED 1187956

IF COUPLERS ARE PROVIDED 1001416

DIFFRENCE 186540

DIFFRENCE IN % 15%

TABLE 23: PROVIDED ALTERNATIVES

Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

T +91 7926302470

F +91 7926302075

Kasturbhai

5.16 ACTIVITY OVER VIEW

5.17 Construction of adit and central cavern by NATM methodology

 Element: Adit 3 between gridline 5 & 7 and central cavern

 Location: upline tunnel at kalbadevi station.

 Clear width: 6 m

 Length of entire adit :23.5M

 Width of cavern:9.5

 Grade of Concrete for shot crete: M35

 Grade of Steel for wire mesh: Fe500D : 150*150*6 mm

 Diameter of rebars for rock bolts: 32mm dia

 Blasting : explosive name – ideal power 90

 Electronic detonators

 Soil strata: grade 2 rock

Quantum of work observed for Adit

 Total excavation:167 m3

 Total shotcrete:37.5m3

 Total explosives :35.36kg

Quantum of work observed for central cavern

 Total explosives :86 kg

5.18 NATM PROCEDURE

New Australian tunnelling method is adopted at places when one has to widen the areawhere underground works are to be carried out and there is no sufficient space available on top for carrying out the activity.It is carried out by the drilling charging and blasting.At Mumbai metro line 3, UGC-02 it is carried out at kalbadevi station which is completely underground.

Main parameters to be kept in mind while carrying out NATM are:

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

5.19

OBSERVED ACTIVITY LOCATION

Raj (UC5316)

ALIGNMENT PLAN

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

5.20 ADITS AND CENTRAL COVERN PLAN

5.21 Organisation chart

5.22 STRATIGRAPHY OF SOIL CONDITION AT KALBADEVI STATION ACCORDING TO THE GEOLOGICAL INVESTIGATION REPORT

Geological setting as per face mapping and probing

Conclusion: During the TBM excavation frequent probing & face mapping was carried out for Kalbadevi station.The geological profile shown below is based on mapping & probing data, RMR at the tunnel face varies here from 64 to 71 thus good quality basalt (grade II) is considered at the excavation face of NATM tunnels as well.

T

FIGURE 10: GEOLOGICAL PROFILE AT KALBADEVI STATION

5.23 GEOLOGICAL PROFILE DETAILS (KALBADEVI )

TABLE 24: GEOLOGICAL DETAILS AT KALBADEVI

During the TBM excavation frequent probing & face mapping was carried out for Kalbadevi station.The geological profile shown below is based on mapping & probing data, RMR at the tunnel face varies here from 64 to 71 thus good quality basalt (grade II) is considered at the excavation face of NATM tunnels as well.

T +91 7926302470

F +91 7926302075

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

FIGURE 11: DIMENSIONS FOR ADITS

5.24 DESIGN METHODOLGY

Analytical methods are based on RMR system.

FEM based analysis uses 2D FEM models with construction stages to work out the stability of the construction process for NATM tunnels and ensure the adequacy of primary supportGround water table is considered at ground level and maximum surcharge is considered asper actual of maximum 130 KPa at foundation level, assuming 10 storey building. The relaxation,capacity of the rock is estimated from the Panet‐ Chern theory.

5.25 Analytical Approach

The RMR‐system

a) Uniaxial compressive strength

b) RQD

c) Spacing of discontinuities

d) Condition of discontinuities

e) Ground water conditions

f) Orientation of discontinuities

The RMR of the rock is worked out as per the above properties and the support is designed for 22 considered excavation using following GUIDELINES FOE

Table 25: RMR TAB

Note-Yellow highlight shows the grade of rock observed at kalbadevi

5.26 INSTRUMENTATION AND MONITORING

• 3D Targets

• Strain gauges

The 3D Targets –FUNCTION

For 3D Targets, the total station used for the monitoring should measure up to the required precision level. To obtain accurate results both high quality 3D targets and a high precision total station are required. For typical details monitoring instruments and procedures reference shall be taken to design manual and NATM specification.

The 3D Targets –LOCATION

5.27 They are located at the periphery of the face of excavation, one on

3D OPTICAL TARGETS

3D OPTICAL TARGETS

3D OPTICAL TARGETS

3D OPTICAL TARGETS

FIGURE 12: INSTRUMENTATION AND MONITORING

DIFFICULTIES FACED

WATER INGRESS

There is always a risk of heavy groundwater inflow in tunnels. Hence, dewatering pumps shall beinstalled while near unsupported face. A detailed calculation for the same would be included in definitive design.

3D OPTICAL TARGETS

3D OPTICAL TARGETS

The crown is always at a higher risk then rest of the tunnel while excavation. Hence, excavation shall begin form crown and then going towards invert.

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

5.28 NATM AT KALDADEVI IN A GLANCE

ENTERING INSDIE

ROCK BOLTING MAIN TUNNEL

STEEL SUPPORT

EXACACVTION USING SPLITTER

PROFILE MARKING

DRILLING AND BLASTING

PROFILE MARKING

CORE CUTTING

SEGMENT REMOVAL

GROUT REMOVAL

FACE READY FOR EXACVATION

FACE DRILLING

FACE DRILLING

CONTROLLED CHARGING

INTIAL CUT TO START SPLITTING

SCALING

CONTROLLED BLASTING

Kasturbhai Lalbhai Campus University Road, Navrangpura

Ahmedabad – 380009, Gujarat

T +91 7926302470

F +91 7926302075

MUCKING

DEFUMING

MIS FIRE CHECKING

GOING FOR NEXT ROUND TO COMPLETE BLASTING ACTIVITY

SCALING AND MUCKING

PRELIMANRY SUPPORT

NEXT CYCLE

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

5.29 PROCEDURE FOR CONSTRUCTION OF ADIT AT KBD STATION

PROVIDING TEMPORARY SUPPORT

CORE CUTTING

SCALING

IT IS CHIIPING AWAY OF LOOSE MATERIASL WHICH ARE NOT COMPLETELY RELEASED FROM THE ROCK DURING BLASTIC PROCEDURE

MUCKING

AFTER SCALING MUCK IS REMOVED BY LOADER AND DUMPED TO THE DISPOSAL AREA WHICH WILL BE LIFTED FROM GANRY CRANE TO MUCK PIT AND LOADED INTO DUMPERS TO DESIGNATED SITES

SURVEY AND FACE MAPPING THE GEOLOSIT WILL INSPECT THE CUT SURFACE AND REMOVE ALL SUSPENDED MATERIAL EXCAVATION PROFILE WILL BE CARRIED OUT BY THE SURVEYOR

PRIMARY LINING

SHOTCRETE

50 MM THICK SHOTCRETE IS DONE THROUGH SHOTCRETE MACHINE

WIRES MESH

150*150*^6 SIZE OF WIRE MESH IS LAID ON THE TOP AND BOTTOM WITH OVERLAPPING OF 150 ON TOP AND 0.3 ON SIDES

ROCK BOLTING 32MM DIA OF BAR IS USED AND INSERTED AT 2.5 M DEPTH ALONG WITH 2 RESIN CAPUSLESNAND FACE PLATES.

WATER PROOFING

SECONDARY LINING

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MARKING

PLAN VIEW OF JUNCTTION AT ADIT AND TBM

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

EXCAVATION IN TRANSITION ZONE

EXCAVATION UPTO PLATFORM LEVEL

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

T +91 7926302470

F +91 7926302075

5.31 BLAST DETAILS FOR ADIT

SKIN TO SKIN HOLES ARE PROVIDED ON THE PERIPHERY THEY HAVE 102 DIA AND THEIR FUNCTION IS TO TANSFER THE VIBRATION TO THE ADJACENT MASS SO THEY HAVE LARGER DIA

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

REAMER HOLES ARE PRESENT ON THE FACE O IN THE MIDDLE THEIR PURPOSE IS TO PROVIDE CLEAR FACE FOR NEXT CYCLE

PRODUCTIVE HOLES ARE PROVIDED IN THE CENTRE BETWEEN PHERIPHERY AND REAMER HOLES

5.32 QUANTITY

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

5.33 PROCEDURE FOR CENTRAL CAVERN

AFTER BREAK THROUGH IN ADIT DONE PROCESS FOR CENTRAL CAVERN IS I INITITATED

BLASTING IS TAKEN

DEFUMING FOR SAFTEY PURPOSE IS DONE

CONTROLLED BLASTING FOR HEADING CARRIED OUT ON FACE FOR THAT MARKING ID DONE BY SURVEYOR

DRILLING OF PERIPHERY HOLES ON FACE FOLLOWED BY REAMER AND PRODUCYIVE HOLES

STEMMING IS DONE WHICH FILLING UP THE1/3 HOLES WITH SAND

CONNECTING WITH THE ELECTRONIC DETONATORS

CHECKS BY THE EXPERTS AFTER THAT PRELIMANEY WORK IS WARRIED OUT SCALING AND MUCKING OF LOOSE MATERIALS

ATTACHING GELATTIN/ CATRIDGE INTO HOLES DRILLED SPACERS ARE INSERTED AS REQUIRED

PRELIMINARY WORKS LIKE PROVIDING AND FIXING WIRE MESH. SHOTCRETE IS CARRIED OUT

SAME PROCESS IS REPEATED FOR BENCHING AND FOLLOWED ALONG THE ENTIRE LENGTH OF CAVERN

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

T +91 7926302470

F +91 7926302075

FIGURE 15: SET OUT POINTS AT CENTRAL CAVERN

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

AFTER THE SEGMENT ID REMOVED DRILLING BY EXACAVTION MEAN IS STARTED

JUMBO DRILLER IS USED TO DRILL INTO THE SEGMENTS

AT EVERY 1 M ADVANCE WIREMESH IS FIXED 150*150*6 MM IN SIZE

DETAILS OF RESIN CAPSULE shelf life: 6 months,gel time: 30 seconds,setting time:120 seconds,dia 33 mm,length300mm,storage 25 degree .They are provided so they can gel the rod inside the drilled holes

SHOTCRETE IS CARRIED OUT IN ADIT BY PNEUMATIC SHOTCRETE MACHINE

NOTE : Drilling and blasting cannot be carried out initially on the face as it can damage the allignment of other adjacent rings to it so firstly excavation is done through excavator and after some distance geologist t intervenes in the process and approves that when it is safe to carry out blasting

At adit 3, excavation was carried out till 5.3 m after that distance blasting was carried out till next 18.63m through out the adit length

Bhumika Raj (UC5316) Semester-08

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

BY TH E MEANS OF EXCAVATOR THE EXCAVATION IS CARRIED OUT FURTHER

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

PRODUCTIVE HOLRS

PERIPHERY HOLES

PERIPHERY HOLES

FIGURE 16: BLAST DETAILS FOR CENTRAL CAVERN

ROCEDUR FOR BLASTING WITH EXPLOSIVES

DRILLING OF HOLES 1.2 M DEPTH

1) PERIPHERY

2) REAMER

3) PRODUCTIVE

INSERTION OF EXPLOSIVE IN HOLE

INSERTING EXPLOSIVE INSIDE THE HOLES AND ADDING SPACER AS REQUIRED WITH THAT ATTACHING THE ELECTRONIC DETONATOR

STEMMING IS DONEWHICH IS FILLING THE HOLE WITH SAND FSO DURING BLAST THERE IS NO REBOUND OF EARTH MATERIIALS

SKIN TO SKIN HOLES ARE PROVIDED ON THE PERIPHERY THEY HAVE 102 DIA AND THEIR FUNCTION IS TO TANSFER THE VIBRATION TO THE ADJACENT MASS

REAMER HOLES ARE PRESENT ON THE FACE O IN THE MIDDLE THEIR PURPOSE IS TO PROVIDE CLEAR FACE FOR NEXT CYCLE

BLASTING IS CARRIED OUT WHICH IS FOLLOWED BY DEFUMING

PRODUCTIVE HOLES ARE PROVIDED IN THE CENTRE BETWEEN PHERIPHERY AND REAMER HOLES

5.34 OBSERVED QAUNTITY FOR BLASTING CENTRAL CAVERN THROUGH ADIT 3

FOR

AT CAVEN ROUND 1

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

FOR ALL THREE ROUNDS

NOTE – ROUND 1 CTS, it refers to the blasting started from chattrapati shivaji station side and same for Mumbai central station mmct.

