A detailed presentation on the

construction of underground Metro

Station
Sarojini Nagar

Under the guidance of

Mr Laksham Hansdash

FEMC PRATIBHA JV DELHI

DMRC CC-18 PROJECT
 CONTENT
Introduction to Project CC-18
Bore Hole Results
Bottom-Up Construction
Excavation/Soil stabilization
Concreting Operation& Repair
Waterproofing of Structure
 Eligibility Criteria for bidding
Work Experience

Financial Standings
a) Liquidity
b) Profitability
c) Net Worth
d) Annual Turnover

Bid Capacity Criteria

Minimum Key staff Requirement

 Bore Hole Data
-Before starting construction Geotechnical data was collected from various
locations along the proposed route to know about soil characteristics.
-Bore Holes were made along the proposed route up to a depth of 30m below
the existing ground level.

Next Image shows the Soil Strata available at various sections of the project.
Based on the samples obtained from the bore holes following tests were conducted
on the samples-

Following tests were then performed on the collected samples-

• Sieve analysis.
• Hydrometer testing
• Moisture content
• Specific gravity
• Dry Density
• Atterbergs limit
• Triaxial shear test(uu, cu, cd)
• Consolidation test
• Direct Shear Test
• Chemical analysis of both soil and water samples
SAROJINI NAGAR
S.NO DESCRIPTION UNIT SCOPE
1 STATION LENGTH M 265
2 WIDTH(BOX) M 21.57
3 Launching Shafts Num 2
4 Entery/Exit Num 4
 1 BLOCK WORK

ROOF SLAB 2 UPE(UNDER PLATFORM EXHAUST)

5 3 OTE(OVER TRACK EXHAUST)

1 9
CONCOURSE SLAB 4 PLATFORM SLAB

7 3 5 FRESH AIR DUCT(ROOF SLAB)

8
4 6 SCUPPER DRAIN(BEHIND BW)

7 FALSE CEILING BELOW CONCOURSE

BASE SLAB
6
2
8 COLUMN

9 RETAINING WALL
BLOCK WORK INFRONT OF RETAINING WALL Dimension of Block– 400*200*200
Mortar-Cement sand mortar with ratio 1:4
Block Strength- 7.5 N/mm2
MIX –M15
ROOF SLAB
Thickness of the bond-10mm
Joint Type-Basic English Bond(1 block thick)

RETAINING WALL
BLOCK WORK IN FRONT
OF RETAINING WALL

INITIAL LAYER OF BLOCK WORK

CONCOURSE SLAB
BLOCK WORK FOR ROOMS

EXAMPLE

U23-SAFETY ROOM
U64-ELECTRICAL APPLIANCE REPAIR
U26-WAITING ROOM ARCHITECTURAL ROOM PLAN(CONCOURSE SLAB)
COOLING MECHANISM OF OTE

OTE LIFTING
FRESH AIR DUCTS
Ventilation systems provided below the roof slab for a constant supply
of fresh air.

ROOF SLAB
SCUPPER DRAIN(BEHIND BLOCK WORK) Water proofing material (Brush Bond Rfx)

DIMENSION- .37m X .3m

PCC M15
Brush bond Rfx Coating for waterproofing of
thickness 1mm

Scupper Drain Behind Block Work

Structural Drawing Scupper Drain
False Ceiling
 Factors that determine the construction approach are

• Soil Profile- As suggested by the geotechnical investigation.

• Site Location-Weather the site is located in an isolated environment or urban dwellings.

• Cost Incurred -Depends

• Surrounding Environment-Weather the Surrounding environment consists of existing

structures and road networks.

• Time Constrain-The total time available for completion of project.

• Availability of Material-The availability of material for filling and construction Activities

to be carried out
Machinery used in excavation HEAD ATTACHMENT FOR
BREAKER

EXCAVATORS
 Hydraulic 220 Excavator
 Hydraulic 210 Excavator
 Hydraulic 215 Excavator
BREAKERS
Hydraulic 340 Breaker
Hydraulic 210 Breaker
Shot creting

 Shot Creting is done according to IS 9012:1978(reaffirmed 2002)

Mesh Dia- 4mm
 Mix- 1:3 To 1:5 is used depending upon surface . W/c is kept at .30-.35
Mesh overlap length- 300mm
 Plasticizer -6% wt of cement( Glenium sky 777)
Min area for applying-300mm*300mm
 Operating temp- 5deg to 30deg Celsius
Procedure For shotcreting 1)Clean the surface off the loose material
and then clean with air compressor.

2) Apply a layer of shortcrete to the surface

and wait for it to cure.

3) Apply the wire mesh on the surface and

bind it to the surface using reinforcements.

4) Now apply the second layer of the

Mechanism for Dry- Mix shot creting shortcrete on the surface . Keep the nozzle
perpendicular at a distance of 1 to 1.4 m
away form surface.
Construction of slabs
Base Slabs

