HCC-SAMSUNG JV CC-34

1. Project Report
On
DELHI METRO RAIL CARPORATION PHASE- 3
Submitted in the partial fulfillment of the requirement for the award of degree of
Bachelors of Technology
in
Civil Engineering
Department of Civil Engineering
GurukulVidyapeeth Institute of Engineering & TechnologyBanur
Under the Guidance of
SAMEED SHAIKH
SITE INCHARGE
Submitted by
NAVEEN JOSHI
1252623

2. Certificate
Certified that this project entitled “DELHI METRO RAIL CARPORATION PHASE-3
UNDERGROUND STATION” submitted by Naveen joshi (1252623), student of Civil
Engineering Department, Gurukul Vidyapeeth Institute of Engineering & Technology, Banur in
the partial fulfillment of the requirement for the award of Bachelors of Technology (Computer
Science & Engineering) Degree of PTU, Jalandhar, is a record of students own study carried
under my supervision & guidance.
This report has not been submitted to any other university or institution for the award of any
degree.
Name of Project Guide
Designation
Er. Sameedshaik
Site Incharge

4. Acknowledgement
I Express my satisfication on the completion of this Four months Software Training
program and Project Report submission as a part of the circulum for the degree of
Bachelor of Technology ,Civil Engineering .I Express my deepest gratitude to my sir
Site Incharge MR. Shameed sheikh and Mr Nagender subedi for his kind guidance during
the entire period of Training .His consistent support and advices has helped me to complete
this Training report successfully. Also I Thank all the members of HCC-SAMSUNG
Department .They have always been a source of insipiration to me.

5. DECLARATION
I Naveen joshi Roll no 1252623, student of B.TECH CIVIL 7-semester here bydeclare thatthe
projectreportentitled“DELHI METRO PROJECT CC-34 REPORT” submittedbyme to GURUKUL
VIDYAPEETHOF ENGINEERINGTECHNOLOGY in partial fulfillmentof the requirementforthe awardof
the degree of B.TECH inCIVILENGINEERING DEPARTMENT isa record of bonfide projectworkcarried
out byme underthe guidance of Mr. SHAMEED DHAIKH.I furtherdeclare thatthe workreportedinthis
projecthas notbeensubmittedandwill notbe submitted,eitherinpartor in full,forthe awardof any
otherdegree ordiplomainthisinstitute oranyotherinstitute oruniversity.
Signature of candidate
NAVEEN JOSHI

6. Abstract
The Construction industry of India is an important indicator of the development as it creates
investment opportunities across various related sectors. The construction industry has
contributed an estimated ₹ 6708 billion to the national GDP in 2011-12 (a share of around 9%).
The industry is fragmented, with a handful of major companies involved in the construction
activities across all segments; medium-sized companies specializing in niche activities; and
small and medium contractors who work on the subcontractor basis and carry out the work in the
field. In 2011, there were slightly over 500 construction equipment manufacturing companies in
all of India.
Being the capital city of India, it doesnot come asashock that NewDelhi is the most populated city in India in
term of people and vehicles. The population of Delhi and vehicles onroadare ever increasing leading to problems
like traffic, pollution and high fuel consumption .Considering all this ―THE DELHI METRO‖ comes as
a huge relief for the people of Delhi.There are no doubts about the social benefits of the Delhi metro. It will
help in reducing traffic and pollution in the capital and more important save alot of time for the daily commuters.
Myproject is based onthe advantage and disadvantage ofmetro and also on the analysis ofconstruction
knowledge which I got from the site.

7. INDEX
Contents
1. Introduction.................................................................................................................................. 3
1.1 HCC GROUP:........................................................................................................................ 7
1.1.1 Vision & mission:................................................................................................................ 8
1.1.2 HCC receives GRI application Level A+......................................................................... 10
1.1.3 HCC receives TUV NORD CERT procedure certificate.................................................. 11
1.1.4 Core business:.................................................................................................................... 12
1.2 SAMSUNG:......................................................................................................................... 14
1.2.1 VALUES FOR SAMSUNG:............................................................................................ 14
1.3 Requirement of metro infrastructure in urban area:............................................................. 15
1.3.1 Suitability of Elevated metro rail:..................................................................................... 16
1.3.2 Suitability of Underground metro rail:.............................................................................. 17
1.3.3 Suitability of On graded metro rail:.................................................................................. 18
2.Project CC-34:............................................................................................................................ 20
2.1 Delhi Metro Rail Transport Service Phase 3:...................................................................... 20
2.2 Alignment:............................................................................................................................ 23
2.3 Organization chart:............................................................................................................... 25
2.4 Cut and cover method:......................................................................................................... 26
2.4.1 Bottom-Up Approach:....................................................................................................... 26
2.4.2 Top-Down approach:........................................................................................................ 28
2.5 Tunnel Boring Machine:....................................................................................................... 30
3.learnings:..................................................................................................................................... 32
3.1 Station Construction:............................................................................................................ 32
3.1.1 Janakpuri West(Bottom-up Method)................................................................................ 32
3.1.2 Dashrathpuri(Top-Down Method).................................................................................... 37
3.2 Tunnel Construction:............................................................................................................ 43
3.2.1 Launching Station:............................................................................................................. 43
3.2.2 Cross Over:....................................................................................................................... 43
3.2.3 Cross passage:................................................................................................................... 43
3.2.4 TBM lowering:.................................................................................................................. 44

8. 3.3 Casting Yard:........................................................................................................................... 47
3.3.1 Concrete mix Designfor segments:................................................................................... 48
3.3.2 Precast Segments:.............................................................................................................. 48
3.3.3 Man Power Distribution Chart:......................................................................................... 53
3.3.4Time Cycle of Segment Production Activity :.................................................................. 55
3.3.5 Rate analysis:..................................................................................................................... 56
3.4 TBM Lowering:.................................................................................................................... 59
3.4.1Time cycle for TBM lowering:........................................................................................... 60
4. Procurement:.............................................................................................................................. 61
5. Heavy Equipments used in project:........................................................................................... 63
5. Heavy Equipments used in project:........................................................................................... 64
6. Health and Safety:...................................................................................................................... 67
6. Health and Safety:...................................................................................................................... 68
7. Contribution:.............................................................................................................................. 70
8. Quality Checklists:..................................................................................................................... 77

