Method Statement For TBM Main Drive From Greenways To Adyar Junction & Greenways To Mandaveli Tunnels

Construction of twelve (12) km Twin Bored tunnels from Kellys station
to Taramani road Jn station and construction of Diaphragm walls of

station box and entry / exit structures of Chetpet Metro, Royapettah
govt. hospital, Thiruvanmiyur Metro stations and part Diaphragm wall
of Greenways Road metro station, including Launching and Retrieval
shafts as required in the above stations -CP31-TU02 Project.
METHOD STATEMENT FOR TBM MAIN DRIVE FROM
Date: 17/06/2023 GREENWAYS TO ADYAR JUNCTION & GREENWAYS TO Revision No: 02
MANDAVELI TUNNELS
Doc No(L&T): P20C03TU02PRW-LANT-CIV-WMS-00111 R (2)
PMIS Ref No.: P20C30TU02PRW-LANT-CIVWMS-00111 (2)

GREENWAYS TO ADYAR JUNCTION & GREENWAYS TO
MANDAVELI TUNNELS
PROCEDURE NO: P20C03TU02PRW-LANT-CIV-WMS-00111 R (2)
CLIENT: CHENNAI METRO RAIL LIMITED
GENERAL CONSULTANTS: NKAB
LARSEN & TOUBRO LIMITED

HEAVY CIVIL INFRASTRUCTURE INDEPENDENT COMPANY
CONTRACT: CHENNAI METRO RAIL PROJECT
PHASE 2, CORRIDOR-3
TENDER NO CP31 -TU02
Page 1 of 110
Sensitivity: Unclassified
station box and entry / exit structures of Chetpet Metro, Royapettah govt.
hospital, Thiruvanmiyur Metro stations and part Diaphragm wall of
Greenways Road metro station, including Launching and Retrieval shafts
as required in the above stations -CP31-TU02 Project.
MANDAVELI TUNNELS
TABLE OF CONTENTS
Sl No. DESCRIPTION Page No.
1 INTRODUCTION 6
2 PURPOSE 7
3 SCOPE 7
4 REFERENCE 8
5 DEFINITIONS & ABBREVIATIONS 9
6 RESPONSIBILITIES 10
7 EQUIPMENT & RESOURCES 13
8 SURFACE SETUP 15
8.1 Gantry Crane 15
8.2 Ventilation System 15
8.3 Electrical Power supply 16
8.4 Grout Plant 16
8.5 Cooling Water Supply Setup 16
8.6 Compressor and Receiver tank 17
8.7 Muck Pit 17
8.8 Medical Lock 17
8.9 Workshop Establishment 17
8.10 Storage of TBM consumables 18
8.11 Wheel Wash 18
8.12 Sedimentation tank and ETP (Effluent Treatment Plant) 18
8.13 Service Utilities 18
9 SHAFT SETUP AND EQUIPMENT 18
9.1 Battery Powered locomotive 18
9.2 Segment Car 19
9.3 Traverser Setup 19
9.4 Muck Car 19
9.4.1 Procedure involved to reconciliation of the excavated muck 19
9.5 Y-Switch 24
9.6 Manchester Gate 24
10 TBM SETUP 25
10.1 Tunnel Boring Machine 25
10.2 Additive Injection Facility 26
10.3 Backfill Grouting Equipment 26
10.3.1 Primary grouting 26
10.3.2 Secondary grouting 27
10.4 Cooling Water 27
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10.5 Greas 27
10.6 Wastewater Pipeline 27
10.7 Consumable Material 28
10.8 Walkway and Cable/ Pipe Bracket in Tunnel 28
10.9 Tunnel Illumination 29
10.10 Fresh Air Installation 29
10.10.1 Technical concept 29
10.10.2 Ventilation duct installation 29
11 WORK PROCEDURE FOR CONVERSION OF INITIAL DRIVE TO MAIN 30
DRIVE
11.1 Preparation for Initial drive 30
11.2 Conversion of Initial drive to Main drive 30
11.3 Reaction frame dismantling 30
11.4 Temporary rings dismantle 30
11.5 Umbilical removal 30
11.6 Cradle dismantle 31
12 TBM BACKUP LOWERING AND ASSEMBLING 31
13 INSPECTION BEFORE MAIN DRIVE 31
14 WORK PROCEDURE OF MAIN DRIVE 32
14.1 TBM Construction Methodology 32
14.2 TBM operation Mode 34
14.3 Advance Parameters 35
14.4 Face Stability Analysis 35
15 TBM OPERATION 36
15.1 Excavation 36
15.2 Primary Grout 38
15.3 Ring Building 39
15.4 Secondary Grout 41
15.5 Foam and Polymer Injection 42
15.6 Foam Injection Ratio 44
15.7 Polymer Injection Method 45
16 PARAMETERS FOR TUNNEL DRIVE 46
17 LIFTING WORK 45
17.1 De-mucking from shaft 46
17.2 Segment lifting and shifting 47
17.3 Other lifting operations 47
18 INTERRUPTION OF PRODUCTION CIRCLE 48
19 CUTTER HEAD INTERVENTION 48
20 TBM CONTROL 48
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21 TUNNEL SURVEY 49
22 INSTRUMENTATION AND MONITORING 51
22.1 Surface Monitoring 51
23 CHECKING THE DEVELOPMENT OF BUILDING DAMAGES 53
23.1 Crack meter 53
23.2 Tilt meter 53
23.3 Type and limits 53
24 QA/QC MONITORING 53
25 SEGMENT LINING INSPECTION 53
25.1 Ring Lining (Steps and Lips) 54
26 TBM MAINTENANCE PLAN 56
26.1 Standard Maintenance 56
26.2 Critical Equipment 56
27 EMERGENCY PLAN 56
27.1 Surface Disturbance 56
27.2 Settlements and Residential area 57
27.3 Vibrations 57
27.4 Building Damages 57
27.5 Blowouts 57
28 PREVENTION OF TBM BREAKDOWN 58
29 SINKHOLES 58
30 BACK-UP POWER AND LIFE SUPPORT EQUIPMENT 59
31 TUNNELING PROCEDURE UNDERNEATH, THE SENSITIVE 59
STRUCTURES/WATER BODIES
32 EMERGENCY CONTACT NUMBERS 60
33 APPENDICES
APPENDIX A - ORGANISATION CHART
APPENDIX B - OHS&E RISK ASSESSMENT
APPENDIX C - INSPECTION TEST PLAN
APPENDIX D – CHECKLISTS AND FORMATS
APPENDIX E – RING BUILDING SEQUENCE
APPENDIX F – WALKWAY AND BRACKET DETAILS
APPENDIX G – CUTTERHEAD POSITION DRAWINGS
APPENDIX H – PROCEDURE FOR REPLACING AND CALIBRATION OF EPB SENSORS
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MANDAVELI TUNNELS
1. INTRODUCTION:
The proposed project Chennai Metro Rail Phase 2 Corridor 3 Package CP31-TU02 has been
awarded to L&T construction Chennai by project authority Chennai Metro Rail Limited for the
Construction of twelve (12) km Twin Bored tunnels from Kellys station to Taramani road Jn
station and construction of Diaphragm walls of station box and entry/exit structures of Chetpet
Metro, Royapettah govt. hospital, Thiruvanmiyur Metro stations and part Diaphragm wall of
Greenways road metro station, including Launching and Retrieval shafts as required in the above
stations of the project in the city of Chennai, India.
Figure 01: Proposed alignment of Chennai metro rail phase-2 corridor-3 CP31-TU02
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2. PURPOSE:
This document sets out the work Method Statement for Greenways to Adyar Jn. & Greenways
to Mandaveli TBM Tunneling operations for CMRL TU-02 using Earth Pressure Balanced TBM
in order to carry out the works in a planned and systematic manner. This Method Statement
identifies and describes the key features of the TBM and its support system, contained both on
the gantries towed behind the TBM shield and housed in the access shaft or along the tunnel
itself. It also includes TBM advance cycle analysis, excavation procedure (including soil
conditioning), segment handling, ring erection, locomotive movements, services installations,
lubricants, rolling stock, rail track, walkway, monitoring of activities/ permanents works, site
organization/management responsibilities and operational crews.
This Method Statement will apply to Greenways to Adyar Jn. & Greenways to Mandaveli
Tunnels.
3. SCOPE:
The scope of this method statement is to describe all activities involved in the completion of the
initial drive.
 SURFACE SETUP
 SHAFT SETUP AND EQUIPMENT
 TBM SETUP
 WORK PROCEDURE FOR CONVERSION OF INITIAL DRIVE TO MAIN DRIVE
 CONVERSION OF INITIAL DRIVE TO MAIN DRIVE
 TBM BACKUP LOWERING AND ASSEMBLING
 INSPECTION BEFORE MAIN DRIVE
 WORK PROCEDURE OF MAIN DRIVE
 TBM TUNNEL CONSTRUCTION METHODOLOGY
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 EXCAVATION WITH PARALLEL ACTIVITIES
 SAND WITH WATER
 MIX GEOLOGY
 ROCK PROFILE
 ERECTION OF THE PRECAST SEGMENT WITH PARALLEL ACTIVITIES
 TBM OPERATION MODE
 CLOSED MODE
 OPEN MODE
 TBM OPERATION
 FOAM AND POLYMER INJECTION
 EFFECT OF INJECTION MATERIAL
 FOAM INJECTION METHOD
 FOAM INJECTION RATIO
 POLYMER INJECTION METHOD
 PARAMETERS FOR TUNNEL DRIVE
 SURFACE MONITORING
 QA/QC MONITORING
 SEGMENT LINING INSPECTION
 TBM MAINTENANCE PLAN
4. REFERENCE:
The reference is made to the contract documents and specifications listed below:
 Contract Document Part: Section Employer’s Requirements Sub Section 1.3.20.2
 OCS Part-2 Section VII Sub Section 2.5.3 Particular Requirements for TBMs
 OCS Part-2 Section VII Sub Section 2.15.2
 OCS Part-2 Section VII Sub Section 2.12.1 & 2.12.2
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 OCS Part-2 Section VII Sub Section 2.7
 Approved Method Statement for TBM Launching and Initial Drive
 Approved Method Statement for Tunnel Primary backfill Grout
 Approved Method Statement for Tunnel Secondary backfill Grout
 Method Statement for Locomotives and Rolling Stock
 Approved Method Statement for Site utilization at launching shaft for TBM
 Approved Method Statement for Atmospheric and Hyperbaric TBM cutter Head
intervention in Tunnels
 BS 6164:2019 COP for H&S in Tunnelling
5. DEFINITIONS & ABBREVIATIONS:

CMRL - Chennai Metro Rail Limited
GC - General Consultant
L&T - Larsen & Toubro
MS - Method Statement
ITP - Inspection and test plan
QA - Quality Assurance
QC - Quality Control
RA - Risk Assessment
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TBM - Tunnel Boring Machine
6. RESPONSIBILITIES:
The reporting structure of personnel involved in Main drive activity shall be as below,
Project Manager  Shall be responsible for overall progress of The Project.
Chief Tunnel  Shall report to the Project Manager

Manager  Shall be responsible for control, supervision & direction for
implementation & execution of construction plans.
 Shall also be responsible for availability of required resources.
 Shall communicate to Client representative day to day activities.
 Shall Supervise the works in part time
Senior Tunnel  In charge of TBM drives allocated.
Manager  Check and control the activity operating.
 In charge of personnel planning and allocation of the same to the
shifts.
 In charge of all quality control procedures pertaining to work
 activity.
 Ensure sequence and work Executions.
 Shall Supervise the works in part time
 Shall communicate to Client representative day to day activities.
 Shall be responsible for day-to-day planning.
Tunnel Shift  Shall report to Senior Tunnel Manager / Chief Tunnel Manager,
Manager  Shall be responsible for day-to-day planning.
 Shall be responsible for ensuring the work as per specifications.
 In charge of personnel planning and allocation of the same to the
shifts.
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Chief QAC Manager  Shall report to the Project Manager
 Shall be responsible for strict implementation of Quality
Management System
 Shall be responsible for control & direction for implementation of
Quality works as per standards & MS
QA/QC Engineer  Shall report to Chief QAC Manager.
 Shall be responsible for overall control of QC activities and
implementation of Project Quality Plan.
 Shall be responsible for ensuring the Quality of work as per
specifications.
P&M Engineer  Ensure continuous availability of P&M at site.
 To Provide necessary equipment’s as per site requirements.
 Ensure periodic preventive maintenance & timely breakdown
repairs of all machinery & electrical equipment as per their
inspection manuals.
Chief OHS & E  Shall report to the Project Manager
Manager  Shall be responsible for the implementation of SOP throughout
the project
 Shall stop the work if unsafe practices are witnessed and promote
‘Don’t Walk by & Commitment to Action attitude’ at all times.
 Shall be responsible to create an awareness of EHS as an integral
part of good management.
Senior OHS & E  Shall report to Chief OHS&E Manager.
Manager  Responsible for conducting weekly toolbox meetings and accident
 investigations with the employees or ensures such meetings are
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 conducted by the respective engineer/supervisor or
subcontractors.
 Ensure relevant statutory requirements for Project OH& S is
 implemented effectively.
 Inspect and rectify any unsafe place of work and unsafe practices.
Survey Manager  Shall report to Project Manager and Chief Tunnel Manager
 Shall be responsible for marking of locations, setting out works as
per drawings.
 Shall be responsible for day-to-day planning and works as per
standards.
Safety Engineer  Shall report to Chief OHS&E Manager.

 Shall observe all safety aspects in all the activities.
 Shall be responsible for risk identification, safety inspection
pertaining to this activity.
Utility Manager  The utility Manager shall report to the Project manager/ Sr.
Tunnel Manager.
 He will communicate to the concerned authorities about the
respective utilities and their diversion (if required).
Geotechnical  The Geotechnical Manager Shall be responsible for Geotechnical
Manager activities & records of ground geology.
 Shall report to Chief Geotechnical and Project Manager.
Geotechnical  The Geotechnical engineer shall be responsible for Geotechnical
Engineer activities & records of ground geology.
 Shall report to Geotechnical Manager and Project Manager.
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Stores in-charge  Maintaining material stock report and minimum stock of
materials.
 Receiving and issue of materials as per requirement.
 Ensuring proper storage of materials as per IS Code 4082, 1996.
7. EQUIPMENT & RESOURCES:
7.1 Labor Plan for Tunneling Work (Day & Night Shift):
TUNNEL MANPOWER
TBM 1 TBM 2
CATEGORY NOS. CATEGORY NOS.
TBM Operator 2 TBM Operator 2
Erector Operator 2 Erector Operator 2
Grout Operator 2 Grout Operator 2
Ring Builder 8 Ring Builder 8
Grout Helper 2 Grout Helper 2
Rail Line & Pipe Line 8 Rail Line & Pipe Line 8
Fitter Fitter
Locomotive operator 2 Locomotive operator 2
Tunnel Worker As Required Tunnel Worker As Required
TUNNEL SHAFT BOTTOM
Shaft Supervisor 2 Shaft Supervisor 2
Signal Man 2 Signal Man 2
Rigger 6 Rigger 6
Helpers As Required Helpers As Required
SURFACE
Gantry Crane operation 2 Gantry Crane operation 2
Signal Man 2 Signal Man 2
Rigger 6 Rigger 6
Surface workers 4 Surface workers 4
The labor plan above is for both shifts. There are two TBM for this project and tunneling work
is carried out by day and night shift.
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7.2 Equipment:
The major Plant and Equipment required for the Tunnel construction are as follows,
SR. EQUIPMENT QUANTITY

1. TBM 2 Nos.
2. Medical lock 1 Nos.
3. Electric locomotives 4 Nos.
4. Muck cars 4-5 Nos./Loco
5. Flat cars 1 Nos./Loco
6. Man rider / Passenger cars 2 Nos
7. Segment carrier 2 Nos./Loco
8. Cooling tower (230m3/hr.+100m3/hr.) 1 No/TBM
9. Chilling plant 1 No/TBM
10. DG Sets (1000 kva) 2 Nos.
11. DG Sets (500 kva) 1 No.
12. Synchronizing panel for 1000 KVA DG sets 1 No.
13. Sub-station (11 kva) 1 No.
14. Grout Plant (30 m3/hr.) 1 No for 2 TBM
15. Cement Silo (100MT) 1 No for 2 TBM
16. Bentonite Silo (10MT) 1 No for 2 TBM
17. Grout transfer pump (20m3/hr.) 1 No for 2 TBM
18. 1 No. for 4
Sodium Silicate Tank (40m3)
TBM
19. Gantry crane (70MT) 1 for each TBM.
20. Electrical Compressor 600cfm 4 Nos.
21. Diesel Compressor 500 cfm 1 No.
22. Air Dryer (Surface) 1 Nos.
23. Air receiver tank 3 Nos.
24. Ventilation fan (33KW) 1 Nos./Tunnel
25. Ventilation duct – flexible As required
26. TBM cooling system pumps As required
27. Fork Lift (5 MT) 1 No.
28. Tipping device (35MT) 1 for each TBM
29. Sedimentation Tank (100000 Ltr.) 1 No.
30. Grout Pump – MAI 400 NT (Secondary Grouting) As required
31. Pneumatic torque wrench As required
32. Hand-tools As required
33. Dewatering pumps – Submersible As required
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34. Dewatering pumps – Slush As required
35. Water feeder 1 for each TBM
36. Return line As required
37. Airline As required
38. Welding machine – Portable As required
39. Hydraulic jacks As required
40. Rail line As required
41. Manchester gate 2 Nos./Tunnel
42. Y-Switch 1 Nos./Tunnel
8. SURFACE SETUP:
The Site utilization method statement submitted separately and approved by GC. Surface set-up
content will be as follows:
8.1 Gantry Crane:

One gantry crane is set up for each tunnel for construction material lifting and muck disposal.
Two units of gantry cranes with a rated load of 70 tons are proposed for this project.
For more detail refer to MS for Site Utilization at Launching shaft for TBM,
P20C03TU02PRW-LANT-CIV-WMS-00067 (1)
8.2 Ventilation System:

The ventilation system shall maintain sufficient fresh air volume inside the bored tunnel(s) to
provide site personnel with a safe working environment. It consists of flexible ducting in sections,
which extends automatically from a cassette container installed on the backup. An axial
multistage fan will be installed at the surface, and each fan will be fitted with suitable silencers.
The air duct will hang from the tunnel crown using steel wire rope supports anchored to the roof
segment. The intake is located in the front of tunneling. Details of the ventilation system shall be
provided under a separate Tunnel Ventilation Method Statement.
For more detail refer to MS for Site Utilization at Launching shaft for TBM,
Quality of Air: Air quality will be check by Safety team time to time.
 Fresh air contains approximately 20.9% oxygen, 79.0% nitrogen and 0.03% carbon dioxide
by volume. The remainder includes argon and other gases.
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 The tunnel atmosphere should be considered oxygen-deficient when the concentration of
oxygen falls below 19.5%.
 The important physical aspects of air quality are temperature, humidity, and velocity.
 The air as supplied should be as cool and dry as is reasonably practicable, as during its
passage into the tunnel its temperature tends to become that of the tunnel walls and take up
moisture in the tunnel.
 A higher temperature can impair working efficiency. Lower temperatures can contribute
greatly to comfort and efficiency
Air quality will be maintained as per ER Part-2-Section VI-A Volume–4 OHS&E-Tunneling
Manual, Sub-Section 26.4.5
8.3 Electrical Power Supply:

Method Statements submitted separately and approved by GC, P20C30TU02PRW-LANT-
CIVWMS-00076 (1).
8.4 Grout Plant:

A grout plant with a capacity of 30 m3/hr was commissioned to supply primary backfill grout to
TBM. Along with a cement silo of 100 MT capacity, a 10 MT bentonite silo will be provided
with an automatic feeding system for cement and bentonite. One grout plant will cater to the
requirements of two TBMs.
Grout plant installation details are provided in MS for Site Utilization at Launching shaft for
TBM, P20C03TU02PRW-LANT-CIV-WMS-00067 (1)
8.5 Cooling Water Supply Setup:

The TBM used for this project is provided with a closed-type cooling water circuit. Each of the
TBM needs to be supplied with cooling water (Approx. 80 m3/hrs.) at 250C (inlet). In order to
supply feed water to TBM as per manufacturer requirement, Chilling plant 260TR with storage
tank system (86 KL) and separate water pumps for each TBM, and an additional water storage
tank with 190 KL will be provided. (Total water storage for each TBM is 276 KL)
For more details please refer MS for Site Utilization at Launching shaft for TBM,
P20C03TU02PRW-LANT-CIV-WMS-00067 (1).
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8.6 Compressor & Receiver Tank:

Compressed Air regulation system supplied through 4” M.S lines from surface to the TBM. For
more details please refer MS for Site Utilization at Launching shaft for TBM,
8.7 Muck Pit:

RCC Muck pit of size 33.5 m X 5.25 m X 3 m alongside longitudinal D-Wall as shown in the
site layout drawings. The gantry foundations will span across the width of the muck pit. A Tilting
frame designed for the purpose of emptying muck skips (19 cum) will be installed as shown in
the site layout drawings.
8.8 Medical Lock:

As per Section VI-A Volume – 4 OHS&E - Tunnelling Manual for medical lock clause 61.8,
61.11.
A suitably built Medical lock will be provided on the shaft surface and used safely for the purpose
of treating persons working in compressed air (Hyperbaric Cutter Head Interventions). The
medical lock shall be placed on hard standing near the launching shaft as per recommended. A
separate breathable air pipeline arrangement will be provided for the medical lock from the
existing compressed air setup available at the surface. The trained medical practitioners will be
engaged as per requirement.
For more details please refer MS for Atmospheric and Hyperbaric TBM cutter Head
intervention in Tunnels, P20C03TU02PRW-LANT-CIV-WMS-00083 (1)
8.9 Workshop Establishment:

A site workshop will be established at the surface and will be provided with the necessary
equipment required to carry out the maintenance works at the site level for efficient working/
TBM operations.
Major and overall maintenance will be carried out in TBM workshop at Vanagaram, Preventive
maintenance / services will be carried out in greenways site
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8.10 Storage of TBM Consumables:

TBM consumables will be stored in a purpose-built shed/container. The shed/container will be
provided with hard standing & separation racks will be provided for various types of TBM
consumables. For more details please refer MS for Site Utilization at Launching shaft for TBM,
8.11 Wheel Wash:

Wheel wash will be provided at the exit location as shown in the site layout drawing for cleaning
the wheels of vehicles.
8.12 Sedimentation Tank and ETP (Effluent Treatment Plant):

The wastewater from TBM operations (such as cleaning grout tanks, agitators, bottom cleaning,
etc.) is brought to the surface by pumping through dewatering lines. Dewatering pumps of
requisite capacity will be installed at TBM, the lowest point in the tunnel & launch shaft bottom.
It shall be put through sedimentation tanks for removal of solid particles before finally
discharging into a drain. The quality of discharge water will be checked at a predetermined
frequency. the treated water will be disposed of as per the environmental norms at the nearby
drain. For more details please refer MS for Site Utilization at Launching shaft for TBM,
8.13 Service Utilities:

Service pipelines for TBM will be laid through in suit trench up to the headwall of D-wall and
from there, service utility lines (temporary and permanent) are supported against the headwall.
9. SHAFT SETUP AND EQUIPMENT:

9.1 Battery-Powered Locomotive:
The railroad system is chosen to be delivering system in tunnel construction, the rail and sleeper
will be laid in position immediately once the space is available. The battery-powered locomotive
is proposed to track the segment car and muck cars into and from the Tunnel.
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For more detailed specifications refer to Method Statement Locomotives and Rolling Stock,
9.2 Segment Car:

Segment cars will be used for segment transportation from the shaft bottom to the segment feeder,
which is available in the TBM area near the erector. The segments are proposed to be lifted from
the ground surface by a gantry crane and placed on 2 segment cars as per the sequence of laying.
The segments will deliver into the tunnel near the segment feeder.
9.3 Traverser Set Up:

100 Ton Motorized Trolley (Traverser with Two Track System) will be installed in each shaft,
which is allowing a horizontal shifting of the rolling stock between four installed rail tracks. This
Traverse is self-propelled and will be operated directly from the platform. This conversion will
be done in two stages.
a. Drive length 100m -225 m -will be placed symmetrical Y switch after 225 M
b. Traverse installed at shaft bottom and Y switch will be installed at 225 m inside the tunnel
9.4 Muck Car:

The excavated material will be transported from the tunnel to the shaft through muck cars. The
loaded muck cars will be brought to the shaft by locomotives for muck disposal, after which the
muck will be lifted from the launch shaft with the help of a gantry crane and emptied into the
muck pit. For more detailed specifications refer to Method Statement Locomotives and Rolling
Stock, P20C03TU02PRW-LANT-CIV-WMS-00088 (1)
9.4.1 Procedure involved to reconciliation of the excavated muck will be carried as following:
By comparing the monitored and theoretical values of muck mass and volume, believe
that the ground settlement caused by over-excavation in the TBM tunnel can be reflected.
Therefore, monitoring the mass and volume of the muck is helpful to prevent instability of the
tunnel face and to avoid further risk of Settlements.
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Step1-Volume Approach (Back-Analyzed Bulking Factor)

This approach analyzes the ratio of the net measured volume to the theoretical volume for
every set of specific rings through the derivation of new bulking factors. In this paper, the
bulking factor is defined as the ratio of the measured excavated material volume to the
expected excavated material volume tabulated based on the cutter head size. The volume
method is defined as follows:
1. The measured excavated material volume is obtained from the volume of the muck skips
used to transport the excavated material out of the tunnel. There is inherent uncertainty in
this measured volume since the excavated material is not leveled in every muck skip.
2. The cutter head size information is processed to obtain the expected excavated material
volume for each tunnel ring.
3. The bulking factor is calculated as:
Bulking Factor = Measured excavated volume
Expected excavated volume
4. Averaged bulking factor is applied back to obtain the corrected excavated volume for each
ring in the set of specific rings used to calculate averaged bulking factor as follows:
Corrected excavated volume = Averaged Bulking Factor × (Expected excavated volume)
5. The over excavation ratio (OER) for each ring is tabulated using the following equation:
OER = (Measured excavated volume − Additives volume)
Corrected excavated volume
NOTE: Additives volume refers to the amount of soil conditioners added during tunneling,
as measured by the tunnel boring machine
Step2- Weight Approach (Correction Factor)
This approach shall derive correction factor with the ratio of site investigation density to back-
analyzed density for every set of specific rings to achieve revised density and more realistic
OERs
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Figure2: Scale to measure density of the excavated soil
The further study of the Weight Approach shall be carried out in a three steps analysis:
Derive Correction factor of spillage (𝑥) per ring:

(𝑥 ∗ Measured Excavated Weight − Additives weight Measured) = (Site investigation)
(Measured Excavated Weight − Additives weight) (Back Analyzed density)
i.e. Back-analyzed density = (Measured Excavated Weight – Additives Weight)
(Expected Excavated Weight)
Revise Density using 𝑥 (check if it is close to SI report density):
Revised Density = (𝑥 ∗ Measured Excavated Weight − Additives weight)
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Expected Excavated Volume
Derive OER% with the above revised density:
OER = (𝑥 ∗ Measured Weight − Additives weight)

(Theoretical Volume × SI Report Density)
Step-3 Conveyor Belt Scaling System:

Span calibration with known material flow
The material test is usually used to determine the correction factor of a calibrated scale.
However, a known quantity of material can also be used to carry out a scale calibration. The
calibration is based on transportation of a known quantity of material, and comprises the
following steps:
Step 1
The belt is warmed-up and the zero point has been determined.
Step 2
 A specific quantity of material is now conveyed by the belt. Before the material
reaches the scale, activate the command "Start span calibration with material batch"
(67).
 The material flow is recorded. The status display indicates that the calibration is
running. When the belt is empty, terminate the calibration using the command "Stop
span calibration with material batch" (68).
 Enter the complete quantity of conveyed material before or after the calibration in
DR3 in the parameter "Calibration quantity (span calibration with material batch)".
Step 3
 Calculate the scale characteristic using the command "Calculate span calibration
point after material batch" (69). The result is displayed in DR4.
 Import the working point into DR3 using the command "Apply span calibration
digits" (89). The characteristic curve has thus been determined. The scale can
calculate the weight values for the complete load range.
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Belt scaling specifications and installation procedure attached.
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9.5 Y-Switch:
Double tracks system is proposed for material delivery and muck disposal in the main drive. Y-
switch will be installed in the tunnel for Rolling Stoke. Shaft to Y-Switch distance will depend
upon tunnel length. Y-switch is fabricated on a 12 mm thick steel plate in 3 detachable portions.
A Manual Switch controller is installed for the operation of the changeover. A trained operator
is only allowed to operate the switch, the same person will be a banksman also.
General /Technical Specification

Type Symmetrical Y-Switch Type Symmetrical Y-Switch
Length 15m Length 15m
Gauge 900mm Gauge 900mm
Rail Type 90lb Rail Type 90lb
Capacity 100 T Capacity 100 T
Figure 3: Reference Image of Y-Switch Figure 4: Reference Image of Manchester

Gate near Y-Switch
9.6 Manchester Gate:

One Manchester gate will be located at the rear part of the backup gantry and one at the near Y-
Switch inside the tunnel to control the movement of rolling stock. The Manchester gate will
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MANDAVELI TUNNELS
remain closed until rolling stock is in a full stop. It will be open during operation and a banksman
will be stationed nearby to direct the entries of rolling stock. For more detailed specifications
refer to Method Statement Locomotives and Rolling Stock, P20C03TU02PRW-LANT-CIV-
WMS-00088 (1)
10. TBM SETUP

10.1 Tunnel Boring Machine (TBM)
Earth Pressure Balance Machine (HK - EPBM) diameter of Ø6.63m will be used in this project
for operation in grade I to IV rock and mixed profile condition. The machines involved in this
project will have the following scheme:
South Shaft: From Greenways to Adyar Jn. a total of 1205m bored tunnel.
North Shaft: From Greenways to Mandavali a total of 660m bored tunnel.
Excavation of the tunnels will be carried out utilizing 4 HK TBMs (2 TBMs driving in parallel
per shaft) installing a segmental lining system.
a) Principal of EPB TBMs:

EPB TBMs have been selected for the construction of the tunnels in the Chennai Metro TU02
Project.
Earth Pressure Balance TBM technology is based upon the use of the excavated soils as the
supporting medium in the excavation chamber. The soil is extruded through the openings of the
cutter head to fill the excavation chamber and screw conveyor during TBM advance.
The EPB Shield TBM has a full-face rotating cutter head which can revolve in both clockwise
and counterclockwise directions. The soil excavated by the cutter-head is mixed with a foaming
agent and fills the soil chamber for balancing TBM earth pressure and water pressure. The
foaming agent was injected directly into the cutter head. The soil is discharged from the cutter
head via a screw conveyor onto the belt conveyor. In conjunction with the excavation by the
cutter head, backfill grout will be injected from the tail skin to fill the annulus void created
between the extrados segment lining and the bored rock mass. Simultaneously, tail seal grease
will also be injected into the tail brushes during backfill grout injection to prevent re-entering of
injected grout, groundwater and any slurry into the tail shield. TBM will move by a series of
shield jacks against the segment lining.
 TBM1 and TBM2 will start boring from the South Launch Shaft at the Greenways Station in
the direction of Adyar Jn Station.
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 TBM3 and TBM4 will start boring from the North Launch Shaft at the Greenways Station in
the direction of Mandavali Station.
10.2 Additive Injection Facility:

Foam/ polymer will be injected for this EPB tunneling work due to the continuous changes in
ground condition and to prevent spoil to stuck in the chamber and conveyor which may result in
the construction to suspend. An additive injection facility is issued for foam or polymer injection
to transform the excavating soil into a plastic fluidity state of the soil, fill the pores in the ground
for ground improvement and minimize the wear or damage of the cutterhead by reducing the
boring torque.
a) Foam Generator Pump:
The foam and polymer pump are situated on gantry No 3 and the foam generator pump placing
at bridge gantry (Location depends upon machine design). 1 number of foam suction lines and 1
polymer, the suction line will be extended along the way of the Tunnel.
10.3 Backfill Grouting Equipment:

Backfill grouting is to prevent ground settlement caused by tail void during tunnel excavation
and to stabilize installed segments. Backfill grouting will be carried out immediately after the
segment leaving the TBM tail with a grout mixer and automatic injection equipment. A
simultaneous automatic backfill grouting system is proposed for this project, consisting of a grout
plant with automatic mixing and transport unit located on the surface. A grouting unit with a
liquid A pump, a liquid B pump, an agitator tank for liquid A, a storage tank for liquid B, a unit
flow meter and an automatic grouting control device is available at TBM.
10.3.1 Primary Grouting:

There will be 2 number of liquid A pipelines (1 active and 1 spare) for each tunnel. These pipes
will be extended along the way. Liquid B will be supplied by pipeline into the Liquid B tank,
situated on TBM Backup.
NOTE: All Four ports must be operational before advance, If One port got chocked down
during advance but attempts to unblock must be made, & if two ports got chocked down during
the advance, then the advance must stop until ports are restored.
For more details follow the TBM manual.
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10.3.2 Secondary Grouting:
Secondary grout pump will be placed a suitable location on TBM backup with some cement bags
and secondary grout related tools and attachments. One MAI pump has been determined for one
TBM, which will always be on TBM.
Secondary grout to counter excessive settlement Compensation grouting will be carried in the
zone 'less than 30m' from front (ie. the screw dump end to inclined conveyor zone) as an
emergency procedure.
10.4 Cooling Water:

Water Cooling System and its associated pumps shall serve as the water supply for all activities
related to the excavation including but not limited to the cooling of tunneling equipment such as
electric motors, TBM circuits, the soil conditioning and the general cleaning of all equipment
installed on the back-up platform.
10.5 Grease:
After the initial drive Tail seal grease pump, EP2 and HBW pumps will be installed on the backup
gantry as per TBM specification.
10.6 Waste Water Pipeline:

One 15Hp dewatering pump will be situated in the ring building area which is connected to a
dewatering tank with a 3” pipeline (as per TBM specification). 4m3 dewatering tank is situated
at backup gantry number 5/6 (as per TBM specification). Centrifugal pump with a capacity of 60
cum/hrs, 45 m head is connected to this dewatering tank. The wastewater from the dewatering
tank will be pumped through 5ʺ pipeline along the tunnel from the dewatering tank on TBM to
the sedimentation tank at the surface. Operation control for the dewatering pump on TBM is
controlled by limit switch arrangements provided on the dewatering tank. This dewatering
pipeline will be extended along with the tunnel.
DEWATERING PUMP DETAILS

Pump Model Centrifugal Slurry Pump (WMI-S4)
Pump Speed 2316 rpm
Outlet DN Size 51 mm
Inlet DN Size 76 mm
Solid Passage 18 mm
Head 45 meters
Motor Power 18 kW
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Figure 5: Centrifugal Slurry Pump
10.7 Consumable Material:

Principal materials as a consumable to be used in the excavation activities are:
 Two-component materials: cement, bentonite, retarder, accelerator
 The chemicals required for TBM functioning: are tail shield grease, main bearing grease,
hydraulic oil, and gearbox oil.
 Materials for soil conditioning (i.e. foam, polymer,)
 Segment Bolt
 Segment Gasket with Glue
10.8 Walkway and Cable/Pipe Bracket in Tunnel:

The walkway is proposed 450 mm in width for both tunnels on one side for workers to travel in
the tunnel. The handrail will be erected 1.0 m Hight, as a divider between the walkway and the
travelling route of rolling stock. For the single rail track section, the walkway is proposed to lay
and tie them on the segment whereby for the double travel track section, due to the limited space
of the tunnel. Phone communication will be provided along the tunnel. This proposed walkway
will be the same in Y-switch.
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10.9 Tunnel Illumination:

At working faces, the illumination shall be provided a minimum of 50 lux. As per OCS Section
VII, Sub-Section-2, Clause 2.15.2 (Underground Facilities), Sub-Clause 5 (Lighting).
10.10 Fresh Air Installation:

10.10.1Technical Concept:
A 1200mm ø ventilation fan will be installed on the shaft surface. That fan will push the air
through continuously in the tunnel with the help of a ventilation duct (Dia. 1200mm). ventilation
duct will be hung in the tunnel crown with the help of steel wire rope. The ventilation cassette is
located on the last TBM gantry. For more detail please follow the TBM manual.
Figure 6: Fresh air set up on Gantry
10.10.2Ventilation Duct Installation:

On every TBM last backup gantry, an additional booster fan is installed which is pushing the air
through the backup system until the TBM. During the advance, at the rear of the TBM Gantries,
the ventilation duct will be pulled out of the exchangeable ventilation storage cassette.
Additionally, a steel rope (6mm) will be installed on which the ventilation duct is then hung. The
steel rope will be fixed onto the segment lining at every second ring. A designated worker will
be available during the excavation to insure a proper fixation of the ventilation duct. Every 25 m,
a heavy-duty turnbuckle will be installed which is allowing a tensioning of the steel robe. The
joint between the ventilation duct segments is a Velcro Joint.
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MANDAVELI TUNNELS
Figure 7: VELCRO Joint ventilation
11. WORK PROCEDURE FOR CONVERSION OF INITIAL DRIVE TO MAIN DRIVE:

11.1 Preparation for Main Drive:
The main drive will commence after the initial drive is finished, this is envisaged to be after
approximately 100 m or equal to TBM length with all backup support along with the rolling
stock of the permanent tunnel built. This length may vary depending on the site and TBM length.
11.2 Conversion of Initial Drive to Main Drive

After completion of the Initial drive, TBM will be entered into the main drive mode. In main
drive mode, TBM will operate with all backups and all related supply supports. Before starting
the main drive have to remove the temporary rings, TBM cradle & reaction frame and give
support to TBM with the full length of muck skips, Y-Switch & Traverser.
11.3 Reaction Frame Dismantling

After completion of the Initial drive and before entering in Main drive, the reaction frame should
be dismantled with help of a gantry crane.
11.4 Temporary Rings Dismantle:

After completion of the Initial drive and before entering in Main drive, the temporary ring should
be dismantled with help of a gantry crane.
11.5 Umbilical Removal:

In the initial drive, all TBM backup systems had been set on top of the shaft and by means of
cables, wires and hoses different fluids or needed electric power had been supplied for the shield.
To convert the main drive all backup systems will be assembled in the tunnel. For lowering and
assembling the backup system, unwanted umbilical will be removed from the shaft.
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11.6 Cradle Dismantle:

Before the commencement of Cradle dismantling work support (Anchors & Bottom support) will
be removed and free for lifting work. The cradle will be dismantled and lifted from the shaft
bottom in order of Module 2 to Module 1 in part by part.
12. TBM BACKUP LOWERING AND ASSEMBLING:

TBM lowering will be done as a lowering sequence. The TBM lowering sequence will start from
the bridge gantry and end at the last backup gantry. After completion of lowering activities
assembling and commissioning will be done for TBM main drive as per the SAT protocol.
For more details please refer the MS for TBM Lowering and Assembling at Greenways Shaft,
P20C03TU02PRW-LANT-CIV-WMS-00110 R(1)
13. INSPECTION BEFORE MAIN DRIVE:

All main drive units are equipped with several sensors and mechanisms to insure the proper
functionality of the component.
 Insure proper lubrication and barrier grease injection according to manufacturer instructions.
 No modifications in the electric and PLC systems are allowed without consulting and approval
of the TBM manufacturer.
 Regular control of oil quality in the main drive and gearboxes. Sample to be analyzed on a
monthly basis.
 Observation of any leak in the system occurring (e.g. into a leak oil tank).
 In case of any indication of a malfunction, the manufacturer will be involved to implement
suitable countermeasures.
 Tightness of bolts and nuts for all components and parts.
 Condition of all joint pins.
 Adequacy of oil level in the oil tank.
 Condition of filter elements (check from indicator).
 Level of lubrication grease content in lubrication pump.
 Condition of oil hoses and electrical pump.
 Condition of voltage range.
 Any abnormal sound or vibration from the motor and oil pump.
 Any leakage from hoses and oil compressor.
 Any abnormal raise in oil temperature and machinery temperature.
 Adequacy of lubrication for speed reducer of the cutter head.
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14. WORK PROCEDURE OF MAIN DRIVE:
14.1 TBM Tunnel Construction Methodology:
The sequences of the operations related to a modified productive cycle for EPB-TBM tunnel
excavation can be differentiated into two phases:
14.1.1 Excavation with Parallel Activities:

During the excavation to maintain the face pressure would be use Water, Polymer, Foam,
Excavated Material and Bentonite with various ratios. during this phase, the grout is injected to
fill up the gap between the lining and the excavated surface. The excavation parameters depend
on the geological conditions. The excavation parameter can be divided into three phases on a
geological basis, which are as follows:
14.1.1.1 Sand with Water:

If ground geology found the maximum percentage of sand with water, then the parameters will
be followed:
a. Excavation: Excavation will be considered blow parameters for tunnel excavation. Some
parameters will be can be changed from time to time according to geological and site
conditions.
 The I&M team will monitor the surface area for monitoring of surface settlement.
 For soil, conditioning will be used Foam + Polymer with 2% v/v.
 FER will be 12 to 15 & FIR will be 40 to 60
 Foam 2% and Polymer 2% Bentonite (Optional)
 Operation mode – Close mode with enough Earth pressure as per designed limits.
 Cutterhead rotation will be 1rpm and the Penetration rate will be less than 20mm/rotation.
 The last 100 mm of tunnel excavation will be done with bentonite to prevent the ground
settlement.
b. Primary Grout: The pressure of the primary grout shall be 0.5 bar to 1.0 bar higher than
the earth pressure and the volume will be 100 to 110%.
c. Secondary grouting (if required) will be done as per the approved method statement.
d. Segment shifting.
e. Rail line, Cables, Service line and Ventilation extension.
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14.1.1.2 Mix Geology:
a. Excavation: Will be considered blow parameters for tunnel excavation. Some parameters
can change from time to time according to site conditions.
 Avoid settlement
 Foam + Polymer
 FER will be 12 to 15
 FIR will be 40 to 60
 Foam 2% and Polymer 2%
 Bentonite (Optional)
 Operation Mode – as per the geology Mode of operation can be adopted by changing the
operating parameters as required.
 Cutterhead rotation will be 2rpm, penetration rate will be less than 20mm/rotation.
 The last 100 mm of mining will be with bentonite.
b. Primary Grout: The pressure of the primary grout shall be 0.5 bar to 1.0 bar higher than the
earth pressure and the volume will be 100 to 110%.
e. Rail line, Cables, Service line and Ventilation extension
14.1.1.3 Rock Profile:

a. Excavation: Will be considered blow parameters for tunnel excavation. Some parameters
can be changed from time to time according to site conditions.
 Avoid settlement
 Foam + Bentonite (Optional) or Foam + Polymer
 FER will be 12 to 15
 FIR will be 40 to 60
 Operation Mode – Open mode with minimum Earth pressure as per design
 Cutterhead rotation will be 2rpm, penetration rate will be less than 20mm/rotation.
 The last 100 mm of mining will be with bentonite.
b. Primary Grout: The pressure of the primary grout shall be 0.3 to 0.5 bar higher than the
earth pressure.
e. Rail, Cables, Service line and Ventilation extension
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14.1.2 Erection of the Precast Segment with Parallel Activities:
During this phase, the precast segment will be erected within a sequence and at the same time
service line also will be extended if required.
 Muck train exchange
 Exchange of consumables (if required)
A typical operation circle for two consecutive rings of the TBM can be considered under normal
conditions as follows:
PRODUCTION 8:00 to 9:00 9:00 to 10:00 10:00 to 11:00
Excavation
Ring Building
Primary Grout
Secondary Grout
Rail Line
Extension
Pipe Line
Extension
Typical Operation Circle
1. Tunnel
Excavation 1. Ring
Building
2. Primary
Grouting 2. Service
line
3. Segment Extension
Unloading
Figure 8: Operation Cycle
14.2 TBM Operation Mode:

All the engaged TBMs are EPB TBMs. All TBMs can execute the below-mentioned mode. Based
on the geological forecast for this project, the following TBM drive mode is considered.
The L&T Tunnel Management Team (Chief Tunnel Manager) will be authorized to decide in
which mode will be adopted for TBM operation.
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14.2.1 Closed Mode:

In the “Closed mode”, the entire excavation chamber is filled with soil to maintain the required
Faces support pressure.
“Closed mode” is the general operation modus throughout the tunnel drives. The applied TBM
cutting tools configuration will be mixed ground with cutters installed in the gauge and transition
zone.
14.2.2 Open Mode:

In “Open Mode” no face support is given, due to gravity, excavation material is diverted to the
screw conveyor inlet and conveyed out without implemented pressure. Atmospheric pressure is
constant in the excavation chamber. The possibility to operate the TBMs in “Open mode” during
the tunnel drives cannot be considered. this mode will be executed if full-face hard rock/ suitable
ground geology is for open mode.
14.3 Advance Parameters:

The following focuses on the calculation of the main TBM operational advance parameters which
have to be monitored during tunnel excavation. In detail, the main parameters connected to the
TBM guidance and operational control are listed below:
 Total thrust force
 Cutter head torque and speed
 Advance rate
 Thrust cylinders extension and force
 Pressure in the excavation chamber
 Muck volume and screw conveyor torque and speed
 Backfilling pressure and volume
From a design standpoint, the most important operational parameter is the pressure of the support
average obtained by adding appropriate conditioners, such as foam or polymers, to the earth
pressure in the excavation chamber.
14.4 Face Stability Analysis:
Based on the geotechnical investigation report and hydrogeological study of the given soil
parameter, the face stability analysis and the face pressure in varying sections are to be addressed
in the lead designer’s report. The counter pressure supporting the excavation face, evaluated
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MANDAVELI TUNNELS
according to the procedure described above, will be kept between two limit values: Attention
limit and Alarm limit.
EPB Pressure calculation is already submitted to GC.
15. TBM OPERATION:

15.1 Excavation:
TBM Tunneling Method is, in principle, the repetition of excavation and lining construction. The
TBM moves forward rotating the cutter head in order to cut the ground ahead. The thrust force
will be obtained by pushing against the erected segment rings. Six numbers of segment pieces will
be placed at the scheduled positions one by one using the segment erector to make a complete
ring. some parallel activities will be also going with excavation. Primary grout is the most
important activity which must be running with excavation. Without primary grout, excavation will
not start. The rail line, pipeline extension, segment offloading and secondary grout also parallel
activities during excavation.
Figure 9: EPB Shield

TBM Scheme
1) Tunnel Face
2) Cutting Wheels
3) Excavation
Chamber
4) Pressure Chamber
5) Thrust Cylinder
6) Screw Conveyor
7) Segments
8) Tail Skin
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station box and entry / exit structures of Chetpet Metro, Royapettah
govt. hospital, Thiruvanmiyur Metro stations and part Diaphragm wall
of Greenways Road metro station, including Launching and Retrieval
shafts as required in the above stations -CP31-TU02 Project.
MANDAVELI TUNNELS
15.1.1 Face Pressure:

In Earth pressure balance TBM, the working chamber of TBM is balanced by the pressure of the
excavated soil and water. The pressure of the soil inside the working chamber is controlled by the
timely release of soil through the screw conveyor. The design of the screw conveyor allows for the
loss of pressure in the soil so that it is eventually discharged under atmospheric pressure at the screw
discharge gate.
All TBMs (HK) are equipped with in total of six Earth Pressure sensors in each of the bulkhead
walls & 3 pressure sensors in the Screw conveyor. Those pressure sensors are submitting the actual
pressure values from the chamber to the visualization in the operator cabinet. The pressure cells are
located in 3 different levels in the front shield as shown in fig.10
For the TBM operation (reg. recommended earth pressure) the upper-pressure sensors (Level 1) will
be taken as reverence by the TBM Operator. All pressure cell values will be indicated with two digits
(e.g. 1.00 bar) in all visualizations. The Face pressure will be controlled by the TBM operator by
optimizing the advance speed with the volume extracted via the screw conveyor (screw rotation
speed). For more detail refer to Face Pressure Calculation (Document No: O21447-REP-0100)
Please refer Appendix H for Replacement of EPB sensors.
Sensitivity: Unclassified Page 37 of 110

MANDAVELI TUNNELS
Soil
Pressure
Earth Pressure in
Soil Chamber
(Face Pressure)
Water
Pressure
Figure 10: TBM Earth Pressure Sensors
15.2 Primary Grout:

During TBM advance, Liquid A (cement grout) and Liquid B (sodium silicate) are pumped into
separate pipelines to a mixing nozzle installed at the TBM tail skin grout port. The mixed grout gel
solidifies as it is pumped through the TBM tail skin and fills the annulus gap around the segments.
15.2.1 Technical Concept:

On the surface, a mixing plant is preparing grout according to the approved mix design. This grout
(Component A) + the accelerator (Component B) is then pumped through separate pipelines from
the plant through the tunnel onto the TBM.
On the TBM, there are storage tanks for components A and component B. The grout filled in the
grout tank will be permanently agitated.
Four independent pumping setups are pumping the components individually to the Tail shield. Each
position has two pipelines (one active + one spare)

MANDAVELI TUNNELS
15.2.2 Grout Operation:

The grout operator will follow the Grouting Control Flow Chart (given by Tunnel Management) to
control the grouting operation. All grouting data will be recorded on the Primary Grouting reports.
All the TBMs are equipped with software which is allowing to operate the system in several modes
(manual, semi-automatic and automatic). Based on the encountered situation, the TBM Operator will
select the preferable mode.
The primary grouting will be executed all the time simultaneously with the excavation of the TBM.
As per HK’s description in the Manual, the last 5-10 cm of tunnelling must be Grouting with
component A only.
15.2.3 Grouting Pressure:

The pressure of the grouting operation will be constantly monitored by the grout operator and will
be specified in the related instruction sheet, given by Sr. Tunnel Manager. The pressure will be
enough to ensure a proper filling of the annulus gap but not to cause stress or distort the installed
tunnel lining, nor to cause other related negative impacts (e.g. heaves on the surface).
Grouting pressures shall not exceed 1 bar above the line pressure and the hydrostatic pressure at the
invert of the tunnel as per OCS Section VII, Sub-Section 2, Clause 12 Subclause 2.12.4. For more
details follow the MS for Primary Grout.
15.3 Ring Building:

15.3.1 Ring Sequence Selection (Key Segment Position):
The correct key segment position on the installed ring is crucial to maintain sufficient clearance
between the shield and segment extrados. A wrong selection of key segment position can lead to
cracks, and deformations in the ring lining and must be avoided.
All TBMs are equipped with software, which considers the actual position of the TBM, the extension
of the thrust rams and the final build ring position. Concerning the next rings, the system
automatically suggests the position of the next key segment.
However, the final decision of the actual next key segment position is incumbent upon the Tunnel
shift engineer. Segment key position considering:
 The horizontal deviation between DTA (Design Tunnel Alignment) and current TBM alignment
 The vertical deviation between DTA and current TBM alignment

MANDAVELI TUNNELS
 Last built ring steps at circumferential joints and radial joints
 Deviation of the leading edge of the last ring-built plane, normal to the longitudinal axis of the
ring.
 Clearance between the extrados of the ring and the TBM.
It might be required to “override” the Software suggestion and the ring sequence selection must be
manually updated accordingly.
After completion of the excavation, the supervisor/erector operator will check tail skin clearance of
4 to 8 locations and feed these readings into VMT guiding system. Jack’s length will automatically
be shown in VMT guiding system. After feeding these data into VMT guiding system, VMT will
self-calculate and give 4 to 6 key positions. The engineer will choose 1 right key position for the
ring building.
15.3.2 Installation of Segment Ring:

During the mining stage, the nominal ring segments (5+1 key) will be transported to the installation
area using the segment feeder. After confirmation of the key position by the Tunnel Engineer/ Tunnel
Shift Manager, the TBM operator will switch to the “Ring Building Mode” thereby enabling the ring
builder to control of erector and thrust rams. TBM operator’s thrust ram control panel is disabled.
The ring build area will be cleaned prior ring build commencing. The first segment will be placed
on the segment feeder and shifted to the ring build area. Erector operator positions and engages the
erector lifting head over the lifting pin that is screwed into the segment steel socket. Applying soap
water onto the EPDM gaskets.
After retracting the rams, the erector operator navigates the segment into the ram retracted area which
is finally positioned to match the alignment and connect to the previous ring with straight bolts by
using pneumatic wrenches, Ring Builders then install and tighten the segment bolts in the
circumferential and radial joints area. The bolts will be tightened with its head firmly sitting on the
grommet and washer until the bolt head is in contact with the concrete surface.
The torque of the wrenches will be adjusted to suit this process. Upon completion of bolts fixing,
the rams are engaged on the new segment and the lifting head of the erector is released.
The segment feeder then delivers the next segment. This process is repeated with the remaining
segments, the final segment will be the key segment. Apply soap lubricant on the longitudinal joints
of the key segment to ease the insertion of the key between the two segments.

MANDAVELI TUNNELS
When ring erection is complete, the TBM operator will switch to thrust ram operation from TBM
control panel thereby erector operator’s ram control panel is disabled, and new muck cycle will
commence.
Make sure the rings will be built within build tolerances & before the next advance rings shall be
checked (in the tailskin) for steps & lips & damage in order that it can be rectified before shoving.
Figure 11: Ring Building
15.4 Secondary Grout:

The secondary grouting of the segmental lining shall take place after annulus grouting i.e. primary
grouting and prior to any consolidation grouting in mixed ground conditions. Secondary grouting is
necessary to ensure that the void around the segmental lining is completely filled with grout and
shall be carried out wherever segmental lining are used. The secondary grouting shall be carried out
at a distance back from the advancing lining section, but in any instance not closer than 30 m or
further than 100m as per OCS Section VII, Sub-Section 2, Clause 12 Sub clause 2.12
The performed grout holes in the segments of every 5th ring is to be drilled out of 650mm or to rock
contact, whichever is greater, and grout injected commencing at the lowest holes to allow any air
and water to be displaced. All the grout holes in the ring being grouted shall be drilled out prior to

MANDAVELI TUNNELS
injection. When interconnections occur, the holes shall be kept open until the emerging grout is of
the same consistency of the grout being injected before closed. Injection shall continue until the hole
refuses to accept grout at the specified maximum pressure. Grouting pressures shall not exceed 1 bar
above the line pressure and the hydrostatic pressure at the invert of the tunnel as per OCS Section
VII, Sub-Section 2, Clause 12 Sub clause 2.12.4. For more details follow the MS for Secondary
Grout.
Figure 12: Progress Flow Chart
15.5 Foam and Polymer Injection:

For EPBM tunneling, additive or foam has to be injected due to complicated changes in ground
condition and to prevent muck to stick in the chamber or at the screw conveyor which may result in
the construction being suspended, the features are as below:
 Make the excavated soil to be in plastic fluidity condition.
 Fill the pores in soil (ground improvement)
 Prevent the soil to stick on TBM parts
 With sealing effect
 Minimize wear or damage on TBM due to operation torque

MANDAVELI TUNNELS
15.5.1 Effect of Injection Material:
Foam as a soil conditioning agent has been extensively employed in earth pressure balanced (EPB)
tunnel boring machines (TBM) to change the mechanical and hydraulic properties of soils for
effective excavation. Foam stability is a critical parameter that influences the performance of foam
and foam-conditioned soils.
Soil conditioning is an important part of the tunneling process with Earth Pressure Balance (EPB)
TBMs. It is used to modify the properties of excavated soil to improve control of the excavation
process and TBM performance.
The water permeability coefficient is larger for a mixed geology profile, as the particles are larger
and larger gaps are expected between the particles. Soil conditioning agents increase the viscosity
of the excavated material.
15.5.2 Foam Injection Method:

The foam will be injected into the face and chamber during excavation. This is to prevent the
excavated soil adhere to the cutter head and to increase the fluidity and water tightness of excavated
soil. As the foam will disappear by itself, no special attention for muck disposal is required.
The characteristic of foam are as follows:
 Increase fluidity of excavated soil in gravel layer, rheological foams work as ball bearings and
increase the fluidity of excavated soil.
 Reduction of fluctuation in face pressure. The compressive character of rheological foams can
reduce the fluctuations in face pressure.
 Higher water tightness of excavated soil water tightness. The groundwater in void space between
soil particles of excavated soil is replaced by tiny foams.
 Easy treatment and disposal of excavated soil. Excavated soil is restored to the original state
when it was in the ground and therefore can be treated or disposed of easily.
 Improve the working environment neither clay nor bentonite is used, so the tunnel is clean and
offers a better working environment.

MANDAVELI TUNNELS
AIR
FOAM WATER
FLUDI
SURFACTANT
Figure 13: Foam Production
15.6 Foam Injection Ratio:

This is the amount of the finished foam which will be introduced into the mixing chamber. This is
normally presented as a % of the soil volume and can range from 10 to 70% as per soil condition.
FOAM SOLUTION
WATER + 95 to 99% +
SURFACTANT
1 to 5% SURFACTANT
FOAM FINISHED FOAM = 5 to 10

SOLUTION Times volume of foam solution
FOAM FINISHED FOAM

SOIL
SOLUTION = 10% to 70%
Figure 14: Typical usage of Foam for injection
FIR = FOAM INJECTION RATIO

FER = FOAM EXPANSION RATIO
𝐹𝐸𝑅 =
_
𝑉
𝐹𝐼𝑅 = × 100
𝑉 _

MANDAVELI TUNNELS
15.7 Polymer Injection Method:

The polymer is injected into the face and the chamber during excavation. The polymer injection is
effective to improve the soil property characteristics of the polymer is the same as the foam injection
method above.
FOAM 96-99.7% foam

SOLUTION solution or water 0.3 to
+ POLYMER 4%
FOAM Finished Foam = 5 to 10
SOLUTION + times Volume of Foam
POLYMER Solution + polymer
FOAM Finished Foam Or water
SOLUTION + plus polymer = 10%-70% SOIL
POLYMER Soil volume
Figure 15: Typical Usage of Polymer for Injection

MANDAVELI TUNNELS
16. PARAMETERS FOR TUNNEL DRIVE:

Tunnel drive parameters depend on the ground geology. Tunnel drive parameters as per ground
geology tunnel will be as follows:
SAND + WATER MIX FACE ROCK

• Avoid settlement GEOLOGY • Foam + Bentonite
• Foam + Polymer (Bentonite is optional)
• Avoid settlement
• FER will be 12 to 15 • Foam + Polymer (Injection
• Foam + Polymer
• FIR will be 40 to 60 in Screw conveyor)
• FER will be 12 to 15
• Foam 2% and Polymer 2% • FER will be as per design
• FIR will be 40 to 60
Bentonite (Optional) • FIR will be as per design
• Foam 2% and Polymer 2%
• Operation mode – Close • Operation Mode – Open
• Bentonite (Optional) mode with correct Earth
mode with correct Earth
pressure as per design • Operation Mode – Semi- pressure 0.3 to 0.7 Bar
close mode with correct • Cutterhead rotation will be
• Cutterhead rotation will be
Earth pressure as per design 4rpm, and the penetration
1rpm, penetration rate will
be less than 20mm/rotation. • Cutterhead rotation will be rate will be less than
2rpm, penetration rate will 20mm/rotation.
• Primary grout pressure will
be less than 20mm/rotation. • Primary grout pressure will
be earth pressure + 0.5 to 1
bar • Primary grout pressure will be earth pressure + 1 bar
be earth pressure + 0.5
• The last 100 mm of mining
will be with bentonite. • Primary grout will be 55
to 60% solder position &
45 to 40 % knee position
• The last 100 mm of mining
will be with bentonite.
17. LIFTING WORK:

For any lifting work only designated and approved personnel will be used. Detailed lifting plans will
be submitted separately after having finalized all planning work and related equipment decisions.
17.1 De-Mucking from Shaft:

 Riggers will guide and attach the arms of the lifting beam onto the designated lifting points of
the muck skip.

MANDAVELI TUNNELS
 Check that there is no loose material in the skip which might fall during the lifting operation,
before lifting.
 lifting of muck skip based on the signals of the signal man.
 The Gantry Crane Operator shall have permanent direct contact with the Signalman.
 The muck skip will be lifted with the help of a gantry crane and transported above the tipping
device.
 Empty the muck skip by taking it to the tipping device.
 The signalman will instruct the crane operator to dump the muck into the muck pit by tipping
the muck skip device.
17.2 Segment Lifting and Shifting:

The weight of a full stack of segments loaded onto the crane hook can be calculated as 5 Segments
a 3.6 ton + 1x 1.5 ton = 19.4 ton
 Riggers will use webbing slings and sling them around the segment stack.
 Edge protection will be used to avoid damage to the segment edges and/or slings
 Riggers will attach a guideline.
 Signalman will give the signal to the Gantry operator and the gantry crane operator will follow
the lifting signal, given by the signalman for lifting work.
 The gantry operator will lift the segments from the surface and move the gantry crane towards
the shaft. Before the segments are lowered into the shaft, the operator shall blow a signal horn to
alert the personnel in the shaft.
 The segment will be placed on the segment car. The riggers in the shaft will place the segment
on the segment car with the help of taglines.
 Signalman will give the signal to the Crane operator for placed the segments on the segment car.
 After placing the sling will be removed.
 With the same process, the other remaining segment is to be placed on the second segment car.
17.3 Other Lifting Operations:

 Rails, and pipes: Lowered in a horizontal position with suitable lifting chains/slings.
 Ventilation Cassettes: Lifted on the designated lifting points.
 Barrels / Drums: Use a designated material basket
 Other consumables (e.g. Bolts, hangers etc.): Use of the designated material basket.

