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Tunnel Construction BACHELOR OF TECHNOLOGY IN CIVIL ENGINEERING

Ruchi Kandpal 139104026 Under the guidance of

Technical Report · June 2018

DOI: 10.13140/RG.2.2.30437.37603

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 Tunnel Construction

A project report submitted in partial fulfillment of the

requirement for the degree of

BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING

Ruchi Kandpal
139104026

Under the guidance of

Dr. Gaurav Sancheti

DEPARTMENT OF CIVIL ENGINEERING

MANIPAL UNIVERSITY JAIPUR
303007, RAJASTHAN, INDIA
June, 2018
 Declaration
This is to certify that I, Ms. Ruchi Kandpal with registration number, 139104026 have
completed my internship for final year project entitled “Tunnel Construction” in
“Bharat Builders” in partial fulfillment for the award of the degree of Bachelor of
Technology in Civil Engineering, Manipal University Jaipur. This report is an authentic
record of my work carried out during a period from January, 2018 - May, 2018 under
the supervision of Mr. J.R. Bhardwaj. The matter presented in this report has not been
submitted for award of any other degree.

Ruchi Kandpal
Regd. No.: 139104026

The report has been prepared as per the prescribed format and has approved for the
submission to the department required for the defense examination.

Mr. J.R. Bhardwaj

Reporting Manager
Bharat Construction

Dr. Gaurav Sancheti

Associate Professor
Civil Engineering Department
Manipal University Jaipur

Prof. Anil Dutt Vyas

Head of the Department
Civil Engineering Department
Manipal University Jaipur
 TABLE OF CONTENTS
Acknowledgement i

