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IN PLANT TRAINING REPORT

Nikhil Kuriakose
M.Tech, Construction Engineering and
Management
SRM University



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L&T SUCG JV CONSTRUCTION OF
UNDERGROUND STATIONS NEHRU PARK,
KMC, PACHAIAPPAS COLLEGE AND
ASSOCIATED TUNNELS
IN CHENNAI






Submitted to







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ACKNOWLEDGEMENT
I sincerely thank Mr Johnson K I for his extraordinary interest in our learning
experience, without whose guidance my training would have had little success. I also thank Mr
Sajith for his excellent lecture of Occupational Health and Safety; Mr Ganesh for giving me
critical support and guiding me throughout my implant training; Mr Murugesh for his revealing
lecture on Contracts and Joint Ventures; Mr Rahul, for his exceptional guidance in the work
site.



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AIM
To experience different aspects of civil construction works, especially in planning department.


SCOPE OF THE WORK

NAME OF PROJECT Contract UAA-04 Design & Construction of Underground
Stations at Nehru Park, Kilpauk Medical College & Pachiappa's College &
Associated Tunnels.

CLIENT Chennai Metro Rail Limited

CONTRACTOR Metro Tunneling Chennai L&T SUCG JV

CONSULTANT General Consultant, M/S Embye Consortium

PROJECT VALUE 930.81 CRORES




SOURCE OF FUNDS
This project is financed through equity participation by the Government of India, the
Government of Tamil Nadu and the Japan International Cooperation Agency (JICA).




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WORK SITE
The project site is located in Chennai, the Capital of Tamil Nadu. Works are in the
centre of Chennai city from Egmore to Shenoy Nagar on Corridor 2, with three underground
stations at Nehru Park, Kilpauk Medical College and Pachaiappas College.


PROJECT STARED ON 7
th
Feb 2011
PROJECT COMPLETES ON 7
th
April 2015
TIME OF COMPLETION OF PROJECT 1251 days
TOTAL TUNNELLING LENGTH 4070 m
STATION LENGTH 228 m
STATION WIDTH 19 m
NO OF CROSS PASSAGE 11










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THE CHENNAI METRO MAP


Total Underground Tunneling by L&T SUCG JV 4.7KM
Total number of stations 3
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UAA 04 STATIONS AND TUNNELS







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OCCUPATIONAL HEALTH & SAFETY (OHS) & E IN CONSTRUCTION
OPERATION

Different aspects regarding the construction safety was introduced. A detailed class
was held discussing the safety aspects while constructing the underground stations as well as
tunnels. Various possibilities of accidents was listed out and the prevention methods to
overcome these were introduced. The presentation urged the adequacy of safety aspects in
construction industry. Working of earth pressure balancing machine and different cases of
accidents while tunnel boring were explained in detail. The discussion helped me in
identifying and explaining the causes of the accident occurred on Arunachala Street in
Chintadripet while tunnelling was done on 12-6-2013. Different codes and standards
regarding safety were familiarised.
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PLANNING SCHEDULING AND UPDATION OF THE PROJECT
I was awarded with an assignment for planning of 20m x 20m roof slab of KMC
underground station box. The construction method adopted in this site is top to down. Various
activities included in the construction of slab were listed after the site visit. Different types of
labourers, equipment involved and their productivity rate were determined based on both
theoretical as well as observed data. Activity precedence relationships (START TO START,
START TO FINISH, FINISH TO START, FINISH TO FINISH) was used to derive Gantt
chart for theoretical as well as observed schedules.

The detailed analysis of theoretical v/s Actual schedule was done both graphically and
numerically. Scheduling was done both graphically and numerically. A detailed discussion was
held after the submission of the assignment. Corrections and proposals suggested by the guide
was used to rectify the report and this enabled the report to appear more professional and
clear-cut. Later another planning report regarding the concourse slab was also submitted.
Quantity as well as total number of labour required was determined.

Application of different software used in planning was mentioned in the planning slot
of in plant training. An overview of MS Excel and Primavera was given in this particular slot.
It explained how to update the project, analyse the project, crash the project duration etc.
using Primavera. The final copy of the submitted excel exhibit 1 sheet is attached with the
report.



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CONTRACTS
A detailed session was held explaining defining the contracts, different types of
contracts, joint venture etc. Different case studies were put for st udy on the discussion. It was
used to explain the different complexities and disputes that may come between the client and
the contractor during planning as well as execution stage. Different techno-legal aspects were
scanned in detail under this slot. FIDIC conditions of contracts were introduced. The chances
of disputes and the dispute solving mechanism were given much importance in the discussion.
Since the topic contract documentation comes under my curriculum the discussion was so
fruitful.











