The document provides details about the Vasant Vihar Metro Station project being constructed by L&T-SUCG JV for DMRC Phase III. It discusses the construction methodology used, which is bottom-up for Vasant Vihar station due to medium hard rock profile, and top-down for other stations. It describes the scope of work including construction of tunnels and 5 underground stations. Safety and environmental management practices are emphasized. Construction activities like excavation, soldier piling, rock bolting, and erection of diaphragm walls and retaining walls are outlined.

1. PROJECT REPORT
DMRC PHASE – III CC:27
L&T-SUCG JV DELHI
VASANT VIHAR METRO STATION
SUBMITTED BY- HARKESH SINGH
DEPARTMENT OF CIVIL ENGINEERING
DRONACHARYA COLLEGE OF ENGG. G.NOIDA

2. ACKNOWLEDGEMENT
I am truly grateful to the entire staff of L&T SUCG JV CC27 who has
helped me inunderstanding each of the construction activity and the
project’s minutest detail and has been sogenerous in sharing their
years of experience with a novice like me. It has been a
wonderfullearning experience for me due to their friendliness and
approachability.
I am deeply obliged to Mr. R. G. Saini (Project Director – CC27) for
providing me theopportunity to learn at this excellent project and
encouraging me to put in my best efforts and alsoMr. S. Hariharan (IR
Manager – CC27) for being always there whenever I needed any
assistance.
I am also grateful toMr. ABHAS KUMARSHARMA (Construction
Manager of VASANT VIHAR) for providing me with his
valuableguidance and support at the very early stage of my training.
I would in particular liketo thank Mr. PRABHAT SINHA , Mr.
ANUBHAV SINGH and Ms. AMITA SHARMA from whom I have been
able to learn so much about the project and each of theconstruction
activity comprehensively and have added depth and perspective to my
understandingof the project.

3. TABLE OF CONTENT
1) INTRODUCTION ABOUT THE COMAPNY
2) DMRC
3) L&T
4) SUCG
5) SAFETY & ENVIRONMENT MANAGEMENT
6) INTRODUCTION ABOUT THE PROJECT
7) DETAILS OFEACH STATION
8) CONSTRUCTION METHODOLOGY
9) BATCHING PLANT
10) CASTING YARD
11) TUNNELING
12) CONCLUSION

4. INTRODUCTION ABOUT THE COMAPNY
LARSEN & TOUBRO SUCG
L&T is India's largest engineering and construction company.
Considered to be the "bellwether of India's engineering &
construction sector", L&T was recognized as the company of the
year in Economic Times 2010 awards.
Delhi Metro is a metro system serving Delhi metropolitan area and
its satellite cities of Gurgaon, Noida, Faridabad and Ghaziabad in the
National Capital Region of India. Delhi Metro has been ranked
second among 18 international Metro systems in terms of overall
customer satisfaction in an online customer survey.
SUCG Infrastructure India Pvt. Ltd. is an international company
which integrates overseas construction, design and management,
investment, and sales of construction equipment.

5. DMRC
The Delhi Metro Rail Corporation Ltd., abbreviated to DMRC, is a state-central owned
company that operates the Delhi Metro. The DMRC is also involved in the planning and
implementation of metro rail, monorail, and high-speed rail projects in India and abroad.
The Delhi Metro Rail Corporation Ltd. was created on 3 May 1995 with E. Sreedharan
serving as the first managing director. Sreedharan handed over charge as MD of DMRC to
Mangu Singh on 31 December 2011.
DMRC has made it compulsory to wear safety helmets on construction sites. It also earns
carbon credits with rainwater harvesting at metro stations and runs an HIV/AIDS programme
for workers.
The DMRC has a business development department which is in charge of the consultancy
services.DMRC has served as the project consultant and has prepared detailed project
reports (DPR) for every metro and monorail project in India, except the Kolkata Metro and
Chennai MRTS, which were constructed before the formation of the DMRC.

