Construction sequence for metro Project (Elevated and Underground) and Time cycle of the metro construction activity

Construction sequence for metro Project (Elevated and Underground) and Time cycle of the metro construction activity . For more details u can contact me on my mail id [email protected]

1. Introduction of METRO RAIL in INDIA Rapid transits in India consist of Metro, Monorails and light rail system How it Began India’s 1 st and Asia’s 5 th Metro rail was introduced in Kolkata in 1984 Delhi Metro was India's first modern metro which began its operation in 2002. Rapid Metro Rail Gurgaon, which started operations in November 2013, is India's first privately owned & operated metro.

2. Why is it Needed ? Unprecedented growth of personal Vehicle Growing Traffic Congestion Air pollution and traffic accidents has become a major concern To avoid congestion at Peak hour Time saving and Reduced fuel consumption

3. METRO RAIL in INDIA Unprecedented growth of personal Vehicle Growing Traffic Congestion Air pollution and traffic accidents has become a major concern To avoid congestion at Peak hour Time saving and Reduced fuel consumption

4. METRO RAIL in INDIA Existing Metro Rail in INDIA Delhi Metro Kolkata Metro Mumbai Metro Chennai Metro Bangalore Metro Jaipur Metro Lucknow Metro Hyderabad Metro Kochi Metro Noida Metro Under construction and proposed Metro Rail in India Ahmedabad Metro Pune Metro Nagpur Metro Indore Metro Bhopal Metro 5) Kanpur Metro

5. Type of metro Type of Metro Elevated Metro Underground Metro On Grade

6. ELEVATED METRO

7. Basic Sequence of Activities For Elevated Metro (Viaduct) Casting of superstructure Segments & parapet Stacking and Transportation of segments Casting Yard Set Up

8. Basic Sequence of Activities For Elevated Metro (Station) Casting of superstructure I -Girder Stacking and Transportation of segments Casting Yard Set Up

9. P n P n+1 Span Length Number of Segments 37 m 13 34 m 12 31 m 11 28 m 10 25 m 9 22 m 8 S7C 3000 S6D 3000 S6U 3000 S5D 3000 S4D 3000 S3D 3000 S2D 3000 S5U 3000 S4U 3000 S3U 3000 S2U 3000 S1U 1975 S1D 1975 Segment Codes Standard Span Length S1U S2U S3U S4U S5U S6U S7C S6D S5D S4D S3D S2D S1D 37 √ √ √ √ √ √ √ √ √ √ √ √ √ 34 √ √ √ √ √ √ x √ √ √ √ √ √ 31 √ √ √ √ √ x √ x √ √ √ √ √ 28 √ √ √ √ √ x x x √ √ √ √ √ 25 √ √ √ √ x x √ x x √ √ √ √ 22 √ √ √ √ x x x x x √ √ √ √ Casting Yard – Segment Details Average 15 Days will be required to cast segments for 37m span.

10. Casting Sequence Segment Id Average Cummulative days 1 S7C 1 2 S1U 2 3 S6U 4 4 S6D 5 5 S2U 6 6 S5U 7 7 S5D 8 8 S4U 9 9 S1D 10 10 S4D 11 11 S2D 12 12 S3U 14 13 S3D 15 Match Casting Activity Short bed Long bed

11. Pier Pile Pile Cap Crash Barrier Pier Cap Upstand/Pedestal Segments (Span) Sub Structure Super Structure Seismic arrester of span Details of Structure

12. Pile 3 4 1 2 Average Time Required for Casting of one Pile will be 12hrs . Average Time take to cast pile group will be 5 Days. Piling Sequence Piling Activity

13. P - 1 P – 2 P -3 P -4 Pile cap shutter 1 Pile cap shutter 2 Pile Cap Reinforcement (3 Days) Average Time take to cast pile cap will be 12 Days. After 1 day Resources movement Pile Cap Pile Pile cap Activity

14. P -1 P -2 P -3 P -4 Pier shutter 1 Pier shutter 1 Pier shutter 2 Pier shutter 3 Pier shutter 1 Pier shutter 2 Pier shutter 3 Pier shutter 2 Pier shutter 3 Pier Pile Cap Pile After 24 Hrs. After 1 day Pier Activity Resources movement Average Time Cycle for Pier 5 days Pier P -5 P -6

15. Pier Cap Preparation of reinforcement Cage (3 Days) Pedestal And shear key Casting (18 Hrs ) After 21 day Average Time cycle for pier cap is 8 days Pier Cap Activity

16. dry matching (8 hrs ) and wet matching (10 hrs ) including cutting and treading and lowering of span. Launching Sequence Activity

17. DETAILS OF LAUNCHING GIRDER

18. COMPONENTS OF LAUNCHING GIRDER MAIN BOX GIRDER FRONT SUPOORT MIDDLE SUPPORT REAR SUPPORT REAR TROLLEY SLIDER BEAM COUNTER WEIGHT FIXED MOUNTED HOIST PLATFORM/ WALK WAYS

