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Dr. Lakshmana Rao Mantri, Assistant General Manager (Designs), and Satya Narayan Kunwar,
Project Manager, AFCONS Infrastructure Ltd. , discuss the design and construction challenges of
constructing India’s deepest underground metro ventilation and escape shaft, how the issues
were addressed, and the preemptive and mitigation measures taken.
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East West Kolkata Metro has bagged national and international accolades by constructing India’s
first under water twin rail transportation tunnel including the deepest underground metro station
of India – the Howrah Metro station, surpassing the Hauz Khas station and Chawri Bazaar station
in Delhi. Kolkata East West Metro Project has also added another feather in its cap by
constructing India’s deepest metro ventilation cum egress shaft very close to the east bank of the
Hooghly River.
India’s deepest underground metro escape shaft, which is not less than an engineering marvel, is
now completed. The excavation depth of shaft is 43.5m, which means it can swallow a 14 storied
building inside it!
The shaft was constructed under very challenging hydro-geological conditions and at an equally
challenging location. This groundbreaking work has pushed design and construction engineering
boundaries and helped in achieving this extraordinary feat.
This article outlines the design and construction challenges and how they have been addressed.
It also outlines the spirit of challenging the status quo and shows how use of the very basic
engineering principles brought about a turnaround and helped us in carving an engineering
marvel. It also highlights the preemptive and mitigation measures that were taken, and which can
be replicated to deal with other unique challenges, though they may require completely different
solutions based on the specific requirements.
Critical Features
a) Precarious Location:
The location of this deepest shaft is very precarious from construction point of view. The shaft is
close to the mighty River Hooghly. Circular Railway track runs abutting to the shaft at west end
and the overly busy Strand Road at east end. The north and south ends of the shaft are occupied
by two bored tunnels, hardly 3.0 m away from the shaft. The ideal construction sequence would
have been to construct the shaft before tunnels are bored for avoiding impact of construction of
shaft on tunnels. But due to unavoidable circumstances, both the tunnels were done before shaft
construction was taken up (figure 1).
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At the west bank of the Hooghly River is the deepest Howrah metro station, whereas at the east
bank sits the deepest metro shaft. Moving ahead from Howrah station, tunnels took plunge into
the Hooghly River at 36m depth and achieved its deepest point, 39m below ground level, at
ventilation shaft. This being deepest point between two stations, the shaft accommodates sump
and pumping arrangement for tunnel drainage apart from housing tunnel ventilation and
emergency egress system. The vertical alignment of the tunnels below river has been kept
sufficiently below the riverbed considering safety and stability of the tunnel under all
circumstances (figure 2).
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c) Unique Hydrogeology
The Shaft is very close to the East Bank of River Ganges and this area has undergone numerous
erratic alluvial subsoil depositions and river course transformation cycles. Apart from that, the city
of Kolkata dates back to more than 200 years making geology of this area very erratic and full of
surprises due to varied land usage over the time. Top 18m of the soil consisted of wooden logs,
boulders, traces of coal, steel pieces, bricks and foundations of the past, now non-existent,
buildings and installations. Such variations and hidden surprises posed enormous difficulty in
mapping the sub-soil strata and carrying out construction activities, especially in construction of
Diaphragm walls and piles (figure 4).
The top 18m of soil is very weak organic soft clay having N value of 5 or less. This layer is
underlain by a 17m thick fine silty sand, a water bearing strata, which is connected to Hooghly
River and has enormous source of water. Since this layer is followed by a 25m thick stiff clay
layer, this water bearing strata is, in fact, a confined aquifer running at high pressure. This
confined aquifer was considered a potential threat during excavation of shaft. Further the stiff
clay stratum is underlain by a coarse sand layer which too is expected to be connected with river
and extends much deeper (nearly 200m deep*). This water bearing sandy strata too is a confined
high-pressure aquifer, as this sandy stratum is followed by a stiff clay stratum (nearly 200m
deep*). The average pressure of this aquifer is 3 bars to 3.3 bars (based on site instrumentation
data) acting at the base of stiff clay layer. This huge pressure in lower confined aquifer was a big
threat for deep excavation and feared to result into hydraulic heave during excavation, as the
factor of safety against hydraulic heave was calculated to be lower than 1.0 much before reaching
final level of excavation.