6. LARSEN AND TOUBRO
HeadquarteredinMumbai,Larsen& ToubroLimitedisone of the largestand most respected
companiesinIndia'sprivate sector.Withover75 yearsof a strong,customerfocusedapproachand
a continuousquestforworld-classquality,L&ThasunmatchedcapabilitiesacrossTechnology,
Engineering,ConstructionandManufacturing,andmaintainsaleadershipinall itsmajorlinesof
business.
Larsen & Toubro is a major technology, engineering, construction, manufacturing and
financial services conglomerate, with global operations. L&T addresses critical needs in key
sectors - Hydrocarbon, Infrastructure, Power, Process Industries and Defense - for customers
in over 30 countries around the world.
L&T is engaged in core, high impact sectors of the economy and our integrated capabilities
span the entire spectrum of ‘design to deliver’. With over 7 decades of a strong, customer
focused approach and a continuous quest for world-class quality, we have unmatched
expertise across Technology, Engineering, Construction, Infrastructure Projects and
Manufacturing, and maintain a leadership in all our major lines of business.
Every aspect of L&T's businesses is characterised by professionalism and high standards of
corporate governance. Sustainability is embedded into our long-term strategy for growth.
The Company’s manufacturing footprint extends across eight countries in addition to India.
L&T has several international offices and a supply chain that extends around the globe.
The company has business interests in engineering, construction, manufacturing goods,
information technology and financial services.The company was founded in Mumbai in
1938 by two DANISH engineers, HENNINGHOLCK-LARSEN and SOREN KRISTIAN TOURBO.
The company began as a representative of DANISH manufacturers of dairy equipment.
For the first quarter of FY 2012-13, L & T Construction has bagged orders worth Rs 2410
CRORES. L&T has expanded its focus to the Middle East, South East ASIA, RUSSIA, CIS,
MAURATIUS, AFRICAN and SAARC countries. It also has keen interest in the markets of
INDIAN OCEAN rim countries, AFRICA and LATIN AMERICA.
L&T is among the top 100 Most Trusted brands of India as published in The Brand Trust
Report.
L&T Won Best Innovation in Logistics-Transportation award on 20 May 2011 from INDIA
International Logistics Forum

7. L&T Won the Financial Express-EVI Green Business Leadership Award for 2010-11. The
award was received from Dr. A.P.J. ABDUL KALAM.
In STOCK MARKET L&T is a very trustable company for investing. Current price of a share is
around Rs 1750 which higher than almost all the other construction companies in INDIA.4
L&T housing finance provides unmatched quality service and transparency right through the
loan procedures.
Company’s motto is IT’S ALL ABOUT IMAGINEERING. IMAGINEERING is a word derived by
two words IMAGINE and ENGINEERING. Thus imagining good stuff and make it real by
means of engineering.

8. SUCG
SHANGHAI URBAN CONSTRUCTION GROUP Corporation, established in October 1996 with
the approval of Shanghai Municipal Party Committee and the Government, is a
comprehensive enterprise particularly supported by the Ministry of Construction and
SHANGHAI Municipal Government.
It is authorized by SHANGHAI State-owned Asset Management Committee to manage the
state-owned assets within the Group. SUCG has the specialclass qualification for municipal
public works, the first-class general contracting qualifications for highway construction,
housing, etc.
In INDIA: With rich experience in design and construction of metro, SUCG has undertaken
three local metro and rail transit projects in the form of EPC, the involved engineering
projects include DELHI.
Elevated Metro Line phase II project BC-7, BC-34, BC-26 project, New Delhi Airport Metro
Express Line C5 project, Chennai Metro phase I UAA-04 project, and Delhi Metro phase III
CC-05 project, Delhi Metro phase III CC-27 project.