*Blasting pattern remains same refer blasting pattern drawing , some improvisations are done on site as site conditions vary,( no of holes may differentiate and no of rounds may reduce or increase )

*The variation is based on the experience of blasting head and engineer and geological condition

Table 27:QUANTITY FOR BLASTING AT CENTRAL CAVERN ROUND 3

5.35 TIME CYCLE ANALYSIS FOR ADIT 3

total 2 shifts of 11 hours with 1 hour break each , pull of 1.15 at adit is observed

surveyor comes in shifts one in morning and then in evening.

1 hours taken to remove muck everyday for 6 pulls

two layers of wiresmesh is laid after every excavation round which consumes 1.5 hours so for 6 pulls

for rock bolting in one pull 2 hours are consumed so for 6 pulls

in 2 rounds it is done and is carried out simultaneously with excavation at every 1.15 m its done which consumes 4 hours for one pull so for 6 pulls

ACTIVITY WISE TIME BREAK UP

INFERENCE :Maximum time consumed is observed in excavation as many diffiuclties like placing and moving the excavator carryoying out activity according to the vibration limit, while least time is carried out in mucking.

5.36 TIME CYCLE ANNALYSIS FOR CAVERN

for one face approximately 2 hours are consumed for drilling and pull is 1.2m on average so for 3 rounds

2.5 hours for entire blasting includes inserting exolosives and attaching electronic detonators for one pull so for 3 rounds

defuming for 1 hour is done after every round so for 3 rounds

5.37 Table 29: TIMECYCLE FOR CENTRAL CAVERN

ACTIVITY WISE TIME BREAK UP FOR CENTRAL CAVERN

INFERENCE :Maximum time consumed is observed in blasting and charging as no of labours were less during the activity and even generally drilling time is also more asit requires time to drill into hard rock

LABOURS INVOLVED IN ACTIVITY

INFERENCE :maximum no of labour force is observed in drilling and blasting as it’s a tedious activity involving more work force while in excavation one operator operating excavator is enough for carrying out the activity

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

Table 30: LABOUR PRODUCTIVITY 5.38

EXACVATION SHOT CRETE(PULL 1.2) WIRE MESH ROCK BOLTS DRILLING AND BLASTING

TABLE 31: RA FOR EXCAVATION OF ADIT

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

NAME:- BHUMIKA RAJCODE NO:-UC5316

PROJECT TRAINING 2019-2020

Measurement Sheet

Providing for and excavating for 6m wide Adit using NATM tunnelling method, as per detailed drawing and specification including lead and lift up to 1.5m

TABLE 32: RA FOR SHOTCRETE

₹SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

NAME:- BHUMIKAAJCODE NO:-UC5316

PROJECT TRAINING 2019-2020 Measurement Sheet

Providing for and carrying out shotcreting for 6m wide cross-passage as per pecification using M35 grade of concrete including batching, transportation, spraying etc.

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

NAME:- BHUMIKA RAJCODE NO:-UC5316

PROJECT TRAINING 2019-2020

Measurement Sheet

Providing for and fixing of wire mesh of size 150*150*6 after 1st and 2nd layer of shotcrete for 6m wide crosspassage including drilling, ransportation etc complete

TABLE 34: RA FOR ROCK BOLTING

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

NAME:- BHUMIKA RAJCODE NO:-UC5316

PROJECT TRAINING 2019-2020 Measurement Sheet

Carrying out rock bolting for 6m wide crosspassage using 32mm dia rebar with face plate of thickness 12 mm and resin capsules including transportation, drilling etc. kg

T

F

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

NAME:- BHUMIKA RAJCODE NO:-UC5316

PROJECT TRAINING 2019-2020

Measurement Sheet

Providing blasting for central cavern at kalbadevi station including inserting explosives and detonators , transportation,fixing etc under supervision of general consultants(for 71.01 cu.m.)

TABLE 35: RA FOR ROCK BOLTING

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

Providing for and excavating for 6m wide cross-passage using NATM tunnelling method, as per detailed drawing and specification including lead and lift up to

refer pg no.84)

Providing for and carrying shotcreting for 6m wide cross-passage as per specification using M35 grade of concrete including batching, transportation, spraying etc.( refer pg no85.)

Providing for and fixing of wire mesh after1st and 2nd layer of shotcrete for 6m wide cross-passage including drilling, transportation etc complete, transportation,

Carrying out rock bolting for 6m wide crosspassage using 32mm dia rebar with face plate of thickness 12 mm and resin capsules including transportation, drilling etc.( refer pg

Providing blasting for central cavern at kalbadevi station including inserting explosives and detonators , transportation,fixing etc under supervision of general consultants( refer

ACTIVITY WISE COST BREAK UP

INFERENCE : Maximum cost is obtained for excavation as it requires more time and equipments compared to other activities also shotcrete is 43% because rebound factor comes into play which happens on site.

excavation shotcrete wiremesh rockbolting blasting

CONCLUSION:

 In NATM works excavation , drilling , blasting and charging play a very important role,.So care should be taken to carry out the blasting and charging activity safely so there is no fatality on site.

 One of the advantage at kalbadevi was that the strata was hard compared to other stations so it was faster to carry out the preliminary works like shotcrete , installing wiremesh and rock bolting( refer pg no.66 for rock strata )

 At kalbadevi there are many old buildings and it’s quite dense also so vibration limit is to maintained which is 3.5Hz which requires continuous monitoring.

 When explosives are blasted ammonium nitrate is produced which is harmful to the environment Flexible – Support provide as required by the ground conditions .

 Economical – Support provided as required by the encountered ground conditions, in contrast to TBM segments, which are designed for worst load case – if needed or not, therefore overdesigned.

 Adaptable – Optimizing equipment and crews, allowing multiple heading operations concurrent

SHOTCRETE: It forms a major part of the activity so extra care should be taken .Before shotcrete is done its trial is carried out where trials are done and compressive strength of shotcrete is measured, and the graph plotted from the data should obtained J2 curve ,below J1 curve the shotcrete should be rejected

5.39 ANALYSIS OF THE ACTIVITY

FIGURE 17: SHOTCRETE STRENGTH GRAPH

LAGGING INDICATORS

LEADING INIDCATORS

Paradigm shift measure

6 CROSS PASSAGE CONSTRUCTION

 Observed activity :Construction of cross passage at Grant road station BY natm method.

 Cross passage details: cross passage 7

 Observed activity location : total 7 cross passages from kalbadevi to grant road.,Cp 7, grant road station chainage 7510 upline . 7490 downline

 Cross passage 7 dimensions:

 Wide-3M

 Length : 14m

 Height: 3.149

 Grade of shotcrete:M35

 dimensions of wiremesh: 150*150*6

Rock bolting details

 20 mm dia rod inserted 1.2 mm deep In rock

Type of lattice girder :

 Type : 70/20/25 Placed at every 1m, steel used Fe500d

6.1 Reason for providing cross passage

 Cross passages are provided for safety purpose, incase of any emergency when passengers have to be shifted from one tunnel to another cross passages can be used for rescue.

 Provided when the distance between two stations is more than 700 m

 Provided at the distance of 250 m each.

 There are total 7 cross passages in UGC02.

6.2 ORGANISATION CHART

Activity

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

6.3 OSERVED ACTIVITY LOCATION

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

(UC5316)

6.5 CROSS PASSAGE DETAILS

6.7 PROCEDURE FOR CONSTRUCTION OF CROSS PASSAGE

PROBE HOLE DRILLING FOR SAFETY PURPOSE

EXCAVATION CARRIED OUT ON FACE 1.5M PULL DOR CROSS PASSAGE

RPROVIDING SUPPORT THEOUGH WALERS AND JACKS

BREAKING OF SEGMENT

PRIMARY LINING SHOTCRETE

50 MM THICK SHOTCRETE IS DONE THROUGH SHOTCRETE MACHINE

CYCLE IS REPEATED THROUGH OUT THE LENGTH OF THE CROSS PASSAGE

MUCKING

AFTER EXCAVATION MUCK IS REMOVED BY LOADER AND DUMPED TO THE DISPOSAL AREA WHICH WILL BE LIFTED FROM GANRY CRANE TO MUCK PIT AND LOADED INTO DUMPERS TO DESIGNATED SITES

SURVEY AND FACE MAPPING THE GEOLOSIT WILL INSPECT THE CUT SURFACE AND REMOVE ALL SUSPENDED MATERIAL

EXCAVATION PROFILE WILL BE CARRIED OUT BY THE SURVEYOR

T

WIRES MESH

150*150*^6 SIZE OF WIRE MESH IS LAID ON THE TOP AND BOTTOM WITH OVERLAPPING OF 150 ON TOP AND 0.3 ON SIDES

.LATTICE GIRDER ERRECTION IS DONE FIRST ABOVE TWO PARTS ARE ERRECTED THEN PATS AT LEGS ARE ERRECTED

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02 STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

6.8 INSTRUMENTATION AND MONITORING

• PLACED ON THE PERIPHERY OF THE CROSS PASSAGE THEY CHECK WHETHER THE VIBRATION IS WITHIN THE LIMITS OR NOT

• THYE ARE PLACED AT THE SIDES AND THEIR FUNCTION IS TO SHOW THE PRESSURE DURING SHOTCRETE WHICH SHOULD NOT EXCEEED

6.9

MUMBAI METRO LINE 3 – PACKAGE 2 UGC02

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

6.10 QUANTITY ESTIMATION FOR LATTICE GIRDER Bar name BAR CUT LENGTH CURVATURE LENGTH

NO OF TRIANGULAR PARTS

TOTAL CURVATURE LENGTH /TRAINGULAR BAR CUT LENGTH mm)=40

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

NAME:- BHUMIKA RAJ CODE NO:-UC5316

PROJECT TRAINING 2019-2020 ( MUMBAI METRO UGC-02)

Kasturbhai Lalbhai

Bhumika Raj (UC5316)

Semester-08

PROJECT TRAINING 2019-2020

TABLE 37: LABOUR ANALYSIS

6.11 LABOUR ANALYSIS FOR CROSS PASSAGE 7 AT GRANT ROAD STATION

LABOURS INVOLVED IN ACTIVITY

Highest number of labours are observed in the installation and making of attice girder while least number is found in excavation as breaking is done through excavator and few people are required for other smaller activities relaed to excavation.

SHOT

1.2) WIRE MESH ROCK BOLTS LATTICE GIRDER

NAME:- BHUMIKA RAJCODE NO:-UC5316

PROJECT TRAINING 2019-2020

Measurement Sheet

Fabrication and Erection of 70/20/25Lattice Girder as per drawings and specification including fabrication of accessories, welding, bolting, transportation etc.under the supervision of general cosnultants

TABLE 38: RA FOR LATTICE GIRDER

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

Inference:The chart depicts that 32 % is the labour cost and 68% is the material cost observed in the following activity.Most important material is shotcrete used in this activIty which takes up the majority part.

Inference:The chart depicts that shotcrete is the most costly activity followed by other activities least is for wiremesh.In case of shotcrete there is rebound upto 10% which adds upto the cost .

Table 39; ABSTRACT SHEET

CHAPTER 4: MANAGEMENT CAR

6.11.1 OWING AND OPERATING

Contarctor has separate plant and machinery department P&M for site which works as separate agency which supllies all required TEP’s on site . the selctio of size , specification and technology of the TEP is purely dependent on site location , project timeline and cost associated with it .

Type of TEP costs

Cost to P&M

IT means the cost at which P7M department buys machineryand calculates its owining and operating cost including capital cost , depreciation , running hour per month , labours ,s spares and agency repairs

Cost ro project :

After caluationg an amount , P&M department deploys machine to site as per demand and requirement of time . so contractor must pay internalhire charge if machine is owned by the company which is inclusive of cost to P&M , fuel and transportation charges , whereas there is other term called external hire charges which is to be paid to machine which are notowmed by company and it hires from other agencies or sub contractors

6.11.2 BUY AND LEASE OPTIONS:

As per observation and data information, about 60% equipments are owned and 40% equipments are hired by the company. This depends on whether the equipment will give enough returns for the project as per desired output required. If the work required to be carried out is more than purchasing is better than leasing/ hiring any equipment.As per financial aspects; it is checked whether the theoretical owning and operating cost, maintenance and operator cost for monthly usage is as per contractor’s hiring cost. Based on this, it is decided to hire/ purchase any equipment. However, there is no calculation done by DSJV for monthly owning and operating cost.

Also, it depends on the type of work to be carried out (like for specialised work in piling, Keller engineering group, Meher foundation is hired to execute work).The P&M department maintains register of their assets, which includes Hired cost register, Maintenance register, Fuel consumption schedule and Usage hours register.All the owned and some hired equipments are operated by CJV staff only. Sub-contractor is just to execute the work with their equipments.

