Training underDMRC

About Project:About Project: Jaipur Metro Rail is proposed to be setup on Jaipur Metro Rail is proposed to be setup on

Public Private Partnership (DBFOT) model. The Public Private Partnership (DBFOT) model. The project is going to have two corridors, one project is going to have two corridors, one running from East to West and the other running from East to West and the other running from North to South. The total length is running from North to South. The total length is around 35 Km. around 35 Km.

Major portion of the East West corridor, i.e 9.25 Major portion of the East West corridor, i.e 9.25 Km out of total length of 11.5 Km, is already Km out of total length of 11.5 Km, is already under construction by the Corporation under construction by the Corporation

East-West Corridor - Mansarovar, New East-West Corridor - Mansarovar, New Aatish Market, Vivek Vihar, Shyam Nagar, Aatish Market, Vivek Vihar, Shyam Nagar, Ram Nagar, Civil Lines, Jaipur Railway Ram Nagar, Civil Lines, Jaipur Railway Station, Sindhi Camp Bus Stand, Station, Sindhi Camp Bus Stand, Chandpole, Choti Chaoupar and Badi Chandpole, Choti Chaoupar and Badi Chaoupar.Chaoupar.

East-West Corridor - Mansarovar, New Aatish East-West Corridor - Mansarovar, New Aatish Market, Vivek Vihar, Shyam Nagar, Ram Nagar, Market, Vivek Vihar, Shyam Nagar, Ram Nagar, Civil Lines, Jaipur Railway Station, Sindhi Camp Bus Civil Lines, Jaipur Railway Station, Sindhi Camp Bus Stand, Chandpole, Choti Chaoupar and Badi Stand, Chandpole, Choti Chaoupar and Badi Chaoupar.Chaoupar.

The East-West corridor of the Metro in The East-West corridor of the Metro in Phase 1Phase 1 is is expected to cost Rs expected to cost Rs 1250 crore1250 crore..

East-West Corridor - Mansarovar, New Aatish East-West Corridor - Mansarovar, New Aatish Market, Vivek Vihar, Shyam Nagar, Ram Nagar, Market, Vivek Vihar, Shyam Nagar, Ram Nagar, Civil Lines, Jaipur Railway Station, Sindhi Camp Bus Civil Lines, Jaipur Railway Station, Sindhi Camp Bus Stand, Chandpole, Choti Chaoupar and Badi Stand, Chandpole, Choti Chaoupar and Badi Chaoupar.Chaoupar.

The East-West corridor of the Metro in The East-West corridor of the Metro in Phase 1Phase 1 is is expected to cost Rs expected to cost Rs 1250 crore1250 crore..

The Phase 2 is expected to cost Rs 7000 crore The Phase 2 is expected to cost Rs 7000 crore

Here are some facts about the Jaipur:Here are some facts about the Jaipur:

• • Number of lines in Jaipur Metro Railways: 2Number of lines in Jaipur Metro Railways: 2• Number of stations : 12 (phase 1)• Number of stations : 12 (phase 1)• Daily ridership: roughly 6 lacks (one way).• Daily ridership: roughly 6 lacks (one way).• Operation Began: 2010 (line 1)• Operation Began: 2010 (line 1)• System length: 32.5 kilometers • System length: 32.5 kilometers • Track gauge: 1,435 mm (4 ft 8+1⁄2 in) • Track gauge: 1,435 mm (4 ft 8+1⁄2 in) • Electrification: 25 kV, 50 Hz AC through overhead • Electrification: 25 kV, 50 Hz AC through overhead • Average speed: 33 km/h (21 mph)• Average speed: 33 km/h (21 mph)• Top speed: 80 km/h (50 mph)• Top speed: 80 km/h (50 mph)• • Jaipur metro rail start dateJaipur metro rail start date: Around June 2013.: Around June 2013.