a) Design Challenges
Construction of India’s deepest Ventilation cum Egress Shaft under challenging geo-hydrological
condition was not less than creating an engineering marvel. It was, in fact, a unique kind of
challenge having no precedence in India or abroad. This situation demanded unique treatment of
the problem and pushed everyone to think beyond boundaries and seek innovative design and
construction solutions. Such construction sequence as constructing square D wall box and
carrying out top-down construction using circular lining wall inscribing the square box has been
adopted for the first time ever and there is no precedence anywhere. The construction sequence
uniquely fitted into our requirements and needed no additional equipment or resources. All the
available resources at the project were used to construct the shaft. Design of lining wall to
function as a strut for deep top-down construction was a unique idea and evaluation of its
equivalent strut function remained debated due to absence of a clear-cut guideline matching to
this situation. But the lining wall performed excellent strut function and kept diaphragm wall
deflection within permissible limit.
Since 500mm thick circular lining wall was inscribing a square box, the thickness of wall was
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varying, the corners of square box being the thickest. This situation was debated extensively as to
whether forces exerted from diaphragm walls onto the lining wall, how the forces from D wall will
be transferred to the lining wall, and how the forces, eventually, will be translated into
compressive force in the lining wall. Whether benefit of circularity could be derived or not.
Various ways of load transfer mechanisms from diaphragm walls onto the lining walls were
modelled and studied and reinforcement of lining wall was designed choosing most likely
situation and rejecting extreme conditions. Since design and construction sequence was quite
new, it was necessary to observe closely the structural behaviors and keep adjusting
reinforcement requirements, construction sequences and time cycles from time to time.
Observatory methods yielded excellent results and helped completing the construction of shaft.
The details pertaining to innovative structural design and observations made during construction
require a separate case study.
Mitigating challenge of Hydraulic Heave has also been treated very uniquely where strength of
soil has been utilized such that the soil cover has been treated as a 9m thick plug negotiating
hydraulic uplift through its weight and frictional resistance between shaft and diaphragm wall.
Accepted calculation methods ended assessing FOS equal to 0.38, much below the FOS assessed
using shaft-plug-friction approach (equal to 1.11). There was no guideline for assessing FOS
based on the concept as stated above. Due to its uniqueness and nontraditional way of
treatment, this approach too remained debated. Its successful implementation using extensive
pre-emptive and mitigation measures along with extensive instrumentation and monitoring will
surely go longways and shape the trend of design and construction strategies under similar
situations (figure 5).
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e) Deep Excavation
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Excavation depth was very high (43.5m). The depth of soil cover above lower confined aquifer
after final excavation was left only 9.0m. Hence the weight of the soil cover after final excavation
against uplift pressure was only 38%. The factor of safety being less than 1 against hydraulic
heave was prohibitive of carrying out excavation without implementing some or another
mitigation measure.
a) Soil Parameters
Tables 1 and 2 show geological profile and design parameters for various soil strata found at
ventilation shaft location. This is based on geological investigations carried out for the project.
b) Hydraulic Heave
Confined aquifers run on pressure and exert pressure on overlying soil stratum. The pressure
exerted by aquifer is overcome by the weight of soil. As excavation progresses, the soil cover
above aquifer reduces and thereby the weight of soil goes down. The risk of hydraulic heave may
occur when the weight of soil cover (stabilising forces) reduces considerably such that it is less
than or equal to the pressure exerted by the underlying aquifer (destabilising forces).
This risk was associated with lower aquifer only. The upper water bearing strata was cut-off due
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As per Euro code 7 for safety against hydraulic heave, destabilizing pore water pressure at
bottom of the column should be less than stabilizing total stress at the bottom of the column.