6.11.3 BILLS

Advance Bills:

Advance bills are prepared for Mobilization of P&M on site, so that afterwards, RA bills can be prepared.It includes-

 .Mobilization Advance -This is based on the work we are giving to other sub-contractors.

 .It is generally about 10 to 15% and maximum of 20% of contract cost.

 .General Advance- It includes Bank Guarantee

RA Bills:

It is made by contractor at site and then, it is compared with sub-contractor working. It includes following things:

 .Measurement sheets- Prepared at site and signed by GC representative.

 Reconciliation sheet, for reinforcement or concrete consumption

 .Summary sheet

 Taxes paid during RA Bills: GST [GOODS AND SERVICE TAX] (18%) of goods value

Escalation Bills

Generally carried out for Diesel, Concrete, Steel, P&M, Labour. It is claimed when rates of all these items change above 20% & their substantial usage of same. This is covered from:



.Profit obtained, by selling steel scrap to authorized recyclers



.Adding wastage to price of steel

 The difference between both will add up to tender quoted by MMRC and CJV.

.The recovery of taxes and advances are done by the clients from every month payment, done to the contractor.It includes deduction of Labour cess ), Education cess), TDC , Surcharge , Mobilization advance from every month payment.

Quality Manual:

Set out the structure and content of management system, linking the policy & objectives with system elements and procedure.

Sets out project organisation, responsibilities. Sets out project organisation, responsibilities and authorities

.Quality Procedure:

Provide detail instruction as what is to be done by whom, where and when and how are the steps to be carried out.Method Statement,Work Instruction/ Work Procedure,.Inspection and Test plan [ITP],Conformance reports/ Check sheet/ Work report sheet

Others

Environmental air monitoring , noise monitoring on daily basis, conducting programs on various subjects so the enginners and workers can improve their efficiency. Example BIM programs, integrated planning programs . drilling and blasting methods sessions etc , also for workers such programs are conducted.

MANAGEMEMENT INFORMATION SYSTEM (MIS)

 Daily progress report

The daily progress report is sent on a daily basis to the client as well as the contractor comprising of the amount of work done on the previous day and details about the work that has been done so far and the amount of work to be done.It also provides information about the daily targets set by the contractor

 The monthly progress report is sent on the first day of the new month, giving a summarized view of the work performed in the previous month.It also contains the reasons for the slow work progress (if any). This report mainly deals at the macro level and can be very helpful in picturing the overall progress of the package.

REPORT INCLUSIONS

• RECONCILATION

• monitor the wastages that are incurred on site.If wastage is more than allowable limit, factors that cause more wastage are mentioned.Status of reconciliation statement of Reinforcement and Cement is made on monthly basis. It has record of total indent quantity, total receipt

• Scrap on site for that month

• .% wastage (wastage/Total Issue

QUALITY EVALUATION SYSTEM:

Quality evaluation is done on various stages and by various internal and external parties. Third Party Inspection is also carried out for quality assurance and evaluation of construction activities.

•Each activity has a list of quality checks which needs to be filled before and after the construction activity. These Checks include Formwork, Reinforcement, Concreting, Boring & General Inspection checklists.

•Each check list is filled, observations are recorded and is submitted which is evaluated and final conclusions are included in the monthly progress reports

 Non-conformance report

A non-conformance is raised by the QA/QC department if the department while inspecting thestructure finds it not meeting the required quality standards. In case of non-conformance, the root cause is identified and preventive measures are suggested.The preventive measures are applied and the quality is assured and the report is closed and saved. so that precautions and preventive measures for any similar non-conformance can be reviewed at a later stage

MATERIAL HANDLING

VALUATION AND SELECTION OF VENDORS/ SUB-CONTRACTORS

• Material issued till previous month, Material issued in this month, Total Material issued till date

• Book stock balance (material on sitematerial issued)

•CJV shall procure materials and services from pre-qualified vendors Qualification of vendors is on the basis of evaluation of their ability to meet the required specifications and delivery This evaluation will include the following as applicable

•Supplier who hold a current ISO 9001 registration

•Review of past records of performance

•Review of supplier's/sub-contractor's quality

•Facility survey Checking with previous clients

•Financial capabilities

MATERIAL HANDLING STORES AND MATERIAL HANDLING

•To make any kind of purchase of the material, the store manager does a complete market study of the material, with at least 3 quotations (varies with project to project) with him, before he can order

•.Indent slips- This document is kept in record by the store keeper It is for 2 types of materials on site- Chargeable Items (nails, hammer etc.) and Free Issue (machines, tools etc.). 2 copies- 1 for store and 1 for accountant

MATERIAL HANDLING RECORD KEEPING

•Purchase orders- These are prepared for materials that are to be authorized by the P M directly 3 copies- 1 for store, 1 for supplier and 1 for accountant

•Delivery challan,Stock register- After every month, the stock of the materials present at site is noted in this register, to calculate the usage for each month

6.11.4 MANAGEMNET ASPECTS OF SITE.

6.12 FEASAIBILIYY

Feasibility Study:

The ridership figures for the Colaba – Bandra – SEEPZ Metro corridor are provided by MMRDA based on the results of its CTS Transport Demand Model The proposed Metro Corridor is expected to have a daily ridership of 16.99 Lakh and Max. PHPDT of 42000 by 2031. The daily ridership and PHPD on the corridor are shown in Table 1

STATUTARY APPROVAL

Indian Road Congress Code IRC: SP:55-2001‘Guidelines on safety in Road Construction Zones’

National Building Codes 2005

RIDERSHIP DETAILS

Inference :So this chart shows that the ridership increases with years , this survey is carried out so one can get an idea of number of passengers to be witnessed for the project and the increment is also predicted . If all. the data and survey suffice the criteria of project then the project can be predicted to be feasible.

CASH FLOW

Cash flow management forms an important part of the organisation, as the money payment and advances are decided based on this, which includes cash inflow and outflow for the project

CASH INFLOW + CASH OUTFLOW= PROJECT PROGRESS FOR THE SITE

[Note: This is done either weekly/ monthly/ quarterly]

This works as per the advances obtained for major materials, before execution of the work [e g For cement, steel, concrete; certain advances are obtained as a revenue from the client i.e. MMRC]. From this revenue, work is executed and hence, earnings is obtained, which is in turn paid to the sub-contractors for execution of their work.

Contractor Labour Act, 1970 and rules 1950

Environment Protection Act, 1986

Motor Vehicle Act, 1999 and Central Motor Vehicle Rule, 1989

Factory Act 1948

FINANCIAL FEASABLITY: The basic Project cost of the metro corridor prices is estimated at Rs 150551 Million. The cost of land is estimated at Rs.15,865 Million. Of the total land cost,Rs 4,985 Million is cost of private land and the cost of government land has been estimated at Rs 10,880 Million. The total cost of project including land, is estimated at Rs 166,416 Million.The Central and State taxes and duties (Customs, Excise and VAT) amount to Rs 25,467Million. Of the total taxes and duties, Rs 20,432 Million are central taxes (Customs and Excise duty) and Rs 5,035 Million are state taxes (Value Added Tax). The component towards Octroi and insurance works out to be Rs. 2121 Million and Rs. 831 Million respectively.For the purpose of financial analysis, only cost of private land being a cash payout has been added to the project. The government land is expected to be available on transfer basis. Further, JICA is expected to part fund the project through soft loan. The completion cost including IDC works out to Rs 217,523 Million

PART 2 TASK 1: PROJECT DELAY

7

INTRODCUTION TO PROJECT DELAY

India, there are currently more than 26 metro rail projects at various levels of planning, construction and operation. A number of new phases of metro rails are being planned and will be launched soon. Various studies have documented delays in planning and execution of metro rail projects in India as well as the world.

In this report, an attempt has been made to understand various issues or impediments which are faced by the metro rail corporation in executing the metro rail projects. There are numerous factors which may cause hindrance to the project execution such as funding capacity of governments, finance arrangements, competing technologies, feasible operational model, stakeholder issues etc

Construction delays can be defined as the late completion of work compared to the planned schedule or contract schedule. Construction delays can be minimized only when their causes are identified. The objective of this study was to identify the major causes of construction delay , methods of delay and methods to minimize delays.In this report prepared , all the factors that hindered the progress of package 2 are discussed.their quantification is done along with their impact on duration of project and remedial solution is also given.A. study on reserach papers are also carried and comparison is done with the data and delays of package 2 with the three research papers.This comparison helped to know which kind of delay was more dominant on the package2 and why was it dominant and what role the authorities played into it.

In the analysis part comparison with research papers is also carried out, which bifurcates the delays witnessed in the project into different types, and relative index calculation is also carried out which helped in identifying which delay played a crucical role in the lag of the project. Why study delays: They help in analyzing which activity was dominant in causing the delay, so if in future it can be learnt what actions are to be taken and what actions are to be avoided for smooth completion of project

7.1 Reasons of delays in developed vs developing countries. Table

Reasons

Developing countries

Developed countries.

Delays in payment by client Weather/ ground conditions

Delays in drawings changes and error in deisgn

Contractors financial difficulties

Delays in drawings changes and error in deisgn

Sub contractor and supplier related issues

Deficincies in planning and scheduling Change orders and increase in scope of work

Dealys in delivery of materials

Slow decision making by owners

Subcontractor related isssues

Delay in monthly payments

Force majeure

Poor site conditions

40: comparison between developed and developing countries

7.2 Task overview

 Enlist delays

 Quantify

 Work out reasons . work out impact

 on overall duration of project.

 Work out corrective action to

 be taken by all project participants

Chronology of of delay in package 2

so if we take into consideration Mumbai metro line 3 project, over all there have been many issues related to this magnum project which bears the responsibility of giving mumbaikars a new transport system. In specifically package 2, is taken into consideration there have been many issues rel

F

IGURE 19: CHRONOLOGY OF DELAYS

7.3 Time line of delays

FIGURE 20: TIMELINE OF DELAYS

7.4 QUANTIFICATION FOR DELAY OF WORK ,TIME AND COSTOVERUN.

Working time caluculation

description unit duration

Total shift hours per day (11 hours per shift * 2 shifts) Hrs 22

Lunch hour per day hr 1

Dinner hour per day Hr 1

Total working hours per day hr 22

For planning purpose, 7 days a week with alternate Sunday off that count of total 28 working days in a month and 10 public holidays / year are considered.

Table 41: working time calculation

Method used for quantification

7.5 Impact of tbm hault: Proceedings were carried out in court :

1 21.05.2018

2 23.05.2018

Petition filed in the court by the Anjuman Atash Behram (Parsi Temple)

Court ordered not to cross Parsi Temple, till the verdict

Court has asked to setup a 5 member (IAS officers) committee to make a detailed report on the issue. MMRC-MD was also a part of the committee.

Court has directed the committee to handover the report on 12.06.2018 4 15.06.2018

3 08.06.2018

5 20.07.2018

6 25.07.2018

5 member committee submitted its assessment report on the issue.

CJV has been instructed by Engineer and Employer to stop the TBM-2 works.

Court has asked VJTI an external body to prepare a detailed expertise report in 10days duration.

It was the 10th day, however report was not been submitted by VJTI and they seek 3 days extension for the submission of report. 8 9.08.2018 VJTI submitted the report to court.

7 06.08.2018

9 13.08.2018

Court hearing took place and asked MMRC to show the implementation of VJTI recommendations.

10 17.08.2018 MMRC briefed the , however the bench has been changed.

11 20.08.2018

12 24.08.2018

New bench has asked both the parties to brief the issue in next 3 days. Also, announced to have the next hearing on 18.09.2018.

Chamber of summons issued by MMRC to pre-pone the case.

13 27.08.2018 ime loss has resulted in no discussion on the issue.

14 28.08.2018

Court has asked MMRC to brief the case on 7th / 10th /11th of September

15 27.09..2018 Explanation on the issue and the stand of each parties were briefed till 29.09.2018

16 28.09.2018

17 28.09.2018

Atash Behrams has provided 8 new proposals on the subject matter for review; However MMRC has not considered the same as a part of petition 18raised.

Also, Considering the Supreme court verdict On”SHABARIMALE” HC has asked both the parties to interpret their opinion in our case as wel

18 28.09.2018 Next hearing on the subject matter is on 08-10-2018

19 28.09.2018 Also, Considering the Supreme court verdict On "SHABARIMALE " HC has asked both the parties to interpret their opinion in our case as well.