19. Maximum height of Front support : 6220mm Minimum height of Front support : 4230mm FRONT SUPPORT TOP BEAM TOP VERTICAL LEG BOTTOM BEAM TELESCOPIC LEG GENERAL ARRANGEMENT OF FRONT SUPPORT

20. TYPICAL ISOMETRIC VIEW OF FRONT SUPPORT

21. MIDDLE SUPPORT Main beam Bracket of main beam Launching bearing Longitudinal side bearing Knuckle bearing Cradle TYPICAL ISOMETRIC VIEW OF MIDDLE SUPPORT

22. Rear support is more or less same replica of middle support accept longitudinal pushing assembly is not provided in this support. REAR SUPPORT TYPICAL ISOMETRIC VIEW OF REAR SUPPORT

23. REAR TROLLEY TYPICAL ISOMETRIC VIEW OF REAR TROLLEY REAR TROLLEY IS POSITIONED AT 4500MM FROM THE REAR END OF THE MAIN GIRDER S8 AND PROVIDES SUPPORTS DURING LONGITUDINAL AUTO LAUNCHING .

24. SLIDER BEAMS TYPICAL FRONT VIEW OF SLIDER BEAM TYPICAL ISOMETRIC VIEW OF SLIDER BEAM Slider beams are independent assembly of two built up I sections connected together with steel diaphragms

25. SCHEME FOR AUTO-LAUNCHING FOR SPANs UPTO 37m Span

26. Step:1 Erect all the segments of the span and do final pre-stressing as per specification in drawing.

27. Step:2 Ensure that erection of all span is completed in all aspects . Release all suspenders from erected span and lower the span on temporary bearing placed on pier cap.

28. Step:3 Bring all the sliders to the rear end.

29. Step:4 Release the middle support from the span and w ith the help of slider beam shift the middle support nearer to the front support on segment S1 as shown in drawing.

30. Step:5 Activate the jacks of middle support on segment S1 and anchor with the span .

31. Step:6 Release the Rear support from the span and with the help of slider beam shift the rear support to the erected span of segment S1.

32. Step:7 Activate the jacks of rear support on segment S1 and anchor with the span .

33. Step:8 Now move both the sliders back to the rear trolley .

34. Step:9 Ensure that middle and rear support are firmly anchored with the span. Now close the telescopic leg of front support so that all load transferred to the middle and rear support.

35. Step:10 Ensure all the supports firmly anchored with the span and make sure that rear trolley free from anchorage from the span.

36. Step:11 Ensure that all supports firmly anchored with super structure. Start Auto-launching and auto launch the launching girder by 1200mm. Check that all supports are firmly anchored or not.

37. Step:12 Now again start auto launching until rear trolley come nearer to the rear support.

38. Step:13 With the help of slider beam move rear support near to the middle support and anchored it with the span.

39. Step:14 Continue auto-launching till front support reaches next pier cap location..

40. Step:15 Open the telescopic leg of front support and activate it. Anchor firmly with pier cap.

41. ERECTION SCHEME FOR 37M SPAN

42. Step: 1 Make sure that launching Girder is ready for erection of new span and lifting of segments. Now move the sliding towards the next span to be erected near front support as shown.

43. Step:2 Move the trailer below the lifting hoist.

44. Step:3 Pull down the lifting beam.

45. Step:4 Fix the lifting beam and temporary pre-stressing beam on segment S1. Now lift the pier segment S1 with the help of lifting hoist. Now move the slider in position to lift the S1 segment.

46. Step:5 Connect the S1 with the slider beam and move it nearer to the middle support .

47. Step:7 Move S2 nearer to the segment S1.

48. Step:8 Move S3 nearer to the segment S2.

49. Step:9 Move S4 nearer to the segment S3 .

50. Step:10 Move S5 nearer to the segment S4.

51. Step:11 Move S6 nearer to the segment S5.

52. Step:11 Move S7 nearer to the segment S6.

53. Step:11 Move all the sliders towards Segment S7.

54. Step:11 Move all the sliders towards Segment S7.

55. Step:11 Now lift the segment S3 upwards then other segments for adjustment of all the segments in fixed length.

56. Step:11 Now lift the segment S3 upwards then other segments for adjustment of all the segments for dry matching.

57. Step:11 Now move remaining sliders towards segment S3.

58. Step:11 Now move remaining sliders towards segment S3.

59. Step: Lift the segment S5 and move it near the segment S6.Now same do same procedure for segment S4.

60. Step:17 Now do dry/wet matching and temporary pre-stressing and follow the procedure for final pre-stressing as per specification given in drawing.