MANDAVELI TUNNELS
 Personnel (for emergency): Use of designated personnel Man basket.
18. INTERRUPTION OF PRODUCTION CIRCLE:

The following interruptions are considered.
 Shift change
 Service extensions (at the rear of the TBM)
 Control survey
 Maintenance and cleaning
 Waiting for Locomotive
 Breakdown of Equipment / Repair.
 Derail of rolling stock.
 No availability of material and consumables.
 Full muck pit
 Missing key personnel (e.g. operator)
To mitigate those interruptions, Tunnel Management will monitor and coordinate closely with
related departments and will implement improving measures accordingly.
19. CUTTER HEAD INTERVENTION:

All the TBMs are equipped with facilities which are allowing to execute hyperbaric interventions if
required. Considering the geological profile throughout the tunnel drives and if the clogging factor
is controllable through soil conditioning, then the amount of required intervention can be considered
as low.
For further details regarding intervention, refer to MS for Atmospheric and Hyperbaric TBM cutter
Head intervention in Tunnels.
20. TBM CONTROL:

The TBM guiding system is basically an extension of tunnel Travers, with a Leica Laser mounted
on a set point bracket within the Backup area, the position of the TBM (laser target mounted on a
designated location in the TBM shield) will be monitored. One Survey Assistant will be on the TBM
who is trained and capable of operating the Leica laser and make required controls to verify the

MANDAVELI TUNNELS
system is working properly. A surveyor Engineer will be on standby to ensure fast response time in
case of a severe system failure and / or required Laser shifting.
Figure 16: TBM Guiding System
21. TUNNEL SURVEY:

As far as feasible it will be tried to schedule the laser shifting and daily control measurement
executed by the Survey team on a regular time. Survey work will be carried out as per the approved
method statement for Tunnel Survey.
PROCEDURE:
Tunnel control survey network and datum transfer shall be done at initial stage of
transferring controls from surface to shafts and tunnels and shall be monitored and updated as
explained below:
 The tunnel network should always be up to date a short distance behind the TBM to be able
to control the guidance system at short notice.

MANDAVELI TUNNELS
 Tunnel control survey network and datum transfer shall be done on twice a week basis or as
per tunnel progress (Not exceeding 200 meters length of tunnel the control points are
stablished and measured at least twice to be used as a reference).
 Tunnel control survey network shall be measured and updated form shaft control points at
every 50 meters (in Curve) of tunnel progress and from primary surface control points if
required. Note the frequency of control survey in straight tunnels will be 70 M.
 Tunnel control survey network and datum transfer shall be checked and verified from
primary surface survey control points at every 1 km and if required the measurement shall
be repeated to Ensure and achieve the theoretical tunnel alignment and TBM drive be on
proposed alignment and within contractual tolerances.
Example:
When TBM is out of tolerance that time surveyor will calculate the value of correction to apply
between 1 to 3 mm per ring or as per discussion with tunnel manager. Correction will be calculated
by considering the quality of tunnel and avoid any steps in rings and damage.
For example, if deviation is 90 mm, then surveyor will calculate the correction maximum 3
mm in one ring it means TBM will back to design alignment in 30 rings (30 rings * 3mm = 90mm).
RESPONSIBILITY FLOW CHART FOR SURVEY WHEN TBM IS OUT OF TOLERANCE

MANDAVELI TUNNELS
22. INSTRUMENTATION AND MONITORING:
The describes the monitoring of geotechnical instruments using GEOFREQ at Shafts & tunnel
alignments within the zone of influence during the construction of Twin Bored tunnels from
Greenways to Adyar Jn Station & Greenways to Mandaveli Station.
The main objectives of the instrumentation monitoring program are to:
 Monitor the effects of construction on adjacent structures.
 Ensure construction safety.
 To provide early warning of possible failure and immediate implementation of protective
measures. Instrumentation must be properly implemented and monitored. Data collected from
the monitoring system can be used to assess ground movement and potential damage to nearby
structures.
Note: Instrumentation and Monitoring work will be carried out as per the approved method statement
for Instrumentation and Monitoring.
22.1 SURFACE MONITORING:

A dedicated instrumentation team will monitor the ground surface and existing structure. Instruments
installed on the surface on the alignment give data for the surface and subsurface conditions.
instrumentation is also done on the structures on the surface which are likely to be affected by the
tunnel construction. The Monitoring Department is responsible for carrying out all this monitoring
work and submitting reports on time.
For more details please refer Approved Method Statement for Instrumentation and Monitoring.
22.1.1 Settlement Monitoring:

a. Preliminary Concept:
Ground settlement markers will be initially installed every 25 meters in the centreline of each tunnel
wherever it is suitable. In the traffic exposed section, the markers will be installed max. 1 week prior
to the expected TBM passing. In the other section, settlement markers will be installed 21 days prior.
Building markers will be installed 4 weeks prior to the expected passing by of the TBM.
Base mark readings will be taken as soon as the installation is completed and recorded for reference
purpose. Along with the TBM excavation on a daily basis, the settlement markers will be measured
in a monitor window of 85 meters (25 m ahead of the TBM shield and 50 meter) behind the TBM
shield. Once a week, the settlement markers till 300 meters behind the shield will be monitored.

MANDAVELI TUNNELS
All the readings records will be forwarded on a daily basis to the relevant Departments.
b. Secondary Concept:
Additional markers will be installed when the following is occurring:
 TBM over-excavation was reported.
 If disturbances on the surface are observed (e.g. cracks, material outflow, etc.)
 Around critical infrastructure (e.g. railways, flyovers etc.) and buildings.
 In the section where cutter head interventions are carried out.
 Tunnel lining shifting is observed.
The quantity and location of the additional markers to be installed are at the discretion of the Survey
and Monitoring Department and will be coordinated by Tunnel Management.
22.1.2 Groundwater Monitoring:

The groundwater monitoring instruments for checking the water level will be:
 Vibrating wire piezometer
 Standpipe piezometer
22.1.3 Vibration Monitoring:

A portable Vibration monitoring instrument will be used to monitor the vibration. The instrument
will be initially installed as per building condition requirements or in case of public complaints.
22.1.4 Existing Structure Monitoring (Cracks, Building):

a. Temporary building support:
Few buildings are precautionarily requiring temporary support to maintain the existing structure and
to reduce the risk of further structural damage Based on the evaluation of a joint inspection (GC and
L&T), it will be decided on the requirement kind and amount of propping to be done.
b. Residents Evacuation:
Some buildings will be classified for evacuation during tunnel operations. The clarification
document regarding the quantity of the buildings will be subject to submission to the GC. Residents
of buildings declared vacant will be shifted to suitable temporary accommodations (like guest
houses, or hotels).

MANDAVELI TUNNELS
23. CHECKING THE DEVELOPMENT OF BUILDING DAMAGES:

23.1 Crack Meter:
A Crack Meter shall be used to monitor changes in the width of existing cracks in the buildings
within the influence zone. The location of crack meters will be decided after a Visual inspection of
the cracks. The crack meter will be installed as per building condition requirements. in case the crack
width Is larger, a crack gauge with a 100mm marking instead of a 50 mm marking will be used.
23.2 Tilt Meter:
A tilt meter shall be used to monitor changes in the tilt of buildings within the influence zone, Tilt
meter will be installed as per building condition requirement.
23.3 Type and Limits:

Alert Level: It is defined as where the ongoing work should be done properly and cautiously.
Action Level: It is defined as proper action must be taken to reduce the risk and repair.
Alarm Level: At alarm all excavation work should be stopped till until all the issues are solved.
24. QA/QC MONITORING:

During the tunnelling time, one designated QA/QC Inspector will be on site to execute the required
quality control on the surface (e.g. segment control) and TBM.
25. SEGMENT LINING INSPECTION:

The QA/QC Inspector and Tunnel Engineer will jointly check all installed segment rings. All the
observed defects will be recorded in the relevant records and then submitted to the relevant
Department for review. Segment lining rings will be checked until max. 8 Rings till to the last build
ring in the tail skin. This will insure, that the recorded rings a properly impeded and settled and
further movement and damages cannot be expected.

MANDAVELI TUNNELS
INSPECTION
Figure 17: Indication of QA/QC inspection zone
All the required repair and rectification work will be executed according to the approved Method
Statement.
25.1 RING LINING (STEPS AND LIPS):

All installed segment rings will be checked visually for step (circumference joint offset) and lips
(radial joint of set) and if detected, then measured with a ruler.
Figure 18: Steps and Lips testing layout
The allowable maximal tolerance as per OCS 2.7.15 is: Step 10mm & Lips 5 mm
25.1.1 Lipping:
The lip between adjacent segments in a ring shall not exceed 5mm and shall not be so great as to
prevent the connections between segments from being correctly installed, not prevent the effective

MANDAVELI TUNNELS
functioning of gaskets, not reduce the face-to-face radial joint bearing area to an extent where
structural efficacy will be compromised.
25.1.2 Stepping:
The step between adjacent rings shall not exceed 10mm and shall not be so great as to prevent the
connection between adjacent rings from being correctly installed, not prevent the effective
functioning of gaskets.
 The plane of the leading face of each ring, including a tapered ring, shall not depart at any point
from the plane surface by more than 6 mm.
 The role of adjacent circle joint bolt holes shall not be greater than 5 mm; the maximum total
allowable bolt hole roll of any ring is 40 mm from the relevant TBM roll.
25.1.3 Cracks:
If cracks are observed in the erected ring lining, then the Tunnel Engineer and Quality Engineer must
be informed GC. The Tunnel Engineer will evaluate the crack cause and implement suitable
countermeasures. Cracks can be caused due to:
 Missing tail skin clearance.
 Wrong segment key position selection or steering operation.
 Wrong ring segment handling during transport and wrong erection procedure.
 Missing or wrong installed load distribution.
 Wrong preliminary grouting parameters.
 Wrong TBM steering parameters.
Observed cracks will be categorized by the QA/QC Department into two kinds:
Dry cracks and Wet cracks depending on the category and measured crack width, an approved
repair method will be implemented as per MS for Segment repair inside tunnel.
25.1.4 Primary Grout Testing:

On the surface batching plant, following tests will be executed by the Quality Department as per
Approved ITP (Inspection Test Plan):
 Component A
 Gel time test of Component B

MANDAVELI TUNNELS
26. TBM MAINTENANCE PLAN:

The maintenance of the TBM will be carried out accurate according to the maintenance instruction
and recommendation of the related TBM manufacture. The maintenance on the equipment will be
carried out from persons who have the appropriate technical knowledge. The related equipment will
be prevented during maintenance work for accidently switching on by the so called “lock off”
system.
26.1 Standard Maintenance:

The maintenance on the TBM and auxiliary equipment will be carried out in a preventive manner
according to the manufacture manual and the guidance of the P&M Department. Wherever possible,
the maintenance will be carried out parallel with the ongoing production without having a negative
impact. If maintenance is requiring a shutdown of TBM essential services, then this work will be
scheduled within an appropriate time window.
Upon the discretion of the P&M Department, a suitable maintenance team and maintenance schedule
will be implemented for the TBM tunnel drives.
26.2 Critical Equipment:

Additional to the standard maintenance protocol, the mechanical team will be directed to pay special
attention to critical TBM components whose failure will lead to serious safety and production loss.
27. EMERGENCY PLAN:

27.1 Surface Disturbance:
As described in Item Monitoring continue surveillance and monitoring will be executed throughout
the tunnel drive. All Tunnel activities will be planned and executed in such a way that disturbances
on the surface and groundwater level are minimised as much as possible.
In the case of occurred surface disturbance, the related Departments will be informed according to
the L&T and CMRL standards.

MANDAVELI TUNNELS
27.2 Settlements & Residential Area:
Survey Department will inform Tunnel Management immediately if ground markers and/or building
markers readings reaching the alarm level. Tunnel Management will evaluate further measures such
as:
 Adjusting TBM and/or grouting parameters base done based on the designed limits.
 Implementation of secondary grouting/ Compensation grouting from the tunnel in necessary in
less than 30 M from the excavated face.
 Implementation of grouting from the surface by Jet /TAM grouting in required.
27.3 Vibrations:
In case official complains are received and vibration are breaching the acceptable limit, then the
Tunnel Management will coordinate with the Geo Department and following measures will be
considered:
 Adjusting TBM parameters
 Adjusting the mining times
27.4 Building Damages:

Prior to the TBM passing, all EBS within the designated influence zone must be completed. In case
of newly reported damages, the EBS report will be taken as a reference. Depending on the reported
magnitude of damages, the Monitoring team together with Tunnel Management will evaluate further
measures.
27.5 Blowouts:
Blow out of mediums (air, foam and water) on the surface can occur due to several reasons (e.g. too
high-pressure soil and or grout, soil disturbances, open bore wells etc.). To avoid blow out following
measures will be in place:
 Continue monitoring the pressure in the excavation chamber and grouting system.
 Ensuring that all charted bore wells are plugged.
 Foam injection (FER) is as low as possible.
In case of a reported material blowout on the surface, then the TBM advance will temporarily stop
and Tunnel Management will review the TBM, Geo and Topographic data. Adjustment (if required)

MANDAVELI TUNNELS
on the related parameters accordingly prior to restarting the mining. All adjustments so parameters
will be with the consultation of the related Departments (Geo, Monitoring etc.)
On the surface, depending on the location and magnitude of the outflow, the related authorities (e.g.
Police) will be informed for further measures (e.g. traffic diversion).
First focus will be given to minimize the impact on to the public environment and to restore the
situation as soon as possible. Barriers will be erected to contain the spillage within the smallest area
and cleaning will be carried out. Additional monitoring (settlements) will be carried out. If possible,
the outflow area will be plugged (concrete, grouting).
TBM advance will restart with following precautions in place:
 Depending on the location, restart only within night shift (e.g. outflow happened on public road)
 Monitoring- and Action Team on standby fully equipped on surface.
 Operator will follow revised mining parameters.
In case of air outflow is observed (during intervention), then the Tunnel Management will be
informed accordingly and the monitoring on surface will be increased.
28. PREVENTION OF TBM BREAKDOWN:

Maintenance and inspection shall be carried out according to the TBM operation manual to ensure
the TBM could run smoothly during construction.
29. SINK HOLES:

A critical aspect of preventing sinkholes in the control of over-excavation during the TBM tunnel.
Therefore, strict attention will be paid on to the muck volume estimation (refer to item Surface
Monitoring Section 20) and surface monitoring.
In case that a sink hole has developed on the surface, the excavation will stop immediately, and
following measures will be executed:
 Barricading of the sinkhole and the surrounding area.
 Informing relevant Departments and Authorities based on the L&T - CMRL standards.
 Evaluate the extent of damage (e.g. on utilities, public properties etc.) and arrange stabilization
and rectification.
 Evaluate and implement permanent stabilization (backfilling) of the sinkhole.
 Restore the situation (repair damage).

MANDAVELI TUNNELS
 Investigate the cause of the sinkhole.
The restart of the TBM is only allowed after a detailed analysis of the root cause and a positive
rectification. However, as a general guideline, the focus should be given to restart the TBM as soon
as possible and commencing excavation and bringing the TBM again into undisturbed soil.
30. BACK-UP POWER AND LIFE SUPPORT EQUIPMENT:

The back-up power for life support system (ventilation, drainage and lightning system) is an
emergency power supply system to protect life when power failure which happened due to accident
or disaster. The emergency power supply system shall equip with main switch which may supply
electrical power to emergency electrical appliances during power failure and capable to resume to
normal power supply after the main power restored. Power generator (Diesel generator) is proposed
and installed with appropriate switched and connectors to prevent crash with main power supply.
The emergency power supply will activate manually.
31. TUNNELING PROCEDURE UNDERNEATH, THE SENSITIVE STRUCTURES/WATER

BODIES.
Ground improvements also serve to control ground water, reduce ground loss and potential
surface settlements and minimize the tunnel deformations during excavation. The variety of
ground improvement techniques available are diverse and include dewatering, jet grouting,
cementitious or chemical permeation grouting, compaction grouting, ground freezing, etc. TAM
grouting can be used to event tunnelling-induced settlements. Instrumentation and monitoring
are critical for detecting ground movement and implementing corrective measures.
Standard practice is to use surface measuring points set out on a square grid along the alignment.
The spacing of the monitoring points must be enough to define the shape of the curve as the
location of the point of inflection in the settlement curve is as significant as the maximum
centreline settlement. In addition to surface monitoring points multipoint extensometers installed
in boreholes should be used to determine settlement at intermediate levels between the tunnel
crown and ground level.

MANDAVELI TUNNELS
In case of necessary additional measures to be taken to avoid settlement, mitigation measures will
be submitted for approval from GC and CMRL.
32. EMERGENCY CONTACT NUMBERS:
SR
NAME DESIGNATION NUMBER
NO
1. Mr. JAYARAMA. H PROJECT DIRECTOR 8286005445
2. Mr. AHMET OZTURK PROJECT MANAGER 7305740701
3. Mr. GANAPATHY ACCOUNTANT HEAD 9444398872
4. Mr. CHEZHIAN D ADMIN HEAD 7550117087
5. Mr. SENTHIL KUMAR.R. P CHIEF OHS & E MANAGER 9500966697
6. Mr. IMAN OSTOVAR CHIEF TUNNEL MANAGER 9566164755
7. Mr. SERGEI PAPIN CHIEF TUNNEL MANAGER 7200094798
8. Mr. K. KALAMEGAM CHIEF QA/QC MANAGER 8248222742
9. Mr. K P SENTHIL KUMAR CONSTRUCTION MANAGER 7395843774
10. Mr. RAJESH B S STATION MANAGER 9483929382
11. Mr. VINOD VILLI SR. TUNNEL MANAGER 6369677487
12. Mr. SHANMUGAM C SR. TUNNEL MANAGER 8525901987
Mr. REYYA
13. P&M MANAGER 8001200608
CHENDRASHEKAR
MR. KARTHIK
14. P&M MANAGER 7840081395
MUTHARASU
15. Mr. PRASANNA NATESH ENVIRONMENT MANAGER 9597987587
16. Mr. SHIDHALINGAPPA C B Dy. QA/QC MANAGER 8091738651
17. Mr. SIVAKUMAR Dy. QA/QC MANAGER 7397063751

MANDAVELI TUNNELS
18. Mr. AYAS AHMED M J SR. OHS & E MANAGER 8825963419
19. Mr. ASHOK KUMAR S SR. OHS & E MANAGER 9962403152
20. Mr. SUNDARARAJAN.C JR.OHS&E MANAGER 8012894994
21. Mr. RASHEED LABOUR WELFARE OFFICER 9884827007
22. Mr. N. MOORTHY PUBLIC LIAISON OFFICER 9940555011
23. Mr. VALIAPPAN JR.OHS&E MANAGER 7200070970
24. Mr. RANJITH KUMAR E. FIRST AIDER 8807278120
25. DR. BAVISH SITE MEDICAL OFFICER 6374921311
26. DR. ASHRAF ALI SITE MEDICAL OFFICER 8489646684
27.
POLICE STATION 100
28. - FIRE STATION 101

29. - AMBULANCE 108
33. APPENDICES:
 APPENDIX A – ORGANISATION CHART

 APPENDIX B - OHS&E RISK ASSESSMENT
 APPENDIX C - INSPECTION TEST PLAN
 APPENDIX D - CHECK LIST & FORMATS
 APPENDIX E – RING BUILDING SEQUENCE
 APPENDIX F – WALKWAY AND BRACKET DETAILS
 APPENDIX G – CUTTERHEAD POSITION DRAWING
 APPENDIX H – PROCEDURE FOR REPLACING AND CALIBRATION OF EPB SENSORS

MANDAVELI TUNNELS
APPENDIX A – ORGANISATION CHART (1TBM DAY & NIGHT SHIFT)