20 28.09.2018 in our case as well. 20 28.09.2018

21 18.10.2018 Next hearing on the subject matter is on 08-10-2018

22 22.10.2018

All arguments and substantiations from both the parties are over , now it left to the Court to give the final verdict.

MMRC has consulted the court for the tentative date of the verdict, in response the court has assured to give the verdict before 3.11.2018 as after 3rd nov-2018 court will be in vacation of Diwali holidays for the next 10 days.

23 30.11.2018 MMRC plead to expedite the verdict and the same is expected by Nov-18 end

24 6.12.2018 Petitioner challenges the verdict in supreme court and mining stopped on 6.12.18

25 10.12.2018 Supreme Court gives it verdict in favour of MMRC and mining resumes on 0.12.18

So due to the parsi temple issue,its impact on the project was such that the tunnel boring machine was halted unnecessary for 134 days. Due to which mining was stopped, so the tbm could not move further in kalbadevi. Other activities like natm were also stopped as it was linked to tbm’s mining activity, so all the activities which had a start to finish relationship with tbm’s activity were affected and delay.

There was unnecessary delay and high cost overruns of about 14 crores was observed

7.5.1 Impact due to Geogology

CJV (construction joint venture ) encountered the change in geological condition after starting the main drive of TBM (downline) later after discussion with gc the rate of mining was considered 10mm/min which gives production of 7 rings a day where as in planned schedule it was considered to be 9 rings a day

So the productivity of tbm was decreased as per decided norms. Hence it would take longer time to erect the segments than that derived by the contractor.Leading to delay in project time line.CJv also carried out bore holes to ascertain the geology to define TBM drive if dual mode was required . In accordance with the lungeon value and grade of roc encountered , the length has been marked where tbm is to be anticipated in closed mode .

7.5.2 The rate of mining will be affected in closed mode from 7 to 3 rings per day Additional 2 weeks for interchanging the tbm mode

7.5.3 Land acquisition issue at kalbadevi

Land Handing Over Details-As per the contract document –Employer’s requirements – Access to works area; the contractual land handing over for Kalbadevi station was to be made at 364 days from the commencement of the project i.e. on 17.07.17 and few parcel by 15.01.18 whereas land were handed over in piece and parcel, the trail of it is mentioned in following table

Table 42: proceedings

7.5.4 Impact due to delayed natm works

Referring to the tender sequence the central cavern was planned after completion of K1 and K2 Block excavation. But due to delay in land handing over and delay in finalisation of layout there:direct impact on central cavern NATM works. To expedite the work CJV changed the sequence of work to breaking of stationcross passages (adits) and commence central cavern works. The adits works started after TBM# 1 retrieval.

As per the geology the grade of rock encounter is of Grade II and Grade III, hencedrilling blasting methodology is adopted to achieve better progress rate. Due to Parsi fire temple issue, the vibration limits are further restricted to lower than permissible values. Secant piling

7.5.5 Impact due to encountered uncharted utilties

The uncharted utility found in the secant pile layout at the garden side required additional time to carry out diversion works hence obstructing the piling works

The secant pile works was affected in garden area due to this uncharted utilities for which application of diversion was done on 28 02 17 and site visit from concerned authority was conducted on 2 03 17 and approval received on 5 07 17

Impact due to Covid -19

Site remained close for 28 days so the entire project schedule is delayed for one month and further even if site will commence from 20 april there will be less labours on site due to safety guidelines of covid 19 and hence the productivity will drastically decrease leading of substantial increase in timeline of the project

Table 43: building demolition status

7.6 Project key dates and delays

COMENCEMENT DATE : 8 JULY 2016

7.7 COMPARISON WITH RESEARCH PAPER NUMBER

The classifications of delays are categorized into four basic ways:

1) Critical or Noncritical delays

2) Excusable or Non-excusable delays

3) Compensable or Non-compensable delays

4) Concurrent or Non-concurrent

 Delays that affect the duration or completion of project are critical delays. The delays do not affect duration or completions of project are noncritical delays.

 The delays which are not predicted under any activity which is apart from the control of contractor are excusable delays. In this type, no one is responsible by law for penalty. In Non-excusable delays, the delays are beyond the control of contractor and these delays are deal with contractor and client may be claim to something for the compensation.

 A compensable delay is a delay where the contractor is designated to prolong the time and to add the compensation. Excusable delays are able to compensate. In Non-compensable delays, the contractor is not able to claim for the compensation from the excusable delays.

 A concurrent delay is the concept of presenting an analysis for common construction delays. The argument of concurrency is not to determine the critical delays point of view but from an attitude responsible for damages connected with the delay to the critical path.

CONSTRUCTION PHASE

QUANTIFICATION OF TYPE OF DELAYS

Quantification of delays

Inference: In MMRL-3 UGC02 external factors are highest cause of delay followed by client related isssues. Contractor related issues are fewer and lowest are that of consultants.

So external factors are dominant in causing the delay in the project

STUDY OF DELAY DURING VARIOUS PHASES OF CONTRUCTION

Planning/scoping phase: Delay can be significant when litigation is initiated.

• Development phase: Permitting (environmental, fish and wildlife, railroad, etc.), right-ofway acquisition, and utility agreements can be significant causes of delay.

• Contracting phase: Generally, this phase has less incidence of delay but can still have issues.

• Construction phase: This phase has numerous opportunities for delay and is often the delay most visible to the public

non critical excusable non excusable compensable non compensable

type of delays

Inference: In MMRL-3 UGC02 critical delays and non excusable delays are major and least delay is caused by excusable and compensable factors

• Permission for utility diversion issues at grant road station 60

• rehabilitation issue at kalbadevi and girgaon land accquisition issue for kalbadevi station box 365

• less awareness lead to protests to oppose the project

• procurement of tunnel boring machine 146

Bhumika Raj (UC5316) Semester-08

CONSTRUCTION PHASE DELAYS

•COVID 19

•TREE PLANTATION ISSUE AT GRANT ROAD

•LATE RESPONSE FROM MGL AT GIRGAON FOR DIV.

•TRAFFIC DIVERSION ISSUE AT GRANT ROAD

•INCREASE IN SCOPE OF WORK OF BCS(BUILDING

•(POUR 4 )CONCRETE PUMP UNAVAILABILITY

•NON AVALIBILITY OF STRUT AND WALER

•REVISION IN GIRGAON STATION PILE PLAN

•TBM HAULT DUE TO PARSI TEMPLE ISSUE.

•SEWER LINE DIVERSION AT GRANT ROAD

•GLOBAL PROCUREMENT ISSUE

•DELAY FOR NATM WORKS AT KALBADEVI

•DELAY AT GIRGAON STATION DUE TO GANESH

Inference : from the above dashboard we can say that the majority delay was caused due to the delay at grant roadstation due to traffic diversion which tokk a lot of time for approvals from authorities while leasr delay is caused due to unavailablility of strut and waler because of the unavailabiliy of material from contractor side

Inference: from the adjacent dashboard we can say that in pre-constructio phase the majority delay is caused due to the rehabilitation issue at kalbadevi and grant road station.

Total duration of the project in contract was 1638 days, but the setback is that the delay is about 93% of the total time duration which is 1526 days.So the project is delayed majorly due to delays in construction phase which is 883 days and in pre construction phase also delay of about 643 days is observed. ( refer pg no.118,119)

As delays till 22 march are curated the project lags behind substantially and it will take almost twice times the time taken for completion and handing over which is tentative 6 nov 2023 instead of 10 jan 2012.

7.8 CONCLUSION:

Construction of infrastructure project like metro in a developing country like India is quite a task, due dilligence and patience is required for carrying out the same.Mumbai metro is one of those mega projects of india, because Mumbai is a mega city with highest number of commuters, but it’s not easy there are obstacles that slow down the cost project time and cause cost over runs

When comparing with the research paper and from my study and observation of delays, majority caused are due to external factors in Mumbai metro line 3 –UGC02, also client related administrative factors have cause delay. Contractor related issues are still prevelant but not at large scale, as they are linked with the client tasks.

In a city like Mumbai which is densely populated and carrying out mega construction in congested and century old areas like kalbadevi and girgaon it’s a task it self. So geography and city’s development also plays an important role in identifying the delays or assuming the delays

So if client related tasks get delayed (eg tbm hault at kalbadevi)

 Entire project time line is disturbed if each project is linked as they have a start to start type relationship.( all tbm related activities hindered)

 Start to finish relationship are not that much affected as they are not linked with any other task( as they are independent( stations works at kalbadevi not hindered)

Effect and project duration

 Total duration of the project in contract was 1638 days, but the setback is that the delay is about 93% of the total time duration which is 1526 days

 As delays till 22 march are curated the project lags behind substantially and it will take almost twice times the time taken for completion and handing over which is tentative 6 nov 2023 instead of 10 jan 2012. ( refer pg no 118,119 )

TASK 2: DESIGNING A LABOUR COLONY

8 DESIGNING A LABOUR COLONY:

PURPOSE :The temporary housing project provides the migrant construction workers and their families a stable option despite the transient nature of their work.Due to rapid urbanisation throughout India, large-scale housing developments litter city margins, catering to a growing middle class. Migrant workers building these high-end developments temporarily live on the construction sites in labour colonies. The labour colonies are innovative and productive, but highly susceptible to dysfunction, suffering from a lack of any basic infrastructure.

Drawing from My site experience and data , I have designed a temporary housing system to accommodate 250 workers and their families. The system aims to improve living conditions for the inhabitants by providing practical aspects of drainage, insulation, ventilation, sanitation, safe spaces for women and children as well as social spaces for communal daily activities, a children’s crèche and open spaces that allows movement.My main aim is to build a housing colony which is sustainable and economically suitable.So the materials and technologies are choosen in such a way that they justify the aim of the project.

CHALLENGES FACE:Mostly the challenges faced are that quality of labour colony provided in india at majority of construction is quite unsuitable. This poses threat to the workers life and their families residing in. Also the contractors usually fail to provide a habitable housing colony,, they end up compromising with the workers habitat. The situation is not that grave now but the difficulties still prevail.

Zonw

Zone

IDEALOGY USED:



ZONE 1:LABOUR ACCOMODATION

Total three buidlings

Two buildings with 2 storey accommodating bachelors with 5 person in one unit, so total 40 units accommodating 200 labours . And for couples 25 accomodations are provided each couple allotted a room of size 4*4 m.

Further semi private area is provided for cooking some minor things so the private area in room doesn’t get affected and damaged by the smoke produced by chulahs and also for the easy movement and keeping in mind privacy.



ZONE 2 : DINING AREA

Dining area is provided adjacent to the boundary of site which is approx. 30% of the labour accommodation including washing area. Drinking water facilities and cooking area also and 20 m away from toilet areas.



ZONE 3:WASHROOMS

The ratio is kept 1:15 for men and women for bathing areas and toiltes as per the They are kept in the vicinity of the labour accomodation so it is safe and also bio toilet blocks are used so the water can be recycled and the methane gas can be stored in form of energy and used for other activities.

 ZONE 4: CRECHES

It is a very important aspect because of most of the female labours in india have infants, Also according to the cenus by an NGO, organisation of labour presented that about 60% of the women labours have infants.

So it was very important to provide a crèche ,so in the designed project is placed in centre of the accommodation so they can keep a check.

 ZONE 5:COMMUNITY GATHERING

A Community space is needed for the activities to be carried out on the labour colony , there can be awareness program or any other programs can be conducted easily.

 ZONE 6:WATER/ DRAINAGE FACILITIES

So four septic tanks are provided for the same purpose , where water can be used for Daily activities and also reverse osmosis water plant is provided which ensures that the people on site get sufficient and safe water for drinking purpose. Sceptic tanks are also provided for waste collection from the site. Per person consumption of water is 4 litres, so for 250 people about 1000 litres of water is needed everyday so each tank of capacity of 250 litres is provided on site.

