Management of Infrastructure Projects_11Sep2025.pdf

This is a presentation about the management of the large Infrastructure projects such as trasnport, mining, industry, etc. Starts with the basics of the project management and then goes on to the Metro project- the issues faced and the execution of various activities. This was presented at the invited talk at the head quarters of the National Aluminium Comapany, Bhubaneswar on 11th Sep25. The programme was started with address by CMD(Sh B P Singh) and was organised by CVO(Sh Pranabjyothi Nath, IAS).

1. HARSIMRAN SINGH, IRSE
FIE, CEng(I), Member/IRC, IPWE, IIBE
CVO, HINDUSTAN COPPER LTD
MANAGEMENT
OF
INFRASTRUCTURE PROJECTS
11.09.2025

2. Characteristicsoftypicalproject:
Temporary - have a definite beginning and an end.
Unique – no two projects are identical.
Predefined goals & objectives – financial/ social/ economic.
Budgets & schedules – prefixed budget and time frame.
Uses Resources including Manpower – these are limited.
Quality/ performance - determined at beginning.
Faces Risks – known and unknown risks
Project : Converting vision into reality.
A set of activities are undertaken to meet the specified
objectives for the changes.

5. Workpackagesarefurther
brokendownintoactivities
thatareusedtoestimate,
schedule,assign,implement
andcontroltheprojectwork.
Timebuffers/reserve/
contingencyarekeptin
scheduletomeet
unanticipateddelay.
TheProjectManagernormallyusesa
formalchangecontrolprocessto
controlanychangesintheschedule.

6. Costsaredirectlyrelatedtoproject:
Labour
Material
Plant&Equipment
Subcontractors
Costs indirectly related to project :
Overhead&administration
Training
Insurance
Inflation&exchangerate
Taxes
Freight
Licenses
Contingencies

7. Don’t make
any changes
in scope,
especially at
later stage

8. RemarksActual
period of
completion
Original
period of
completion
Date of
issue of
LOA(*)
Actual Cost of
execution
including price
escalation (in
Rs.Cr.)
Original
Cost
(in Rs. Cr.)
Project NameSl
Delay due to non-
availability of
complete site.
Cost overrun – 6%.
Phase I- 16
months
Phase-II 26
months
12.5 months26.07.1089.1284.21Diesel Loco
Component Factory,
Dankuni.
1.
Cost overrun – 10%21 months15 months20.07.11107.6395.17DMU Factory, Haldia2.
Delay due to late
shifting of High
Tension wires
infringing the main
shed. All other site
was available. Cost
overrun – 2% till
15.10.2014 (30%
finally)
26 months18 months02.10.13149.39 (Final
cost is to be
likely 190)
146.44Electric Locomotive
Factory, Dankuni
3.

9. 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
STAKEHOLDERS MANAGEMENT

10. Properplanningbeforecallingthetender.
Coveralltheaspectssuchasspecificationsof
materials/equipment,methodologyofconstruction
includingtemporarystructures/processes,requirement
ofkeypersonnel&equipmentfortheprojectwork,etc.
Freezedesignsanddrawings&scopeofworkclearly
elaboratingtheseintenderdocument.
Onceexecutionstarts,nochangesinplanningandscope
tobeentertainedunlessextremelyurgentandcritical.
Whenchangesareinevitable,repercussionofcostand
timetobeclearlyanalysed.5DBIMcanhelpinthis
regardasprojectprogressandcostcanbedeterminedat
variousstagesfordifferentscenariosandbestalternative
canbeselected.
TIPS FOR SUCCESS OF INFRA PROJECT

11. Ref: https://www.topbimcompany.com/5d-bim-construction-planning-management/
5D BIM
Integrating 3-dimensional geometry with 4
th
dimension
of time for scheduling and 5
th
dimension of cost for
budget control and estimation

12. Accurategeotechinvestigationandsurveydetails
mustbeprovidedtothebidders.
Variousclearancesrequiredandtheirstatusmust
beinformed.
Alleffortsmustbemadetoremoveinfringements
beforehand.Thoseleftoutmustbeclearlycharted
alongwithplanningforremoval/diversion.
Incongestedmetrocities,wherelotofutilities
exist,it’sessentialtoaccuratelychartthosewith
GPSsurveyandtrialtrenches.
Worldovertheprojectshavebeenaffectedbecauseofpoor
estimation,landacquisitiondelays,changesinscope,
unforeseengroundconditionsandlackofconsistentand
transparentcoordinationamongstvariousstakeholdersleading
todisputes.
TIPS FOR SUCCESS OF INFRA PROJECT