9. SAFETY & ENVIRONMENT MANAGEMENT
The Environmental and Safety Management System helps translate our HSE
policy into practice. The Health, Safety and Environmental Management
System (HSEMS) provides a clear and precise description of HOW & WHAT
we do to meet the HSE requirements defined by Legislation and National,
Corporateand International Regulations & Standards. Plan and procedures are
periodically reviewed and upgraded to achieve high HSE performance
standards. We are committed to strengthen HSE management through periodic
audits, training and interaction with national and international organizations.
IMPORTENT WORK FOR SAFTEY ON SITE :-
Wearing of proper helmet, Safety jacket and safety shoes.
Proper housekeeping of all the machines and equipment.
Any sortof misses and warning mustbe properly taken care of.
Cylinder leaks should be regularly checked.
Electric appliance should be properly used.
Proper training of all the workers.

10. :

11. INTRODUCTION ABOUT THE PROJECT
Scope of Work :-Design & Construction of Tunnel from end of underground ramp (near
Shankar Vihar metro station) to HauzKhas Metro Station and
Underground ramp near Shankar Vihar Metro Station and underground metro stations at
VasantVihar,Munirka, R.K. Puram, IIT and HauzKhas on Janakpuri West – Botanical Garden
Corridor of Delhi MRTS Project of Phase – III.Works under Delhi MRTS Project of Phase –III.
Client : Delhi Metro Rail Corporation Ltd. (DMRC)
Contract : CC-27 (UG-2)
Contract Period : 42 Months
Contractor : L&T SUCG JV
JV Partners
: Larsen & Toubro Limited
: Shanghai Urban Construction Group
DMRC’s LOA : DMRC/20/III-057/2012 dated: 1st Nov’ 2012
Date of Signing of Contract : 22-Jan-13
Date of Commencement /
Notice to Proceed :12-Nov-12
Date of Completion of work : 9-May-16
Contract Period : 42 Months
Total Project Value : INR 1252.6 Cr

12. DETAILS OF EACH STATION
VASANTVIHAR
Bottom to up method
265m length
1546m tunnel
VASANT VIHAR is the only metro station of the project CC-27 which is constructed using
Bottom-Up construction methodology. The ground profile of this station is medium hard
rocks. As a result of this, bottom-up method is preferred for this particular station. The TBM
used for tunnelling is also Rock TBM (HERRENKNECHT). There are total 26 grids on this
station. There are 2 back off houses from grid 1 to 7 and grid 20 to 26.
HAUZ KHAS
Top to down method
265m length
36m height
806m tunnel
HAUZ KHAS is an already existing station on yellow line. The second part of HAUZ KHAS
metro station is under construction joining IIT, MUNIRKA, R.K.PURAM and VASANT VIHAR.
The placement of these stations below the ground was to avoid the interruptions in the
traffic caused by the metro rail and the problems caused during the construction of the
station at that location. The road adjoining the station site carries a great amount of load
every day round the clock. The entrance to the station is located on OUTER RING ROAD.
IIT
Top to bottom method
265m length
673m tunnel

13. The station at the IIT is an underground station. The length of the IIT station is 265 m. The
width of the station is 21.57 m. All the stations are built with a basic bench mark. Every part
of the station is made with reference to this bench mark. The station at IIT is predicted to be
used by a huge crowd. As this metro station connects one of the prestigious institute of
India, IIT Delhi and also SDA market is behind IIT Station.
R.K PURAM
Top to bottom method
265m length
1067m tunnel
The approximate length and depth of this station is 265 m and 22m respectively. This station
connects Central Government Employees residential colony in South West DELHI. R.K
PURAM is roughly rectangular, enclosed by RING ROAD to the north, OUTER RING ROAD to
the south facing VASANT VIHAR, RAO TULA RAM MARG to the west and AFRICA AVENUE to
the east. The north-eastern corner of this area is a separate commercial centre called
MADAM BHIKAJI KAMA.
MUNIRKA
Top to bottom method
265m length
1241m tunnelMUNIRKA station is another underground station.. MUNIRKA
station connects JNU campus on south, VASANT VIHAR on North-West, RK PURAM on
northern side and IIT campus and BER SERAI on south-eastern front.

