Detailed Specification of construction carried out for the Box-Framed Structure Tunnel

1. Construction of Utility
Tunnel Phase -ll
Prepared by:- Ravi Bhadani

3. Gift City Overview
● Gift is designed to be a global financial services hub
● The project is an initiative of Government of Gujarat (GoG), India.
● The most proactive state in India with a strong emphasis on infrastructure.
● It is being developed and implemented by Gujarat International Finance
Tec-City Company Limited (GIFTCL), a joint venture Company:-
○ Gujarat Urban Development Company Limited (GUDCL)
○ Infrastructure Leasing and Financial Services Ltd (IL&FS)
● Project to be implemented on a Public Private Partnership format.
● The development of the project is planned in 3 phases of 4 years each with
a budgeted cost of Rs. 70,000 crores.
● The City is going to be a business hub attracting I.T. Tech firms, Banks,
Stock Exchanges, Educational Institutions and others.

4. Utility Tunnel
● The Utility provided in Tunnel are:-
○ Power Cable
○ Raw water supply line
○ District Cooling Pipeline
○ Automated Waste Collection pipe
line
○ Fire hydrant water pipe line.
● Total length of the Tunnel within
GIFT City shall be approx. 16.45 km.
● Tunnel is provided with Ventilation
system and Fire & Smoke Detection
System for the purpose of safety.
● The size of the Tunnel shall vary may
go up to as large as 8 M wide x 11M
deep.

6. Design view of Tunnel
● Box Structure
● Haunch are provided so that the
load at the corner is distributed
● Insert plate are inserted at distance
of 1450mm c/c. during concreting
so that there is no need wielding
● Utilities rest on steel hollow
section welded with Insert plate
● Drain is provided so that the
overflow of storm water don’t
take place.
● Sump is provided at every 200m
so that using motor the water is
extracted out.
● Saddle are provided so that DCS
pipe of Diameter of 1000mm is
rested on it.

7. List of Activities During Training
● What are the Materials used in Construction?
● Heavy Equipment used in Construction
● How to layout Baseline and P.C.C ?
● How the Excavation is carried out ?
● Formwork used in Tunnel Construction.
● Reinforcement used in Tunnel Components.
● Design Mix Concrete M30.
● Soil Report and Surface Finishing.
● Defects in Construction work.

8. What are the Materials used in
Construction?
● Cuplock Scaffolding
● Barricades
● Chairs
● Acrow span
● Soldiers
● Tie rods
● Shuttering plates
● Needle vibrator
● steel channel
● Nuts and Bolts
● Insert plate
● jacks and props.
● Concrete Breaker
● Grinding machine

9. Heavy Equipment Used in Construction
● Hydra Mobile Crane (14T
and 25T).
● Concrete Boom Placer
● Volvo Hydraulic Excavator
● Volvo Compactor
● Transits Concrete Mixer
● Mahindra Blazo 25 Dumper
-14m3

10. How to Layout Baseline and P.C.C?
● For a working space of 3m each side marking temporary point on
ground, parallel to tunnel reference point with distance of 3m.
● Layout of an excavation baseline of width 14m and length 20m
from the reference point.
● For P.C.C, M15 is used
● Depth of P.C.C is 100mm.
● Providing 150mm extra width from outer side of wall on both sides.
● Support is provided by shuttering the channel of 100mm on the
ends.
● Inserting the steel rod in earth for checking the surface level at
several intervals.

12. How the Excavation is carried out ?
● After the layout of the Boundary line, with
the help of Hydraulic Excavator the
excavation is carried out in two phase of 5m
each.
● Making the ramp on the other end for further
deep excavation.
● Excavator working 7 hrs/day.
● Lead of 1Km is included in cost of
Excavation
● Appx.10 working days is required for
excavation of length 45m, breath 14m and
depth 10m.
● Excavation Rates:-
○ Upto 4m = 90Rs/m3
○ 4m to 8m = 120Rs/m3
○ 8m to 12m = 150Rs/m3

13. Formwork used in Tunnel Construction
● Various sizes of steel plates are used for formwork.
● Tie rods are used to tighten the formwork while concreting.
● The panel units are held together through the use of suitable clamps or bolts
and nuts.
● For haunch special panels are fabricated in desired shape.
● Stripping time of formwork for component of Tunnel are:-