TU-02 , GREENWAYS TUNNEL OPERATION MANPOWER, REV-0
CHIEF TUNNEL MANAGER -1

Mr. Sergei Papin
Mob: 7200094798
SENIOR TUNNEL MANAGER -1

Mr. Vinoth Villi
Mob: 6369677487
SHIFT TUNNEL MANAGER-1 SHIFT TUNNEL MANAGER-1

Mr. Meesala Sivaprasad Mr.Saikat Chakraborty
Mob: 9985575040 Mob: 7501134802
TUNNEL TEAM DAY LIFTING TEAM DAY SURFACE TEAM DAY TUNNEL TEAM NIGHT LIFTING TEAM NIGHT SURFACE TEAM NIGHT
TUNNEL ENGINEER-1 TUNNEL ENGINEER-2

Mr.Jaspreet Singh
7996409079
TBM OPERATOR-1 1 LIFTING SUPERVISOR SHAFT -1 SURFACE & LIFTING SUPERVISOR-1 TUNNEL SUPERVISOR-2 1 LIFTING SUPERVISOR SHAFT -2 SURFACE &LIFTING SUPERVISOR-2
TUNNEL SUPERVISOR-1 1 GROUT PLANT OPERATOR-1 TBM OPERATOR-2 1 GROUT PLANT OPERATOR-2
2 GANTRY CRANE OPERATOR-1 2 GANTRY CRANE OPERATOR-2
1 TBM GROUT OPERATOR-1 2 COMPRESSOR AND CHILLER OPERATOR-1 1 TBM GROUT OPERATOR-2 2 COMPRESSOR AND CHILLER OPERATOR-2
3 RIGGER MAN SURFACE-1 3 RIGGER MAN SURFACE-4
2 ASST.GROUT OPERATOR -1 3 ETP PLANT OPERATOR-1 2 ASS.GROUT OPERATOR -2 3 ETP PLANT OPERATOR-2
3 ERECTOR OPERATOR-1 4 PLANT HELPER-1 3 ERECTOR OPERATOR-2 4 PLANT HELPER-2

4 ASST.ERECTOR OPERATOR-1 5 PLANT HELPER-2 4 ASST.ERECTOR OPERATOR-2 5 PLANT HELPER-2

6 SIGNAL MAN SURFACE-1 6 SIGNAL MAN SURFACE-2
5 RING BUILDER-1 6 PLANT HELPER-3 5 RING BUILDER-4 6 PLANT HELPER-3

7 RIGGER MAN SHAFT-1 7 RIGGER MAN SHAFT-4
6 RING BUILDER-2 7 WASHING BAY OPERATOR-1 6 RING BUILDER-5 7 WASHING BAY OPERATOR-1
8 RIGGER MAN SHAFT-2 8 RIGGER MAN SHAFT-5
7 RING BUILDER-3 8 CONFINED SPACE ATTENDER-1 7 RING BUILDER-6 8 CONFINED SPACE ATTENDER-1
9 SIGNAL MAN SHAFT-1 9 SIGNAL MAN SHAFT-2
8 PIPE FITTER -1 9 TBM SURFACE WATCHMAN-1 8 PIPE FITTER -4 9 TBM SURFACE WATCHMAN-1
10 SHAFT TRAVERSE OPERATOR-1 10 SHAFT TRAVERSE OPERATOR-2
9 PIPE FITTER -2 10 MAN HOIST OPERATOR-1 9 PIPE FITTER -5 10 MAN HOIST OPERATOR-1
11 Y-SWITCH OPERATOR-1 11 Y-SWITCH OPERATOR-2
10 PIPE FITTER-3 10 PIPE FITTER -6

12 SEGMENT GASKET INSTALLER-1
MECHANICAL SUPERVISOR PLANT-1 MECHANICAL SUPERVISOR PLANT-1
11 WELDER CUM PIPE FITTER-1 11 WELDER CUM PIPE FITTER-2
ELECTRICAL SUPERVISOR PLANT-1 ELECTRICAL SUPERVISOR PLANT-1
12 LOCOMOTIVE OPERATOR-1 12 LOCOMOTIVE OPERATOR-3
11 PLANT MECHANIC-1 11 PLANT MECHANIC-1
13 LOCOMOTIVE OPERATOR-2 13 LOCOMOTIVE OPERATOR-4
12 PLANT ELECTRISEN -1 12 PLANT ELECTRISEN -1
MECHANICAL SUPERVISOR TBM-1 13 PLANT MECH HELPER -1 MECHANICAL SUPERVISOR TBM-2
PLC ELECTRICAL SUPERVISOR TBM-1 PLC ELECTRICAL SUPERVISOR TBM-2
14 TBM MECHANIC-1 14 TBM MECHANIC-2
Sensitivity: LNT Construction Internal Use

#
15 TBM ELECTRISEN -1 15 TBM ELECTRISEN -2

Page 63 of 110
MANDAVELI TUNNELS
APPENDIX B – OHS&E RISK ASSESSMENT
Page 64 of 110
Page 65 of 110
Environment, Health and Safety
Standard Operating Procedures
P2-CP31-TU02 Project
Ref: OP 12 A
066. OHS&E RISK ASSESSMENT – TUNNEL MAIN DRIVE
Assessment Assessment Re-assessment
Emergency Situation
Resid Business Risk
/Abnormal(A)/
Non-Routine
Routine(R)/
Normal(N)
Risk/ Risk/ ual and/or
Sl People/Property/
(NR)
(E)
Activity Hazard/Aspect Risk/Impact Involved Impa Control Measures Impa Additional Control Measures Risk/ Opportunity
No Resource at risk P S P S P S
ct ct Impac Y/N (If yes
Level Level t explain)
Level
➢ Daily pre-start verification and briefing
shall be conducted to all the workmen by
site engineer.
➢ All workmen shall be undergone the Tunnel ➢ Site Engineer has to be allocate the
Deployment of workmen
General Tunnel
1. Mistakes in safety induction training separately. workmen for the specific jobs.
worker,
Operations. ➢ Only skilled and trained workmen shall be ➢ Strict supervisor shall be ensured at all
Welder, gas
2. Mishandling of engaged. time and no work shall be performed
Routine(R)
Normal(N)
Unskilled & cutter, grinder.
equipment. ➢ Medical fitness and health condition of the without site supervisors.
01 Unqualified Driller, Riggers, 4 4 16 2 4 8 1 4 4 No
3. Serious injuries. workmen also ensured before start of the work. ➢ Lone working shall be avoided.
workmen Lifting
4. Unsafe behaviour ➢ Project ID Card shall be issued to all the ➢ Site supervisor shall submit supervisor’s
Supervisor,
at work. workmen. Safety checklist to OHS&E Department
Site engineers ➢ Frequent violators shall be punished and shall for each shift.
Visitors be warned for their unsafe practices. ➢ Defaulters must be identified and they
should undergo BBS Training regularly.
➢ Sikhs also shall wear safety helmet while
working at height.
➢ Every access point into a Shaft Tunnel or ➢ No person can enter a Tunnel, Confined
confined space must have a controlled access Space or Shaft without formal documented
point which is manned by a competent person. authorization.
➢ The competent person assigned for ➢ Authorization can only be granted when
access/egress of persons must document, verify the person has undertaken a tunnel
and authorize the access/egress of every person. awareness briefing, or formal Tunnel
Induction training.
➢ Placing of the access/egress control point is to
General Tunnel ➢
Tunnel Access Control
1. Tunnel incidents be placed at either the top of a shaft or at the The pedestrian route should be clearly
worker, tunnel entrance along/before tunnel walkway. defined, and signage posted as appropriate.
2. Mistakes in
Welder, gas
Operations. ➢ Electronic tally system or RFID: Automatic ➢ The height of handrails shall be between
Routine(R)
Normal(N)
Unauthorised cutter, grinder.

3. Mishandling of counting of people going inside or outside the 0.9m to 1.2m and mid-rails to be provided
02 personnel entry Driller, Riggers, 3 3 9 2 3 6 1 3 3 No
equipment. tunnel through suitable electronic device for at 0.5m height.
into tunnel Lifting
tunnel access control system was used to
4. Serious injuries. Supervisor, ➢ Where continuous clearance with the
monitor the number of persons available inside
5. Unsafe behaviour Site engineers recommended minimum dimensions is not
the tunnel at any point of time.
at work. practicable, refuges should be provided at
Visitors
➢ Pedestrian access should be properly identified intervals related to visibility, the curvature
and provided by walkways in the tunnel. and gradient of the tunnel and to traffic
speed.
➢ Every tunnel should have a safe pedestrian route
from face to pit bottom, with escape routes ➢ Where necessary a traffic light system may
properly signed to the ladder or stair tower to be employed for the safe movement of
the surface. plant and pedestrians.
➢ All walkways shall be physically separated from ➢ The emergency man riding cage is to be
OP: 12 – EHS Risk Management Revision 03 dt: 03.08.2018 Page 2 of 9 Page 66 of 110

Ref: OP 12 A
any traffic route, where this is not possible other placed at a designated point at either top of
precautions should be taken to safeguard any shaft, or bottom where immediate access
persons having access into the tunnel during the can be gained and be part of the
movement of plant and pedestrians. emergency plan procedures.
➢ Extra clearances should be allowed for Turning
and reversing of vehicles.
General Tunnel
➢ Only trained and competent person to operate
1. Injury worker,
Routine(R)
Normal(N)
segment erector.
Operation of 2. Crushing Lifting ➢ Unauthorized person to be kept away.
03 Segment erector 3. Fracture Supervisor, 4 4 16 ➢ Proper coordination between operatives. 2 4 8 1 4 4 No
4. Fatality Tunnel engineers ➢ Tested and approved equipment shall be used.

Visitors
General Tunnel
1. Crushing injury worker, ➢ Only trained workers to be deployed.
Routine(R)
Normal(N)
2. Fracture ➢ Proper co-ordination between the
Handling of Lifting
04 3. Fatality 4 4 16 ➢ Proper support to be fixed for the stability of the 2 4 8 operatives. 1 4 4 No
segments Supervisor,
4. Toppling of segment at the shaft bottom.
Tunnel engineers
segments
Visitors
TBM Operations
➢ Movement of personal to be monitors via a tally

General Tunnel board or a similar arrangement.
1. Fire worker, ➢ No unauthorized entry into shaft.
➢
Routine(R)
Normal(N)
Emergency rescue basket to be kept at surface

Movement of 2. Flooding Lifting
Personal in and within the reach of crane. ➢ Tally board system provided at shaft
05 3. Injuries while Supervisor, 4 4 16 2 4 8 1 4 4 No
out of shaft working in the ➢ The crane used for emergency rescue basket and
shaft Tunnel engineers
rescue basket to be certified every 6 months
Visitors installed with a dead man's lock.
➢ Eye wash stations to be available in the tally hut

and in the main welfare facility.
➢ Ensure that hazardous materials are placed back
General Tunnel into appropriate secured storage after use.
1. Serious Injury
worker,
Routine(R)
Normal(N)
Hazardous
2. Death
Lifting ➢ Do not store hazardous substances above 2m ➢ First aid kits to be available in the tally hut
06 Substances 3. Injuries while Supervisor, 4 4 16 height 2 4 8 and in the pit bottom. 1 4 4 No
working in the
shaft
Tunnel engineers ➢ Always follow manufacturer instructions.
Visitors
➢ Compliance to MSDS requirements.
➢ MSDS to be available at the location of usage of
hazardous substance.

Ref: OP 12 A
➢ Install I&M instruments on the existing ➢ Perform secondary grouting for every 2
buildings and Keep records and continuous rings. Yes
Emergency Situation
monitoring.
➢ Vacate the residents of the buildings well
Non-Routine
Stoppage of
1. Settlement of ➢ Communicate to the residents of the building in advance while tunnelling and provide work/ Public
(NR)
Tunnelling under Residents of the
(E)
07 existing building 4 4 16 about the procedures and risk involved while 2 4 8 temporary accommodation to the residents. 1 4 4 interference /
existing buildings building
2. Threat to public tunnelling.
➢ If required, involve Government Complaints
➢ Deploy emergency team at the surface level to emergency services for emergency from Statutory
authorities
handle emergency situations. situations.
➢ Install I&M instruments on the existing near by

structures and Keep records and continuous
monitoring.
➢ Perform secondary grouting for every 2
➢ Confirmatory Bore hole to be done at the river
rings. Yes
Emergency Situation
General Tunnel bed and Geology condition along river bed to be
➢ Keep de-watering arrangements and Stoppage of
Non-Routine
worker, verified for the calculation overburden above
1. Flooding or inrush Tunnel crown. adequate numbers of pumps and work/ Public
(NR)
Tunnelling under Lifting
(E)
08 of water 4 4 16 2 4 8 connections. 1 4 4 interference /
water bodies Supervisor, ➢ Control grout pressure /volume should be done
2. Threat to workers
Tunnel engineers according to theories. ➢ If required, involve Government Complaints
Visitors emergency services for emergency from Statutory
➢ Deploy emergency team at the surface level to authorities
situations.
handle emergency situations.
➢ Evacuate workers from tunnel when there is an
emergency.
➢ Install I&M instruments on the existing

buildings and Keep records and continuous
monitoring.
➢ Communicate to the owner of the petrol bunk ➢ Perform secondary grouting for every 2
Yes
Emergency Situation
about the procedures and risk involved while rings.

Non-Routine
tunnelling. Stoppage of
1. Settlement of ➢ Vacate the people from the petrol bunk
work/ Public
➢
(NR)
Tunnelling under Residents of the Stop the functioning of petrol bunk while area and restrict the entry.
(E)
09 existing building 4 4 16 2 4 8 1 4 4 interference /

petrol bunks building tunnelling and empty the storage of flammable
2. Threat to public ➢ If required, involve Government
liquids in the petrol bunk. Complaints
emergency services for emergency from Statutory
➢ Keep the necessary firefighting arrangements to situations. authorities
overcome the emergency situations.
➢ Deploy emergency team at the surface level to
handle emergency situations.

Ref: OP 12 A
➢ Emergency telephone should be provided at

start of the tunnel & every 100 meters of the
➢ The system should be independent of the
tunnel length and to the above locations,
tunnel power supply.
prominently located below the emergency light
area and conspicuously located and identifiable ➢ It should be so installed that destruction of
on less visibility also with retroreflective one unit will not interrupt the use of other
material. units in the system.
Tunnel Communication
➢ Equipment should be always maintained and ➢ All wirings used to transmit warnings in an
1. Failure to General Tunnel kept in good working order. emergency should be fire-resistant and
worker,
Routine(R)
communicate on
Normal(N)
protected from water and against
Lack of time Lifting ➢ Any fixed communication or temporary station
mechanical impact.
10 Communication Supervisor, 3 3 9 is required to be brought forward / extended as 2 3 6 1 3 3 No
2. Lack of
emergency Tunnel engineers the face is advanced. ➢ Any communication Equipment used on
procedures site where BLASTING is being carried out
Visitors ➢ Suitable soundproof enclosures should be
should only be used with predetermined
provided as necessary.
procedures.
➢ Signals to machine operators should normally
➢ The machine operators shall respond to
be given only by banksmen or other persons
signals only from the appointed signaller
authorized to do so, but all persons involved in
but shall obey “Stop Signal” at any time
the operations should be made familiar with the
no matter who gives it.
code through induction training and/or other
means such as toolbox talks.
➢ Higher lighting levels should be provided
locally, particularly on TBMs, at the face and
other working areas.
➢ The use of LED lighting should be considered
in preference to other types because of its low ➢ Emergency luminaires (with battery
power demand and low operating temperature. backup) should be installed along the
➢ Suitable electrical cables and non‑metallic, tunnel’s intervals of every alternate 5th
fireproof male‑female sockets are used for this light to allow safe egress from the tunnel.
purpose. These cables are laid on fabricated and ➢ The condition of the emergency luminaires
Tunnel Illumination
insulated hooks fitted on tunnel linings at equal should be regularly checked, and any Yes
General Tunnel
1. Poor illumination intervals. faults immediately rectified. The proper
Abnormal(A)
Non-Routine
worker, Stoppage of
Lack of 2. No illumination Lifting ➢ Only competent electricians (ITI qualified and functioning of the emergency lighting work/ Public
(NR)
11 illumination 3. Lack of Supervisor, 3 3 9 Govt. B licensed) are allowed to work on this 2 3 6 system should be functionally tested at 1 3 3 interference /
emergency Tunnel engineers tunnel light extension and repair job. intervals not exceeding 3 months Complaints
procedures from Statutory
Visitors ➢ On access routes accommodating both ➢ Regular maintenance, including cleaning
authorities
pedestrians and vehicles, suitable lighting of the luminaires, should be carried out to
should be sited to minimize shadows cast on maintain the light output and the area
walkways or workplaces by obstructions or lighting level. The luminaires should
plant and vehicles. therefore be as easily accessible as
possible.
➢ Lighting levels can be measured with a light
meter and should be as high as is reasonably
practicable, considering the work to be
undertaken in the area. i.e. 33 lux at walkway
level, 110 lux at working surfaces. Etc.

Ref: OP 12 A
➢ All plant and equipment used underground

➢ A temporary fire main providing water for constitutes a major source of both fuel and
firefighting should be made available ignition and should be fitted with fire
throughout the tunnel. suppression systems.
➢ The temporary fire main should be provided ➢ Flammable liquids should always be
with twin outlets (suitable for fire and rescue contained in tightly sealed and properly
service standard instantaneous couplings) at labelled metal containers.
intervals not exceeding 50 m. Such outlets ➢ Flammable liquids should be stored apart
should be clearly marked and readily accessible. from other combustible materials and at
➢ The water supply should be sufficient in volume safe distances from access and escape
and pressure for the operation of fire hoses, routes, refuge chambers, areas of high
water sprays or other fire-fighting equipment, activity and electrical installations. Not
and the advice of the fire service should be more than one day’s supply of such liquids
sought regarding this, if necessary. should be kept in a tunnel.
➢ In the confined space of a tunnel, all sources of ➢ Means should be provided to contain
fuel and ignition should be eliminated or spillage of the entire contents of containers
controlled. of flammable liquids. Drip pans should be
provided to catch any leakage from
➢ The amount of combustible material should be containers.
kept to a minimum for the day or shift only,
excess combustible materials should be shifted ➢ Care should be taken to remove flammable
Fire and explosion
liquids from tunnel machinery (e.g. TBM) Yes
Emergency Situation
to a surface storage area.
General Tunnel before it is dismantled underground.
Non-Routine
1. Fire worker, ➢ All heat or spark producing activities i.e. hot Stoppage of
2. Explosion Lifting work activity should be controlled by means of ➢ Whenever possible, welding and cutting work/ Public
(NR)
(E)
12 Fire & Explosion Supervisor, 4 4 16 2 4 8 should be undertaken at the surface or cold 1 4 4 interference /
3. Property damage work to permit.
Tunnel engineers processes should be adopted underground. Complaints
4. Loss of life ➢ Electrical equipment should also be considered
Visitors ➢ Fumes are generated should be removed from Statutory
as sources of fuel and ignition and should be authorities
protected accordingly. using Local exhaust ventilation to remove
the contaminants.
➢ Smoking was prohibited in the underground and
only be permitted in designated areas on the ➢ No work should be carried out on fuel or
surface away from combustible materials. oil tanks until they have been purged and
certified gas-free. If LEL is detected of
➢ Compressed gas cylinders should be controlled 5%, all hot works should be ceased
and only permitted underground in accordance immediately.
with a permit to work.
➢ No person carrying out welding or cutting
➢ Any lighting fixtures in storage areas for should be allowed to work alone, as they
combustible materials or flammable liquids might fail to notice a fire developing or be
should be constructed, located and maintained unable to extinguish it successfully.
so that combustible materials cannot be ignited
by the heat that the fixtures produce. ➢ All mechanical plant and equipment
should have fixed fire suppression systems
➢ Cold LED lighting should be preferred for such covering the fire-risk areas of the machine.
applications.
➢ All TBMs should be fitted with a water
➢ Explosives should not normally be stored spray curtain at their out-bye end to
underground. Only sufficient explosive material control smoke to aid escape of persons.
for individual blasts should be taken The curtain should cover the full cross-
underground at a time. section of the tunnel, particularly in the
crown.