9. 1. Introduction
Delhi, the capital of India and an important city in the world, is growing in all directions.
The city is situated to the north side of the country and is built by the side of the Yamuna
river. The area occupied by Delhi is spread around 1483 km2. Delhi is an ancient city and
home to around 16.4 million people who need to commute on a daily basis. Being the
capital of a large country it is necessary that it has a large and world class infrastructure,
the Delhi metro rail is a gift to the people of Delhi and is considered as the city’s lifeline.
With the present metro phase 1 & 2 running on a successful path.
LINE TERMINAL
Red Line Dilshad garden Rithala
Yellow line Jahangirpuri Huda city center
Noida city center Dwarka sector-21
Blue line
Yamuna bank Vaishali
Inderlok Mundka
Green line
Ashok park Kirtinagar
Violet line ITO Badarpur
Airport line(Orange line) New delhi Dwarka sector 21

10. Delhi Metro Rail Network as of 29th June 2014
Construction of phase 3 has already begun. The deadline for completion of phase 3 is 2016.
April 2014 the Delhi Government gave approval for further extension.

11. LINE TERMINAL
Red line extension Dilshad garden New bus station gaziabad
Green line extension mundka Bahadurgarh
Blue line extension Noida city center Noida electronic city
Dwarka Nagafgarh
Yellow line extension jahangirpuri Samaypur
Violet line extension Central secretariat Kashmiri gate
badarpur Ballabgarh
Pink line mukundpur Shiv vihar
Brown line Sector 52 noida Depot station
Magenta line Janakpuri west Botanical garden

13. 1.1 HCC GROUP:
HCC is a business group of global scale developing and building responsible infrastructure
through next practices. With a group turnover of Rs. 10,353 crore as on March 2014-15, its
businesses span the sectors of Engineering & Construction, Real Estate, Infrastructure, Urban
development Management.
The HCC group of companies comprises HCC Ltd (Engg& Construction), and its
subsidiaries HCC Infrastructure Ltd, Lavasa Corporation Ltd, High bar Technologies and
Steiner AG. To learn more about HCC's group companies click on the various company logos
below
HCC focuses on constructing landmark projects of high complexity where it applies its core
competencies and skills to deliver world class infrastructure. It has constructed 28% of India's
hydel power and 65% of India's nuclear power generation capacities, over 3600 lane Km of
Expressways and Highways, more than 300 Km of complex Tunneling and over 356 Bridges.
HCC infrastructure Ltd. is engaged in the creation and management of assets in the areas of
Transportation, Power and Water. Since its inception, HCC Infrastructure has grown its
portfolio to Rs. 5,500 Cr. ($1 bn) in 2013-14, which includes six NHAI concessions.
Lavasa India's first planned hill city, is located at a 3 hour- drive from Mumbai and spread
across a picturesque landscape of over 10,000 hectares. Meticulously master planned by
leading U.S based town planners - HOK International Ltd., the Lavasa city plan has won
several international awards. The integrated development at Lavasa will include five self-
sustaining towns with a
permanent population of over 300,000 people.

14. 1.1.1 Vision & mission:
The HCC vision. Seeing into the future
"To be the Industry Leader and a Market - Driven Engineering Construction Company
renowned for excellence, quality, performance and reliability in all types of construction"
The Vision Statement has been inspired by the global infrastructure development needs of
tomorrow, with the Customer as the central focus. It was developed after conducting a
series of in-house workshops. Senior Leaders within the organization are actively involved
in developing and maintaining an effective and efficient management system to disseminate
the Vision across HCC in order to achieve" Customer Delight".
The HCC Corporate Mission is derived from the Vision Statement to encompass the
overall strategies, objectives and goals of the Organization.
The HCC Mission. Driven by excellence
 To be a leading construction company in the global market. 

 To become the customers' most preferred choice by attaining excellence in quality
and timely completed value added projects. 

 To continually innovate, develop and adopt state-of-the-art technology in methods
and materials to enhance productivity and cost effectiveness. 

 To continually improve the competence of our people and make them proud to
work at HCC. 

 To build a safety culture aimed at continually reducing the frequency severity
rate towards achieving zero accidents. 

 To identify and mitigate all the environmental impacts arising from our activities
and comply with applicable environmental norms. 
 To develop and adopt eco-friendly concrete technology to reduce one million tons of
greenhouse gas (GHG) emissions in the next 10 years. 

 To contribute to the development of the local community and society at large as a part of
our corporate social responsibility. 

15. 1.1.2 HCC receives GRIapplication
Level A+ Certificate: GRI Application
Level Check
Year: 2014
Award Won from: Global Reporting Initiative(GRI)
Remarks:
 Hindustan Construction Company Ltd(HCC) has presented its report
'Responsible Infrastructure' 2011 to GRI's Report Services 

 GRI Report services concluded HCC fulfills the requirement of Application Level A+ 

16. 1.1.3 HCC receives TUV NORD CERT
procedurecertificate : TUV NORD CERT procedure
check
Year: 2008
Award Won from: TUV NORD CERT
Remarks:
 HCC presented its management system for an audit 

TUV NORD CERT certified that the system fulfilled the requirements for project
management, engineering and design, procurement, construction, operation and
maintenance of construction projects. 