-M40 Grade Concrete was used

-Reinforcement conforming to FE500D shall be used on site.
-Water Stops –PVC water stop will be used to arrest the water leakage (at construction joints)
-Binding wire used for binding reinforcement has a core dia of 1.25mm
-Formwork ply 12mm thick coated with Formwork oil for easy removal of formwork
-Cover blocks should be used depending on clearance that needs to be provided to the reinforcement(50mm Base slab)
-Vibrator of 60mm Dia 4nos.
Mix Design of concrete M 40
Following admixture were used
MATERIAL QUANTIY(KG) TYPE
Masterglenium 147 provides
 Extended workability
 Providing the ultimate high strength, especially ready.
CEMENT 380 ULTRA TECH(OPC 53 GRADE)
Application
FLYASH 80 Ashtech:IS3812(NTPC BADARPUR)
Add to the mixture 80% -90% of the calculated water for
AGGREGATE(10mm) 481 Kotpulti
AGGREGATE(20mm) 666 Kotpulti
the concrete mix and then, with the remaining water
RIVER SAND 677 Yamuna Nagar
masterglenium 147 must be added to the mixture,
W/C RATIO .35
ADMIXTURE @ .85% 3.91 Glenium 147,Suretec(BASF) Water Proofing Campound used-
W/P CAMPOunds@1% 4.6 MasterPel 760(BASF) Masterpel 760
WATER 161 R.O Water at Batching Plant  Provides resistance to water penetration either under
M-40 has been used for 3 slabs and retaining walls hydrostatic pressure or capillary absorption.
 Imparts integral water tightness to structures.
Application
MasterPel 760 is a ready-to-use powder which is
dispensed into the concrete together with the cement.
Concreting Operations

Proper vibration should be provided in order

to avoid cold joints

Earth Compactor Concrete pour sequence

Concreting on site
• After the final set has taken place wet hessian cloth shall be placed and covered by polythene sheet. The
hessian cloth shall be kept permanently damp
• After 24Hours hessian cloth and the polythene sheet shall be removed and the area would be ponded with
water .
• For vertical curing the hessian cloth along with polythene sheet shall secure the surface for at leasdays
before next vertical pouring begins. The hessian cloth should be damp all the time.
Concourse Slab

Concrtete-M40
5.25 m below roof level
Formwork & scaffolding for Concourse slab
Thickness- 550mm
 Reinforcement For concourse slab

Cut outs provided both on concourse and roof slab

 Roof Slab

Cut Outs of the roof Slab( Sattelite view

Sealing Of construction Joints on roof slab

Design Mix M-40

Thickness-1.8m
Roof level
Machinery used for Concreting

Volume-6cum but loaded up to 5-5.5cum.

Rotations –Depend upon distance and Mix

BOOM PLACER

Concrete Bucket Vol 1-1.2cum

CONCRETING THROUGH PIPES
Mix Design M-50
MasterGlenium SKY 8777 -is the super plasticizer based on
MATERIAL QUANTIY(KG) TYPE
second generation polycarboxylic ether polymers,
CEMENT 410 ULTRA TECH(OPC 53 GRADE) developed using nano-technology. The product has been
MICRO SILICA 22 TAM CEM primarily developed for applications in high performance
AGGREGATE(10mm) 457 Kotpulti ready-mix concrete to facilitate
 Capability of delivering high quality concrete at any
AGGREGATE(20mm) 686 Kotpulti
time to the job site in place.Production of concrete with
RIVER SAND 765 Yamuna Nagar
low w/c ratio that meets international guidelines for
W/C RATIO .37 consistency classes (EN 206-1) without loss of
ADMIXTURE @ 2.16 Glenium sky 777 workability.
.85%
TAM CEM
WATER 151 R.O Water at Batching Plant
TamCem Micro Silica is composed of silicon dioxide
M 50 was used for concreting of columns (5i02).Collected from silicon metal and ferrosilicon.
TamCem Micro Silica will react with the Calcium Hydroxide
from the cement, which will form more of the Calcium
Silicate hydrate, increasing the strength of the concrete.
Concrete Repairing
BULGED CONCRETE
Bulged Concrete – Bulging in concrete takes place due to displacement of formwork.

Surface preparation: The bulged area on concrete surface shall be hacked with chisel to
required line, level. All dirt, dust shall be cleaned with brush and water.

Repairing: Hacked area will be patched up with cement: sand mortar of proportion 1:4.
On the completion of patch up work, the exposed area shall be thoroughly cured.

Grout Loss Exposed aggregate surface created by exit of cement slurry/grout mortar from
the gaps of formwork due to excessive vibration, unsealed joint of formwork
during pouring of concrete.
Repair
-The concrete surface is cleaned and free from dust/oil/grease etc by using
broom or wire mesh by scrubbing vigorously.
-After removal of loose particles surface is washed with water.
-Patch-up is done at cleaned surface with non-shrink Grout conbextra GP2
Minor Honey Combing
It is due segregation of aggregates and mortar into the concrete.
Honeycomb creates in structures due to mainly improper
compaction in terms of excessive/insufficient vibration at the
time of placing.

Major Honeycombing

Repairing Involves-
The loose aggregate that are exposed shall be removed by
gently tapping on it. After removal of all loose aggregate,
dust, dirt etc. by wire/Soft brush then surface will be
cleaned with Water. Patchup is done by using conbextra
GP2/Rendroc which is mixed with cement and then the
paste is applied.
Waterproofing of Structure
Chemicals used for Waterproofing
-For Priming Purpose
Master Seal M501&502(Provided In two component A & B)
-Waterproofing Layer
Master Seal M800(Provided In two component A & B)

Master Seal M501&502-Master Emaco 2525 is a solvent free, high-performance, versatile epoxy binder that can be used
to produce a range of epoxy resin based mortars.
Used For-
 Structural bonding of new to old concrete
 Production of epoxy resin mortars to grout bolt holes
 Steel bonding
-MIXING
• Application of Primer Involves mixing of component A and B and application on
the surface as shown MIXING OF A & B

-Thin coat of mixed primer (RESIN + HARDNER) on the surface shall be

mechanically & uniformly applied, ensuring continuous film soon after surface
preparation is complete.
-Moisture content in the substrate shall be less than 5 %.
-The drying period of primer depends on the ambient temperature and relative
humidity.
Backfilling Operations
THANK YOU!!!