13. Modularconstructionshouldbeadoptedas
faraspossibletoensurefast,cost-efficient
workwithleastwastageandbestqualityas
themanufacturingisdoneincontrolled
environment.
Erectionatsiteiseasyandthereisflexibility
ofscalability.
ThesegmentalconstructionwithPSCbox
segmentmodulescastinthecastingyard
anderectedatsitewithLaunchingGirger,
hasmadethemetroconstructionfeasiblein
busyurbanenvironment.
TIPS FOR SUCCESS OF INFRA PROJECT

14. MANUFACTURE HIGH QUALITY PRECAST BOX SEGMENTS
FABRICATION OF REINFORCEMENT CAGES
LIFTING OF REINFORCEMENT
CAGE USING LIFTING BEAM
FIXING OF HDPE SHEATHING
PIPE FOR HT STRANDS
FIXING OF RAIL FOR INNER
TROLLEY
SEMENT AFTER DESHUTTERING
SEGMENT CASTING
PRECAST MODULAR CONSTRUCTION
WITH CONCRETE

15. PRECAST FOR BETTER QUALITY CONTROL
BOX SEGMENTS ERECTION WITH LAUNCHING GIRDER

16. NextlevelofmodularconstructionachievedinIndia's
Bullettrainprojectwherefullspanof600Tisbeing
cast,loadedontotransportertruck&takento
LaunchingGirderforaccuratelyplacingitinproper
lineandlevel.
Indiaisoneofthefewcountriestohaveadoptedand
masteredthistechnique.
NewTechnologiessuchasUltraHighPerformance
Concrete(UPHC)mustbeexploredanddeveloped.
ByusingUHPCweightofconcretestructurescanbe
reducedbyabout70%,allowingslendersections
withoutorlittleamountofreinforcement.
TIPS FOR SUCCESS OF INFRA PROJECT

17. INDIA’S BULLET TRAIN PROJECT

18. Strength: Over 150Mpa
Feature:It hasa
discontinuous pore
structurethatreducesliquid
ingress,significantly
enhancingdurability
comparedtoconventional
andhigh-performance
concretes.UHPCisbeing
consideredforuseinawide
varietyofhighway
infrastructureapplications.
UPHC

19. 3D PRINTING
It utilizes robotics to deposit
construction materials in precise layers,
effectively creating walls, floors, and
even roofs with speed.
Can prefabricate essential supports and
reinforcements that are seamlessly
integrated into the structure.
The next big leap for the construction
sector.
With an estimated urban housing
shortage of 29 million units, 3D printing
could help meet the country's housing
needs efficiently.
3D Printed Post Office
in Bangalore,
Constructed in
43days by L&T

20. GEOSYNTHETIC CEMENTITIOUS MAT :
CONCRETE CANVAS
Ithasbeeninnovativelyusedtocover
thegapsbetweenthecurvedparapet
wallsinKolkataMetroRailwayby
RVNL,asitcaneasilytakethecurved
shape.
ConcreteCanvas(tradename)
isaconcrete-impregnatedfabric
thathardenswhenhydratedto
formastrong,durable,fireand
waterprooflayer.Itcanbe
innovativelyusedtolinethe
earthendrains,canalsand
slopesapartfromother
functions.

21. The Underground Metro from Mominpurto Esplanade(5.3KM)
with 4 stations and Ramp
Estimate Originally put up by General Consultant : Rs
3200Cr(Approx)
Final Estimate adopted for calling Tender : Rs2571Cr
L1: L&T : Rs2448Cr (4.8% below)
L2: ITD Cem : 3.8% below
L3: Afcons : 3.3% below
Stiff Competition amongst
best agencies with rates
within the estimate
SUCCESS DEPENDS ON SUCCESSFUL BIDDING
AN EXAMPLE OF SUCCESSFUL BIDDING

22. Flagship greenfield highway project aimed at
revolutionizing road connectivity between India’s two
largest metropolitan cities.

Length:1,386 km

Timeline:Started in Mar 2019,
Original completion targeted was January
2023. Substantially completed (about 82%).

Cost:Estimated at around ₹1 lakh crore. Likely to be
completed within the estimated cost

Some work balance in few stretches affected by land
acquisition. Likely to be completed by 2026 or 2027
DELHI–MUMBAI EXPRESSWAY

23. 
Will reduce travel time from Delhi to Mumbai from 24
hours to 12 hours.

Designed for 8 lanes, expandable to 12 lanes.

52 packages (contracts)-31 awarded on EPC basis,
21awarded on Hybrid Annuity Model (HAM)

Runs parallel to the Western Dedicated Freight
Corridor (DFC), forming the backbone of the Delhi–
Mumbai Industrial Corridor(DMIC).

