SUMMER TRAINING REPORT ON

“DESIGN AND CONSTRUCTION OF UNDER-GROUND

METRO STATION”
AT
L&T SUCG JV, MUNIRKA STATION-NEW DELHI
(DMRC, CC-27)

SUBMITTED TO: SUBMITTED BY:

MR. R.G.SAINI PRATEEK KUMAR MEENA

(PROJECT DIRECTOR) CIVIL ENGINEERING

Larsen and toubro. IIT DELHI, HAUZ KHAS

 INDEX

TOPIC PAGE NO.

1. Acknowledgement…………………………………………3
2. Company profile…………………………………………...4
3. Introduction about project………………………………..6
4. Construction Methodology………………………………..7
5. Construction sequence…………………………………….12
6. Excavation………………………………………………….19
7. Excavation equipments…………………………………….22
8. Design consideration……………………………………….22
9. Guide wall (g-wall)………………………………………....23
10. Diaphragm wall (d-wall)………………………………….27
11. D-Wall Construction Sequence…………………………..33
12. Plunge -in column…………………………………………38
13. Grouting……………………………………………………42
14. Cross Passage………………………………………………43
15. QA & QC…………………………………………………..49
**

ACKNOWLEDGEMENT
I would like to express my deepest appreciation to all those who
provided the possibility to complete this report. A special gratitude we
give to our final Project Director, Mr. R.G. Saini, Project Leader, Mr.
Sandeep Singh, IR Manager Mr. S. Hariharan whose contribution in
stimulating suggestions and encouragement, helped us to coordinate our
project especially in writing this report.
Furthermore we would also like to acknowledge with much appreciation
the crucial role of the L&T staff of Munirka Site and Pushpvihar site,
who gave the permission to use all required equipment and the necessary
material to complete training. A special thanks goes to Station Manager
Mr. P.J. Rao, Mr. Mahendra Singh, Mr. Shahrukh and Mr.
Vinayak who guided me to throughout our tenure.
 COMPANY PROFILE

Larsen & Toubro Limited (L&T) is a technology, engineering,

construction and manufacturing company. It is one of the largest
and most respected companies in India’s private sector.
More than seven decades of a strong, customer-focused
approach and the continuous quest for world –class quality have
enabled it to attain and sustain leadership in all its major lines of
business.
L&T has an international presence, with a global spread of
offices. A thrust on international business has seen overseas
earnings grow significantly. It continues to grow its global
footprint, with offices and manufacturing facilities in multiple
countries.
The company’s business are supported by a wide marketing and
distribution network, and have established a reputation for
strong customer support.
L&T believes that progress must be achieved in harmony with
the environment. A commitment to community welfare and
environmental protection are an integral part of the corporate
vision.
In response to changing market dynamics, L&T has gone
through a phased process of redefining its organization model
that facilitates growth through greater levels of empowerment.
The new structure is built around multiple business designated
‘Independent Companies’ or ‘ICs’.
L&T Construction has played a prominent role in India’s
industrial and infrastructure development by executing several
projects across length and breadth of the country and abroad
It was decided in January 2011, that company will be
reconstructed into nine virtual companies for ease of
operations and better management.
INTRODUCTION TO THE PROJECT
Client: - DMRC (Delhi Metro Rail Corporation limited)
Contractor: - L&T-SUCG JV (Larsen & Toubro and Shanghai Urban
Construction Group Joint Venture)
Contract: - Contract CC-27

PROJECT: CONTRACT CC-27 (UG-2)

“Design & construction of tunnel from end of Underground
RAMP (Near Shankar Vihar Metro Station) to HauzKhas Metro
Station and Underground Ramp Near Shankar Vihar Metro Station
and Underground Metro Stations at Vasant Vihar, Munirka , R.K
Puram, IIT and HauzKhas on Janakpuri West-Botanical Garden
Corridor of Delhi MRTS project of phase-3.”

STATION DETAILS OF MUNIRKA :

Length of station = 269.08 m

Width of station = 20.37m
Depth of station = 22 m

Construction methodology

Top-down construction method as the name implies, is a construction

method, which builds the permanent structure members of the basement
along with the excavation from the top to the bottom. Top-down method
is mainly used for two types of urban structures, tall buildings with deep
basements and underground structures such as car parks, underpasses
and subway stations. In this case the basement floors are constructed as
the excavation progresses. The top/down method has been used for deep
excavation projects where tieback installation was not feasible and soil
movements had to be minimized. Top-down construction method which
provides the significant saving of the overall construction time has been
adopted for some major projects where time factor is of primary
importance. The sequence construction begins with retaining wall
installation and then load-bearing elements that will carry the future
super-structure. The basement columns (typically steel beams) are
constructed before any excavation takes place and rest on the load
bearing elements. These load bearing elements are typically concrete
barrettes constructed under slurry (or caissons).

Top-Down Method

 The vertical retaining panels (piles, diaphragm walls etc.) along the
perimeter of the excavation to follow are constructed from the surface.
  An excavation is initially carried out up to the level of the roof slab of
the structure. Depending upon the excavation depth, a light retaining of
the slopes may be needed.
 The roof slab on the excavation bottom is concreted. The slab is
connected with the perimeter retaining and it is supported on it.
 The excavation works for the station or the tunnel commence
underneath the roof slab by means of the ramp which has been left at a
certain point. The excavation is executed in phases, while the required
retaining elements (e.g. anchors, struts) are installed gradually.
 Upon completion of excavation of the entire trench, works related to
the construction of the permanent bearing structure elements commence.
These elements usually consist in the raft (foundation slab) and the
lateral walls, while in case of a station it is also the construction of the
intermediate floor slabs. In case of diaphragm walls are used as a lateral
retaining means, other permanent walls are not constructed, since the
same diaphragm wall act as a final perimeter structure.