17. 1.1.4 Core business:
With nearly a century's heritage in construction, HCC has evolved into an engineering and
construction leader. We have established a vast presence and gained recognition in the
sectors of Hydro Power, Water Solutions, Transportation and Nuclear Power. Through every
project and at every step, we aim to set new benchmarks and deliver world class
infrastructure.
HCC has expanded its construction capabilities to serve the entire spectrum of requirements
of the Hydro Power segment. HCC's accomplishments in this geologically complex area of
work include several first-of-its-kind dams, barrages, tunnels, underground power stations
and surface power stations, along with water conductor systems like surge shafts, pressure
shafts and penstocks. Today, we undertake Hydro Power projects on EPC basis as well.....
HCC's extensive experience and expertise has powered the progress in the Water
Solutions segment. Since our debut, we have executed a number of challenging projects
including the world's longest barrage. With a strong focus on standards and quality, HCC
has developed specialized systems to offer total solutions for high value projects, such as
urban water supply systems, pumping stations, water treatment plants and lift irrigation
for the rural sector...
HCC has built over 65% of India's nuclear power generation capacity. For all 8 phases of the
Rajasthan Atomic Power Project HCC has been the construction partner since the first Unit
completed in 1972. HCC specializes in pre-stressed containment structures for reactor
buildings. The company has executed India's largest nuclear power plant in Kudankulam
(2X1000 MW) comprising the country's first Pressurized Light Water Reactors.. .

18. HCC has built some of the most remarkable transportation projects in India. Be it India’s first
sea link or metro rail systems or a railway tunnel deep in the mountains connecting Jammu &
Kashmir, our technical knowledge and project management experience have guaranteed the
successful execution of futuristic and technologically advanced construction. A number of
projects are taken on as EPC (engineering, procurement and construction) contracts...
1.2 SAMSUNG:
Samsung C&T Corporation (C&T = Construction &Trading) (formerly Samsung
Corporation) (Korean: 삼성물산), was founded in 1938 as a parent company of Samsung
Group to engage in overseas sales operations. Since 1995, it has been largely focused on
global
engineering and construction projects, trade and investment, fashion and resorts. The
corporation
is governed by an 11-member Board of Directors, made up of the President and CEOs of its
four
working groups (Engineering & Construction, Trading & Investment, Fashion and Resort &
Construction the corporation’s CFO, and six independent members. Samsung C&T
employees
are just under 13,000 people.
1.2.1 VALUES FOR SAMSUNG:

19. MANAGEMENT OF SAMSUNG:
1.3 Requirement of metro infrastructure in urban area:
 Urban India today, faces serious challenges of growth and its management.
Across geographic, issues of urbanization manifests in the form of overcrowding,

20. congestion, insufficient infrastructure, inadequate service provisioning – mainly
transport, environmental degradation and pollution etc. 

 Infrastructure facility in the city is directly depends on the resources available to
develop the infrastructure facilities. 

 Growing cities, growing population and growing traffic has invariably called for a
shift from private modes of transport to public mode of transport. 

 Use of metro rail will result in prevention emission of green house gases. 

 Averts the accidents. 

 It runs on electricity so it will reduce the pollution. 

 Use of metro rail will result in saving fuel cost, vehicle cost
etc. Save time: 
International standard for metro rail with maximum speed of 80kmph and minimum
35kmph will helps in saving time.
 Provide comfort: 

Modern service like automatic ticket system, ultra modern coaches, security
system (ATM, food, cafe) 
1.3.1 Suitability of Elevatedmetro rail:
Newly developing areas where city having wide roads, elevated corridors can be
the choice: It would take up some of the width of the road.
Advantages:
 Elevated metro rail follows the existing road network, it will
helps to increase conveniences of people to transport one to other
place. 


Disadvantages: 

 Elevated metro structure affects the visual character of the city. 

 Elevated construction needs to follows the existing road network, space etc. 

 Interchange between two elevated lines is much more difficult. 

21. 
 The Elevated areas may encroach some private properties. Elevated station close to
the residential properties may become difficult to stay to the people. It may result
into property value going down. 

 The Elevated corridors may face major delays and cost increases due to land
acquisition issues (Physical relocation of residents and other properties) 
1.3.2 Suitability of Underground metro rail:
Underground corridors are adopted in the areas where there are interchanges of different
metro lines and the alignment is passing through the populated area.
Advantages:
 Underground metro structure not affects the visual character of the city. 

 There are no needs to follow the existing road network, space etc. 

 Interchange between two Underground metro lines will be comparatively easy. 
Disadvantages:
 Underground construction will be 2.5 to 3 times more expensive than elevated. 
 Underground metro construction cost increase due to ventilation, lighting, air-
conditioning, escalator system, fire safety system, maintenance etc as compare to
elevated structure.
 Technology and machines used in tunnel are more expensive.
 Water table that raises the cost of construction.
 Vibration would be a major threat posed to residents, monument etc in
case of underground corridors. 

 The passenger evacuation in case of any emergency becomes a critical issue in
case of underground metro. (not suitable for earthquake restricted areas) 

1.3.3 Suitability of On gradedmetro rail:

 Newly developing area where city have large space. It would take up half of the
width of road. 


22. 
Advantages: 

 Require less maintenance. 

 Cost will reduce because of no need of lifts, stairs, air conditioning, escalator
facilities. 

 Passengers evacuation plan will be more easy 

 Elevated metro rail follows the existing road network; it will
help to increase conveniences of people to transport one to other
place. 

 Interchange between two elevated lines is easier. 


Disadvantages: 

 On grade construction needs to follows the existing road network, space etc. 

 Interchange between two elevated lines is much more difficult. 

 The areas may encroach some private properties. Elevated station close to the
residential properties may become difficult to stay to the people. It may result into
property value going down. 

 This may face major delays and cost increases due to land acquisition issues
(Physical relocation of residents and other properties) 

2. ProjectCC-34
2.1 Delhi Metro Rail Transport Service Phase 3:
CC-34 Outer Ring Road Line-Magenta line (Janakpuri west To Botanical Garden
Corridor)
Design and construction of tunnels from near Janakpuri West underground station to Palam
underground metro station by shield TBM, Janakpuri, Dabrimor, Dashrathpuri underground
stations by Cut and Cover methods and works in connection with interchange facilities
between existing elevated metro station and underground metro station at Janakpuri West
on Janakpuri West to Botanical garden corridor under Delhi MRTS project phase-3.