Abstract ii

List of tables iii

List of figures iv

Chapter 1: Introduction 1

1.1. The Company 1

1.2. Overview 1

1.3. The Project 1

1.4. Applications and advantages 2

1.5. Project statement/Objectives 2

1.6. Specification of work 3

Chapter 2: Materials 5

2.1 Based on Texture 5

2.1.1. Coarse aggregates 5

2.1.2. Fine aggregates 5

2.2. Based on shape 5

2.2.1. Angular aggregates 5

2.2.2. Rounded aggregates 5

2.3. Rebar 5

2.4. Cement 6

2.4.1. Chemical Properties 6

2.4.2. Physical Properties 6

2.4.2.1. Fineness 7

2.4.2.2. Setting time 7

2.4.2.3. Soundness 7

2.4.2.4. Crushing Strength 7

2.5. Water 7

2.6. Rates analysis 8

2.6.1. Billing of quantity 8

2.6.2. Estimation of quantity 10

2.6.3. Estimation of cement, sand and steel 10

2.6.3.1. Estimation of cement used in RCC wall 10

Chapter 3: Methodology 16

3.1. Method: Cut and Cover 16

3.2. Equipment used 16

3.2.1. Excavator 16

3.2.2. Travelling Gantry Formwork 17

3.2.3. Concrete pump 18

3.2.4. Batching plant 19

3.2.5. Hydraulic Impact Breaker 19

3.2.6. Concrete mixer 20

3.3.Time cycle of equipment 20

3.4.Issues at site 21
3.5.Quality Assurance 22

3.6.Quality Control 22

3.7.Safety at site 23

3.7.1. Significance of safety 23

3.7.2. Modes used for safety 24

3.7.3. Accessories of safety 25

Chapter 4: Concepts and Technologies used 26

4.1. Excavation 26

4.1.1. Heading 26

4.1.2. Benching 29

4.2.Tunnel Lining 26

4.2.1. Primary Support (initial) 27

4.2.1.1.Ribs installation 27

4.2.1.2.Primary lining using M15 concrete 28

4.2.2. Final support (final) 28

4.2.2.1.Steel Reinforcement 28

4.2.2.2.Final Concrete Lining using M35 concrete 29

4.3.Water Proofing 29

4.4.Shuttering 29

4.5.Drains 30

4.6.Crash Barrier 30

4.7.Weep Holes 31
4.8.Retaining Wall 32

4.9.Raft 33

Chapter 5: Results, Analysis and Discussion 35

5.1.Aggregate Gradation Test (IS: 383) 35

5.2. Sieve Analysis of Coarse Aggregates 37

5.3. Slump Test (IS 1199, 1959) 38

5.4.Compression Cube Test 39

Chapter 6: Summary and Conclusions 41

Chapter 7: Future Scope and Limitations 42

References 43

Annexures 44
 ACKNOWLEDGMENT

I would like to acknowledge the enormous help given to me for learning practical
concepts through this project. I like to thank our Civil Department, HOD, Dr. A.D.
Vyas who was an inspiration for me right from the start. I also feel grateful to have
a very experienced professor, Dr. Gaurav Sancheti as my faculty guide. I wish to
thank Mr. J.R. Bhardwaj to give me this opportunity in the first place. For their
memories, their patience, and their guidance, I wish to thank the site engineers
Gulshan Sir and Mahindra Sir. I would also like to thank my parents for their
persistent love and support.

Ruchi Kandpal
139104026
Civil Engineering Department

i
 ABSTRACT
Traffic jams in the tunnel on the NH-72A near Dat Kali temple could be resolved in the
future. The State Forest Minister Dinesh Aggarwal said that 0.52 hectare forest land
area has been conditionally transferred to the Public Works Department for non-forestry
works to facilitate construction of a double-lane tunnel on the national highway near
Dat Kali temple. It should be mentioned here that traffic jams on the tunnel near Dat
Kali temple are known to cause major inconvenience frequently. The construction of
another tunnel is expected to facilitate smoother flow of traffic on this stretch of the 45
kilometre long NH 72 A linking Dehradun with Chhutmalpur on NH 73 in Uttar
Pradesh. The NH 72 A sustains dense traffic to Saharanpur in neighbouring UP and to
Delhi.

Equipment like batching plant, concrete pump, concrete mixer, excavator, travelling
gantry formwork, hydraulic impact breaker was used for this project. First there was the
excavation and then construction of the tunnel lining.

Retaining wall was constructed to bear the load of the backfill. AutoCAD was used for
drawing of the structure. Staad.pro vi8 was used for load and moment calculations.

After Geotechnical tests, like Sieve Analysis of coarse aggregates and aggregate
gradation test, the soil type was found to be sand gravel. Slump test helped determine
the workability of concrete. Cube Compression Test helped determine the strength of
concrete after 28 days.

Tunnel Boring Machine was opted out in this project since it was very costly instead
Hydraulic Impact Breaker was used.

ii
 LIST OF TABLES

Table No. Table Title Page No.

2.1 Water usage in cement 8

2.2 Quantity used in drain of 20 m 9

2.3 Quantity used in retaining wall (4 m) of length 10 m 9

2.4 Retaining wall (2 meter) length 20 m 9

2.5 Cut & Cover (10 meter) Invert 9

2.6 Cut & Cover (10 meter) Overt 10

5.1 Observation table for Gradation test for fine 35

aggregates

5.2 Mix Proportion according to I.S. Code 36

5.3 Observation Table for Sieve Analysis of Coarse 38

Aggregates

5.4 Slump Test Values 39

5.5 Observation Table for Compression Cube Test 40

iii
 LIST OF FIGURES

Table No. Figure Title Page No.