Delhi Metro Rail CorporationDelhi Metro Rail Corporation

INTRODUCTIONINTRODUCTION For implementation and subsequent For implementation and subsequent

operation of Delhi MRTS, a company operation of Delhi MRTS, a company under the name DELHI METRO RAIL under the name DELHI METRO RAIL CORPORATION was registered on 03-CORPORATION was registered on 03-05-95 under the Companies Act, 05-95 under the Companies Act, 1956. DMRC has equal equity 1956. DMRC has equal equity participation from GOI and GNCTD.participation from GOI and GNCTD.

Pile Foundation

Construction of Construction of Pile FoundationPile Foundation of the elevated structure for the of the elevated structure for the

transition of transition of Metro Rail Metro Rail & also for & also for the the Metro StationsMetro Stations..

Indian Standards on PilesIndian Standards on Piles

IS 2911 : Part 1 : Sec 1 : 1979 Driven cast in-situ concrete IS 2911 : Part 1 : Sec 1 : 1979 Driven cast in-situ concrete pilespiles

IS 2911 : Part 1 : Sec 2 : 1979 Bored cast-in-situ pilesIS 2911 : Part 1 : Sec 2 : 1979 Bored cast-in-situ piles IS 2911 : Part 1 : Sec 3 : 1979 Driven precast concrete pilesIS 2911 : Part 1 : Sec 3 : 1979 Driven precast concrete piles IS 2911 : Part 1 : Sec 4 : 1984 Bored precast concrete pilesIS 2911 : Part 1 : Sec 4 : 1984 Bored precast concrete piles IS 2911 : Part 2 : 1980 Timber pilesIS 2911 : Part 2 : 1980 Timber piles IS 2911 : Part 3 : 1980 Under reamed pilesIS 2911 : Part 3 : 1980 Under reamed piles IS 2911 : Part 4 : 1985 Load test on pilesIS 2911 : Part 4 : 1985 Load test on piles

Pile foundations are adopted generally in the Pile foundations are adopted generally in the following situationfollowing situation

• • Low Bearing Capacity of soil.Low Bearing Capacity of soil.

• • Non availability of proper bearing stratum at Non availability of proper bearing stratum at shallow shallow depths. depths.

• • Heavy loads from the super structure for Heavy loads from the super structure for which which shallow foundation may not be shallow foundation may not be economical or economical or feasible. feasible.

Pile Foundations

Classification of Piles :Classification of Piles : Based on material Based on material

ConcreteConcrete SteelSteel TimberTimber

Classification of Piles :Classification of Piles : Based on material Based on material

ConcreteConcrete SteelSteel TimberTimber

Based on method of construction/installation.:Based on method of construction/installation.: Driven /Displacement Pre cast Piles Driven /Displacement Pre cast Piles Driven/Displacement Cast in Situ Piles Driven/Displacement Cast in Situ Piles Bored/ Replacement Pre cast piles Bored/ Replacement Pre cast piles Bored/ Replacement Cast in situ pilesBored/ Replacement Cast in situ piles

Classification of Piles :Classification of Piles : Based on material Based on material

ConcreteConcrete SteelSteel TimberTimber

Based on method of construction/installation.:Based on method of construction/installation.: Driven /Displacement Pre cast Piles Driven /Displacement Pre cast Piles Driven/Displacement Cast in Situ Piles Driven/Displacement Cast in Situ Piles Bored/ Replacement Pre cast piles Bored/ Replacement Pre cast piles Bored/ Replacement Cast in situ pilesBored/ Replacement Cast in situ piles

Based on Load transfer mechanism:Based on Load transfer mechanism: Friction/Floating pilesFriction/Floating piles Bearing cum Friction piles Bearing cum Friction piles

Based on sectional area :Based on sectional area : CircularCircular SquareSquare H ShapeH Shape OctagonalOctagonal TubularTubular

Based on sectional area :Based on sectional area : CircularCircular SquareSquare H ShapeH Shape OctagonalOctagonal TubularTubular

Based on size:Based on size: Micro piles Dia. < 150 mmMicro piles Dia. < 150 mm Small dia. Pile Dia. > 150 mm and Dia. < 600 mmSmall dia. Pile Dia. > 150 mm and Dia. < 600 mm Large Dia. Piles Dia. > 600 mmLarge Dia. Piles Dia. > 600 mm

SOFT SOILPILES

We used Friction Piles in Metro Foundation

If the firm soil is at a considerable depth, it may be very expensive to use end bearing piles. In such situations, the piles are driven through the penetrable soil for some distance. The piles transmit the load of structure to the penetrable soil by means of skin friction between the soil.

