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Introduction
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- 4. engineering and services extend to large industrial and infrastructure projects from concept to commissioning. L&T Construction has played a prominent role in India’s industrial and infrastructure development by executing several projects across length and breadth of the country and abroad. For ease of operations and better project management, in‐depth technology and business development as well as to focus attention on domestic and international project execution, entire operations of L&T Construction are structured into four Independent Companies: ● Infrastructure ● Buildings and factories ●Power transmission and distribution projects Metallurgical and material handling projects ACKNOWLEDGEMENT It’s been a great honor to have been trained under this esteemed organization and to have gained such knowledge which we can implement in our future .
- 5. Firstly we thankMr. Dhiraj Kumar HR to have offered us this internship and we would want to also thank Mr. Jagadish – PM of stage2 for guiding us throughout the internship. We also thank each and every person who has helped us gain knowledge.
- 6. HYDERABAD METRO RAIL PROJECT Mission of HMR: "To create anefficient, safe, reliable, economical & world class public transportation system in Hyderabad which will facilitate the city's transformation as a competitive global city with high quality of life"
- 7. Need for Metro: Greater Hyderabad isa mega city that covers 625 sq. km. of municipal corporation area and 6,852 sq. km. of metropolitan area. It is fast emerging as the hub of IT/ITES, Biotech, Pharma and Tourism sectors. Its strategic geographical location, multilingual and cosmopolitan culture, tremendous growth potential and investment‐friendly economic policy are all making it an attractive destination for corporates, entrepreneurs, academicians and homemakers alike. • Its population stands at 8 million and is projected to touch 13.6 million by 2021. • Currently, over 3 million personalized vehicles ply on Hyderabad roads, with an addition of 0.20 million vehicles every year. • 8 million motorized trips are made every day, of which, only about 3.2 million or 40% are made by the Public Transportation System (PTS) i.e. buses and local trains. That means the rest of the trips are made by personal vehicles leading to traffic bottlenecks, high pollution levels and a steep increase in fuel consumption.
- 8. • A people‐friendlycity is that which provides a good quality of life. An efficient, safe, reliable and comfortable public transportation system is one of the pre‐requisites of good living. • The increasing pressure of the burgeoning population is putting Hyderabad's Transportation System under constant pressure. The need of the hour is a robust system that is dependable, comfortable, affordable and sustainable. The answer lies in Mass Rapid Transit System (MRTS). Accordingly, the development of Metro Rail was approved for 72 km., covering three high density traffic corridors of Hyderabad. The Project is being developed on Design‐Build‐Finance‐Operate‐Transfer (DBFOT) basis in Public Private Partnership (PPP) mode.
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- 11. Construction Schedule: Corridor Number Corridor Details Corridor I Miyapur to LB Nagar Stage 2 Miyapur to S R Nagar Stage 5 S R Nagar to L B Nagar Corridor II JBS to Falaknuma Stage 6 JBS to Falaknuma Corridor III Nagole to Shilparamam Stage 1 Nagole to Mettuguda Stage 3 Mettuguda to Begumpet Stage 4 Begumpet to Shilparamam Stage wise details: Stage TOTAL KMS TOTAL PIERS TOTAL STATIONS Stage‐1 8.01 315 7 Stage‐2 11.90 456 10 Stage‐3 8.25 306 6 Stage‐4 11.03 430 10 Stage‐5 17.31 653 17
- 12. Stage‐5/1 8.05 305 9 Stage‐5/2 9.25 348 8 Stage‐6 15.19 588 14 Stage‐6/1 7.37 287 7 Stage‐6/2 7.87 7 The metro will include 66 ultra modern stations with state of art depots and Complete infrastructure. This is phase I of the construction, if the metro is satisfactory then there will be phase II and further construction will be taking place to connect different parts of the city much better. Then the number of corridors will increase from three, as various others areas will also be covered.