23. Map of extension orange line of Delhi metro
Contractor: HCC-SAMSUNG JV (Joint venture)
Client : DMRC (Delhi Metro Rail Corporation Limited)
Metro Bhavan, Fire Bridge Lane, Barahambha Road,
New Delhi-110001
Starting Date: 18/2/2013
Completion date: 17/5/2016
Duration: 39 months (169 Weeks)
Contract Rs: 8,659,800,000
Performance security: 10 %( General security) +1 %( extra due to foreign
partner SAMSUNG)
Defect liability period: 52 Weeks (1 year)

24. Amount of third party insurance: Rs 50 million for any incident with no. of
incident unlimited
Insurance for contractor’s equipments: Full replacement 100% price
Insurance for injury to person and property damage: insured performance certificate
Needed.

Chart: 1: ContractValue
Schedule A1 general items
3% 1% Schedule A2 stations
5% 6%
27% Schedule A3 TBM
58%
Schedule A4 Cross pasage
Schedule B items in DSR
Schedule C items not given
in DSR

25. Contract values
TBM – 5034610800
Stations – 2371139280
General item – 487220400
Cross passage – 227369520
2.2 Alignment:
Tunneling: 4.1 km
Vikashpuri: -830.920
To
Palam: +4591.630
Cross over:
1. Kerela school
2. Janakpuri west
Launching station:
1. Vikashpuri
2. Janakpuri west
3. Dashrathpuri
Retrievalshaft
1. Janakpuri weast
2. Dabri mor
3. Palam
TBM bored tunnel having finished diameter of 5.8meter .
Cross over at Kerala school 110 Rmt and next to Janakpuri station 154 Rmt by Cut and
Cover method.

26. Total stretch length- 5422.542 m
Total length of Cut and Cover- 290.488 m
Total length of station- 784.528 m
Total length of Tunnel- 4347.530 m
2.3 Organization chart:

27. Project CC-34
Station (Cut and cover) Cross over (cut and cover) Tunnel(tbm)
2.4 Cut and covermethod:
It is a simple method of construction for shallow depth allowing for excavation to be carried
out from the surface. The two forms of cut & cover tunneling used on site:
1. Bottom-up approach
2. Top-down approach
2.4.1Bottom-Up Approach:
 Bottom-up, cut & cover tunneling begins with the construction of the tunnels
supporting walls or piles. 

 Once the piles are constructed an excavator is used to remove soil and rock to
required depth. 

 During excavation ground anchors will be installed to provide support for the
excavated walls. 

 Construct the roof slab first, once the roof slab is constructed install a strut and
excavate below strut -1. 

 Install strut-2 and excavate below it. 

 After installing 3rd strut construct the base slab and remove it. 

 Construct permanent walls, prepare temporary form work up to concourse level. 

 Construct concourse slab and remove all the form work and struts. 

1. Piling
2. Excavation and ground anchors
3. Roof slab
4. Installation of strut-1 and excavation
5. Installation of strut-2 & 3and excavation below
6. Construct base slab

28. Piles alignment
2.4.2 Top-Downapproach:
 Diaphragm wall Installed in both side up to design depth with coupler bars/dowel bars
for different level slabs as per alignment. if span is more between diaphragm wall
Barrette Piles can be use as a intermediate Columns to support the slabs. 

 The soil is excavated just below roof slab level with margin for P.C.C. thickness, if
roof slab level is more than 3 meter and span is more than structural strut to be
provided to support diaphragm wall as per design. 

 Area to be well compacted and P.C.C to be laid (Thk 50 MM), the top of P.C.C.
should bottom of Slab. over than 3 mm ply to be nailed with concrete surface of
P.C.C., joints between Ply to be sealed with PVC Tape. so ply, PVC sheet will act
as a separator between R.C.C. Slabs and P.C.C. surface. 

 Coupler bars/ Dowel bars to be exposed from Diaphragm wall both end
reinforcement to be completed as per design. 

 R.C.C. slab to be cast with suitable size openings for further Construction in
suitable interval (around 40 t0 50 mt) suit to site and for proper air ventilation. 

 Coupler bars/Dowels bars provisions to be kept for centre wall (In Tunnel case) and
opening closing after construction. 100 mm pipe (1 meter C/C)opening to be kept in

29. roof slab thickness for concreting of center wall. 

 After Casting of slab, excavation to be continued through opening provided with the
help of Long arm excavators/Crane and Bucket. 

 Small excavator to be lowered inside to feed soils for long arm
excavator.(Proper Lighting, Air Circulation is must). 

 P.C.C. to be break by using small excavator and excavation to be continued till base
slab level. 

 Coupler bars to be exposed and base slab to be cast as per design. 

 Center wall to be cast with dowel bars from Base slab and finally connect with
coupler bars from roof slab. 

 Scaffolding and bottom form work to be fixed below openings, coupler bars to be
exposed and reinforcement for opening to be completed and concreting to be
done. 

 After concreting of openings, water proofing if required to be done than backfilling
to be done in layers and finally surface to be leveled and reinstating the same. 

2.5 Tunnel Boring Machine:
Earth Pressure Balance Machine type TBM

30. Components Functions
Shield with screw conveyor and man lock To retain earth and support cutter head, the
conveyor moves the soil away. Man lock is for
maintenance purpose.
Cutting wheel To cut earth strata using pressure and energy
Erector For pick up and moves the segments
Back Up system It consists of separate gantries successively
aligned to supply items
Circuits and Network To control works of TBM and to give
commands to TBM
3.learnings:
3.1 Station Construction:
3.1.1 JanakpuriWest(Bottom-upMethod)
 Surveying 

 Soldier piles installation 

o It is an earth retention technique that retains soil with vertical steel piles
with horizontal lagging. 

o H piles were driven at regular interval along the planned
excavation. o It is a retaining wall with steel. 

 Strutting 

o Struts are fixed with water beam. 

o Between pile and water beam a concrete cover is used normally, but here they
used steel part because in case of concrete cover more time taken for gaining
strength. 