Will connect major cities enroute and provide modern
wayside amenities.
DELHI–MUMBAI EXPRESSWAY
FEATURES

24. 5D BIM integrated with common data environment accessed by
all stakeholders is utilised for real time monitoring and
predictive analysis to control cost and time over run. Quick
issue detection and mitigation are done online.
DELHI–MUMBAI EXPRESSWAY
As per hon’ble Union Road
Transport and Highways
Minister Shri Nitin Gadkari ji-
"As of February 2025, a total
length of 1,156 km out of
1,386 km of the Delhi-
Mumbai Expressway has
been completed across
States, Out of this, 756 km
has been operationalized."

25. Mumbai–Ahmedabad High Speed Railway Project
India’s largest ever infrastructure project, supported by
Japanese funding and technology
Cost: Around ₹1.08 lakh crore, with significant soft loan
support from Japan.
Length: 508 km
Technology: Shinkansen based on Japanese expertise.
Speed: Trains will run at 320 km/h operating speed,
reducing travel time from 7 h to 2.07hr with limited stops
(with all stops it will be 2.58h)
INDIA’S BULLET TRAIN PROJECT

26. 
Salient features:

12 state of the art station. 1
st
station is UG at BKC.

94% alignment in elevated. 26KM is UG including
longest tunnel of India-21KM which is 7KM under
sea(Thane Creek)

1435MM Guage(Standard guage), 4.5M Track Cente

Timeline:

Project launched in 2017 but work actually started in
2022. Targeted to be completed in 2025 but will take 3-5y
more

Land acquisition done and construction works ongoing,
with phased commissioning expected between 2027–2028.
INDIA’S BULLET TRAIN PROJECT

27. 
Progress:

Around 250 km of viaduct completed. Work
substantially completed in Gujrat state.

Target is to run services on some sections
between 2027–2028.

The BIM concept has been used with substantial
use of technology for monitoring and project
management and record keeping. However,
whether the 5D BIM has been fully utilised or not is
not known.
INDIA’S BULLET TRAIN PROJECT

28. INDIA’S BULLET TRAIN PROJECT

29. INDIA’S BULLET TRAIN PROJECT

30. INDIA’S BULLET TRAIN PROJECT
IN FRONT OF THE ADIT TUNNEL

31. 
Implementing Agency:Maharashtra Metro Rail
Corporation Ltd (MahaMetro).

Project Cost (Approx):
Phase-I: ₹8700 Cr, Completion Cost: ₹9300 Cr
Phase-II: ₹6000 Cr, Completion Cost: ₹6700 Cr
Phase I: (38KM)
Orange Line and Aqua Line , Both Commisioned
Construction started in Nov 2015, project completed
by December 2022.
NAGPUR METRO PROJECT

32. 
Phase II: 44KM
Extension of both Orange and Aqua lines.
Phase II work commenced in 2020–21.
Target for commissioning: 2026 (originally), Later
revised to 2027

One of the first mega projects in India to adopt 5D BIM>
Used primavera for scheduling, RIBiTWO,
Bentley(Openrailassetwise, projectwise).

Saved about Rs 800Cr by use of 5D BIM and other
technologies.(As per media information)
NAGPUR METRO PROJECT

33. 33

34. JOKA-Taratala (6.5KM (c/c of Stations) was
inaugurated by Hon’ble PM on 30
th
Dec, 2022.
Taratala-Majerhat Section (1.250 KM, c/c of
Stations) was inaugurated by Hon’ble PM on 6
th
Mar,
2024
Work is under execution for the balance elevated
section from Majerhat-Mominpore(1.006KM) and
underground section from Mominpore to
Esplanade(5.18KM)
JOKA –ESPLANADE METRO CORRIDOR

35. 35
INAUGURATION OF JOKA-TARATALA SECTION

36. 36
THE FIRST WHEEL ROLLS OVER ON THE
TRACK FROM JOKA DEPOT TO TARATALA
ON 15.09.2022

37. 37
JOKA-TARATALA METRO

38. 38
JOKA-TARATALA METRO

39. 39
JOKA-TARATALA METRO

40. JOKA-TARATALA METRO

41. Line of Elevation
TRACK LEVELS IN JOKA –ESPLANADE METRO

43. M35
M40
M50
TYPICAL 3D VIEW OF MAJERHAT-
MOMINPUR VIADUCT

44. 5
Survey of Taratala-Majerhat Section
Instrumentused:
i)Autolevel:B40ofSokkia
ii)ElectronicTotalstation:SokkiaCX101
TraversereportofViaduct:Desired accuracy = 1 in 50,000
Survey
Accuracy
Pier
Descriptionasper
submittedreport
SL
No.
1in50963P233-P255TaratalatoBuffer1
1in50393P255-P276BuffertoP2762
1in62671P276-P277
P276toP277(Majherhat
Station)
3
1in64519P277-P297
P277(MajherjatStation)
ToBuffer
4