61. Concourse Level Track Level Platform Level Road Level CANTILEVER TYPE STATION Bored Cast-in situ Piles Pile Cap Pier Crash Barrier Pier Head at CL Staircase Precast I-girders Deck slab at CL Pier Heads at PL & TL Pre-cast I-girders PEB Roofing Deck Slab at PL & TL 61

62. Concourse Level Track Level Platform Level Road Level PORTAL TYPE STATION Bored Cast-in situ Piles Pile Cap Pier Crash Barrier Portal Beam at CL Staircase Precast I-girders Deck slab at CL Pier Heads at PL & TL Pre-cast I-girders PEB Roofing Deck Slab at PL & TL 62

63. Underground Metro Tunnel Cut and Cover Bored Tunnel Station Top –Down Bottom-up

64. Stage – 03. Stop End inserted in both end of the trench. Stop End Stop End Installation Stage – 05. Concrete placing through tremie pipe as polymer slurry is displaced. Panel Concreting ` DIAPHRAGM WALL CONSTRUCTION METHODOLOGY.

65. Excavation Methods Bottom Up Method: Slabs will be laid from Bottom to Top such that Base slab will be constructed first Base slab Concourse Slab Roof Slab GL GL D-wall Top Down Method: Slabs will be laid from Top to Bottom such that Top slab will be constructed first Top slab Concourse Slab Base Slab GL GL D-wall 65

66. Completion of all D wall Works Start excavation for 1 st layer D wall King Post Bottom Up Method : Launching shaft Construction (Stage 1)

67. Excavation upto 1 m Below Temporary Sturt -1 From one side D wall King Post Bottom Up Method : Launching shaft Construction (Stage 1)

68. 50 T Gantry D Wall Road Waler Start Fixing brackets form one side Start Fixing of Waler form one side Bottom Up Method : Launching shaft Construction (Stage 2)

69. 50 T Gantry D Wall Waler Road Erection of Diagonal Strut Start Fixing Diagonal Strut Start Fixing of Waler for Straight Strut Bottom Up Method : Launching shaft Construction (Stage 2)

70. Start Fixing Straight Strut Start Fixing of Waler for Diagonal Strut 50 T Gantry D Wall Diagonal Strut Road Erection of Straight Strut Erection of Waler for Diagonal strut Bottom Up Method : Launching shaft Construction (Stage 2)

71. Completion of Strut erection Start on 1 st Layer Excavation for 2 nd layer Diagonal Strut Road Straight Strut Erection of Diagonal strut D Wall 50 T Gantry Bottom Up Method : Launching shaft Construction (Stage 2)

72. Erection of 2 nd Strut Layer Excavation upto 1 m Below Temporary Sturt -2 From one side D wall King Post Bottom Up Method : Launching shaft Construction (Stage 3 )

73. Start Fixing of Brackets from One side Start Fixing of Waler from One side Erection of 2 nd Strut Layer Excavation upto 1 m Below Temporary Sturt – 3 From one side King Post D wall Bottom Up Method : Launching shaft Construction (Stage 4)

74. Start Fixing of Brackets from One side Start Fixing of Waler from One side Erection of 3 rd Strut Layer Excavation upto 1 m Below Temporary Sturt – 4 From one side King Post D wall Bottom Up Method : Launching shaft Construction (Stage 5)

75. Start Fixing of Brackets from One side Start Fixing of Waler from One side Erection of 4 th Strut Layer Excavation upto Base Slab Level From one side King Post D wall Bottom Up Method : Launching shaft Construction (Stage 6)

76. Excavation upto Base Slab Level Levelling Surface for Base slab construction King Post D wall Bottom Up Method : Launching shaft Construction (Stage 7)

77. Casting of Base Slab Attain required strength for Base slab Removal of 4 th Level strut Cast reaction Frame support for Pedestal Handover the shaft to TBM operations Base Slab King Post D wall Bottom Up Method : Launching shaft Construction (Stage 8)