31. Retaining wall formwork lowering

 Retaining wall 

o Installation of Reinforcement cage
o Water stop with plastic sleeves 

o Joint couplers with tie nut of formwork
o Concreting 

o Remove formwork
o Curing 
 Roof slab construction 

o Excavation: Confirmation of formation level 

o Preparation of D-wall surface and exposure of couplers by chipping off the concrete
surface using Electric chipping machine. 

o Removal of bad concrete and cleaned properly by use of air or water jet. 
 Preparation of formation. 

o Lying 50mm thick PCC and curing done by water sprinkling and hessian cloths for 1
day. 

O 3mm thick ply was laid over it. 

o Installing bars. Top bars and Bottom bars. Couplers installation joint with wall an
slab. 

o Concrete placing for roof slab 

o Column Fabrication and concreting.

32. o Curing slab and columns. 

 Excavation 
o Excavation below roof slab up to bottom of base level. Lower the excavator from cut
out on the roof slab.
 Base slab Construction with same method. 

o Fixed alignment for columns
o Foundation work for column
o Lying 50mm thick PCC and curing done by water sprinkling and hessian cloths for 1
day.
o 3mm thick ply was laid over it.
o Installing bars. Top bars and Bottom bars. Couplers installation joint with wall an
slab.
o Concrete placing for roof slab
o Column Fabrication and concreting.
o Curing slab and columns.
 Concourse
slab 
o Staging 

o Ply lying 

o Reinforcement and concreting
o Removal of ply 

o Curing 

o Removal of struts 

 Column construction 


 RCC block wall 

o RCC blocks walls concourse level up to roof base level and base level up to
concourse base level. 

o Between two rows of blocks chicken mesh is provided.
o Column and beams are provided between two walls. 

o Reinforcement of column and beams are done by drilling.
o Concreting in column and beams. 

33.  Construction of Platform: Construction of UPE
walls.
o Fixing of alignment 

o Reinforcement for UPE walls.
o Shuttering 

o Concreting 

o De-shuttering
o Curing 

o Staging for platform level
o Ply lying 
o Reinforcement and concreting
o Removal of ply 

o Curing 

o Water proofing 
 Cut outs 

o Cross members (ISMB 100@ 1000mm c/c) 

o U ties with bottom cross members threaded at both ends. 

o Placing Bearer member orthogonal to cross members (ISMC 75@300 c/c) fixing it by
welding. 

o Placing of 12 mm thick ply board. 

o Lifting the whole assembly to the position of top to bottom.

34. o U-ties will be covered by sleeves. 

o Reinforcing and Concreting 
Achievement of concrete characteristic strength during de-shuttering the u-ties has
connected with long rebar of same diameter by coupler, than the locking of u-tie was
released and gradually the shutter was lowered.
3.1.2 Dashrathpuri(Top-DownMethod)
 Surveying 

 Fix alignment of Diaphragm walls. 

Alignment of D-wall fixed on the ground with the help of total station as per the
relevant drawings. 

 Guide wall installation 

Guide wall of 1.2 m depth is made of reinforcement cement concrete. Distance
between internal face of guide wall is maintained 630mm. 


35. 

Diagram of guide wall



 Construction of D-wall. 
o First Boring was done by means of wire rope grab operator. After
completion of boring bentonite slurry was pumped in.
o Stop end tubes lowered up to the bottom of trench maintaining specified
distance. Verticality measured by plumb bomb.
o Cleaning of excavated trench.
o Installation of Reinforcement cage
inside. o Water bar installation.
o It is done by alternate panel method. Primary panels were casted first leaving
suitable gaps in between.
o Following panels and closing panels were casted in these gaps.
o T shape panels are also used at some places for better support to D-wall if there
is no column near that D-wall.
o Tremmie pipe of 200mm dia was used for concreting. Continuously

36. pouring of Cement bentonite slurry.
o The stop end pipe was removed gradually by use of crane.
Reinforcement cage lifting for diaphragm wall panel construction
Once the bottom of the panel is reached (and cleaned), the reinforcement cage can be lowered
into position. The reinforcement cage is typically suspended from the guide wall panels, and
must have enough transverse and diagonal reinforcement to permit it to be properly lifted and
lowered into place. Sufficient space must be left for at least two or three tremie pipes so that
tremieing can take place.
Concrete tremieing refers to the process of replacing the supporting slurry with the permanent
concrete with the use of vertical pipes called tremies. With the tremies, concreting of a
diaphragm wall starts from the bottom and the tremies are lifted progressively as the concrete
level rises. During this process the tremies are maintained within the freshly poured concrete
for a minimum depth of 2ft or (0.6m). Overpouring might be required to make sure that all
slurry is

37. Reinforcement cage of D-wall
displaced from the panel by concrete. Poor tremieing can result in slurry pockets getting
entraped within the diaphragm wall concrete.
 Construction of Plunge column 
o Prefabricated in advance.
o Welding of plunge column.
o Surveying and setting out. Center points were fixed.
o Barrette piling setup. It is done by means of pilling rig. Verticality check with plumb
line.
o Mud cleaning and disposal.
o Fabrication of cage. Tie wires and tack welded for tie main bars so that it will not
deform while lifting by crane.
o Boring operation. Verticality check by means of spirit level.

38. o The temporary steel casting was driven into stable stratum.
o Koden instrument (Ultrasonic echo sounder) was used to measure the diameter of the
bore.
o The fabricated cage was lifted from one end with crane and other support from bottom
to avoid overstress and bending.
o The plunge column was lifted and inserted vertically.
Picture of plunge column
o Tremmie pipe installed on one side of plunge column. Minimum 3 hours time interval
second stage of concrete took place.
o Backfilling of the trench between plunge column and excavated hole up to guide wall
was carried out after minimum 8 hours of concreting.
 Construction of Slab roof 

o Excavation: Confirmation of formation level 

o Preparation of D-wall surface and exposure of couplers by chipping off the concrete
surface using Electric chipping machine. 