45. CONSTRUCTIONOFVIADUCTFORMETROLINEBETWEENTARATALATOMAJERHAT
Items
TaratalatoBuffer
BuffertoMajerhat
Station
MajerhatStation
MajerhatStationto
Buffer
Total
P/233to P/255 P/255to P/276 P276toP277P277toP297
Pile 127 65 188 115 495
Pilecap 27 15 14 21 77
Pier 27 15 14 21 77
Piercap 19 15 15 20 89
HammerHead -NA- 01 -NA- 16 17
L-PierHead 02 04 -NA- 04 10
PortalBeam 04 -NA- -NA- 01 05
SeismicRestrainer 23 15 -NA- 21 59
Pedestals(ingroup) 23 15 28 21 87
CrashBarrier 27 15 -NA- 21 63
SegmentCasting 202 190 -NA- -NA- 392
SegmentErectioninspan 23 14 -NA- -NA- 37
SegmentStressing&Groutingin
span
23 14 -NA- -NA- 37
PscI-GirderCasting -NA- -NA- -NA- 76 76
PscI-GirderErectionISpan
-NA-
-NA- -NA- 76 76
PscI-GirderStressing& Grouting
-NA-
-NA- -NA- 76 76
SteelGirder -NA- -NA- 33 04 37
SteelGirderErectioninSpan -NA- -NA- 33 04 37
ElastomericBearinginspan 23 14 28 20 85
SpericalBearingBearinginspan -NA- -NA- -NA- 08 08
SteelPlateBearing -NA- -NA- 60 -NA- 60
ParapetCastinginnos. 404 124 75*2M 392 920
ParapeterectioninSpan 23 14 -NA- 21 58

46. PILE LOAD TESTS
Remarks
Available
Test
Report
Type of TestFor
Stations
IS2911PARTIV
(1985)Clause4.1
02-Vertical
02-Horizontal
INITIALPILELOAD
TEST
IS2911PARTIV
(1985)Clause4.2
04ROUTINEPILELOAD
TEST
These tests must be done meticulously and interpreted very
carefully to ensure safety of structures and economy of the project
•Vertical Capacity of bored cast-in-placecircularpileisdeterminedusingtwo
approachesandleastoftwoisusedtodetermineitscapacityforgivenpile
length.Firstiscalculatedby1
st
byStaticformulaasgiveninIS:2911(Part
1/Section2)andthencheckedbyinitialtest.
•Lateral Capacity ofpileisalsodeterminedbothfromtheempiricalformulaas
giveninIS:2911(Part1/Section2)andfrominitialloadtestasperIS:2911
(Part4);andleastistakenascapacityundernormalloading.

47. ROUTINELOADTESTS
Detailsofloadtestconducted
Depth
of
Pile(m)
Dia.of
Pile (mm)
PileId
RemarkSettle
ment
(mm)
Testload
(T)
Design
load(T)
Vertical
Failure as per
old code. Pass
as per new
code.
14803489351200P262
Pass9.2735.5489351200P266
Lateral
Pass (less than
5mm)
1.272020451200
P298/1
Pass (less than
5mm)
1.11515451200
P305/3As per IS code issued in 2013, settlement should not cross 18mm or 2%
of pile diameter whichever is less for piles above 600mm diameter, and
12mm for piles upto 600mm diameter. Earlier, it used to be 12mm
settlement limit.

48. SERVICE LIFE
120yearsMainstructuralelementsi)
15yearsElastomericBearingsii)
20years
Minorcomponentsthat
canbereplacedwithout
completeremovaland
interruptiontotraffic
iii)
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.
DESIGN BASIS

49. CLEARANCE REQUIREMENTS
•ForRoadTraffic
:
Verticalclearanceaftermediankerb(whichcomprises
centercolumn/piershaftprotectedbycrashbarrier)is
kept6.00mfromroadtoplevel.
•ForRollingStock:
Allstructuresareplacedbeyondthefixedstructurelineas
perItem4ofChapter1,ScheduleofDimension(SOD)
ofMetroRailwayapprovedbyRailwayBoardRef.
83/MTP/C/22dated30.11.94.
DESIGN BASIS
Greatcareisneededattheplanningstagetoensure
thatnoinfringementstakeplacewhenprojectcomes
tocommissioningstage.