The recommended F.O.S against hydraulic heave is 1.5 (Euro code 7, Table A.17)[1].
For Vent shaft location, however, the Factor of safety without implementing any mitigation
measure is calculated as 0.38. Detailed calculation for this is shown in table 3.
The above calculation shows that the factor of safety is much lower than the recommended FOS
and there exists possibility of hydraulic heave due to deep excavation.
Initially, it was thought to implement a dewatering regime during excavation inside the shaft in
the lower water bearing strata to reduce the hydraulic pressure at the bottom of overlying stiff
clay to avoid the risk of hydraulic heave.
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The head was kept -38.5 mMSL and the flow was estimated in the PLAXIS model.
Total flow through wells provided in vent shaft = 8.71 m3/hr. As the Hooghly River is at 50-60m
from the Vent Shaft location it was expected that the inflow of water will be continuous. Hence it
was proposed to install two pumping wells with submersible pumps in Unit 3b Layer (or lower
water bearing stratum) for reducing the hydrostatic pressure at bottom of Unit 3a layer (or stiff
clay layer). Pumping wells in this layer shall be activated after the excavation reaches 20m below
the ground level. As the excavation progresses beyond 20m, the piezometric head shall be
maintained minimum of 1 meter below the excavation level by operating dewatering pimps.
Table 4 shows summary of the analysis results.
The PLAXIS analysis along with dewatering regime using two borewells showed achievement of
required FOS against Hydraulic Heave, but there were practical difficulties indicating that this
methodology may backfire.
The lower water bearing strata is very vast and connected to river. Actual water flow
quantum may be far more than estimated through analysis, and borewells may go out of
control before the excavation will reach its final level.
There was odd experience of such dewatering regime under similar circumstances at
Howrah Station. Due to enormity of water associated with lower water bearing strata there
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was hardly any long term impact on water head due to dewatering and operation of
borewells.
With the progress of excavation, the discharge of borewells was found increasing drastically
during excavation at Howrah Station, indicating the borewells may fail here too due to
excessive discharge. It was also feared that the water may even seep into shaft from the
periphery of borewell due to small left out soil plug at the end of excavation.
Considering above it was necessary to revisit the design philosophy pertaining to hydraulic heave
and/or workout alternate mitigation measures for ensuring safety against hydraulic heave.
It is evident that the depth of soil cover was very important for revised design consideration. In
order to ascertain the extent of stiff clay stratum at Vent Shaft location, confirmatory soil
investigation was done. The details are given in the table 5.
Final Excavation Level of Vent shaft is -38.0 mMSL and Diaphragm toe level is -50.0 mMSL. Based
on the boreholes data presented, top of Sand layer/Bottom of clay (as presented in the table
above) was considered at -47 mMSL for calculation purpose.
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• Adhesion factor α
Average undrained cohesion of clay plug encountered between -38 mMSL and -47 mMSL is
around 180 kPa. Various literature is published by different authors correlating Adhesion factor
(α) and undrained cohesion (Cu) for bored piles. Based on these published works, it is found that
for an average cohesion of 180 kPa, α ranges between 0.35 and 0.6 has been proposed by
various authors (table 6).
Considering the level of piezometric head in lower water bearing stratum (Unit 3b) at -14 mMSL,
final excavation level as -38 mMSL and Bottom of clay layer as -47 mMSL, factor of safety against
uplift of bottom clay plug is checked and is found to be 1.11. Water pressure acting at bottom of
Unit 3a is considered as uplift force, Shaft skin friction between the D-Wall & Clay layer and self-
weight of clay are considered as resisting forces against this uplift force. A detailed calculation is
shown in figure 10.