39. 
o Removal of bad concrete and cleaned properly by use of air or water jet.
o Preparation of formation. 

o Lying 50mm thick PCC and curing done by water sprinkling and hessian cloths for 1
day. 

o 3mm thick ply was laid over it. 

o Installing bars. Top bars and Bottom bars. Couplers installation joint with wall an
slab. 

4(no of bars) – T25 (type and dia) – 501 (bar marking) – 125 (spacing) – T1
(position) 

o Concrete placing for roof slab. 

o Column Fabrication and concreting. 

o Sprinkling of Reo-mix for avoid cold joint between D-wall and slab. o
Curing slab and columns. 

o Excavation below roof slab up to bottom of concourse level. from cut out on the
roof slab. 

o Construction of Concourse slab with same cut outs. Columns Constructions. 

o Base slab construction and columns construction. Excavator was lowered 

40. 
 Construction of Platform: Construction of UPE
walls.
o Fixing of alignment 
o Reinforcement for UPE walls.
o Shuttering 

o Concreting 

o De-shuttering 

Platform and UPE wall
o Curing
o Staging for platform level
o Ply lying
o Reinforcement and concreting
o Removal of ply
o Curing

41.  RCC block walls 

o RCC blocks walls concourse level up to roof base level and base level up to
concourse base level.
o Between two rows of blocks chicken mesh is provided.
o Column and beams are provided between two walls.
o Reinforcement of column and beams are done by drilling.
o Concreting in column and beams.
 Roof Cut Outs 

o Cross members (ISMB 100@ 1000mm c/c) 

o U ties with bottom cross members threaded at both ends. 

o Placing Bearer member orthogonal to cross members (ISMC 75@300 c/c) fixing it by
welding. 

o Placing of 12 mm thick ply board. 

o Lifting the whole assembly to the position of top to bottom.
o U-ties will be covered by sleeves. 

o Reinforcing and Concreting 

o Achievement of concrete characteristic strength during de-shuttering the u-ties has
connected with long rebar of same dia by coupler, than the locking of u-tie was
released and gradually the shutter was lowered. 

42. 3.2 Tunnel Construction:
3.2.1 Launching Station:
From where TBM is launched. Here they used 4 TBM.
TBM 1 and 2 launched from Vikaspuri to Janakpuri. TBM 3 and 4 launched from
Janakpuri West to Dashrathpuri. TBM 1 and 2 they used it again from Dashrathpuri to
palam.
3.2.2 Cross Over:
Generally cross over is provided at the last station of one route. It connects two parallel
rail tracks allowing a train on one track to cross over to the other.
3.2.3 Cross passage:
Cross passage is a way between two parallel tunnels. The cross passage is fitted out with
electrical panels, cabling, fire deluge system which along with providing a safe access
between the two tunnels in the event of an emergency.
Here in specific project CC-34 it built by the simple excavation and shotcrete (steel

43. and polypropylene fiber) method.
 The excavation is immediately protected by a layer of sprayed concrete
commonly referred to as shotcrete. 

 Other support measures used are steel arches, rock bolts, mesh etc. This creates a
natural load bearing ring which minimize the deformation of soil. FI 
3.2.4 TBM lowering:
 Tunnel depth is Secant piles are used at the starting edge of Tunnel. 

It is used to transfer lateral, vertical or a combination of both the loads through weak
soil layers to a suitable bearing layer. They can be drilled in all types of configuration
that can form an interlocking water weight wall. 
It is important to install a rail track so that the lowering works can be made faster. 
 Survey points for TBM location on wall. 

From main survey bench mark on site the points are transferred on the wall by total
station, based on which TBM level is decided. Points marked as a permanent survey
colors. 

 The main process was basically based on the lowering of TBM parts. 

The parts of TBM lowered and then joined it because it’s not possible to lower it directly.
o Preparation of base 

o Crane assembly 

o Transportation of parts
o Connection of parts 

o Erection frame and rail line work 


44. o Base slab was made leveled and clean. 

o Steel plates are laid on the surface. Steel plates are welded together as required. 

o Crane always coming on site in parts: 

o Crawlers assemble – Main body parts joined with crawler – Boom is assemble –
Ropes and hooks are installed. 

o Transportation of parts 

o Erection frame and rail line work 

For muck retrieval and segment transportation loco named diesel generated small train engine
is used. This will be resting on the rail so it
Picture of pile breaker and secant piles

45. Initial inspection
Conformation of main power
Grease supply
Start up power unit
Emergency stop analysis
Segment mode Tunnel mode Interlock mode
Segment erection Start cutter rotation checking of each
part
Excavation completion
Stop all activities

46. 3.3 Casting Yard:
A casting yard is a confined place where all the concrete structures like segments, parapets, I-
girders/beams, boundary wall panels, cable troughs etc. Re-casted/manufactured, shifted to
their
stack yard, cured for the specific period/days and then shifted to the working site/viaduct
after
they gain their required strength.
Area of casting yard: 40018.86 m^2
Production scope: Theoretical Production excluding wastage is about 6234
rings Ring dimension: 2900 mm inner radius
275 mm thickness
Width varying from 1380 – 1420 mm

47. 3.3.1 Concrete mix Designforsegments:
3.3.2 PrecastSegments:
Precast concrete segments used in tunnel construction in specific project CC-34.
Production sequence of precast segments on casting yard:
Production process in casting yard:
The casting yard is a very important part of project though the construction activities bond to
casting yard is totally different than the other construction process. The setup of casting yard
is more of factory type production. We can divide the activities of segment production in
main four steps.

48. Types of segments:
1. Left hand tapper
2. Right hand tapper
Both types of rings have 6 segments: 1 key segment + 5 segments
In soft soil strata there will be a problem of wet and damp places where water will be the big
issue. So, direct shotcreting is not possible. . There for they have provided rings which
directly retain the soil mass and by grouting the joints will become strong.

