A TECHNICAL REPORT

ON

INDUSTRIAL TRAINING (CIVIL)

PROGRAM

CONDUCTED AT
Delhi Metro Rail Corporation(DMRC)

SUBMITTED BY

Rakesh Kumar Pandey

1609100091

SUBMITTED TO

JSS MAHAVIDYAPEETHA

JSS ACADEMY OF TECHNICAL EDUCATION

DEPARTMENT OF CIVIL ENGINEERING

C-20/1, SECTOR 62, NOIDA-201301

 ABSTRACT
The Industrial Training (Civil) program enables students to go out and gain more
practical knowledge of what of what they have been taught in College and to acquire industrial
based skills.

Office work procedure covering introduction to ethics, architectural and structural

drawing was explained with the relevant signs and symbols representing various items on such
drawing.

Site work for the period of training was under certain precautions and guidance of
experts. the project consists of my learnings during site visits which includes learning of
building twin tunnel for the passage of metrobwith the help of shield TBM machine and gaining
experiance about how various theories and tests I studied in class are being applied.
 ACKNOWLEDGEMENT
My Profound gratitude goes to the Er.Amit Kumar, Assistant Vigilance Officer in DMRC along
with the staff with him, and also to all the worker and staff who supported me throughout in
completion of the program. May almighty God continue to be with them, bless and favour them
abundantly till the end of their lifetime.

My appreciation also goes to my lovely parents, Mr.&Mrs.A.K PANDEY for their moral,
spiritual and financial assistance before, during and after the program.

Finally, I appreciate the support of everyone that had contributed in one way or the other
towards the success of this program.
 FOREWORD

Every year Delhi Metro Rail Corporation Ltd. Organise summer training camp for under
graduate students of various streams to explore their knowledge and provide the platform to
learn in practical manner. This is the platform where one can see the application of their
theoretical knowledge and understand the concept in crystal clear manner. DMRC is one of the
most prestigious and authentic organisations of country and it has a very high work precision
and the level of accuracy. Participating in training program organise by DMRC is like a dream
for students and getting oppurtuninty to learn and being a part of training program under the
DMRC is an honour.

This is all about to getting the concept of whatever you are learning and keep it in mind . but
there is difference in theoretical knowledge and practical knowledge. Practical knowledge is
only possible when one can correlate their theoretical knowledge with the outside world. And
the organisation like DMRC provides the oppurtunity and platform to do best as musch as you
can.

We are very thankful to all the officers of Metro Bhavan at Barakhamba, all the engineers of
DHARAMRAJ CONTRACTS PVT Ltd. and all the staff members for supporting and co-
ordinating us in each learning steps during one month training.

DATE: RAKESH KUMAR PANDEY

Department of civil engineering

JSSATE NOIDA
 TABLE OF CONTENT

1. Title page..........................................................................................01
2. Abstract............................................................................................02
3. Acknowledgement............................................................................03
4. Foreword..........................................................................................04
5. Table of Content..............................................................................05
6. Certificate.........................................................................................06
7. Introduction......................................................................................07
8. Safety Induction................................................................................08
9. Planning & Preliminary survey/investigation...................................09
10. Tendering of work............................................................................10
11. Project management /Quality control...............................................11
12. General layout of shield TBM method.............................................14
13. Design..............................................................................................19
14. Overview and Conclusion................................................................20
15. Site visit...........................................................................................21
16. References........................................................................................26
 INTRODUCTION
The industrial training(Civil) program is designed to acquint students with the practical or
hands-on knowledge of the past presentand the future. By the past, it affords the students an
oppurtunity to witness practically what they have read in books i.e. the reality of the 100%
assumption of the theories. it also affords the students the current knowledge of what the field
works is all about, getting familiar with new advancement in technology. the future refers to
foreknowledge of what should be axpected when he/she bigins to practice the profession.

Furthermore, it avails the students an oppurtunity to learn inter and intra personal relationship,
administrative skills, site management identification of equipment among other oppurtunities.

This project is belonging to design and construction of subway connection by shield TBM
method between Dwarka to Najafgarh and tunnel by shield TBM method underneath subway
box including entry/exit structure and finishing works of phase-III Delhi MTRS projects.

