A PPT ON –CONSTRUCTION OF CROSS PASSAGES VARIED

GEOLOGY

By Parasuram.B
Project Engineer
SRI INFRA PROJECTS
DELHI METRO CC 27 – Tunnel /Cross Passage Status

Tunnel Completion Status

- 9.45 km/10.05 km
Shankar Mun Completed (94%)
Vihar

Vihar
1065m RK

1424m
505m IIT

Khas

804m

Cross passage
completed

Cross Passage Completed – 15/19 Cross passage in

(79%) progress

Tunneling Completed
 T U N N E L C R O S S PA S S A G E S
Cross passage : Is the safety zone of tunnel…
• Its interval should not be crucial to people’s safe escape
• As per NFPA 250 m is the conservative value of cross
passage interval in tunnel.

3
PLAN & ELEVATION OF A TYPICAL CROSS PASSAGE -CC 27
PROJECT
 CROSS PASSAGE IN SOIL STRATA :

• Marking up of the survey lines (for excavation purpose) with the help of
total station.
• Ring girder erection, which consisted of I-sections being fixed in the form
of a polygon.
• Packing of the ring girder with wooden wedges so as to fill the void spaces
between the tunnel segment and the ring members thereby increasing
the contact area and thus the overall strength of the system.
• Core cutting with the help of a 150mm diameter core cutter.
• Excavation work is carried out after core cutting. In the course of
excavation , structural steel member ISMB 125 or ISMB 150, as per the
design considerations, is placed near the main tunnel segment to support
the excavated soil strata, where in the load gets transferred by ‘arch effect.
D RING INSTALLATION AND SEGMENT BEING TAKEN OUT
 The excavation work is further divided into two parts:
Heading
• The upper half of the excavation is known as Heading. It was kept at
a height of 1.8m-2m.
• After excavating for every heading, of 750mm in length, arch-shaped
ribs are fixed followed by fixing of wire mesh between two
consecutive ribs.
• After this, shot creting using M30 grade concrete mix was done to
prevent collapsing of roof & side wall soil and strengthen these
surfaces. 50mm thickness of shotcrete layer was maintained
throughout the procedure.
• The shotcrete mix contained a chemical named ‘Master ROCS 540’
for the early setting of the mix (approximately 3-4 hours).
• Any further excavation was done only after checking the strength of
the shotcrete mix, sprayed over the soil surface, which should be
more than 10kN/mm2 per 750mm mesh layer.
 Benching:
• The lower half of the excavation is known as Benching.
• It is generally at a depth of 2.2m below heading.
• Benching can be done up to a length short of heading i.e. there should
always be one extra heading than benching till the last part.
• Rib-fixing and shot-creting etc. follows benching as mentioned above.
SHOTCRETE
ISMB -150 -
RIBS
WIRE
MESH

HEADING AND
BENCHING IN
PROGRESS
• After this stage, permanent lining is constructed by using M40 grade Water
Proofing Course concrete.
• Method of construction is similar to any RCC structure. Rebar is fixed first;
followed by shuttering form-work before pouring of the concrete mix.
• Note that the main reinforcement has to be provided as per the design,
considering the overburden and lateral earth pressures of the location being
considered.

