DMRC REPORT

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An Industrial Training Report Submitted
In Partial Fulfillment of the Requirements
For the Degree of
BACHELOR OF TECHNOLOGY
in
CIVIL ENGINEERING
by
MD. SHADAB
(Roll No: 1413200099)
Under the Supervision of
Mr. Umesh Billore (Executive Engg.)
Greater Noida Institute of Technology, Greater Noida
NOVEMBER 2017

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CERTIFICATE
Certified that MD. SHADAB (1413200099) has carried out the Industrial Training presented in this
report during the period 10/07/2017 to 10/08/2017 on “DELHI METRO RAIL PROJECT PHASE-III
(UNDERGROUND CONSTRUCTION) ” at “J.KUMAR & CRTG” to fulfill the requirements for the
award of Degree of Bachelor of Technology in Civil engineering from Greater Noida Institute of
Technology, (APJAKTU), under our supervision. The report embodies results of original work, and
trainingis carriedout bythe studenthimself andthe contentsof the reportdonot formthe basisfor
the award of any other degree to the candidate or to anybody else from this or any other
University/Institution. Plagiarism related issue solely stands with the candidate.
Signature Signature
(Dr. B.K.Singh) Ms. KOMAL CHAUDHARY
(HOD/Civil) (Assistant Professor)
GNIOT GNIOT

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DECLARATION
I hereby declare that the Industrial Training Report entitled ("DELHI METRO RAIL
PROJECT PHASE-III, UNDERGROUND CONSTRUCTION") is an authentic record of my
own work as requirements of Industrial Training during the period from 10.07.2017 to
10.08.2017 for the award of degree of B.Tech. in Civil Engineering, Gretaer Noida Institute
of Technology, Greater Noida, under the guidance of Ms. KOMAL CHAUDHARY.
MD. SHADAB
ROLL NO: 1413200099

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ACKNOWLEDGEMENT
I express my satisfactions on the completion of this summer training program and project
report submission as a part of the curriculum for the degree of Bachelor of Technology, Civil
Engineering. I express my deepest gratitude to my supervisor and mentor Mr.Umesh Billore
for his kind guidance during the entire period of training. His consistent support and advices
has helped me to complete this research project successfully. Also I thank all the member of
J. Kumar & CRTG for their kind support. They have always been a source of inspiration to
me.
DATE:- 09/08/17 MD. SHADAB

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TABLE OF CONTEN
. No. Content Page No.
1. Introduction About The Company 6-10
2. EHS Policy 11-12
3. Construction Methodology 13-20
4. Finishing Work 21-25
5. Tunnelling 26-28
6. Batching Plant 28-33
7. Casting Yard 34-39
8. Conclusion 40
9. Reference 41

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1 INTRODUCTION ABOUT THE COMPANY
1.1 About the DMRC
The Delhi Metro Rail Corporation Ltd. (DMRC) is a state owned company that operates
the Delhi Metro in the National Capital Region of India. It was founded on May 3, 1995.
Besides operating the metro, the DMRC is also involved in the planning and implementation
of metro rail, monorail and high speed rail projects in India. The DMRC has equal equity
participation from the Government of India and the Government of Delhi. Its chairman is Dr.
Sudhir Krishna and Managing Director is Mr. Mangu Singh. Mission of Delhi Metro Rail
Corporation:
To cover the whole of Delhi with a Metro Network by the year 2021. · Delhi Metro to be of
world class standards in regard to safety, reliability, punctuality, comfort and customer
satisfaction.Metro to operate on sound commercial lines obviating the need for Government
support.
Delhi Metro is the world's 13th largest metro system in terms of length. Delhi Metro is
India's first modern public transportation system, which has revolutionized travel by
providing a fast, reliable, safe, and comfortable means of transport. All stations have
escalators, elevators, and tactile tiles to guide the visually impaired from station entrances to
trains. It has a combination of elevated, at-grade, and underground lines, and uses both broad
gauge and standard gauge rolling stock. Delhi Metro is the First Railway Project in the world
to be registered for carbon credits by UN. It has been certified that Delhi Metro has saved
90,000 tons of CO2 emissions.
(a) Mission of DMRC:
(b) To cover the whole of Delhi with a Metro Network by the year 2021.
(c) Delhi Metro to be of world class standards in regard to safety, reliability, punctuality,
comfort and Customer satisfaction.
(d) Metro to operate on sound commercial lines obviating the need for Government support
The rail based system will have the following advantages:
1) A high capacity to accommodate adequate number of people and transport them safely.
2) It runs on electricity instead of fuel, reducing the pollution.