Method ForMethod ForThe ConstructionThe Construction OfOf Pile Pile

FoundationFoundation

The following steps were observed in the The following steps were observed in the construction:construction: SETTING OUTSETTING OUT DRIVING OF TEMPORARY CASINGDRIVING OF TEMPORARY CASING BoringBoring REINFORCEMENT CAGE LOWERINGREINFORCEMENT CAGE LOWERING REINFORCEMENT COVER BLOCKREINFORCEMENT COVER BLOCK FLUSHING OPERATIONFLUSHING OPERATION CONCRETINGCONCRETING

S.No. DESCRIPTION TYPE CAPACITY

1. Pilling Rig Mait HR 130 130 KN

2. Crane TATA 320

3. Excavator JCB .25 cum

4. Dumpers TATA/AL 4 cum

5. Batching Plant M1 30 cum/hr

6. Transit Mixers 6/4 cum

7. Welding Generator 400 Amps

8. Tremie Pipe 250 mm dia 25-35 mt

9. Hopper

CONSTRUCTION EQUIPMENTS

Soil BucketSoil Bucket

Light weightLight weight Large storage Large storage

capacitycapacity DurableDurable ReliableReliable

Tremie PipesTremie Pipes

quick disconnect quick disconnect couplings couplings

O ring seals for O ring seals for easy installationeasy installation

leak proof leak proof connectionsconnections

Various lengths Various lengths can be providedcan be provided

METHODOLOGYMETHODOLOGY

SETTING OUT:SETTING OUT: Necessary survey was conducted and Necessary survey was conducted and

pile points were marked. The pile pile points were marked. The pile location was set out with respect to the location was set out with respect to the control points by suitable pin marked at control points by suitable pin marked at location and checked by Engineer’s location and checked by Engineer’s representative.representative.

DRIVING OF TEMPORARY CASING:DRIVING OF TEMPORARY CASING:

• Rotating drilling rig fitted with suitable tool (soil boring tool) to be positioned at the pre-marked pile point and boring was started

• On completion of boring up to about 1m casing pipe was installed in position using special attachment to the rotary head

• Diameter of the cutting tool was diameter of the pile minus 75mm

Material UsedMaterial Used::

Bentonite:Bentonite:

used to stabilize the sides of the used to stabilize the sides of the pile borehole.pile borehole.

Bentonite was saturated for Bentonite was saturated for 24hrs and then used.24hrs and then used.

Frequency test: 24hrs after Frequency test: 24hrs after mixing, prior to concreting.mixing, prior to concreting.

The properties of bentonite slurry The properties of bentonite slurry met at the site were:met at the site were:

S.no. Type of test Required Value

Equipment to be used

1. Mud density 1.05 g/cc Hydrometer

2. Viscosity prior to concrete

30 – 40 second Marsh cone

3. pH value 9.5 to 12 pH meter

4. Sand content 1% Sieve Analysis

5. Liquid limit 400% Casagranda

Concrete:Concrete:

Grade of concrete: M35Grade of concrete: M35 Slump of concrete: 150 to 200 mmSlump of concrete: 150 to 200 mm The maximum size of Coarse aggregate was The maximum size of Coarse aggregate was

20mm20mm The cement used for pilling work as per IS:455 The cement used for pilling work as per IS:455

specification for Portland slag cement.specification for Portland slag cement. Minimum cement content for the design mix Minimum cement content for the design mix

was not kept less than 400kg/mwas not kept less than 400kg/m33

Reinforcement Steel:Reinforcement Steel:

TMT bars were used.TMT bars were used. G.I wires were used for binding reinforcement.G.I wires were used for binding reinforcement. Bending of reinforcement was as per IS: Bending of reinforcement was as per IS:

25021963.25021963. The reinforcement was extended to the full The reinforcement was extended to the full

length of the pile and was projected 60 times length of the pile and was projected 60 times diameter above the cut-off level.diameter above the cut-off level.