49. 
















segments lifted by erecter of tunnel bore machine



 Segment type 1, 6 & 2 have very special importance. The Key segment is inserted at
last and while placing this it is assured that sufficient pressure will be generated
between segments. 

50. 
 All the segments are joined with the galvanized bolts and black sockets are
inserted during casting to make good bond and provide grip to the joint. 

 The circular dots at intrados are very important. The main reason of providing
them is they stop amplification of sound waves by breaking them. 

 The periphery part of segments are with little shepherded edge and gap is provided
between them to avoid collision of edges while placement that stop erection damages. 

 The marking of each segment will be done with mould number, types of rings,
project name, and name of segment type. So that the misunderstanding and
misplacements can be avoided. 

 It is essential to change key segment position in adjacent rings for proper load
transfer and for provision of staged joints. 

 They used 6 pipes: Inlet water, Outlet water, Dewatering, Cement sand water,
Silicate, Extra pipe. 
 Cement and Silicate mix with each other and it will provide strong joint.
Lafarge cement (OPC 53): 390kg 
Bentonite: 15kg
Accelerator: 95kg
Retarder: 2kg
Water:797 kg
Different pipeline used for watering, dewatering process

51. Ventilationpipe andlocomachine intunnel

52. 3.3.3 ManPowerDistribution Chart:
No Activity Skilled Unskilled Total
Cage Fabrication
1 Cage welding 7 11 18
2 Rebar and Cage shifting 2 2
3 House keeping 1 1
4 Super vision and inspection 1 1
5 Reinforcement machine operator 2 2 4
Casting of segments
6 Mould cleaning and apply deshuttering oil 1 4 5
7 Cage fixing 1 1 2
8 Concreting 3 1 4
9 Segment finishing 2 2
10 Steam curing 2 2
11 Micro finishing 1 2 3
12 Application of curing compound 1 1
13 Segment shifting 2 2 4
14 Housekeeping 4 4
15 Segment stamping 1 1
Extra Activities
16 Cement feeding 10 10
17 Batching plant maintenance 2 4 6
18 Chiller plant maintenance 1 1 2
19 RO plant maintenance 2 1 3
20 Drivers of forklift, excavator, crane 5 5
21 Gentry operator 3 3
Total 37 46 83

53. Concrete mix proportion
Grade of concrete- M50
OPC-53 Ultratech and Lafarge
Microsilica-Elkem
Admixture-BASF/6 ACE30jp
W/c ratio-0.36
Weigh batching
MATERIAL WEIGHT(ULTRATECH) WEIGHT(LAFARGE)
Cement 410.00 400.00
Sand 729.21 788.65
Micro silica 21.00 20.00
10mm aggregate 496.47 567.45
20mm aggregate 604.52 567.45
Water 155.20 152.00
Admixture 2.37 2.10
Batching plant- Schwing stetter-0.5m^3
Total batching plant production of concrete for 1 ring is about 7.50 m^3.Thus for 1
segment ring 15 batches prepared and time taken for total continues production is about
10 to 12 minutes.

54. Time Cycle of SegmentProduction Activity :
Activity Start time End time Total
time
Reinforcement cage preparation 00.00 01.15 01.15
Mould cleaning 00.00 00.15 00.15
Cage transport and fixing 00.15 00.40 00.25
Concrete pouring 00.40 00.50 00.10
Initial setting 00.50 3.20 02.30
Finishing work of top surface of concrete 03.20 3.35 00.15
Steam curing 03.35 8.20 04.45
Cooling and setting of mould 08.20 9.30 01.10
Transportation to repair yard 09.30 10.10 00.40
Repair works and marking 10.10 10.35 00.25
Application of curing compound 10.35 10.50 00.15
Transportation to storage area 10.50 11.10 00.20
Total 12.25

55. 3.3.5 Rate analysis:

57. Tools equipment and plants requirement for segment rings

58. TBM Lowering:
TBM is divided in mainly three parts:
1. Cutter head
2. Main bearing
3. tail skin
Actual sequence of lowering:

59. 3.4.1 Time cycle for TBM lowering:

60. 4.Procurement:
It includes purchasing and other activities like transportation of materials from
store to construction site, Receiving, testing, inspection etc.
Store keeping:
Materials arrives in
truck at Main
gate
Security department make necessary Security
entries and clear the consignment register
receiving
Identify consignment by means of order &
Purchase
Check for damages ordercopy
Notifyprocurement
Discrepancyreport
Issue gate pass for going to store
Prepare goods receipt note Goodsreceipt
Unload unpack Qualitycontrol
Quality control tests
report
Prepare rejectionnote
Returnto supplier
Accepted material report back to store
Update stock registered

61. 5.HeavyEquipments used in project:
Heavy equipment refers to heavy-duty vehicles, specially designed for executing
construction tasks, most frequently ones involving earthwork operations. They are also
known as heavy machines, heavy trucks, construction equipment, engineering equipment,
heavy vehicles, or heavy hydraulics. They usually comprise five equipment systems:
implement, traction, structure, power train, control and information. Heavy equipment
functions through the mechanical advantage of a simple machine, the ratio between input
force applied and force exerted is multiplied. Some equipment uses hydraulic drives as a
primary source of motion.
Electricgeneratorandbulker
These subdivisions, in this order, are the standard heavy equipment categorization. Some
contractors place numbers on the side of their equipment corresponding to the category -
Grader '02' - followed by a sequential number that usually corresponds to the number it was
purchased, for example, 02-112, is the 112th grader a company has purchased since their
founding. This allows for easy recognition of the equipment type and the relevant age.