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EXECUTION








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PLANNING AND SITE ESTABLISHMENT

SURVEY
The survey of the area is done after the clearance of the site and the site area is levelled.
The complete survey is done with the help of total station






SITE PLAN

The site plan is prepared according to the requirement of the area necessary for various
purpose such as
Reinforcement fabrication yard (26x6m)
Cutting and bending yard (12x6m)
Reinforcement stacking area (26x6m)
Stop end area (30x3m)
Steel scrap yard (5x6m)
Rig area (10x5m)
Crane area (5x3.6m)
Musk stocking area (7x10m)

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The space for all the requirement are planned and clearance is made such as, trees
traffic signals where the tress are replaced to other place or new sapling are planted at the ratio
of 1:12,like that the traffic signals are provided according to the municipals need.
Alternate light has to be provided as the street lamps are removed.
Barricading board should be provided around the work site. The barricading board is of width
2.5m and height 2m.




UTILITY DIVERSION

Trial pits will be made at the site to check the utility at the site and all of them are
found out and diversion is made accordingly
The Two types are:
Dry utility deals with Electrical cables and Telephone cables
Wet utility deals with Sewer lines


DRY UTILITY

Optic fibre cable, high tension (HT), Low tension (LT) cables


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WET UTILITY

Water pipe, sewage pipe


FABRICATION OF REINFORCMENT CAGE

Type of bar HYSD500D (High Yield Strength Deformed bar)

Varies bars used in cage preparation
32mm - main rebar
20mm - main rebar
25mm - main rebar
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16mm - binding rebar
12mm- sacral area rebar

Specially bended bars

Z bar provided to add strength to the cage .Number of z bars in a cage varies from
32 to 110.


V hook is added in the top of the cage for the lifting and placing of the cage in trench.

COUPLERS

Couplers are used in the place where the D wall is connected to the base slab,
concourse slab, roof slab of the station box .There are two types of couplers type A and type
B

Type A Half Threaded
Type B Full Threaded



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HALF THREADED COUPLER

The coupler is stable and the reinforcement of following slab is rotated .The internal
diameter is 25mm and the external diameter is 40mm.



The reinforcement in the slab is stable and the coupler is rotated. The internal
diameter is 32mm and the external diameter is 52mm.





These couplers are packed completely so that it does not get contact with the
concrete which will not be difficult during slab concreting .it packed with the help of thermo
Cole the on the top wooden plank are kept and tied



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DETAIL OF THE PANEL IN ALL THE STATION

SL. NO Particulars Nehru Park Kilpak medical
College
Pachaiappas
College
1 Length of dwall in
station box
516 516 516
2 Depth of D-wall 22-24 23-25 26-28
3 Total number of
panel
114 109 108
4 Entry /exit shaft
length
150 150 150



CONSTRUCTION OF THE STATION BOX

The station can be constructed in two method namely

Top down method
Bottom up method


TOP DOWN METHOD (OR) COVER AND CUT METHOD
In this method the construction is done from the top where the roof slab is constructed
first in which some space will be left free in the middle in two r three place which facilitate for
the construction of the concourse slab ,then on the same way the base slab is completed .



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BOTTOM UP METHOD (OR) CUT AND COVER METHOD:
In this method as soon as the dwall is constructed the soil is excavated till the desired
depth and the base slab is constructed and then the concourse slab then the roof slab

The launching shaft region is constructed in this method.


PLUNGE COLOUMN
Plunge columns can be installed into rotary bored piles to allow for a top-down
construction sequence, 'launching' structures before the basement is excavated.
CONSTRUCTION PROCESS
A rotary bored pile is excavated to the required depth, a reinforcement cage is then
installed and then the void is filled with concrete stopping the required distance below ground
level. Whilst the concrete is still wet a hydraulic plunging frame is installed within the
temporary casing and then the plunge column is installed to structural tolerances. The concrete
is then left to set in the pile and once this is complete the empty bore above is backfilled.
The plunge column is of 1 m wide and the barrets which act like a footing at the base
weighs about 1.65 tons
The reinforcement cage weighs about 11 to 13 tons
Rods used in barrets are 500 mm In diameter
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M 35 grade concrete is used for plunge column
Stop ends are used along with water stopper. It is 800 mm wide at T ends and 1000
mm at the rest of the places





JET GROUTING
Before starting the Cross passage excavations, it is necessary to improve the soil
characteristics around CPs.
High Pressure Jet grouting method will improve the soil stabilization.
It uses high kinetic energy liquid spurt (jet) for chopping up the ground around and
mixing it with binding agent. In most cases this binding agent is the chopping jet itself.
This way all materials situated in the ground the soil, backfilling or even waste - are
mixed in situ with injection material and thus a homogeneous block is created that
hardens in time. This technique is different from all other grouting techniques in its
method of demolishing and reshaping original soil structure.
Jet grouting can be used regardless of type, delivery value or grading etc. of soil. As a
reason, theoretically it can be used for treating most soil types from soft soils and silt until
sand and gravel. Although it is possible to use any kind of binding agent in Jet Grouting, the
water/ cement or, in case of wish to rise water delivery value of soil water/ cement/ bentonite
mixture is used in practice. Shape, size, composition and stability of jet pile depends on
mechanic characteristics of soil, type of binding agent, mode of injection, flow velocity during
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injection, pressure conditions and movements of drill rod. Reachable strength values in
different soils.