PROCEDURE
The typical construction procedure of top down construction is as
follows
         Construct the retaining wall.
          Construct piles. Place the steel columns or stanchions where the
piles are constructed.
         Proceed to the first stage of excavation.
         cast the floor slab of first basement level
         Begin to construct the superstructure
         Proceed to the second stage of excavation; cast the floor slab of the
second basement level.
         Repeat the same procedure till the desired depth is reached
         Construct the foundation slab and ground beams, etc. Complete the
basement
         keep constructing the superstructure till it gets finished.

INSTALLATION OF RETAINING WALL

The underground retaining wall which is usually a diaphragm wall, is

installed before excavation commences.

Excavation and installation of steel strut

The soil is excavated just below roof slab level of the underground
structure. Struts are installed to support the retaining walls, which in turn
support the soil at the sides

Construction of underground structure

The roof slab is constructed, with access openings provided on the slab
for works to proceed downwards. The roof slabs not only provides a
massive support across the .

Construction of underground structure

The next level of slab is constructed, and  this process progresses
downwards till the base slab is completed

Construction of underground structure

The side walls are constructed upwards, followed by removal of the

intermediate struts. The access openings on the roof  slab are then
sealed.
 Backfilling and reinstatement

After the underground structure is completed, the soil is backfilled to the

top strut level before the strut is removed. This is followed by
completely backfilling the top of the underground structure and finally
reinstating the surface areas.

Advantages:

The advantages of this method consists in the reduced time of extended worksite
occupations and the rate of reinstatement and release of the area for use (vehicular
circulation, squares etc.) and finally the mitigation of disturbance as to the
functions of the city.

Disadvantages:

Its disadvantages are the increased cost and the more complicated construction
procedure.
CONSTRUCTION SEQUENCE FOR TOP DOWN APPROACH AT
MUNIRKA.
 EXCAVATION

 Excavation will be carried out in stages depending upon the

method of excavation.
 For Top Down construction it will be carried on by casting of roof
intermediate, concourse and base slabs at appropriate levels until
the final level of excavation is reached.

STATION BOX AREA

 After the construction of diaphragm wall and installation of plunge
columns, carry out the excavation to the underside of top slab level
using suitable excavator and dump trucks.
 Sequence of excavation shall be as per submitted construction
programme and accordingly if required traffic shall be diverted on
temporary basis as per the site conditions.
 After formation level of top slab is achieved, place blinding layer
and construct the top slab with openings in accordance with
drawings.
 If specified barricading shall be installed around the top slab
openings.
 For the temporary traffic diversion and movement of construction
equipments, temporary backfill shall be done over the cast top slab.
However in the meantime, temporary backfill shall be removed
and reinstatement work shall be done as per the design drawing.
 After the top slab attains the required /specified strength,
excavation shall be carried out using long arm boom excavator
through the openings provided in the top slabs.
 Mini backhoe/EX-70 will be lowered through the openings to carry
out the excavation beneath the slab.
 A wheel loader/JCB shall be lowered through the opening which
will carry the excavated soil to opening.
 Excavated materials will be lifted up by arm boom/crane bucket.
Construction equipments shall stand/move only on designated
location over the top slab.
 After formation level for the concourse slab is achieved, place
blinding layer and construct the concourse slab with openings
 After concourse slab attains the required/specified strength,
excavation will be carried out using crane bucket through the
opening provided in the top, intermediate and concourse.
 Mini backhoe/EX-70 will be lowered inside through the opening to
carry out the excavation beneath the slab.
 A wheel loader/JCB shall be lowered through the openings and
will carry the excavated soil to the openings and excavated
materials will be lifted up by crane bucket.
  During the excavation beneath the slab, blinding concrete shall be
removed using beaker mounted on excavator or equivalent.
 All the excavated material will be disposed in dumping yard using
tipper.
 While excavation is carried out by mechanical means, the bottom
of excavation shall be recompacted to achieve a dense, smooth and
level surface both longitudinally and transversely and compacted
to 25% of the maximum dry density depending upon the depth of
the layer.

CONSTRUCTION EQUIPMENTS FOR EXCAVATION

EQUIPMENTS QUANTITY

 Excavator Ex-200 1
 Excavator Ex-70 2
 Long Arm Stick 1
 JCB/Loader 2
 Hydraulic Breaker 1
 Crane 75 Ton capacity 2
 Auto Level/Total Station 1
 Dump Truck 10
Steel Bucket 1
 GUIDE WALL

Guide Wall will be constructed by inverted “L” shaped RCC walls

forming a support to the earth and prevents it from collapse when the
boring of diaphragm wall is being carried out. Guide wall shall be
constructed prior to the excavation of the diaphragm wall.

 The purpose of the guide wall is :

1. To provide a permanent alignment for the grab.

2. To prevent the collapsing of soil near the surface.
3. To provide the temporary supports for the reinforcing steel cage.
4. To provide a support for suspending the stop-end joint.
 Construction Procedure

 Survey works:-
Survey and setting out operations shall be carried out in accordance with
approved drawings. Sufficient reference datum and lines shall be
available and visible on site for reference.
Survey and setting out will be done in the following manner:

 Control points will be fixed by Surveyor prior to start of the Guide

Walls.
 Temporary pillars for separate centerline and edge line will be
made and Centre points will be marked with the help of total
station.
 The Guide wall will be constructed with respect to this Centre line.
Then the reference lines will be marked again on the Guide wall
itself for construction of Diaphragm wall.

