PRESENTED BY :AMIT KUMAR (1303200018)

ANIMESH RANJAN (1303200023)

CIVIL DEPARTMENT, 4TH YEARABES ENGINEERING COLLEGE

CONSTRUCTION OF METRO STATION

CONTENT: INTRODUCTION TO PROJECT CC-27 TENDERING FOR THE PROJECT BORE HOLE RESULTS VASANT VIHAR STRUCTURE LAY OUT BOTTOM-UP CONSTRUCTION EXCAVATION/SOIL STABILIZATION CONCRETING OPERATION& REPAIR WATERPROOFING OF STRUCTURE

PROJECT NAME-DESIGN AND CONSTRUCTION OF TUNNEL & UNDERGROUND METRO STATIONS FROM JANAKPURI WEST TO BOTANICAL GARDEN(CC-27)

KEY DETAILS

COST OF PROJECT(App) INR 1435 CRORESCOMPLETION PERIOD(Expected)

42 MONTHS

TENDER SECURITY AMOUNT INR 14.35 CRORESTENDERING AGENCY DMRCTENDER GIVEN TO L&TQuoted Price & Final Price 1265 CRORES

PROPOSED ROUTE MAP FOR CC-27

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.

BORE HOLE

61

BORE HOLE

35

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 SAMPLE

THE COLLECTED ROCK CORE SAMPLES(VASANT VIHAR SITE) WERE TAKEN AND THE FOLLOWING TESTS WERE CONDUCTED ON THEM-• DENSITY TEST• WATER ABSORPTION& POROSITY• HARDNESS• UNCONFINED COMPRESSION TEST• POINT LOAD INDEX

• VASANT VIHAR-HARD ROCK STRATA (BOTTOM-UP CONSTRUCTION APPROACH)

• HAUZ KHAS - SOFT SOIL STRATA(TOP-BOTTOM CONSTRUCTION APPROACH)

VASANT VIHAR STATION

TOP VIEW – VASANT VIHAR

METHOD OF CONSTRUCTION- BOTTOM UP CONSTRUCTION

EAST SIDE WEST SIDE

ROOF SLAB

CONCOURSE SLAB

BASE SLAB

1

2

3

4

5

6

78

1 BLOCK WORK

2 UPE(UNDER PLATFORM

EXHAUST)

3 OTE(OVER TRACK EXHAUST)

4 PLATFORM SLAB

5 FRESH AIR DUCT(ROOF SLAB)

6 SCUPPER DRAIN(BEHIND BW)

7 FALSE CEILING BELOW

CONCOURSE

8 COLUMN

9 RETAINING WALL

CROSS SECTIONAL VIEW VASANT VIHAR

9

BLOCK WORK INFRONT OF RETAINING WALL

Dimension of Block– 400*200*200Mortar-Cement sand mortar with ratio 1:4Block Strength- 7.5 N/mm2 MIX –M15Thickness of the bond-10mmJoint Type-Basic English Bond(1 block thick)

CONCOURSE SLAB

ROOF SLAB

BLOCK WORK IN FRONT OF

RETAINING WALLRETAINING

WALL

INITIAL LAYER OF BLOCK WORK

UPE(UNDER PLATFORM EXHAUST)

BASE SLAB

UPE CUTOUT

PLATFORM SLAB

UNDER PLATFROM EXHAUST

(UNDER PLATFROM EXHAUST ) are basically cut outs provided below the platform slab

OTE(OVER TRACK EXHAUST)

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

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.

• 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

VASANT VIHAR STATION

Area-33,706 sqm

HAUZ KHAS STATION

Area- 15,533.69sqm

BOTTOM UP CONSTRUCTION

METHOD(VASANT VIHAR)BOTTOM UP CONSTRUCTION INVOLVES EXCAVATION & SOIL

STABILIZATION CONSTRUCTION OF BASE

SLAB, CONCOURSE SLAB & ROOF SLAB

CONSTRUCTION OF COLUMNS AND RETAINING WALL. WATERPROOFING OF

STRUCTURE FILLING OPERATIONS

EXCAVATION

• EXCAVATION ON SITE WAS CARRIED OUT ACCORDING TO IS 3764:1992.• EXCAVATION CAN BE DONE IN MANY WAYS DEPENDING ON THE SOIL

PROFILE IN OUR CASE IT WAS DONE USING BREAKERS AND EXCAVATORS. • EXCAVATION VOLUME= 18*265*26=124020 CUM(LUMP SUM)

MACHINERY USED IN EXCAVATION

EXCAVATORS HYDRAULIC 220 EXCAVATOR HYDRAULIC 210 EXCAVATOR HYDRAULIC 215 EXCAVATORBREAKERS HYDRAULIC 340 BREAKER HYDRAULIC 210 BREAKER

HEAD ATTACHMENT FOR BREAKER

SLOPE/SOIL STABILIZATION

SOLDIER PILLING

SHOT CRETING

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

Mix- 1:3 To 1:5 is used depending upon surface . W/c is kept at .30-.35

Plasticizer -6% wt of cement( Glenium sky 777)

Operating temp- 5deg to 30deg Celsius

Mesh Dia- 4mm

Mesh overlap length- 300mm

Min area for applying-300mm*300mm

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 SHORTCRETE ON THE SURFACE . KEEP THE NOZZLE PERPENDICULAR AT A DISTANCE OF 1 TO 1.4 M AWAY FORM SURFACE.Mechanism for Dry- Mix shot creting

CONSTRUCTION OF 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.

