Infra PPT for Enginnering Institutes_3Sep25.pdf

This is the work presented during the invited talk at the Indian Institute of Engineering, Science & Technology(IIEST), Shibpur, Kolkata. There was a lively interaction with the faculty and UG & PG students of Civil Engg Deptt of IIEST, India's 2nd oldest Engineering Institute. It was a great session focussed on the role of Ethics in journey of Developed India@2047, and the story of Joka-Esplanade Metro centred around Majerhat Metro Station, the unique elevated station across suburban station and canal. The complete project implementation from concept to commissioing in urban environment was explained and discussed.

1. THE ROLE OF ETHICS IN
INFRASTRUCTURE DEVELOPMENT
&
THE STORY OF MAJERHAT METRO
03.09.2025
HARSIMRAN SINGH, IRSE
FIE, CEng(I), Member of IRC, IPWE, IIBE
CVO, HINDUSTAN COPPER LTD

2. ➢Thegrowthofacountryiscloselylinkedtothe
developmentoftheinfrastructureandindustry.
➢Needsconsiderableinvestment.
➢Fasttrackimplementationofprojects.
➢Needmanpowerwhoisefficientinhandlingthe
infrastructureprojectswhicharegenerallyof
verylargescale.
➢Targetmustbetoimplementtheprojectinthe
leastpossibletimewithleastpossiblecostand
withbestpossiblequality.
BUILDING THE NATION

3. ➢Executionofinfrastructuralprojectsnormally
requirescoordinationwithnumerousstake
holders
➢Involvescomplexprojectmanagementwith
severalinterdependentactivities.
ForaMiningProject:MoM,MOEF,IBM,DGMS,State
Govt(DisttAdmn, MiningDeptt,LandDeptt,
ForestDeptt),Customerslikeindustry(Copper
Smelters),Workers,Contractors,etc.
ForaRailwayProject:MoR,MOEF,NHAI,State
Govt(DisttAdmn, MiningDeptt,LandDeptt),
Customerslikeindustry(Steel/Coal/Cement/Bauxite),
FCI,passengers,MoD,etc
VIKSIT BHARAT@2047

4. INFRASTRUCTURE TARGETS FOR 2047
1.$5 trillion GDP by 2027 and $30tn by 2047 with growth rate
of 7–8% annually.
2.High Income Country by growing per capita income from
about $2878 to $18000.
3.2-3 fold increase in inter-city transport where 60%
passengers will use HS and Semi-High Speed trains and
there will be 32000KM expressways in comparison to about
4000KM at present.
4.To eliminate WL in passenger trains.
5.Increasing freight traffic of Railway and ports from 1600MT
and 2600MT respectively to 10000MT each.
6.Increasing Railway network from 0.69Lakh RKM to 1Lakh
RKM and speed of construction from 14KM/d to over
40KM/d, and modal share of Railway from 26% to 45%.

5. INFRASTRUCTURE BY 2047
7.Increasing Metro network from 1000KM in 23
cities to 5000KM in 75cities.
8.Increasing nosof airports from 157 to 350
including 20 aerotropolis .
9.Developing all cities as Smart Cities with focus on
digital twins, integrated command centres,
climate-resilient design with green mobility,
universal access to clean drinking water and 100%
sewerage.
10.500 GW installed capacity of green energy 2030,
and about 1800GW of green energy installed
capacity by 2047.
11.Expanding Bharat Net to all gram panchayats, and
rollout the 5G-enabled smart transport systems.

6. VIKSIT BHARAT@2047
➢What does it require:
➢To carry out reformsin various sectors
and place these on the superhighway of
fast track development
➢To transform the quality of our human
resources so that they can deliver the
required development
➢To take advantage of the new trends in
global polity and economy, and
technologyso that the growth is fast
tracked and sustained for atleastthree
decades.

7. LARGEST ECONOMIES IN THE WORLD BY GDP (NOMINAL) IN APR 2025
AS PER IMFESTIMATES
GDP PER CAPITA in 2024 AS PER IMF ESTIMATES (in US$)
Luxembourg : 140941 (Rank: 1)
Ireland : 108919(Rank:2)
Switzerland : 104896 (Rank : 3)
Singapore : 92932 (Rank :4)
Iceland : 90932 (Rank: 5)
Norway : 89694 (Rank: 6)
USA : 89105 (Rank: 7)
China : 13687 (Rank: 69)
Germany : 55911 (rank: 17)
Japan : 33956 (Rank: 33)
INDIA: 2872 (Rank-138)
GDP: Monetary measure of
the market value of the final
goods produced and
services rendered in a year
by the country.

8. TOP 5 HIC s
Liechenstein: 116380 (Rank:1,
2009)
Norway : 98280 (Rank: 2)
Switzerland : 95900 (Rank:3)
Luxembourg : 91470 (Rank: 4)
USA : 83660 (Rank : 5)
USA : 83660 (Rank: 5)
China : 13400 (Rank: 64)
Germany : 54960 (rank: 15)
Japan : 36030 (Rank: 29)
INDIA: 2650 (Rank-140)
UK : 48660 (Rank : 23)
Canada : 53340 (Rank : 18)
Iceland : 78480 (Rank: 6)
Denmark : 73790 (Rank: 10)
Netherland : 62840 (Rank: 11)
Russia : 15320 (Rank: 61)
Finland : 51710 (Rank : 20)
New Zealand : 46280 (Rank : 24)
Ahigh-incomecountryisacountrywithahighgrossnational
income(GNI)percapita.TheWBdefinesahigh-incomeeconomy
asacountrywithaGNIpercapitaof$13935ormorein2024.
GNI PER CAPITA in 2024 AS PER IMF ESTIMATES (in US$)
HIGH INCOME COUNTRIES
Large
Econ
o-
mies

9. INDIA
VIS-A-VIS
WORLD

10. CORRUPTION PERCEPTION INDEX BY
TRANSPARENCY INTERNATIONAL
The 2024 CPI, published in February 2025, currently ranks
180 countries "on a scale from 100 (very clean) to 0 (highly
corrupt)" based on the situation between 1 May 2022 and
30 April 2023.
Denmark, Finland, Singapore, New Zealnad, Luxembourg,
Norway, Switzerland & Sweden(all scoring above 80 over
the last four years), are perceived as the least corrupt
nations in the world —ranking consistently high among
internationalfinancial transparency.
Apparently most corrupt is South Sudan(scoring 8)
alongwithSomalia (9) & Venezuela (10)

11. THE CORRUPTION PERCEPTION
INDEX 2024
INDIA STANDS 96
th
with low index of 38
(Last year India was better at 93
rd
with index of 39)

12. UNDP’s HDI 2024
INDIA STANDS at 134
with HDI of 0.6441  Switzerland0.967
2 Norway 0.966
3 Iceland0.959
4 Hong Kong0.956
 Denmark
 Sweden
5 0.952
TOP RANKERS IN HDI
GENERAL TREND SHOWS THAT TRANSPARENCY IS PROPORTIONAL TO
DEVELOPMENT OF THE NATION

13. DEVELOPED AND DEVELOPING
ECONOMIES

14. ➢So to become developed economy, we must have
High transparency (High CPI),and
Good Health, Educatedand Incomeof the Citizens
This implies, we need to work on human quality.
We need to impart Ethical values and Knowledge. We
need to make citizens healthyand enhance their
income.
WAY FORWARD

15. NEED OF ETHICS & QUALITY FOR PROJECT
IMPLEMENTATION AND INFRASTRUCTURE
OPERATION & MAINTENANCE
We need to have Best Quality of Design, Construction& Maintenancewith
Best Quality of Processesand Methodsand with Best Quality of
Equipment, All handled by Best Quality of Manpower.
Manpower that has
(i)strong ethical values of integrity, hardwork, sincerity
&
(ii) best skills and knowledge.
This matter is required to be dealt
(i)at level of family, institutions and society
&
(ii) through policy frameworks, institutions and organizations.

16. ROLE OF EDUCATIONAL INSTITUITIONS, SKILL
DEVELOPMENT INSTITUTES, GOVT & INDUSTRY, &
SOCIETY
WE NEED TO AIM FOR
Best Consulting Engineers
Best Project Managers/Engineers and
Supervisors
Best Equipment Operators, Construction Material
Handing Workers
Best Quality Control And Assurance Engineers
Best Safety Officers
Best Agencies for Execution of Works
Best Equipment
And above all Best MEN

17. 17
“INTEGRITYISDOINGTHERIGHTTHING,
EVENWHENNOONEISWATCHING”.
CSLEWIS
➢Ethicsisthefundamental
introspectionofwhatisright
andwrong.
➢Moralvaluesandprinciplesthat
helpinmakingdecisionswhich
reflectrespectforSocietyand
Humanity.
ETHICS-THEMORALVALUES
Autonomy(Respectingothersrights),Justice(Fairness
intreatmentandallocationofresources),Beneficence
(Obligationtodogood),Non-maleficence(Avoiding
harmtoothers),Honesty,Integrity,Loyalty,….

18. ➢Procurement:Itisavastarearangingfrom
procurementofworks,stores&services.Itisoneofthe
majorcorruptionproneareasinallorganizations.
➢Saleofgoodsandservices:Reverseofprocurement
➢Humanresourcemanagement:Processesrelatingto
recruitment,promotion,transferandposting
➢Deliveryofservicestopublic:MajorGovernment
DepartmentsandsomePSUsareinvolvedindeliveryof
serviceswhichareapotentialareaofcorruption.
➢Enforcement:TheenforcementofActs,Rulesand
Regulationsisalsoanareavulnerabletocorruption
mainlyduetolackofawarenessamongcitizensand
ineffectivegrievanceredressalmechanism.
POTENTIAL AREAS OF CONCERN

20. ➢JOKA-Taratala(6.5KM(c/cofStations)was
inauguratedbyHon’blePMon30
th
Dec,2022.
➢Taratala-MajerhatSection(1.250KM,c/cof
Stations)wasinauguratedbyHon’blePMon6
th
Mar,
2024
➢Workisunderexecutionforthebalanceelevated
sectionfromMajerhat-Mominpore(1.006KM)and
underground sectionfromMominpore to
Esplanade(5.18KM)
JOKA – ESPLANADE METRO CORRIDOR

21. 21
INAUGURATION OF JOKA -TARATALA SECTION

22. 22
THE FIRST WHEEL ROLLS OVER ON THE
TRACK FROM JOKA DEPOT TO TARATALA
ON 15.09.2022

23. 23
JOKA-TARATALA METRO

24. 24
JOKA-TARATALA METRO

25. 25
JOKA-TARATALA METRO

26. JOKA-TARATALA METRO

27. Section is elevated from JOKA to Mominpur (8 stations)
and underground beyond Mominpur, i.e. from
Khidderpore to Esplanade (4 stations)
Work Completed between Joka to Majerhat including depot
approach. Viaduct completed for 10.188 km.
Taratala-Majerhat Section (1.250KM, Station Centre to
Station Centre)
JOKA – ESPLANADE METRO (14.211 Km)
❖Consultant for Viaduct and Stations- M/s Consulting Engineering
Services(CES) (Now M/S JACOBs)
❖Proof Consultant for Viaduct and Stations - IIT Delhi
❖Detailed Design Consultant for BLT- M/s Primerail Infralabs Pvt.
Ltd.
❖Proof Consultant for BLT- M/s ETUDE and IIT Guwahati

28. Drawings- Cross section of Viaduct with Track and 3D Superstructure

29. Typical 3D of MJT Viaduct
M35
M40
M50

30. 5
Survey of Taratala- Majerhat Section
Instrument used:
i)Auto level : B40 of Sokkia
ii) Electronic Total station :Sokkia CX101
Traverse report of Viaduct :Desiredaccuracy=1in50,000
SL
No.
Description as per
submitted report
Pier
Survey
Accuracy
1 Taratala to Buffer P233-P255 1 in 50963
2 Buffer to P276 P255-P276 1 in 50393
3
P276 to P277 (Majherhat
Station)
P276-P277 1 in 62671
4
P277 (Majherjat Station)
To Buffer
P277-P297 1 in 64519

31. CONSTRUCTION OF VIADUCT FOR METRO LINE BETWEEN TARATALA TO MAJERHAT
Items
Taratala to Buffer
Buffer to Majerhat
Station
Majerhat Station
Majerhat Station to
Buffer
Total
P/233 to P/255 P/255 to P/276 P276 to P277 P277 to P297
Pile 127 65 188 115 495
Pile cap 27 15 14 21 77
Pier 27 15 14 21 77
Pier cap 19 15 15 20 89
Hammer Head -NA- 01 -NA- 16 17
L-Pier Head 02 04 -NA- 04 10
Portal Beam 04 -NA- -NA- 01 05
Seismic Restrainer 23 15 -NA- 21 59
Pedestals (in group) 23 15 28 21 87
Crash Barrier 27 15 -NA- 21 63
Segment Casting 202 190 -NA- -NA- 392
Segment Erection in span 23 14 -NA- -NA- 37
Segment Stressing & Grouting in
span
23 14 -NA- -NA- 37
Psc I-Girder Casting -NA- -NA- -NA- 76 76
Psc I-Girder Erection I Span
-NA-
-NA- -NA- 76 76
Psc I-Girder Stressing & Grouting
-NA-
-NA- -NA- 76 76
Steel Girder -NA- -NA- 33 04 37
Steel Girder Erection in Span -NA- -NA- 33 04 37
Elastomeric Bearing in span 23 14 28 20 85
Sperical Bearing Bearing in span -NA- -NA- -NA- 08 08
Steel Plate Bearing -NA- -NA- 60 -NA- 60
Parapet Casting in nos. 404 124 75*2 M 392 920
Parapet erection in Span 23 14 -NA- 21 58

32. PILE LOAD TESTS
Type of TestFor
Stations
Available
Test
Report
Remarks
INITIAL PILE LOAD
TEST
02-Vertical
02-Horizontal
IS 2911 PART IV
(1985) Clause 4.1
ROUTINE PILE LOAD
TEST
04 IS 2911 PART IV
(1985) Clause 4.2
These tests must be done meticulously and interpreted very
carefully to ensure safety of structures and economy of the project
•VerticalCapacityofboredcast-in-placecircularpileisdeterminedusingtwo
approachesandleastoftwoisusedtodetermineitscapacityforgivenpile
length.Firstiscalculatedby1
stbyStaticformulaasgiveninIS:2911(Part
1/Section2)andthencheckedbyinitialtest.
•LateralCapacityofpileisalsodeterminedbothfromtheempiricalformulaas
giveninIS:2911(Part1/Section2)andfrominitialloadtestasperIS:2911
(Part4);andleastistakenascapacityundernormalloading.

33. INITIAL PILE LOAD TEST DETAILS IN STATION AREA OF TARATALA & MAJERHAT
Station
Name
Scope of
Pile (Nos.)
Dia
of
Pile
(MM
)
Vertical Load Test
Vertical
Load
corres-
pondin
g to 12
mm
settle-
ment
Vertical
Safe
Load
(2/3rd
at 12
mm
settle-
ment)
Horizontal Load
Test
Desig
n
Load
(Ton)
Test
load
(Ton
)
Gross
Deflec
- tion
(MM)
Desig
n
Load
(Ton)
Test
Loa
d
(Ton
)
Test
Pile
length
(M)
Gross
Settle
-
ment
(MM)
Taratala 58 12004409682628.663820.2546.820 506.670
Majerhat 275 12005501381.0
5
4010.33
…. ….
(Safe
load=
1/2 of
final
load=69
0T)
2767.52.70
Safe Vertical Load : (i) 2/3 rdof Load corresponding to 12mm settlement (As per IS
Code issued in 2013, it’s 18mm or 2% of pile dia, which ever is less)
: (ii) half of the total load at which total displacement is equal to 10%
of pile diameter
Safe Lateral Load : ½ of Load corresponding to 12mm settlement
: Load corresponding to 5mm settlement

34. ROUTINE LOAD TESTS
PileId
Dia.of
Pile (mm)Depth
of
Pile (m)
Details of load test conducted
Design
load (T)
Test load
(T)
Settle
ment
(mm)
Remark
Vertical
P262 1200 35 489 803 14 Failure as per
old code. Pass
as per new
code.
P266 1200 35 489 735.5 9.2 Pass
Lateral
P298/1
1200 45 20 20 1.27
Pass (less than
5mm)
P305/3
1200 45 15 15 1.1
Pass (less than
5mm)
AsperIScodeissuedin2013,settlementshouldnotcross18mmor2%
ofpilediameterwhicheverislessforpilesabove600mmdiameter,and
12mmforpilesupto600mmdiameter.Earlier,itusedtobe12mm
settlementlimit.

35. BEARINGS USED
S.N.TYPE OF
BEARING
SIZE(mm)/Type
1
ELASTOMERIC
BEARING
(Segmental Box
Girder)
600x575x96
550x550x80
500x500x80
475x475x64
2
ELASTOMERIC
BEARING
(PSC I-Girder)
350x350x52
400x400x80
425x425x80
3
ELASTOMERIC
BEARING
(Steel Girder/MJT
Yard)
270x270x48
330x330x64
4
Steel Plate
BEARING
(Steel
Girder/MJT
Yard)
570x280x25x2
620x280x25x2
5
SPERICAL
BEARING
(Steel Girder/50
M)
535x590x157
510x765x177
465x500x120
550x880x207

36. Track Geometry, Track Structure and Rolling Stock
i)Gauge :Broad Gauge 1676 mm (Laid on 1673MM (+)2 (-)0)
ii)Track centres :4200 mm
iii)Vertical alignment:In zero gradient within station portion
iv)Horizontal
alignment
:In Taratala-Majerhat section,
Maximum Curvature: 1300M
(1.346°).
v)Rolling Stock :RTS(Rapid Transit System) Coach (as indicated in
theloading diagram of Metro Schedule of Dimension)
vi)Track :Ballast less track with a minimum plinth
thickness of 185 mm. The track will consist of 60kg
UIC 1080 grade HH rails with bearing plates
fastenings and other accessories.
DESIGN BASIS

37. SERVICE LIFE
i)Main structural elements 120 years
ii)Elastomeric Bearings 15 years
iii)
Minor components that
can be replaced without
complete removal and
interruption to traffic
20 years
We should try to have longer life components. Research is needed
in this field to have more durable and economical components
especially bearings.
Indegenouscompanies must come up and prove their credentials.
DESIGNBASIS

38. CLEARANCE REQUIREMENTS
•For Road Traffic :
Vertical clearance after median kerb (which comprises
center column/pier shaft protected by crash barrier) is
kept 6.00m from road top level.
•For Rolling Stock :
All structures are placed beyond the fixed structure line as
per Item 4 of Chapter 1, Schedule of Dimension (SOD)
of Metro Railway approved by Railway Board Ref.
83/MTP/C/22 dated 30.11.94.
DESIGN BASIS
Greatcareisneededattheplanningstagetoensure
thatnoinfringementstakeplacewhenprojectcomes
tocommissioningstage.

39. MINIMUM CONCRETE GRADES
Pile & pile cap, open foundation M35
Concentric pier cap and pier shaftM40, (M50& M60 in special cases)
M50 -for L-pier&
M60–for pier cap of L- pier
Hammerhead pier cap for platform
girders
M40
Cast-in-place superstructure:
Segment Box Girder,
M50
Precast I-girder M50
Bearing Pedestals M60
Precast barrier cum parapet M40
Cast-in-place crash barrier around
piershaft/columns
M40
Other miscellaneous structures M35
Materialpropertiesmustbedecidedkeepingin
viewdesignrequirements,availabilityof
materialsandcosteconomics.
DESIGN BASIS

40. APPROVED MIX DESIGN SUMMARY
SL. No.
Grade of
Concrete & ID
W/C
Cement
Content
(Kg)
Brand Water (Kg)20mm (Kg)10mm (Kg)Sand (Kg)
Admixture
(Kg)
Admixture
Name
Admixture
Dose (%)
Strength
7 days
Mpa
Strength
28 days
Mpa
1 M15 0.48 302Ramco OPC53 145 656 536 849 1.96
Chryso Fluid
Optima S812
0.65 16.324.15
2 M25 0.4 380Ramco OPC43 152 712 475 797 2.47
Chryso Fluid
Optima S812
0.65 24.4435.78
3 M35(Pile) 0.38 421Ramco OPC53 160 628 514 755 2.95
Chryso Fluid
Optima S812
0.7 34.8548.15
4 M35(Pile Cap)0.36 412Ramco OPC53 148 595 595 776 2.88
Chryso Fluid
Optima S812
0.69 36.4251.78
5 M35(Pile) 0.35 450 Ramco PPC 157 615 503 723 3.37
Chryso Fluid
Optima S812
0.75 37.7849.78
6 M35(Pile) 0.38 421 RamcoOPC43 160 688 514 755 3.16
Chryso Fluid
Optima S812
0.75 41.1947.26
7 M35(Pile Cap)0.36 412Ramco OPC43 148 587 587 765 3.09
Chryso Fluid
Optima S812
0.75 41.4850.37
8 M35(Pile) 0.34 450Ultratech PPC 153 584 584 750 3.37
Chryso Fluid
Optima S812
0.75 36.7450.07
9 M35(Pile) 0.34 450 Nuvoco PPC 153 584 584 750 3.37
Chryso Fluid
Optima S812
0.75 38.6752.74
10 M40 0.35 430
Coromandel
OPC 53
151 581 581 752 3.66
Chryso Fluid
Optima S812
0.85 38.6560.15
11 M40 0.35 430
Coromandel
OPC 43
151 581 581 752 3.66
Chryso Fluid
Optima S812
0.85 39.759.11
12 M50 0.32 485Ramco OPC53 155 511 625 719 3.88
Chryso Fluid
Optima S812
0.85 51.4165.12
13 M50 0.33 485Ramco OPC53 160 507 619 717 2.91
Chryso Fluid
Optima S812
0.6 50.2265.78
14 M60 0.3 495Ramco OPC53 149 516 631 715 4.46
Chryso Fluid
Optima S812
0.9 62.0780.15

41. STANDARD DEVIATION
SL.NO GRADE OF CONCRETE MONTHLY STANDARD
DEVIATION OBSERVED
1 M35(Pile ,Pile Cap ) 0.5-2.35
2 M40(Pier Column &above
Structure)
0.89-3.06
VIADUCT PORTION
SL.NOGRADE OF CONCRETE MONTHLYSTANDARD
DEVIATIONOBSERVED
1 M35(Pile) 0.46-1.73
2 M35(Pile cap) 0.7-1.94
3 M40(Pier, Pier Cap, Stitch Beam,
Parapet&Crash Barrier)
0.72-1.76
4 M50(Segment) 0.57-2.53
5 M60(Pedestal) 1.38-1.79
STATION PORTION

42. Location LOAD COMBINATION TAKEN REFERENCES
Elevate
d
Viaduct
Portion
1)Normal Case
2)Seismic on Loaded Structure case
3)Seismic on Unloaded Structure case
4)Temperature effects
5)Derailment condition
Table no 12 of IRS CBC
updated by Addendum &
Corrigendum slip no 13
dated 25 Nov 2010.
Station
Viaduct
Portion
1)Basic load combinations and associated
partial load factors
2)Normal load cases and partial load factors
3)Seismic load cases on loaded structure
and partial load factors
4)Seismic load cases on unloaded structure
and partial load factors
5)Erection cases and partial load factors
6)Temperature load cases and partial load
factors
7)Derailment load case and partial load factors
Table no 12 of IRS CBC
updated by Addendum &
Corrigendum slip no 13
dated 25 Nov 2010.
Station
Portion
1)Normal load case and partial load factors
2)Seismic load cases without live loads and
partial load
factors
3)Seismic load cases with live loads and partial
load factors
4)Wind load cases and partial load factors
5)Temperature load cases and partial load
factors
It is prepared from both IRS
CBC and IS: 456 the partial
load factors are however
taken IS:456 because of
higher values than
prescribed in IRS CBC
LOAD COMBINATIONS
DESIGN BASIS

43. LOAD COMBINATIONS FOR BLT
SN LOAD COMBINATION
1LC1 :Dead Load, SIDL and Live Load
2LC2A : Dead Load, SIDL and Wind Load with Live Load
3LC2B : Dead Load, SIDL and Wind Load without Live Load
4LC2C : Dead Load, SIDL and Seismic Load with Live Load
5LC2D : Dead Load, SIDL and Seismic Load without Live Load
6LC3 :Dead Load, SIDL and Live load with Radial Force and
TempLoad
7LC4 :DeadLoad,SIDLandLWRLoad
8LC5 :Dead Load, SIDL and Derailment Load
DESIGN BASIS

44. CLEARANCEREQUIREMENTS
•For Road Traffic :
Vertical clearance after median kerb (which
comprises center column/pier shaft protected by
crash barrier) is kept6.00m from road top level.
•For Rolling Stock :
All structures are placed beyond the fixed
structure line as per Item 4 of Chapter 1,
Schedule of Dimension (SOD) of Metro Railway
approved by Railway Board Ref. 83/MTP/C/22
dated 30.11.94.
DESIGNBASIS

45. STATION VIADUCT PORTION
•Superstructure is analyzed in longitudinal direction as a
simple beamsubjected to uniform loading due to Self
Weight Load, Super imposed Deadload and Moving Load
due to trains with appropriate coefficient of dynamic
augmentation, following the principle of statics.
•In transverse direction the box section of unit width is
analysed as a frame section supported over two bottom
supports at soffit level.
•The pier cap is analyzed as a corbel or a cantilever beam
depending uponthe depth to shear span ratio.
•The pier column is analysed as a cantilever column, fixed
at pier base and free at bearing level.
•Pile cap up to four piles are analysed using strut-and-tie
model and simplebeam model.
•All analysis is done by DDC using in-house
developed spread sheets,which is validated by
employing general purpose FEM package STAAD pro.

46. STATION BUILDING PORTION WITH CONCOURSE
•Station building portion comprises of a special
moment resistingRCC framed building supported
over pile foundations.
•All the building frames are modelled in general
purpose FEM package STAAD Pro using
centerline dimensions of respective beam-column
elements.
•The floor slab is modelled by imposing kinematic
constraints to simulate its rigidity under in-plane
loading,such as wind and seismic forces and
flexibility under out-of-plane loading such as
gravity loads.
•The underground tanks are model with plate
elements to analyzethe structure for various forces
described earlier.

47. PERMISSIBLE DEFLECTION TO SATISFY LIMIT STATE
Member Loading Limit Reference
Viaduct
superstructure
Vehicular LL Span/800
Clause no 12.4.1
of IRC:112
Vehicular+
pedestrian
Span/1000
Vehicular on
Cantilever
Span/300
Building members All loads Span/350
Clause no 23.2
of IS:456
Purlin
members
DL + LL Span/250
Clause no. 5.6.1
of IS:800DL + LL + WL Span/200
Inter storey drift
ratio
DL+EQ with 1.0
partial load
factors
0.40%
Clause no 7.11.1
of IS:1893
(part 1)

48. DURABILITY ASPECTS
➢In order to ensure good structural performance of structures under
this moderate environment exposure, following aspects are
considered.
➢By limiting crack width of flexural members under service loads to
0.20mm, as recommended by IRS/CBC
➢A minimum cover to any reinforcement is provided as per IRS/CBC
and IS:456 recommendations.
Sl. No. Type of Structure Minimum Clear Cover
1 Pile 75 mm
2 Pile Cap 75 mm
3 Pier, L-Pier & Pier Cap 50 mm
4 Stitch Beam 40 mm
5 Portal Beam, parapet 40 mm
6 Pedestal 50 mm
7 Segment 40 mm
8 PSC I-Girders 40 mm

49. ➢Minimum cement content and other aspects such as
acceptable permeability, workmanship during concreting work
etc., are maintained.
➢For permeability test the depth of penetration of moisture
shall not exceed 25 mm as per clause 5.5.3 of IRS/CBC)
➢The durability requirements are generally addressed in Cl
5.4 ofIRS/CBC.
TYPE OF structure
Type of cement
used
Min. Cement
content
Pile, Pile Cap PSC 400(KG/M3)
Pier, Pier cap OPC 43 Grade
430 (KG/M3)
SegmentalBoxGirder,
PSC I-Girders, Pedestal
OPC 53 Grade
430(KG/M3)
DURABILITYASPECTS
NOW IT’S TIME TO EXPLORE AND DEVELOP UPHC FOR
SLENDER & MORE DURABLE STRUCTURES, & LONGER SPANS

50. ELEVATED STATIONS
•Indian Railway/ RDSO,
Kolkata Metro Railway
•Bureau of Indian Standard
•IRC / MORTH
•AASTHO Standard
•UIC recommendation and
publication
•ICE, International
Electromechanical
Commission
recommendation
•NFPA 130 standard for
fixed guide way system for
fire safety design
VIADUCT PORTION
•Indian Railway/
RDSO,
Kolkata Metro Railway
•IRC and MORTH
•Bureau of Indian Standard
•AASTHO Standard
•UIC recommendation and
publication
•ICE, International
Electromechanical
Commission
recommendation
•NFPA 130 standard for
fixed guide way system for
fire safety design
DESIGNSTANDARDS

51. 1200 mm diameter bored cast in situ piles have been
used. At entry structures of stations 750mm diameter
bored cast in situ piles have been used.
PILE FOUNDATION WORK
Setting Out
(10 mins)
Setting of
Piling Rig
(30 mints)
Boring
of Piles
(5-6 hrs)
Cleaning
of the
Borehole
(1-2 hrs)
Borehole
Stabilization
Reinforcement
Placing
(1-1.5 hrs)
Concrete
Pouring
(1-2 hrs)

52. Viaduct portion:
Sl.Description of Hindrances Authority Concerned Impediment Removal Date
1Shifting of Tramline CTC June 2011
2Dismantling of unauthorized boundary wall from Irrigation
land near CharialBridge
I&W Dept. July 2012
3Shifting of WBSEDCL & WBSETCL lines near Depot
approach
WBSEDCL
WBSETCL
December 2013
4Dismantling unauthorized structure from Irrigation land
near BankrahatRoad
I&W Dept. July 2014
5Shifting of PHE Pipeline PHE August 2014
6Shifting of WBSETCL WBSEDCL January 2014
7Dismantling of C. ComenceBuilding (G+2) C. Comence April.2015
8Shifting of Gas Pipelines GCGSCL August –Sept. 2015 (In phases)
9Dismantling of boundary wall of CESC Building CESC June 2016
10Removal of infringement from Depot approach (P38D) June 2016
11Dismantling of Rehabilitation India Building (G+2) KMDA March 2017
12Permission for dismantling of KMC’s Bus-Stand near CESC
office
CESC September 2017
13Mint Post Office.(Old) Postal Dept. & MintSeptember 2017
14Dismantling of Mother Diary & Old Age Home Mother Diary & KoPTNovember 2017
14India Govt. Mint grant permission in phases MINT January2017toMay2018(in04
differentspells)
15DiversionofBoxdrain,KMCpipelinesetc.forconstruction
ofViaductbetweenMajerhattoMominpur
Traffic, PWD, KMCDec.2019
IMPEDIMENTS (JOKA-MAJERHAT)
As in Aug23

53. RELOCATION OF OLD AGE HOME
AFTER
BEFORE
Shifting of Trams

54. Station portion:
Sl.Description of Hindrances Authority
Concerned
Removal feature
1Shifting of PHE Pipeline PHE June 2013
2Shifting of KMC Pipelineat Majerhat KMC December 2014 (North)
June 2014 (South)
3Shifting of KMC Pipelineat Taratala KMC January 2014 (East)
4Shifting of KMC Pipeline at Behala Bazar KMC February 2014(East )
August 2014 (West)
5Shifting of KMC Pipeline at Thakurpukur KMC December 2013(East)
February 2014(West)
6Shifting of KMC Pipeline at Sakherbazar KMC February 2014(East)
November 2013(West)
7Shifting of KMC Pipeline at Behala Chowrasta KMC June 2015(East)
October 2015(West)
8Removal of shop/encroachments from Joka,
Thakurpukur& Sakherbazarstation
KMC September 2013
IMPEDIMENTS (JOKA-MAJERHAT)
As in Aug23

55. Sl.Description of
Hindrances
Authority
Concerned
Present Status
9Acquisition of
privatelandforJoka
Depot
Metro Rly&
State Govt.
Possessionof22.742ha.ofland(86.71%)handedover
toRVNL.Butentirelandundernotificationhas
practicallycomewithintheJokaDepotboundary.
OnlyfewclaimcasesareunderproceedingsatCA/AA
courtfordisposal.
10Acquisition of
PrivateLandbeyond
Majerhat
Metro Rly Notformallyconcluded,butworkdonebytaking
possession.
11Acquisition of
Mominpur Petrol
Pump
Metro Rly.Couldnotget,henceGADofMominporeStation
changedandfreshsetofInfringementremoval
proposed
12Majerhat Metro
Station viaduct
infringeddueto
constructionof
MajerhatROB
PWD Worksuspendedsince06.09.2018forinvestigationby
SITandconstructionofnewROBbyPWD.Tower
craneremovedfromMajerhatinDec,20
13ConstructionofPier
NoP285-288
Traffic, PWD, WorkremainedsuspendedtillJuly,2020.
As in Aug23
IMPEDIMENTS (JOKA-MAJERHAT)

56. PHOTOGRAPH S DURING DIFFERENT PHASE OF CONSTRUCTION

57. PILECAPWORKATTARATALA-MAJHERHAT
M35 Grade RCC pile caps have been cast. The top level of pile cap has been
normally kept 0.5m below the road level.
Earthwork in Excavation
Chipping/
Trimming of
Pile Head
Laying of PCC
as Leveling
Course
CONSTRUCTION METHOD:
Bending and
Fixing of
Reinforcement
Steel
Fitting, fixing of
Shuttering and
de-shuttering
ConcretingCuringBackfilling

58. PIER & PIER CAP
Concentricpiersare of 2000 mm diameter and have been cast with M40
grade RCC.L-piers have been cast of size(1950x3550) mm and with M50
Grade of RCC.Portalpiershave been cast of size(1950X1950) mm and
Generally cast with M40 or M50 Grade of RCC.

59. SEGMENT CASTING
M50 grade Segments have been cast of 2000mm overall depth.
LONG LINE BEDS
•The length and width of bed for straight and curved spans are taken as per
drawing. In a typical casting sequence, two pier segments have been cast on
pier segment beds separately and placed at their final locations on either side of
long line bed. One intermediate segment is match cast starting from one end.
•In case of casting of non standard span (length), the sequence of casting is
same as that of standard span except thatduring casting of mid
segment/adjacent segment, two neighboring segments are lifted and re-
positioned on the bed maintaining the correct length required for the mid
segment/adjacent segment to be cast.

60. FIXTURES IN SEGMENT
•Embedded items such as HDPE pipe, anchorages etc. are fixed as
per drawing.
•All other fixtures such as drainage spout etc. are provided at
specified locations as detailed in the drawings.
LIFTING OF SEGMENTS
•The match cast segment has been fitted with a lifting frame through
the lifting holes provided as per drawing at the time of casting of the
segment.
•The segment islifted from the soffit shutter by the 65T capacity
Goliath Crane and placed in the stacking yard. The lifting of
segment is been done after it attains minimum cube strength of
25MPa.
SEGMENT CASTING

61. Launching girders of Bridge cone type with 270T total weight
and capable of lifting segments upto 580T totalweight and
working with curvature upto 8.65 degree have been used.
SEGMENT LAUNCHING

62. SEGMENT LAUNCHING

63. SEGMENT LAUNCHING

64. SEGMENT LAUNCHING

65. SEGMENT LAUNCHING

66. SEGMENT LAUNCHING

67. SEGMENT LAUNCHING

68. SEGMENT LAUNCHING

69. SEGMENT LAUNCHING

70. SEGMENT LAUNCHING

72. SEGMENT LAUNCHING

73. SEGMENT LAUNCHING

74. SEG-1
Pedestal
Bearing
Tendon
SEG-2 SEG-3
1
2
3
4/5
SEGMENT LAUNCHING

75. ERECTION OF SEGMENTS BY LAUNCHING GIRDER

76. The PSC I girder span is designed considering four numbers of I-
girders spanning longitudinally and transversely spanning cast-in
place deck slab providing composite action with the longitudinal main
girders. Two RCC cross girders at diaphragm location and one RCC
cross girder at mid span location ties the main girders transversely
providing lateral stability. Provisions for future pre stressing is included
in the design.
Attheultimatelimitstate,criticalsectionsinlongitudinaldirection
are checkedforflexureandshearconsideringprestressingforces
afterall losses.
Attheserviceabilitylimitstate,thesectionsarecheckedfor
residual compressionatsoffitanddeflectionatmidspan.All thedesigns
havebeen doneinaccordancewithrelevantIRS/CBCstandards.
Transversespanningdeckslabischeckedforflexureandshearat
the ultimateandserviceabilitylimitstates.
PRESTRESSED CONCRETE I -GIRDERS

77. PSC I-GIRDER CASTING
M50gradeI-Girdershavebeencastof1800mmoverall
depth.
LIFTING OF I-Girders
•The I-Giders has been fitted with a lifting hook through the
reinforcement provided as per drawing at the time of casting of
the I-Giders.
•The I-Girders have been lifted from the bed by the 65T
capacity Goliath Crane and placed at the stacking yard. The
lifting of I-Girder has been done after it attains minimum target
cube strength of 54 MPa.

78. ERECTION OF PSC I-GIRDERS BY CRANE

79. ERECTION OF PSC I-GIRDERS BY CRANE

80. ERECTION OF PSC I-GIRDERS BY CRANE

81. ERECTIONWORKOFPSCI-GIRDERS

82. The steel girder span is designed considering longitudinally
spanning four number fabricated steel girders and
transversely spanning cast-in place deck slab providing
composite action with the longitudinal main girders.
Cross girders are provided at end support locations and
intermediate location to ensure proper load distribution and
provide lateral stability.
Main girders are provided with transverse stiffeners and
bracings as per the design requirement.
E410gradeSteelGirders havebeenFabricatedof1300-
2600mmoveralldepth.
Fabrication : Thecutting,machining andpaintingofsteel
girdermaintainsRDSOguidelines.
Finalcheckingof trailassemblyverifiedbytheRDSO.
50M STEEL GIRDER SPAN

83. ERECTION OF 50M PLATE GIRDER SPAN AT MAJERHAT ON
DIAMOND HARBOUR ROAD AT BURDWAN CROSSING

84. •Megatrafficblockof24hrsinahighlycongestedcrossingandinvery
closevicinityofaPetrolPump,shopsandresidences.
•Veryhighlevelofplanning,removalofseveralutilities
•4roadmountedcranes-2Nosof250TandoneNoof150T,withone300T
stand-bycranewereused.
•1specialaxle16-wheeltrailerof31Mcapacityandtwo12-wheelflatbed
trailersof20mcapacityeachweredeputedfortransportingthe
assembledgirdersin4piecesof2×30.75m,and2x18.35m.
•Twopiecesofeachpairofgirdersweresplicedtogetherduringblockwith
1108HSFGboltsof10.9SGrade.Totalof2216boltswerefixedand
tightenedbytorquewrenches.
ERECTION OF 50M PLATE GIRDER SPAN AT MAJERHAT ON
DIAMOND HARBOUR ROAD AT BURDWAN CROSSING

85. WORKSHOP WORK FLOW CHART
Raw Material
from
Rolling Mill
Cutting
Section
Straightening
Section
Assembly
Section
(Jig Fixing)
Welding
(If required)
Drilling
Light Member
Section
Initial
Assembly
Riveting/HSFG Bolt
(If required)
Final Assembly
Inspection
(Including RDSO)
Dispatch Blasting and Painting
Raw Material
Inspection

86. SUBMERGED ARC WELDING (SAW) & METAL
INERT GAS (MIG) WELDING MACHINE

87. END MILLING MACHINE & BEAM STRAIGHTENING
MACHINE
END MILLING MACHINE PLATE STRAIGHTENING MACHINE

88. Welding
Inspection
(UT, MPT,
LPT, RT)
Measurement
using gauges
WELD INSPECTION

89. STUD WELDING

90. UG Reservoir
with Pump
House
UG Reservoir &
Pump House
PD Buiding
BCC Buiding
Suburban Station
School
VIEW OF MAJERHAT METRO STATION
WITH SURROUNDINGS

91. •40 curved steel I-beams connected to steel
columns of I-section at either end. These
were erected using a special crane.
•2mm Polycarbonate sheet at middle top
location of roof is provided for daylight.
•Zincalumesteel sheets of rib height 28 to 30
mm with pitch of 200 mm are used over
entire balance area.
•The thickness of sheets is 0.6 mm with bare
metal thickness of 0.53mm.
•To reduce maintenance issue rolled section
of built up sections with element thickness
more than 6mm are used.
ROOF STRUCTURE OF STATION

93. BASEMENT DESIGN AND CONSTRUCTION
•The PD building and BCC building are planned
and designed to be eight storied structures with
basements, accommodating various facilities for
the station and future property development.
•Because of loose topsoil and clayey strata, the
pile lengths were becoming long. So, to take care
of that, advantage of big raft over piles was taken
by considering load transfer from raft to the
ground in addition to piles.
•Due to the presence of water table at a very shallow depth and canal nearby,
the basement was also checked for floatation, due to buoyancy effect during
construction time.
•This was critical for large water reservoirs which did not have piles.

94. •During construction of basement,
many a times it got flooded with
water and was required to be
dewatered especially during
monsoon seasons.
•During basement construction of PD building, there was leakage
of nearby water supply main pipe valve, which caused heavy
flooding of already excavated portion of the basement.
•Sheet piles were used to safeguard the existing railway platform
and dewatering was carried out with precautions as the sudden
change in water level could affect the sheet piles negatively.

95. BASEMENT OF BCC BUILDING
•Challenges due to proximity of canal.
•750mm diameter contiguous bored piles
were used with 3m edge distance from
canal.
•These were designed to withstand a fill
height of 5m approx. for a length of
around 40m.

96. TYPICAL CROSS SECTION OF MAJERHAT YARD
M35
M40
Steel Section
M40

97. CENTRAL PORTION OF METRO STATION
•Launching was to be done across 7 railway
tracks and canal at 3 levels.
•It was decided to go with steel as material for
construction as that is lighter, easier to erect
and can span long.
•6 pile group of 1200mm diameter piles with
staggered arrangement was used.
•Width of the pile cap could be restricted
within 3400mm which could be just adjusted
within the series of tracks keeping safe
distance from the trains.

98. 258 hours of block were
taken on 93 days to
complete piles and pile
caps
CENTRAL PORTION OF METRO STATION

99. CENTRAL PORTION OF METRO STATION

100. 7 pairs of trestles erected to support rolling beams over which the
girders were placed and rolled
CENTRAL PORTION OF METRO STATION

101. CENTRAL PORTION OF METRO STATION

102. TRACK
LEVEL
GIRDERS
TEMPORARY SPLICE TO BE
REMOVED TO ENABLE LOWERING
OF GIRDERS
CONCOURSE
LEVEL
GIRDER
CENTRAL PORTION OF METRO STATION
TRACK LEVEL
SLAB

103. ELEMENTSOFTRACK
Rails
Rails in railway track context is a beam which provides
running surface- the carrier & the wheel guiding system.
Fastenings
Fastenings are set of fixing arrangement to hold the rails in
position during the passage of wheel. Two bolt fastening to be
required as the maximum Radius of curvature of this section is
1300M, which can be considered as Straight.
Track Plinth / Track slabs
•When the Rails for a tracks are fixed on plinth beams or slabs
on bridges or embankment, through a fixing(anchoring)
arrangement, it is called Ballastless Track.
•Rails are laid with specificfastening arrangement.

105. Ballast less Track Design – Alignment
Design considerations
1)Alignment design has been done by considering the as built survey data
2)Minimum track to track center distance has been considered as 4.20m.
3)80 kmph is consider as the maximum design speed
4)Minimum Horizontal radius has been considered as 200m as it is the safest
value and to be considered in the design as compared with 175m as
mentioned in Schedule of Dimension
5)For Speed and Cant calculation following the limiting values are consider:
oMaximum Cant applied -
oMaximum Cant deficiency
oLateral Acceleration
oRate of change of cant
oRate of change of deficiency-
oCant Gradient -
150 mm
- 75 mm
- 0.45 m/s2
- 55 mm/s
55 mm/s
1 in 333.33

106. BALLASTLESSTRACKDESIGN–ALIGNMENT

107. BALLASTLESSTRACKDESIGN–ALIGNMENT

108. Drawings-Plinth at straight & Mild curve (Radius >218m) – 0mm Cant

109. Drawings-3
rd
Rail Bracket and pedestal arrangement

110. Drawings- Layout of Track Junction (Crossover-1 in 12 )
B.I.M-Diversion with combined
Track slab

111. Drawings- Crossover-1 in 12 /B.I.M-Diversion with combined Track slab

112. FRICTION BUFFER

113. DESTRUCTIVE BUFFER IMPACT TEST FOR
METRO SYSTEM (FIRST TME IN INDIA)
IMPACT TEST CONDUCTED ON 25.11.2023
IMPACT TEST CONDUCTED
ON 25.11.2023

114. 1IN12CROSSOVER

115. TRACK IN CURVE

116. CURVENEARSTATION

117. PANDROLFASTENINGCOMPONENTS

118. RAPID PRECISE SPAN DEFLECTION TEST AT
BURDWAN ROAD CROSSING ON 50M SPAN

119. GIRDER
NO.
LOCA-
TION
THEORETICAL
CALCULATED
DEFLECTION
(mm)
ACTUAL
DEFLECTION
(mm)
G1
L/4 24.742 19.8
L/2 35.030 28.8
3L/4 24.663 19.8
G2
L/4 24.742 19.9
L/2 35.060 28.9
3L/4 24.341 19.8
G3
L/4 24.742 19.7
L/2 35.060 28.8
3L/4 24.341 19.6
G4
L/4 24.742 19.5
L/2 35.030 28.7
3L/4 24.663 19.2
Recovery at Mid span = G1 –95.45%, G2 –95.15%, G3-95.13%
and G4 -95.47 i.emore than 75% as per IRC-SP-51 (2015)

120. DETAILSOFSPANLOADTEST(25M SPAN)
Bridge/
GirderNo.
Km
(from
Taratal
a)
Overall
span
(inMts)
Overall
depthof
Girder(in
Mts)
Design
Load
EUDL
(MT)
Test
Load
EDUL
(MT)
Design
deflection
undertest
loadinmm.
Actual
deflection
undertest
loadin
mm.
Deflection
recovered
after
unloadingin
mm
%of
recovery
Acceptance
Criteria
P264-
P265
1.01525 2000334.95334.953.80 5.151 3.60 94.74%
Minimum
percentage
of
Recovery
shallbe
morethan
85%asper
clause6.8
ofIRCSP-
51-2014

124. PASSENGER AMENITIES
•TactilePaving
•Signage
•CCTVSurveillance(Underimplementation)
•PASystem
•Lifts&Escalators
•AFCGates(Underimplementation)
•EmergencyExitsandFireman’sEntry
•FireDetection&Suppression
•SmokeExtraction
•EmergencyLighting
•First–Aidkits,Stretcher,WheelChair,
OxygenCylinder& Mask
169

125. ELECTRICAL WORKS FOR THE STATION
ESS
PANEL IN ESS BATTERY SET IN ESS
ESSCABLE TRAYS
BENEATH CONCOURSE

126. ELECTRICAL WORKS
DIESEL GENERATOR
LAYINGPOWER CABLES
ON VIADUCT
FIXING THIRD RAIL FOR
TRACTION POWER
PUMPING SYSTEM AT UG RESERVOIR

127. •Fire Detection System
•SmokeExtraction
•FireHydrants
•FireExtinguishers
•Signage
171
ELECTRICAL WORKS

128. Electricalpanelfor
firefightingsystem
GasRealisingPanel
FireSuppression
GAS BASED FIRE FIGHTING SYSTEM

129. UG Reservoir
with Pump
House
UG Reservoir &
Pump House
PD Buiding
BCC Buiding
Suburban Station
School
VIEW OF MAJERHAT METRO STATION
WITH SURROUNDINGS

130. VIEW OF THE METRO STATION WITH
SURROUNDINGS
New Rob Built By State Govt
Metro Station
BCC Buiding
PD Buiding
Private
Buiding
Suburban Station

132. METRO CAR DEPOT
JOKA
AREA: 25Ha(Approx), Boundary: 4.2KM,
Road: 4.9KM, Track: 14KM

133. JOKA Metro Car DepotMETRO CAR DEPOT, JOKA

134. STRUCTURES/ BUILDINGS
INSPECTION SHED WITH LIFTING BAY
PIT WHEEL LATHE

136. धन्यवाद
THANK YOU
धन्यवाद
जय हिन्द
THANK YOU
JAI HIND