1.1 Map of site location 3

1.2 Chainage of tunnel 4

1.3 Shape of the tunnel 4

1.4 Forces acting on the tunnel 4

2.1 Steel bars 6

2.2 6.0 m height Retaining Wall Structural 11

Drawing

2.3 4.0 m height Retaining Wall Structural 13

Drawing

2.4 2.0 m height Retaining Wall Structural 14

Drawing

3.1 a, b Excavator and its parts 17

3.2 Travelling Gantry Formwork 18

3.3 a, b Concrete Pump with separate pipeline 18

3.4 Batching plant 19

3.5 The breaking point of Hydraulic Impact 19

Breaker

3.6 Concrete Mixer 20

3.7 Part of the mountain that wasn’t 21

permitted to be excavated

4.1 Benching 26

4.2 Primary lining 27

4.3 Shuttering of primary lining 29

4.4 Shuttering Plate 30

4.5 Structural Details of the Outfall 30

iv
4.6 Crash Barrier 31

4.7 Weep Holes 31

4.8 Retaining Wall 33

4.9 Parts of the Retaining Wall 33

5.0 Laying of the Raft 34

5.1 Graph showing relationship between 37

particle size and percentage by weight

5.2 Textural classification of soil 37

5.3 Sieves 38

5.4 Compression Testing Machine 39

v
 Chapter-1
INTRODUCTION
1.1. The Company
The name of the company is Bharat Construction. Its office is situated in PPCl Colony,
Uday Vihar, Dehradun. It is a contractor company. It is known for the construction of
Real Estate projects and one of the nation's premier construction company. For more
than 50 years, Bharat Builders has designed and constructed buildings of the highest
quality and design excellence. It has built more than 100 projects across the country
over the last 5 decades. At Bharat Builders one can expect high quality construction,
unique architecture and quality. Bharat Builders began in 1950, which was founded by
Mr. Abdul Shukoor. Bharat Builders is one of the nation's largest and most successful
construction companies. This pride comes from knowing construction as a tradition.
From Mr. Abdul Shukoor, which was later carried on by his son Mr. Abdul Gaffar and
grandson Mr. Mohamed Arshad, who carry a tradition of our long-standing commitment
to excellence in design and craftsmanship that has earned the trust and respect of the
client year after year.

1.2. Overview

Tunnels are unlike any other civil engineering structures. In buildings or bridges, the
building materials have design properties and they can be tested to ensure they meet
these, whereas this is not the case in tunneling. Although, a tunnel structure often needs
support systems made up of concrete and steel, it is the ground that is the major part of
the structure, and this can have both a supporting and a loading role.

1.3. The Project

Near Dat Kali temple in km 33-34 of NH72A, a 2-lane Tunnel is being constructed by
Bharat Builders. The total tender cost for the project is Rs. 560101151.00. The date of
start of the project was on 3rd of May, 2017. Its expected date of completion is 2nd of
May, 2019. The total time of completion for this project is 2 years. The defect liability
period of this project is 4 years.

1
1.4. Applications & Advantages

A tunnel is an elongate, narrow, essentially linear excavated underground opening with

a length greatly exceeding its width or height. Rock-mechanics investigations have
provided a vast reservoir of knowledge concerning the behavior of rocks under stress,
and this knowledge can be applied to the planning and design of tunnels to the extent
that underground geological conditions can be predicted.
Tunnels have been constructed for a great variety of purposes. A classification of tunnels
by use follows:
1. Tunnels driven to gain access to economic mineral deposits and to provide haul-ways
for extracted materials. Commonly, such tunnels provide drainage of underground
water. In some mining operations tunnels are driven to provide adequate circulation of
air in underground workings.
2. Transportation tunnels, including pedestrian, highway, navigational, and rail- road
tunnels. These are among the largest, and, at times, the most difficult of all tunnels to
excavate.
3. Water (and sewage) tunnels: These tunnels may or may not be constructed so as to
transport liquids under pressure, and a distinction is made between gravity- flow tunnels
and pressure tunnels. The latter are designed to contain without leakage water under a
hydrostatic or force-pressure head.
4. Military tunnels: These tunnels are driven in connection with underground military
operations.
5. Access tunnels to underground chambers or vaults.
6.. Tunnels to provide protection from atomic explosions
7. Utility tunnels: Built to contain power and communication transmission lines, gas
lines, air-pressure lines, etc.