14. CONSTRUCTIONMETHODOLOGY
TOP TO BOTTOM
It is a construction method in which the permanent slabs, in the form of perimeter ring, act
to resist the lateral forces by soil pressure to retaining wall (diaphragm wall) during
excavation of station box. The sequence of slab construction is from the roof slab to the
base slab.
It allows early restoration of the ground surface above the tunnel. Some of the temporary
supports of excavation walls are used as the permanent structural walls. The structural
slabs will act as internal bracing for the support of excavation. It requires less width of
construction area. Construction of roof slab is easy.
Not able to install external waterproofing outside the station box. More complicated
connections for the roof, concourse and base slab. Potential water leakage at the joints
between the slabs and the walls since water bar installation is not possible. Maintaining
quality of construction is difficult.
PROCESS ----
D.WALL ROOF SLAB CONCORSE SLAB BASE SLAB
PALTFORM LEVEL
Component of Works for Top-Down Construction:
1. Earthwork
2. Retaining Structure (Diaphragm Wall)
3. Deep Excavation
4. RCC Works - Columns, Beams, Slabs
5. Finishing

15. BOTTOM TO UP
Quality can be maintained. Waterproofing can be applied to the station box.Drainage
systems can be installed outside the structure to channel water or divert it away from the
structure. No water leakage at the joints between the slabs and the walls since water bars
can be easily installed.
More machinery required for construction than Top-Down construction. The ground
surface can’t be restored to its final condition until the construction is complete. May
require de-watering that could have adverse effects on surrounding infrastructure.
Component of Works for Bottom-Up Construction:
1. Earthworks (Same as in Top-Down method)
2. Excavation and Temporary Retaining structures- Rock anchoring/ Strut waler
arrangement
3. RCC Works- Columns, Beams, Slabs, External Wall.
4. Finishing
EARTHWORKS
Fill material, other than for road works, should be evenly graded granular material. Material
with more than 20% passing a 75 micron sieve or more than 10 % in excess of 75 mm size is
unlikely to be suitable for use. Clods or hard lumps of earth over 75 mm in greatest
dimension shall be broken up before compacting of the material in embankment.
Following types of material are considered unsuitable and shall not be used for fill for
embankment:
Materials brought from swamps, marshes or blogs
Peat, loam, fine silt, log, stump or organic or perishable materials
Material susceptible to spontaneous combustion
Clay of liquid limit exceeding 80 and plasticity index exceeding 55

16. EXCAVATION
Excavation should be carried out by mechanized method up to the formation level at
stages. The activities for carrying out excavation are mainly rock excavation, SHOTCRETE,
ROCK BOLTING, disposal of excavated materials and grout monitoring. Excavation should
be carried out in proper sequence. Before excavating, a trial trench is dug for a depth of
1.5m.
Also, the site should be checked for utility lines and proper diversions should be done
beforehand. Traffic diversion plans should be made and it should be diverted before
starting the excavation. After all these things have been done, excavation is started.
Excavation of the soil can be done in two ways depending on the soil profile.
Soldier Pile
The soldier piles are I-beams that are running through-out the depth of the station and
provide a support to the roof slab and the concourse slab until the base slab is in place to
stabilize the structure. These piles are placed close to the diaphragm walls provideadditional
support to the excavated side in order to avoid the collapse of the soil during the piling
work.
This completes the construction of the supports structure to the main station structure. The
construction of the main station box is then initiated.
METHODOLOGY
1) Boring in soil with casing pipe if required and stabilizing liquid to rock head level
followed by drilling into rock to designed socket depth.
2) Installation of H-beam.
3) Backfilling of the borehole.
4) Extraction of the casing.

17. PLACING OF DIAGONAL STRUT AND SOLDIER PILES
Soldier piles are used where load on the side is greater
ROCK BOLTING
When rock surface is exposed, Geologist shall be contracted to do the mapping of the
rock surface.
METHODOLOGY
1) Drilling
2) Grouting & Installation
3) Testing of Rock Bolts
RETAINING WALL
Retaining walls are structures designed to restrain soil to unnatural slopes. They are used to
bound soils between two different elevations often in areas of terrain possessing
undesirable slopes or in areas where the landscape needs to be shaped severely and
engineered for more specific purposes like hillside farming or roadway overpasses.

