METRO TRAINING PPT BOTTOM UP CONSTRUCTION

1. A detailed presentation on the
construction of underground Metro
Station
Sukhdarshan
Under the guidance of
Mr Tanuj Chopra
L&T SUCG JV DELHI
DMRC CC-27 PROJECT

2. CONTENT
Introduction to Project CC-27
Tendering For the Project
Bore Hole Results
Vasant Vihar structure lay out
Bottom-Up Construction
Excavation/Soil stabilization
Concreting Operation& Repair
Waterproofing of Structure

3. Project Name-Design and construction of tunnel & underground metro stations from Janakpuri
West to Botanical Garden(CC-27)
Key Details
COST OF PROJECT(App) INR 1435 CRORES
COMPLETION PERIOD(Expected) 42 MONTHS
TENDER SECURITY AMOUNT INR 14.35 CRORES
TENDERING AGENCY DMRC
TENDER GIVEN TO L&T-SUCG-JV
Quoted Price & Final Price 1265 CRORES

4. Proposed Route Map for CC-27

5. Tendering For the Project
Tender document is further divided into volumes that define the scope
and procedure for various activities related to project. The CC-27 Tender
Document was further divided into 9 volumes
 Volume 1- Instructions for tenderer and form of tender.
 Volume 2-General conditions and special conditions for contract
 Volume 3-Emplyers Requirement about Functional, Design &
construction.
 Volume 4-Outline Design Specifications
 Volume 5-Outline Construction Specifications
 Volume 6-Tender Drawings
 Volume 7-Bill of Quantities
 Volume 8-Vonditions on Safety, Health & Environment
 Volume 9-Reference Document(Geotechnical report)

6. Eligibility Criteria for bidding
Work Experience
Financial Standings
a) Liquidity
b) Profitability
c) Net Worth
d) Annual Turnover
Bid Capacity Criteria
Minimum Key staff Requirement

7. AWARDING OF TENDER
• The most basic criteria for awarding the tender is as follows but not
limited to it
“The employer awards the contract to the tenderer whose tender has
been determined to be substantially responsive and compliant to the
requirements contained in the tender document & who has offered the
lowest evaluated tender price”

8. MY CONCLUSION
TENDER
A-Z Everything on site …..is done according to the tender document.

9. Bore Hole Data
-Before starting construction Geotechnical data was collected from various
locations along the proposed route to know about soil characteristics.
-Bore Holes were made along the proposed route up to a depth of 30m below
the existing ground level.
Next Image shows the Soil Strata available at various sections of the project.

10. BORE
HOLE
61
BORE
HOLE
35

11. Based on the samples obtained from the bore holes following tests were conducted
on the samples-
Following tests were then performed on the collected samples-
• Sieve analysis.
• Hydrometer testing
• Moisture content
• Specific gravity
• Dry Density
• Atterbergs limit
• Triaxial shear test(uu, cu, cd)
• Consolidation test
• Direct Shear Test
• Chemical analysis of both soil and water samples

12. The collected rock core samples(VASANT VIHAR SITE) were taken and the following tests
were conducted on them-
• Density test
• Water absorption& porosity
• Hardness
• Ucs
• Point load index
• Vasant Vihar-Hard Rock strata (Bottom-Up construction approach)
• Hauz Khas - Soft Soil strata(Top-Bottom construction approach)

13. Vasant Vihar Station
TOP VIEW – VASANT VIHAR
METHOD OF CONSTRUCTION- BOTTOM UP CONSTRUCTION
EAST SIDE
WEST SIDE

14. VASANT VIHAR PLAN
1
2
3
4
D
S.NO DESCRIPTION UNIT SCOPE
1 STATION LENGTH M 265
2 WIDTH(BOX) M 21.57
3 Launching Shafts Num 2
4 Entery/Exit Num 4
East Side
West Side

15. ROOF SLAB
CONCOURSE SLAB
BASE SLAB
1
2
3
4
5
6
7
8
1 BLOCK WORK
2 UPE(UNDER PLATFORM EXHAUST)
3 OTE(OVER TRACK EXHAUST)
4 PLATFORM SLAB
5 FRESH AIR DUCT(ROOF SLAB)
6 SCUPPER DRAIN(BEHIND BW)
7 FALSE CEILING BELOW CONCOURSE
8 COLUMN
9 RETAINING WALL
CROSS SECTIONAL VIEW VASANT VIHAR
9

16. BLOCK WORK INFRONT OF RETAINING WALL Dimension of Block– 400*200*200
Mortar-Cement sand mortar with ratio 1:4
Block Strength- 7.5 N/mm2
MIX –M15
Thickness of the bond-10mm
Joint Type-Basic English Bond(1 block thick)
CONCOURSE SLAB
ROOF SLAB
BLOCK WORK IN FRONT
OF RETAINING WALL
RETAINING WALL
INITIAL LAYER OF BLOCK WORK

17. BLOCK WORK FOR ROOMS
ARCHITECTURAL ROOM PLAN(CONCOURSE SLAB)
EXAMPLE
U23-SAFETY ROOM
U64-ELECTRICAL APPLIANCE REPAIR
U26-WAITING ROOM

18. UPE(UNDER PLATFORM EXHAUST)
BASE SLAB
UPE CUTOUT
PLATFORM SLAB
UNDER PLATFROM
EXHAUST
(UNDER PLATFROM EXHAUST ) are basically cut outs provided below the platform slab

19. OTE(Over Track Exhaust)

20. COOLING MECHANISM OF OTE
OTE LIFTING

21. FRESH AIR DUCTS
Ventilation systems provided below the roof slab for a constant supply
of fresh air.
ROOF SLAB

22. SCUPPER DRAIN(BEHIND BLOCK WORK) Water proofing material (Brush Bond Rfx)
Scupper Drain Behind Block Work
DIMENSION- .37m X .3m
PCC M15
Brush bond Rfx Coating for waterproofing of
thickness 1mm

23. Structural Drawing Scupper Drain

24. False Ceiling

25. Factors that determine the construction approach are
• Soil Profile- As suggested by the geotechnical investigation.
• Site Location-Weather the site is located in an isolated environment or urban dwellings.
• Cost Incurred -Depends
• Surrounding Environment-Weather the Surrounding environment consists of existing
structures and road networks.
• Time Constrain-The total time available for completion of project.
• Availability of Material-The availability of material for filling and construction Activities
to be carried out

26. Vasant Vihar Station
Area-33,706 sqm

27. Hauz Khas Station
Area- 15,533.69sqm

28. Bottom Up construction Method(VASANT VIHAR)
Bottom up construction
involves
Excavation & Soil
Stabilization
Construction of Base slab,
Concourse slab & Roof slab
Construction of Columns and
Retaining wall.
Waterproofing of structure
Filling Operations

29. Excavation
• Excavation on site was carried out according to IS 3764:1992.
• Excavation can be done in many ways depending on the soil profile in our
case it was done using Breakers and Excavators.
• Excavation Volume= 18*265*26=124020 cum(Lump sum)

30. Machinery used in excavation
EXCAVATORS
 Hydraulic 220 Excavator
 Hydraulic 210 Excavator
 Hydraulic 215 Excavator
BREAKERS
Hydraulic 340 Breaker
Hydraulic 210 Breaker
HEAD ATTACHMENT FOR
BREAKER

31. Slope/Soil Stabilization
Soldier Pilling

32. Shot creting
 Shot Creting is done according to IS 9012:1978(reaffirmed 2002)
 Mix- 1:3 To 1:5 is used depending upon surface . W/c is kept at .30-.35
 Plasticizer -6% wt of cement( Glenium sky 777)
 Operating temp- 5deg to 30deg Celsius
Mesh Dia- 4mm
Mesh overlap length- 300mm
Min area for applying-300mm*300mm

33. Procedure For shotcreting 1)Clean the surface off the loose material
and then clean with air compressor.
2) Apply a layer of shortcrete to the surface
and wait for it to cure.
3) Apply the wire mesh on the surface and
bind it to the surface using reinforcements.
4) Now apply the second layer of the
shortcrete on the surface . Keep the nozzle
perpendicular at a distance of 1 to 1.4 m
away form surface.
Mechanism for Dry- Mix shot creting

34. Construction of slabs
Base Slabs
-M40 Grade Concrete was used
-Reinforcement conforming to FE500D shall be used on site.
-Water Stops –PVC water stop will be used to arrest the water leakage (at construction joints)
-Binding wire used for binding reinforcement has a core dia of 1.25mm
-Formwork ply 12mm thick coated with Formwork oil for easy removal of formwork
-Cover blocks should be used depending on clearance that needs to be provided to the reinforcement(50mm Base slab)
-Vibrator of 60mm Dia 4nos.

35. Mix Design of concrete M 40
MATERIAL QUANTIY(KG) TYPE
CEMENT 380 ULTRA TECH(OPC 53 GRADE)
FLYASH 80 Ashtech:IS3812(NTPC BADARPUR)
AGGREGATE(10mm) 481 Kotpulti
AGGREGATE(20mm) 666 Kotpulti
RIVER SAND 677 Yamuna Nagar
W/C RATIO .35
ADMIXTURE @ .85% 3.91 Glenium 147,Suretec(BASF)
W/P CAMPOunds@1% 4.6 MasterPel 760(BASF)
WATER 161 R.O Water at Batching Plant
Following admixture were used
Masterglenium 147 provides
 Extended workability
 Providing the ultimate high strength, especially ready.
Application
Add to the mixture 80% -90% of the calculated water for
the concrete mix and then, with the remaining water
masterglenium 147 must be added to the mixture,
Water Proofing Campound used-
Masterpel 760
 Provides resistance to water penetration either under
hydrostatic pressure or capillary absorption.
 Imparts integral water tightness to structures.
Application
MasterPel 760 is a ready-to-use powder which is
dispensed into the concrete together with the cement.
M-40 has been used for 3 slabs and retaining walls

36. Concreting Operations
Earth CompactorConcreting on site
Proper vibration should be provided in order
to avoid cold joints
Concrete pour sequence

37. • After the final set has taken place wet hessian cloth shall be placed and covered by polythene sheet. The
hessian cloth shall be kept permanently damp
• After 24Hours hessian cloth and the polythene sheet shall be removed and the area would be ponded with
water .
• For vertical curing the hessian cloth along with polythene sheet shall secure the surface for at leasdays
before next vertical pouring begins. The hessian cloth should be damp all the time.

38. Concourse Slab
Concrtete-M40
5.25 m below roof level
Thickness- 550mm
Formwork & scaffolding for Concourse slab

39. Reinforcement For concourse slab
Cut outs provided both on concourse and roof slab

40. Roof Slab
Sealing Of construction Joints on roof slab
Cut Outs of the roof Slab( Sattelite view
Design Mix M-40
Thickness-1.8m
Roof level

41. Machinery used for Concreting
Volume-6cum but loaded up to 5-5.5cum.
Rotations –Depend upon distance and Mix
BOOM PLACER
Concrete Bucket Vol 1-1.2cum
CONCRETING THROUGH PIPES

42. Mix Design M-50
MATERIAL QUANTIY(KG) TYPE
CEMENT 410 ULTRA TECH(OPC 53 GRADE)
MICRO SILICA 22 TAM CEM
AGGREGATE(10mm) 457 Kotpulti
AGGREGATE(20mm) 686 Kotpulti
RIVER SAND 765 Yamuna Nagar
W/C RATIO .37
ADMIXTURE @
.85%
2.16 Glenium sky 777
WATER 151 R.O Water at Batching Plant
M 50 was used for concreting of columns
MasterGlenium SKY 8777 -is the super plasticizer based on
second generation polycarboxylic ether polymers,
developed using nano-technology. The product has been
primarily developed for applications in high performance
ready-mix concrete to facilitate
 Capability of delivering high quality concrete at any
time to the job site in place.Production of concrete with
low w/c ratio that meets international guidelines for
consistency classes (EN 206-1) without loss of
workability.
TAM CEM
TamCem Micro Silica is composed of silicon dioxide
(5i02).Collected from silicon metal and ferrosilicon.
TamCem Micro Silica will react with the Calcium Hydroxide
from the cement, which will form more of the Calcium
Silicate hydrate, increasing the strength of the concrete.