FIGURE 22: GRID LAYOUT

FIGURE 23: FOOTING LAYOUT

FIGURE 24: COLUMN LAYOUT

8.6 METHODOLOGY

1 AFTER FOUNDATION WORK IS DONE BASE PLATE AND COLUMNS ARE CONNECTED TOGETHER

2 AFTER VERTICAL ELEMNTS ARE ERRECTED , HORIZONTAL ISMC IS FIXED WITH NUT AND BOLT

3 TUBULARS ARE PLACED ON THE ISMC AT THE SPACING DECIDED

4 ROOFING SHEET IS ATTACHED AR GROUND LEVEL THEN SAME PROCESS IS REPEATED FOR SECOND FLOOR

BENEFITS OF USING MODULAR STEEL AND CONCRETE STRUCTURE

QUALITY SPEED REUSE

5 IN THE END ALL THE PALL PANELS ARE ASSEMBLED and doors and windows are attached

SUSTAINABLE LESS MAN POWER

FIGURE 27: METHODOLOGY OF MODULAR CONSTRUCTION

FACULTY OF TECHNOLOGY (PROJECT TRAINING 2020) CEPT UNIVERSITY) ABSRACT SHEET

Name: BHUMIKA RAJ Code : UC5316

Project Name: LABOUR COLONY MMRC-3 UGC02

1.01

Excavation in hard rock / boulders (more than 1/2 Cum in size) by chiselling to required level for foundation, trenches, rafts, plinths, levelling area etc , upto required depth including disposing off excavated material at a location within site as per direction of the PM by stacking or spreading compacting as per direction of PM; shoring, strutting, stepping,dressing,gradding, cleaning, removing and excavating loose pockets and consolidating them by backfilling as directed by the PM etc. All complete as detailed in

specification and conforming to safety rules of authority from time to time.

Earth work in surface excavation not exceeding 30 cm in depth but exceeding 1.5 m in width as well as 10 sqm on plan including getting out and disposal of excavated earth upto 50 m and lift upto 1.5 m, as directed by Engineer-in- Charge

1.03

Back filling /Filling with approved good quality earth in plinths, area levelling etc. In layers each not exceeding 200mm in depth, breaking clods, watering, compacting each layer with vibratory compactor and at inaccessible places with wooden/steel rammers to achieve 95% proctor density at optimum moisture content; dressing up embankments; if required bailing/pumping out of water by localised dewatering system to keep site dry while back filling; costs includes transportation of all materials, labour, machinery etc, complete as per direction and to the satisfaction of the

T

F

Delhi Schedule of Rates/2.1.1 /Pg7 9)

(Refer Delhi Schedule of Rates/2.25/ Pg11 6)

1.04

Consultants and or Technical Specifications..

2.00

Anti-Termite Treatment

Supplying and spreading pesticides CHLORPYRIPHOS or other chemical approved by central insecticides Board as directed by the manufacturer and spraying the mixture uniformly by sprayer as pre-construction anti- termite treatment at the rate of 7.5 litres (or as directed by the manufacturer specification) per sqm on vertical and 5 liters. (or as directed by the manufacturer specification) per sqm on horizontal surfaces of the sub- structure, within the trenches, 50% of the emulsion to be filled in the holes made in trenches at 150 mm centre to centre etc. complete all as per IS 6313 Part-II(latest) specification & as directed by the Engineer-incharge.

2.02

CONCRETE

Providing, transporting, pumping and laying approved M25 grade designed mix batched, controlled reinforced cement concrete, manufactured at site , conforming to with minimum cementitious content as per IS including flyash upto maximum 33% of the cementitious material and maximum water cement ratio 0.45 or as specified by Structural Consultant including using approved quality ingredients and admixtures and placed either with pump/manual/lift of concrete at any lead, lift, height or depth, including compacting with vibrators,curing and hacking / preparing the exposed surface wherever required to receive plaster or floated with powered rafts / foundations, steel troweled surface wherever specified, curing etc.

For Footing

3.00 BRICK MASONRY

3.01

Providing and laying common burnt claybuilding brick having crushing strengthnot less than 35 kg/sq.cm. in cement mortar 1 : 6 (cement : fine sand )including transportation, tools, curing and erecting in line and level above plinth etc. complete

4.00 FORMWORK

4.01

Designing, Providing, erecting and fixing in position customs / system designed form work true to line and level, for foundation, columns etc with use of plywood with required steel props and staging, applyingshuttering removal emulsion/oil as approved, required bracing, making leak proof joints etc, complete at all heights, depths, leads and lifts. System design should be such that staging, supporting, holding shall be strong enough not to allow any sagging, deformation, bending, curving, undulation in vertical plane and in length. Exposed surfaces shall be free of blemish, residues of curing compound uniform in colour, free of construction joint System to be from approved proprietary make to achieve approved no of days cycle. Form work should be designed for fixing at interned location allowing expected dead and live loads during working. Also it should be able to carry dynamic loads side thrust etc.Also include removing and dismantling the aforesaid assembly after specified or as approved period from the day of casting of concreting to the satisfaction of the PM. All staging and formwork systems must be designed for the loading criteria stipulated by the consultant and such design shall be approved by the PM before implementing on the site. The rate quoted shall be for erecting staging, form- work dismantling, dewatering etc.. All Supporting system of form work will be only with steel props & staging shall be duly designed to carry proposed loads.

(Refer Delhi Schedule of Rates/5.9.1/ 5.9. 2/Pg188,189 )

a For Labour Colony

5.00 REINFORCEMENT

5.01

Providing, Supplying, Transporting to site, storing, decoiling, straightening, cutting, bending, spirally hooping, bundling and placing, in position HYSD Fe500 reinforcement bars, to correct shape and size as per detailed drawings, specifications preparing and getting approved bar-bending schedules for all reinforced concrete work such as footings, walls, columns / slab columns, beams, slabs, staircase, rafts etc. with correct size of concrete cover blocks (of equivalent approved) of same grade as of concrete and galvanized binding wire of 18 gauge; required dewatering, Provide required labour and machine / equipment's / tools / tackles for handling, shifting, bending, binding, etc.

6.00 STRUCTURAL STEEL

6.01

Providing, preparing shop drawings, obtaining Structural Consultants approval, supplying, fabricating in accordance with IS:800, delivering at site, hoisting and fixing in position at all locations, heights, lifts, leads and levels, including all temporary staging and supporting work and making all structural steel work in accordance with the design, drawings prepared by the Consultants. The rate of steel work shall include cutting, grinding, machining, assembly, welding, jointing, of single / building up new sections with anchors, angles, beams, canopy, supports, column, trenches angel protections, trench covers etc. cost of fasteners (nuts, bolts and washers), pre-heating the sections to temperatures up to 250 degree C if thickness of the section is equal to or more than 25mm. Fabrication wall involve connections using plates, channels and angles, gusset plate, foundation bolts, cleats, fasteners, stiffeners etc. as per drawing steel conforming to IS : 226 and IS : 2062 with minimum yield strength of 350 Mpa.The rate shall also include one coat of rich primer after properly cleaning the steel surface with wire brush and mild acid solution followed by washing with water and drying the surface completely, to be applied to individual fabricated parts of the structure prior to their erection & assembly in their final place. The rate shall also include the synthetic enamel paint system in approved shade and of approved make as per recommendations of the paint manufacturer to the approval of PM etc.complete

(Refer Delhi Schedule of Rates/10.1/Pg 66 7)

b For Canteen

c For Creche

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

Providing and laying Kota stone slab flooring over 20 mm (average) thick base laid over and jointed with grey cement slurry mixed with pigment to match the shade of the slab, including rubbing and polishing complete with base of cement mortar 1 : 4 (1cement : 4 coarse sand) including tools, labours etc. complete

Providing and fixing M.S. angle 96x48x1.6 mm to act as nosing with lugs of M.S. flat 10x5 mm, 10 cm long, forked at end 60cm apart (minimum three lugs to be provided), including necessary welding and applying a priming coat of approved primer on exposed surface etc. complete.

(Refer Delhi Schedule of Rates/11.35/P g7 71)

ROOFING

Providing and fixing corrugated G.I. sheet roofing 0.07 mm thick with zinc coating not less than 275 gm/m² including vertical / curved surface fixed with polymer coated J or L hooks, bolts and nuts 8 mm diameter with bitumen and G.I. limpet washers or with G.I. limpet washers filled with white lead, including a coat of approved steel primer and two coats of approved paint on overlapping of sheets complete (up to any pitch in horizontal/ vertical or curved surfaces), excluding the cost of purlins, rafters and trusses and including cutting to size and shape wherever required etc. complete

(Refer Delhi Schedule of Rates/12.1.1/P g 80)

9.00 WALL PANELS

d

Providing and fixing partition upto ceiling height consisting of G.I. frame and required board, including providing and fixing of frame work made of special section power pressed/ roll form G.I. sheet with zinc coating of 120 gms/sqm(both side inclusive), consisting of floor and ceiling channel 50mm wide having equal flanges of 32 mm and 0.50 mm thick, fixed to the floor and ceiling at the spacing of 610 mm centre to centre with dash fastener of 12.5 mm dia meter 50 mm length or suitable anchor fastener or metal screws with nylon plugs and the studs 48 mm wide having one flange of 34 mm and other flange 36 mm and 0.50 mm thick fixed vertically within flanges of floor and ceiling channel and placed at a spacing of 610 mm centre to centre by 6 mm dia bolts and nuts, including fixing of studs along both ends of partition fixed flush to wall with suitable anchor fastener or metal screws with nylon plugs at spacing of 450 mm centre to centre, and fixing of boards to both side of frame work by 25 mm long dry wall screws on studs, floor and ceiling channels at the spacing of 300 mm centre to centre., Galvanised M.S. fixing channel of 99 mm width (0.9 mm thick having two flanges of 9.5 mm each with zinc coating of 120 gms/sqm(both side inclusive)) to be provided at the horizontal joints of two boards.

10.00 WHITE WASHING

Providing and finishing with white washing lime on walls to give even shade after throughly brushing surfaces to remove dirts, remains of loose particles including scaffolding, tools and labours etc. complete

11.00 DOOR,WINDOW

Providing and fixing ISI marked flush door shutters conforming to IS : 2202(Part I) non-decorative type, core of block board construction with frame of 1st class hard wood and well matched commercial 3 ply veneering with vertical grains or cross bands and face veneers on both faces of shutters: 35 mm thick including ISI marked Stainless Steel butt hinges with necessary

12.00 MISCELLANEOUS

Providing bio toilet of Dimension 1*1*2.5 m of Color White of suitable brand of Material PUF Panel Feature Portable and Prefab Bidet Size 600 x 450 mm on site with specific drainage facitlities and water pipe facilties

F

(Refer Delhi Schedule of Rates/9.105/P g5 59)

(Refer Delhi Schedule of Rates/Vol.2/13 .3 8/Pg931)

ALTERNATIVE ACTIVITY

This activity aims to to provide an alternative to the Natm method used at kalbadevi station, so the alternative adopted ADECCO-RS method which uses the concept of Analysis of Controlled Deformation in Rock & Soils. ADECCO-RS method is proposed for the construction adit 3 and central cavern length of Kalbadevi station of Mumbai Metro Line 3 –UGC_02

Details of the project:

Name of the project: Mumbai metro line 3-UGC-02

SITE OFFICE ADDRESS – Gate 3, Azad Maidan, Nr. Metro Cinema, Mumbai – 400001, Maharashtra

SCOPE OF WORK – Design and construction of Underground Stations namely CST Metro, Kalbadevi, Girgaum and Grant Road and Twin Tunnel between CST and Mumbai Central – Up Line (from Ch. 3770.58 m to Ch. 7842.62 m) and Down Line (from Ch. 3801.05 to Ch. 7860.22 m) by TBM including Scope of works comprising of Civil, Architectural, E&M works as defined in agreements.

PROJECT TYPE – EPC (Engineering, procurement and construction) Contact. EPC Contractor is responsible for all activities engineering, procurement and construction and hand – overs the project to the owner.

Scope of the Alternative : kalbadevi station consists of three adits and one central cavern

And its work is carried out natm method(New Australian Tunnelling Method) so the alternative suggested is Adecoo-RS method .

Elements observed: Proposed alternative method Adecco-RS method on stretch of 451m from Kalbadevi to Girgaon station.Elements covered are : one adit and central

Alternative activity suggested: This activity aims to to provide an alternative to the Natm method used at kalbadevi station, so the alternative adopted ADECCO-RS method which uses the concept of Analysis of Controlled Deformation in Rock & Soils. ADECCO-RS method is proposed for the construction adit 3 and central cavern length of Kalbadevi station of Mumbai Metro Line 3 –UGC_02

8.7 METHOD STATEMENT FOR CONSTRUCTION OF TUNNEL BY ADECCO-RS

DESCRIPTION OF ADECCO-RS METHOD

This method was developed in eighties in Italy by Professor Lunardi. As the name ADECORS (L’Analisi delle Deformazioni Controllate nelle Rocce e nei Suoli) says, it is a method of controlled deformation. Its introduction to tunnelling practice can be dated as occurring in 1985 when it was tried out for the first time in the world by the Professor Lunardi and Doctor Bindi during the construction of some tunnels on the Florence-Arezzo section of the new high speed railway line between Rome and Florence.