1.5. Project statement/Objective

An old tunnel was constructed near Dat Kali in the 18th century, due to heavy load this
tunnel is not sufficient to carry the traffic load. Hence, construction of a tunnel was
proposed to ease traffic flow.

2
 Figure 1.1: Map of the site location

1.6. Specification of work

The design length of the tunnel is 330.00 m. The length of portal is 5.00 m on each side.
The carriageway including kerb shyness is 7.50 m. The footpath is (2*1.50) m or 3.00
m. The crash barrier is (2*0.450) m = 0.90 m.
The total width of the tunnel is 11.400 m. The minimum vertical clearance in
carriageway system is 5.50 m. The longitudinal slope in tunnel is 4.0%. The client of
Bharat Builders for this 2-lane tunnel construction is PWD Roorkee. Bharat Builders is
working in EPC mode for this project. The width of the tunnel is 11.875 m, whereas the
carriageway is 7.5 m.
Tunnels can be in all shapes and sizes, including round, horseshoe, square, and
rectangular or just any geometric shape.

3
 Figure 1.2: Chainage of the Tunnel

The shape of this tunnel is horseshoe shape. This design is used to balance the horizontal
and vertical forces acting on the structure.

Figure 1.3: Shape of the tunnel

Figure 1.4: Forces acting on the tunnel.

4
 Chapter-2
MATERIALS
2.1. Based on Texture
2.1.1. Coarse Aggregate: Aggregate retained on 4.75 mm sieve are identified as coarse.
They are obtained by natural disintegration or by artificial crushing of rocks. The
maximum size of aggregate can be 80 mm. The size is governed by the thickness of
section, spacing of reinforcement, clear cover, mixing, handling and placing methods.
For economy the maximum size should be as large as possible but not more than one-
fourth of the minimum thickness of the member. For reinforced sections the maximum
size should be at least 5 mm less than the clear spacing between the reinforcement and
also at least 5 mm less than the clear cover. Aggregate more than 20 mm size are seldom
used for reinforced cement concrete structural members.
2.1.2. Fine Aggregate: Aggregate passing through 4.75 mm sieve are defined as fine.
They may be natural sand—deposited by rivers, crushed stone sand—obtained by
crushing stones and crushed gravel sand. The smallest size of fine aggregate (sand) is
0.06 mm. Depending upon the particle size, fine aggregates are described as fine,
medium and coarse sands. (IS: 383).
2.2. Based on shape:
2.2.1. Angular Aggregate: They have sharp, angular and rough particles having
maximum voids (about 40 per cent). Angular aggregate provides very good bond than
the earlier two, are most suitable for high strength concrete and pavements; the
requirement of cement paste is relatively more.
2.2.2. Rounded Aggregates: These are generally obtained from river or sea shore and
produce minimum voids (about 32 per cent) in the concrete. They have minimum ratio
of surface area to the volume, and the cement paste required is minimum.
2.3.Rebar:
Steel is the most suitable building material among metallic materials. This is due to a
wide range and combination of physical and mechanical properties that steels can have.
By suitably controlling the carbon content, alloying elements and heat treatment, a
desired combination of hardness, ductility and strength can be obtained in steel.

5
 Figure 2.1: Steel bars
The presence of carbon in steel gives high degree of hardness and strength. The addition
of carbon to iron decreases the malleability and ductility of the metal and reduces its
permeability to magnetic forces.