This report entails some of the experiance I was able to acquire in my short period of
attachment.
 SAFETY INDUCTION
In safety induction safety engineer told us about the use of safety equipment and Personal
Protective Equipment(PPE) at construction site.

1. Safety Glasses
2. Safety Gloves
3. Nose Mask
4. Safety shoes
5. Ear Plug
6. Safety Helmet

2.1 Colour Code for Safety Helmets

 Safety Helmet Colour Person to Use

 White All DMRC staff
 Grey All Designer, Architect, Consultants etc
 Violet Main Contractors(Engineers/Supervisors)
 Blue Electricians
 Orange Security Gaurds/Taffic Marshals
 Yellow All workmen
 White Visitors
 PLANNING AND PRELIMINARY SURVEY/INVESTIGATION

Need and feasibility of project

As we know that the changes come when it demands. Due to continuously increment in
population and traffic the government has decided to extend to make smooth movement of
traffic and reduce traffic jams. Construction of metro also helps in reducing the pollution and
crowded produced by the auto rickshaws, buses, cars etc.

Planning of project is one of huge and sensitive works. All the engineers of each department
work together and design all the component of the project very carefully. Planning scopes from
finding the reduce level of open lar tothe finishing structure. Each design and stragies are
inspected to various times and after that if it looks good to it passes to future for execution.

Soil investigation
Before constructing the structure there are testing of soil takes place. Each and every properties
of soil are tested. If all the properties lie in permissible range given in IS Codes then execution
of work started otherwise some modifications are applied.

There are following soil test and their corresponding IS Codes are mentioned
below.

Properties IS Codes
 Classification and identification of soil for engineering purpose IS 1498
 Method of load test on soil IS 1888
 Subsurface investigation for foundation IS 1892
 Method of standard penetration test of soil IS 2131
 Code of practice for earthing IS 3043
 ode for insitu vane shear test IS 4434
 Permeability test of soil IS 5529
 TENDERING OF WORK
 Tendering is the process of making an offer, bid proposal or expressing interest in response
to an invitation or request for tender.

PROCESS OF TENDER
 Notice inviting tender
 The tender notice should all in cases state
1. Name and place of work.
2. Approximate cost of work.
3. Amount of earnest money and the form in which it is deposited.
4. Period of completion.
5. Place and time where tender document can be seen.
6. Place and time where tender document can be obtained.
7. Date and time up to which tender documents will be sold.
8. The amount, if any, to be paid for such documents.
9. The place where the date on which the time when tender are to be submitted and are to be
opened.
10. Any other information relevant in tender notice.

 How to invite tenders?

1. Notice in headquaters.
2. Advertisements in vernacular/local newspaper
3. Advertisements in national/ international newspaper.
4. Registered letter to approved contractors.

 Time frame
1. Normally, tender notice should be published at least a month advance of date of opening.
extremely urgent works, three week notice.
2. Tender paper for sale should be available three weeks before opening of tender.

 Tender documents
1. Instructions to the tenderers and conditions of tenders.
2. Regulations of tenders&contract,GCC,&standard specification.
3. Special conditions of contract.
 PROJECT MANAGEMENT/ QUALITY CONTROL
 Quality assurance/Quality control
1. In quality assuarance/ quality control lab various construction materials takes place to ensure
the quality of the materials.
2. Ensuring the quality of material is necessary because failure in structure can costs too much for
life and capita.

Following two types of tests are performed:

1) In-house tests on construction materials.

In house test are those tests which are performed in the laboratory established at the
construction site.

a) Testing of aggregates.
i. There are various tests like sieve analysis, specific gravity, impact load test, gradual load
test, water absorption test etc. are performed in lab.
ii. These tests are done for both coarse and fine aggregates.
iii. IS Code 2720 is specially design for sieve analysis.
iv. Detailed specification of aggregates for design mix are mentioned in IS Code 383:2386.

b) Testing of cement
i. There are various tests of cement like consistency of cement, initial and final setting of
cement, soundness of cement, compressive strength of cement etc.
ii. IS Code 4031,IS 4032 are used for physical and chemical testing of cement respectively.