BORINGBORING

Initial Boring of Initial Boring of 1.5 meters was 1.5 meters was done by using done by using augerauger

temporary temporary casing was casing was installed in the installed in the boreholeborehole

Bentonite suspension was then filled in the Bentonite suspension was then filled in the borehole for stabilising sides before starting borehole for stabilising sides before starting boring below bottom of temporary slurryboring below bottom of temporary slurry

The level of bentonite was always kept 1.5 meters The level of bentonite was always kept 1.5 meters above the bottom of casing during grabbingabove the bottom of casing during grabbing

Further boring was done using soil bucket till the Further boring was done using soil bucket till the required depth was reachedrequired depth was reached

Once the bore has depth has reached to the Once the bore has depth has reached to the desired depth, the bottom of the bore was desired depth, the bottom of the bore was cleaned by Bentonite flushingcleaned by Bentonite flushing

REINFORCEMENT CAGE REINFORCEMENT CAGE LOWERINGLOWERING

The reinforcement was cut and bent to The reinforcement was cut and bent to required shape and sizerequired shape and size

The reinforcement cage was fabricated at the fabrication yard The reinforcement cage was fabricated at the fabrication yard and was transported to the siteand was transported to the site

Specified cover blocks were provided to the reinforcement Specified cover blocks were provided to the reinforcement cage for the pilecage for the pile

The cage was lowered in 3 pieces or more depending upon the The cage was lowered in 3 pieces or more depending upon the length of pile.length of pile.

Bottom cage was lowered inside the borehole and temporarily Bottom cage was lowered inside the borehole and temporarily supported on the casing pipe top, keeping the dowel length supported on the casing pipe top, keeping the dowel length projecting above and second cage lifted and lapped by projecting above and second cage lifted and lapped by welding.welding.

The minimum lap length was 60d. Helical was tied more The minimum lap length was 60d. Helical was tied more closely at the welding zone then the whole cage length.closely at the welding zone then the whole cage length.

The whole cage then lowered inside The whole cage then lowered inside the bore hole. the reinforcement was the bore hole. the reinforcement was projected 60 times bar diameter projected 60 times bar diameter above the cut off level.above the cut off level.

REINFORCEMENT COVER REINFORCEMENT COVER BLOCKBLOCK

Circular cover blocks of 150mm Circular cover blocks of 150mm diameter was made with the same diameter was made with the same grade of concrete as that of pile grade of concrete as that of pile concrete and fixed to helical.concrete and fixed to helical.

The cover block was provided at The cover block was provided at approximately 2m intervals and approximately 2m intervals and suitably staggered.suitably staggered.

FLUSHING OPERATIONFLUSHING OPERATION Before concreting the borehole was flushed again with Before concreting the borehole was flushed again with

fresh bentonite suspension. Immediately after lowering of fresh bentonite suspension. Immediately after lowering of the cage.the cage.

Tremie pipes of 250mm diameter of length 1.5m length Tremie pipes of 250mm diameter of length 1.5m length were joined together and lowered into the bore and the were joined together and lowered into the bore and the bentonite was pumped through the pipe.bentonite was pumped through the pipe.

During flushing, contaminated bentonite from bottom of During flushing, contaminated bentonite from bottom of the pile was collected in the tank through Tremie outlet & the pile was collected in the tank through Tremie outlet & fresh bentonite was pumped to maintain the bentonite at fresh bentonite was pumped to maintain the bentonite at required level.required level.