1)PURPOSE

This document sets out the method statement for exacavtion, mucking and deposition in order to carry out works In a planned and systematic manner. The aim of this document is to carry out outline the method to be deployed for construction of adit , widening of tunnel and excavation for central cavern

2)SCOPE

To set out the requirements for adit , cavern and tunnel widening by ADECCO-RS works on the kalbadvei station of MML-3 and maintaining safety quality and environmental compliance

3)

8.8 METHODOLOGY INTRODUCTION(ADECCO-RS)

This method was developed in eighties in Italy by Professor Lunardi. As the name ADECORS (L’Analisi delle Deformazioni Controllate nelle Rocce e nei Suoli) says, it is a method of controlled deformation. Its introduction to tunnelling practice can be dated as occurring in 1985 when it was tried out for the first time in the world by the Professor Lunardi and Doctor Bindi during the construction of some tunnels on the Florence-Arezzo section of the new high speed railway line between Rome and Florence.This method is based on the Analysis of the COntrolled DEformation in Rocks and Soils” (ADECO-RS).

Survey phase/Design phase

Design Stage

Diagonsis phase stabilisation measures

 Survey Phase - Determine the Characteristics of the medium.

1)Geological, geo-morphological and hydro-geological characteristics of the area.

2)Location and definition of terrain through which the alignment passes.

3)Tectonics, geological structure and the stress state of the rock mass.

4)Hydro-geological regime of the rock mass. 5)mechanical characteristics of the materials

 Diagnosis Phase – Divide the tunnel sections in Category A, B or C, defining the details of deformation development and types of loads mobilised by excavation.

1)Using Analytical and/or Numerical Methods, predict the behavior category and deformation response for various sections of the tunnel alignment

 Therapy Phase – Decide type of confinement and/or pre-confinement and test their effectiveness by mathematical modelling

1)Decide about confinement and/or pre-confinement measures, for various sections of tunnel alignment.

2)Decide about excavation systems also, simultaneously, for various sections of tunnel alignment.

 By using this approach, which is based on a clear distinction between the design stage and the construction stage of tunnels. it was possible to reliably estimate construction costs and times for the project in advance and this in turn made it possible to award contracts for the work on a lump sum “turnkey” basis for the first time in the history of underground works for projects of these dimensions and difficulty.

 Other important characteristics of the ADECO-RS approach are the centrality of the deformation response of the ground to the action of excavation and the use of full face advance employed even under the most difficult condition

DIAGONIS

Characterisation of the medium in terms of rocks

Deciding the intervention measures in the basis of behaviour categories

composition of tunnel section type

longitudinal and cross section

PHASE

FIGURE 28: ZONES FOR CONSTRUCTION

FIGURE 29: TIMELINE FOR ADDECO -RS APPROACH

8.9 DEFINITION OF CASES

On the basis of the methodologies adopted there were three outcomes wbich were analysed.

Case Type-1

Stable Core Face - Rock Type Behaviour

The face as a whole is Stable. Only local instability is found due to the fall of isolated blocks. Stabilisation techniques needed for preventing deterioration of rock and to maintain profile of the excavation.

Case Type-2

Stable Core Face in Short Term - Cohesive Type Behaviour

if Medium is stressed in the “Elasto-plastic range”.

 Stress sate is low in relation to the characteristics of the medium.

 Sufficient to intervene on cavity only using radial action and no longitudinal intervention in advance core is needed.

Instability manifests in the form of widespread spalling at the face and around the cavity.Allows sufficient time to employ traditional radial confinement measures, after passage of face.In some circumstances, it may be necessary to resort to pre-confinement of cavity, to contain deformation within acceptable limits.Presence of water to be prevented by suitable drainage arrangements.

Case Type - 3

 If Medium is stressed in the “Failure range”.

 Stress state is high in relation to the characteristics of the medium.

 It is of primary importance to stiffen the advance core with pre-confinement of cavity, which may be supplemented with confinement of cavity after the passage of the face.Deformation is unacceptable because it develops immediately in failure range. Ground reinforcement needed ahead of face to

380009, Gujarat

T +91 7926302470

F +91 7926302075

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad –

FIGURE 30: EXAVATION FOR HARD ROCK

FIGURE 31: EXCAVATION FOR COHESIVE ROCK

FIGURE 32: EXCAVAVTION FOR SOFT ROCK

develop pre-confinement action. Presence of water is absolutely unacceptable and shall be prevented by drainage arrangements.

8.10 STABILITY MEASURES

On the basis of the deformation response there is ANALYSIS done and further stbaility/ intervention measures are suggested on basis of that

1 Protective Intervention :The intervention channels the stresses around the advance core to perform protective function, that ensures that the natural strength and deformation properties of the core are conservedFull face sub horizontal grouting Full face mechanical precutting

Reinforcement Intervention The intervention acts directly on the consistency of the advance core to improve its’ natural strength and deformation properties by means of appropriate ground reinforcement techniques.

8.11 STEPWISE PROCEDURE

T

STEP 2 FULL FACE EXCAVATION BY CASCAGER

STEP 3 PLACEMENT OF LAYER OF SHOTCRETE ON FACE

STEP 4 PRECUTTING

STEP 5 Positioning of the Steel Rib under the last precut and shotcreting

STEP 6 The Cycle continues repeating Phase-2, 3, 4 & 5,until advance length is complete

STEP –7 : Excavation and Casting of Invert STEP -8: The Cycle returns to Phase-1

STEP -9 : Waterproofing is placed and Final lining is cast

STATIONS : CST, KALBADEVI, GIRGAUM, GRANT ROAD.

8.11.1 Methodology :

UNDISTURBED ZONE

Phase–1: Reinforcement of the Core Face using fibre Glass Tubular Elements

TATA HITACHI EXCAVATOR

DRAINAGE PIPES FOR DEWATERING

REINFORCED TUBE EXTENDED ABOUT 1224 M LONG

UNDISTURBED ZONE

UNDISTURBED ZONE

Phase-2: Full Face Excavation

AUTOMATIC SHOTCRETE MACHINE IS USED FOR THIS PURPOSE

EXCAVATION OF THE FACE IS CARRIED OUT TILL 1M ADAVANCE

UNDISTURBED ZONE

Phase-3 : Placement of a layer of Shotcrete on the Face

STEEL RIB/ LATTICE GIRDER IS PLACE AT INTRVALS OF 1M.

Phase–4: Positioning of the Steel Rib under the last pre-cut and shotcreting

Kasturbhai Lalbhai Campus University Road, Navrangpura

Ahmedabad – 380009, Gujarat

T +91 7926302470

F +91 7926302075

SHOTCRETE IS CARRRIED OUT TILL 1M

NATM(New Australian tunnelling method)

HOW METHODOLGY DIFFERS FROM NATM

ADECCO-RS

 It was first developed in alpine region used for excavation and widening purposes .drilling and blasting plays a major role in this method

 Full face excavation is carried out according to the marking profile made by the blast experts, so that design is followed by the engineers facing setbacks like undercut and over cuts.

 There is no provision like tubes made in the area beyond the face of excavation for stabilisation of soil ahead, natm is carried out solely on the basis of drilling blasting methods.

 Also there is no provision made to reduce or eliminate the hydraulic pressure caused due to water ingress it can be detected only when problem is faced not like Adecco-rs method where we can reduce the water levels by dewatering

 After excavation of one cycle of 1m , the structure is supported by rockbolting , wiresmesh and shotcrete which is called the primary lining and secondary lining is done quite later .

 At MMRCL-LINE3 UGC02 Shotcrete is carried out by pneumatic shotcrete machine

 Advance per day achieved is about 1 m in rocky stable soil condition(basalt rock in South Mumbai )

• The ADECO-RS, an Italian tunnelling method known also as the Lunardi method, was used for the excavation. Full-face excavation without regard to geological conditions is a typical feature of this method.

• The full-face excavation was carried out under the protection of canopy tube presupport; the excavation was stabilised by horizontal jet grouting and, under extremely bad geological conditions, even by 12m long glassfibre reinforced plastic anchors

• Stabilisation of the excavation roof by long boreholes; pressure injection of grout into the boreholes for the 13m long perforated tubes forming the canopy tube pre-support; injection of grout into the tubes

• Each of each borehole provided with a drainage casing pipe, which was designed to eliminate the hydraulic pressure on the excavation face. The abovementioned operations were carried out by means of a Casagrande drilling rig and a high-performance grouting set, which was placed on the surface.

• Before the work on the stabilisation of the excavation face and roof could begin, it was necessary to support the concavely moulded excavation face by a 15cm thick layer of steel fibre reinforced shotcrete.to optimise the effect of the grouti

• ng and reinforce the excavation face so that it resisted the ground and grouting pressures.

• Shotcrete is carried out by automatic shotcrete machine instead of pneumatic shotcrete

• Advance per day is about 3 m for per day excavation for face

8.12 QUANTITY ANALYSIS

Note :refer car 3 for detailed analysis of quanity for (explosives , detonators and other activities ) for natm

*Considering the dimensions of adit and central cavern remain same so for both methods the quantity for shotcrete and installation lattice girder/ steel rib stays same(refer car 3)

*Change is seen in the no of holes as for ADDECO –rs method there are drainage holes and holes for reinforced glass tubes also provided which increases the no of holes compared to natm

QUANTITY ESTIMATION BY ADDECO RS METHOD BY ADECCO-RS

Tubular holes

Drainage holes

Drainage holes: 6 Holes OF Length 9 m for 10 m long cavern face( reference comparison of natm and adeco-rs methods,Using monte cuneo tunnel, italy, as an example Peter balušík, libor MAŘÍK)

Tubular holes: At the distance of 200mm 13 m long beneath the roof stabilising boreholes so total 250 number in grid pattern ( reference comparison of natm and adeco-rs methods,Using monte cuneo tunnel, italy, as an example Peter balušík, libor MAŘÍK)

Total holes - 6+250=256

=6*9*0.05 – 2.7 m3

=250*13*0.05-162.5m

8.13 TIMECYCLE FOR ADECCO –RS METHODLOGY

( reference comparison of natm and adeco-rs methods,Using monte cuneo tunnel, italy, as an example Peter balušík, libor MAŘÍK)

of

with 1 hour break each , pull of 1.15 at adit is observed

8.14 COST ANALYSIS FOR ADDECO-RS

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY NAME:-

RAJCODE NO:-UC5316

PROJECT TRAINING 2019-2020 ABSTRACT SHEET

Drilling 75 mm diameter drainage holes vertical or inclined in rock / concrete in tunnel by percussion drilling method using waggon drill or other suitable drilling equipment including cost of all materials, machinery, labour, ventilation, lighting, drainage etc., complete.

Grouting Drilling 35 mm diameter grout holes in concrete / rock by percussion drilling using jack hammer or stooper drills as directed to specified depth for consolidation / contact grouting including cost of all materials, machinery, labour, ventilation, lighting, drainage, cleaning holes, and all other ancillary operations etc., complete.

Grouting cement slurry in grout holes under specified pressure for consolidation / contact grouting including cost of all materials, machinery, labour, ventilation, lighting, drainage, redrilling wherever necessary, and all other ancillary operations etc., complete with lead upto 1 km and all lifts.

Providing for and carrying shotcreting for 6m wide cross-passage as per specification using M35 grade of concrete including batching,

Steel rib Fabrication and Erection of 70/20/25Lattice Girder as per drawings andspecification including fabrication of accessories, welding, bolting, transportation

Providing for and fixing of wire mesh after1st and 2nd layer of shotcrete for 6m wide cross-passage including drilling,transportation etc complete,transportation, spraying etc.

Providing for and carrying shotcreting for 6m wide cross-passage as per specification using M35 grade of concrete including

TABLE 46: COST ANALYSIS ADDECO-RS METHOD

T

346.00(refer pg

item no 6.21

METHOD

ADECCO-RS

Concept It is the method of controlled deformation

Construction phases

It is carried out on the basis of deformation response

Approach While this method deals with 3dimensional approach

Geological conditions

Hydrological conditions

equipments

NATM

It is based on the principle of controlled blasting and drilling

It is based on RMR (Rock mass classification)

It deals in 2 dimensional approach

No stabilisation is done, directly drilling or blasting is carried out. Settlement risk is less Settlement risk is higher

Ground is stabilised by using reinforcement tubular fibre glass

Dewatering is done by Drainage pipes which used before carrying out the excavation

Due to dewatering it is possible to eliminate the hydraulic pressure on the excavation face

Equipments used are a bit costly, like tunnel rig which is not traditionally used in india

labour Labour force required in this process is low but high as highly skilled labours are used

Environmental impact Low noise and vibrations encountered .