- 13. ENVIRONMENT, HEALTH AND SAFETY Safety Safety is anintegral part of any construction and its un‐interrupted continuation of the process. It is for the safety of workers, health and working conditions of the site and its workers. For prevention of accidents and loss of human life safety measures are must. The site is divided in to PPE and NON‐PPE zone which says whether you are supposed to have your personal protective equipment or whether it is an official area. Good housekeeping is also an integral part of the neatness in the site. All the workers who come are supervised by safety stewards or safety supervisors and are instructed on a daily basis about the safety measures to be taken. And any new members are to be employed a safety induction schedule is made and they are shown videos about safety measures and do’s and don’ts on the site. The videos are
- 14. available in thelocal language as well as Hindi and English. They are animated and user friendly and make the workers clear about how small safety precautions can prevent an accident from taking place. There is an assembly point where all the workers should reach during any emergency and should not do anything and wait for the instructions from the safety supervisors. Mock drills are constructed frequently to educate the employees and prepare them for the emergency situations. L&T also provides awards and rewards for the site which has a zero accident track record as a measure to encourage more sites to follow the same and create a good and safe environment for workers and the construction process not getting any delay due to the accidents and the issues caused due to it. There are different safety measures shown on different segments like, safety during concreting, shuttering, electrical appliance connections etc. During the night shift of the construction proper lighting should be provided and every worker has to wear his reflective jacket and proper illumination of the site is required. Diesel Generators are maintained in case of power failure. Proper barricades should be provided on the road at the pier construction site on the road. Instructions such as keep left, reduced
- 15. carriage area, menat work 50m etc. has to be provided on all the sites where barricades are kept on the road and are to be illuminated in the night. Nets are to be placed for high rise constructions to avoid the dropping of heavy instruments and other materials on the people working on the ground by mistake. Workers are not advised to stand under heavy carrying cranes as there is a chance of failure and the load may directly fall on the workers. Only trained personnel are allowed to use the heavy machinery such as roller, excavator, crane etc. EHS: A Environment, Health and Safety (EHS) Plan has been prepared for the execution of the HMR Miyapur depot. This EHS Plan is a guideline for all employees and personnel working at the site. As well as its subcontractors for ensuring minimum risk to environment, property and human beings working on site or using the roads where construction activity is in progress. This EHS Plan will enable the control of Environment, Health & Safety risks and help in the continual improvement of its EHS performance.
- 16. Certified Integrated ManagementSystem for EHS ➢OHSAS : 18001 ➢ISO : 14001 ➢ISO 9001 : 2008 Objectives of EHS: Establish & define line of command for resolution of all hazard prevention issues. ➢Define individual responsibilities hazard prevention & safety promotion responsibility at each level of the construction team.
- 17. ➢Identify highly hazardousoperations within the scope of work and specify integrated preventive measures to mitigate the same. General EHS PPE’S And Safety Devices These are the various PPE’s and safety devices which are used for various type of protection at site: ➢Head Protection: All personals engaged for this job has to wear safety helmet along with chin strap. ➢Hand Protection: Appropriated hand gloves will be used for materials handling, concreting, welding, grinding, gas cutting, for chemical handling & Electrical work. ➢Eye Protection: Suitable goggles must be ensured for the personnel deployed for welding (Face Shield), Grinding, Gas Cutting, Concreting, Chipping etc. work at site. ➢Ear Protection: The personnel engaged in the noise zone such as compressor operator, Pneumatic Vibrators & Breakers, DG Operator etc. will be equipped with suitable ear protection. ➢Protection from Dust & other poisonous gases: Suitable
- 18. nose mask, faceshield are to be used by the individuals to protect them from dust, fumes & poisonous and toxic gases. ➢Body protection: Appropriate body protection like Boiler Suit, Aprons must be used by the concern personnel at site. ➢Fall protection: All personnel working over 2.0 meter height must have the safety belt tied in his waste at the ground level. Further he will have to anchor the safety belt with a fixed structure before starting the work at height. Some special type of safety belt like fall arrest devices also will be in used according to the nature & area of work. General Guidelines which has to be followed in site: ➢Road Safety inside project:All the roads inside the project area must be in good condition. The repair of the same from time to time should be ensure for safe movement of the vehicles inside the project area will be not more than 15KM / Hrs. At places the boards indicating the speed limit, diversions, steep slope, bend /
- 19. turns will beprovided so as to aware the operator about the site safety rule pertaining to roads. ➢Access, Egress & workstation safety: Proper access to the work place will be provided by suitable means before engaging workmen inside the work area. The accesses must be suitable, stronger & firm enough as per the standard norm. The stacking of materials on the access points should be avoided so as to facilitate the workmen for free movement. The housekeeping & illumination of the on the access will be also ensured. The work area will be made clear from unwanted materials. Suitable platforms are to be provided before allowing any workmen to work at height. The elevated platforms are to be provided by our standard doka Form work system with adequate supports so as to ensure the stability of the working platforms. The openings & cut outs are to be strictly avoided in the work area or working platforms to avoid fall of person & materials form height. ➢Safe use of construction power supply and upkeep / maintenance of Installations:The lay out plan & sketch of construction power sub‐ stations cable laying is to be prepared. The cables for construction supply must be routed through underground with cable indicators so as to locate & maintain the same will be convenient. The sub stations & distribution Boards
- 20. are to beinspected regularly by the concern person (Electrical Dept.) at least once in a month. All the power supply to construction site for portable tools must be routed trough circuit breakers or earth leakage Circuit breakers. ➢Use, Maintenance and Inspection of Plant & Machinery: All the tools, tackles & portable machinery are to be thoroughly inspected & checked before issuing them for site use. Further the maintenance of all such machinery are to be conducted regularly in a proper interval (once in a week) to ensure better utilization of the same at site. The maintenance of plant & machinery like Cranes, Dozers and Vehicles etc. ate to be conducted properly once in a week by the P&M Dept. however the inspection for the same equipment will also carried out jointly by SED & P&M Dept. once in month to ensure the safe use of the same in construction activities. The tools & tackles are to be thoroughly checked by the concern engineer for its capability & suitability before deployment of the same at site. ➢Work Permit System: The work permit systems applicable for the site are to be followed.
- 21. I) Use ofsafe materials & personal Handling Devices as per requirement: II) Special type of safety belts (fall arrester devices) will be used for the workmen Safety Work Procedures Procedures: Safety procedures provide specific step‐by‐step information for all the employees and outline how to conduct a particular task. Purpose: The purpose of safety at the site is to provide guidance for achieving compliance with the requirements at the construction site. In addition to that we have to ensure that all the employers and employees are trained properly and comply with the developed procedures. The main aspects to be followed in safety are: I. ELEMINATION II. SUBSTITUTING
- 22. III. SUPPORTING IV. ADMINISTRATIVE V.PPE (People Protection Equipment’s) I .Elimination This is adopted to reduce the effect of harm caused to the workers at the site or completely eliminate the obstacle which causes problem to the worker. II .Supporting This is adopted when elimination and substitution is not possible. In this the object is provided with supports so that risk assessment is reduced. III .Substitution This is adopted when elimination can't be done i.e. replacing the object which has the same properties in desired position. IV .Administrative
- 23. Barricades are providedby the administrative in prohibited areas which are generally of two types. The main aim of administrative by provide barricades in prohibited areas which generally by two ways. 1. Soft Barricades: These are the barricades which are surrounded by soft plastic material. 2. Rough Barricades: These barricades are surrounded by fencing wire. V. People Protection Equipments It is general method where all the workers are provided with basic equipments to protect themselves from danger by which reduction of harm will be less. Generalize Rules and Regulations: This section shall detail the general HSE rules and regulations to be adopted in the site.
- 24. ➢Use of PersonalProtective Equipments and safety devices relevant to the site activities. ➢General housekeeping stacking of materials. ➢Road safety inside project. ➢Access, Egress, and work station safety. ➢Safe use of construction power supply and up keeping maintenance of installations. ➢Maintenance and Inspection of plant and machinery. ➢ Scaffolding and formwork. SCREENING OF WORKMEN: ➢Screening format is collected from time office by s/c supervisor and filled ➢Signature from site engineer. ➢Safety video is shown in induction room. ➢Signature from safety engineer. ➢CAUTION: (18<Age<55)!!
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- 27. Every Time. All the Time !” – Larsen & Toubro Tests for aggregates : ● Sieve analysis ● Gradation ●Flakiness elongation test ● Aggregate impact value ● Specific gravity and water absorption Sieve analysis: A sample of sky of aggregates taken for test for CA (20mm). Last sieve 4.75mm not equals 1.26mm For FA (10mm) Last sieve 75 microns Sieves ‐4.75mm ‐2.31mm ‐1.18mm ‐0.59mm . .
- 28. . 75microns Flakiness elongation test : Flakiness = thickness 60mm 40mm 31mm Aggregate impact test : ➢12.5mm sieve used for gradation. ➢Aggregate is filled in 4 layers in the cylinder provided below. ➢For each layer 25 blows is given with tapering void . ➢Then the load is allowed to get impacted on the aggregates by lifting and releasing the handler of AIV instrument suddenly. ➢AIV should be greater than 45% always. Specific gravity and water absorbtion tests:
- 29. ➢Specific gravity of aggregate should be in between 2.36‐2.45. Water absorbtion test: ➢CA (wire bucket method) ➢ FA (specific gravity)(pycnometer method) . Wire bucket method: ➢Initial weight of aggregates is noted along with hanger . ➢Water is poured in to the bucket and the hanger is hung to the wire and the aggregate are allowed to soak. ➢Now the hanger is taken out of bucket and aggregates are allowed to dry. ➢Again aggregate weight is noted down. ➢Difference in weights of aggregates before and after soaking in water gives water absorbtion . Pycnometer method: This method is useful for determining specific gravity of aggregates. Weight of aggregates =w1 Weight of (bottle+ water+ sand)=w2
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- 34. BASIC DETAILS: ● Length of the station ‐ 135 m ● Width of the station ‐ 20 m ●Number of piers ‐ 10 ● Number of spans ‐ 9 ● Piers named as ‐ A,B,C,D,E,F,G,H,J,K. Each station has 3 levels namely: ➢Ground level ➢Con‐course level
- 35. ➢Platform level Ground level: The entryand exit takes place at the street level. This is the level access to the concourse level. In a station the street consists of fire water sump and pump house, domestic water pump and pump house and also a diesel generator foundation. There are four arms in the station which provides entry and exit namely arm1, 2, 3, 4. All the arms consist of staircases and two arms have escalators and elevators. Arm 1 and arm 3 are diagonal and they are similar which have staircase and a lift. Arm 2 and arm 4 are diagonal and similar which contains a staircase and an escalator. The arms have their landings on either side of the road that goes beneath the station. PIERS :
- 36. Types Of Piers: ● Normal pier. ● Portal piers & beams. ● Cantilever pier. WORK PROCEDURE ➢ Obtaining Statutory Work Permits: ● The work shall be commenced after obtaining statutory permits from the ● Traffic police department and Greater Hyderabad Municipality Corporation ● And other Government bodies. ➢ Training on Construction Work Procedure:
- 37. ● Construction team shall be trained / detailed about the approved ● Construction Work Procedure (CWP) by Construction manager and Stage . ➢Reinforcement : ● Material ● Preparation of BBS & Submission to Reinforcement Fabrication Yard ● Cutting & Bending of Reinforcement ● Transportation of Reinforcement: ● Placing / fixing of reinforcement ➢ Marking of Pier Coordinates : Marking of pier as per coordinates shall be done as per the GFC drawing at site and co‐ordinates furnished by designer four corner points shall be marked on the pedestal for checking the positioning of the pier starter.
- 38. ➢ Starter concrete : ● Rebar tying ●Formwork ● Concreting including joint preparation ➢ Pier / Pier cap : ● Rebar tying in stages ( including staging)including placing drain pipe and ● Inserts. ● Placing of concrete block ● Formwork in stages ● Checking co‐ordinate for the pier cap center and bearing pedestal. ● Inserting tremie pipe for concreting ● Access ladder ● Concreting and Joint preparation ➢ De Shuttering :
- 39. ● De shuttering shall start after 24 hours of concreting. ● De shuttering shall be done in the reverse sequence described in the formwork of piers. ● De shuttering shall be done carefully so as to avoid any damages to the edges of the pier. ➢ Curing : ● Curing of concrete shall start immediately after removing of formwork. ● Curing shall be done by moist curing (till approval of curing compound is ● obtained) by wrapping the pier with hessian cloth and kept in moist condition for 14 days.
- 40. Concourse level : Stations will becovered by an overlapping roofing system, covering the platform, stairs and escalators. This concourse level for every station is constructed on the piers. This is the level at which technical rooms such as ASS, SER, TER…etc, and non technical rooms such as retail rooms, public toilets, cash toilets...etc, are situated. The height of the concourse level above the ground is 6.75m. LIST OF TECHNICAL ROOMS: ➢ASS‐Auxiliary sub station ➢SER‐Signaling equipment room ➢TER‐Telecom equipment room ➢CGP‐Clean gas room ➢SCR‐Station control room ➢EFO‐Excess fare office ➢UPS‐Uninterruptable power supply room ➢FEA‐fire equipment accessory shaft ➢SMR‐Station manager room ➢TO‐Ticket room LIST OF NON TECHNICAL ROOMS ➢RETAIL ROOMS ➢PUBLIC TOILETS
- 41. ➢CASH ROOM Screed: ● Afloor screed is usually a cementious material made from a 1:3 or 1:4.5 ratio of cement to sharp sand. It may be applied onto either a solid in‐situ concrete ground floor slab or onto a precast concrete floor unit. ● The screed may be directly bonded to the base, with a minimum thickness of 40mm, laid unbounded onto a suitable damp proof membrane which is placed over the slab, with a minimum thickness of 50mm, or, if containing underfloor heating pipes a minimum of 65mm thick. IPS Floor finishing in progress using Tremex Power Float. IPS Flooring: IPS flooring stands for Indian patent stone flooring; it is a basic type of flooring which provides good wearing properties. It is generally used for all types of floors and mix of concrete used for
- 42. IPS flooring specificationis 1:1.5:3 (cement, sand and stone aggregates). As per the nature of use the flooring thickness of concrete is decided from 25 mm to 50 mm. It is laid over the concrete base (1:4:8), which is almost 3 to 4 inches thick plain cement concrete (PCC) base. ● For curing of IPS concrete flooring surface pond or wet Hessian clothes are spread over surface for 15 days. Platform level: This is the level where passengers board the train. This is at height of 5 to 6 meters above the ground level. On this platform level comes the track on which the metro rail travels. It also consists of the roof structure for the platform.
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- 44. ● These tie beams are not provided at expansion joints. i.e. between 5‐6, 11‐12,15‐16,21‐22 rafters. Cross bracings: ● Cross bracing is a system utilized to reinforce building structures in which diagonal supports intersect. ●Cross bracing can increase a building’s capability to withstand seismic activity from an earthquake. ● Cross bracing is usually seen with two diagonal supports placed in an X shaped manner; these support compression and tension forces. ● Depending on the forces, one brace may be in tension while the other is slack. ● Number of cross bracings at each station ‐53 ● As per design cross bracings are provided between 1‐2, 8‐9, 13‐14, 18‐19, 25‐26 Bracing bay.