2.4.Cement
Cement is a commonly used binding material in the construction. The cement is
obtained by burning a mixture of calcareous (calcium) and argillaceous (clay) material
at a very high temperature and then grinding the clinker so produced to a fine powder.
The cement used for the entire construction was Ordinary Portland cement.
2.4.1. Chemical properties: Portland cement consists of the following chemical
compounds:
1. Tri-calcium silicate (3CaO. SiO2 C3 S): 40%
2. Di-calcium silicate (CaO. SiO2 (C2 S): 30%
Tri-calcium aluminate: (3CaO. Al2 O3 (C3 A)): 11%
3. Tetra-calcium aluminate: (4CaO. Al2 O3 . Fe2 O3 (C3 AF): 11%
There may be small quantities of impurities present such as calcium oxide (CaO) and
magnesium oxide (MgO).
When water is added to cement, C3 A is the first to react and cause initial set. It generates
great amount of heat. C3 S hydrates early and develops strength in the first 28 days. It
also generates heat. C2 S is the next to hydrate. It hydrates slowly and is responsible for
increase in ultimate strength. C4 AF is comparatively inactive compound.
2.4.2. Physical properties: The following physical properties should be checked before
selecting a Portland cement for the civil engineering works.

6
IS 269–1967 specifies the method of testing and prescribes the limits.

2.4.2.1. Fineness: It is measured in terms of percentage of weight retained after sieving

the cement through 90 microns sieve or by surface area of cement in square centimeters
per grams of cement. According to IS code specification weight retained on the sieve
should not be more than 10 per cent. In terms of specific surface should not be less than
2250 cm2/gm.

2.4.2.2. Setting time: A period of 30 minutes as minimum setting time for initial setting
and a maximum period of 600 minutes as maximum setting time is specified by IS code,
provided the tests are conducted as per the procedure prescribed by IS 269-1967.

2.4.2.3. Soundness: Once the concrete has hardened it is necessary to ensure that no
volumetric changes takes place. The cement is said to be unsound, if it exhibits
volumetric instability after hardening. IS code recommend test with Le Chatlier mold
for testing this property. At the end of the test, the indicator of Le Chatelier mold should
not expand by more than 10 mm.

2.4.2.4. Crushing strength: For this mortar cubes are made with standard sand and
tested in compression testing machine as per the specification of IS code. The minimum
N N
strength specified is 16 mm2 after 3 days and 22 mm2 after 7 days of curing.

2.5.Water
Almost any natural potable water that has no pronounced taste or odor is acceptable for
the concrete mix. Many sources of water unsuitable for drinking may also be used. In
case of a doubt, water samples should be tested for suitability. Excessive impurities may
affect setting time, strength, durability and may cause efflorescence, surface
discoloration, and corrosion of steel. When aggregates are washed with water containing
impurities, they get coated with layers of silt, salts and organic matters. These reduce
the bond between the aggregates and cement and markedly affect the strength. Water fit
for making concrete can be used for curing.

7
Waters containing impurities and leading to stains is objectionable. When concrete is
subjected to prolonged wetting, even a very low concentration of iron and organic matter
may cause staining. Water containing more than 0.08 ppm of iron is not recommended
for curing.

Table 2.1: Water usage in cement

Grades Ratio Water usage

M5 1:5:10 46 L

M 7.5 1:4:8 39 L

M 10 1:3:6 34 L

M 15 1:2:4 30 L

M 20 1:1.5:3 27 L

M 25 1:1:2 25 L

2.6.Rates Analysis
The estimation of rate per unit of a particular item from the cost of quantities of material,
the cost of labor and other miscellaneous petty expenses required for completion is
known as Rate Analysis. A profit of 10% for the contractor is also included in the rate
of analysis. Rates of material are usually taken as the rates delivered at the site of work
and include the first cost (cost of origin), cost of transport, railway freight if any, taxes,
etc. If a material is transported from a distance greater than 8 km the price of
transportation is also added. The rates of material and labor vary from place to place.
Hence the item of work differs from place to place.

2.6.1. Billing of Quantity

Quantity of any item should be known as it helps in estimation of price as the
construction materials are costly and wastage is the least thing that is desired by any
designer or an engineer.