No explosives used so air quality is not detoriated and does not impact the quality of life there.

saftey Life of workers is at potential risk due to drilling and blasting

Instrumentation and monitoring

3D optical targets and strain guage are used

Time Advance of 5m /day is observed (refer pg- timecycle derived

cost It is avery expensive method but ensures safety and quality

No facility of dewatering is possible

Hydraulic pressure cannot be controlled

Equipemnsts are comparartively cheap and easily available

Labour force required in this process is quite high as highly skilled labours are used

Noise and vibrations are comparatively high

Air quality detoriates as explosives emit ammonium nitrate which is hazardous to workers and exacerbates the quality of air

Life of workers is at potential risk due to drilling and blasting

3D optical targets and strain guage are used

Advance of 1m is observed per day (refer pg- time cycle derived

Its I less expensive compared to the addecoo-rs aapproach

T

8.15 PIPE JACKING

Activity : Proposing the construction of cross passage by pipe jacking method as an alternative method of construction of cross passage over the maual excavation method at grant road (UGC_02) at Mumbai Metro Line 3 with the objective to propose an alternative and comparing both with parameters such as quality , safety , time and cost.



8.16 Details of cross passage :

 Cross passage details:

cross

passage 7

 Observed activity location : total 7 cross passages from kalbadevi to grant road.,Cp 7, grant road station chainage 7510 upline . 7490 downline

 Cross passage 7 dimensions:

 Wide-3M



Length : 14m



Height: 3.149

What is pipe jacking

Pipe jacking/microtunnelling* is a non-disruptive method of installing utility tunnels and conduits by thrusting pipes through the ground as controlled excavation is undertaken at the face. Pipes manufactured in a variety of materials to include concrete, clay, grp and steel can be jacked and standard pipe diameters generally range from 150mm to 2,400mm, or greater when required.

Jacking lengths achievable can be considerably in excess of 1km depending on pipe diameters, ground conditions and excavation methods. Drive lengths are only limited by practical engineering considerations and economics and drives either in a straight line or to a radius or a series of radii are readily achievable.

Pipe jacking can deliver environmental benefits in excess of 75% as measured by reduced carbon emissions compared to disruptive open-cut construction, which requires considerably greater amounts of excavation and substantial backfill material. Long- term damage to existing installed infrastructure is alsominimised.

*Microtunnelling - originally used todescribetheconstructionoffully automated non man entry pipe jackedtunnelsinsmallerdiameters, the term is now also sometimes appliedtofullyautomated pipejacks in larger diameters which may be controlledfromaboveground

JACKING METHOD:

DESCRIPTION OF PIPE JACKING METHOD:

Pipe jacking/microtunnelling* is a non-disruptive method of installing utility tunnels and conduits by thrusting pipes through the ground as controlled excavation is undertaken at the face. Pipes manufactured in a variety of materials to include concrete, clay, grp and steel can be jacked and standard pipe diameters generally range from 150mm to 2,400mm, or greater when required.

1)PURPOSE:This document sets out the method statement for exacavtion, mucking and deposition in order to carry out works In a planned and systematic manner for cross passage . The aim of this document is to carry out outline the method to be deployed for construction of cross passage and its activities

2)SCOPE: Total scope is 7 cross passages in the entire UGC-02 package .To set out the construction requirements for construction of cross passage on the kalbadvei station to girgaon station stretch of MML-3 UGC-02 and maintaining safety quality and environmental compliance.

8.17 METHODOLOGY

thrust and reception pits are constructed,

A thrust ring, mounted on the jacking rig, is used to transfer the loads. The jacks are interconnected hydraulically to ensure that the thrust from each is the same

Pit sizes will vary according to the excavation methods employed,

A thrust wall is constructed to provide a reaction against which to jack.To ensure that the jacking forces are distributed around the circumference of a pipe being jacked,

A reception pit of sufficient size for removal of the jacking shield is normally required at the completed end of each drive

To maintain accuracy of alignment during pipe jacking, it is necessary to use a steerable shield, which must be frequently checked for line and level from a fixed reference

First box enters the opening at other end.

˗ Finally, jacks between the boxes are removed one by one and gap is closed successively.

˗ Joints are sealed to prevent ingress of water in the opening

8.18 SCHEMATIC DIAGRAM FOR PIPE JACKING SYSTEM

CUTTER HEAD TYPE: BACKACTER SHIELD

BENTONITE SLURRY

CONCRETE PIPE

JACKING SYSTEM

Pipe jacking/microtunnelling* is a non-disruptive method of installing utility tunnels and conduits by thrusting pipes through the ground as controlled excavation is undertaken at the face. Pipes manufactured in a variety of materials to include concrete, clay,grp and steel can be jacked and standard pipe diameters generally range from 150mm to 2,400mm, or greater when required. ly in excess of 1km depending on pipe diameters, ground conditions and excavation methods. Drive lengths are only limited by practical engineering considerations and economics and drives either in astraight line or to a radius or a series of radii are readily achievable

Jacking lengths achievable can be considerable ,When PIPE is ready for pushing, pockets are cleaned and pushing pins are fixed in them followed by fixing of jacks. Thereafter, pushing is carried out in increments. Once a box is completely pushed from thrust bed, another box is placed behind it and pushing is continued along with excavation of soil.

 The process is continued until all boxes are pushed.

 First box enters the opening at other end.

 Finally, jacks between the boxes are removed one by one and gap is closed successively.

 Joints are sealed to prevent ingress of water in the opening.

FIGURE 33: PIPE JACKING METHOD

CUTTER HEAD

Machinery selection criteria :

refer (Copyright © Pipe Jacking AssociationISBN 978-1-5272-0341-9)

DRY GROUND

WET GROUND

EXCAVATION METHOD

PIPELINE INTERNAL DIAMETER

(Drycohesive,drynon-cohesiveanddry mixed and fillconditions)

(Wet cohesive, wet non-cohesive and wet mixed and fill conditions)

Only applicable to stable face conditions, including rock

Only applicable to stable face conditions

Cutter boom shield

Only applicable to strong cohesive soils and soft rock -

Chemical stabilisation Suspension grouts Well points

Only applicable to stable face conditions -

Deep wells

Backacter shield

In-built method -

Additives in certain ground conditions Limited to water pressure head

Note :*So green highlighted portion shows the type of cutter head used due to the geological conditions prevailing , Mumbai metro line 3-UGC-02 encountered basalt rock which is strong and quite stable so backacter shield was best suitable on basis of that assumption

Cutter head

Open face shield in which a mechanical backacter is mounted forexcavation

Concrete pipes are aligned with the help of jacking system

FIGURE 35: CUTTER HEAD

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

T +91 7926302470

F +91 7926302075

FIGURE 34: CONCRETE PIPE

Type of materials used for pipe

Pipesarenormallysuppliedinlengths ofbetween1.2and2.5mandfeature a joint incorporating an elastomeric gasket to provide a watertight connection.Thejointdesignincludes including capacityforjointdeflection and draw as defined in the product standard. Secondary seals may be incorporatedintothejointifrequired.

Quantity estimation

*Total length is 14 m for cross passage so concrete pipes of length 4 m each are provided along the entire length of cross passage , yellow blocks indicate the plan view of concrete pipes assembled and connected by bolting system and blue blocks indicated the space needed for the thrust bed and jacking assembly So total 3.5 pipes used

FIGURE 36:PLAN VIEW OF CROSS PASSAGE INDICATING THE ORIENTATION OF CONCRETE PIPES TO BE INSTALLED

CONSTRUCTION OF CROSS PASSAGE BY PIPE JACKING

Tunnels acting as space for installation of steel thrust beds

Tunnels acting as space for installation of steel thrust beds

TIME CYCLE FOR ADIT3 ( CLASS 2 ROCK)

8.20 RATE ANALYSIS

TABLE 47:COST ANALYSIS FOR CROSS PASSAGE BY PIPE

total 2 shifts of 11 hours with 1 hour break each , pull of 1.15 at adit is observed

surveyor comes in shifts one in morning and then in evening.

SCHOOL OF BUILDING SCIENCE AND TECHNOLOGY

Earth work in excavation by mechanical means (Hydraulic excavator)/manual means over areas (exceeding 30 cm in depth, 1.5 m in width as well as 10 sqm on plan) including getting out and disposal of excavated earth lead upto 50 m and lift upto 1.5 m, as directed by Engineer-incharge. M3

Providing and erecting concrete pipe of thickness 275 mm using hydraulic jacks and bolting including transportation of pipes in the tunnel, etc. complete as per engineer in

and GC.

381(refer pg 74 DSR 20142015)

TECHNOLOGY FOR CROSS PASSAGE

MANUAL METHOD( PRACTISED ON SITE) PIPE JACKING( ALTERNATIVE METHOD)

Concept It is method involving excavation by excavators , in sequential manner the excavation is done and then mucking and disposal is carried out.

Primary lining and secondary lining is also carried out

Excavation by exacavtors and breaker or splitters followed by primary linings and settings

Easy checking and inspection through directly connected house connections

It is a trenchless method of pipe installation where a pipe is jacked behind cutter Machine which is shoved forward as the pipe is installed by avoiding man entry. Generally guided by a laser and most often used for the installation of gravity flow systems

Speed ofinstallation onsiderably less joints than asegmental tunnel

Easy checking and inspection through directly connected house connections

Geological conditions More risk of settlement Less risk ofsettlement

Hydrological conditions Water ingress is a major issue which has occurred on site while construction of cross passage.

equipments

Less heavy machiney is required

labour More labours are required for carrying out primary lining and secondary lining in the process

Environmental impact Due to more disposal of excavated material more vehicular motion results in more carbon emissios

saftey It is comparatively lacks behind in term of workplace safety

Time Advance of 1m /day is observed (refer pg-35 timecycle derived

cost Cost is comparatively low

Prevention of ground water ingress by use of pipes with sealed flexible joints.

Cutter head, excavators and cranes so heavy machinery is required for it.

Use of labour is reduced to quite an extent due to mechanisation and elimination of primary lining

This in turn leads to reduced vehicle movements and subsequently less associated disruption

In many cases the use of pipe jacking techniques instead of open trenching will contribute positively towards workplace safety

Advance of 25 m is observed per monthrefer pg-34 time cycle derived

Cost is comparatively high

NOTE AND COMPARISON :ADOPTED METHODOLGY VS ALTERNATIVE METHODOLOGY

T

8.21 DIAPHRAGM WALLS

This activity aims to to provide an alternative to the Secant piling method used at CST station, so the alternative adopted Diaphgram wall method which uses the concept. Diaphgram wall method is proposed for the cst station near ancillary building areas .

8.22 Method statement

REFERENCE : (Guideline for construction of d-walls, vol 2 )

Guide wall – guide wall is two parallel concrete beams constructed along the side of the wall as a guide to the clamshell which is used for the excavation of the diaphragm wall trenches.

Trench excavation – In normal soil condition excavation is done using a clamshell or grab suspended by cables to a crane. The grab can easily cut through soft ground. In case of encountering boulders, a gravity hammer (chisel) will be used to break the rock and then take the spoil out using the grab.

Excavation support – the sides inside the trench cut can collapse easily. Bentonite slurry is used to protect the sides of soil. Bentonite is a specially selected fine clay, when added to water, forms an impervious cakelike slurry with very large viscosity. The slurry will produce a great lateral pressure sufficient enough to retain the vertical soil.

Reinforcement – reinforcement is inserted in the form of a steel cage, but may be required to lap a few sections in order to reach the required length. Concreting – placing of oncrete is done using tremie pipes to avoid the segregation of concrete. As Concrete being poured down, bentonite will be displaced due to its lower density than concrete.

Bentonite is then collected and reused. Joining for the diaphragm wall panel – Diaphragm wall cannot be constructed continually for a very long section due to limitation and size of the mechanical plant. The wall is usually constructed in alternative section

Two stop end tubes will be placed at the ends of the excavated trench before concreting. The tubes are withdrawn at the same time of concreting so that a semi-circular end section is formed. Wall sections are formed alternatively leaving an intermediate section in between.