 Excavation Of Guide Wall:-

Guide wall trench excavation will be done by manual/JCB,
excavation for the Guide wall of 1.5 m depth from the existing
ground level. The excavated area will be barricaded all around the
trench.
 Fixing Of Reinforcement:-

 After dressing and leveling, reinforcement fixing work shall be

taken up.
 Fixing of reinforcement will be done as per the approved
drawing.
 The minimum cover to reinforcement shall be as per the
approved drawings.
 Necessary checking will be done by the site Engineer before
placing of shutter.

 Fixing Of Shutters:-

 Formwork will be fixed after proper cleaning the inner face and
applying proper de-shuttering oil.
 The clear horizontal distance of guide wall i.e. diaphragm wall
width plus 50 mm will be maintained.
 Cover blocks will be inserted to maintain specified cover at both
faces of reinforcement cage.
 Joints between shutters will be sealed to avoid leakage of
cement slurry.
 Shuttering is checked with respect to the dimensions, line,
alignment and verticality.

 Placing Of Concrete:-
  Approved grade of concrete mix (M20) will be placed.
 Placing of concrete and compaction will be taken care.

 De-Shuttering:-

 De-shuttering will be done after concrete gets set and the area
will be backfilled for the safety purpose.
 Curing shall be taken care by site Engineer and randomly
checked by QC personnel.

 Guide wall shall be made from M-20 reinforced concrete.

 The wall is 1500 mm high and the width of the flange is 800 mm.
 The overall thickness of the wall is 200 mm.
 Thermo-mechanically treated bars are used of grade Fe-500 D of
dia 8 mm @ 150 c/c.
 The maximum clear cover at the guide wall is 75 mm.
 DIAPHRAGM WALL

Construction Sequence :
 The diaphragm wall panels basically comprise of :
a) Primary panels
b) Secondary panels
c) Closing panels
  The arrangements of panels allows greater flexibility in terms of
commencement and conclusion of panels .
 The primary panel is the starting panel, which is cast with 2stop
ends in place. These panels are logistically placed to suit
construction schedule. The panel proceeds in both directions from
the primary panel using secondary panels, which are cast with a
single stop end in a place. The closing panel is the final panel,
which is cast after the removal of both stop-ends.
 The panel length is defined as the distance between center lines of
the two stop end (including the water stop).The orientation of the
stop end can therefore be changed without effect to the
reinforcement cage position or size.
DIAPHRAGM WALL EXCAVATION
 The diaphragm wall will be located between the guide walls. The
guide wall will be marked with the panel reference no. and Centre
line of stop-end position.
 The trenching will be carried out by the grab attached to the
telescopic Kelley who is mounted on hydraulic rigs. The hydraulic
rigs support and operate Kelly bars and the grabs through hydraulic
power of the rig. The swing, leveling, hoisting, closing and
lowering of grab is controlled by the rig.
 Once the grab is set up over the designated location, the operator
shall lower the grab onto the ground and commence trenching.
 Excavation by grabbing will be done in presence of the poly mud
solution. The density of fresh polymer solution for circulation will
be kept more than the normal density to ensure the stability of the
trench.
 The standard panel will be excavated in three main “bites”.
 The first “bite” will be excavated to the design toe level. The
second “bite” will be a repeat of the first and finally the third
“bite” will be the center portion.
 Grabbing will be start in presence of polymer solution from one
bites of the panel and will excavate up-to founding level i.e. up-to
the required depth of excavation as per the cross section details of
approved drawings.
 The rig is then shifted to the second bite of the panel and excavates
up-to the founding level. Then the rig is shifted to the middle bite
of the panel and excavates up-to a required depth. This gives a full
length excavated trench of the panel.
The panel bottom is then cleaned by final grabbing.
 Excavated muck mixed with polymer slurry will be kept aside, and
the same will be disposed in the dumping yard at appropriate
designated dumping yard.
 When the grab reaches at guide wall level upon exit, a momentary
suspension is recommended to allow the excess mud to drain from
the spoil through the drainage holes of the grab.
 The operator then rotates the rig via crane swing and discharges
the spoil either into skips or onto the ground.
 An excavation exceeds, poly mud is pumped in to the excavated
trench to ensure that it shall kept full and the level of polymer
slurry must always be above the bottom of the guide wall. During
the course of the excavation, and upon reaching final depth, the
panel depth is verified using a sounding chain and 30 m tape.
Logging of the slurry will be carried out during the excavation to
check the slurry losses.
 Checking for the verticality of the trench will be carried out by
KODEN instrument.
 Verticality shall be checked for every D-wall panel by KODEN
.during excavation of each panel verticality by panel shall be
checked two times(after 50% excavation and 100% excavation of
D-wall panel for initial five panels subsequently it shall be checked
after 100% excavation for each panel.
 The panel of D-wall face to be exposed shall be vertical to within a
tolerance of 1:200, relative to a vertical line projected from the
base of the guide wall.
 The ends of the panel shall be vertical to within a tolerance of 1:80.
 The stopend with waterstop attached will be lowered in to position.
 Disposal of polymer is not required as it can be cleaned in the
trench using polymud.
 Excavated soil shall be disposed during night shift at the
designated dumping yard.
 Procedure for Rock chiseling in D-wall panel:

 The soil grabbing is done with the help of trenching machine up to

the rock level.
 During the excavation of D-wall if hard strata encounter the
following arrangements will arranged.
 After the completion of the soil grabbing the rock chiseling
arrangement will be attached to the grabber with the help of crane
(P&H crane 335/440) and chisel of weight 3.5 MT with successive
bytes.
 The chiseling operation is continued up to a depth of 200 to
300mm for entire length of panel, and trenching machine is used
for cleaning the trench.
 Once the cleaning of trench is completed the rock chiselling is
again continued with the crane and chisel. And the same procedure
is continued till the required depth is attained up-to the required
founding level.
 After attaining the required depth the trench will be cleaned finally
and stop end will be lowered.
Mud cleaning and disposal:
Mud cleaning and disposal will be in accordance with contract/technical
specifications.
 Cleaning of D-walls by sedimentation of the suspended particles to
the bottom of the excavation, ensuring the stability.
 Spoil slurry mixed with the excavated soil will be kept
aside/loaded on trucks with JCB the safely transported and
disposed at approved dumping yard.
 There will be a provision of cleaning arrangement to ensure proper
cleaning of the entire sub-frame of dumpers before it fly on public
road.
 During the transportation special care will be taken to avoid
spillage of mud from the trucks.
 Since it is an environmentally friendly so it can be used for any
land filling without any further treatment.
REINFORCEMENT
 The reinforcement cage will be fabricated on the ground and
welded. The staging of the reinforcement will be done on
ground surface with help of 200 mm wooden sleepers.
 The rebar cage will be made upto the cut off level and the lifting
hook & resting or holding bar will be extended till the existing
ground level in order to hold the rebar on top surface of guide
wall.
 Couplers will be fixed in proper level and position.
 Track weld will be done to cage to avoid any deformation
during lifting process.
 The minimum clear cover to main reinforcement of 75 mm
shall be maintained.
CAGE LIFTING AND PLACING

 Lifting and placing of cage will be done with the help of 2 cranes
and the cage lifter assembly. The cage lifter will be fixed directly
to the lifting hooks of the cage with D’ shackles and slings of the
80/100 MT lifting capacity cranes. The bottom end of the cage
 shall be fixed to the second crane (minimum 50 MT capacity
service crane) with two slings will be ensured.
 The lifting beam will be designed acc. The calculation provided by
design team will be ensured for fabrications.
 The cage will be lifted slowly with 80/100 MT crane operating
both the slings and bottom shall be lifted by the supporting second
crane which will move at a synchronized speed with the movement
of the cage under skilled supervision. When the cage is fully lifted,
the load in service crane shall be freed so that the entire load of the
cage will come on 80/100 MT crane.
 After completion of lifting process, the cage will be lowered
slowly in –to the panel and positioned with verifying the line
verticality with plumb-bobs.
Placing of Concrete-

 Concreting of diaphragm wall shall be done continuously without

interruption to ensure no mixing of polymer with concrete.
 Before start of concrete works a steel grill will be provided over
the guide wall to prevent the falling of persons in the excavated
trench.
 Before concreting the following parameters value shall be
followed.
The admissible time for pouring concrete after the concrete mixer
has left the batching plant is 2 hours.

Parameter Value
Slump 150-200 mm
Temperature >5 & <32 degree Celsius
Frequency of cube sampling A set of 3 cubes will be casted
for every 25 cum of concrete

 With the steel reinforcement in place the tremie pipe of internal

diameter of 250mm along with the hopper attachment is lowered at
the centre of the point to have uniform fill of compacting concrete
in panels. The tremie pipe is set at 300mm from the bottom of the
excavation and suspended by a self-locking working platform.
 This will be done by skilled supervision on daily basis to ensure
the correct procedures to carry out all measurements and recording.
 At the start of concrete placement, a plug is placed at the bottom of
the funnel, protected by a shovel until the hopper is full of
concrete. The shovel is then removed and the concrete gushes
down the tremie, thus keeping the concrete away from mixing with
the polymer slurry.
 During the concreting tremie pipe will be kept immersed below the
surface of the fresh concrete at all times. Except at the beginning,
the immersion depth inside the concrete will be not less than 2m.
 The concrete level will be measured at regular intervals after
evacuating each tansit mixer by measuring tape with sounding
chain so that the actual volume of concrete placed can be
compared with theoretical panel volume.
 Concrete will be poured continuously till the panel is filled up
above the theoretical cut-off level. Concrete will be poured upto
1m above the Cut-Off level.
 To prevent collapse of earth between concrete cut-off level and
ground level, concrete will be poured upto guide wall top level to
retain earth.
 After completion of concreting and final setting of the concrete,
the stop ends are fully removed out of the panel with the help of
extracting jack system and crane. The jacking up the stop end tube
would start 10 hours after completion of DW pouring.
 PLUNGE COULMN

The plunge columns are vertical members which act as permanent

columns to provide support to slabs during construction and shall be
encased in later stage with appropriate grade of concrete to convert into
permanent columns.
Construction Methodology
 Pile excavation by piling rig
Before the excavation to start, the circulation of polymer must be
established. Sufficient polymer shall be kept ready in the working
circulation tank to feed the panel.
The trench will be excavated by a hydraulic piling rig until the
hard strata and in shale layer (hard layer) is excavated by hydraulic
rig using rock bucket or core barrel. It is proposed to do pile
excavation of 1500 mm dia. Piling would be carried on up till toe
level of pile is reached .