8
Table 2.2: Quantity used in Drain of 20 m

Table 2.3: Quantity used in Retaining wall (4m) of length 10 meter

Table 2.4: Retaining Wall (2 m) length 20 meters

Table 2.5: Cut & Cover (10 meter) Invert

9
Table 2.6: Cut & Cover (10 meter) Overt

2.6.2. Estimation of quantity

The daily consumption of fuel (diesel) spent per day is 800 liters including Direct
Generator. The average costing is 16,000 INR. On an average the money spent on the
project is 8-9 crore on steel and 2-3 crore in cement.
2.6.3. Estimation of cement, sand and steel
According to the government prices in the market:
1. Cost of cement: 335-340 per bag of Ordinary Portland Cement + transportation
charges.
2. Reinforce steel: 46,000 INR per metric ton + 18% extra + transportation
3. Sand price: 900 INR per metric ton + 5% GST + transportation
4. Aggregate price: 700 INR per metric ton + 5% GST + transportation charges
2.6.3.1. Estimation of cement used in RCC wall

Towards Dehradun side:

1. For chainage: (845 m – 870 m)

Length: 25 m
Height: 6 m
Top width of stem= 250 mm
Bottom width of the stem= 500 mm
Width of the toe= 1000 mm
Width of base slab= 3600 mm
Height of wall above base slab= 5500 mm
Depth of base slab= 500 mm
Depth of shear key= 750 mm

10
Width of shear key= 500 mm
Consider volume= 1 cub. m. or m3
M15= (1:2:4)
Sum of ratio= 7
Dry volume= (1* 1.54) cub. m.= 1.54 cub. m.
Cement in cub. m.= (1.54*0.14) cub. m. = 0.22 cub. m.
In kg= (0.22* 1440) = 316.8 kg
316.8
We know 1 bag of cement weighs 50 kgThen 316.8 kg contains = 6.34 bags
50
2
(1.54* ) = 0.44 cu. m.
7

Figure 2.2: 6.0 m height retaining wall Structural Drawing

11
In kg= (0.44* 1450) kg= 638 kg
Unit weight of sand varies between 1450-1500 kg/m3
(250+500)
Area of stem= ∗ 5500 sq. mm = 2.062 sq. m.
2

Area of base slab= (3600*500) sq. mm = 1.800 sq. m.

Total area= (2.062 + 1.800) sq. m. = 3.862 m
Volume of concrete= (25 * 3.862) cub. m. = 96.55 cu. m.
No. of bags @ 6.47 bags per cub. m.= 624.67
Sand @ 0.44 cub. m./ cub. m.= (96.55*0.44) cub. m. = 42.482 cub. m.
Bajri @ 0.88 cub. m./cub. m. = (96.55 * 0.88) cub. m.= 84.964 cub. m.

2. For chainage: (870 m – 900 m)

Height: 4 m
Length: 30 m
Top width of stem= 250 mm
Bottom width of the stem= 300 mm
Width of the toe= 1000 mm
Width of base slab= 2400 mm
Height of wall above base slab= 3600 mm
250+300
Area of stem= ( *3600) mm2 = 0.99 𝑚2
2

Area of base slab= (2400*400) mm2 = 0.08 𝑚2

Total area = 1.07 𝑚2
Volume of concrete= (30*1.07) 𝑚3 = 32.10 𝑚3
Number of bags @ 6.47 bags per cub. m.= 207.687
Sand @ 0.44 cub. m./ cub. m.= (32.10*0.44) cub. m.= 14.124 cub. m.
Bajri @ 0.88 cub. m./cub. = (32.10*0.88) cub. m.= 28.248 cub. m.