Flushing was continued till the density of the return mud Flushing was continued till the density of the return mud was less then 1.2gm/cc.was less then 1.2gm/cc.

CONCRETINGCONCRETING

• The concrete was placed in the bore through the tremie pipe.• The bottom of the tremie was 300mm above the bottom of the bore.• During concreting the care was taken to keep the tremie pipe 1.5m embedded in the concrete.

On completion of concreting to the On completion of concreting to the required level elevation, temporary required level elevation, temporary casing was withdrawn either by the casing was withdrawn either by the crane or drilling rig.crane or drilling rig.

The grade of concrete used in the The grade of concrete used in the pile was M35.pile was M35.

Workability of concrete and concrete Workability of concrete and concrete cubes were prepared to check the cubes were prepared to check the strength of concrete after 7 and 28 strength of concrete after 7 and 28 days.days.

Cast in Situ Replacement Cast in Situ Replacement PilePile

Advantage Disadvantages Less noise or vibration problem Concrete cannot be inspected after

installation

Equipment can break up practically all kinds of obstructions

Liable to squeezing or necking

Can be installed in a very long length Raking bored pile are difficult to construct

No ground heave Drilling a number of pile groups may cause ground loss and settlement of adjacent structures

Depth and diameter can varied easily Cannot be extended above ground level without special adaptation

UNDERGROUND METRO UNDERGROUND METRO STATION AT CHANDPOLESTATION AT CHANDPOLE

GENERAL ABOUT THE PROJECT GENERAL ABOUT THE PROJECT FOR UNDERGROUND METRO FOR UNDERGROUND METRO

STATIONSTATION SCOPE- Construction of guide wall, trench SCOPE- Construction of guide wall, trench excavation under bentonite, placing of excavation under bentonite, placing of reinforcement cage and concreting of reinforcement cage and concreting of diaphragm wall.diaphragm wall.

OWNER- DMRCOWNER- DMRC

CONTRACTOR- ITD Cementation India Ltd.CONTRACTOR- ITD Cementation India Ltd.

TOTAL COST- 102Cr(approx)TOTAL COST- 102Cr(approx)

LIST OF MAJOR PLANTS AND LIST OF MAJOR PLANTS AND EQUIPMENTSEQUIPMENTS

S NO.

Plant/Equipment Type Number

1. 75t Capacity Crawler Excavation Crane/(Service)

2

2. Hydraulic and/or Rope Grabs 1

3. Bentonite Facility and Equipment 1(set)

4. Stopend System As required

Continue …Continue …

S NO. Plant/Equipment

Type

Number

5. Stopend Chisel As required

6. Tremie Pipe System(250mmdia) inc Hopper

2

7. Welding Sets 4

METHODOLOGY FOR THE METHODOLOGY FOR THE CONSTRUCTION OF DIAPHRAGM CONSTRUCTION OF DIAPHRAGM

WALLWALL

The following steps were observed in the The following steps were observed in the construction:construction:

1.1.Guide WallGuide Wall

2.2.Bentonite MixingBentonite Mixing

3.3.ExcavationExcavation

CONTINUE …CONTINUE …

4.4. Installation Of Stopened And Installation Of Stopened And WaterstopenedWaterstopened

5.5. Reinforcement & ConcretingReinforcement & Concreting

GUIDE WALLGUIDE WALL

It is temporary structure constructed It is temporary structure constructed priorprior

to excavation of diaphragm wall.to excavation of diaphragm wall.

Purpose of guide wall:Purpose of guide wall: To ensure the stability and prevent To ensure the stability and prevent

the collapsing of the soil strata.the collapsing of the soil strata. To provide temporary support for To provide temporary support for

the reinforcement cage.the reinforcement cage. To provide the supports to Stopend.To provide the supports to Stopend.