19. BOOM PLACER (pouring of concrete in roof slab of ancillary building)
Vibrators :-

20. BASE SLAB
The base slab supports the whole weight of the station. The diaphragm walls of the
station sustain huge amounts of lateral pressure from the backfill. This makes the
diaphragm wall act as a cantilever and it tends to lean inwards, but to sustain the
pressure the roof slab is constructed. The roof slab provides the support at one point.
The concourse slab built after the roof slab provides extra support to the D-wall. When
the base slab is constructed, it completes the box structure and provides additional
support and gives stability to the structure. The major work of the base slab is to support
the tracks and resist the vertical pressure from the ground. The construction process to
construct this slab is also the same as the roof slab and the concourse slab. The base slab
is placed 6.86 meters below the base of concourse slab and it is 900mm thick.
REINFORCEMENT STEEL IN BASE SLAB OF FINISHED BASE SLAB OF ES02
ES02
Steel of the base slab is not placed directly on soil because steel bars corrode in presence of
moisture, it weakens our structure. So first we do PCC on ground
PCC is plain cement concrete. PCC is a construction material generally used in binding
purposes and is composed of Portland cement, fly ash slag cement, aggregate, water and
chemical admixtures.

21. COLOUMS
Columns or pillar in architecture and structural engineering is a structural element that
transmits, through compression, the weight of the structure above to other structural
elements below. It is a compression bar. Below every column there is FOOTING.
FOOTING
Footing is an element of an architectural structure which connects is to the ground, and
transfers loads from the structure to the ground.

22. Reinforcement of column and below the column footing is ready
At our station every column represents a grid. There are 26 grids on our station and 2 extra
grids also.
Roof slab
It is top most slab of the station box which is constructed the first in Top-Down method. For
the construction of the same, excavation is required at first. The excavation may cause a
major problem to the traffic flowing through the area. In that case, proper planning has to
be done beforehand for the diversion of traffic. Excavation should be started only after the
diversion has been done. This soil is then lined with 50mm thick PCC layer and 3mm thick
ply. These ply act as a base support for the concrete layer; it also gives a fine finishand a
uniform surface to the concrete layer. At the time of making of roof slab, several cut-outs
are left for further excavation required for construction of concourse and base slab and for
lowering of TBM for tunnelling.
POURING OF CONCRETE IN ROOF SLAB OF ANCILLARY
BY BOOM PLACER
CONCOURSE SLAB
Outlook of the station is said to be concourse slab. The activities at the station other than
the train tracks are all available on this slab. The slab serves as the gallery of the metro
station. It contains the entry and exit gates to the station, the ticket counters, and security
and fire escape provisions. The construction of the concourse slab is carried out in the

23. same manner as the roof slab. This slab contains larger temporary cut- outs than the roof
slab. Thesecut-out spaces help in the laying and development of the base slab and lowering
of TBM for tunnelling. These cut-outs are closed during the final phase of the construction.
These cut- outs are initially supported by beams to provide stability to the D-walls. These
beams are removed after the structure is stabilized by the construction of the base slab. The
concourse slab is placed 5.25m below the base of the roof slab. Its thickness is 550mm. The
concourse slab contains exhaust vents (Over Track Exhaust ducts) at the sides of the slab.
The concourse slab contains the cavity provided to place the service lines inside the station.
The concourse slab is connected to the base slab with the help of stair case, escalator and
lift.
BLOCK WORK
Block work is required on many places at the site. Block work is expensive than brick work
also more time consuming, but it lasts long. At VASANT VIHAR site after placing of 3 layers
of block 2 steel bars are placed. During block work a LINTEL is provided after 2.35m height
and a column (MULLION) is provided after every 4.2m length and after every 45m length at
station a DOUBLE COLUMN is provided. THERMOCOL is used between double-column to fill
space. Cut-outs are also provided in block work. 10mm thick mortar layer is done between 2
blocks.Block’s size is 400mm*200mm*200mm. Block contain M7.5 grade concrete.
BLOCK WORK AT STATION
Retaining wall is in direct contact with soil, therefore seepage is common problem. So we do
block work in front of the wall. We make SCUPPER DRAIN in between the gap of retaining
wall and block work