50. MINIMUM CONCRETE GRADES
M35Pile&pilecap,openfoundation
M40,(M50&M60 in specialcases)
M50-forL-pier&
M60–for pier cap of L-pier
Concentricpiercapandpiershaft
M40Hammerheadpiercapforplatform
girders
M50Cast-in-placesuperstructure:
SegmentBox Girder,
M50PrecastI-girder
M60Bearing Pedestals
M40Precastbarriercumparapet
M40Cast-in-placecrashbarrieraround
piershaft/columns
M35Othermiscellaneousstructures
Material properties must be decided keeping in
view design requirements, availability of
materials and cost economics.
DESIGN BASIS

51. APPROVEDMIXDESIGNSUMMARY
Strength
28days
Mpa
Strength
7days
Mpa
Admixture
Dose(%)
Admixture
Name
Admixture
(Kg)
Sand(Kg)10mm(Kg)20mm(Kg)Water(Kg)Brand
Cement
Content
(Kg)
W/C
Gradeof
Concrete& ID
SL.No.
24.1516.3
0.65
ChrysoFluid
OptimaS812
1.96849536656145RamcoOPC533020.48M151
35.7824.44
0.65
ChrysoFluid
OptimaS812
2.47797475712152RamcoOPC433800.4M252
48.1534.85
0.7
ChrysoFluid
OptimaS812
2.95755514628160RamcoOPC534210.38M35(Pile)3
51.7836.42
0.69
ChrysoFluid
OptimaS812
2.88776595595148RamcoOPC534120.36M35(PileCap)4
49.7837.78
0.75
ChrysoFluid
OptimaS812
3.37723503615157RamcoPPC4500.35M35(Pile)5
47.2641.19
0.75
ChrysoFluid
OptimaS812
3.16755514688160RamcoOPC434210.38M35(Pile)6
50.3741.48
0.75
ChrysoFluid
OptimaS812
3.09765587587148RamcoOPC434120.36M35(PileCap)7
50.0736.74
0.75
ChrysoFluid
OptimaS812
3.37750584584153UltratechPPC4500.34M35(Pile)8 52.7438.67
0.75
ChrysoFluid
OptimaS812
3.37750584584153NuvocoPPC4500.34M35(Pile)9
60.1538.65
0.85
ChrysoFluid
OptimaS812
3.66752581581151
Coromandel
OPC53
4300.35M4010
59.1139.7
0.85
ChrysoFluid
OptimaS812
3.66752581581151
Coromandel
OPC43
4300.35M4011
65.1251.41
0.85
ChrysoFluid
OptimaS812
3.88719625511155RamcoOPC534850.32M5012
65.7850.22
0.6
ChrysoFluid
OptimaS812
2.91717619507160RamcoOPC534850.33M5013
80.1562.07
0.9
ChrysoFluid
OptimaS812
4.46715631516149RamcoOPC534950.3M6014

52. STANDARDDEVIATION
MONTHLYSTANDARD
DEVIATION OBSERVED
GRADEOFCONCRETESL.NO
0.5-2.35M35(Pile,PileCap)1
0.89-3.06M40(PierColumn&above
Structure)
2
VIADUCT PORTION
MONTHLYSTANDARD
DEVIATIONOBSERVED
GRADEOF CONCRETESL.NO
0.46-1.73M35(Pile)1
0.7-1.94M35(Pilecap)2
0.72-1.76M40(Pier,PierCap,StitchBeam,
Parapet&CrashBarrier)
3
0.57-2.53M50(Segment)4
1.38-1.79M60(Pedestal)5
STATIONPORTION

53. PERMISSIBLE DEFLECTION TOSATISFYLIMITSTATE
ReferenceLimitLoadingMember
Clauseno12.4.1
ofIRC:112
Span/800VehicularLL
Viaduct
superstructure
Span/1000
Vehicular+
pedestrian
Span/300Vehicularon
Cantilever
Clauseno23.2
ofIS:456
Span/350AllloadsBuildingmembers
Clauseno.5.6.1
ofIS:800
Span/250DL+LL
Purlin
members
Span/200DL+LL+WL
Clauseno7.11.1
ofIS:1893
(part1)
0.40%
DL+EQwith1.0
partialload
factors
Interstoreydrift
ratio

54. DURABILITYASPECTS
Inordertoensuregoodstructuralperformanceofstructuresunder
thismoderateenvironmentexposure,followingaspectsare
considered.
Bylimitingcrackwidthofflexuralmembersunderserviceloadsto
0.20mm,asrecommendedbyIRS/CBC
AminimumcovertoanyreinforcementisprovidedasperIRS/CBC
andIS:456recommendations.
MinimumClearCoverTypeofStructureSl.No.
75mmPile1
75mmPileCap2
50mmPier,L-Pier&PierCap3
40mmStitchBeam4
40mmPortalBeam,parapet5
50mmPedestal6
40mmSegment7
40mmPSCI-Girders8

55. 1200mmdiameterboredcastinsitupileshavebeen
used.Atentrystructuresofstations750mmdiameter
boredcastinsitupileshavebeenused.
PILE FOUNDATION WORK
SettingOut
(10 mins)
Settingof
PilingRig
(30 mints)
Boring
ofPiles
(5-6 hrs)
Cleaning
ofthe
Borehole
(1-2 hrs)
Borehole
Stabilization
Reinforcement
Placing
(1-1.5 hrs)
Concrete
Pouring
(1-2 hrs)

56. Viaduct portion:
Impediment Removal DateAuthority ConcernedDescription of HindrancesSl.
June 2011CTC Shifting of Tramline1
July 2012I&W Dept.Dismantling of unauthorized boundary wall from Irrigation
land near CharialBridge
2
December 2013WBSEDCL
WBSETCL
Shifting of WBSEDCL & WBSETCL lines near Depot
approach
3
July 2014I&W Dept.Dismantling unauthorized structure from Irrigation land
near BankrahatRoad
4
August 2014PHEShifting of PHE Pipeline5
January 2014WBSEDCLShifting of WBSETCL6
April.2015C. ComenceDismantling of C. ComenceBuilding (G+2)7
August –Sept. 2015 (In phases)GCGSCLShifting of Gas Pipelines8
June 2016CESCDismantling of boundary wall of CESC Building9
June 2016Removal of infringement from Depot approach
(P38D)
10
March 2017 KMDADismantling of Rehabilitation India Building (G+2)11
September 2017CESCPermission for dismantling of KMC’s Bus-Stand near CESC
office
12
September 2017Postal Dept. & MintMint Post Office.(Old)13
November 2017Mother Diary & KoPTDismantling of Mother Diary & Old Age Home14
January2017toMay2018(in04
differentspells)
MINTIndia Govt. Mint grant permission in phases14
Dec.2019Traffic, PWD, KMCDiversionofBoxdrain,KMCpipelinesetc.forconstruction
ofViaductbetweenMajerhattoMominpur
15
IMPEDIMENTS (JOKA-MAJERHAT)
As in Aug23

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

58. Station portion:
Removal featureAuthority
Concerned
Description of HindrancesSl.
June 2013PHEShifting of PHE Pipeline1
December 2014 (North)KMCShifting of KMC Pipelineat Majerhat2
June 2014 (South)
January 2014 (East)KMCShifting of KMC Pipelineat Taratala3
February 2014(East )KMCShifting of KMC Pipeline at Behala Bazar4
August 2014 (West)
December 2013(East)KMCShifting of KMC Pipeline at Thakurpukur5
February 2014(West)
February 2014(East)KMCShifting of KMC Pipeline at Sakherbazar6
November 2013(West)
June 2015(East)KMCShifting of KMC Pipeline at Behala Chowrasta7
October 2015(West)
September 2013KMCRemoval of shop/encroachments from Joka,
Thakurpukur& Sakherbazarstation
8
IMPEDIMENTS (JOKA-MAJERHAT)
As in Aug23

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

60. PHOTOGRAPHSDURINGDIFFERENTPHASEOFCONSTRUCTION

61. PILECAPWORKATTARATALA-MAJHERHAT
M35GradeRCCpilecapshavebeencast.Thetoplevelofpilecaphasbeen
normallykept0.5mbelowtheroadlevel.
Earthworkin Excavation
Chipping/
Trimmingof
PileHead
LayingofPCC
asLeveling
Course
CONSTRUCTIONMETHOD:
Bendingand
Fixingof
Reinforcement
Steel
Fitting,fixingof
Shutteringand
de-shuttering
ConcretingCuringBackfilling

62. PIER&PIERCAP
Concentric piers areof2000mmdiameterandhavebeencastwithM40
gradeRCC.L-piershavebeencastofsize(1950x3550)mm
and
withM50
GradeofRCC.Portal piers havebeencastofsize(1950X1950)mmand
GenerallycastwithM40orM50GradeofRCC.

63. LaunchinggirdersofBridgeconetypewith270Ttotalweight
andcapableofliftingsegmentsupto580Ttotalweightand
workingwithcurvatureupto8.65degreehavebeenused.
SEGMENT LAUNCHING

64. SEGMENT LAUNCHING

65. SEGMENT LAUNCHING

66. SEGMENT LAUNCHING

67. SEGMENT LAUNCHING

68. SEGMENT LAUNCHING

69. SEGMENT LAUNCHING

70. SEGMENT LAUNCHING

71. SEGMENT LAUNCHING

72. SEGMENT LAUNCHING

74. SEGMENT LAUNCHING

75. SEGMENT LAUNCHING

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

77. ERECTIONOFSEGMENTSBYLAUNCHINGGIRDER

78. Thesteelgirderspanisdesignedconsideringlongitudinally
spanningfour numberfabricatedsteelgirdersand
transverselyspanningcast-inplace deckslabproviding
compositeactionwiththelongitudinalmaingirders.
Cross girders are provided at end support locations and
intermediate location to ensure proper load distribution and
provide lateral stability.
Maingirdersare providedwithtransversestiffenersand
bracingsasperthedesign requirement.
E410gradeSteelGirders havebeenFabricatedof1300-
2600mmoveralldepth.
Fabrication : Thecutting,machining andpaintingofsteel
girdermaintainsRDSOguidelines.
Finalcheckingof trailassemblyverifiedbytheRDSO.
50M STEEL GIRDER SPAN