STRUCTURAL DETAILS OF STRUCTURAL DETAILS OF GUIDE WALLGUIDE WALL

Grade of concrete- M15Grade of concrete- M15

Thickness of Guide wall- 150mmThickness of Guide wall- 150mm

Depth of Guide wall- 1500mmDepth of Guide wall- 1500mm

Continue…Continue…

Clear cover- 25mmClear cover- 25mm

Dia. of steel used- 10mm & 8 mm at a Dia. of steel used- 10mm & 8 mm at a distance of 250mm center to center.distance of 250mm center to center.

Clear distance between inner faces of Clear distance between inner faces of guide wall-600mm(diaphragm wall)guide wall-600mm(diaphragm wall)+50mm+50mm

Guide wall Guide wall

BENTONITE MIXINGBENTONITE MIXING

Mixing unit was erected on impermeable Mixing unit was erected on impermeable base to check spillage.base to check spillage.

Kept in storage tank for 24hrs to hydrate.Kept in storage tank for 24hrs to hydrate.

Continuously agitated using vertical pump.Continuously agitated using vertical pump.

Daily bentonite test that were conducted-Daily bentonite test that were conducted- 1. ph- 8.91. ph- 8.9 (9to11.5 as IS code9556-1980)(9to11.5 as IS code9556-1980)

2. Density- 1.112. Density- 1.11 (1.06to1.12 as Is code 9556-1980)(1.06to1.12 as Is code 9556-1980)

Bentonite Bentonite 3. Sand 3. Sand

Content-Content-fresh(2%) & fresh(2%) & contaminatcontaminated(3%){7% ed(3%){7% as per Is as per Is code 9556-code 9556-1980}1980}

4. Viscosity- 4. Viscosity- 45sec(32-45sec(32-90 sec as 90 sec as per Is code-per Is code-9556-1980)9556-1980)

Mixing Tank for Bentonite

DIAPHRGAM WALL DIAPHRGAM WALL EXCAVATIONEXCAVATION

Wall is located between Guide wall.Wall is located between Guide wall. The trench was excavated using The trench was excavated using

Hydraulic Drilling Rig .Hydraulic Drilling Rig . Stopened with water stopened was Stopened with water stopened was

then lowered into the trench.then lowered into the trench. Excavation was done in three Excavation was done in three

panel(primary, secondary & closing).panel(primary, secondary & closing). Excavation was done with bentonite Excavation was done with bentonite

filled to top level.filled to top level.

Diaphrgam wallDiaphrgam wall

REINFORCEMENT & REINFORCEMENT & CONCRETINGCONCRETING

Grade of steel- Fe500Grade of steel- Fe500

Grade of concrete- M35Grade of concrete- M35

Dia of steels used- 35mm & Dia of steels used- 35mm & 25mm25mm

Continue …Continue …

Minimum clear cover- 75mmMinimum clear cover- 75mm

Shape of cover blocks- CircularShape of cover blocks- Circular

Horizontal distance of cover blocks- Horizontal distance of cover blocks- 1500mm1500mm

• Vertical distance of cover blocks-2000mm

• Dia of tremie pipe- 250mm

• Length to which pipe was dipped inside the concrete- 2m

• Concreting was done to 1m above the cut off level.

Concreting of Diaphrgam wallConcreting of Diaphrgam wall

Slump Test Slump Test

The test is an empirical test that The test is an empirical test that measures the workability of fresh measures the workability of fresh concrete. More specifically, it measures concrete. More specifically, it measures consistency between batches. The test is consistency between batches. The test is popular due to the simplicity of popular due to the simplicity of apparatus used and simple procedure. apparatus used and simple procedure. The slump test is used to ensure The slump test is used to ensure uniformity for different batches of similar uniformity for different batches of similar concrete under field conditions.concrete under field conditions.

Types of slumpTypes of slump

Continue…Continue…

Collapse Shear True

In a collapse slump the concrete collapses completely. [2]

In a shear slump the top portion of the concrete shears off and slips sideways.[2]

In a true slump the concrete simply subsides, keeping more or less to shape.[2]

Slump TestSlump Test

Thank you…Thank you…