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IN PLANT TRAINING REPORT

Nikhil Kuriakose

M.Tech, Construction Engineering and

Management

SRM University

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L&T SUCG JV CONSTRUCTION OF

UNDERGROUND STATIONS NEHRU PARK,

KMC, PACHAIAPPA’S COLLEGE AND

ASSOCIATED TUNNELS

IN CHENNAI

Submitted to

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ACKNOWLEDGEMENT

I sincerely thank Mr Johnson K I for his extraordinary interest in our learning

experience, without whose guidance my training would have had little success. I also thank Mr

Sajith for his excellent lecture of Occupational Health and Safety; Mr Ganesh for giving me

critical support and guiding me throughout my implant training; Mr Murugesh for his revealing

lecture on Contracts and Joint Ventures; Mr Rahul, for his exceptional guidance in the work

site.

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AIM

To experience different aspects of civil construction works, especially in planning department.

SCOPE OF THE WORK

NAME OF PROJECT Contract UAA-04 Design & Construction of Underground

Stations at Nehru Park, Kilpauk Medical College & Pachiappa's College &

Associated Tunnels.

CLIENT Chennai Metro Rail Limited

CONTRACTOR Metro Tunneling Chennai – L&T SUCG JV

CONSULTANT General Consultant, M/S Embye Consortium

PROJECT VALUE 930.81 CRORES

SOURCE OF FUNDS

This project is financed through equity participation by the Government of India, the

Government of Tamil Nadu and the Japan International Cooperation Agency (JICA).

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WORK SITE

The project site is located in Chennai, the Capital of Tamil Nadu. Works are in the

centre of Chennai city from Egmore to Shenoy Nagar on Corridor 2, with three underground

stations at Nehru Park, Kilpauk Medical College and Pachaiappa’s College.

PROJECT STARED ON 7th Feb 2011

PROJECT COMPLETES ON 7th April 2015

TIME OF COMPLETION OF PROJECT 1251 days

TOTAL TUNNELLING LENGTH 4070 m

STATION LENGTH 228 m

STATION WIDTH 19 m

NO OF CROSS PASSAGE 11

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THE CHENNAI METRO MAP

Total Underground Tunneling by L&T SUCG JV 4.7KM

Total number of stations 3

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UAA 04 STATIONS AND TUNNELS

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OCCUPATIONAL HEALTH & SAFETY (OHS) & E IN CONSTRUCTION

OPERATION

Different aspects regarding the construction safety was introduced. A detailed class

was held discussing the safety aspects while constructing the underground stations as well as

tunnels. Various possibilities of accidents was listed out and the prevention methods to

overcome these were introduced. The presentation urged the adequacy of safety aspects in

construction industry. Working of earth pressure balancing machine and different cases of

accidents while tunnel boring were explained in detail. The discussion helped me in

identifying and explaining the causes of the accident occurred on Arunachala Street in

Chintadripet while tunnelling was done on 12-6-2013. Different codes and standards

regarding safety were familiarised.

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PLANNING SCHEDULING AND UPDATION OF THE PROJECT

I was awarded with an assignment for planning of 20m x 20m roof slab of KMC

underground station box. The construction method adopted in this site is top to down. Various

activities included in the construction of slab were listed after the site visit. Different types of

labourers, equipment involved and their productivity rate were determined based on both

theoretical as well as observed data. Activity precedence relationships (START TO START,

START TO FINISH, FINISH TO START, FINISH TO FINISH) was used to derive Gantt

chart for theoretical as well as observed schedules.

The detailed analysis of theoretical v/s Actual schedule was done both graphically and

numerically. Scheduling was done both graphically and numerically. A detailed discussion was

held after the submission of the assignment. Corrections and proposals suggested by the guide

was used to rectify the report and this enabled the report to appear more professional and

clear-cut. Later another planning report regarding the concourse slab was also submitted.

Quantity as well as total number of labour required was determined.

Application of different software used in planning was mentioned in the planning slot

of in plant training. An overview of MS Excel and Primavera was given in this particular slot.

It explained how to update the project, analyse the project, crash the project duration etc.

using Primavera. The final copy of the submitted excel exhibit 1 sheet is attached with the

report.

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CONTRACTS

A detailed session was held explaining defining the contracts, different types of

contracts, joint venture etc. Different case studies were put for study on the discussion. It was

used to explain the different complexities and disputes that may come between the client and

the contractor during planning as well as execution stage. Different techno-legal aspects were

scanned in detail under this slot. FIDIC conditions of contracts were introduced. The chances

of disputes and the dispute solving mechanism were given much importance in the discussion.

Since the topic contract documentation comes under my curriculum the discussion was so

fruitful.

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EXECUTION

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PLANNING AND SITE ESTABLISHMENT

SURVEY

The survey of the area is done after the clearance of the site and the site area is levelled.