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3) Reduces the number of people commuting by private vehicles thus reduces pollution.
4) The tracks will be laid in a manner not to disturb the surroundings and occupy less space.
5) It is fast, reliable, safe and comfortable for the commuters.
DELHI METRO (INTRODUCTION):-
Delhi Metro is a rapid transit system serving Delhi, Gurgaon, Noida, and Ghaziabad in the
National Capital Region of India. Delhi Metro is the world's 13th largest metro system in
terms of length. Delhi Metro is India's first modern public transportation system, which has
revolutionized travel by providing a fast, reliable, safe, and comfortable means of transport.
The network consists of six lines with a total length of 189.63 kilometers (117.83 mi)
with142 stations, of which 35 are underground, five are at-grade, and the remainder are
elevated.

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1.2 J. KUMAR
M/s J. Kumar & Co. is formed in the year 1980 and it is registered independently as Class I-
A Contractor with P.W.D., Government of Maharashtra, registered as Class 'A' contractor
with Mumbai Municipal Corporation, registered as Group 'A' Class I with Vidharbha
Irrigation Development Corporation Nagpur. M/s J. Kumar & Co. is converted into M/s J.
Kumar & Co. (India) Pvt. Ltd., a company registered under Companies Act 1956 and
registered in Class 1-A with Public Works Department, Government of Maharashtra w.e.f.
02.12.1999. As per Memorandum of Association of M/s J. Kumar & Co. (India) Pvt. Ltd.,
the main object of the company is to take over the existing business of Proprietorship
Concern M/s J. Kumar & Co. along with all its liabilities and assets including deposits. M/s
J. Kumar & Co.(India) Pvt. Ltd. has taken over the proprietary concern J. Kumar &
Company. The name of M/s. J. Kumar & Co. (I) Pvt. Ltd. has been changed in to M/s. J.
Kumar Infraprojects Pvt. Ltd., w. e. f. 08.01.07. The same company has been converted into
a Public Limited Company i.e. J. Kumar Infraprojects Ltd., w. e. f. 31.01.07 and registered
with Registrar of Companies, Maharashtra, Mumbai and also registered in Class 1-A with
Public Works Department, Government of Maharashtra w.e.f 30.08.2007. The registrations
of Municipal Corporation of Greater Mumbai and is also obtained in the name of J. Kumar
Infraprojects Ltd.

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1.3 CRTG
China Railway Tunnel Group Co., Ltd. ( CRTG in short), the largest specialized company
in the field of underground works, which integrates design, construction, scientific research
and manufacture into a single entity and is subordinated to China Railway Group Ltd. (
CREC in short), one of the Top 500 World Enterprises and Top 500 World Brands.
CRTG has 14 wholly-owned subsidiaries, 3 holding subsidiaries, 2 share holding
subsidiaries and 8 branch companies. Of which, 5 are tunnel design and survey companies
(inclusive of design review and consultation and project supervision), 7 tunneling
engineering companies, 1 bridge engineering company and 1 electromechanical engineering
company as well as more than 10 other subsidiaries covering the tunneling science research,
tunneling equipment manufacture, engineering testing and inspection, oversea project
construction, national key laboratory and national-level technical center. The engineering
projects currently undertaken by CRTG amounts to 320 in China. 7 branch offices was
established abroad including Singapore, Malaysia, Uzbekistan, Peru, Israel and Greece and 1
in Macao.

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1.4 INTRODUCTIONABOUT THE PROJECT
PARTICULARS OF THE PROJECT:-
CLIENT: Delhi Metro Rail Corporation Limited
CONTRACTOR: J.KUMAR CRTG Joint Venture
BUDGET OF CONTRACT: Rs 374 Cr
CONTRACT PERIOD: 36 Months
COMPLETION DATE: Ongoing
DESIGNER: AECOM
BRIEF SPECIFICATION OF EACH STATION:-
NARAINA VIHAR: Top to Down Method
LENGTH of STATION: 221.33m
LENGTH of TUNNEL: 806.788 m
PROJECT FEATURES:-
LENGTH OF PROJECT: 2 Km
STATION NAMES: NARAINA VIHAR