CONCRETING OPERATIONS

Earth Compactor Concreting on site

Proper vibration should be provided in order to avoid cold

joints

• 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-M405.25 m below roof level Thickness- 550mm

Formwork & scaffolding for Concourse slab

ROOF SLAB

Sealing Of construction Joints on roof slab

Cut Outs of the roof Slab( Satellite view)

Design Mix M-40Thickness-1.8mRoof level

MIX DESIGN OF CONCRETE M 40 MATERIAL QUANTIY(KG) TYPE

CEMENT 380 ULTRA TECH(OPC 53

GRADE)FLYASH 80 Ashtech:IS3812(NTPC

BADARPUR)AGGREGATE(10mm) 481 KotpultiAGGREGATE(20mm) 666 KotpultiRIVER SAND 677 Yamuna NagarW/C RATIO .35 ADMIXTURE @ .85% 3.91 Glenium

147,Suretec(BASF)W/P CAMPOunds@1%

4.6 MasterPel 760(BASF)

WATER 161 R.O Water at Batching Plant

Following admixture were usedMasterglenium 147 provides Extended workability Providing the ultimate high strength, especially ready.ApplicationAdd to the mixture 80% -90% of the calculated water for the concrete mix and then, with the remaining water masterglenium 147 must be added to the mixture,

Water Proofing Campound used-Masterpel 760 Provides resistance to water penetration either under

hydrostatic pressure or capillary absorption. Imparts integral water tightness to structures.ApplicationMasterPel 760 is a ready-to-use powder which is dispensed into the concrete together with the cement.

M-40 has been used for 3 slabs and retaining walls

MIX DESIGN M-50 MATERIAL

QUANTIY(KG) TYPE

CEMENT 410 ULTRA TECH(OPC 53 GRADE)

MICRO SILICA 22 TAM CEMAGGREGATE(10mm)

457 Kotpulti

AGGREGATE(20mm)

686 Kotpulti

RIVER SAND 765 Yamuna NagarW/C RATIO .37

ADMIXTURE @ .85%

2.16 Glenium sky 777

WATER 151 R.O Water at Batching Plant

M 50 was used for concreting of columns

MasterGlenium SKY 8777 is the super plasticizer based on second generation

polycarboxylic ether polymers, developed using nano-technology. The product has been primarily developed for

applications in high performance ready-mix concrete to facilitate

Capability of delivering high quality concrete at any time to the job site in place.

Tam CemTamCem Micro Silica is composed of silicon dioxide (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.

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

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

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.

Minor Honey Combing

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 M2525(PROVIDED IN TWO COMPONENT A & B)

-WATERPROOFING LAYER

MASTER SEAL M800(PROVIDED IN TWO COMPONENT A & B)

MASTER SEAL M800

A HIGHLY ELASTIC, SOLVENT FREE, ULTRA-FAST CURING, SPRAY APPLIED POLYURETHANE COATING AND IT IS USED IN WATERPROOFING APPLICATIONS. MASTER SEAL M800 IS A SOLVENT FREE, TWO COMPONENT SUBSTANCE. IT IS A HIGHLY REACTIVE TWO COMPONENT MIXTURE USED FOR WATERPROOFING IN TUNNELING AND CUT & COVER STATIONS

USES-

WATERPROOFING COMPOUND WITH A SETTING TIME OF 2-3SECONDS

STEP WISE PROCESS FOR WATERPROOFING.

-SURFACE CONDITIONS

THE RCC SURFACE SHALL BE DRY BEFORE WATERPROOFING.

ANY INGRESS FOR WATER SEEPAGE SHALL BE IDENTIFIED AND TREATED.

CONSTRUCTION JOINT SHALL BE FILLED WITH HIGH PERFORMANCE WATER STOP GROUT OF CRYSTALLINE GROWTH.

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.

Checking moisture before application of primer.

BASF AGGREGATESBASF AGGREGATES are sprinkled over the primer layer

immediately after application of the primer. Aggregates help in roughening the surface of primer for proper

bonding between the primer layer and the waterproofing membrane layer.

Application of the water proofing Layer with 2 component gun

Special 2 Component gun used for applying waterproofing campound

-MasterSeal M800 is available with the Part A coloured white and the Part B colored black.

-This results in a uniform grey colour of the sprayed material thus giving the sprayer a visual control of the quality of the mixing, and machine faults become immediately obvious. If the membrane colour changes, stop spraying and check machine .

-MasterSeal M800 is normally applied at 1.5–2.0kg/SQM this corresponds to a thickness of 1.5–2.0mm.

Ponding test

PROTECTIVE COVERING TO WATERPROOFING MEMBRANE

THANK YOU!!!