Ref: OP 12 A
➢ A minimum fresh air supply must comply with ➢ The oxygen percentage should not be less
BS 6164 or equivalent. i.e. (0.3m3/min. per than 19.5%
person).
➢ Carbon monoxide percentage should not
➢ If plant is engaged, exhaust emissions and or exceed 0.5%
heat generated in Tunnel additional air supply
should be calculated in accordance with BS ➢ recommended minimum air velocity in the
6164 or equivalent. Tunnel should be 0.5m/s to contain dust
and 2.0m/s to prevent methane layering
➢ Any leaks in a damaged duct should be sealed.
Regular testing the operation and efficiency of ➢ Inflammable gases shall not exceed 1.25%
each ventilation system and for its regular ➢ The wet bulb temperature shall not exceed
maintenance, particularly in long tunnels. 27°c
➢ Tests should also determine whether the system ➢ The Nitrogen monoxide should not exceed
continues to meet operational requirements, 5ppm
taking account of changes in tunnel length or
Tunnel Ventilation
1. Respirable dusts ➢ Gas exposure shall be monitored Yes
Emergency Situation
General Tunnel configuration since the previous check.
2. Suffocation continuously and recorded using fixed gas
Non-Routine
1. Dust worker, Stoppage of
3. Asphyxiations ➢ Appropriate repairs and modifications should be monitors located at the tunnel excavation
Lifting work/ Public
(NR)
2. Toxic gases made as necessary
(E)
13 4. Health risks 4 4 16 2 4 8 faces and at work locations along the 1 4 4 interference /
3. Explosive Supervisor,
5. Occupational ➢ Only Fresh air should be used for ventilation to length of the tunnel such as low points,
environment Tunnel engineers Complaints
diseases improve the quality of air in the tunnel and cross passages and sumps that are
Visitors from Statutory
6. Loss of Life oxygen should never be discharged to susceptible to the presence of gases. Gas to authorities
counteract low oxygen levels. be monitored are O2, NO2, CH4, CO,
H2S.
➢ Air intake fans on the surface should be sited
away from sources of contamination. Air ➢ The workforce should be trained in the
exhaust fans should be sited away from working correct use of the portable gas monitors
areas. and associated safety procedures to follow
when the alarm levels are triggered.
➢ All ducts, fan bodies, casings and support
structures should be properly bonded to each ➢ The portable gas detectors shall be
other and to an adequate earth. Air movers’ regularly checked for its good condition
devices should also be earthed. and calibrated as per the manufacturer’s
instructions.
➢ Projects or areas of a project that are not
covered by a fixed gas monitoring system ➢ Before taking gas detectors to workplace
should use portable gas monitors to determine its battery charge level shall be checked
worker exposure to gases. and confirmed.
➢ No person shall be allowed to travel in ➢ Locomotive drivers shall be authorized in

locomotives inside tunnel. writing by the site management after their
1. Hit with training, testing and issue of a ‘training
➢ Only operator should be seated in the Operator
Transportation
General Tunnel certificate’.

Rail / LOCO
Locomotive
worker, cabin, no other personnel can sit or ride in the
Routine(R)
1. Loco
Normal(N)
2. Struck with track Loco. Operator cabin door should have ➢ All locomotive drivers should be in radio
Movement Lifting 16
14 3. Run over by Supervisor, 4 4 interlock arrangement to stop the engine when 2 4 8 contact with the train control point as part 1 4 4 No
2. Movement of Locomotive
personnel Tunnel engineers the cabin door was open or not closed properly. of the train control system
4. Fatality
Visitors ➢ Walkways will be segregated from vehicle ➢ Other uses of CCTV in tunneling which
5. Serious injuries
movement and installed adjacent to the track to should be considered are on TBMs, on
provide access for maintenance only. locomotives, and in the pit bottom.

Ref: OP 12 A
➢ Track maintenance will not be attempted during ➢ Track inspection and maintenance should
train operations and maintenance on both track not normally be attempted during train
and rolling stock will be kept in maintenance operations.
records.
➢ TBM track and loco rail track extension shall be
carried out as TBM advances.
➢ The rails shall be fixed on steel sleepers with
help of rail locks.
➢ End stoppers shall be provided at the end after
each extension.
➢ All electrical cable must be fire resistant and
meets the requirements of BS 6164 i.e. low ➢ HT cable and tunnel lighting extension are
smoke and fume cables or equivalent. carried‑out, as TBM advances, by the
professional and qualified personnel.
➢ All temporary electrical cables and trailing
cables connection to be checked/inspected ➢ Shall ensure that as far as practicable, no
periodically to prevent from damage. wiring, which may come in contact with
water or which may be mechanically
➢ An earthing cable shall be connected to the
damaged, is left on ground or floor.
TBM and grounded outside the tunnel.
➢ All safety precautions are being taken into
➢ All junction boxes are to be fitted on fabricated
consideration during these extensions and
stand and rubber mat, fixed on tunnel lining,
any isolations must be suitably planned
and must be earthed.
and Lock Out Tag Out (LOTO) system to
➢ Cable and panel notification for safety be followed.
Electrical Installations
precaution and symbol with painted board is

➢ A passageway not less than 60 cm wide
provided as per requirement. Yes
Emergency Situation
General Tunnel shall be maintained in front of

Non-Routine
1. Fire worker, ➢ Armored cable is provided for tunnel lighting switchboards. Stoppage of
Usage of work/ Public
2. Electrocution Lifting purpose.
(NR)
➢
(E)
15 electrical tools 4 4 16 2 4 8 Rubber mats shall be provided in front and 1 4 4 interference /

3. Major Injury Supervisor,
and equipments. ➢ Any electrical cables used nearby the blasting in back of the switch boards. No one shall
4. Fatal Tunnel engineers Complaints
area should be protected with the separate be permitted at the back of switchboards
Visitors from Statutory
enclosure made of concrete to protect from any when the current is on. authorities
leakage or induction.
➢ In no case, space in front or back of a
➢ Tunnel lighting panels fitted on firm stands are switchboard shall be allowed to be used as
provided at regular intervals. a change ‘room, locker or storage room.
➢ All cables are to be laid on fabricated hooks on ➢ Shall ensure at a site that all portable
the opposite side of the pipeline connection with electrical hand tools and inspection lamps
extra insulation for cable. used tunnelling work are operated at a
voltage not exceeding twenty-four volts.
➢ In workplaces where the exact location of
underground electric power line is not known, ➢ All electric wires carrying voltage 440 and
the workers using jack hammers, crow bars or above installed underground shall be in the
other hand-tools which may come in contact form of insulated, lead covered cables,
with a live electrical line, shall be provided with armored effectively against abrasion and
insulated protective gloves and footwear of the effectively grounded.
type in accordance with the national standards.

Ref: OP 12 A
➢ Cold water is supplied from storage tank on

surface to TBM through the pipelines into the
TBM (coloured with Green paint with inward
arrow).
➢ Hot water from all the heat exchangers, Main
drive motors and gear boxes and other cooling
equipment is pumped out from the TBM to the
Types of Services in Tunnel
cooling tower through pipeline (coloured with

green paint with outward arrow). Yes
Emergency Situation
General Tunnel
➢ Wastewater from TBM is pumped out to ➢ All the dry utilities shall be routed right Stoppage of
Non-Routine
1. Errors in worker,
Routing of Sedimentation tank at base slab through side of the tunnel work/ Public
connections Lifting
(NR)
(E)
16 pipelines along 4 4 16 pipeline. (Coloured with light blue paint with 2 4 8 1 4 4 interference /
2. Catastrophic Supervisor, ➢ All the Wet utilities shall be routed left
tunnel outwards arrow).
incidents Tunnel engineers side of the tunnel. Complaints
Visitors ➢ Grout from plant to TBM is pumped through from Statutory
pipeline of grove type with quick release clamp. authorities
(Coloured with grey paint with inwards arrow).
➢ Sodium silicate from grout plant to TBM is
pumped through G.I. pipe. (Coloured with white
paint with inwards arrow).
➢ All these pipelines are laid with fabricated
hooks on the one side of the tunnel and
extended as TBM advances.
P: Probability, S: Severity, R: Routine, NR: Non-Routine, N: Normal, A: Abnormal

MANDAVELI TUNNELS
APPENDIX C – INSPECTION TEST PLAN
Page 74 of 110
Construction of twelve (12) km Twin Bored tunnels from Kellys station to Taramani road Jn station and construction of Diaphragm walls of station box and entry / exit structures of
ChetpetMetro, Royapettah govt. hospital, ThiruvanmiyurMetro stations and part Diaphragmwall of Greenways road metrostation, including Launching and Retrieval shafts as required in the
above stations-CP31-TU02 Project.
INSPECTION TEST PLAN FOR TBM MAIN DRIVE

CLIENT : CHENNAI METRO RAIL LIMITED Date : 19-06-2023
GENERAL CONSULTANTS: NKAB

P20C03TU02PRW-LANT-QMS-ITP-
00083 R(2)
CONTRACTOR : L&T CONSTRUCTION
ACCEPTANCE CRITERIA ACTION RESPONSBILITY

SR.No ACTIVITY DESCRIPTION VERIFICATION DOCUMENTS REMARKS
REFERENCE SPECIFICATION/
ACCEPTANCE CRITERIA FREQUENCY OF ACTIVITY L&T GC
STANDARD
1 Approved Method Statement As per Technical Specifications GC Approval Prior to TBM Start QA/QC Dep. H H GC Approval
Geotechnical &
Conformance Report of TBM Initial
2 Backup Gantry Assembled OCS Part-2 Section VII Sub Section 3.3 Approved Method Statement Prior to TBM Start Instrumentation H R
Drive
team
Installation of TBM Guidance System
3 OCS Part-2 Section VII Sub Section 2.4 Approved Method Statement Prior to TBM Start Survey Team H H
Drive
Approval of TBM Primary and Secondary Grout Mix

Approved Method Statement & Approved Mix Conformance Report of TBM Initial
4 OCS Part-2 Section VII Sub Section 2.12 Prior to TBM Start QC Team H H
Design Drive
5 Inspection of Ring OCS Part-2 Section VII Sub Section 2.7 Approved Method Statement Each Ring QC Team H R Post Ring Checklist
EPBM Alignment
6 OCS Part-2 Section VII Sub Section 2.4 Approved Method Statement Continuous Survey Team H R
Drive
Checklist for Segment inspection at

Ring Inspection Before Erection
Fixing of EPDM Gasket Correctly, Major
7 OCS Part-2 Section VII Sub Section 2.7 Each Ring Tunnel Team H R surface: P20C30TU02PRW-LANT-
Damage not acceptable, Segment cracks
QMS-REC-00205 R(0)
Ring inspection Checklist:

8 Ring Inspection after Erection OCS Part-2 Section VII Sub Section 2.7 Damages recorded/Correct nos of Bolts tightened Each Ring Tunnel Team H R P20C03TU02PRW-LANT-QMS-
REC-00185 R(0)
Checklist for Primary grouting:

Primary Grouting
OCS Part-2 Section VII Sub Section
9 As per Approved Grout mix Design Prior to Compressed air work Tunnel Team H R 20C30TU02PRW-LANT-QMS-REC-
2.12.1
00192 R(1)
Checklist for Secondary grouting:

Secondary Grouting
OCS Part-2 Section VII Sub Section
10 As per Approved Grout mix Design Every 5th Ring Tunnel Team H R 20C30TU02PRW-LANT-QMS-REC-
2.12.2
00193 R(0)
TBM Grout test report:

Casting of Specimen for Primary Grouting
3 Nos of Cubes of (IOOx100x100mm) for 1 cube
11 OCS Part-2 Section VII Sub Section 2.12 2Mpa after 28 Days QC Team H R P20C30TU02PRW LANT-QMS-
for 7 & 2 cubes for 28 days
REC-00131 R(0)
LEGEND : H - HOLD , R-REVIEW, W - WITNESS, TPTL - THIRD PARTY TESTING LABORATORY, GC- GENERAL CONSULTANTS, MTC- MANUFACTURE TEST CERTIFICATE.
Page 75 of 110

#
MANDAVELI TUNNELS
APPENDIX D – CHECKLISTS & FORMATS
Page 76 of 110
CONSTRUCTION OF TWELVE (12) Km TWIN BORED TUNNELS FROM KELLYS STATION TO TARAMANI ROAD
JN STATION AND CONSTRUCTION OF DIAPHRAGM WALLS OF STATION BOX AND ENTRY/ EXIT STRUCTURES
OF CHETPET METRO, ROYAPEETAH GOVT.HOSPITAL, THIRUVANMIYUR METRO STATIONS AND PART
DIAPHRAGMWALL OF GREENWAYS ROAD METROSTATION, INCLUDING LAUNCHING AND RETRIEVAL
SHAFTS AS REDQUIRED IN THE ABOVE STATIONS-CP31-TU02 PROJECT.
SEGMENT DELIVERY REPORT

CLIENT : Chennai Metro Rail Limited
P20C30TU02PRW-
GENERAL LANT-QMS-REC-
NKAB
CONSULTANT : 00134 R(0)
Tunnel/ Drive: Date:
From: To:
Permanent Ring
Shift:
No:
DATE OF INSPECTION/
DATE OF CASTING SEGMENT ID VISUAL CHECK REMARKS
DISPATCH
AT CASTING YARD
Received by: L&T - Representative GC- Representative
Name:
Signature:
Designation
Date:
AT SITE
Received by: L&T - Representative GC- Representative
Name:
Signature:
Designation
Date: Page 77 of 110

CONSTRUCTION OF TWELVE (12) Km TWIN BORED TUNNELS FROM KELLYS STATION TO TARAMANI ROAD JN STATION AND
CONSTRUCTION OF DIAPHRAGM WALLS OF STATION BOX AND ENTRY/ EXIT STRUCTURES OF CHETPET METRO, ROYAPEETAH
GOVT.HOSPITAL, THIRUVANMIYUR METRO STATIONS AND PART DIAPHRAGMWALL OF GREENWAYS ROAD METROSTATION, INCLUDING
LAUNCHING AND RETRIEVAL SHAFTS AS REDQUIRED IN THE ABOVE STATIONS-CP31-TU02 PROJECT.
CHECKLIST FOR RING INSPECTION AT CASTING YARD

P20C30TU02PRW-
GENERAL LANT-QMS-REC-
NKAB
CONSULTANT : 00179 R(1)
Site: Shift:
Permanent Ring
No:
Segment type
Sl. No. Check Points Remarks
S1 S2 S3 S4 S5 S6
1 Inspection of Precast Segments Before Dispatch
2 Name and Identification of Segments (mould no.)
3 Date of Casting
4 Cube Compressive Strength for 28 days
5 Finishing of Segments as per Method Statement
6 Repairing of Segments as per Method Statement
7 Grouting Sockets and bolts Inserts
8 Any structural micro crack observed
9 No honey combing/ spacing of concrete observed
10 Fitting of EPDM Gasket as per standards
11 Cleaning of Socket & Bolt Holes
12 03 mm Ply-wood packers installed
L&T - Representative
GC- Representative
Site Engineer QC Engineer
Name:
Signature:
Designation
Date:
Page 78 of 110
CONSTRUCTION OF TWELVE (12) Km TWIN BORED TUNNELS FROM KELLYS STATION TO TARAMANI ROAD JN STATION AND
CONSTRUCTION OF DIAPHRAGM WALLS OF STATION BOX AND ENTRY/ EXIT STRUCTURES OF CHETPET METRO, ROYAPEETAH
GOVT.HOSPITAL, THIRUVANMIYUR METRO STATIONS AND PART DIAPHRAGMWALL OF GREENWAYS ROAD METROSTATION, INCLUDING
LAUNCHING AND RETRIEVAL SHAFTS AS REDQUIRED IN THE ABOVE STATIONS-CP31-TU02 PROJECT.
CHECKLIST FOR RING INSPECTION AT TUNNEL SITE SURFACE

P20C30TU02PRW-
GENERAL LANT-QMS-
NKAB
CONSULTANT : REC-00190 R(1)
Site: Shift:
Permanent Ring
No:
Segment type
Sl. No. Check Points Remarks
S1 S2 S3 S4 S5 S6
Visual Inspection of Precast Segments at Tunnel site
1
surface
2 Name and Identification of Segments (mould no.)
3 Date of Casting
4 Cube Compressive Strength for 28 days
5 Fitting of EPDM Gasket as per standards
6 Cleaning of Socket & Bolt Holes
7 03 mm Ply-wood packers installed
Repairing of Segments as per Method Statement (if

8
required)
Delivery of elements to site: Delivery of correct
9
Segments and proper loading on track
L&T - Representative
GC- Representative
Tunnel Engineer QC Engineer
Name:
Signature:
Designation
Date:
Page 79 of 110
Construction of twelve (12) km Twin Bored tunnels from Kellys station to Taramani road Jn station and construction of
Diaphragm walls of station box and entry / exit structures of ChetpetMetro, Royapettah govt. hospital, ThiruvanmiyurMetro stations and
part Diaphragmwall of Greenways road metrostation, including Launching and Retrieval shafts as required in the above stations-CP31-
TU02 Project.
RING BUILDING PROTOCOL
Client: Chennai Metro Rail Limited

P20C03TU02PRW-LANT-QMS-REC-00184
GC: NKAB
R(1)
Contractor: L&T Construction
Date: Shift: Ring Roll:….......................................... Ring Type: Ring No:
Shift Engineer: Day (+) Positive Right Roll…....................... Chainage:
Erector Opt: Night (-) Negative Right Roll…....................... Key Position :
Tail Skin Gap (mm)

Tail Skin Gap (mm) Before
Before After
After Ram Extension Ram Extension
Before mm Before mm
After mm After mm
TBM Position
Position Front Center Back
Horizontal
Vertical
Ram Extension Ram Extension

Before mm Before mm
After mm After mm Tail Skin Gap (mm)
Tail Skin Gap (mm) Before
Before After
After
Remarks
Tunnel Engineer QC Engineer Tunnel Manager GC Representative
Name:
Signature:
Designation:
Date:
Page 80 of 110
# Sensitivity: LNT Construction Internal Use

POKB JV-TUN-FM-07-A, Rev. 00
Construction of twelve (12) km Twin Bored tunnels from Kellys station to Taramani road Jn station and construction of Diaphragm
walls of station box and entry / exit structures of ChetpetMetro, Royapettah govt. hospital, ThiruvanmiyurMetro stations and part
Diaphragmwall of Greenways road metrostation, including Launching and Retrieval shafts as required in the above stations-CP31-
TU02 Project.
RING INSPECTION SHEET
Client: Chennai Metro Rail Limited P20C03TU02PRW-LANT-QMS-REC-00185
GC: NKAB R(0)
Contractor: L&T Construction Date:

Tunnel Drive RING Type
From To A B C
U/L D/L
Ring No: ______ Key: ______ Date: ___________
S5 S4 S3 S2 K S6
Comments
Roll: mm
Steps Yes No NCR Required? Yes No
Lips Yes No NCR Number Checklist:-
Damage Report 1. Bolts Tightened Yes No
Damage No Segment Location Type Dimensions LxWxD Segment Date 2. Grout Plugs Installed Yes No
1 3. Hydrophilic Washers Installed Yes No
2 4. Compressive Packing Yes No
3 (All Trailing Edge Circle Joint)
4
5
6 * Lips between radius segments
After ring built After ring is out of tailskin

* Steps between circumference segments
Site Engineer QC Engineer GC Representative

Name:
Signature:
Designation:
Date: Page 81 of 110

#
Construction of twelve (12) km Twin Bored tunnels from Kellys station to Taramani road Jn station and construction of Diaphragm
walls of station box and entry / exit structures of ChetpetMetro, Royapettah govt. hospital, ThiruvanmiyurMetro stations and part
Diaphragmwall of Greenways road metrostation, including Launching and Retrieval shafts as required in the above stations-CP31-
TU02 Project.
CHECKLIST FOR EXCAVATION MANAGEMENT
P20C03TU02PRW-
GC: NKAB LANT-QMS-REC-
00207 R(0)
Date: Shift: Tunnel & Drive:
Weight of Muck Skip

% of Over and
(MT)
Sr. No. Ring No. No. of Skip Start Stroke End Stroke Under Remarks
Empty Loaded Theoretical Actual Excavation
TBM Operator Tunnel Supervisor Shift Manager
Name
Signature:
Date:
* Theoretical Volume (V)=π〖(d/2)〗^(2 ) X stroke length (V- muck volume, d- cutting diameter). theoretical volume is actual dry volume.
* Actual Volume = Theoretical Volume + Bulk factor + Injected Material (Water, form, polymer, bentonite etc.)
* Bulking factor depends upon soil condition and calculate accordingly.
Page 82 of 110

#
CONSTRUCTION OF TWELVE (12) Km TWIN BORED TUNNELS FROM KELLYS STATION TO TARAMANI ROAD JN STATION AND CONSTRUCTION OF DIAPHRAGM WALLS OF STATION BOX AND ENTRY/ EXIT
STRUCTURES OF CHETPET METRO, ROYAPEETAH GOVT.HOSPITAL, THIRUVANMIYUR METRO STATIONS AND PART DIAPHRAGMWALL OF GREENWAYS ROAD METROSTATION, INCLUDING LAUNCHING
AND RETRIEVAL SHAFTS AS REDQUIRED IN THE ABOVE STATIONS-CP31-TU02 PROJECT.
TBM GROUT TEST REPORT

P20C30TU02PRW-
GC: NKAB LANT-QMS-REC-00131
R(0)
Location: Date of Casting : Date of Testing:
Grout A B Compressive
Weight of cube (In UTM Load in Avg. Compressive strength
SL.NO MIX Code WATER Cement Bentonite Retarder Time of casting Age of cube in days strengh
Sodium silcate (Kg) Kg) reading KN (Mpa)
(Kg) (Kg) (Kg) (Kg) (Mpa)
Marsh Cone Visocity:
Gel Time:
Test Requirement : Compressive strength of 28 days 2 Mpa
Remarks :
L&T QC Engineer GC Representative
Name:
Signature:
Date:
Page 83 of 110
#Sensitivity: LNT Construction Internal Use

Construction of twelve (12) km Twin Bored tunnels from Kellys station to Taramani road Jn station and construction of Diaphragm walls of station box and entry / exit structures of
ChetpetMetro, Royapettah govt. hospital, ThiruvanmiyurMetro stations and part Diaphragmwall of Greenways road metrostation, including Launching and Retrieval shafts as required
in the above stations-CP31-TU02 Project.
Date:…........................................................ TBM OPERATION PARAMETER INSTRUCTION Tunnel Drive:…...............................................................