24. SCUPPER DRAIN
GROUTING
Grout is generally a mixture of water, cement, sand and sometimes fine gravel (if it is being
used to fill the cores of concrete blocks). It is applied as a thick emulsion and hardens over
time, much like its close relative mortar.
GROUTING PUMP

25. FINISHING WORKS
Finishing works is a final stage of each construction which is a fine job to bring the beauty of
the construction. It also hides the services like conduits, ducting, piping etc. Several types of
finishes can be used based on the material used, environmental conditions and costs.
Finishing can be divided into several sections:
Floor
Wall
Ceiling
FLOORING
Flooring is a general term for a permanent covering of a floor or for the work of
installing such a floor covering.
Floor covering is a term to describe any finish material applied over a floor structure
to provide a walking space.
TYPES OF FLOORING AT VASANT VIHAR
1) Honed/ Polished Granite with Tactile Floor Strip
2) False Floor (600x600mm Floor Tile) 450mm high with Anti Dust sealer coat on
concrete floor below false floor
3) Polished vitrified tiles (600x600mm)
4) 450mm High filled floor with 600x600mm polished vitrified tile flooring
5) Polished KOTA stone (550x550mm)
6) HARDONITE flooring
7) Matt Vitrified tiles 600x600mm
HARDONITE FLOORING
This flooring is done where heavy machineries are there because they create
vibrations, so some hard flooring is required to overcome this.

26. FLOORING DONE IN ALTERNATE PANELS
WATER LEVEL TO MEASURE THE HEIGHT OF DIFFERENT LEVELS
Flooring is done in alternate panels because we have to adjust the ASBESTOS STRIPS in
between adjacent panels that could prevent a crack in 1 panel to pass in another panel.
A non metallic hardener is used in HARDONITE flooring in a quantity of 5 kg/m^2.
This type of flooring is done with the help of FLOATER BLADE and FLOATER DISK

27. ASBESTOS STRIPS
NON METALLIC HARDENER

28. FLOATER DISK FLOATER BLADE
Floater disk is used for levelling surface and floater blade is used for surface smoothness
WALL FINISHING
As the name ‘Wall Finishes’ itself suggests that it is finish given to the wall to enhance the
interior or exterior look of the structure. Wall finishes used for the interiors are quite
delicate and need maintenance.
Wall Finishes provide a decorative skin to conceal building components incl. structural
members, insulation, duct work, pipes and wires etc.
TYPES OF WALL FINISH AT STATION
Polished Granite Cladding
Polished Vitrified Tiles
Glazed Ceramic Tiles
Stainless Steel Cladding
Glass Cladding with Vinyl
Hand Made Tiles Cladding
ANTI DUST PAINT Total quantityinone station:3635 SQM
TEXTURED PAINT Total quantity in one station:1200 SQM
Plaster is required before doing textured paint
Plaster is a building material used for coating walls and ceilings. Plaster is
manufactured as a dry powder and is mixed with water to form a paste when used.
The reaction with water liberates heat through crystallization and the hydrated
plaster that hardens.
CEILING FINISH
A dropped ceiling is a secondary ceiling, hung below the main structural ceiling, is
called false
It is used to conceal various services lines, structural features, open pipes, wiring and
air conditioning ducts.

29. It gives more options to use special lighting systems such as cove lighting, wall
washers etc.
TYPES OF CEILING FINISH AT STATION
Baffle Ceiling (Qty in one station: 3302 SQM)
Metal False Ceiling (Qty in one station: 1616 SQM)
CalciumSilicate (Qty in one station: 40 SQM)
BAFFLE FALSE CEILING METAL FALSE CEILING CALCIUM SILICATE FALSE
SKIRTING
This is a strip of wood or any type marble or anything like that sit in the corner made by the
floor and the wall.