c) Testing of concrete
i. There are many tests of concrete are also performed in quality control lab.
ii. Compressive strenth of concrete, slump test, permeability test of concrete, segregation and
bleeding tests of concrete, etc are performed.
iii. IS Code 1199 is specially designed for slump test.
iv. IS Code 14858 is specially designed for compressive strength of concrete.
2. Third party lab test on construction materials

Testing of steels/reinforcement: steel reinforcement generally being tested for its following
chemical and mechanical/physical properties as per IS-1786 in 3rd party laboratory.

a) Chemical properties:(as per IS-1786)

i. Carbon
ii. Sulphur
iii. Phosporous
iv. Phosporous+silver

b) Mechanical/physical properties:(as per IS-1786)

i. Yield strenth
ii. Tensile strenth
iii. Elongation
iv. Bend

Testing of cement:following chemical&mechanical tests are being conducted in 3rd party lab
for cement:

c) Chemical properties: (as per IS-8112)

i. Lime saturation factor
ii. Alumina iron ratio
iii. Insoluble residue
iv. Magnesia
v. Sulphur content
vi. Total loss on ignition

d) Mechanical properties: (as per IS-8112)

i. Soundness
ii. Fineness
iii. Consistency
iv. Initial and final setting time
v. Compressive strength
Testing of aggregates: following chemical&mechanical tests are being conducted in 3rd
party lab for cement:

e) Chemical properties:(as per IS-383)

i. Alkali aggregative reactivity
ii. petro graphic
iii. chloride content % by mass.
iv. Estimation of deleterious materials.
v. sulphur content % by mass.

f) Mechanical/Physical properties: (as per IS-383)

i. Gradation
ii. Flakiness index
iii. elongation index
iv. Aggregate impact value
v. soundness
vi. Specific gravity
vii. Water absorption
viii. Crushing value
ix. Abrasion value
 GENERAL LAYOUT OF SHIELD TBM METHOD
A TBM also known as a mole is a machine used to excavate tunnels with a circular cross section
through a variety of soil and rock strata. They can bore through hard rock, sand, and almost
anything in between. Tunnel diameters can range from a metre to almost 16 metres to
date.Tunnels of less than a metre or so in diameter are typically done using trenchless
construction methods or horizontal directional drilling rather than TBMs.

TBM are used as an alternative to drilling and blasting methods in rock and convention hand
mining in soil. TBMs have the advantages of limiting the disturbance to the surrounding ground
and producing a smooth tunnel wall. This significantly reduces the cost of lining the tunnel, and
makes them suitable to use in heavily urbanised areas. The major disadvantage is the upfront
cost. TBMs are expensive to construct, and can be difficult to transport. However, as modern
tunnels become longer, the cost of TBM versus D&B is actually less- this is because tunnelling
with TBMs is much more efficient and results in shorter project.

The largest diameter TBM, at 15.43m, was built by Herrenknecht AG for a recent project in
shanghai, china. The machine was built to bore through soft ground including sand and clay. The
largest diameter hard rock TBM, at 14.4m, was manufactured by The Robbins Company for
canada’s Niagara Tunnel project. The machine is currently boring a hydroelectric tunnel beneath
Niagara, the machine iscurrently boring a hydroelectric tunnel beneath Niagara Falls, the
machine has been named "Big Becky inreference to the Sir Adam Beck hydroelectric dams to
which it is tunneling to provide an additional hydroelectric tunnel.

Figure 1: Back-up systems

Behind all types of tunnel boring machines, inside the finished part of the tunnel, are trailing
support decks known as the back-up system. Support mechanisms located on the back-up can
include: conveyors or other systems for muck removal, slurry pipeline if applicable, control
room, electrical systems, dust removal, ventilation an mechanism for transport of pre-cast
segments.

VARIOUS CLASSIFICATION OF TBM

1. Slurry Pressure balance(SPM) TBM

The basicv principle of this is to maintain the face pressure during the excavation phase
by filling the working chamber, located behind the cutter head, with slurry.

Figure 2: Slurry Pressure balance(SPM) TBM

 Advantages
i. Allows soft, wet, or unstable ground to be tunnelled with a speed and safety not
previously possible.
ii. Suitable for ground with high water pressures (below water table).
iii. Limits ground settlement and produces a smooth tunnel wall. This significantly
reduces the cost of lining the turnel.

