Summer Internship presentation4/5/2015 – 13/6/2015

By : SHUBHAM RANA 12113104

Proposed Project

Lucknow Metro LKCC 01Lucknow , Uttar Pradesh

Phase 1 Priority Corridor “Chaudhary Charan Singh Airport to Charbagh Railway Station”

Total Stretch 8.5 Km

PROJECT DETAILS

PROJECT - LUCKNOW METRO

CLIENT -LUCKNOW METRO RAIL

CORPORATION

CONSULTANT - SYSTRA MVA Consulting (I) Pvt Ltd.

CONTRACTOR–L&T

CONSTRUCTION , HEAVY CIVIL INFRA IC

TYPE OF CONTRACT – LUMPSUM CONTRACT

PROJECT COST - 4992 Crores

CONSTRUCTION PERIOD = September 2014 – December 2016

PROJECT COMPONENT–Pre Cast YardU GirdersBeamsPiers Pier CapPiles Pile Cap

PROJECT LOCATION –Near Domestic Airport , Lucknow.

Salient Features Width of gauge : Standard (1435 mm)

Axle Load: To be designed for 16T

Max Acceleration: 1.0 m/s2 to 1.1 m/s2 ± 5%

Max Deceleration: 1.1 m/s2 (Normal Brake) >1.3m/s2 (Emergency Brake)

Maximum Design Speed: 80 kmph

Maximum Schedule Speed: 34 kmph

Why Metro ? Why is it needed ?

It will provide speedy mass transport for the people of Lucknow.

Helps in reducing a traffic congestion on city roads.

A better means of connectivity from Airport to Railway Station for passengers travelling to and fro.

VARIOUS ASPECTS OF THE PROJECT

ALLIGNMENT : Super elevation on curves is applied to counter the effect of lateral force felt by passengers.

CIRCULAR CURVES : The minimum length of the circular curves should not be less than 25 m in order to accommodate full length of coach.

VERTICAL CURVES : Vertical curves are to be provided when change in gradient exceeds 0.4%

TRACK : From considerations of maintainability, the complete track is proposed to be joint-less and is made of LWR/CWR rails.

RAIL SECTION : Keeping in view the proposed axle load , it is proposed to adopt UIC-60 (60 kg. /m) rail section.

PRE – CAST YARD

Pre Cast is Basically situated in the outskirts of City Region .

This is a confined place where all the concrete Superstructure components for this project are been casted here.

Casting yard stores all the made units prior to erection in viaduct .

It also contains a Fabrication and Scrap Yard Unit , Batching Plants , Storage of Aggregate Fine and Coarse and Prestressing Units.

Precast yard serves an economical and quality control way of constructing components and hence beneficial in projects where mass production is done.

Yard is spread in 27 acres.

Place is suited so as to provide less hindrance to traffic movement while transporting transit mixer and to avoid other nuisance to the public.

Cement used to Mix Design is of OPC 43 grade. Before casting any Structure at Site mix design has to go through several

tests.

7 days Compressive Strength of 6 concrete cube is determined . Strength should come accordingly specified by the consultant , If not then the whole structure is discarded .

Slump test is also conducted at the spot so as to determine the workability of Concrete .If it comes less ,then desired proportions of admixtures are added (plasticizers/water reducer).

COMPONENTS FOR THE SUPERSTRUCTURE1) U – GIRDER

This is a specially designed U shaped Girder which basically provides a track for the running of Metro Train .

Design is maintained in a such a shape so as to provide an Aesthetic attractiveness , Flexible shape to modify, A very Robust Cross Section.

Twin U Girders are placed parallel to each other for the whole length of Track , One for upgoing Train and other downgoing Train. Total of 478 U Girder are Required .

SPECIFICATION :

Length = 27000 mm Concrete Grade = M 55 Breadth = 5050 mm Concrete Quantity = 57m3 Height = 1870 mm Reinforcement = 10.076 MT Dimension of Bars : 12 mm and 16 mm

Cleaning of Formworks using Buffing Machine

Placing of Bars In Reinforcement Jigs

Prestressing Strands are Introduced into the U Girder from one end of the structure to the other .

Hoyer or Long Line Method is adopted , at a time 6 U Girders are Prestressed Simultaneously .

For Prestressing work, low relaxation high tensile steel strands conforming to (IS:14268) 7 Ply Strands of 15.2 mm are drawn through the Structure. Total Strands 72.

Breaking Strength of each Strand 260.7 KN conforming to IS :14268 - 1970.

After Providing Cables , Prestressing strands are fixed against the abutment at one side and at the other side it is fixed to the Prestressing Jacks.

6 Prestressing Jacks , with each jacks connected to 12 strands are stretched to provide required Prestressing before the Concreting is being done .

After Prestressing , strands are anchored at both ends to restrain the prestress.

Concreting

Curing is done for around 7 Days in Formwork itself by using Gunny Bags, so as to maintain required moisture throughout

the day. After 7 days it is being transported by using cranes and stacked above another U Girder

And cured for another 7 days.

Final Step of giving finish and checking tyre pressure before transporting it through Trailors.

2) Pier Cap

The Upper or Bearing part of Bridge or Viaduct , Usually made of Concrete or Hard Stone , which is designed to distribute concentrated loads evenly over the area of the pier.

No. Of Pier Caps Constructed for the project are around 230.

SPECIFICATIONS

Length: 9200 mm

Breadth : 2800 mm

Height : 2000 mm

Diameter of Bars : 16 and 25mm

Concrete Grade : M 45 Concrete Quantity: 27.3 m3 Reinforcement: 3.491 MT

Pier Cap Installation

3) Beams

A beam is a structural element that is capable of withstanding load primarily by resisting bending.

For the purpose of this project beams are made to be placed before placing of slabs for Stations and also I Shaped Girder are casted, which are used in some places instead of U Girder because of Uneven span and curvilinear portion .

Beams of different dimensions are casted depending upon the requirement as per drawing. Length of single beam varies from 10 m to 16 m.

SPECIFICATIONS :

Length : 10 m to 16 m Breadth : 1000mm Height : 1000mm Bar Dimensions : 32mm in longitudinal and 25 mm in Transverse.

Concrete Grade : M 40 Concrete Quantity: 16 to 20 m3 Reinforcement :2.5 to 3 MT

VIADUCT

GEOTECHNICAL INVESTIGATION Geotechnical investigations have been carried out along theproposed alignments to determine the strata, depth of foundation and safe bearing capacity of foundations required.

Subsurface explorations were carried out, 30m bore holes were done at every 500m at the proposed corridor .

Water level was found at a varying depth of about 18 to 27 m that to only in some boreholes only.

The subsoil strata at proposed site is generally homogeneous and comprises of :

Silty Sand /Sandy Silt of Low Plasticity and (Classification as per Clayey Silt of Low Plasticity IS 1498-1970)

PILES

A pile is a vertical structural element of a deep foundation, driven deep into the ground at the building site.

Cast in situ bored Pile are made below the ground level to support all the structures above the ground .

SPECIFICATIONS :

Length of Pile = 30m deep below ground level

Diameter Of Pile = 1200 mm

Capacity of one Pile (Design Load) =400 MT

Ultimate Load =1000 MT

Concrete Grade = M 40

Clear Cover to Any Reinforcement in Pile = 75 mm

Quantity of Concrete in one Pile = 36 m3

Reinforcement : Circular bars = Outer one 16 mm dia. and Spacer bar 25 mm dia. Longitudinal Bar = 8 mm – 16 mm dia. Bars

Construction Methodology of Piles PREBORING

It is suggested that all utilities such as (cables, pipelines ,gaslines , sewerlines) falling within excavation area are diverted away in advance to avoid damage to such utilities during the excavation/ construction phase.

Initial hard strata of the ground is cut by a “Drilling Bucket” , which is a box like structure attached to Rig machine and has a sharp toothed like structure below it .

Then a temporary Mild Steel casing for about 4 to 6 m (approx) length from the ground level will be driven to protect loose soil from falling in the bore hole.

Then a Polymer Powder is added to form a slurry which provides a clear, solid-free, viscous borehole stabilizing fluid till the excavation is done for the piles. Polymer Slurry has a pH of 11 to 12, Specific Gravity of 1-1.04 and Viscosity 65 to 140.

After drilling borehole, reinforcement cage (with sonic tubes of 50mm dia. and 2.9 mm thick attached to the inner rebar cage)is lowered into it . While lowering the cage care has to be taken to install it in gap of 10 m and fillet weld of 6mm is to be provided to join upper end of previous cage with lower end of cage to be lowered.

Sonic Tubes

After cage lowering , Tremie Pipe generally of diameter 200mm and 2-3 m length are lowered one by one and tied to each other . The gap between the bottom of the bore to the end of tremie pipe will be min 300mm.

Upper end of the tremie pipe is connecter to funnel shaped “Hopper” , to which concrete mix is poured .

As the Concreting Proceeds Concrete mix being denser replaces the Polymer slurry and slurry comes out of the borehole and is diverted away from the hole.

A very high Slump Concrete 150 – 200 mm is needed for piling ,regular compaction to be provided by Hydraulic Drilling Machine so as to ensure proper lowering of concrete .

After Few days of setting sonic tubes are filled with water and then in one tube ultrasonic wave emitter probe and in other receiver probes are inserted, knowing the distance between the two tubes , Relative energy, waveform and differential time are recorded and mapped. This is called “Cross Hole Sonic Logging”.

This gives qualitative idea of the structural soundness of the concrete throughout the pile and hence structural integrity of pile can be verified by this method.

PILE CAP

A pile cap is a thick concrete mat that rests on concrete or timber piles that have been driven into soft or unstable ground to provide a suitable stable foundation.

It usually forms part of the foundation of a piers and above superstructure and support base for heavy equipment.

Pile cap is constructed over Piles after they acquire the desired strength , Pile cut off level extends to about 75 mm in the Pile Cap as per the drawing of the site.

SPECIFICATIONS :

Generally for 4 Piles Dimension of Pile Cap is 5300mm x 5300 mm For 6 piles 5300 x 8900 mm For 8 piles 5300 x 12500 mm Height of Pile Cap 1800 mm Clear cover to Reinforcement 75 mm Concrete Grade : M 40

Pile Cap Concrete Volume : pile cap with 4 piles 50.5 m3.For pile cap with 6 piles 85 m3 and so on.

Reinforcement : Top Reinforcement : 16 mm dia. bars on both axis Bottom Reinforcement : 32 & 25 mm dia. bars. Stirrups : 12 mm Dia.

• ,

Pile Cap Cut off level should be at least 500mm below ground level .

After Concreting and few days of curing , Over Pile cap a layer of PCC (Plain Cement Concrete) of 75 mm height is laid , having Compressive Strength of M 15. PCC provides even surface for Pier formation.

After 7 days of continuous curing Pier construction activities are started.

PIER

A pier is a raised structure typically supported by well-spaced piles or pillars.

Pier casted at the viaduct starts from the 0.5 m below the ground level.

Piers are made of varying height giving a slope of about 0.3 for effective flow of Rainwater . Height varies as per the drawing.

Through the piers a 15cm diameter drainage pipe HDPE is inserted to

reach to the ground.

SPECIFICATIONS :

Diameter = 1700 mm Height = 12 m average

Concrete Grade for Pier = M 45 to M 60 as per drawing .

Clear Cover = 50 mm

Reinforcement : Outer Circular Bar 16 mm dia. Spacer Bar = 32 mm Longitudinal Bar = 20 mm - 32 mm depending upon drawings. Starter Bar should start from atleast 300 mm from edge of pier.

CRASH BARRIER To prevent Pier from wear and Tear due to Crashing of vehicles, a

protective Concrete Structure is made around Pier to a height of about 1.5 m from ground level.

It works as a shock absorber and protect pier from Road Accidents.

It has a dimension of 2200 mm diameter.

Concrete Grade = M 30

Clear Cover = 40mm

Gap between the Pier and Crash Barrier boundary is around 250 mm.

BATCHING PLANT

It is a machine that combines various ingredients to form concrete. Some of these inputs include sand, water, aggregate (rocks, gravel, etc.), fly ash, potash, and cement.

At this site there were 2 Batching Plants. CP 30 = which generates 30m3 of concrete in 1hour. CP 60 = which generates 60m3 of concrete in 1 hour.

TRANSIT MIXER

Special concrete transport trucks (in–transit mixers) are made to transport and mix concrete up to the construction site.

One Transit Mixer has the capacity of loading 6m3 of Concrete at a time to the site.

The concrete mixing transport truck maintains the material's liquid state through agitation, or turning of the drum, until delivery.

BOOM PLACER

A concrete pump is a machine used for transferring liquid concrete by pumping.It is known as a trailer-mounted boom concrete pump because it uses a remote controlled articulating robotic arm (called a boom) to place concrete accurate.

GANTRY

Gantry cranes are a type of crane built atop a gantry, which is a structure used to straddle an object or workspace.

These Gantry cranes run over the rail track which are laid in the precast yard.

At the project location they were 4 in Nos. with 3 having capacity of 100 MT for lifting (U-Girders, Pier Cap , Beam , I-Girder), while 1 is of 25 MT for ( Steel Yard).

Thank You