78. Station Construction Top – Down Method

79. Top Down Method : Station Construction (Stage 1 )- Excavation still Roof Slab

80. Top Down Method : Station Construction (Stage 2)- Casting of Roof Slab and Excavation till Roof Slab

81. Top Down Method : Station Construction (Stage 3 )-Excavation for Concourse Slab

82. Top Down Method : Station Construction (Stage 4)-Excavation for Concourse Slab and Completion of Roof Slab

83. Top Down Method : Station Construction (Stage 5 )- Casting Concourse Slab

84. Top Down Method : Station Construction (Stage 6)- Excavation of Base slab and Casting of Concourse Slab

85. Top Down Method : Station Construction (Stage 7 )- Completion of concourse and Casting of Base Slab

86. Top Down Method : Station Construction (Stage 8)- Casting of Base Slab

87. Station Construction Bottom – Up Method

88. Bottom UP Method : Station Construction (Stage 1 )- Excavation still Roof Slab and Fixing of Strut

89. Bottom UP Method : Station Construction (Stage 2)- Excavation still Concourse Slab and Fixing of Strut

90. Bottom UP Method : Station Construction (Stage 3 )- Excavation still Base Slab and Casting of Base Slab

91. Bottom UP Method : Station Construction (Stage 4 )- Casting of Concousre Slab

92. Bottom UP Method : Station Construction (Stage 5 )- Casting of Roof Slab

93. Bottom UP Method : Station Construction (Stage 6)- Backfill

94. Cut and Cover Method

95. Tunnel Segment

96. TUNNEL SEGMENT CYCLE TIME Sr.No Activity Duration In Minutes Start Finish 1 Mould Opening 30 30 2 Cleaning of Mould 40 30 70 3 Placing of reinforcement 20 70 90 4 Insert Fixing 10 90 100 5 Checking of reinforcement 20 100 120 6 Concrete Pouring 20 120 140 7 Steam Curing 420 140 560 8 Removal of Segment 40 560 600   In Minutes 600       In Hours 10     Average Time take for 1 Tunnel Segment will be 10 Hrs

97. TUNNEL SEGMENT CYCLE TIME (6 Nos of Mould) Sr.No Activity Mould 1 Mould 2 Mould3 Mould 4 Mould 5 Mould 6 1 Mould Opening 30 30 30 30 30 30   Duration ( In Minutes) 0-30 30-60 60-90 0-30 30-60 60-90 2 Cleaning of Mould 40 40 40 40 40 40   Duration ( In Minutes) 30-70 70-110 110-150 30-70 70-110 110-150 3 Placing of reinforcement 20 20 20 20 20 20   Duration ( In Minutes) 70-90 110-130 150-170 70-90 110-130 150-170 4 Insert Fixing 10 10 10 10 10 10   Duration ( In Minutes) 90-100 130-140 170-180 90-100 130-140 170-180 5 Checking of reinforcement 20 20 20 20 20 20   Duration ( In Minutes) 100-120 140-160 180-200 100-120 140-160 180-200 6 Concrete Pouring 20 20 20 20 20 20   Duration ( In Minutes) 120-140 160-180 200-220 120-140 160-180 200-220 7 Steam Curing 420 420 420 420 420 420   Duration ( In Minutes) 140-560 180-600 240-640 140-560 180-600 240-640 8 Removal of Segment 40 40 40 40 40 40   Duration ( In Minutes) 560-600 600-640 640-680 560-600 600-640 640-680 Total Time for Casting ( For each Mould) 600 Min 10 Hours Total Time for casting (For 6 Mould) 680 Min 11.33 Hours Total Repeatative Ring casting in 22 hours 22/11.33 1.94 Repition No.Of working Days 26   Total no of casting by each mould each month 50 Rings   Total Number of Casting 302 Rings   Average.Casting Per Day 12 Rings 10 Rings Consider in DWP

98. 8 hr for Concreting to Harden Lift Precast segment out of Mould After 8 hours

99. Type of Tunnel Boring Machine EPB Machine Slurry Machine EPB and Slurry Machine

100. Parts of TBM machine

101. Working of TBM

102. Ahmedabad Metro

103. PROJECT ALIGNMENT (UG2)

104. Package: UG2 – 4.102 Km (11620.302m  7518.161 m) Shafts Launching Shaft - Top Down (40 m length) Stations Ghee Kanta - Top Down (170 m length) Shahpur - Top Down (260 m length) Tunnel & Cross Passage TBM Tunnel - 3300 m length × 2 Cross Passage - 13 Nos. Ramp West Ramp - Bottom Up (286 m length) Entry & Exit Entry / Exits - 07 Nos. (3 nos. – Ghee Kanta, 4 nos. – Shahpur) SCOPE OF WORKS (UG2) 116

105. Description Launching Shaft Intermediate Shaft Ghee Kanta Shahpur Arrival Shaft Construction Method Bottom Up Bottom Up Top Down Top Down Bottom Up Length (Outer Length) 40 30 170 260 25 Width (C/C) 25 25 22 22 22 Depth (Base Slab) 20 21 19.5 18.5 18.5 No of Entrances -- -- 3 4 -- Ancillary Building -- -- 1 1 -- SCOPE OF WORKS (UG2) : GENERAL DETAIL

106. TBM PATH ( UG2) TBM 2 TBM 1 TBM 3 Tunneling Configuration

107. Completion of all D wall Works Start excavation for 1 st layer Excavation upto 1 m Below Temporary Sturt -1 From one side Start Fixing brackets form one side Start Fixing of Waler form one side THALTEJ GAM (WEST) VASTRAL GAM (EAST) LAUNCHING SHAFT SEQUENCE

108. CONSTRUCTION SEQUENCE OF GHEEKANTA