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

80. •Megatrafficblockof24hrsinahighlycongested
crossingandinveryclosevicinityofaPetrolPump,
shopsandresidences.
•Veryhighlevelofplanning,removalofseveralutilities
•4roadmountedcranes-2Nosof250TandoneNoof
150T,withone300Tstand-bycranewereused.
•1specialaxle16-wheeltrailerof31Mcapacityandtwo
12-wheelflatbedtrailersof20mcapacityeachwere
deputedfortransportingtheassembledgirdersin4
piecesof2×30.75m,and2x18.35m.
•Twopiecesofeachpairofgirderswerespliced
togetherduringblockwith1108HSFGboltsof10.9S
Grade.Total of 2216 boltswerefixedandtightenedby
torquewrenches.
ERECTION OF 50M PLATE GIRDER SPAN AT MAJERHAT ON
DIAMOND HARBOUR ROAD AT BURDWAN CROSSING

81. Truck Mounted Rig
(TMR)
Direct Mud Circulation Rig
(DMC)
Hydraulic Rig
TYPES OF PILING EQUIPMENT
HydraulicRigs,DirectMudCirculationMethod(DMC)&
TruckMountedRigs(TMR)arebeingusedforboredcast
in-situpiles.

82. PRODUCTIVITY OF PILING EQUIPMENT
Equipment mobilization should be planned depending upon site conditions,
availability of time and economy. Mobilization of Hydraulic rotary rig is costly
and may not be feasible at all locations.

83. Inspection and Test Plan (ITP) For Concrete Works
Acceptanc
e CriteriaApproval
By
Document
Inspection Agency
Test
Centre
Frequency of testDescription
Test
Method
Employer
/PMC
Contractor
Fresh Concrete
IS 1199
Employe
r /PMC
Lab Register /
Pour /
Delivery Card
Witness Testing
In-
house
For each
Concrete Transit
Mixer
Slump Test
IS 456 -do--do--do--do--do--do-Temperature
IS 456 -do-QA-QC-FORM -do--do--do-
As directed by
Engineer
Air Content
IS 1199 -do--do--do--do--do--do-Yield
IS 456 / IS
4926
Employe
r /PMC
--do--do--do-As per IS 456
Sampling of
Cube
Hardened Concrete
IS 516
Employe
r /PMC
QA-QC FORM Witness Testing
In-
house
As per IS 456
Compressive
strength
IS 456 -do-
QA-QC FORM/
EXTERNAL
REPORT
Witness/
Review
Testing/
Review
Indepe
ndent
house
As directed by
Engineer
Chloride
Penetration
Test
MORT&H-do--do--do--do--do-
For each Grade
of Concrete
(RCC) / As
required
Permeability
Test

84. Concreteshouldbecompactedduring
placingbyapprovedinternalvibrators.
Sparevibratorsmustbeavailableduring
eachconcretepour.
COMPACTION FOR QUALITY CONCRETE
Theconcreteshouldbecompactedby
holdingthevibratorinpositionuntil:
i.Airbubblesceasetocometosurface.
ii.Resumptionofsteadyfrequencyof
vibratoraftertheinitialshortperiodofdrop
inthefrequency,whenthevibratorisfirst
inserted.
iii.Thetoneofthevibratedconcrete
becomesuniform.
iv.Flattened,glisteningsurface,withcoarse
aggregatesparticlesblendedintoit
appearsonthesurface.

85. Thetemperatureofconcreteshouldnotgenerallybemorethan
32
o
Cnorbelow5
o
C.
Maximumconcretetemperatureafterplacingshouldnot
exceedtemperature50
o
Cor30
o
Cabovetheconcrete
temperatureatthetimeofplacingwhicheveristhelower.
Maximumtemperatureisgenerallyrequiredtobecontrolledby
addingicetothewaterusedformixinginhotweather.
Thermometersarerequiredtocheckthetemperaturerise
duringcastingespeciallyinmassconcretejobs.
PRECAUTION FOR CONCRETE POURING
•Adequate lighting should be provided where mixing, transportation
and pouring are in progress.