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2 EHS POLICY
EHS: - Environment, Health & Safety
To implement and maintain, as far as is reasonably practicable, the activities of the company
in such a manner, as to prevent harm or damage to persons and property respectfully.
Safety, health and protection of the environment will form an integral part of our planning
and decision making. We will manage our company, wherever we do business, in an ethical
way that strikes an appropriate and well-reasoned balance between economic, social and
environmental needs.
We are committed to:
(a) Conducting our business with respect and care for people and the environment.
(b) Responsible utilization of natural resources.
(c) Continually improving our safety, health and environmental performance.
(d) Complying, as a minimum, with all applicable legal and other agreed requirements.
(e) Promoting dialogue with stakeholders about safety, health and environmental
performance.
We will achieve these by:
(a) Implementing safety, health, environmental management system.
(b) Informing and appropriately training all employees and contractors on safety, health and
environmental matters.
(c) Responding effectively to safety, health and environmental emergencies involving our
actives and products.
(d) As far as reasonably practicable, providing appropriate resources required to implement
the above.
(e) Ensure that the health, safety and environmental policy is reviewed at periods not
exceeding three years from the effective date or by a date set by the Chief Executive Officer.

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2.1 IMPORTANT WORK FOR SAFTEY ON SITE:-
Wearing of proper helmet, Safety jacket and safety shoes.
Proper housekeeping of all the machines and equipment.
Any sort of misses and warning must be properly taken care of.
Cylinder leaks should be regularly checked.
Electric appliance should be properly used.
Proper training of all the workers.
:

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3 CONSTRUCTION METHODOLOGY
3.1 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.
3.2 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

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3.3 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:
(a) Earthworks (Same as in Top-Down method)
(b) Excavation and Temporary Retaining structures- Rock anchoring/ Strut water
arrangement
(c) RCC Works- Columns, Beams, Slabs, External Wall.
(d) Finishing
3.4 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

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3.5 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 provide additional 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.
3.6 METHODOLOGY
Boring in soil with casing pipe if required and stabilizing liquid to rock head level followed
by drilling into rock to designed socket depth.
(a) Installation of H-beam.
(b) Backfilling of the borehole.
(c) Extraction of the casing.
(d) Soldier piles are used where load on the side is greater

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PLACING OF DIAGONAL STRUT AND SOLDIER PILES
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
3.7 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.

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BOOM PLACER (pouring of concrete in roof slab of ancillary building)

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VIBRATORS
3.8 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 FINISHED BASE SLAB

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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.
3.9 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.

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3.10 FOOTING
Footing is an element of an architectural structure which connects is to the ground, and
transfers loads from the structure to the ground.
Reinforcement ofcolumn and belowthe column footing is ready
At our station every column represents a grid. There are 26 grids on our station and 2 extra
grids also.
3.11 Roofslab
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.

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4 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
4.1 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.

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FLOORING DONE IN ALTERNATE PANELS
WATER LEVEL TO MEASURE THE HEIGHTOF 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

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ASBESTOS STRIPS
NON METALLIC HARDENER
FLOATER DISK FLOATER BLADE
Floater disk is used for levelling surface and floater blade is used for surface smoothness

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4.2 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 quantity in one 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.
4.3 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.
It gives more options to use special lighting systems such as cove lighting, wall washers etc.

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TYPES OF CEILING FINISH AT STATION
Baffle Ceiling (Qty in one station: 3302 SQM)
Metal False Ceiling (Qty in one station: 1616 SQM)
Calcium Silicate (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.

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5 TUNNELING
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. It can bore
through anything from hard rock to sand. Tunnel diameters can range from a meter (using
micro TMB) to 19.25m.Tunnels of less than a meter or so in diameter are typically done
using trenchless construction methods or horizontal Directional drilling rather than TBMs.
Tunnel boring machines are used as an alternative to drilling and blasting (D&B) methods in
rock and conventional 'hand mining' in soil. A TBM has the advantages of limiting the
disturbance to the surrounding ground and producing a smooth tunnel wall. This significantly
reduces the cost of lining the tunnel, and makes them suitable to use in heavily urbanized
areas. TBMs are difficult to transport and require significant infrastructure. The biggest is
built by Herrenknecht AG of Schwanau, Germany to dig the 57km Gotthard Base Tunnel
with a diameter of 19 meters.
A TBM typically consists of one or two shields (large metal cylinders) and trailing support
mechanisms. At the front end of the shield is a rotating cutting wheel.
TBM AT NARAINA