Sr. Parameter Unit Ring…..... Ring…..... Ring…..... Ring…..... Ring…..... Ring…..... Ring…..... Ring…..... Ring…..... Ring…..... Ring….....
1 Chainage m
2 Segment Reinforcement type A,B C
3 Segment Key Position 1 to 16
4 H-Deviation from DTA mm
5 V-Deviation from DTA mm
6 HORIZONTAL Angle degree
7 Vertical Angle degree
8 Cutterhead Torque Range kNm
9 Cutter rotation Speed RPM (range) rpm
10 Thrust Force (Max) kN
11 Thrust Speed mm/min
12 Face Pressure (Min to Max) bar
13 Target Face Pressure bar
14 Grout volume (100 to 110%) m3/ring
15 Grout pressure Range bar
NOTE:- *Key Selection to be done at site According to Cylinder length and Tail Skin Gap measured manually
*Universal Ring Segment will use in Tunnel Drive
Prepared by Sr. Tunnel Manager:
Expected Ground Conditions
Date:
Structures and utilties above tunnel
Checked by Geotech Manager:
Stoppages / Cutterhead interventions

Date:
Approved by Chief Tunnel Manager:
Remarks:
Date:
Page 84 of 110
Page 78 of 80
#Sensitivity: LNT Construction Internal Use
Construction of twelve (12) km Twin Bored tunnels from Kellys station to Taramani road Jn station and construction
SB-TUN-FM-07
of Diaphragm walls of station box and entry / exit structures of ChetpetMetro, Royapettah govt. hospital,
ThiruvanmiyurMetro stations and part Diaphragmwall of Greenways road metrostation, including Launching and
Retrieval shafts as required in the above stations-CP31-TU02 Project. P20C03TU02PRW-LANT-QMS-REC-
00219 R(0)
Muck Reconciliation Sheet-Initial Drive

Location:SGW to SAR - Downline Ring No: T3 Date: (D/N)
Shield Jack Stroke Dry Pre Additives

Time Muck Unit Wt Actual Dry Soil
(mm) ( C ) Theoretic Muck Skip Muck Occupie Muck Skip (E) Bulking
Skip of Volume Net volume
al Theoretical Skip d Actual Factor
Actual Saturate Excavated K=(M/B)
Skip No Total Excavatio Volume Total wt Volume Volume Bentonit (1.01- Remarks
Start Finish Net Start SJ Finished SJ weight d soil Foam Water Polymer (m³) 0.85≤ M/B
Stroke n Volume (m³) (Ton ) of Muck (m³) e 1.5)
(24 hrs: (24 hrs : Stroke (m) (m) (Ton) (T/m3) (m³) (m³) (m³) M=(G-H-I-J- ≤1.15
(m) (A)=(3) X (B) (C) (Ton) (G=E*F) (m3) (L)
Min) Min) (m) (1) (2) (E=C-D) (F) (H) (J) (K) K)×L
3= (2-1) 34.64 (D ) (I)
10
11
12
Total 0.00 0.000 0 #DIV/0!
NOTE: 1). If change in excavated material put in remarks. 2.If net volumeis more than1.1 notify Engineer 3). If net volumeis more than1.15 stop mining notify TM
Recorded by Shift Incharge : Verified by Samsung Shift Incharge : Witnessed by QPs :

Page 85 of 110
MANDAVELI TUNNELS
APPENDIX E – RING BUILDING SEQUENCE
Page 86 of 110
8
1395
13
8
1375
.146
9
1400
.6
.12
5
4.52
1404.8
.10
0.6
0
6
137
1409
9.26
1422.27
138
1376
142
1375.4
142
1417
1415.66
1386.1
1413.89
8
140
1390.76
.9
1423
1
13
140
7.86
82 7.6
3.07
.3 2 1 6
13
S1 14 .14 .10 13
.26
82
00
13
09 23 25 83
09
76
14
14
.32
14 14 .07
.52
8
14
.90
24
4.8 0 13
86
14
137 7
14 9
S6 S2 .11
S5
7.86 3.8
1422.2
S2
139 13
6
141
S3
0 .27
0.76 90
1415.6
2 137
S4
140 6 5 .66
1375.4 142 1390
S3 5.6
8 1424.52 .7
S6
141 6
S4
S1
9
S5
1395.12 1413.8
1386.11 1395
.12
1375 1425
1375.48
K13
6 1409.26
K1
1400
K7
1417.68
S3 1390.6
1383.07
1400
S4
K4
S5
S1
1423.10 1377.86
K10
S2
S6
S4
S3
142 1404.8
.90 3.10 8
1376 32
S6
140
2.
S5
S2
9.1 6.90
140 1409
1409
138 0
2
S4 46 137 142
5 1382.3
.26
.146
14
140
S3
S5
14
.07
4.8
S1
15
8 142 13
83
S6 S2
4.52 .89
14
1
.66
13
.76
.86
14
1
14
1
14
90
S1
77
00
6.1
14 6
8
15
3.8
8
13
17
13
.48
22 0.6
9
6.1
.76
.66
5
.12
5.4
1409
13
5
.68
.12
.27 139
5
7
.86
138
95
3.07
137
13
.26
137
142
1390
139
13
1400
140
141
138
5
0
1377
1422.2
3.10
7
1390.66
7.68
137
1425
1382.32
1424.52
1376.90
1404.88
1409.146
137
6
1390.6
138
6
5
137
6
1400
.26
1395.12
5
1390
.14
2.3
1423.10
.27
5.6
13
.88
1417.68
9
2
140
142
1377.86
2
138
1376.90
1375.48
.76
.89
1382.3
86
4.52
04
1409
4.8
13
3.8
2
141
46
140
13
13
142
14
.52
.11
.1
138
3.07
75
13
.27
142
77
139
6
14
.66
24
141
140
13
09
83
.26
22
25
.48
14
15
.86
76
0.6
.11
14
09
13
.07
13
14
6
13
14
14
.90
00
75 14
77
S1 90
14 .7
13
.48
.86
139 6
95
137 S6 5.1
S3
5 2
.12
S5
.68
S4
S2
S6
138 1417 7.68 1376
S5
3.10
S1 .10 0
.90
3.07 0
141 138
140
142 1400
140 1390.66 1423
2 .3
S2 2
S4
S3
S1
1386.1
S2
1 1404.88
S4
S5
S6
S5
1376.90 1422.27 1390.76
S3
K8
K14
1409.146 1375
K5
1425
1409.146 1415.66
1390.6
1382.32 S6 6
1390.76
1409.26
142
K2
K16
4.52 1404.88 1
K11
1424.52 8
S2
1413.89 1386.1
S1
1375.4
S4
S3 142
9
1413.8 1395.12
S1
3.07 5
138
140
0
140
140 0 .86
141 3.07 1422.2 7
7 7.86
7
S5
S4 9.26 138 137 140
.68 0
S6
137 S4
S2 1415.6
1
S6
6
S3
6.1 8 2
S2
S3
138 5.4 S5 9 5.1 14
14
6
0
137 13 04
23
14
0.7
6.9
14 14 .88
9
S1
7
.32
0.6
14
22
.10
09 17 14
13
13
14 82
09
.27
141
.26 .68 13 23
139
00 .14
142
2
75 6
.66 .10
3.8
13
141
1400
9
1415.6
1409
0.76
90
.12
4.52
6
.90
142
5.6
1413.8
6
13
6
142
9
142
1400
139
1382.3
1409.26
1404.8
1417
.146
5
1375.48
137
1395
.6
137
1377.86
1386.11
8
4.52
1423.10
1383.07
1422.27
7
137
.10
1425
139
3
1383.07
1386.11
6.90
1424.52
1409.26
.68
13
1413.8
0.76
142
1400
1422.2
1377
1382.32
75
139
13
1415.6
1409.146
.68
13
1404.88
1390.66
417
13
.86
13
1
.1 00
140
17
90
75.
5.1
95
.66
2
75 14
23
14
48
.1
.76
15
2
14
00
139 .27 14
137
14 0.6 22 .89
138
6 13
5.4
14
6.1 8
8 14
1
S3
4.8 S1 4.52
S5
S6 140
46
1377
142 .26
.1
S4 138 9.26 .86
140
1409
137
S1 46 S2 1409 5
S4
6
S2
3.07
5
142
.90 9.1 1382.3 142
S5 140 2 8
1404.8
S3 1413.89
4.52
142
S6 1415.66 1382.32
K3
1400
S1
S4
K9
1376.90
1400
1422.27
K6
S2 S3
1383.07
S6
1417.68
K12
1377.86
K15
1423.10
2
S5
.1
1395
1386.11 1375.48
S3
.76
S2 1390.66
S6
1423
1390
.66
1417 .10
142 90
S4 .68
2.2 141 13
5
7 S5
S1
0.76
S3 5.6 1 137 2
5 6 5.1
S5
139 137
6.1
S2
14 8 .48 139
S6
24 S4 141 13 75 14
14
.32
.86
.52 3.8 13 00
9
14
09
S1
.07
77
14
82
25
14 83 14
14
.14
14
13
00
13
140
0
6
25 13 24
09
04
142
6.9
4.8
140
.52
2
.26
.90
8
.88
9
37
140
7.86
1
2.3
0
.27
140
.14
6
137
1
138
1376
1423
3.07
1375.4
9.26
1417.68
140
.10
1395.12
0
1390.6
138
1413.89
1415.66
1375
1386.1
1390.76
Page 87 of 110
MANDAVELI TUNNELS
APPENDIX F – WALKWAY AND BRACKET DETAILS
Page 88 of 110
Page 89 of 110
Page 90 of 110
Page 91 of 110
Page 92 of 110
Page 93 of 110
Page 94 of 110
Original Drawing Size A2
V3 V3
HAND RAIL
8
V1 120
V2
100
Ø6 Ø6
35 35
0 0
V2 04 ISA 80x80x6
01
Ø5 Ø5
293
569 Lg.
45°
800 800 4
38
03
(TYP)
65
7
4
42
0
4 12 ISA 50x50x6
02
399 Lg.
22.5°
22.5°
V1
500
500
LHS SIDE RHS SIDE 569
LHS SIDE
500
500
RHS SIDE
BRACKET @ BRACKET @ DETAIL - D1

1.4m (or) 2.8m 1.4m (or) 2.8m (SCALE-1:10)
INTERVAL INTERVAL
D1 D1
2070
1987
450 58 450 58
585
100
(TYP) 6
2068
100
2068
V3 V3
TYPICAL SECTION FOR STEEL WALKWAY INSIDE TBM TUNNEL TYPICAL SECTION FOR STEEL WALKWAY INSIDE TBM TUNNEL
(SCALE-1:40) (Y-SWITCH LOCATION) 04 #
(SCALE-1:40)
(TYP)
4
650
01
6
(TYP) 02
100
03
CL OF TUNNEL
LHS SIDE 130 04

03
PLT. 8 THK.
KEY SEGMENT 03
100x650
(TYP)
62
WALKWAY
°
6
5800
6350
BRACKET (TYP)
0
(TYP)
10
TBM MOVING
45
PLT. 8 THK. 4
22.5°
04 R1 8
DIRECTION 100x130 5 VIEW V1-V1
(SCALE-1:10)
5
R4
SEGMENT (TYP)
VIEW V2-V2
DETAIL OF ITEM NO: 04
PLATE 8MM THK LEG FIXED WITH
(SCALE-1:5)
SEGMENT CURVED BOLT
1400 2800 1400 1400 2800 1400 2800 (SCALE-1:5)
VIEW V3-V3
(OTHER DETAILS NOT SHOWN FOR CLARITY)
(POSSIBLE BOLTING PATTERNS BASED ON RING ORIENTATION)
(SCALE-1:100)
# ANCHOR PLATE LOCATION SHALL BE IN THE OPPOSITE DIRECTION FOR

TBM'S WITH WALKWAY ON RHS SIDE OF TUNNEL DRIVE.
SPECIAL NOTES:-
LIVE LOAD CONSIDERED ON WALKWAY = 150KG/m2
REVISIONS GENERAL CONSULTANT CLIENT CONTRACTOR DETAIL DESIGN CONSULTANT CLIENT

NOTES CHENNAI METRO RAIL LIMITED.
ADMINISTRATIVE BUILDING, CMRL DEPOT, POONAMALLEE HIGH ROAD, KOYAMBEDU, CHENNAI - 600107 (INDIA)
1. ALL DIMENSIONS ARE IN MILLIMETRES L&T CONSTRUCTION L&T EDRC - CMPC DRAWING TITLE Issue Approved
HEAVY CIVIL INFRA Record for Issue
Notification :
2. ALL WELDS ARE 4mm FILLET WELD U.O.S
A B C
TUNNEL WALKWAY Preliminary Design
3. GRADE OF ALL STRUCTURAL STEEL SHALL CONFIRM TO IS As noted in the DSR No. -------------------------- dated ----------------
PROJECT TITLE
BRACKET
2062-2011 (GRADE E250 A OR B) A : Objection A complete resubmission is required.
B : No Objection with comments.
CHENNAI METRO RAIL PROJECT - PHASE 2 Definitive Design
4. WELDING PROCEDURES SHALL CONFIRM TO LATEST C : Notice of No objection. CORRIDOR-3, CONTRACT - CP31/TU02 CRD
C 04-07-22 SLB RDV DLH/ TVK CHECKED BY REVIEWED BY APPROVED BY DATE
FOR CLIENT SUBMISSION
IS CODES (IS816 AND IS1024) / AWS/ASME TMS CONSTRUCTION TWIN BORED TUNNELS FROM KELLYS STATION TO TARAMANI ROAD JN STATION AND
CONSTRUCTION OF DIAPHRAGM WALLS OF STATION BOX AND ENTRY / EXIT STRUCTURES OF CHETPET METRO, ROYAPETTAH GOVT. HOSPITAL,
CORRIDOR & PACKAGE DRAWING NUMBER REV GFC
B 13-06-22 SLB RDV DLH/ TVK
REVISED AS PER SITE COMMENTS
A 11-05-22 FOR APPROVAL
TMS
DLH/
BY CONTRACTOR
THIRUVANMIYUR METRO STATIONS AND PART DIAPHRAGM WALL OF GREENWAYS ROAD METRO STATION, INCLUDING LAUNCHING AND
RETRIEVAL SHAFTS AS REQUIRED IN THE ABOVE STATIONS.
CP31-TU02 O21447-TEM-FB-6068 C As Built
SLB RDV TVK DESIGNED BY CHECKED BY APPROVED BY DATE
TMS
CAD FILE
REV. DATE DESCRIPTION DRAWN DESIGN CHKD APP. R.DIVYA LINGESH D / T.VIJAYA KUMAR 11-05-2022 This document should not be relied on or used in circumstances other than those for which it was originally prepared and for which L&T Construction was O21447-TEM-FB-6068 (REV-C) SCALE 1:20
T.MOHANASUNDARAM commisioned. L&T construction accepts no responsibility for this document to any other party other than the person by whom it was commisioned.
Page 95 of 110
S5 Original Drawing Size A2
452
TOP PIPE
NB 32 PIPE (M) NB 32 PIPE (M) 07 1 450 1
(TYP) 07 (TYP) (TYP)
3 2800 Lg. 3 3 63 103
03 20
(NTS)
(CLEAR) (TYP)
500
HANDRAIL POST
1
06 06
* * NB 32 PIPE (M) 06
40
NB 25 PIPE (M)
20
(TYP) 08
3 2800 Lg. MID PIPE
NB 25 PIPE (M) 08 (TYP)
1 20(80)20 (TYP) 02
(NTS)
1000
(TYP) 2
1 (80)20(80)
SECTION S1-S1 SHS 20x20x2.2
04
NB 32 PIPE (M) (TYP) (TYP) 450 Lg.
(SCALE-1:5)
06
1158 Lg.
* 3 3
452
(NTS)
500
PLT. 3 THK. 1 450 1
05 09 05 05 05
150x2800 03 63 02 103 20
M10x65mm BOLT WITH
S4
09 (CLEAR) (TYP) (TYP)
1
NUT & DOUBLE WASHER
150
(TYP) 14mm (PLAIN)
40
3
75
20
40
3 (TYP)
(TYP) 2
2800 S5 3 1400
5 60 165 60
NTS NTS SHS 40x40x1.6 (TYP)
01 2
VIEW V1-V1 450 Lg. 3 Nos. 14Ø HOLE FOR
SECTION S5-S5 S4
(SCALE-1:10) M12 BOLTS 10.9 GRADE
(SCALE-1:10)
S3 SECTION S2-S2 (TYP)
2800
(SCALE-1:5)
1 2798 1
(GAP.) (GAP.) ERECTED PANEL
237 5x465=2325
1
02 PANEL TO BE ERECTED
103
3 Nos. 14Ø HOLE FOR #

452
450
103
01 M12 BOLTS 10.9 GRADE

(TYP)
SECTION S4-S4
103
(SCALE-1:5)
NOTES
71
03 1. ALL DIMENSIONS ARE IN MILLIMETRES

1
1.0mm M.S PERFORATED DETAIL OF ITEM NO : 03 2. ALL WELDS ARE 4mm FILLET WELD U.O.S
1
03
482x2798 S3 (SCALE-1:10) 20mm HOLE (TYP)
3. GRADE OF ALL STRUCTURAL STEEL SHALL CONFIRM TO IS
15
2062-2011 (GRADE E250 A OR B)
2800 1400 2800 1 450 1 4. ALL BOLTS SHALL BE 10.9 GRADE AND CONFIRM TO REQUIREMENT
(SUPPORTING BRACKET C/C) WITH LATEST REAFFIRMED EDITION OF IS1367 (PART-2) (OR) ISO 4759 & IS 4000.
452 5. WELDING PROCEDURES SHALL CONFIRM TO LATEST
20 450 465 465 465 465 450 20 450 465 465 465 465 450 20
IS CODES (IS816 AND IS1024) / AWS/ASME
6. GRADE OF HOLLOW STRUCTURAL STEEL SHALL BE Yst 240.
SECTION S3-S3 7. ENSURE THAT ALL THE BOLTS SHALL BE PROVIDED WITH NUTS &
(SCALE-1:10) WASHER,TIGHTNESS SHALL BE ENSURED.
# (TYP) 04 (TYP) 01 SHS 40x40x1.6 # 2mm GAP. (TYP) 04 01 (TYP) 02 # 2mm GAP.
02
2798 Lg.
VIEW V2-V2
(SCALE-1:10)
S1 (TYP) 02 (TYP) 04 03 S2 S1 (TYP) 02 S2

(TYP) 01 (TYP) 04 (TYP) 01 03
V2 V2
(TYP)
81
V1 S1 S2 S1 S2 V1
449 465 465 465 465 449 449 465 465 465 465 450
2800 1400 2800