30. TUNNELING
A tunnel is an underground or underwater passageway, enclosed except for entrance
and exit, commonly at each end.
The tunnelling in CC-27 project is taken care by SUCG Infrastructure Pvt. Ltd. There are
different techniques of tunnelling viz. drilling and blasting, NATM, hydraulic splitter,
slurry shield machine, etc. All the tunnels in project CC-27 are to be made using TBM. A
Tunnel Boring Machine (TBM), also known as a "mole", is a machine used to excavate
tunnels with a circular cross section through a variety of soil and rock strata. TBMs and
associated back-up systems are used to highly automate the entire tunnelling process,
reducing tunnelling costs. In certain predominantly urban applications, tunnel boring is
viewed as quick and cost effective alternative to laying surface rails and roads. Expensive
compulsory purchase of buildings and land, with potentially lengthy planning inquiries, is
eliminated.
There are a variety of TBM designs that can operate in a variety of conditions, from hard
rock to soft water-bearing ground. Some types of TBMs, the slurry and earth-pressure
balance machines, have pressurized compartments at the front end, allowing them to be
used in difficult conditions below the water table. This pressurizes the ground ahead of
the TBM cutter head to balance the water pressure. The operators work in normal air
pressure behind the pressurized compartment, but may occasionally have toenter that
compartment to renew or repair the cutters. This requires special precautions, such as
local ground treatment or halting the TBMat a position free from water. Despite these
difficulties, TBMs are now preferred over the older method of tunnelling in compressed
air, with an air lock/decompression chamber some way back from the TBM, which
required operators to work in high pressure and go through decompression procedures
at the end of their shifts, much like deep-sea divers.
The TBMs operating in Project CC-27 are:
1. THI 1 TBM
2. THI 2 TBM
3. OKUMURA TBM
4. HERRENKNECHT TBM

31. 5. MITSUBISHI TBM
.
Initial setups to be done before drive:
1. Ground Treatment
2. Installation of Cradle
3. TBM lifting & assembly
4. Installation of Reaction Frame
5. Installation of Temporary segments
6. Tunnel Eye breaking
Before starting the tunnelling activities, it is necessary to improve the soil characteristics
at the head of the launching shaft /retrieval shaft and along the cross passage. High
Pressure Jet grouting method to improve the soil stabilization (350 to 400 bar pressure).
Cradle is fixed according to the tunnel centre line before TBM unloading.

32. TBM AT VASANT VIHAR
PARTS OF TBM

33. READY TUNNEL
BATCHING PLANT AND CASTING YARD
BATCHING PLANT
Concrete is the basic engineering material used in most of the civil engineering
structures. Its popularity as basic building material in construction is because of, its
economy of use, good durability and ease with which it can be manufactured at site. The
ability to mould it into any shape and size, because of its plasticity in green state and its
subsequent hardening to achieve strength, is particularly useful. Concrete like other
engineering materials needs to be designed for properties like strength, durability,
workability and cohesion. Concrete mix design is the science of deciding relative
proportions of ingredients of concrete, to achieve the desired properties in the most
economical way. With advent of high-rise buildings and pre-stressed concrete, use of
higher grades of concrete is becoming more common. Even the revised IS 456-2000
advocates use of higher grade of concrete for more severe conditions of exposure, for
durability considerations. With advent of new generation admixtures, it is possible to
achieve higher grades of concrete with high workability levels economically. Use of
mineral admixtures like fly ash, slag and silica fume have revolutionised the concrete
technology by increasing strength and durability of concrete by many folds. Mix design
of concrete is becoming more relevant in the above mentioned scenario. However, it
should be borne in mind that mix design when adoptedat site should be implemented
with proper understanding and with necessary precautions.
MIX DESIGN
Concrete is an extremely versatile building material because, it can be designed for
strength ranging from M10 (10MPA) to M100 (100 MPA) and workability ranging from 0
mm slump to 150 mm slump. In all these cases the basic ingredients of concrete are the
same, but it is their relative proportioning that makes the difference.
Batching plant of CC27 L&T-SUCG JV is situated in PUSHP VIHAR. Since it is batching
plant where concrete batch production takes place therefore there is a need of QUALITY
ASSURANCE/ QUALITY CONTROL lab at batching plant. There are two batching systems
at PUSHP VIHAR, CP60 and CP30.