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Behind the cutting wheel is a chamber where, depending on the type of the TBM, the
excavated soil is mixed with slurry. The choice of TBM type depends on the soil
conditions. Systems for removal of the soil are also incorporated into the machine system.
Behind the chamber there is a set of hydraulic jacks supported by the finished part of the
tunnel which push the TBM forward. The action here is much like an earthworm. The
rear section of the TBM is braced against the tunnel walls and used to push the TBM head
forward. At maximum extension the TBM head is then braced against the tunnel walls
and the TBM rear is dragged forward. Behind the shield, inside the finished part of the
tunnel, several support mechanisms which are part of the TBM are located. The systems
are mainly planted for the works such as dirt removal, slurry pipelines if applicable,
control rooms, and rails for transport of the precast segments. The cutting wheel will
typically rotate at 1 to 10 rpm (depending on size and stratum), cutting the rock face into
chips or excavating soil (known as muck). Depending on the type of TBM, the muck will
fall onto a conveyor belt system and be carried out of the tunnel, or be mixed with slurry
and pumped back to the tunnel entrance. Depending on rock strata and tunnel
requirements, the tunnel may be cased, lined, or left unlined. This may be done by
bringing in precast concrete sections that are jacked into place as the TBM moves
forward, by assembling concrete forms, or in some hard rock strata, leaving the tunnel
unlined and relying on the surrounding rock to handle and distribute the load. Tunneling
using TBM is much more efficient and results in a shorter project.

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PARTS OF TBM
READY TUNNEL
6 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 grade 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 level economically. Use of mineral
admixtures like fly ash, slag and silica fume have revolutionized the concrete technology by
increasing strength and durability of concrete by many folds.

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6.1 MIX DESIGN
Concrete is extremely versatile building material because, it can be designed for strength
ranging from M10(10MPa) to M100(100MPa) and workability ranging from 0mm slump to
150mm 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 J.KUMAR CRTG JV is situated in MAYAPURI. 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.
TEST IN LABORATORY
Test of Cement
 Fineness Not less than 225 Sq. m/kg (IS 12269)
Initial & Final Setting Time:-
 Initial not less than 30 min
 Final not greater than 600 min. (IS 12269)
Compressive Strength:
 3 days-Not less than-27 Mpa,
 7 days-Not less than-37 Mpa,
 28 days-Not less than-53 Mpa
Soundness (Le-Chatelier Method):-
 Expansion not more than 10 mm.
 Slump Test
Test of COARSE AGGREGATE:-
Gradation :- As per IS 383/2386
Water absorption :- Less than 30% by weight (IS 383/2386)
Moisture Content :- As per IS 383/2386
Flakiness :- Max 35% · Impact Value :- Max 45% (IS 2386)
Crushing Value :- Max 45% · Bulk Density :- As per IS 383/2386

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

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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

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2) COMPRESSION TEST
3) AGGREGATE IMPACT VALUE TEST

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4) AGGREGATE CRUSHING VALUE TEST
5) FLAKINESS INDEX

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7 CASTING YARD
Casting yard of J.KUMAR CRTG JV CC-20 is located in MAYAPURI. Casting of OTE
DUCT, BLOCKS and SEGMENTS OF RING takes place there.
BLOCK CASTING
Concrete grade:- M7.5.
Size of block:- 400mmx200mmx200mm.
Weight of the block:- 35kg.
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 these block have very less water cement ratio.
SEGMENT CASTING
Grade of concrete used is M50.
In 1 ring concrete used is about 8 cumec.
Demoulding of the segments is done by vacuum.
There are 2 types of rings are casted and are 5.7 dia and 5.8 dia. 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.

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PROCEDURE FOR MAKING ANY SEGMENT:-
1. Ready Mould.
2. Fit r/f cage.
3. Banana bolt.
4. Grouting socket.
5. Concrete Demoulding.
6. Micro finishing.
7. Curing.
8. Gascket (hydrophilic)
9. Transport.
There are 2 type of r/f done in the ring A type and B type. A type r/f is heavy than B type r/f.
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.

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TRIAL ASSEMBLY
WATER PROOFING
Waterproofing is the creation of a relatively impervious membrane, coating, or sealer used in
concealed locations to prevent water from entering or passing through either horizontal or
vertical building materials.
 Chemicals used:
For Priming
Master Emaco 2525 is a solvent free, high-performance, versatile epoxy binder that can be
used to produce a range of epoxy resin based mortars. Master Emaco 2525 can be applied to
both dry and damp surfaces and adheres to most substrates after proper preparation.
Recommended use:
1. Structural bonding of new to old concrete.
2. Production of epoxy resin mortars for floor toppings.
3. Production of epoxy resin mortars to grout bolt holes.
4. Steel bonding.
5. Rapid structural repair of concrete.
6. Grouting dowels.
7. Priming of concrete floors prior to applying Master top Flooring System and master seal.
8. Membrane Systems to achieve structural bond.

