Summer Internship presentation

Company : Maharashtra Metro Rail Corporation Limited (Maha-metro)

Duration : 22nd May 2018 to 02nd july 2018 (6 week )

rajesh
 Behind the project

• On 22 February 2012, the Nagpur Improvement Trust (NIT) signed an agreement with Delhi Metro Rail
Corporation (DMRC) to prepare the Detailed Project Report (DPR) for the metro in Nagpur.

• Maha-metro is a 50:50 jointly owned company of government of india and government of Maharashtra

• The existing Nagpur Metro Rail Corporation Limited (NMRCL) will be reconstituted into Maha Metro for
implementation of all Maharashtra state metro projects.

• 50% of the total expenditure is being financed by loans from German based government bank (kfw)
and Afd ( a french development agency).
 Internship Responsibilities

• I have to be puntual and regular on the site, so that I can better understand how to live professional life
like an real site engineer.

• I have to observe things on the site and try to ask as many questions from the engineers so that i can
relate it better with the academic knowledge.

• I should never try to intrupt and distrurb their work.

• As on site, always their is risks of something mishappen, I should always wear PPE (personal protective
equipments ) for my personal safety.
 Documents

• DPR ( Detailed project report ) : DPR is base document for planning the project and implementing the
project. From the study of this report and after getting assured for the project feasibility, project owner will
approve investment for the project.

• Preparation of DPR is a costly and time-taking job.The Central Ministry had allocated ₹2.5 crore to the State
Government for carrying out the DPR work.

Objectives of Detailed Project Report (DPR)

1. The report should be with sufficient details to indicate the possible fate of the project when implemented.
2. It should include various type of analysis such as financial, technical, social etc.
3. Before going for overseas technology collaborator, all established technology within country should be
explored. It would be cheaper and nationalistic!
4. It will be discussing about the location and the benefits of such loaction inside it.
Method statements

Method statements are widely used in construction as a means of controlling specific health and
safety risks that have been identified. It helps manage the work and ensures that the necessary
precautions have been communicated to those involved

1. They are identified by HSE(Health and safety executive) after assesing risks, managing risks
and many more factors.

Content it includes

• Details of organisation and individual responsible for the activity.

• A step-by-step description of activities to be perform.
• The procedure for changing the proposed method of work if necessary.
• Equipment required and their details.

more...
 Routes

Alignment 1: North-South Corridor (Orange Line) Alignment 2: East-West Corridor (Blue Line)

No. of stations - 20 No. of stations -20

Rail length - 19 km Rail length - 18 km

*Elevated-15 *All Elevated

*At-grade- 5
 Boreholes
Obejective:

1. Geotechnical investigation, site exploration, site assesment, extraction of water etc.

2.To determine the subsurface profile of the underlying strata.

Total borehole for whole project - 80 boreholes

For Orange Line - 41 Boreholes (Automotive square to Khapri )

For Blue Line - 39 Boreholes (Lokmanya nagar to prajapati nagar)

Range of borehole Depth - 10.5m to 25m

Type of foundation going to be there depend on the geotechnical investigation results!!

Subhash nagar

Borehole no. Type of Depth of Size of Bearing

foundation Foundation foundation capacity

10 Square footing 3m 5 to 6m 20t/m2

 Engineering Aspects
Type of structure : Elevated structure
Mode of construction : Segmental

Advantages
• Segmental construction is efficient and cost effective.
• Also time saving, as segments may be manufactured while substructure, stations work may proceed.
• Interfernce in traffic flow is significantly reduced.

Elevated Segment
Main components of Elevated structure

• Precast Segmental Box Girder

• Pier (support superstructure such as viaduct)

As span increase,dead load increase. To reduce

dead load, unnecessary material, which is not
utilized to its full capcity, is removed out of section.
Hence we come up with BOX GIRDER.

main reason behind choosing Box-girder :

torsional stiffness.
Type of foundations

• Bored caste in-situ piles

• Open Square footing

* maximum permissible settlement - 40mm

** The recommended type of foundation is

generally pile foundation except for a few locations
where hard strata was located close to ground
level.
** Allowable bearing capacity for shallow open
footing has been computed from the equation as
per IS: 6403 – 1981
Casting Yard

• Afcons infrastructure
• ITD Cementation Ltd.

Casting of :
1. Box girders or segments
2. Pre-stresses I-girders

for casting of segments two methods were adopted:

1. long line method
2. short line method or match cast
Long line casting method

• Long line casting method is good for span

curved in plan.
• It will be needing more space.
• It uses less staff and more cost effecive.
• A high degree of accuracy is required for setting
out the curves
• on long line method for which pre calculation of
offsets is necessary
• Forms are often not reusable
• All segments are cast along a single soffit for
the full length of the span or cantilever.
 Short line casting method or match casting

• Short line casting method is more suitable

more for straight span.
• Forms are highly reusable and require little space.
• Stationary forms are used next to previously cast
segment in order to get a homogenous perfect
fitting match-cast joint.
• Rate of prodction is slow.
• Usually two segments are in the casting cell at one time.

The cast segments are cured on the bed as well as in stacking yard !!
 Equipment used in tensioning and stressing

• Hydraulic mono jack for pre-stressing

• Hydraulic multi-jack for post-tensioning
• High tension cables
15.2 mm dia
7wire per strands (Usha martin)
• HDPE Pipes
 Type of stressing

• Pre-stressing ( In I-girder )
• Post-tensioning ( Box-girder )

construction of I-girder

• Reinforcement cage is prepared.