Muck Removal
The bore muck generated from the excavation process shall be shifted to
space available near by the work area using JCB/Excavator.
After completion of piling the working area shall be cleaned for stacking
of plunge column and reinforcement cage.
The bore muck should be shifted to designated dumping yard by leak
proof tipper / truck.
Preparation of Rebar cage
 Reinforcement steel Cage Cutting , Bending
After completion of excavation, the reinforcement cage shall be lowered
into trench. The reinforcement shall be cut and bent at steel yard or at
site as per bar bending schedule and cages will be prepared at site over a
level ground. Necessary spacer bars, fixtures, inserts and cover blocks
will be provided along with the reinforcement cage. While cage
fabrication, roller blocks shall be introduced to the outer rebars before
fixing. Cover of 150 mm shall be maintained as per drawing.
 Fabrication of Rebar cage:
Based on the approved reinforcement drawing, the bar bending schedule
shall be prepared. The reinforcement is then cut and bent as per bar
bending schedule, and cage is prepared in reinforcement yard at site. The
reinforcement cage shall be tied using the winding wire and wherever
required welding will be done.
The cage shall be fabricated over the fabrication bed consisting either of
steel chairs, channels or wooden sleepers. The clear cover shall be
maintained as per design which is 150mm. lifting hooks and resting
hooks shall be provided as per requirement.
PILE CAGE LOWERING
After cage fabrication, cage lifter will be fixed directly to the lifting
hooks of the cage with shackles and slings of the crane and cage lifting
will be done with help of cranes and cage will be lowered upto desired
depth and will be rested with help of steel beams located at the top of
prefabricated casing to connect the plunge column in order to secure the
plunge column exact position as per drawing. Lifting points and lifting
lugs are designed in such a manner which will not cause distortion of the
cage.

PLUNGE COULMN LOWERING

After resting the cage in resting beam, plunge column is lifted using
crane and marched to the plunge column location. Plunge column is
lowered into the reinforcement cage to the correct position. After
positioning the plunge column and checking the verticality, plunge
column is welded with the rebar cage to secure the exact position. Then
a temporary guide frame arrangement shall be placed over the
prefabricated casing to maintain the verticality of plunge column .With
the help of temporary frame arrangements plunge column is lowered
upto desired depth .After lowering to the toe level of the pile, the plunge
column is welded to the guide frame to arrest the movement during
concreting and backfilling.

TREMIE LOWERING

After lowering the rebar cage and plunge column, tremie of minimum
200mm dia and length of 1.2m to 3m will be lowered into the trench and
connected while lowering for full depth of trench with the help of
service crane. Concrete funnel/hopper of approx. 1.5cum capacity will
be attached to the top tremie pipes.
 GROUTING

Grout is a construction material used to embed rebars in masonry

walls, connect sections of pre-cast concrete, fill voids, and seal joints
(like those between tiles). Grout is generally composed of a mixture of
water, cement, sand, often color tint, and sometimes fine gravel (if it is
being used to fill the cores of cement blocks).It is applied as a thick
emulsion and hardens over time, much like its close relative mortar.
Main varieties include: tiling grout (either urethane, cement-based
orepoxy), flooring grout, resin grout, non-shrink grout, structural grout
and thixotropic grout. Structural grout is used in reinforced masonry to
fill voids in masonry housing reinforcing steel, securing the steel in
place and bonding it to the masonry. Non-shrink grout is used beneath
metal bearing plates to ensure a consistent bearing surface between
the plate and its substrate. The main purpose of Grouting is to Decrease
the shrinkage of cement. Grout material helps in increasing flow ability.
It gives expansion in concrete to increase tightness of hole or crack etc.
It is self-compactable and nearby it gain strength of M12 in one day
 CROSS PASSAGE
Tunneling in hard rock generally employs: Heading and
benching method

Heading and Benching Method

Tunnel cross section is divided into two parts, the top portion of
the tunnel is known as the heading and the bottom portion
as bench. Usually this method is adopted for railway tunnels. In
this method of tunneling, top portion or heading will be about
3.70 to 9.6 m ahead of the bottom portion as shown in the
figure below. In hard rock which may permit the roof to
withstand without supports, the top heading generally is
advanced by one round of bottom portion. If the rock is broken
then heading may be driven well ahead of the bottom portion
and after giving proper support to the roof, the bottom portion
is completed. In hard rock the heading is bored first and the
holes are driven for the bench portion at the same time as the
removal of the muck. This required less explosive than the full
face method, but due to the development of the drill carriage
or jumbo, the use of this method is decreasing.

Heading and Benching Method (Tunneling)

 CROSS PASSAGE AT MUNIRKA
REPORT TILL -30TH JUNE 2015
CROSS PASSAGE NO 13 BETWEEN MUNIRKA AND R K
PURAM

TILL DATE 25TH JUNE 2015 :-

 The work is in progress and till now 7 heading and

5 benches were already constructed from up line .
 Shotcreting is going on .
 7 worker were working in one shift .
 Approx. time for completion of CP-13 will be one
month.(sir has ensured that it will cover up with in the
given time period )
 JCB is continuously working in that area for removal
of soil and rock which is taken from the CP.
 I am persuing M.TECH in survey so I have deep
interest in checking the slope stability so I gather
information about how to check the stability so that
roof fall can be avoided , this whole process is done
with the help of total station.
PICTURE THAT BELONGS TO CP -13
UPDATED PIC OF 30TH JUNE 2015

CROSS PASSAGE NO -14 BETWEEN MUNIRKA AND R K

PURAM
TILL DATE 25TH JUNE 2015 :-

 3 meter of cutting has been done .

 3rd no heading is done only no benching yet
done
 Gudders where fixed to support the CP-14
 Only gudders where constructed to support
the roof .
 Core cutting is started from down link.
 Expected date of completion one month .

PICTURE THAT BELONGS TO CP -14

 PUSHPVIHAR SITE
Quality control /Quality Assurance

A. Tests At Batching Plant

 Tests conducted on Cement
1. Normal Consistency
2. Initial and Final setting time
3. Soundness
4. Fineness
 Tests conducted on Aggregates
1. Impact Value
2. Flakiness and Elongation
3. Crushing Value
 Tests conducted on Concrete
1. Compressive Strength
2. Slump Cone Test

Tests on cement

1. NORMAL CONSISTENCY
Object:
Determination of the quantity of water required to produce a
cement paste of standard consistency.