The complete survey is done with the help of total station

SITE PLAN

The site plan is prepared according to the requirement of the area necessary for various

purpose such as

Reinforcement fabrication yard (26x6m)

Cutting and bending yard (12x6m)

Reinforcement stacking area (26x6m)

Stop end area (30x3m)

Steel scrap yard (5x6m)

Rig area (10x5m)

Crane area (5x3.6m)

Musk stocking area (7x10m)

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The space for all the requirement are planned and clearance is made such as, trees

traffic signals where the tress are replaced to other place or new sapling are planted at the ratio

of 1:12,like that the traffic signals are provided according to the municipals need.

Alternate light has to be provided as the street lamps are removed.

Barricading board should be provided around the work site. The barricading board is of width

2.5m and height 2m.

UTILITY DIVERSION

Trial pits will be made at the site to check the utility at the site and all of them are

found out and diversion is made accordingly

The Two types are:

Dry utility deals with Electrical cables and Telephone cables

Wet utility deals with Sewer lines

DRY UTILITY

Optic fibre cable, high tension (HT), Low tension (LT) cables

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WET UTILITY

Water pipe, sewage pipe

FABRICATION OF REINFORCMENT CAGE

Type of bar HYSD500D (High Yield Strength Deformed bar)

Varies bars used in cage preparation

32mm - main rebar

20mm - main rebar

25mm - main rebar

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16mm - binding rebar

12mm- sacral area rebar

Specially bended bars

Z bar provided to add strength to the cage .Number of z bars in a cage varies from

32 to 110.

V hook is added in the top of the cage for the lifting and placing of the cage in trench.

COUPLERS

Couplers are used in the place where the D wall is connected to the base slab,

concourse slab, roof slab of the station box .There are two types of couplers type A and type

B

Type A Half Threaded

Type B Full Threaded

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HALF THREADED COUPLER

The coupler is stable and the reinforcement of following slab is rotated .The internal

diameter is 25mm and the external diameter is 40mm.

The reinforcement in the slab is stable and the coupler is rotated. The internal

diameter is 32mm and the external diameter is 52mm.

These couplers are packed completely so that it does not get contact with the

concrete which will not be difficult during slab concreting .it packed with the help of thermo

Cole the on the top wooden plank are kept and tied

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DETAIL OF THE PANEL IN ALL THE STATION

SL. NO Particulars Nehru Park Kilpak medical

College

Pachaiappa’s

College

1 Length of dwall in

station box

516 516 516

2 Depth of D-wall 22-24 23-25 26-28

3 Total number of

panel

114 109 108

4 Entry /exit shaft

length

150 150 150

CONSTRUCTION OF THE STATION BOX

The station can be constructed in two method namely

Top down method

Bottom up method

TOP DOWN METHOD (OR) COVER AND CUT METHOD

In this method the construction is done from the top where the roof slab is constructed

first in which some space will be left free in the middle in two r three place which facilitate for

the construction of the concourse slab ,then on the same way the base slab is completed .

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BOTTOM UP METHOD (OR) CUT AND COVER METHOD:

In this method as soon as the dwall is constructed the soil is excavated till the desired

depth and the base slab is constructed and then the concourse slab then the roof slab

The launching shaft region is constructed in this method.

PLUNGE COLOUMN

Plunge columns can be installed into rotary bored piles to allow for a ‘top-down’

construction sequence, 'launching' structures before the basement is excavated.

CONSTRUCTION PROCESS

A rotary bored pile is excavated to the required depth, a reinforcement cage is then

installed and then the void is filled with concrete stopping the required distance below ground

level. Whilst the concrete is still wet a hydraulic plunging frame is installed within the

temporary casing and then the plunge column is installed to structural tolerances. The concrete

is then left to set in the pile and once this is complete the empty bore above is backfilled.

The plunge column is of 1 m wide and the barrets which act like a footing at the base

weighs about 1.65 tons

The reinforcement cage weighs about 11 to 13 tons

Rods used in barrets are 500 mm In diameter

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M 35 grade concrete is used for plunge column

Stop ends are used along with water stopper. It is 800 mm wide at T ends and 1000

mm at the rest of the places

JET GROUTING

Before starting the Cross passage excavations, it is necessary to improve the soil

characteristics around CPs.

High Pressure Jet grouting method will improve the soil stabilization.

It uses high kinetic energy liquid spurt (jet) for chopping up the ground around and

mixing it with binding agent. In most cases this binding agent is the chopping jet itself.

This way all materials situated in the ground – the soil, backfilling or even waste - are

mixed in situ with injection material and thus a homogeneous block is created that

hardens in time. This technique is different from all other grouting techniques in its

method of demolishing and reshaping original soil structure.

Jet grouting can be used regardless of type, delivery value or grading etc. of soil. As a

reason, theoretically it can be used for treating most soil types from soft soils and silt until

sand and gravel. Although it is possible to use any kind of binding agent in Jet Grouting, the

water/ cement or, in case of wish to rise water delivery value of soil water/ cement/ bentonite

mixture is used in practice. Shape, size, composition and stability of jet pile depends on

mechanic characteristics of soil, type of binding agent, mode of injection, flow velocity during

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injection, pressure conditions and movements of drill rod. Reachable strength values in

different soils.