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The cohesive soils do not suffer liquefaction or erosion of soil continuum as is typical with sandy
soils. Soil structure failure for such a high cohesion as evident in the concerned clay layer is
highly improbable (We did face opinion difference among designers that the high pressure at the
bottom of stiff clay layer may lead to failure of soil structure and the clay plug will ultimately thin
down and weaken, the same was ruled out by the majority). Hence theoretically, clay plug was
found to be safe and there was remote possibility of hydraulic heave, set aside the possibility of
something happening suddenly without sufficient warning. However, to reduce the risk of failure
of clay plug due to uncertainties involved in ground variation, errors in geotechnical investigation
and variation in adhesion factors, additional preemptive and mitigation measures were necessary.
The mitigation measures adopted were very elaborate and designed and planned for taking
necessary action during any trigger of associated problems.
Preemptive Measures
b) Estimation of flow
Flow through each pumping well in Unit 3B (deep) layer is estimated based on equations
presented in CIRIA 113 [4].
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Total quantity of water from each pumping well within the shaft area is estimated based on
equation mentioned below:
Where,
rW is radius of well.
Permeability of the Unit 3b (Deep) layer is expected to be in order of 5 x 10-5 m/sec. To account
variability in the ground quantum of flow is estimated for two set of permeability of 5 x 10-5
m/sec and 7.5 x 10-5 m/sec.
In general, initial flow of water from pumping well is higher as compared to steady flow. Expected
quantity of flow under steady state condition is 400 to 500 lit/min per well. To account flow of
initial stage, pumping capacity should higher than steady state condition. Based on previous
dewatering experience on the project, it was suggested to install the pump which are having
capacity to pump the water 1000 lit/min.
d) Monitoring of Heave
During excavation heave monitoring was necessary and very vital. The excavation was planned to
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be carried out in the lifts of 1.5m. During each lift of excavation the soil was expected to relax
resulting into elastic rebound. This elastic rebound could be misleading and create a notion of
hydraulic heave during various stages of excavation (table 7).
To eliminate the chances of confusion, the elastic heave during each stage of excavation was
estimated and used for comparing the actual heave recorded. The “linier elastic continuum
approach” has been used for estimation of heave due to removal of over burden soil at various
stages of excavation.
In a PLAXIS analysis the rebound due to excavation showed an uplift of 45mm which is quite
close to the above calculation. The comparison of box was presented in graph 1.
An FE analysis was carried out using GEOSTUDIO. SEEP/W module was used to carry out Steady
State Analysis and Transient Analysis to assess hydraulic condition at the excavation base. The
water inflow output at the base of excavation was negligeable. SIGMA/W module of GEOSTUDIO
was used to carry out Load – Deformation analysis to assess upward movement of soil mass at
excavation level. The upward movement value achieved was 125mm which was primarily
attributable to rebound of soil on account of stress relief due to unloading of soil post
excavation. The difference in upward movement values between PLAXIS analysis and the analysis
using GEOSTUDIO was due to the values of stiffness modulus used for modeling in PLAXIS (Eur)
and GEOSTUDIO (E50). PLAXIS uses Eur value which is 3 times the E50 value, and when
appropriate adjustments are made the elastic rebound values matched well. Hence all three
methods of estimating elastic rebound were consistent and closely matching (figure 11).
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Also, the soil adhered to the shaft wall was poked manually to see the quality of adhesion.
We found that considerable effort was required to dislodge the adhered soil from the shaft
wall. This indicated that the shaft and clay cover friction will be adequately achieved. Such
field techniques enhanced confidence for carrying out further excavation.
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Moisture content test of the soil was also tested and monitored after each stage of
excavation using rapid moisture meter and in the lab. It was assumed that the moisture
content of stiff clay will remain the same or reduce with the progress of excavation. The
trace of excess moisture compared to the moisture content of the soil from previous stages
of excavation would indicate water being forced into the soil from lower water bearing
stratum. The moisture content found was between 20% to 22% which represents a near dry
stiff clay soil.
g) Other Observations
Some other observations were also carried out to keep complete track and capture any sign of
distress at the earliest. They may be summarized as follows.
Photographic observation of interface between D-wall and soil layer after excavation for
each lining wall from 20th lift onwards. The photographic observations provided excellent
record of soil wall interface conditions. These photographic observations were minutely
examined by the experts and consultants including TTAJV team.
Videography of shaft after excavation was also kept for records. This was helpful for
reviewing previous stages of excavation with current stage of excavation in case of
requirement.
Minute examine of D-wall face like any seepage, its locations, its directions of flow. It was
also necessary to see if there was any sign of seepage at the soil and wall interface.
Water content measurement report at site by Rapid Moisture Meter. Also, moisture content
was measured in the lab using samples collected from excavation.
UDS collection for strength test and water content measurement at laboratory by IIEST,
Shibpur.
DDC / GC / IIEST-Shibpur / TTAJV used to visit jointly to assess the physical condition at
each excavation stage.
Contingency Measures
Above preemptive measures were put in place to monitor and regulate the excavation work and
keep an eye on the triggers of hydraulic heave. It may also be noted that this phenomenon was
not expected to happen overnight and will provide sufficient warning for carrying out mitigation
measure to prevent or minimize the impact of hydraulic heave. Following measures were put in
place as part of contingency measures that could be run as per need in case of any contingent
situation demanding drastic action.
suitably for placing of excavator such that the excavator could quickly push the stored soil into
the shaft within a short period of time. A couple of mockups were carried out to make sure that
in case of requirement backfilling of the shaft with stored soil can be done without any problem.
It is interesting to note that the excavation of the shaft came to a halt due to the nationwide
lockdown imposed during onset of pandemic. This stored soil was then put into the shaft during
lockdown period to ensure enhanced FOS of soil cover and eliminate any surprise. The soil was
again removed when the lockdown was relaxed and construction work started moving.
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If backfilling of soil, pumping of stored water at shaft location and pumping of water from river
Hooghly run simultaneously, the shaft could be filled to the desired level within 4 hours from its
deepest level of excavation.
Conclusion
Design and construction of India’s Deepest Ventilation cum Evacuation shaft came with unique
challenges. Several options for design and construction were worked out but were discarded on
some or another grounds. The finally chosen design and construction methodology was fitting
into our requirement but still was quite challenging due to its uniqueness and lack of precedence
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requiring careful analysis and implementation. With this success story it can be concluded that
any challenge can be negotiated if we venture to challenge the status quo, follow the basics of
engineering and exercise utmost care and precaution. The team left no stone unturned to make it
a success with the strong support from our experts and seniors at Head Office.
Lakshmana Rao Mantri, a competent Civil Engineer, has over 18 years of experience in civil
engineering project coordination, design coordination of underground metro projects, design,
tendering, risk analysis, monitoring and execution of different project works, slope stabilization
works, geotechnical investigation works including onshore, nearshore/offshore, preparation of
scope of work, preparation of technical specifications, evaluation of factual and interpretative
reports, reinforced soil structures works, gabion walls works, raw water reservoir works,
temporary retaining structures such as cofferdams & sheet piling works, deformation of tunnels
& tunnel lining works, flood protection & river training works, diaphragm walls, deep
foundations, rockfall netting systems, flexible & rigid pavements, MSW landfills, hazardous waste
landfills, slope protection measures and ground improvement works for roads, rail, industrial,
residential, commercial, water supply, power plants, oil and gas projects in India and other
countries.
He has received the Industry Expert National Award 2020 from IRDP Group of Journals; Sir M V
Award from Smart Infra EST, Hyderabad in 2020; Sir M V Awards from Karnataka State
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Engineering Association for providing innovative solutions for landfills in 2014; and Achievement
awards from NHAI in 2018 for providing solutions in sustainable Infrastructure in N-E Region.
He is a member of the Indian Geotechnical Society (IGS), Deep Foundation Institute (DFI), Indian
Road Congress (IRC) and International Society of Soil Mechanics and Ground Engineering
(MISSGE)
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12/04/2023, 12:12 Hydraulic Heave Failure Mitigation Approach for the construction of the Deepest Metro Ventilation and Egress Shaft in India
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