AN INDUSTRIAL TRAINING REPORT

ON

INA METRO STATION

PHASE-III

Starting Date of Training: 01/06/2018

Completion Date of Training: 30/06/2018

By

DUSHYANT KUMAR SINGH

UNIVERSITY ROLL NO- 171099011

Year-2019-2020

DEPARTMENT OF CIVIL ENGINEERING

(INSTITUTE OF ENGINEERING &TECHNOLOGY)

GLA UNIVERSITY, MATHURA UTTAR PRADESH –

281406

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 ACKNOWLEDGEMENT

I am extremely thankful to Mr. Sanjeev Kumar, Division of Utility Department, for helping me
to undertake this work.
I extremely heartfelt gratitude to my respected Report guide Mr. Vikramjeet for this kind and
inspiring advice which helped me to understand the subject and its semantic significance. He
enriched me with valuable suggestions regarding me topic and presentation issues.
I am also very thankful to my colleagues who helped and co-operated with me in conducting the
training by their active participation.

DATE:07/07/2018 DUSHYANT KUMAR SINGH

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TABLE OF CONTENTS:

1. Guide Wall…………………………………………………………………..……..……6

1.1 Importance………………………………………………………………………7

1.2 Construction process……………………………………………………………7

2. Diaphragm Wall………………………………………………………...……………….10

2.1 Scope…………………………………………………………………………….11

2.2 Tools and Equipments…………………………………………………………..11

2.3 Materials used…………………………………………………………………...16

2.4 General data……………………………………………………………………..17

2.5 Construction Method……………………………………………………………18

3. Soldier Pile………..………………………….………………………………………….26

3.1 Tools and Equipments used…………………………………………………….26

3.2 Materials used…………………………………………………………………...27

3.3 Construction Method……………………………………………………………27

3.4 Advantages……………………………………………………………………....30

3.5 Disadvantages…………………………………………………………………...30
4. Geotechnical Survey…………………………..………………………………………...31
5. Water Proofing…………………………………..……………..………………………..35
6. Block work………………………………………………………………………………37

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Fig.1 Plan showing D wall layout of INA Phase III Metro station

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GUIDE WALL

 Guide wall is two parallel concrete beams constructed along the side of the wall as a
guide to the clamshell which is made of concrete.
 Used for the excavation of D wall trenches. Constructed in situ( natural) typically as
lightly reinforced concrete elements.
 It maintains the horizontal alignment and continuity of D wall.
 It provide support for upper soil during panel excavation.

Fig. 2 Guide wall

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 Importance:

 It is important as the slurry levels vary during construction and the upper few feet or 1m
of wall tends to be unstable
 It helps to guide D wall grabs vertically and aid in the positioning of the final structure.

Construction process:

 A trench is excavated to create a form for each wall, then filled with slurry. It is kept full
of slurry at all the times.
 Function of slurry: It prevents the trench from collapsing by providing outward pressure
which balances the inward hydraulic forces and prevent water flow into the trench.

Fig. 3 Workers carrying Guide wall cage

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  Reinforcement is then lowered in and the trench is filled with concrete which displaces the
slurry.
 The guide walls are constructed on the ground surface to outline the desired slurry trench
and guide excavation.
 Excavation is done using a special clamshell shaped digger.
 The excavation digs down to design depth, or bed rock, for the first cut.
 The excavation is then lifted and moved along the trench guide walls to continue the
trench with successive cuts as needed.
 The trench is kept filled with slurry ( usually a mixture of Bentonite and water) at all times
to prevent the collapse.

