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

Introduction of METRO RAIL in INDIA
Rapid transits in India consist of Metro, Monorails and light rail system
How it Began
India’s 1st and Asia’s 5th 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.

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

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

METRO RAIL in INDIA
Existing Metro Rail in INDIA
1) Delhi Metro
2) Kolkata Metro
3) Mumbai Metro
4) Chennai Metro
5) Bangalore Metro
6) Jaipur Metro
7) Lucknow Metro
8) Hyderabad Metro
9) Kochi Metro
10) Noida Metro
Under construction and proposed Metro Rail in India
1) Ahmedabad Metro
2) Pune Metro
3) Nagpur Metro
4) Indore Metro
5) Bhopal Metro
5) Kanpur Metro

Type of metro
Type of Metro
1) Elevated Metro
2) Underground Metro
3) On Grade

Basic Sequence of Activities For Elevated Metro (Viaduct)
Obtain site
acquired by the
Client
Preliminary
Survey Works
Barricading Utilities
Identification
Shifting of Utilities
Test Pile Casting &
Testing (Vertical &
Lateral Load Tests)
Pile FoundationPile CapPiersPier Cap
Erection of
Segments
Pre stressing of
Span & Grouting
Alignment, &
Bearing
Parapet Erection
Cable Trough
Erection
Fixing of vertical
bearing & Shear
key Bar
Handing Over
Casting of
superstructure
Segments &
parapet
Stacking and
Transportatio
n of segments
Casting Yard Set
Up

Basic Sequence of Activities For Elevated Metro (Station)
Obtain site
acquired by the
Client
Preliminary Survey
Works
Barricading
Utilities
Identification Shifting of Utilities
Test Pile Casting &
Testing (Vertical &
Lateral Load Tests
Pile FoundationPile Cap
Pier up to CL
Beam Bottom
Pier Arm/Portal
Beams at CL
Pier up to PL
Beam Bottom
Pier Heads at PL &
TL
Girder Launching Deck Slab at CL, PL
& TL
Deck Slab PL & TL Entry & Exit
Roofing works at
PL
Finishing Works
MEP & FFTG
Works
General
Development &
Road Works
Handing Over
Casting of
superstructure I -
Girder
Stacking and
Transportation of
segments
Casting Yard Set Up

P nP 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
Preparation
of
Reinforcem
ent Cage
(3 days)
Placing of
cage,
Profiling
Shuttering
(18 Hrs.)
Concreting
(4 Hrs.)
Deshutteri
ng
(5 Hrs.)
Lifting and
stacking in
C.Y
(3 Hrs.)
Curing will
be done for
14 days and
after 28
days ,
Ready for
Launching Average 15 Days will be
required to cast segments
for 37m span.

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

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

Pile
3 4
12
Average Time
Required for
Casting of one
Pile will be
12hrs.
Pile
Boring
(5 hrs )
Transportati
on of Caging
(1Hr)
Cage
placing
(3 hrs)
Pile
concrete
(3hrs)
Casing
removal
(1 hr)
Average Time take to cast
pile group will be 5 Days.
Piling Sequence
Piling Activity

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

P -1 P -2 P -3 P -4
Piershutter1
Pier
shutter 1
Piershutter2
Piershutter3
Piershutter1
Piershutter2
Piershutter3
Pier
shutter 2
Pier
shutter 3
Pier
Pile Cap
Pile
Pier
reinforcement
(2 days)
Pier
starter
(6 Hrs)
Pier
shutter
(2 Days)
Pier
concreting
(6 Hrs)
Pier
Deshuttering
(12 Hrs)
After 24 Hrs.
After 1 day
Pier Activity
Resources movement
Average Time
Cycle for Pier
5 days
Pier
P -5 P -6

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

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

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

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

TYPICAL ISOMETRIC VIEW OF FRONT SUPPORT

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

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

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.

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

SCHEME FOR AUTO-LAUNCHING
FOR SPANs UPTO 37m Span

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

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.

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

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

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

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.

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

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

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.

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

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.

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

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

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

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

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.

Step:2 Move the trailer below the lifting hoist.

Step:3 Pull down the lifting beam.

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.

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

Step:7 Move S2 nearer to the segment S1.

Step:11 Move all the sliders towards Segment S7.

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

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

Step:11 Now move remaining sliders towards segment S3.

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

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.

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

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

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

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.