(SUPPORTING BRACKET C/C) (SUPPORTING BRACKET C/C) (SUPPORTING BRACKET C/C)
21 2758 2759 20
# ALL PANELS SHALL BE BOLT CONNECTED AT BOTH
21 21
SPECIAL NOTES:- ENDS BEFORE ANY APPLICATION OF ANY LOAD.
WALKWAY PLAN
LIVE LOAD CONSIDERED ON WALKWAY = 150KG/m2 VERTICAL POST SHALL BE PROVIDED AT EVERY BRACKET LOCATION
(SCALE-1:10)
*
CHENNAI METRO RAIL LIMITED.
L&T CONSTRUCTION L&T EDRC - CMPC DRAWING TITLE Issue Approved

Notification :
TUNNEL WALKWAY
A B C Preliminary Design
As noted in the DSR No. -------------------------- dated ----------------
PROJECT TITLE PANEL & HAND RAIL
A : Objection A complete resubmission is required. CHENNAI METRO RAIL PROJECT - PHASE 2 Definitive Design
C : Notice of No objection. CORRIDOR-3, CONTRACT - CP31/TU02 CRD
CHECKED BY REVIEWED BY APPROVED BY DATE
CONSTRUCTION TWIN BORED TUNNELS FROM KELLYS STATION TO TARAMANI ROAD JN STATION AND CORRIDOR & PACKAGE DRAWING NUMBER REV
CONSTRUCTION OF DIAPHRAGM WALLS OF STATION BOX AND ENTRY / EXIT STRUCTURES OF CHETPET METRO, ROYAPETTAH GOVT. HOSPITAL, GFC
B 04-07-22 SLB RDV DLH/ TVK
FOR CLIENT SUBMISSION
A 11-05-22
TMS
DLH/
BY CONTRACTOR
CP31-TU02 O21447-TEM-FB-6069 B As Built
FOR APPROVAL SLB RDV TVK DESIGNED BY CHECKED BY APPROVED BY DATE
TMS
CAD FILE
REV. DATE DESCRIPTION DRAWN DESIGN CHKD APP. R.DIVYA LINGESH D / T.VIJAYA KUMAR 11-05-2022 This document should not be relied on or used in circumstances other than those for which it was originally prepared and for which L&T Construction was O21447-TEM-FB-6069 (REV-B) SCALE 1:20
Page 96 of 110
6
(TYP)
Ø25 mm SODIUM Original Drawing Size A2
50/60 SILICATE
50
01 V1
02
6
(TYP)
138
Ø75 mm GROUT
138
°
62
55
10
V2
45
100
0
8 130 02
Ø5
Ø75 mm GROUT
80
Ø
# 02
63
0
50
V2
SEGMENT (TYP) Ø100 mm AIR
VIEW V2-V2
Ø100 mm AIR
PLATE 8MM THK LEG FIXED WITH 01
55
SEGMENT CURVED BOLT
(SCALE-1:5) Ø125 mm WATER
15 *
0
5
15
LT CABLE ZONE D3
(LIGHT & LT HANGER) (TYP) 3
75
Ø125 mm WATER
1475
3
14
FIXED ALTERNATIVELY
(TYPE -1 & TYPE - 2) RHS SIDE
22.5°
* Ø125 mm DEWATERING
V1
8
01
PLT. 8 THK.
50x1475
70
LHS SIDE
22.5°
D2
130
18
(HT CABLE ZONE) 8 Ø REBAR 5 0 01 03
0
1
R15
* (TYP)
04 05
6
(TYP)
PLT. 8 THK.
02
100x130
5
8 Ø REBAR
R4
DETAIL - D1 (TYP)
(SCALE-1:10) VIEW V1-V1
(PIPE ZONE) DETAIL OF ITEM NO: 02
(SCALE-1:5) (CABLE ZONE)
(SCALE-1:10)
02
D1 (PIPE ZONE) 03 3 (TYP)
*
75 CLEARANCE 6 3
(TYP) 60
TO LOCO WHEELS V3 02
75
#
75
60
460
TYPICAL SECTION FOR UTILITY SUPPORTING ARRANGEMENT R
(Y-SWITCH LOCATION) V2 V2
460
(SCALE-1:30)
60 (TYP)
2
05 R
V2 V2 6 # V3
(TYP)
V2 V2
75
8 Ø REBAR
02 V4 02
0
5a PLT. 8 THK.
75
R6
3 (TYP) 2mm PVC INSULATION (TYP) 8 03
6 3 60x460
V4 (TYP) 8 Ø ROADS, 2mm PVC
60 105
DETAIL - D2 VIEW V3-V3 INSULATION (TYP)
PLT. 4 THK.
75
02 04
75
8 Ø REBAR 2mm PVC (SCALE-1:10) (SCALE-1:10)

60x120
INSULATION (TYP) 8 Ø REBAR
532
533
R
300
2mm PVC
300
30 2
(TYP) 120 120
02 INSULATION (TYP)
#
R3
R 0 (TYP) 3 04
30 3
PLT. 8 THK.
5a 8 Ø REBAR, 2mm PVC PLT. 8 THK.
V4 60x300 R3 05
8 60 INSULATION (TYP) 60x532
0
8 Ø REBAR, 2mm PVC 60
DETAIL - D3 VIEW V4-V4 V4 INSULATION (TYP)
(TYPE-1) (SCALE-1:10) DETAIL - D3 VIEW V4-V4
(SCALE-1:10) (TYPE-2) (SCALE-1:10)
(SCALE-1:10)
* SPECIAL NOTES:-
1. BRACKET SHALL BE PLACED AT EVERY 1.4m OR 2.8m BASED # ANCHOR PLATE LOCATION SHALL BE IN THE OPPOSITE DIRECTION FOR
ON TUNNEL RING ORIENTATION TBM'S WITH UTILITY HANGERS ON LHS SIDE OF TUNNEL DRIVE.
NOTES CHENNAI METRO RAIL LIMITED.
1. ALL DIMENSIONS ARE IN MILLIMETRES L&T CONSTRUCTION L&T EDRC - CMPC DRAWING TITLE Issue Approved
Notification :
2. ALL WELDS ARE 4mm FILLET WELD U.O.S
A B C Preliminary Design
3. GRADE OF ALL STRUCTURAL STEEL SHALL CONFIRM TO IS As noted in the DSR No. -------------------------- dated ----------------
PROJECT TITLE UTILITY HOLDING ARRANGEMENT
2062-2011 (GRADE E250 A OR B) A : Objection A complete resubmission is required.
CHENNAI METRO RAIL PROJECT - PHASE 2 Definitive Design
4. WELDING PROCEDURES SHALL CONFIRM TO LATEST C : Notice of No objection. CORRIDOR-3, CONTRACT - CP31/TU02 CRD
C 04-07-22 FOR CLIENT SUBMISSION DLH/ CHECKED BY REVIEWED BY APPROVED BY DATE
IS CODES (IS816 AND IS1024) / AWS/ASME SLB RDV
TMS
TVK CONSTRUCTION TWIN BORED TUNNELS FROM KELLYS STATION TO TARAMANI ROAD JN STATION AND CORRIDOR & PACKAGE DRAWING NUMBER REV GFC
DLH/ CONSTRUCTION OF DIAPHRAGM WALLS OF STATION BOX AND ENTRY / EXIT STRUCTURES OF CHETPET METRO, ROYAPETTAH GOVT. HOSPITAL,
B 13-06-22 REVISED AS PER SITE COMMENTS SLB RDV TVK
A 11-05-22 FOR APPROVAL

TMS
DLH/
BY CONTRACTOR
CP31-TU02 O21447-TEM-FB-6070 C As Built
SLB RDV TVK DESIGNED BY CHECKED BY APPROVED BY DATE
TMS
CAD FILE
REV. DATE DESCRIPTION DRAWN DESIGN CHKD APP. R.DIVYA LINGESH D / T.VIJAYA KUMAR 11-05-2022 This document should not be relied on or used in circumstances other than those for which it was originally prepared and for which L&T Construction was O21447-TEM-FB-6070 (REV-C) SCALE 1:20
Page 97 of 110
MANDAVELI TUNNELS
APPENDIX G – CUTTERHEAD POSITION DRAWING
Page 98 of 110
CHAINAGE)
NE
TRO (SHIFTED
P LINE
1
00
KELLYS
25
G
CHENNAI METRO RAIL LIMITED.
of 110
2
00
25
21038.577 21039.779
Page 99
-8 -8 G
GREENWAYS TO ADYAR JN
-7 -7
INITIAL DRIVE FINISHED
3
UPLINE TBM POSITION
-6 -6
00
25
11.050
-5
-4 4 G
00
-3
1 25
-2 -0 5 G
IE 00
0.150
21049.627 -1 21049.455 -1 J- 25
21050.627
1
- AD G
0.850
6R
Tailskin From Outer Wall 10.07
2 6
0.72
CORRIDOR & PACKAGE
9.266 3 S0G0 1 00
CP31-TU02
25 -0 G25
DRAWING TITLE
1.5M DEPTH
4
SINK HOLE
02 G SP
14.55
3 5
02 6 E-0 W-
5
J-
CLIENT
P- -I V -01 AD
-S 7 J J- VW R- 01
DJ AD AD J- G
-A R- 8 - 9 08 D 7 S 250
R 00 0 00 1.0010
CONSTRUCTION OF DIAPHRAGM WALLS OF STATION BOX AND ENTRY / EXIT STRUCTURES OF CHETPET METRO, ROYAPETTAH GOVT. HOSPITAL,
A
R SG 9SG 25 25 R- U
SG 1.50 10 G G SG G
25
11
BLOWOUT
01
0.76
12 2
HOLE
0 -0
1 01 1302 0.83 IE X-
2 01 25 X- J- J-
R
25 -R 14
HO LE
4 3 01 G D
AD
01 J A 15
OU T
25 G R-
15
01 AD 16 R-
BLOW
5 25 25 G -0
3
01 G R- S G G P
CONSTRUCTION TWIN BORED TUNNELS FROM KELLYS STATION TO TARAMANI ROAD JN STATION AND
L&T CONSTRUCTION
G S
25 SG
17
-S
G 18 DJ 6 6A
-A 01
01
19
R
25 25
CHENNAI METRO RAIL PROJECT - PHASE 2
27
20 20
8 7 SG G G
50 21 1B 01 01
00 25
CORRIDOR-3, CONTRACT - CP31/TU02
02
6 5 22
5 9 25 G
25 02 23 U2 01 G
G 25 24 25
G G RETRIEVAL SHAFTS AS REQUIRED IN THE ABOVE STATIONS.
25 25
E
26
27 0
3 28 2
2
4 02 0 1 A 04
02 25 2 02
1 292
5
00 ST
25 G 02 25
G
25 O
G 25 G
30
U 30
4 G 31
-0
CLIENT CONTRACTOR
32
SP
PROJECT TITLE
J- 33
AD 34
R- 21+100 35 35 1
SG 36
37
A
21+100
O
ST
04
TS
38 20
02 50
C
21+103.221
39 0 2
25
NKAB
40 G 40
U 09
1A
41
50
02 P2
B
42 3
25 -0 10 0
GENERAL CONSULTANT
43
G R
X 50 04
44
J- P2 ST
03 AD 45
KELLYS TO THARAMANI
A
45 O
46 50
2 R-
U
47 SG 2
01
Date: 15062023
48 5 11
P2 50
Time:08.20am
49
1C 04 P2
50 00 X- 50
51 25 R
14
U J- 13
52
-A
D 50 50
53 R P2 P2
54 SG
04
108.41
55 0 5 55
6 56 25 01
-0 57
U 25
SP P 5
J- 58 33 32 3 0 00 29 8
AD 35 59 50 50 1 50 25 0 02
R- 0 2 2 03 2 U 25 25
25 60 G G
25 G 60 G
SG
E
G G 5 G
SC
4 61
03 -0
SP
62
25 63 J-
G
0 03
9
25
03
8
25
03
7
G
2 503
6 64
65
66 SG
R-
AD
65 20
21+138.221
04 25 G G 21+146.139 67 05 06 50
25 G
68 X- 250 P2
G
69 J-
R U
7 0 01
AD 16 00 25 21
TS 70
00
7
R- 50 25 S 70 50
P2
REVISIONS
P2
IV
SG U
71
72
73 00
6
IV
23
Traffic Sign Pole

75 005 75 50
Signal Pole
Water Tap
17 8 2
4IV 50 00 P 002 24
02 2
04 004 3 2 1
25
P2
1
25 50 22
01 01 00 00 00
50 21158.19 IV IV 25 IV IV IV IV U
P2 3
G S P2250
01 2 P
01 04 F
8
IV
80IV00 80 43 5
50 25
0
19 2 12 E
P2 G 50
G 5 0 2 1
08 5 P2 B2 01 04
04 5
Telephone Post
07
9
03 50 25
00
B2 25 3
G 5 00
OFC Stone
50
IV
50 P2 G 2G 06
85 S2
P2 18 85 01 S2 25
25
0
50 25 50
0
01 05 S
04 IV
P2 B P2 50
50 S2
P2 4
00
90 90 1 0 25 26
Manhole Hole
S 50
Name Board
50
Row Stone
9
S2
2 27 P2
Statue
Pylon
50
21+181.139 50
P2 28 P2
50
9 P2 30
SC 95 95 500 50
S2 P28
Hectometer Stone
9 0
05
0
04 50
Transformer
Hand Pump
S2
Lamp Post
25 25
G G
100 10047 6
04 1
8 0 32
04 25 25 3
G 250 50
25 G
P P2
G
06 07
50 50
Electrical Jn. Box

105 105
Electrical Post
P2 P2
21+200
Bore Well
21+200
Gate
Flag
110 110
Cross Road Edge

Main Road Edge
09 10
CCTV Camera
0 0
Foot Path
25 25
Drain
D
U U
115 115
THARAMANI
LEGEND:
120 120
MANDAVELI TUNNELS
APPENDIX H – PROCEDURE FOR REPLACING AND CALIBRATION

OF EPB SENSORS
Page 100 of 110
E AR TH P RE S S U RE S E NS O R S
MAI NTE NA NCE
8.3 Exchange of earth pressure sensors

8.3.1 Earth pressure sensors in the bulkhead/shield
Requirement:
Tunnelling stop
Assembly screws, lock nuts and new earth pressure sensors are ready
for use.
Procedure
1. Release and remove sensor connection.
Figure VIII - 44:
P O S I T IO N DE S CR I P TI O N
1 Sensor connection socket

Document: 126468-001
VIII - 76 S-1327A CHENNAI METRO VE R S I O N 0 0 1 EDITION 07/2022
Page 101 of 110

E AR TH P R ES S U RE S E NS O R S
MAI NTE NAN CE
2. Screw the lock nuts onto the assembly screws and screw in the
assembly screws.
2 1
Figure VIII - 45:
P O S IT IO N DE S C RI P TIO N
1 Assembly screws
2 Lock nuts
DOCUMENT: 126468-001
EDITION 07/2022 VE R S I O N 0 0 1 S-1327A CHENNAI METRO VIII - 77
Page 102 of 110

MAI NTE NA NCE
3. Release and remove the retaining screws.
Figure VIII - 46:
1 Retaining screws
Page 103 of 110

MAI NTE NAN CE
4. Slowly and evenly screw out the lock nuts. In doing so, pull out the earth
pressure sensor together with the reception tube until it hits the stop.
Figure VIII - 47:
1 Reception tube
Page 104 of 110

MAI NTE NA NCE
5. Release retaining screws of the slider plate slightly so that the slider
plate can be moved.
6. In order to close the opening, close the slider plate to the stop.
7. Retighten retaining screws of the slider plate.
Figure VIII - 48:
1 Slider plate
2 Retaining screws of the slider plate
8. Release and remove assembly screws.

9. Remove earth pressure sensor with retaining tube.
10.Clean the contact surface.
11.Exchange ring if it is damaged.
12.Remove old earth pressure sensor from retaining tube and insert new
earth pressure sensor.

13.Insert retaining pipe with earth pressure sensor. Make sure not to
damage the O-ring in the process.
14.Screw in the assembly screws and secure the retaining tube with the
lock nuts.
Page 105 of 110

MAI NTE NAN CE
Installation is carried out in reverse order.

Tighten with the specified torque!
Page 106 of 110

MAI NTE NA NCE
8.3.2 Earth pressure sensor at the screw conveyor
Requirement:
Tunnelling stop
New earth pressure sensors ready for use
Procedure
1. Release and remove sensor connection.
Figure VIII - 49:
1 Sensor connection socket

Page 107 of 110

MAI NTE NAN CE
2. Release and remove the retaining screws.
1
Figure VIII - 50:
1 Retaining screws
Page 108 of 110

MAI NTE NA NCE
3. Slowly and evenly screw out the lock nuts. In doing so, pull out the earth
pressure sensor together with the reception tube until it hits the stop.
Figure VIII - 51:
1 Reception tube
4. Release retaining screws of the slider plate slightly so that the slider
plate can be moved.
5. In order to close the opening, close the slider plate to the stop.
6. Retighten retaining screws of the slider plate.
7. Release and remove assembly screws.
8. Remove earth pressure sensor with retaining tube.
9. Clean the contact surface.
10.Exchange ring if it is damaged.
11.Remove old earth pressure sensor from retaining tube and insert new
earth pressure sensor.

12.Insert retaining pipe with earth pressure sensor. Make sure not to
damage the O-ring in the process.
13.Screw in the assembly screws and secure the retaining tube with the
lock nuts.
Page 109 of 110

MAI NTE NAN CE
Installation is carried out in reverse order.

Tighten with the specified torque!
Page 110 of 110

Method Statement For TBM Main Drive From Greenways To Adyar Junction & Greenways To Mandaveli Tunnels

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Method Statement For TBM Main Drive From Greenways To Adyar Junction & Greenways To Mandaveli Tunnels

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Construction of twelve (12) km Twin Bored tunnels from Kellys station

to Taramani road Jn station and construction of Diaphragm walls of

METHOD STATEMENT FOR TBM MAIN DRIVE FROM

CLIENT: CHENNAI METRO RAIL LIMITED

GENERAL CONSULTANTS: NKAB

LARSEN & TOUBRO LIMITED

5. DEFINITIONS & ABBREVIATIONS:

Project Manager  Shall be responsible for overall progress of The Project.

Chief Tunnel  Shall report to the Project Manager

Safety Engineer  Shall report to Chief OHS&E Manager.

7. EQUIPMENT & RESOURCES:

SR. EQUIPMENT QUANTITY

8.1 Gantry Crane:

8.2 Ventilation System:

8.3 Electrical Power Supply:

8.4 Grout Plant:

8.5 Cooling Water Supply Setup:

8.6 Compressor & Receiver Tank:

8.7 Muck Pit:

8.8 Medical Lock:

8.9 Workshop Establishment:

8.10 Storage of TBM Consumables:

8.11 Wheel Wash:

8.12 Sedimentation Tank and ETP (Effluent Treatment Plant):

8.13 Service Utilities:

9. SHAFT SETUP AND EQUIPMENT:

9.2 Segment Car:

9.3 Traverser Set Up:

9.4 Muck Car:

Step1-Volume Approach (Back-Analyzed Bulking Factor)

Figure2: Scale to measure density of the excavated soil

Derive Correction factor of spillage (𝑥) per ring:

Revised Density = (𝑥 ∗ Measured Excavated Weight − Additives weight)

Derive OER% with the above revised density:

OER = (𝑥 ∗ Measured Weight − Additives weight)

Step-3 Conveyor Belt Scaling System:

General /Technical Specification

Figure 3: Reference Image of Y-Switch Figure 4: Reference Image of Manchester

9.6 Manchester Gate:

10. TBM SETUP

a) Principal of EPB TBMs:

10.2 Additive Injection Facility:

10.3 Backfill Grouting Equipment:

10.3.1 Primary Grouting:

10.4 Cooling Water:

10.6 Waste Water Pipeline:

DEWATERING PUMP DETAILS

Figure 5: Centrifugal Slurry Pump

10.7 Consumable Material:

10.8 Walkway and Cable/Pipe Bracket in Tunnel:

10.9 Tunnel Illumination:

10.10 Fresh Air Installation:

Figure 6: Fresh air set up on Gantry

10.10.2Ventilation Duct Installation:

Figure 7: VELCRO Joint ventilation

11. WORK PROCEDURE FOR CONVERSION OF INITIAL DRIVE TO MAIN DRIVE:

11.2 Conversion of Initial Drive to Main Drive

11.3 Reaction Frame Dismantling

11.4 Temporary Rings Dismantle:

11.5 Umbilical Removal:

11.6 Cradle Dismantle:

12. TBM BACKUP LOWERING AND ASSEMBLING:

13. INSPECTION BEFORE MAIN DRIVE: