INDUSTRIAL TRAINING REPORT

On
“CONSTRUCTION OF UNDERGROUND STATION
AT DHANSA, NAJAFGARH”
SESSION 2018-2019

Undertaken at
“DMRC – STEC SUCGIN - JV”
Submitted in partial fulfillment of the requirement
for the award of the degree

BACHELOR OF TECHNOLOGY
in
Civil Engineering

Under the Guidance of: Submitted By:

Name- Chandra Bhushan Kumar Shadab Ahmed
(CM Dhansa)
(1603000082)
DMRC

Inderprastha Engineering College Sahibabad, Ghaziabad

APJ Abdul Kalam Technical University
 Acknowledgement

I take this opportunity to express a deep sense of gratitude to Mr. Sanjay Singh and Mr.
Anubhav Triphati, JE Dhansa, DMRC, for his cordial support, valuable information and
guidance, which helped me in completing this task through various stages.
I am also obliged to staff members of DMRC STEC SUCGIN-JV, for the valuable
information provided by them in their respective fields. I am grateful for their cooperation
during the period of my Industrial Training.
I would like to express my sincere gratitude to my Prof. Seema Khan for giving me the
opportunity to complete my industrial training. It would never be possible for us to take this
project to this level without his innovative ideas and his relent less support and encouragement.

SHADAB AHMED
(1603000082)
(CE IV SEM)
 Declaration
I hereby declare that the Industrial training report entitled (“CONSTRUCTION
OF UNDERGROUND STATION AT DHANSA, NAJAFGARH”) is an
authentic record of my own work as requirement of Industrial training during
the period of 11 June, 2018 to 06 July, 2018 for the award of degree of B.Tech
(Civil Engineering), INDERPRASTHA ENGINEERING COLLEGE, under
the of Junior Engineer.

Signature
(Shadab Ahmed)
Date: 31-07-2019 (1603000082)
 Index
List Of Table ………………………………………………………………………………iii
List Of Figure ……………………………………...………………………………………iv

Chapter 1 Introduction
1.1 General………………………………………………………………………………….1
1.1.2 Project Details…………………………….…………………………….……….2
1.1.3 Site Location……...……………………………….………………….…...….…3
1.1.4 Safety Induction…...………………...….…………………………………….…4
1.2 General Construction Activity………………………………………………….……...4
1.2.1 Precondition Building Survey……………………………………………..…….5
1.2.2 Geotechnical Investigation………………………………………………..……..6
1.2.3 Utility Diversion…………………………………………………………...…….6

Chapter 2 Station
2.1 Guide Wall……………………………………………………………………….…...…8
2.2 Diaphragm Wall………………………………………………………..………………..9
2.2.1 Diaphragm Wall Excavation………………………………….………………..10
2.2.2 Cage Lifting And Placing………………………………………………………12
2.2.3 Placing Of Concrete……………………………………………………………13
2.2.4 Poly Mud Slurry………………………………………………….…………….14
2.3 Plunge Column……………………………………………………….……..………….16

Chapter 5 Conclusion…………………...……………………………………..…..……….52

Chapter 6 Reference………………………………………………………….……….……53
List Of Table

Table 1 Station Detail 2

Table 2 Concreting Parameters 13
Table 3 Specification Of Polymer 15
List Of Figure

Figure 1 Metro Map 1

Figure 2 Metro 2
Figure 3 Site Location 3
Figure 4 Station on Metro Map 3
Figure 5 PPE (Personal Protective Equipment) 4
Figure 6 Colour Code For Lifting Tool 4
Figure 7 Utility Diversion 7
Figure 8 Guide Wall 9
Figure 9 Diaphragm Wall Pannel 10
Figure 10 Diaphragm Wall Layout 10
Figure 11 Diaphragm Wall Excavation 11
Figure 12 Cage Lifting 12
Figure 13 Tremie Pipes and Hopper 14
Figure 14 Marsh Cone For Viscosity Test 15
Figure 15 Fabrication Of Plunge Column 16
 Chapter 1
INTRODUCTION
1.1 General
The Delhi Metro has been instrumental in ushering in a new era in the sphere of mass urban
transportation in India. The swanky and modern Metro system introduced comfortable, air
conditioned and eco-friendly services for the first time in India and completely revolutionized
the mass transportation scenario not only in the National Capital Region but the entire country.
Having constructed a massive network of about 373 Km with 271 stations in record time in
Delhi, NCR, the DMRC today stands out as a shining example of how a mammoth technically
complex infrastructure project can be completed before time and within budgeted cost by a
Government agency.
The Delhi Metro Rail Corporation Limited (DMRC) was registered on 3rd May 1995 under the
Companies Act, 1956 with equal equity participation of the Government of the National Capital
Territory of Delhi (GNCTD) and the Central Government to implement the dream of
construction and operation of a world- class Mass Rapid Transport System (MRTS).
The DMRC opened its first corridor between Shahdara and Tis Hazari on 25th December,
2002. Subsequently, the first phase of construction worth 65 kilometres of Metro lines was
finished two years and nine months ahead of schedule in 2005. Since then the DMRC has also
completed the construction of another 125 kilometres of Metro corridors under the second phase
in only four and a half years.
 Figure 1 Metro Map

1.1.2 PROJECT DETAILS

“Design and construction of twin tunnel by shield TBM, Cut and Cover Tunnel Box and One
Underground Station namely Dhansa Stand including architectural finishing, water supply,
sanitary installation and drainage works from chainage 4121.350 to 5340.00 for extension of
Dwarka Najafgarh metro corridor of Delhi MRTS phase -III “CONTRACT: CC-126.

Table 1 Station Details

Location Dhansa Bus Stand, New Delhi

Starting Date 23rd October 2017

Completion Date 22nd October 2020

Client DMRC

Contractor STEC-SUCGIN JV

Contract Value INR 334,99,81,200.00

Figure 2 Metro

Project Scope-
1 - Underground Station Tunnel Cut and Cover Tunnel.
 Dimension: 200.055 X 33.737 m
 Depth : 19.7 m
 Construction Methodology: Top Down Method
 Location: Dhansa Stand
 Exit/Entry:03 No’s
1.1.3 Site Location

Figure 3 Site Location

 Figure 4 Station on Metro Map

1.1.4 Safety Induction

In safety induction safety engineer told us about the use of safety equipment and PPE(Personal
Protective Equipment) at construction site.

Figure 5 PPE(Personal Protective Equipment) Figure 6 Colour Code For Lifting Tools
1.2 General Construction Activity
Complete Summary of Steps Involved
A. Survey work
a) Preconditioning Building Survey
b) Geotechnical Investigation
c) Topography and Tunnelling Survey
d) Utility Diversions
B. Construction Work
a) Guide Wall
b) Diaphragm Wall
c) Permanent Columns
d) Top Slab
e) Second Slab Underground Station
f) Third Slab
g) Base Slab
h) Staircase
i) Lifts and Escalators
j) Operational Rooms
k) TBM Launching Shaft
l) Boring Tunnel Underground Tunnel Construction
m) Retrieval Shaft

C. Track Laying, Electrical and Finishing Work

a) Track Laying
b) Electrical Power Supply
c) Signals
d) Drainage Works
e) Water Supply
f) Sanitary Works
g) Arch textural Finishing
1.2.1 Precondition Building Survey
A detailed condition assessment survey is required to be carried out for all buildings falling in
the influence zone of Station and tunnel alignment, the purpose of which is summarized as
follows:
 To have a detailed description of any deficiencies such as existing settlement, cracks
accompanied, by photographs as required, to delineate fully the extent of deficiencies and
their respective locations in the structure.
 To recommend the property owner to get any major defects detected, rectified, prior to
the start of construction work.
 To collect sufficient information on pre-construction condition of structures to counter
any false claims for damages which are not caused by works related to this project.
 To determine and identify locations where crack gauges, tilt plates and mirror targets
should be installed on the structures to monitor them during construction process.

ZONE OF INFLUENCE
The pre-construction and post construction condition survey will be carried out for structure and
building located within the zone of influence of underground metro tunnel and station.

EQUIPMENT AND MATERIALS

1. Digital Camera
2. Crack width ruler
3. Directional Compass
4. Measuring Tape

1.2.2 Geotechnical Investigation

The purposes of a Geotechnical Investigation are to investigate the soil and geologic conditions
of a property and to provide recommendations and design criteria for construction. The scope of
a Geotechnical Investigation includes review of available literature; conducting on-site
exploration, mapping/logging and sampling; and laboratory testing of samples obtained in the
field. The collected data is analyzed and geotechnical criteria for foundations, retaining walls,
site grading and site drainage are developed. This criterion chiefly consists of the load bearing
capacities and anticipated lateral forces from the onsite soil and rock. The culmination of the
investigation is a report summarizing the field and lab findings; conclusions regarding the
geotechnical impacts of the site; and recommendations for the most geotechnical suitable
construction.

In other words, the Geotechnical Consultant will define the anticipated effects of the earth on
man-made features at the site as well as the impacts the development could impose on the land.
The Geotechnical Consultant along with the client, builder, architect, civil engineer and
structural engineer endeavor to implement the most efficient and cost-effective construction
methods.

The Geotechnical Investigation typically costs a few percent of the total project costs but can
reduce the risk of costly problems during construction and in the future.

1.2.3 Utility Diversion

All projects require connections to utilities such as gas, water and electricity and many projects
involve diversion of utilities. Getting the aspects of project right can be critical factors in
ensuring it is completed safely on time, on budget and with minimum disruptions. They can also
affect the long-term efficiency and fitness for purpose of the building.
List of utilities at Dhanasa Stand Metro station were:
 Water supply line of diameter 400mm and 800mm.
 BSES electric supply line.
 Storm water drain.
 450mm diameter sewer line.
 MTNL line.
 IGL line
 Figure 7 Uitility Diversion

Chapter 2
STATION- I
2.1 Guide Wall
Two parallel concrete beams constructed along the side of the wall as a guide to the clamshell.
Guide wall trench excavation will be excavated by manual/JCB excavation for the guide wall of
1.5m depth of existing ground level.
Guide wall will be constructed by inverted L shaped RCC walls forming a support to the earth
and prevents it from collapsing when the boring of the diaphragm wall.
The purpose of guide wall is
 To provide a permanent alignment for the grab.
  To provide edge protection to the diaphragm wall and to prevent the collapsing of soil
during excavation.
 To act as a platform to hang the reinforcement cage and maintain the coupler levels.
Steps involved in construction of guide wall are:
a) Before excavation a valid “Permit for work” must be issued.
b) The trench will be excavated as per set out and indicated alignment.
c) Manual excavation for guide wall trench up to 1.5 m depth from the existing ground
level.
d) Fixing of reinforcement will be done as per the approved drawings.
e) The minimum cover to reinforcement shall be done as per the reinforced drawings.
f) The clear horizontal distance of guide wall i.e diaphragm wall width plus 50mm will be
maintained.
g) Placing of M20 grade of concrete with proper compaction.
h) De-shuttering will be done after concrete gets set and the area will be backfilled for
safety purpose.
i) After concrete gets hardened curing shall be done with clean water.
j) The trench face of the guide wall on the side of the trench nearest to the subsequent main
excavation shall be vertical to within 1:200.
 Figure 8 Guide Wall

2.2 Diaphragm Wall

It is a reinforced concrete structure constructed in-situ panel by panel. A diaphragm wall is
constructed using a narrow trench excavated in ground and supported by an engineered fluid
(typically a bentonite mud) until the mud is replaced by the permanent material. Generally,
diaphragm walls are made from reinforced concrete,though unreinforced walls.

Construction of diaphragm wall panel sequence.

a) The diaphragm wall panels basically comprise of:
 Primary Panel
 Secondary Panel
 Closing Panel
b) The primary panel is the starting panel, which is cast with 2 stopend in place. These panels
are logistically placed to suite construction schedule. The panel proceeds in both directions
from the primary using secondary panels, which are cast with a single stopend in place. The
closing panel is the final panel, which is cast after the removal of both stopend.
c) The panel length is defined as the distance between the centre lines of the two stopend.
 Figure 9 Diaphragm Wall Panel Figure 10 Diaphragm Wall Layout

2.2.1 Diaphragm Wall Excavation

a) Diaphragm wall will be located between guide walls. The guide wall will be marked with
the panel reference number and centre line of stopend position.
b) The trenching will be carried out by grab attached by telescope Kelley which are
mounted on hydraulic rings.
c) Once the grab is setup over designated location, the operator shall lower the grab onto the
ground and commence trenching.
d) Prior to commencing actual excavation, the grab rig will be set up vertically, either on
one side of the diaphragm wall axis.
e) Vertically the grab attached to the guide shall be checked by using the computerized
sophisticated electronic verticality meter attached to the device and will be used and
constantly monitored to immediately detect a tendency of the excavation to deviate.
f) Excavation by grabbing will be done in presence of poly mud solution.
g) The standard panel will be excavated in three main “bites”.
h) The first bite will be excavated to the design toe level. The second bite will be repeat of
first and finally third bite will be the centre position.
i) Grabbing will start in presence of polymer solution from one bites of the panel and will
excavate up to the founding level.
j) The rig is then shifted to the second bite of the panel and excavates up to the founding
level. Then rig is shifted to the middle bite of the panel and excavates up to the required
depth.
k) Excavated muck mixed with polymer slurry will be kept aside, and the same level will be
disposed in the dumping yard at appropriate designated dumping yard.
l) When the grab reaches guide wall level upon exit, a momentary suspension is
recommended to drain from the spoil through the drainage holes of the grab. The operator
then rotates the rig via crane swing and discharges the spoil either into skips or onto the
ground.
m) As excavation proceeds, poly mud is pumped into the excavated trench to ensure that it
shall kept full.
n) Checking the verticality of the trench will be carried out by Koden instrument.
o) The ends of panel shall be vertical to within a tolerance of 1:80.
p) The stopend with water stop attached will be lowered into position.
q) Disposal of polymer is not required as can be cleaned in the trench using poly mud.
 r) Excavated soil shall be disposed during night shaft at the designated dumping yard.

Figure 11 Diaphragm Wall Excavation

2.2.2 Cage Lifting and Placing

a) Lifting and placing of cage will be done with the help of 2 no’s of cranes and the cage lifter
assembly. The cage lifter will be fixed directly to the lifting hooks of the cage with D’
shackles and slings of the 100MT lifting capacity cranes. The bottom end of the cage shall be
fixed to the second crane with two slings will be ensured.
b) The lifting beam will be designed and according the calculation provided by design team be
ensured for fabrication.
c) The cage will be lifted slowly with 100MT Crane operating both the slings and bottom shall
be lifted by the supporting second crane which will move at a synchronised speed and the
movement of cage under skilled supervision. When the cage is fully lifted, the load in service
crane shall be freed so that the entire load of the cage will come on the 100M crane.
d) After completion of lifting process, the cage will be lowered slowly in to the panel and
positioned with verifying the line vertically with plump-bobs.
 Figure 12 Cage Lifting

2.2.3 Placing of concrete

a) Concreting of diaphragm wall shall be done continuously without interruption to ensure no
mixing of polymer with concrete.
b) Before start of concrete works a steel grill will be provided over the guide wall to prevent the
falling of persons in the excavated trench.
Table 2 concreting parameters
Parameter Value
Slump 150-200 mm
Temperature >5°C &<32°C
Frequency of cube sampling A set of 3 cubes will be casted for every 25
cum of concrete
c) With the steel reinforcement in place the tremie pipe of internal diameter of 250mm along
with the hopper attachment is lowered at the centre of the point to have uniform fill of
compaction concrete in panels.
d) The tremie pipe is set at 300mm from the bottom of the excavation and suspended by a self-
locking working platform.
e) This will be done on skilled supervision on daily basis to ensure the correct procedures to
carry out measurements and recording.
f) At the start of concrete placement, a plug is placed at the bottom of the funnel, protected by a
shovel until the hopper is full of concrete. The shovel is then removed and the concrete
gushes down the tremie, thus keeping the concrete away from mixing the polymer slurry.
g) During the concreting tremie pipe will be kept immersed below the surface of the fresh
concrete always. Except at the beginning, the immersion depth inside the concrete will be not
less than 2m. The concrete level will be measured at regular intervals after evacuating each
transit mixer by measuring tape with sounding chain so that the actual volume of concrete
placed can be compared with theoretical panel volume.
h) Concrete will be poured continuously till the panel is filed up above the theoretical cut-off
level.
i) After completion of concreting and final setting of the concrete, the stop ends are fully
removed out of the panel with the help of extracting jack system and crane.
 Figure 13 Tremie Pipes & Hopper