FIXING OF REINFORCEMENT BARS- PERMANENT LINING

 PERMANENT LINING COMPLETED –WALLS
REBAR FIXING IN PROGRESS ,CROWN
 STAGES OF CONSTRUCTION

Temporary Popping Drilling Excavation

Providing Ventilation System Reinforcement Final stage

 Safety Measures while Construction
• The entire construction process is done following the necessary safety
measures. The measures taken are as follows:
• All the workers should be cladded with proper safety equipment.
• Regular checking of gaseous release from the soil. As the soil may contain
minor portions of lime, daily checks for ‘carbon mono-oxide’ should be
carried out so as to prevent any mishap.
• Adequate Lighting to be provided in the tunnels, with illumination at the
work area (in cross-passage) being 100 lux and elsewhere 50 lux.
Emergency lighting units also to be provided so as to facilitate safe egress
in the event of power failure.
• The processes of heading and benching is carried out alternately, with one
benching after one heading. If more than one heading or benching is to be
done, there was a chance that the soil may have settled due to lack of
binding force.
• While shot-creating, gas masks, rubber gloves and boots, eye-gear and ear-
protecting gear is to be used so as to prevent any fatalities due to inhaling
of pressured fumes coming out with concrete and damage to eyes and ears
and body parts in contact with the shot-creating equipment.
TEMPORARY SUPPORTS-NEW METHOD – D SHAPED RING
 USE OF D-SHAPED SUPPORT IN CROSS PASSAGE
CONSTRUCTION

ERECTION TIME = 10 DAYS ERECTION TIME = 3 DAYS

 CONSTRUCTION OF CROSS PASSAGE IN ROCK
• Marking of Core & D Ring Installation.
• Core Cutting
• Excavation by Heading & Benching by Blasting method
• Drilling of holes with jack hammers of 25 to 32mm dia.
• Periphery holes are left as dummy holes which prevents over break of
rock.
• Blasting done with explosives comprising of power gel and NED (Non
Electric Detonator).
• Auto Stem also used for blasting in areas wherever built up area is above
CP so as to cause lesser vibrations & Noise.
• First layer Shotcrete followed by wire mesh fixing .
• Rock bolting done to stabilize the rock mass.
• Ribs Installed according to the class of rock .
• Second layer of Shotcrete – approx. 150mm thick .
• Benching done only after approx. 5m of Heading excavation is carried out.
• Reinforcement Fixing followed Permanent Lining – with appropriate WPC
Admixture .
EXCAVATION OF ROCK WITH JACK HAMMER EXCAVATED FACE AFTER HEADING &
BENCHING
 CHALLENGES WHILE CONCRETING IN CROSS PASSAGES

• When distance of CP is more than 100m from the nearest cut out
feeding of concrete is not possible without the use of Transit Mixer .
• Difficulty of using 6Cum transit Mixer inside tunnel, therefore Mini
TM of 4cum is required for feeding the concrete to pump.
• Cycle time of Concrete Increases due to the usage of a Mini TM .
• Probability of accidents increases with use ofTransit Mixer inside
tunnel due to space constraints.
• Special safety precautions are to be taken while concreting of CP.

PLACING OF HOP UP AT EVERY 50M INTERVAL CONCRETING VIA MINI TRANSIT MIXER
 ADVANCEMENT IN BLASTING TECHNLOGY USING AUTO STEM

• Ecofriendly which involves non explosive rock blasting , using deflagration

technology.
• Worlds first only viable non Detonating self Stemming rock breaking
cartridge .
• Safe, easy to use and easily transported by Aircraft .
• No Stemming , Minimum manpower ,time and cost .
• Low Vibrations, Noise and Dust .
• No Flying of Rocks ,fumes and over break in tunnels.
• Can be used in built Up Areas due to extremely Safety distance.
• Can be used under water up to 50m .
• Never Explodes and Catches fire in case of Accidental Firing .
• No Contamination of Air, water and Soil .
 TRIAL BLAST DONE AT THE SURFACE WITH
AUTO STEM AUTO STEM
 CROSS PASSAGE WORK WHILE TUNNELING OPERATION :
• First time construction of CP during tunneling operation.
• Construction of working platform.
• Marking of Core & D Ring Installation.
• Core Cutting
• Excavation by Heading & Benching
• Installation of Manchester Gates at 2 ends of the Cross Passage .
• Mucking by Usage of Locomotive .
• Heading –Excavation followed by first layer of shotcrete.
• Wire mesh fixing after first layer of Shotcreting.
• Erection of Ribs at appropriate spacing .
• Second layer of Shotcrete – approx. 150mm thick .
• Benching done only after approx. 5m of Heading excavation is carried out.
WORKING PLATFORM CONSTRUCTION MANCHESTER GATE INSTALLED

Working Platform
Installed TUNNEL
WALKWAY ACCESS

Manchester Gate