43. Concrete Repairing
BULGED CONCRETE
Bulged Concrete – Bulging in concrete takes place due to displacement of formwork.
Surface preparation: The bulged area on concrete surface shall be hacked with chisel to
required line, level. All dirt, dust shall be cleaned with brush and water.
Repairing: Hacked area will be patched up with cement: sand mortar of proportion 1:4.
On the completion of patch up work, the exposed area shall be thoroughly cured.
Grout Loss Exposed aggregate surface created by exit of cement slurry/grout mortar from
the gaps of formwork due to excessive vibration, unsealed joint of formwork
during pouring of concrete.
Repair
-The concrete surface is cleaned and free from dust/oil/grease etc by using
broom or wire mesh by scrubbing vigorously.
-After removal of loose particles surface is washed with water.
-Patch-up is done at cleaned surface with non-shrink Grout conbextra GP2

44. It is due segregation of aggregates and mortar into the concrete.
Honeycomb creates in structures due to mainly improper
compaction in terms of excessive/insufficient vibration at the
time of placing.
Minor Honey Combing
Major Honeycombing
Repairing Involves-
The loose aggregate that are exposed shall be removed by
gently tapping on it. After removal of all loose aggregate,
dust, dirt etc. by wire/Soft brush then surface will be
cleaned with Water. Patchup is done by using conbextra
GP2/Rendroc which is mixed with cement and then the
paste is applied.

45. Waterproofing of Structure
Chemicals used for Waterproofing
-For Priming Purpose
Master Seal M2525(Provided In two component A & B)
-Waterproofing Layer
Master Seal M800(Provided In two component A & B)
Master Seal M2525-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.
Used For-
 Structural bonding of new to old concrete
 Production of epoxy resin mortars to grout bolt holes
 Steel bonding

46. Master Seal M800
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 substance. It is a
highly reactive two component mixture used for waterproofing in tunneling and cut & cover stations
Uses-
Waterproofing compound with a setting time of 2-3seconds
Step wise Process for Waterproofing.
-SURFACE CONDITIONS
The RCC surface shall be dry before waterproofing.
Any ingress for water seepage shall be identified and treated.
Construction Joint shall be filled with high performance water stop grout of crystalline growth.
Step 1 Surface Preparation & Filling of
any voids by Epoxy and Cement

47. -MIXING
• Application of Primer Involves mixing of component A and B and application on
the surface as shown MIXING OF A & B
-Thin coat of mixed primer (RESIN + HARDNER) on the surface shall be
mechanically & uniformly applied, ensuring continuous film soon after surface
preparation is complete.
-Moisture content in the substrate shall be less than 5 %.
-The drying period of primer depends on the ambient temperature and relative
humidity.

48. Checking moisture before application of
primer.
BASF AGGREGATES
BASF AGGREGATES are sprinkled over the primer layer immediately after application of
the primer. Aggregates help in roughening the surface of primer for proper bonding
between the primer layer and the waterproofing membrane layer.

49. Application of the water proofing
Layer with 2 component gun
Special 2 Component
gun used for applying
waterproofing
campound
-MasterSeal M800 is available with the Part A coloured white
and the Part B colored black.
-This results in a uniform grey colour 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 colour changes, stop spraying and check
machine .
-MasterSeal M800 is normally applied at 1.5–2.0kg/SQM this
corresponds to a thickness of 1.5–2.0mm.
Ponding test

50. Protective Covering to Waterproofing membrane

51. Backfilling Operations

52. THANK YOU!!!