 Disadvantages
i. The major disadvantage is the upfront capital cost. TBMs are expensive to construct,
difficult to transport, required significant backup systems and power.
ii. Drive can be hindered by large stones and boulders.
 2. Earth Pressure Balance (EPB) TBM

This is a mechanised tunnelling method in which soil is admitted into the tunnel boring
machine (TBM) via a screw conveyor arrangement which allows the pressure at the
face of the TBM to remain balanced without the use of slurry.

Figure 3: Earth Pressure Balance (EPB) TBM

 Advantages
i. Allows soft, wet, or unstable ground to be tunnelled with a speed and safety not
previously possible.
ii. Limits ground settlement and produces a smooth tunnel wall. This significantly
reduces the cost of lining the tunnel and makes it suitable to use in heavily urbanized
areas.

 Disadvantages
i. The major disadvantage is the upfront capital cost. TBMs are expensive to construct,
difficult to transport, require significant backup systems and power.
ii. Their applicability is long tunnels where the high rates of advance and tunnel quality
can offset their high capital cost.
 3. Hard Rock TBM
This method involves the use of a Tunnelling machine with a shield and cutter
head suitable for hard rock.

Figure 4: Hard Rock TBM

 Advantages
i. They offer a continuous and controlled means of tunnelling capable of high rates of
advance under favourable conditions.

 Disadvantages
ii. The major disadvantage is the upfront capital cost. TBMs are expensiv to construct,
difficult to transport, require significant backup systems and power.
iii. Their applicability is limited to long tunnels where the high rates of advance and
tunnel quality can offset their high capital cost.
STAGES DURING CONSTRUCTION

Figure 5: Stages During Construction

 OVERVIEW AND CONCLUSIONS

Environmental constraints require avoidance of open cuts or aesthetic degradation. The

main advantages of the method can be recapped as following:"shield TBM’’ technique
allows safe initiation and completion of highway tunnels as well as safe work progress in
unstable weak ground in rural projects. The technique may applied in form of sequential
construction in case of most adverse geotechnical conditions. Although the applicability
of the method is reduced in case of deep overburden and the construction cost increases
significantly, new technologies in trenching and earth retaining nowadays allow the use
of shield TBM technique at great depths and very close to, or even under existing tall
buildings. Tunnel portals are very often sensitive areas for excavation, since the
constitutive rock material is likely to be weathered and quite unstable.
Serious problems of instability, identified and quantified by geotechnical investigation,
cannot be handled through the common excavation procedure or by the "shield TBM"
technique. When the landslide risk cannot be accurately assessed in extent, direction and
severity, a more effective and reduced-risk method is required.
The solution is provided by shield TBM method establishing full protection during the
construction and the operation stage. The method is characterized by rapidity and
accuracy and may be applied to short-length segment (usually 10-20 m) at tunnel
entrances. In all case studies in highway engineering, the technique prove to be safe and
efficient. Stability problems were adequately handled and the duration of the construction
stage was hardly affected. Nevertheless, in highway construction, where the "cost" factor
is of critical importance,method should be limited to cases of serious rock fall and
landslide risk. Indeed, since the method prescribes a "double concrete lining", the
construction cost is relatively high compared to the respective budget figures of the
conventional methods. This is certainly a drawback but it is rather of secondary
importance if the application is of limited extent which is the case of tunnel portals. On
the other hand, when the method is preferred to the current "non-retained excavation" for
full tunnel construction, it is certain that efficiency in managing geotechnical problems
joins economy and environment preservation through a simple construction process.
 SITE VISIT

Figure 6 : DRAWING OF PROJECT

Figure 7: SURFACE VIBRATOR
Figure 8: HYDRAULIC EXCAVATOR
Figure 9: TESTING OF BLOCKS
Figure 10: CONSTRUCTION PHASE OF ARRIVAL
 REFERENCES

1. Indian standard codes

 IS CODE 456-2000
 IS CODE 800
 IS CODE 1199
 IS CODE 2911
 IS CODE 2720
 IS CODE 875

2.TENDER documents.

3.Outline design specifications

4.Design report of project.