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
GLGL
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
GLGL
D-wall
65

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

1) Excavation upto 1 m Below Temporary Sturt -1 From one side
D wall
King Post

50 T Gantry
D Wall
Road
Waler
1) Start Fixing brackets form one side
2) Start Fixing of Waler form one side

50 T Gantry
D Wall
Waler
Road
Erection of Diagonal
Strut
1) Start Fixing Diagonal Strut
2) Start Fixing of Waler for Straight Strut

1) Start Fixing Straight Strut
2) 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

1) Completion of Strut erection Start on 1st Layer
2) Excavation for 2nd layer
Diagonal Strut
Road
Straight Strut
Erection of Diagonal strut
D Wall
50 T Gantry

1) Erection of 2nd Strut Layer
2) Excavation upto 1 m Below Temporary Sturt -2 From one side
D wall
King Post

1) Start Fixing of Brackets from One side
2) Start Fixing of Waler from One side
3) Erection of 2nd Strut Layer
4) Excavation upto 1 m Below Temporary Sturt – 3 From one side
King Post
D wall

3) Erection of 3rd Strut Layer
4) Excavation upto 1 m Below Temporary Sturt – 4 From one side
King Post
D wall

3) Erection of 4th Strut Layer
4) Excavation upto Base Slab Level From one side
King Post
D wall

1) Excavation upto Base Slab Level
2) Levelling Surface for Base slab construction
King Post
D wall

1) Casting of Base Slab
2) Attain required strength for Base slab
3) Removal of 4th Level strut
4) Cast reaction Frame support for Pedestal
5) Handover the shaft to TBM operations
Base Slab
King Post
D wall

Station Construction
Top – Down Method

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

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

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

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

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

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

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

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

Station Construction
Bottom – Up Method

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

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

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

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

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

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

TUNNEL SEGMENT CYCLE TIME
Sr.N
o
Activity Duration In Minutes Start Finish
1Mould Opening 30 0 30
2Cleaning of Mould 40 30 70
3Placing of reinforcement 20 70 90
4Insert Fixing 10 90 100
5Checking of reinforcement 20 100 120
6Concrete Pouring 20 120 140
7Steam Curing 420 140 560
8Removal of Segment 40 560 600
In Minutes 600
In Hours 10 Mould
Opening(3
0 min)
Cleaning
of Mould
(40 Min)
Placing of
Reinforce
ment(20
Min)
Insert
Fixing (10
min)
Checking
of
Reinforce
ment(20
Min)
Concreting
(20 Min)
Steam
Curing
(7 hrs
Removal
of
Segment(4
0 Min)
Average Time take
for 1 Tunnel
Segment will be
10 Hrs

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
3 Placing of reinforcement 20 20 20 20 20 20
4 Insert Fixing 10 10 10 10 10 10
5 Checking of reinforcement 20 20 20 20 20 20
6 Concrete Pouring 20 20 20 20 20 20
7 Steam Curing 420 420 420 420 420 420
8 Removal of Segment 40 40 40 40 40 40
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

Lift Precast segment out of
Mould After 8 hours

Type of Tunnel Boring Machine
1) EPB Machine
2) Slurry Machine
3) EPB and Slurry Machine

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

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

25 M 109 M 21 M 40 M
AS IMS
30-Mar-19
02-May-19
12-Apr-18
09-May-18
12-Feb-18
29-May-18
30-Aug-18
19-Aug-18TBM-1 Reach
TBM-2 Reach
TBM-1 Re-launch
TBM-2 Re-launch
Roof Slab
Concousre Slab 17-Sep-18
TBM-1 Reach
TBM-1
TBM-2
02-Mar-18
27-Mar-18
03-Mar-18
06-Apr-18
05-Apr-18
21-Jul-18
31-Dec-18
TBM -3 Completion
TBM -1 Completion
Roof Slab
Concousre Slab
Base Slab
TBM-1 Reach
TBM-2 Reach
TBM-3 Launch
TBM-1 Re-launch
05-Oct-18
02-Sep-18
CUT & COVER SHAHPUR STATION LAUNCHING
SHAFT
GHEE KANTA STATION
Base Slab
TUNNEL -1
TUNNEL-2
East West Corridor - UG2 PACKAGE LENTGH - 4.10 KMS (DWP Programme)
286 M 260 M 170 M 666 M1338 M1203 M
TBM1TBM2
TBM1TBM2
TBM1TBM2
TBM1TBM3
TBM PATH (UG2)
TBM 2TBM 1 TBM 3
Tunneling Configuration

1) Completion of all D wall Works
2) Start excavation for 1st layer1) Excavation upto 1 m Below Temporary Sturt -1
From one side
1) Start Fixing brackets form one side
2) Start Fixing of Waler form one side
THALTEJ GAM (WEST) VASTRAL GAM (EAST)
LAUNCHING SHAFT SEQUENCE

CONSTRUCTION SEQUENCE OF GHEEKANTA

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

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