34. M1 AT PUSHP VIHAR
OPERATED BY COMPUTER
System is completely automatic and run by computer. From this plant concrete is
transferred directly to miller (TM).

35. MILLER
Many tests are conducted on this concrete or material by which this concrete is made.
Some of the tests are-:
1) WATER PERMEABLITY TEST
2) COMPRESSION TEST

36. 3) AGGREGATE IMPACT VALUE TEST
4) AGGREGATE CRUSHING VALUE TEST

37. 5) FLAKINESS INDEX
6) SPECIFIC GRAVITY OF COARSE AND FINE AGGREGATE AND CEMENT
7) CUBE TEST TO CHECK COMPRESSIVE AND TESILE STRENGTH

38. CURING
Curing is the very important thing needed in any type of work either brick work,
block work or concrete work. Curing increases the strength of the structure.
CASTING YARD
Casting yard of CC27 L&T-SUCG JV is located in MUNDKA. Casting of OTE DUCT,
BLOCKS and SEGMENTS OF RING takes place there.
BLOCK CASTING
Concrete grade M7.5 is used in casting. Size of the block is 400mm*200mm*200mm.
Weight of the block is about 38 kg. Machine used to cast block at casting yard can
cast 3 blocks at a time. 3 blocks can be casted by the machine in 1.5 min.
Concrete used in casting of this block have very less water cement ratio.

39. SEGMENT CASTING
Grade of concrete used is M50. In 1 ring concrete used is about 8 CUBM. DEMOULDING
of the segments is done by vacuum. 2 types of rings are casted there 5.7DIA and 5.8DIA.
In first type of ring three different types of rings are made depending on the direction in
which tunnel has to go LEFT, RIGHT or STRAIGHT.
In second type of ring it is of universal type direction is controlled only by changing the
position of KEY SEGMENT.

40. SEGMENT LIFTED BY CREATING VACCUM
KEY SEGMENT JUST BEFORE CONCRETE
PROCEDURE FOR MAKING ANY SEGMENT
1) READY MOULD

41. 2) FIT REINFORCEMENT CAGE
3) BANANA BOLTS
4) GROUTING SOCKET
5) CONCRETE
6) DEMOULDING
7) MICRO FINISHING
8) CURING
9) GASCKET(HYDROPHYLLIC)
10) TRANSPORT
CONCRETE POURING

42. MICROFINISHING
READY SEGMENTS WITH GASCKETS
There are 2 type of reinforcements done in the rings A type and B type. A type
reinforcement is heavy than B type reinforcements. A type rings are used in the region
where there is sand and B type is used in rocky region. Also when some rings are ready
we try a trial assembly to see that it is going in the required direction or not.

43. TRIAL ASSEMBLY

44. CONCLUSION
DELHI Metro is a world-class metro. DELHI Metro to be of world class standards in regard
to safety, reliability, punctuality, comfort and customer satisfaction. Duration of this
project is of 42 months, which includesConstruction of Tunnel from end of underground
ramp (near SHANKAR VIHAR metro station) to HAUZKHAS Metro Station and
Underground ramp near SHANKAR VIHAR Metro Station and Underground metro Station
at VASANT VIHAR, MUNIRKA, R.K. PURAM, IIT and HAUZ KHAS on JANAKPURI West.
All the work is carried out as per the proper methodology stated given by contractor (L &
T) which is approved by client (DMRC).Good Co-ordination among all the peoples working
at site as well as regional office. This helps the company achieve its targets within the
desired period.The workers on site are skilled and well aware of the techniques They are
well guided by supervisors and the engineers on site. This helps to improve the efficiency
and quality of the work.