Apparatus:
Vicat apparatus with plunger (10mm in dia.).

Theory:
The standard consistency of a cement paste is defined as that
consistency which will permit the Vicat plunger to
penetrate to a point 5 to 7 mm from the bottom of the Vicat
mould, when the cement paste is tested.

Procedure:
Prepare a paste of weighted quantity of cement (350g) with a weighted
quantity of water, start with 30% water of 350 g of cement taking care
that the time of gauging is not less than 3 minutes and not more than 5
minutes and the gauging shall be completed before any sign of setting
occurs. The gauging time shall be counted from the time of adding the
water to the dry cement until commencing to fill the mould. Fill the
Vicat mould with this paste, the mould resting upon a non-porous plate.
After completely filling the mould, trim off the surface of the paste,
making it in level with the top of the mould. The mould may slightly be
shaken to expel the air. Place the test
block with the mould, together with the non-porous resting plate,
under the rod bearing the plunger (10mm dia.)
lower the plunger gently to touch the surface of the test block and
quickly release, allowing it to penetrate into the paste. This operation
shall carried out immediately after filling the mould. Prepare trial pastes
with varying percentages of water and test as described above until the
amount of water necessary for making the standard consistency as
defined above is obtained. Express the amount of water as a percentage
by weight of the dry cement.
Observation :

S.No weight of water water penetration of needle

. sample(gram added (%) added(grams from bottom(mm)
 s) )

1 350 27 94.5 4

2 350 29 101.5 6

3 350 30 105 8
Result:
Normal consistency = 29%
Precautions:
Use clean appliances for gauging. The temperature of cement and water
and that of test room, at the time when the above operations are being
performed, shall be 270C +/- 20C.
The room temperature shall be maintained at 270C +/- 20C.

2. INITIAL AND FINAL SETTING TIME

Object:Determination of Initial and Final setting time of the cement.
Apparatus:
The Vicat apparatus (conforming to IS: 5513 – 1968).

Sample:
350 g of cement is taken.

Procedure:
Preparation of Test Block :
Prepare a neat cement paste by gauging 350g of cement with 0.85
times the water required to give a paste of standard consistency. The
paste shall be gauged in the manner and under the conditions
prescribed in determination of consistency of standard cement paste.
Start a stopwatch at the instant when water is added to the cement. Fill
the mould with the cement paste gauged as above, the mould resting on
a non-porous plate, fill the mould completely and smooth off the surface
of the paste making it level with the top of the mould. The cement
block thus prepared in the mould is the test block. Use clean
appliances for gauging. The temperature of water and that of the test
room, and the time gauging, shall be 270C +/- 20C. During the test, the
block shall be kept at a temperature of 270C +/- 20C and at not less than
90% relative humidity.

Determination of Initial Setting Time:

Place the test block confined in the mould and resting on the non-porous
plate, under the rod bearing initial setting needle, lower the needle
gently in contact with the surface of the test block and quickly
release, allowing it to penetrate into the test block. In the
beginning the needle will completely pierce the test block. Repeat this
procedure until the needle, when brought in contact with the test block
and released as described above, fails to pierce the block for 5 +/- 0.5
mm measured from the bottom of the mould. The period lapsing
between the time water is added to the cement and the time at which the
needle
fails to pierce the test block by 5 +/- 0.5 mm shall be the initial setting
time.

Determination of Final Setting Time:

Replace the needle of the Vicat apparatus by the needle with an annular
ring. The cement shall be considered as finally set when, upon applying
the needle gently to the surface of
the test block, the needle makes an impression thereon, while the outer
ring fails to do so. The period elapsing between the time when water is
added to the cement and the time at which the needle makes an
impression on the surface of the test block while the attachment
fails to do so, shall be the final setting time.
Limits: Initial Setting Time, minimum - 30 minutes.
Final Setting Time, maximum - 600 minutes.

3.SOUNDNESS
Object:
Determination of the Soundness of cement by the Le Chatelier method.

Apparatus:
The apparatus for conducting the test consists of small split
cylinder of spring brass or other suitable metal of 0.5 mm thickness,
forming a mould 30 mm internal diameter and 30 mm high. On either
side of the split mould are attached two indicators with pointed
ends, the distance from these ends to the center of the cylinder being 165
mm. The mould shall be kept in good condition with the Jaws not more
than 0.50 mm apart.

Procedure:
Place the mould on a glass sheet and fill it with cement paste formed by
gauging cement with 0.78 times the water required to give a paste of
standard consistency. The paste shall
be gauged in the manner and under the conditions prescribed in
determination of consistency of standard cement paste, taking care to
keep the edges of the mould gently together while this operation is being
performed. Cover the mould with another piece of glass sheet, place a
small weight on this covering glass sheet and immediately submerge the
whole assembly in water at a temperature of 27degree C +/-
2degree C and keep there for 24 hours. Measure the distance
separating the indicator points. Submerge the moulds again in water at
the temperature prescribed above. Bring the water to boiling, with the
mould
kept submerge, in 25 to 30 minutes, and keep it boiling for three
hours. Remove the mould from the water, allow it to cool and
measure the distance between the indicator points. The difference
between these two measurements represents the expansion of the
cement.

Limits:
Expansion should not be more than 10 mm.
4.FINENESS

Object:
To determine the fineness of cement by dry sieving.

Apparatus:
a) Standard balance with 100 g. weighing capacity.
b) IS: 90 micron sieve confirming to IS : 460 – 1962 and a Brush.