62. Poke liner and gantry crane
crawler crane

63. Tunnel bore machine

64. 6. Health and Safety:
HCC offer a portfolio of various health and safety training courses, including courses on
manual handling, fire awareness, first aid, Control of Substances Hazardous to Health and
Reporting Injuries, Diseases and Dangerous Occurrences Regulations (RIDDOR).
We are currently working towards offering the NEBOSH General Certficate which we can
deliver as an open or dedicated event. We are also able to provide IOSH courses for both
managers and supervisors.
HCC Health Insurance policy
 Accessto our vastpan IndiaCashlessNetworkcomprising4300+ hospitals
 Coverage of Day-care procedurescosts
 Reimbursementof Pre andposthospitalizationrelatedexpenses
 Twice the sum insuredin case of diagnosisof anyof the 20 maincritical illnesses(on
selectedhealthplans)
 Unlimitedroomrent(onselectedhealthplans)
 Benefitof life longrenewal
 Tax benefitsof uptoRs 25,000 undersection80 (D)
 Multichannel 24x7claimintimationand assistance
 Simple,hasslefree claimsettlementprocess
 Renewal discountof 5%eachclaimfree yearup to a maximumof 5 years ona progressive
scale
 DedicatedClaimsHandlerforhealthinsurance claims.

65. Employee Health and Safety
At HCC, safety at project sites has always been an area of utmost priority
, as reflected in the integrated approach towards Quality, Environmental, Health and Safety
we have adopted in our company Over the past year, we have made significant efforts to meet
the following Occupational Health and safety.
Safety Policyobjectives:
 Minimize risk to our employees and other interested parties who may be exposed
to Occupational Health & Safety risks associated with our activities.
 Continual improvement of the OH & S Management System.
 Reducing the frequency of all incidents and minimizing/eliminating loss of man
days.
 Train and retrain the Site Personnel for enhancing their competence and expertise
with the
 view to reduce accidents/incidents.
 Procure best quality and ensure use of Personal Protective Equipment (PPE)thus
minimizing the exposure to physical risks.
 Integrate OH & S with other business processes




66.  
protection equipments


Safety induction program 

 Training 

 Internal and External (200 workers) 

 Audits and Inspection 

 Internal and External (Quarterly) 

 Token system (underground) 

 I-cards 

 PPE 

 First aid rooms 

 First aid box (Underground 100m) 

 Fire ext 

 Toxic gas control 
 Gas contents checking (4 hours) 

 Color coding (equipment checking) 

 Telephone 

 Helpline numbers 


67. Safety sign Board









 Red signal light 

 Air ventilation 

 Safety notice boards 

 Temperature machine 

69. 8.Quality Checklists:
Construction projects are a balance between cost, time and quality. It is possible to have high
quality and low cost, but at the expense of time, and conversely to have high quality and a
fast project, but at a cost. If both time and money are restricted, then quality is likely to
suffer. High quality is not always the primary objective for the client; time or cost may be
more important. It is only realistic to specify a very high standard of quality if the budget is
available to achieve that standard.
When defining objectives for quality the client should consider:
 Available funding and time.
 Existing corporate policies (such as environmental policies).
 Key requirements of the business.
 Key requirements of stakeholders.
 The views of external organisations such as the local planning authority,
 Local and national legislation (for example local planning requirements for energy
use).
Test of construction materialsat site
 Workabilitytestof concrete –slumptest
 Compressive strengthtest
 Cementtest

70. Future scope and its objectives
Objectives
 To analyze the strength and weakness of the Delhi Metro from socio-economic perspective
 To model the demand-supply curve and various revenue functions
 To estimate the break-even for Delhi Metro
To understand the effect ofDelhi Metro onother modes oftransportation and to study the effects of
common wealth games onrevenues
Future scope
This analysis will help the other metro proposals in pipe-line tostreamline the process ofplanning and assist
the Delhi Metro to improvise its revenue generation &further expansion. Italso provides the assistance for
Delhi government toplan for the other modes oftransport likeLight Rail Transit System, Mono Rail and
dedicated bus corridor Subject to clearance, the Delhi Metro plans to commence work on phase
IV even before work on phase III is completed.
Phase III of the Metro network is scheduled to be completed in 2016, while the DMRC plans
to start work on phase IV by mid-2015. Metro officials hope the project report would get a
final nod by December. The latest proposed phase is scheduled to be completed by 2021. As
per the project report, 67 new stations would come up on six new corridors proposed by the
Delhi Metro. The new corridors include Rithala – Narela (21.73km), Janakpuri West – R.K.
Ashram (28.92km), Mukundpur – Maujpur (12.54km), Inderlok – Indraprastha (12.58km),
Tughlakabad – Aerocity (20.20 km), Lajpat Nagar – Saket G-Block (7.96 km). Completion of
the new corridors would bring remote locations like Narela, Maujpur, Madangir, Bawana,
Barwala, Mukundpur, Najafgarh, Chhawla and Mahipalpur on the Metro map.
“The detail project report has been submitted to the Delhi government and the Union
Ministry of Urban Development. "Six new proposed corridors will add more than 100km to
the existing Metro rail network,” said DMRC spokesperson Anuj Dayal.

71. 9.Conclusion
It was a very good learning experience at HCC-SAMSUNG JV for two months
in New Delhi. I gained a lot of knowledge regarding almost every aspect of
site. I was given exposure in almost all the departments at the site. The friendly
welcome from all the employees is appreciating, sharing their experience and
giving their peace of wisdom which they have gained in long journey of work.
I hope this experience will surely help me in my future and also in shaping my
career.
Thank You
NAVEEN JOSHI

72. References
 Delhi metro books
 From Internet
 Delhi metro Map master plan 2021.
 Delhi Metro Rail Corporation TrafficInfraTech Magazine.
 Delhi Metro website www.dmrc.ltd
 Delhi Metro Rail Corporation Ltd

 G. S. Dhillon (29 January 2004). "Trenchless tunnelling". The Tribune.
 "A dream revisited: an archival journey into the making of the Delhi
Metro Rail". DMRC. 2003. OCLC 54073649.
 "A journey to remember". DMRC. 2008. p. 94. OCLC 300027063.
 "Annual Report 2014-2015" (PDF). DMRC.
 http://www.dailypioneer.com/sunday-edition/sunday-
pioneer/landmark/delhi-metro-to-be-7th-largest-in-world-by-2016.html