Fig. 4 Cage placed at Guide wall

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DIAPHRAGAM WALL

 Diaphragm wall is a continuous wall in ground to facilitate certain construction facilities

such as:
 As a retaining wall
 As a cutoff provision to support deep excavation.
 As the final wall for basement or other underground structure (eg. Tunnel and shaft)
 As a separating structure between major underground facilities

Fig. 5 Diaphragm Wall

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Scope: It includes:

 Excavation of D wall by grab using polymer

 Check the verticality of trench
 Insert water stopper in stop end groove.
 Lowering the stop end by using crane
 Reinforcement cage fabrication
 Insert couplers as per levels
 Lowering the reinforcement cage by using crane
 Lowering the tremie pipe for concreting
 Procedure of concreting
 Stop end excavation by using hydraulic jack and crane

Tools and Equipments:

 100 ton capacity crawler crane
 Service crane
 Polymer mixing pump
 Welding set
 Cutting and bending set
 Dewatering pumping
 Total station
 Sounding chain and steel measuring tape
 Gas cutting
 Dumper
 Vibrator ( 40 mm needle)
 Koden instrument
 Hydraulic Jack ( 50 ton)
 Polymer checking kit
 Vibrator ( 40 mm needle)
 Koden instrument
 Hydraulic Jack ( 50 ton)

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 Polymer checking kit
 D wall grab

Fig. 6: D wall grab

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  Polymer tank

Fig. 7: Polymer Tank

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  JCB

Fig. 8: JCB

 Tremie pipe ( 250 mm dia.) with hopper

Fig. 9: Tremie pipe

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  Stop end
 Air compressor

Fig. 10 :Compressor

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 Material used:

 Approved grade of concrete of D wall

 TMT reinforcement bars acc. to IS 1786- 2008

Fig. 11: TMT bars

 Polymer: The polymud shall be in accordance to the manufacturer recommendation

 PVC water stop confirming to IS:15058

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  Couplers

Fig. 12: Couplers at Lower level

General Data:

 Total no. of D walls: 158

 Total no. of shallow depth panels: 29
 Total no. of larger depth panels: 129
 Thickness of D wall: 800 mm
 Standard height of D wall: 18 m
 Maximum height of D wall: 25 m
 Grade of concrete used: M40
 Grade of reinforcement used: Fe500
 Diameter of Reinforcement used: 12 mm – 32 mm
 Maximum length of D wall panel ( deep): 5585 mm
 Minimum length of D wall panel ( deep): 2500 mm

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  Maximum length of D wall panel ( shallow): 6390 mm
 Minimum length of D wall panel ( shallow): 2500 mm

Construction Method:

 Its construction Requires that a proper sequence of work is followed.

 Specialized excavating equipment should be used.

A. Pre Excavation:

 Prior to the D wall grab starting excavation, the slurry pump must be fully submerged in
Bentonite slurry. To achive this a small initial excavation by grab.
 For removing certain obstructions pre excavation is required.

Fig. 13: Pre Excavation

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B. Primary panel Excavation:

 First of all, these are excavated.

 The minimum length of this panel is 3.0 m.
 If soil is stable then constructed in multiple bites.
 In this case, panel can be subdivided into three bites with the left and right panels
excavated first while the middle bite is excavated last.
 Following the same process, D wall of 6.5 m to 8.0 m are achived as per drawing.

C. Slurry cleaning:

 The supporting slurry fluid must be cleaned so that its properties are within permissible
limit before tremieng the concrete.
 With the help of regeneration plant, the slurry is circulated at regular intervals throughout
the construction.
 Otherwise, fresh slurry fluid can also be used although this approach is not the most
economical.

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Fig. 14: Mixing of Polymer forming Slurry

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D. Joint construction between Panels:

 Various joint types are available for D walls.

 Joint selection depends on excavating equipment as it can be flat, circular, with steel
beams or special grooved type with water stops.
 Grooved type joints with water stops are typically preferred in India.
 Flat panels and circular joints are generally avoided.

Fig. 15: Stop end connecting two panels

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E. Reinforcement cage lowering and concrete tremieng:

 The reinforcement cage can be lowered after clearing the bottom of trench.
 The reinforcement cage is suspended from the guide wall panel and must have enough
transverse and diagonal reinforcement to permit it to be properly lifted and lowered into
place
 Sufficient space must be left for atleast two or three tremie pipes so that tremieing can
take place.
 Concrete tremieing: It is the process of replacing the supporting slurry with the
permanent concrete with the use of vertical pipes called tremie.
 Concreting of D wall starts from bottom and the tremie are lifted progressively as the
concrete level rise.
 During this process the tremie are maintained within the freshly poured concrete for a
minimum depth of 0.6 m.
 Poor tremieing can result in certain portions of the central in slurry pockets getting
entrapped within D wall concrete.
 It leads to excessive and costly underground water leaks or even blowouts.
 Check for tolerance and verticality: Tolerance shall be as under: D wall face which will
exposed shall be vertical within a tolerance of 75 mm.

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 Fig. 16: Reinforcement cage of D wall

 Method of testing verticality of D wall:

o In initial 3-4 panels of D walls , verticality of D walls shall be checked using Koden
equipment.
o Once the confidence level is achieved verticality shall be checked after every 5 m.
o When trenching is done by Hydraulic grab, verticality shall be confirmed for every 5 m.
In case the hydraulic integrated rig with hydraulically operated grab is fitted with
indicator of verticality.
o Whole panel shall be checked at three places along length of panel to re ascertain the
verticality from top to bottom.
o The measuring device Koden which gives analytical graphical representation of
verticality is placed at desired location ( supported over the guide wall with proper safety
measures and the machine is activated with electricity or battery) and the probe is
lowered to desired depth.

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Fig. 17: Lowering of cage by using hooks

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 F. Secondary panel excavation:

 These are constructed between primary D wall panels.

 When trench cutters are used, the primary panel is formed with a single bite excavation.
 When trench cutters a flat panel joint is typically used, but the trench cutter eats into
unreinforced concrete of the adjacent primary panels.
 After the specified depth is reached, the reinforced cage is lowered into position and
concrete is tremeied with tremie pipes from the bottom to top.

Fig. 18: Final D wall

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 SOLDIER PILES:

 Soldier pile is some of the oldest forms of retaining system used in deep excavations.
 It is successfully being used since the last 18th century in metropolitan cities.
 The method is commonly known as “ Berlin Wall” when steel piles and timber lagging
are used.
 Alternatively caissons, circular pipes or concrete piles can also be used as soldier piles.

Fig. 19: Soldier Piles

Tools and Equipments:

 Drilling Machine
 Crawler crane
 Dumper
 Trailer
 Steel tape

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Material Used:

 Steel structure: As per drawing the steel structure should be used at the site such as either
H beam or I beam.
 Water: Water used in cement and mortar should be clean, clear and free from salt, acid
and organic matter.
 Filling Material: As per drawing the filling material should be sand or mixture of cement
and soil.

Construction Method:

I. Boring:

 First of all location should be marked.

 Drilling machine should be placed at the point.
 The machine must be set up horizontal so that drilling should be as vertical as possible.
 The diameter of piling should be as per drawing.
 Then the tools is rotated and lowered into the ground.
 During this process the bucket starts filling with soil.
 When it is completely filled , it is being emptied.
 During the drilling process, it is also filled with polymer so that collapsing of soil is
stopped.

II. Pile verticality:

 The permissible value of deviated finished pile is 1 in 75 from vertical.

 Check the verticality of case during installation by plumbing from the perpendicular
direction.
 Variation of levels at the top shall not be beyond 25mm.

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III. Lowering of H section: The H section for soldier pile with a cage at the lowermost
position shall be lowered into the drilled borehole with the help of the crane.

IV. Concreting:

 Pour the concrete of grade M40 with slump in the range of 175+25mm or 175-25mm
upto pile reinforcement.
 Concrete shall be placed using tremie pipes.
 The other end of the tremie pipe should not be more than 300 mm above the bottom of
pile.
 Care should be taken that free fall of concrete shall not be more than 1.5m.
 The truck filled with concrete should be joined with the tremie pipe is used for pouring it.
 The pipe is taken up as required.

V. Backfilling:

 The filling of bore hole is then done with sand or mixture of cement and sand in the ratio
1:10 with the water make a isolated mixture.

VI. Removal of H section:

 After construction of permanent columns the soldier piles are removed by breaking the
hardened cement and soil with breaker.
 It should be done safely without disturbing the other work.
 The H section is cut down and removed from site or station with the help of crane.

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Fig. 20: Cross section of breaked pile

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Advantages:

a. It doesn’t require advance construction techniques.

b. It is fast to construct.
c. Its construction is economical.
d. Installation is versatile and adjustment can be done easily.

Disadvantages:

a. Used only for temporary construction.

b. They are not so hard
c. Settlement is possible if backfilling is not done properly.
d. Dangerous to use in the regions of high water table.

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GEOTECHNICAL SURVEY

 Before any construction at site, various tests should be performed to know the condition
of soil over there.
This should be done to know any differential settlement is going to take place in future.

Various Tests and Equipments:

1. Inclinometer: It is used to know the vertical deflection.

2. Strained gauge: Used to know the pressure load on any structure.
3. Pavement settlement method: For settlement of surface.

Fig. 21: Inclinometer

4. Building settlement method: For building settlement.

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 Fig. 22: Inclinometer at Building to know settlement

5. Outside monitoring: Used to check the vertical deflection in existing D wall.

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 Fig. 23: Inclinometer at Tunnel area

6. Ground settlement method: Check the surface of soil by using 150 mm rod.

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7. Tilt plate: To check the building tiltness ( in degree)
8. Bi reflex target: This tells us the building Settlement at high level.
9. Beam sensor: It gives the online data at the surface of the area where we can’t reach
easily.
10. Online crack meter: It gives the crack measurement by sensor.
11. UDS: It is a kind of soil testing in tunnel area.
12. Standard penetration test
13. Soil resistibility test
14. Magnetic testometer
15. Piezometre vibrating wire: To measure water pressure.

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 WATER PROOFING

It is done to prevent the movement of water into the structure.

Procedure:

1. First of all, cleaning of surface is done by using wire brush.

2. Then chemical mixture of Master B (No. 25) and Master C ( No. 25) is applied on surface
by using primer.

Fig. 24: Primer

3. The mixture is applied to fill the gaps in the surface which is known as the first priming.
4. The mixture is applied on the surface by using Compressor.

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5. The thickness of this layer is 2.5mm.
6. After priming Insu board are placed along with the black polythene.

Fig. 25: Chemicals used for Primer

7. Furthermost 100mm plain cement concrete is applied.

8. At the end the remaining area is filled with soil.
9. If water proofing is done in inclined position then brickwork is used instead of PCC.

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BLOCK WORK

In case of heavy structures, block work is used instead of brickwork.

Fig. 26: Block work at Station Area

Size of blocks used:

1. ( 200*200*400)cubic mm
2. ( 100*100*400)cubic mm
3. ( 200*200*300)cubic mm

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 The size of block should be chose as per drawing.
 The material u8sed for binding the blocks is having 1:6 where 1 is cement and 6 is sand.
 After every third layer, reinforcement has been provided having diameter of 10mm.

Fig. 27: Reinforcement provided at every third layer

 The thickness of binding material between blocks should not be more than 10 mm.

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 CONCLUSION
This six weeks training gave me the opportunity to work with
some of the best engineering minds in the country and solve
complex engineering & management problems that occur on
field.

1. Construction of underground structures is always a

challenge because of the large amount of machinery and
labor involved; hence an engineer on field should also
possess management skills.

2. The use of admixtures, not only shorten the project

duration but also help in constructing a more quality
structure with superior aspects as compared to a
conventional one. Admixtures and Chemical were used
widely on site.
3. Adequate measures have been taken to ensure the safety
of environment and health.
4. The soil used for filling on site was so as to achieve the
criteria for the fill.
5. This Project helped me to get acquainted with the pinnacle
of technology available for construction. TBM (Tunnel
Boring Machine) was one of them.
6. Rail Transportation systems form the backbone of a city
and hence must be designed for at least a century with no
compromise in quality.

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 REFERENCES:

1. MS of INA Metro Station at Era Infra Engineering Ltd.

2. IS 1786-2008
3. www.dwallindia.com
4. www.diaphragmwallconstruction.com
5. www.wbdg.org/design/env_wall.php

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