Procedure:
a) Break down any air-set lumps in the cement sample with fingers.
b) Weigh accurately 100 g of the cement and place it on a standard 90
micron IS Sieve.
c) Continuously sieve the sample for 15 minutes.
d) Weigh the residue left after 15 minutes of sieving. This completes the
test.

Result:
The percentage weight of residue over the total sample is reported.
Weight of Sample Retained on the Sieve = 4 gms
% Weight of Residue = 4 %
Total Weight of the Sample =100 gms
Limits:
The percentage residue should not exceed 10%.

Precautions:
Sieving shall be done holding the sieve in both hands and gentle wrist
motion, this will involve no danger of spilling the cement, which
shall be kept well spread out on the screen. More or less
continuous rotation of the sieve shall be carried out throughout
sieving. Washers, shots and slugs shall not be used on the sieve.
The underside of the sieve shall be lightly brushed with a 25 or 40 mm
bristle brush after every five minutes of sieving. Mechanical sieving
devices may be used, but the cement shall not be rejected if it meets the
fineness requirement when tested by the hand method.

Tests On Aggregates
1. IMPACT STRENGTH

Object: To determine the impact strength of aggregates.

Apparatus :
Aggregate testing machine.
Steel measuring cup of dia 75mm & height 50mm.
Cylindrical cup steel dia 102mm &height 50mm.
Balance to an accuracy of 0.1gm.
Oven.
Sieves of sizes -12.5mm,10mm,2.36mm.
Procedure :
Take the sample passing through 12.5 mm sieve and retained in 10 mm
sieve and keep it in oven for 24 hrs. Fill the sample in measuring cup in
three layers for each layer weigh the sample(A).
Transfer the sample to the cylinder steel cup and tamp for 25 times and
fix it in the testing machine. The hammer of the testing machine shall be
allowed to fall freely for 15 times in 15 seconds from a height of 380
mm. Take the sample out of the cup and sieve it through 2.36mm sieve
and weigh the sample (B).
Observation table:
 RESULT
SR DESCRIPTION
No 1 2
1 Weight of Dry Aggregate (W1) gms 370  336 
2 Weight of Aggregate retained on 2.36mm 315 260 
Weight of Aggregate Passing through 2.36mm
3
Sieve ( W2) gms 55  76 
4 Impact Value = W2/W1x100 % 14.86  22.62 
5 Average Impact Value % 18.74 

Calculation :
Aggregate impact value = (b/a)*100
AIV=18.74 %

2. CRUSHING VALUE
Object :
To determine the crushing strength of aggregates when a compressive
load is applied gradually.
Apparatus :
Compression testing machine
Calibrated sieves of size 12.5mm, 10mm, 2.36mm
Crushing mould
Balance readable to an accuracy of 1 gm
Stop watch
Measuring cylinder of dia 11.5 cm and height 18 cm
Tamping rod of 16 mm dia and 45 to 60 cm long
Preparation of test sample :
Take approx. 6.5kg of sample which is passing through 12.5mm and
retained in 10mm sieve.
Now fill the sample in the measuring cylinder in three layers, each layer
being tamped 25 times.
Now level the sample in the measuring cylinder.
Note down the weight of the sample (A).
Test Procedure :
Fix the crushing cylinder in the base plate and put the weighed sample in
the mould in three layers and tamped for 25 strokes in each layer.
Keep the plunger in position on top of the aggregate.
Place the sample in Compression Testing Machine, centre it and apply a
uniform load of 40 t reached in 10 minutes.
Release the load. Take the sample out of the mould and sieve through
2.36mm
The fraction passing through 2.36mm sieve shall be noted down (B).
Calculate the crushing value of the aggregate by using the formula,
B/A*100
Two trials shall be done and the mean value to be reported.
Observation table:
Total weight of sample gms, 2959 
Weight of sample passes in 12.5mm sieve and
2425 
retained on 10 mm sieve in gms , A
weight of fraction passing the 2.36mm sieve in gms,
534 
B
Crushing value = B/A * 100 %
18.05 
3.Flakiness Index:-
Object:
To determine the flakiness index(“is the percentage by weight whose
least dimension(thickness) is less than 3/5 th of their mean dimension”) of
the aggregate.
Apparatus/Equipment:
1.Metal gauge-Thickness gauge & Length gauge
2.IS:Sieve of sizes 63,50,40,31.5,25,20,16,12.5,10,6.3 mm
3.Balence of accuracy of 0.1% of the total weight of aggregate.
Test Procedure:
1) The sample shall be sieved through the sieves specified in table:
Dimension of Thickness and
  Length gauge    
       
Passing through Thickness gauge Length
IS sieve Retained on IS sieve (mm) gauge
(A) (B) (C) (D)
63 mm 50 mm 33.9 …
50 mm 4o mm 27 81
40 mm 31.5 mm 21.5 64.4
31.5 mm 25 mm 16.95 …
25 mm 20 mm 13.5 40.5
20 mm 16 mm 10.8 32.4
16 mm 12.5 mm 8.55 25.6
12.5 mm 10 mm 6.75 20.2
10 mm 6.3 mm 4.89 14.7

2) At least 200 pieces shall be taken from each fraction and the flaky
samples shall be weighted to an accuracy of 0.1% of the test sample.
3)Calculate the flakiness index
= ( Wt.of flaky samples(passing)/(Wt. of total sample taken for
test))*100

sieve size (w1)g (w2)g (w3)g

(mm) m m m
passi retain
ng ed      
63 50      
50 40      
40 25      
31.25 25      
25 20      
20 16      
16 12.5      
12.5 10 368 290 78
10 6.3 222 192 30
total weight 590 482 108
. W1= total wt. of aggregate retained on sieve
W2= total wt. of aggregate retained on thickness guage
W3=total wt. of aggregate passing through thickness guage
Flakiness Index (FI) = [w3/w1]*100
= 18.31 %
Limit of Flakiness Index (Max.) = 35 %

Tests On Concrete
1. COMPRESSIVE STRENGTH

Object : Determination of compressive strength of concrete.