86. Check weather and plan for all eventualities before majour
casting

87. Concretemustbedeliveredtothepointofplacementwithout
significantlyalteringitsdesiredpropertieswithregardto
water-cementratio,slump,segregationandhomogeneity.
Itshouldbetransportedbyagitatingtransitmixers,buckets,
pumps,etc.
Itmustbeplacedinpositionbeforeitattainstheinitialset.
Additionofwatertocompensateforslumplossduring
transportationshouldnotberesortedto.(itwillchangethe
water-cementratio).
Additionaldoseofretarderbeusedtocompensatethelossof
slumpwhenpermittedbyEngineer.
TRANSPORTATION OF GREEN CONCRETE

88. Samplingatboth,truckdischargeandpointoffinal
placementshouldbeemployedtodetermineifany
changesintheslumpandothersignificantmix
characteristicsoccur.
However,fordeterminingstrengthofconcrete,
cubesshouldbetakenfromtheplacementend.
FIELD CONTROL

89. For , God’s sake, keep the wet concrete safe
from all ends and also keep all at safe distance
from it !
Else, you will get
big impressions !!

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

92. 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.

93. TYPICAL CROSS SECTION OF MAJERHAT YARD
M35
M40
SteelSection
M40

94. 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.

95. 258 hours of block were
taken on 93 days to
complete piles and pile
caps
CENTRAL PORTION OF METRO STATION

96. CENTRAL PORTION OF METRO STATION

97. 7 pairs of trestles erected to support rolling beams over which the
girders were placed and rolled
CENTRAL PORTION OF METRO STATION

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

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

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

102. ACTUAL
DEFLECTION
(mm)
THEORETICAL
CALCULATED
DEFLECTION
(mm)
LOCA-
TION
GIRDER
NO.
19.824.742L/4
G1 28.8 35.030L/2
19.824.6633L/4
19.924.742L/4
G2 28.9 35.060L/2
19.824.3413L/4
19.724.742L/4
G3 28.8 35.060L/2
19.624.3413L/4
19.524.742L/4
G4 28.7 35.030L/2
19.224.6633L/4
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)

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

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

109. JOKA Metro Car Depot
METRO CAR DEPOT, JOKA

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

111. PRE-ENGINEERED BUILDING
•Economical Design of Structure
(nearly 20% saving)
•No Welding at Site
•Reputed
Manufacturereswho
can be contacted
later for modification/
extension

112. QUALITY FABRICATION IN WORKSHOP

113. SURFACE FINISH SA 2½
SHOT BLASTING MACHINE

114. RAW MATERIAL (Structural Steel)
Materials
Plate: IS 2062 E350
Angle, channel: IS 2062 E240
Z-purlin : IS 2062 Gr.50 E345
Bracing/Sag rod: IS 2062 E240
Fasteners:
Primary connection : IS 3757 Gr.8.8
Others: IS1363 Grade 4.6
Anchor Bolt ASTM F1554, 250Mpa
RawMaterialisprocured
directlyfromManufacturersas
perapprovedsuppliers–RINL,
SAIL,TataSteels,JSPL.

115. QUALITY CONTROL-STAGES OF INSPECTION
Inspection report –LPT and Ultra sonic Testing

116. AUTO PAINT LINE

117. QUALITY CONTROL IN PAINTING
•DFTmeasurementiscarriedouttomeasurethe
coatingthicknessbyElcometer.
•ShadeMatchingisdonewiththehelpofRALcard.

118. Z-PURLIN MANUFACTURE

119. SHEET PROFILING

120. SHIPMENT PROCESS

121. Tool box meeting by erection
Engineer.
Check tools, safety materials.
Check the PPE's.
SITE BRIEFING.
Sequence of work to
be carried out.
ConfirmtheFFLlevelwith
customerandalsocheckfrom
thedrawings.
Cleananchorboltbefore
erection.
Tiethecolumnproperlyand
followthesafetynorms.
ERECTION OF
COLUMN.
ERECTION METHOD

122. Assemble the correct member
and orientation.
Tie the slings properly in proper
location. Lift the rafter just
above the ground level and
check the CG.
Tie the guy ropes for controlling
the swing of rafter.
Truss GIRDER
ASSEMBLY AND
ERECTION
Install roof purlins to make
stable.
Install flange Bracings.
Install brace rods/portal
bracing.
Tie the ropes to heavy objects.
Check the alignment and level
before proceeding further.
Check all bolts tightened.
BRACED BAY
ERECTION &
SECONDARY
MEMBERS
ERECTION METHOD

123. Check the alignment.
Show the alignment to the
EOT crane agency.
Generate the joint report.
CRANE BEAM
ERECTION
Crane beam
installation.
Care should to be taken not
to damage the sheet and the
structure.
Erection of
Galvalume Sheet
ERECTION METHOD

124. TORQUING OF HT BOLTS

125. Torqueing of Bolts
Torquingof HT Bolt of connecting members

126. ERECTION OF EOT CRANES
ENSURE THE CORRECTNESS OF RAIL LEVELS AND THE
CENTRE TO CENTRE DISTANCE

128. ध?यवाद
THANK YOU
ध?यवाद

जय ?ह?द
THANK YOU
JAI HIND