The in-between sections are built similarly afterward but without the end tube. At the end a continual diaphragm wall is constructed with the panel sections tightly joined by the semi-circular groove.

Lalbhai Campus University Road, Navrangpura Ahmedabad –

T

Guide wall

F

Constructing cast-in situ RCC diaphragm wall by for diaphragm wall having thickness as per approved structural design not exceeding 600 mm, in pannels of required depth and lengths as per approved drawing, including constructing necessary guide walls as required and as specified including boring in all kinds of soils and rocks, including working in or under water and / or liquid mud, in foul conditions and pumping or bailing out of water and removing slush, including disposal of earth/ rock / slush etc. for all leads and all lifts, including preparing, providing and re-circulating bentonite slurry in the trench as and when required for all depths, including agitating bentonite slurry during trenching etc., providing and fixing stop ends or form tubes, upto the required depth of diaphragm wall as engineer in charge and General consultants authority etc

providing and laying reinforcement bars of fe500 grade for DIAPHGRAM walls as per drawings including cutting ,welding tieing with binding wires ,assembling etc and providing 40 mm cover as engineer in charge and General consultants authority

Providing and laying CONCRETE OF M40 grade for diaphragm walls for specified depth inlcuding transportation, pouring, casing with tremie pipe finishing etc as per the direction of

) 937894.68

8.23 Outcome:

In a nutshell, the main idealogy of selection of methodology was compare the adopted and alternative technology and come to a conducive analysis of the pros and cons of both the methods. At the risk of costing ,finances over time or vice versa.

Major reasons why contractors are keen in using the traditional methodology is because they have expertise over it, not all but if few methods altered can bring quite a change in quality and speed of the construction methodology.

Like if Adecco-rs has a huge advantage of stabilising and dewatering the forth soil, which reduces the water ingress and soil settlement risk to a great extent.it uses expensive machinery but work done is quite fast and also environmental friendly as no blasting is done. ( refer pg no.150.)

If pipe jacking is carried out for cross passage instead of manual method, it elimated the cost of lining processes like shotcrete , lattice girder etc which saves the cost to

a considerable amount as pipes used give a good finishing.

Also cross passages are used only for safety purpose so pipe jacking is quite a suitable alternative. It requires high expertise but lot of time is saved . ( refer pg no 157.)

Main reason for adopting d-walls is they are quite rigid structures and perform better than secant piles but it requires heavy machinery like Kelly grab etc so secant pile is chosen. It gives best performance in terms of safety. ( refer pg no.160)

TABLE 49: COMPARISON TABLE

*If new methodologies which are a bit costlier but inclined to give faster results are adopted the on the principle of trading time with cost should be adopted, so cash outflow can also be recovered.And it becomes very crucial to study the alternatives too for a holistic approach and better site management.

3D MODEL OF NATM WORKS AT KALBADEVI STATION

3D MODEL OF NATM WOR KS AT KALBADEVI STAT ION

Kalbadevi station has two boxes LEFT box and RIGHT box connected by a central passage.Height of -27.3m from ground level 0.00. The Upline and Downline tunnel is connected by3 adits and further one central cavern in middle which gives acces to all the adits . ( refer pg no 164 )

PROJECT HIGH TLIGHT

Kalbadevi station is a typical station out of all the stations in MMRL-3 UGC_02

Entire station below the ground is constructed through natm ,which was caused due to the land acquisition isssues so cut and cover method was not possible so the contractor had to shift to natm method.

SCOP E Adit | total 3

Two of the Adits are 6m wide and one adit is 3m wide constructed entirely by natm method of construction.

Central cavern | total 1

One central cavern of width 10 m which connects all the adits from upline tunnel to downline tunnel whose construction is carried out through natm method.

CURRENT STATUS

Adit | adit 1 and 3 are through while benching is left for adit 2.

Temporary lining works (shotcrete, rockbolting laying wiremesh etc )are carried out

Central cavern | heading of central cavern id done while benching is still left.

Temporary lining works (shotcrete, rockbolting laying wiremesh etc are carried out

ACTIVITIES OF THE E LEMENTS

LIST

• drilling

• blasting

• laying wiremesh

• shotcrete

• rockbolting

• temporary and permanent lining

Bhumika Raj (UC5316) Semester-08

FIGURE 39: 3D MODEL

SKETCH UP MODEL FOR PLATFORM AND CONCOURSE/ MEZZANINE AND ACCESS LEVEL AT KALBADEVI STATION

SKETCH UP MODEL FOR PLATFORM AND CONCOURSE/ MEZZANINE AND ACCESS LEVEL AT KALBADEVI STATION

SKETCH UP MODEL FOR PLATFORM AND CONCOURSE/ MEZZANINE LEVEL AT KALBADEVI STATION

SKETCH UP MODEL FOR PLATFORM AND CONCOURSE/ MEZZANINE LEVEL AT KALBADEVI STATION

SKETCH UP MODEL FOR PLATFORM AND UNDERCROFT LEVEL AT KALBADEVI STATION

Bhumika Raj (UC5316) Semester-08

Simultaneously rock bolting is carried out by drilling in the roads and adding resin capsules ad needed inside the drill holes

Simultaneously rock bolting is carried out by drilling in the roads and adding resin capsules ad needed inside the drill holes

Bhumika Raj (UC5316) Semester-08

Kalbadevi station

Kalbadevi station

Drilling into the segment face

Drilling into the segment face

Removal of segments

Removal of segments

Drilling into the adit after removal of segments and shot crete done through pneumatic shotcrete machine.

Drilling into the adit after removal of segments and shot crete done through pneumatic shotcrete machine.

Adit is made through from downline tunnel to upline tunnel.

Adit is made through from downline tunnel to upline tunnel.

Adit is made through from downline tunnel to upline tunnel, after that central cavern works are carried out

Adit is made through from downline tunnel to upline tunnel, after that central cavern works are carried out

Drilling is carried for heading part in the central vaern area

Heading and bemching is carried out by using explosives and detonators

Heading and bemching is carried out by using explosives and detonators

Blasting is done by using tnt detonators placed on the working platform , tnt is pressed and blasting is carried out inside the cavern

Blasting is done by using tnt detonators placed on the working platform , tnt is pressed and blasting is carried out inside the cavern

Blast done at the cavern heading portion

Blast done at the cavern heading portion

After blasting works is over defuming is carried out and other preliminary works are like shotcrete , wiremesh and rock bolting is carried out in the cavern works

After blasting works is over defuming is carried out and other preliminary works are like shotcrete , wiremesh and rock bolting is carried out in the cavern works

Bhumika Raj (UC5316) Semester-08

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat T +91 7926302470 F +91 7926302075

3D VIEW SHOWING ONE ADIT THROUGH THE CENTRAL CAVERN

https://youtu.be/ob5pYj-qAdA

https://www.youtube.com/watch?v=L a1JaGLr5t8

https://youtu.be/-CY5BYcBdWU

TRAINING

Kasturbhai Lalbhai Campus University Road, Navrangpura Ahmedabad – 380009, Gujarat

+91 7926302470

3d view showing One adit through the central cavern

3D VIEW OF CENTRAL CAVERN THROUGH ALL THE ADITS AT THE KALBADEVI STATION

3d view of central cavern through all the adits at the kalbadevi station

Video link

So I would say that from my learnings and outcomes at Mumbai Metro Line 3 –UGC02 , Construction industry has many aspects. There are few parameters which play a crucial role are often less visible and taken into consideration one of them is lack of innovation In construction industry. Building information should be given a priority as on my site experience though there were BIM midels created there was no real time monitoring nor the model was accessible to the engineers. Only the BIM specialist could access to it, which creates problem in work flow.

Observations and Learnings

Target Value Design: This is to set the target value less than market value so if the contractor keeps the track of the graph and observes the cash flow seems to go above the market value they can work out possibilities and lower the graph .So contractor can save the money and use it for other capital investments

Better Interoperobaility :By doing the real time coordinaton with building information model the contractor can reduce rework which can save resources to an extent. As BIM can also perform 4-D( real time monitoring with time ) 5-D ( real time monitoring with cost ) and even 6-D, it can really help in reducing the time, also all the information is available on one screen which can help in using time more efficiently.Also clash detection helps in reducing reworks as changes can be made on screen if errors detected and not on field, this saves the machinery and manpower to a great extent.

As per my observation the BIM Models were generated but there was no real time monitoring Also the models were not easily accessible to the engineers.so this depicts that though innovative models are used there is no proper work flow or accessibility to them.As without a BIM specialist it was not possible for the people on field to operate them.

Inference :The dashboard shows the cash flow fluctuating between market value and target value .This shows that the target value should be set lower than the market value of the project. The contactor should keep a track of the cash flow and if the graph seems to exceed the market value the contractor can work out measures and keep the graph within the limit.The contractor can do the savings in this way and invest more efficiently.

BLIND SPOT

Visible Parameters

OVERRUNS AND TIME LOSS DEFECTS

LATE APPROVALS BY AUTHORITIES

Less visible Parameters

POOR PLANNING , POOR FEASABILITY STUDY AND LACK IN REAL TIME COORDINATION

LABOUR STRIKES / NATURAL DISASTER(COVID 19) AND OTHERS

BUILDING INFORMATION PROJECT IS LESS PROMINENT WHICH IS LESS INNOVATIVE TECHNIQUES USED .

POOR TARINING PROGRAMS CONDUCTED

Also overall one of the most overlooked thing is not identifying the root causes for the lags and focussing only on the most visible parameter of the delay.if the root causes of the problem is addressed it will ease the impediments and create a better work flow for the professionals .

Example : In Mumbai Metro line 3 UGC-02 one of the most highlighted delay was the delay due to Parsi fire temple issue, it had created headlines for almost a year and the committee had to go through various legal proceedings.(refer pg 130: project delay task) . According to the feasibility study carried out before the project nobody from the parsi community had raised any objection. It was only after the constructed started.so if the loophole in the feasibility study would be discovered earlier about 8 months of the time could be saved.

So if in near future few of the parameters mentioned above are brought into practice the metro construction in india can really progress. Making connectivity strong is one of thr key aspects for a developing country like India,though there is a lot of capital investments and soft loan taken for such projects but there is no doubt that if the construction industry adopts innovation and addresses the root causes a lot can change.

CONCLUSION “CONNECTING THE UNCONNECTED “

If I had to sum up my experience I would say Over all it was an amazing experienced at site to witness all the construction activities visiting tunnels and learning new technologies. On site experience plays a major role in understanding a project. This project training pretty much sufficed that parameters for me. Also the geographical location plays a major role in construction of a project and in a congested area like South Mumbai called SOBO” where logistics is an issue and also the home of majority heritage structures there was a lot to learn.

It was only after commuting in local trains I realised that why there is a need of Metro in the city, the local trains carry 6 times the passengers then their design capacity.After the construction of metro there would be a great difference in travelling experience of the people residing in the city.

After this training I am able to interpret things more technically and have evolved my understanding about how the infrastructure projects function. 3 months experience also gave me a broader perspective on every aspect of construction, whether it was execution , planning , BIM or management. Project training is the foundation for a better future and its very important to work with organised firms, and I am grateful for the opportunity I received to work with HCC. Also doing the internship from client side I gained a lot of knowledge from MMRC staff,as I got an holistic understanding of how work gets done in the organisation.

I would conclude by saying the opportunity I got changed my approach towards construction industry .I would like to apply all the learning in my professional career in future with utmost diligence .

REFERENCES:

 Monthly project report ( document)

 Study of msp schedule

 Contracts book

 Online articles

 Accelerated program report

 Method statements.

 International Journal of Current Research Vol. 6, Issue, 06, pp.7219-7222, June, 2014

 Delay analysis and its effects in construction industry Ram B. Tosniwal1, Prof. Shashank U.

International Journal of Students’ Research in Technology & Management eissn: 2321-2543, Vol 6, No 1, 2018, pp 30-39 https://doi.org/10.18510/ijsrtm.2018.615

 Delays in construction projects: a review Of causes, need and scope for further Research Prasad Kudrekodlu Venkatesh and Vasugi Venkatesan,School of Mechanical & Building Sciences, VIT University, Chennai, India, 600127

 Guideline for construction of d-walls, vol 2

 Copyright © Pipe Jacking AssociationISBN 978-1-5272-0341-9)

 Comparison of natm and adeco-rs methods,Using monte cuneo tunnel, italy, as an example Peter balušík, libor MAŘÍK

 Mmrcl official website.