Apparatus:
Testing Machine: The testing machine may be of any reliable type of
sufficient capacity for the tests and capable of applying the load at the
specified rate. The permissible error shall not be greater than 2
percent of the maximum load. The testing machine shall be
equipped with two steel bearing platens with hardened faces. One of the
platens shall be fitted with a ball seating in the form the portion of a
sphere, the center of which coincides with the central point of the
face of the platen. The other compression platen shall be plain rigid
bearing block. The bearing faces of both platens shall be at least as
larger as, and preferably larger than the nominal size of the specimen to
which the load is applied.
The bearing surface of the platens, when new, shall not depart from a
plane by more than 0.01mm at any point, and they shall be maintained
with a permissible variation limit of 0.02mm. the movable portion of the
spherical seated compression platen shall be held on the spherical seat,
but the design shall be such that the bearing face can be rotated freely
and tilted through small angles in any direction.

Age at test: Tests shall be made at recognized ages of the test

specimens, the most usual being 7 and 28 days. The ages shall be
calculated from the time of the addition of water of the dry ingredients.
Number of Specimens: At least three specimens, preferably from
different batches, shall be made for testing at each selected age.

Procedure:
Specimens stored in water shall be tested immediately on removal
from the water and while they are still in the wet condition.
Surface water and grit shall be wiped off the
Specimens and any projecting find removed specimens when received
dry shall be kept in water for 24 hours before they are taken for testing.
The dimensions of the specimens to the nearest 0.2mm and their weight
shall be noted before testing. Placing the specimen in the testing
machine the bearing surface of the testing machine shall be wiped clean
and any loose sand or other material removed from the surface of the
specimen, which are to
be in contact with the compression platens. In the case of cubes,
the specimen shall be placed in the machine in such a manner that the
load shall be applied to opposite sides of the cubes as cast, that is,
not to the top and bottom. The axis of the specimen shall be
carefully aligned with the center of thrust of the spherically seated
platen. No packing
shall be used between the faces of the test specimen and the steel
platen of the testing machine. As the spherically seated block is
brought to bear on the specimen the movable
portion shall be rotated gently by hand so that uniform seating may be
obtained. The load shall be applied without shock and increased
continuously at a rate of approximately 140 kg/cm2/min. until the
resistance of the specimen to the increasing load breaks down and no
grater load can be sustained. The maximum load applied to the specimen
shall then be recorded and the appearance of the concrete and any
unusual features in the type of failure shall be noted.

Calculation: The measured compressive strength of the specimen shall

be calculated by dividing the maximum load applied to the specimen
during the test by the cross sectional area, calculated from the mean
dimensions of the section and shall be expressed to the nearest kg
per cm2. Average of three values shall be taken as the
representative of the batch provided the individual variation is not
more than +/-15 percent of the average.
Otherwise repeat tests shall be made. A correction factor according
to the height / diameter ratio of specimen after capping shall be
obtained from the curve shown in Fig.1
of IS:516-1959. The product of this correction factor and the
measured compressive strength shall be known as the corrected
compressive strength this being the equivalent
strength of a cylinder having a height/diameter ratio of two. The
equivalent cube strength of the concrete shall be determined by
multiplying the corrected cylinder strength by 5/4.

2. Slump Cone Test

Object:
This method of test specifies the procedure to be adopted, either
in the laboratory or during the progress of work in the field, for
determining, by the slump test, the consistency of concrete.

Apparatus:
a) Mould: the mould for the test specimen shall be in the form of the
frustum of a cone having the following internal dimensions:
Dimensions cm:-
Bottom diameter:- 20
Top diameter:-. 10
Height:- 30

b) Tamping Rod: The tamping rod shall be of steel or other suitable

material, 16 mm in diameter, 0.6m long and rounded at one end.
Procedure:
The internal surface of the mould shall be thoroughly cleaned and freed
from superfluous moisture and any set concrete before commencing the
test. The mould shall be placed on a smooth, horizontal, rigid and
non-absorbent surface, such as a carefully leveled metal plate, the
mould being firmly held in place while it is being filled. The
mould shall be filled in four layers, each approximately one-quarter
of the height of the mould. Each layer shall be tamping with 25
strokes of the rounded end of the tamping rod. The strokes shall be
distributed in a uniform manner over the cross-section of the mould and
for the second and subsequent layers shall penetrate into the underlying
layer. The bottom layer shall be tamped throughout its depth. After
the top layer has been rodded, the concrete shall be struck off level
with a trowel or the tamping the rod, so that the mould is exactly filled.
Any mortar, which may have leaked out between the mould and
the base plate,
shall be cleaned away. The mould shall be removed from the
concrete immediately by raising it slowly and carefully in a vertical
direction. This allows the concrete to subside and the slump shall be
measured immediately by determining the difference between the height
of the mould and that of the highest point of the specimen being tested.
The above operation shall be carried out at a place free from vibration or
shock, and within a period of two minutes after sampling. The slump
measured shall be recorded in terms of millimeters of subsidence
of the specimen during the test. Any slump specimen which
collapses or shears off laterally gives incorrect result and if this
occurs the test shall be repeated with another sample.
Limits:
1. For tremie pipe limits 150 to 200 mm.
2. For boom placer limits 75 to 125 mm.