2.2.4 Poly Mud Slurry

a) Polymer should be test as per SOP.
b) The diaphragm wall excavation will be done by soil support polymer slurry to prevent
collapsing/caving in soil inside the panel.
c) Polymer shall be stored in designated area, under shed/Cover.
d) Suspension will be prepared accordingly to the manufacture specification and any other
indications given by Geo technical consultants on site.
e) Polymer slurry is prepared in a predetermined ratio accordingly to technical advice and using
a free water discharge in a mixing tank prepared with air agitation and close circulation as
indicated in the SOP.
f) To assure that the polymer slurry is in accordance with SOP, the quality of the slurry used for
the excavation will be verified during preparation and excavation, prior to concreting.
 Density
 Marsh Viscosity
 Sand content
 pH
g) The site shall be equipped with the following instruments:
 Fluid sampler
 Marsh Funnel
 Stopwatch
 Graduated Cylinder
 Mud Balance
 Sand-content kit
 pH papers
h) If a panel were to remain open for 24 hours, each shift the above mentioned tests will be
performed and the panel trench-topped up with fresh mud : if necessary the slurry will be
replaced or regenerated. Quality of slurry will be verified twice per panel.
Table 3 Specifications of Polymer

Parameter Fresh Mix Reused Slurry Before Concrete Pour

Viscosity 55-140 55-140 50-140

Density 1.00-1.04 <=1.08 1.00 to 1.06
Sand Content - <=2% <=2%
Ph 11-13 11-13 9-12

Figure 14 Marsh Cone for viscosity test

2.3 Plunge Columns

This deals with the construction of pile along plunge column for top down construction
method. The plunge columns are vertical columns which act as permanent columns to support
the slabs during constructions and shall be encased in later stage with appropriate grade of
concrete(M40) to convert into permanent column. Steps to be followed are:
1. Setting out survey reference points for boring of plunge column and pile.
2. Boring of pile and column using polymer.
3. Plunge column fabrication.
4. Reinforcement cage fabrication.
5. Lowering of cage with cranes.
6. Lifting of plunge column and welding with pile cage.
7. Lowering of cage and plunge column.
8. Fixing of adopter over plunge column.
9. Lowering of plunge column with adopter.
10. Lowering the tremie pipe for concreting.
11. Procedure of concreting.
12. Removal of adopter
13. Excavated muck disposal.

Figure 15 Fabrication of plunge column

 Chapter 5
CONCLUSION

 Najafgarh –Dhansa Bus Stand Metro Extension is estimated to serve the travel needs of
an additional 10,000 passengers per day catering to the needs of people of Nangloi,
Dhansa, Bahadurgarh and the adjoining areas.

 As per 2016 estimates, 3.61 lakh vehicle trips are generated at Najafgarh. Since the area
between Najafgarh and Dhansa is densely populated with substantial built up areas,
extension to Dhansa Bus Stand has been made Under Ground.

 The 1218.650 m Najafgarh- Dhansa Metro Section, approved in September, 2017 is

likely to be completed by October 2020.
 Chapter 6
REFERENCE

 Contract Agreement Part 2.

 NIT(Notice Invite Tender)
 MS (Method Statement)
 PIB (Press Information Bureau)
 DMRC (Delhi Metro Rail Corporation)