14. 1. Formwork of Raft
● Locating the temporary
boundary line with white
powder for the side formwork
of raft.
● With the plates of 1250 x 2300
the plates are joined with the
nuts and bolts to form the
horizontal alignment on the
outer side.
● Total width of raft is 6800 mm
and depth of 750 mm

15. 2. Formwork of Haunch and side wall
● Haunch plates of (200 x 425x 300)
and plate 500x1250 are fixed for
concreting.
● Formwork of haunch also acts a
starter of 200mm for the side walls.
● Plates of 1250 x 1250 and soldier of
200x3750 is used for side formwork
● On the sides of plates, soldier of
width 200 mm and height 3750 mm
is attached to attain width of 1450
mm.
● As for placing insert plate length
3340 at distance of 1450 mm c/c,
soldier is placed on surface of insert
plate so that concreting not take
place at surface.

16. ● Slab of width 1750 mm and
depth 250 mm
● Cup-lock scaffolding is framed
with verticals and ledgers up
to height of 4.7m.
● Steel plates of 500x1250 and
haunch plates of 250x1250 are
used for centering
● For 12.5m length, 30 plates of
size (500x1250) and 10
haunch plates of size
(250x1250

17. ● With the help of standards
and ledgers cup-lock
scaffolding is framed for
bottom support.
● For centering plates of
(600x900), (300x900),
(1250x500) and (250x1250)
is used.
● Plates are supported by
adjustable span of 3300mm.
● Spacing of adjustable span
scaffolding is 900mm c/c.

19. ● Mostly reinforcement is from Essar Company.
● Rate of reinforcement (Including binding, cutting bending,
transportation and binding wire) = Rs 63000/MT
● Diameter of bar used in Reinforcing Tunnel component are: - Y8,
Y10, Y12, Y16, Y20, Y25 and Y32.
● As per IS 456:2000, Lap length used is – 50D
● As per IS 456:2000, Development length used is – 50D
● Chairs of Y10 are used in CT slab and top slab at spacing of
1.5m.
● Chairs of Y12 are used in Raft at spacing of 1.5m
● Binding of Main and distribution bars is of wrap and saddle ties.
● If required diameter of bar is not available at site, bundled bars

21. Design Mix Concrete M30
● Admixture used is Yashka
SuperplastE5.
● Concrete M30 is poured by pumping
method at pressure of 71bar.
● Curing of the top slab is done by
ponding atleast 7 days.
● Curing of the wall, CT slab, CT wall
and raft is done by sprinkling of
water.
● Epoxy Resin Bonding is used for old
and new concrete construction joints.
● Construction joints shall be made by
wooden block of width 100mm, after
final placing of concrete
Sr.N
o
Material
Quantity
per cubic
meter
Quantity
per kg
1 Cement in kg 400.0 50.0
2 Sand in kg 792.7 99.1
3
Coarse Aggregate,
20mm
667.9 83.5
4
Coarse Aggregate,
10mm
445.2 55.7
5 Water in liter 187.9 23.5
6 Admixture in liter 4.0 0.50

22. Soil Report and Surface Finishing
● Safe Bearing Capacity at founding level is 25T/SQM.
● Base on soil investigation, the site for proposed construction of
utility tunnel at Gift Gandhinagar is observed silty clay
followed by sandy clay underlain by clayey sand up to 20.0m
termination below OGL.
● The Ground water table was not encountered in the boreholes
up to 20.0m
● The soil is having low swelling properties; hence it can be
used for back or plinth filling purpose.
● For Surface Finishing Grouting and Epoxy Tar based Paint is
used.

23. Defects in Construction Work
● Honey-Combing
● Improper Curing
● Loose Formwork
● Reinforcement
● Collapsing of the soil

24. ● I have learned different parameters to check formwork and shuttering of
R.C.C. elements
● before casting. I also learn the calculation of material required for
shuttering.
● I have learned to prepare BBS and check reinforcement according to
drawing. (Diameter
● of bars, length of bars, lap length and development length etc).
● I have learned how to layout the baseline using co-ordinates on ground
with the help of Total Station.
● In office hours, I learned to scrutinize Bar Bending Schedule (BBS)
prepared by contractor and corrected wherever needed.
● I have visited the RMC plant and studied the Mix design procedure and
sources of material.
● Checking bills claimed by contractor for payment and learned how to
prepare bill file.

25. Thank You