• Strands are passed through reinforcement cage and stressed with the help of hydraulic mono jack (after
removing slack by some intitial stress) and anchored at the end.
• shuttering and form work is placed around the cage.
• Temperature controlled concreting (grade of concrete M45 for all precast girders and viaduct ), in done
and kept for setting.
• Destressing after 4 days of curing at the casting place (on 4th days it attain 60% of the required strength
i.e 30 to 35Mpa ), so we can lift and take it to the staking yard.
• Curing for 28 days to get 95% or higher strength.
Construction of Box-girder

Long-line method ( plan curve )

• Proper offseting of casting bed is done using

total station.
• Shuttering is placed over bed.
• Reinforcement is lowered.
• HDPE ducts profiling ( for later post-tensioning )
• Inner formwork is placed/pushed into its
position.
• Formwork is placed around.
• Concreting is done after approved from
appointed engineer for standard checks.
• After curing for 4days or after 60% strength Parabolic profiling of HDPE pipes in
attain, Girder
it is lifted and shifted to staking yard.
• furthur curing for 24 days.
Post-tensioning

• Post-tensioning is a form of prestressing. Pre-stressing simply means steel is in stress before coming
of service load.
• Post-tensioning is technique which allow us to form thinner and long span girder as it help also to resist
lateral loads.
• When all the segments of viaduct are positioned properly with help of launching girder.
• Steel cables are positioned in HDPE ducts.
• Afterwards, once the concrete has gained strength but before the service loads are applied. The cables
are pulled tight, or tensioned, and anchored against the outer edges of the concrete.
Grade of concrete

It is proposed to carry out construction work with design mix concrete through computerized automatic Batching
Plants with following grade of concrete for various members as per design requirement/durability considerations.

• All precast element for viaduct and station - M-45

• Cantilever piers and portals - M-45 or - M-60
• pier - M-40
• Piles - M-35

Track structure
As track on metro system is subjected to intensive usage with very little time for day-to-day maintenance.
Thus, track should be long lasting, ensure safety, comfort, with minimum noise and vibrations.

Ballastless track : These is the railway track whose bed is composed of concrete and bituminous
mixture, etc.
This track structure is proposed for viaduct, inside tunnels as regular cleaning and replacement is not
possible at such locations.
*Less maintenance cost and maintenance are major factor while taking it into consideration.
**Investment is higher than ballasted track, and possibility of improvement is less in such track structure.
 Station Planning
The locations of the station have been identified taking into consideration the constraints in land
acquisition and congestion issues. Stations are proposed in such a way so as to attract maximum
demand in general.

Elevaeted Station has three

parts:

1. Ground Level
2. Concourse Level
3. Platform Level

Concourse furthur has Public and non-Public zones

Non-public zone - Include Signalroom,battery room,security room etc.

Public zone has Paid and Un-paid area

Paid area - which visitor or passenger requires a valid ticket, checked smartcard or a pass to get in ( include
excess to the platform)
Un-Paid area - where passengers gain access to the system, obtain travel information and purchase tickets.
Sitabuldi station ( Interchange)

Sitabuldi serves as the interchange station allowing passengers to transfer between the Orange
Line and the Blue Line of the Nagpur Metro.

Zero Mile

Zero Mile is a metro station on the Orange (North-South) line of the Nagpur Metro in the city of
Nagpur, Maharashtra. It is named after the nearby Zero Mile Stone which was built in 1907 to mark
the Great Trigonometrical Survey of India.

The Zero Mile station is a 20-storey building with two basements.also features multi-level parking
with a capacity to accommodate 244 cars. Apart from the metro station and related facilities, the
station building also contains hotels, restaurants, commercial places.
Huge Machines involved

1. Gantry
2. Launching Girder
3. Pile digging machine
4. Cranes
Launching Girders

• Launching girder is specially designed for launching of segments.

• The suggested launching scheme is designed in such a way that initially the launching girder is
erected on pier head at one end of the work.
• The segments are lifted in sequence and when the lifting is over, they are dry matched while hanging
from the launching girder
• After dry matching, Segments are glued with epoxy and pre-stressed from one end.
• The launching girder then moves over the launched span to next span and the sequences continue.
 Learned and Its future use

Many things on site, I've heard of but never seen before during my academic

1. Management - I've seen how a real engineer work, how he/she manages the project and try to solve issues
on sites, It could be a major learning for me during my internship

2. Stressing - It is the technique which is used now a days more frequently, so now after doing internship, I
would be easier to get its mathematics and science easily.

3. Box casting methods - I've never heard of this casting methodology and technique involved in it, again it
would be new and great experience for me as a intern there.

4. Launchig Girders - It is great to see such heavy machine moving along the span. Here I learned, how very
big girders are placed on the piers and joined by post-tensioning.
Conclusions

1. The entire period of 6 weeks proved to be good source of experience.

2. All Observations and techincal knowledge I've gained during my Internship will help during my
studies.

3. It will help me in getting things more easily, so that i can relate academic knowledge with the site
issues.

4. We should always wear PPE while working on site.

5. You should be work hard and never take things on site lightly, because it could be risk not only for
you but also many more people around.