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Advantages:
1. Adheres to wet or damp surfaces – Wide application area
2. solvent free - Low VOC and non-shrink
3. Pre-proportioned packaging - No job site errors
4. Multi-purpose binder - Many uses
5. Low viscosity - Easy to apply as primer
6. High abrasion and chemical resistance
7. Can be used as wearing surface Approved to AS/NZS 4020:2002
8. Cures hard at low temperatures – Wide application rang
MASTER SEAL M800:
Description- A highly elastic, solvent free, ultra-fast curing, spray applied polyurethane
coating and it is used in waterproofing applications. Master Seal M800 is a solvent free, two
component.
It is highly reactive and can only be applied by special two component spray equipment
Master Seal M800 is used in a variety of waterproofing applications including roofing,
balconies, podium and car park decks, cut and cover tunneling and basement waterproofing.
FEATURES AND BENEFITS
1. Easy application to complicated details
2. Fast installation
3. Can be applied to a wide range of substrates with the appropriate primer
4. Monolithic – no welds or seams
5. No welding, no torches, no hot works
6. High water vapour permeability – low risk of blistering
7. Excellent mechanical properties
8. Excellent crack bridging properties
9. Root resistant
10. Resistant to standing water
11. Application to vertical surfaces without runs
STEP WISE PROCEDURE OF WATER-PROOFING. SURFACE CONDITIONS:
1. The RCC surface shall be dry before waterproofing.
2. Any ingress for water seepage shall be identified and treated.
3. Construction Joint shall be filled with high performance water stop grout
of crystalline growth.

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The gap between D-wall and slab shall be filled with micro concrete (As shown in figure)
The concrete shall be fully cured before The surface shall be cleaned with wire brush to
remove all algae, fungus and voids, pinholes, cracks shall be treated to level and smoothen
the surface are starting of waterproofing works.
APPLICATION OF WATER PROFFING MEMBRANE:-
Water proofing membrane shall be applied in double layers such that dry film thickness of
the membrane is minimum of 2.5 mm. The entire 2.5 mm layer shall be single monolithic
layer built in two applications.
Master Seal M800 can only be applied by means of a suitable two component spray machine.
The choice of machine depends on the type and size of work and the ease of access.
Master Seal M800 is available with the Part A colored white and the Part B colored black.
This results in a uniform grey color of the sprayed material thus giving the sprayer a visual
control of the quality of the mixing, and machine faults become immediately obvious. If the
membrane color changes, stop spraying anD check machine settings etc.
Master Seal M800 is normally applied at 1.5–2.0kg/SQM this corresponds to a thickness of
1.5–2.0mm.
SPECIAL TWO COMPONENT SPRAY GUN

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MACHINERY REQUIRED
Tunnel bearing machine (TBM)
Vertical grabbing machine (casagrande B 125)
Crawler crane (TATA ,SANY,TFC280)
Tyre crane (TRX1250, Escort)
Silent generator (Cummins, Atarcon, IPEX,EXEL)
Bauer machine (BG20H)
JCB-3D
Rebar Cutting Machine
Soil Compactor
Bar Straightening & cutting machine
Transit Mixer
Boom Lifter etc.

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CONCLUSION
This six weeks training gave me the opportunity to work with some of the best engineering
minds in the country and solve complex engineering & management problems that occur on
field.
1. Construction of underground structures is always a challenge because of the large amount
of machinery and labor involved; hence an engineer on field should also possess
management skills.
2. The use of admixtures, not only shorten the project duration but also help in constructing
a more quality structure with superior aspects as compared to a conventional one.
Admixtures and Chemical were used widely on site.
3. Adequate measures have been taken to ensure the safety of environment and health.
4. The soil used for filling on site was so as to achieve the criteria for the fill.
5. This Project helped me to get acquainted with the pinnacle of technology available for
construction. TBM (Tunnel Boring Machine) was one of them.
6. Rail Transportation systems form the backbone of a city and hence must be designed for
at least a century with no compromise in quality.

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REFERNCE
1. TEXT BOOK OF BUILDING CONSTRUCTION AND MATERIALS (S.K. KATARIA
and SONS).
2. ER. UMESH BILLORE (NARAINA VIHAR).
3. INTERNET