- 45. Splice plate: ● A plate laid overjoint and fastened to the pieces being joined to provide stiffness. ● The splice joint is used when the material being joined is not available in the length required. It is an alternative to other joints such as the butt joint and the scarf joint ` Gutters: ● Gutter is a narrow trough or duct which collects rainwater from the roof of a station and diverts it away from the structure, typically into a drain. ● Number of gutters used in each station ‐54. Track work: SN. CRITERIA DIMENSION 1. Gauge 1435 mm
- 46. 2. Design speed Max. operating speed 90 Kmph 80 Kmph 3. Max. axle load, loaded condition 17 tonne 4. Maximum Gradient Normal / desirable Limit Exceptional Limit 2.5% 4% 5. Sharpest vertical curve radius Sharpest horizontal curve radius 1500m 120 m (main line track) 90 m (depot track 6. Traction power collection Overhead Catenary system (OCS) at 25kV(AC) Rails shall be used for traction return current. 7. Inclination of Rail 1 in 40 8. Wheel tread profile UIC 510‐2 (S1002); to be interfaced with Rolling Stock Contractor.
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- 48. Some Processes CarriedOut to Build this Mega Structure BATCHING: ● Batching is a process of mixing coarse aggregate, fine aggregates, binding material and admixtures in proportions as per mix design. ● The place where the Batching process is carried out is called Batching Plant. ● Coarse aggregate: 10 mm aggregates, 20 mm aggregates. ● Fine aggregate: Crusher dust.(River sand is avoided as its usage increasing the river depth)
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- 52. ● The slurry was pumped into the pipes with specific pressure and the pipes were closed using end caps after pumping the slurry to required volume. ● A Pressure gauge was used in order to monitor the whole process. Formwork: Formworkis a die or a mould including all supporting structures, used to shape and support the concrete until it attains sufficient strength to carry its own weight. It should be capable of carrying all imposed dead and live loads apart from its own weight. Formwork systems are the backbone of construction activity especially for high‐rise buildings. According to the System Formwork Manual of L&T ECCD, formwork systems constitute about 40% of the cost and 60% of the time for any construction activity. Requirement of a good formwork system ➢How formwork can be erected and de‐shuttered fast. ➢How good concrete quality and surface finish can be achieved. ➢What is the optimum stock of formwork required for the size of work force, the specified time schedule and flow of materials. ➢How safety can be improved for the site personnel.
- 53. ➢What is theoverall cost savings that can be achieved using the right type of formwork Safety in the use of formwork Ensured if ➢ Components are light in weight for handling and placing ➢ Loose or hanging components are minimal ➢ Minimum operations are involved during each repetition ➢ Individual components are self standing ➢ Less making is involved at site formwork Systems facilitates fixing and removal at each location without the use of any sophisticated tools and tackles System has provision for fixing working / Control platforms. FLOORING WORKS The flooring done at the concourse level of any metro station is typical granite flooring. The execution of work is done as per the approved drawing and technical specifications at station.
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- 57. insulation capacity. These blocks are stacked one at a time and held together with fresh concrete mortar to form the desired length and height of the wall. In the site fly ash concrete blocks of size 600X200X200 mm are used. A machine is used to cut the blocks into desired size in the site. There are three bonds involved in blockwork: 1) Stretcher bond 2) English bond 3)Flemish bond Stretcher bond is the bond used in the construction of walls in the site A stretcher bond also known as running bond consists entirely of courses of stretchers, with the bricks in each successive course staggered by half a stretcher. Headers are used as quoins on alternating stretching courses in order to achieve the necessary off‐set. It does not require any header bricks. It is the easiest bond and a minimum amount of cutting is required.
- 58. Precast yard: If in‐situ casting is not possible at site of construction then the sub‐structures are casted in pc yard and brought to site for construction. ● Structures casted can be of three types 1. Pre tensioned. 2.Post tensioned. 3. Casting situ (RCC). 1. In LTHMRP precast yard is a center for casting 1. Spines. 2. Wings. 3. Beams. 4. Planks. 5. Staircase. 6. Lift pit.
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