12
 Figure 2.3: 4.0 m retaining wall Structural Drawing
3. Chainage: (900 m - 955 m)
Length = 55 m
Height: 2 m
Top width of stem= 200 mm
Bottom width of the stem= 250 mm
Width of the toe= 550 mm
Width of base slab= 1200 mm
Height of wall above base slab= 1750 mm
(200+250)
Area of stem= * 1750 mm2=0.393 m2
2

Area of base slab= (250*1200) mm2 = 0.300 m2

Total area = 0.6937 𝑚2
Volume of concrete= (55*0.6937) 𝑚3 = 38.15 𝑚3
Number of bags @ 6.47 bags per cub. m.= 246.83
Sand @ 0.44 cub. m./ cub. m.= (38.15*0.44) cub. m= 16.786 cub.m.
Bajri @ 0.88 cub. m./cub. = 33.572 cub.m.

13
 Figure 2.4: 2.0 height retaining wall Structural Drawing
Towards Ganeshpur side:
4. For chainage 500 m – 430 m
Length: 70 m
Height: 4 m
Top width of stem= 250 mm
Bottom width of the stem= 300 mm
Width of the toe= 1000 mm
Width of base slab= 2400 mm
Height of wall above base slab= 3600 mm
250+300
Area of stem= ( *3600) mm2 = 0.99 m2
2

Area of base slab= (2400*400) mm2 = 0.08 m2

Total area = 1.07 m2
Volume of concrete= (70*1.07) m3 = 74.9 m3
Number of bags @ 6.47 bags per cub. m.= 484.603
Sand @ 0.44 cub. m./ cub. m.= (74.9*0.44) cub. m.= 32.956 cub. m.
Bajri @ 0.88 cub. m./cub. = (32.10*0.88) cub. m.= 65.912 cub. m.

14
5. For chainage (430 m – 421m)
Length: 9 m, Height: 4 m
Top width of stem= 250 mm
Bottom width of the stem= 300 mm
Width of the toe= 1000 mm, Width of base slab= 2400 mm
Height of wall above base slab= 3600 mm
250+300
Area of stem= ( *3600) mm2 = 0.99 m2
2

Area of base slab= (2400*400) mm2 = 0.08 m2

Total area = 1.07 m2 Volume of concrete= (9*1.07) m3 = 9.63 m3
Number of bags @ 6.47 bags per cub. m.= 62.306
Sand @ 0.44 cub. m./ cub. m.= (9.63*0.44) cub. m.= 4.23 cub. m.
Bajri @ 0.88 cub. m./cub. = (9.63*0.88) cub. m.= 8.474 cub. m.

15
 Chapter 3
METHODOLOGY
3.1. Method: Cut and Cover
This method is used for the construction of shallow tunnels where a trench is and
roofed over with an overhead support system strong enough to carry the load of what
is to be built above the tunnel. It is a construction sequence adopted to influence the
design of the tunnel section. The diaphragm wall is constructed first for temporary
retaining wall around portal perimeter by trenching to the required length followed by
concreting till the soffit level of the crown followed by casting of crown level.
3.2. Equipment used:
Modern construction projects are complex in nature and success of a project depends
greatly on proper and scientific planning. Before starting a project, its planning is done
with great care, as the efficiency of the complete project depends on planning.
Equipment planning, execution planning and extent of mechanism helps decide the
efficiency of a project. Equipment selection depends on:
1. Quantum of work: If work is too much, the bigger size equipment is used.
2. Working days available for completing of project: The rated output of the
equipment helps decide the number of equipment required
3. Number of shifts planned: This depends on the rated output of the equipment and
number of days available.
3.2.1.Excavator:
The excavator combines digging and lifting abilities. Excavators come in a wide range
of sizes. Bucket size, boom length, and operating speed are primary considerations for
choosing the proper excavator. The faster the operating speed, the faster the machine
can load, swing, dump, return and dig. Excavators are ideal for digging and dumping
into a dump truck or a pile. Excavator attachments are run by hydraulics. The weight
of the soil in the bucket can sometimes make the excavator unstable. The rated load
should not exceed 75% of the tipping load. Attention to the setup and load weight is
essential. A typical excavator cycle is as follows: fill the bucket (load), raise load
above grade or to the necessary height, swing the load to the dump point, dump the
load, swing the empty bucket back to the excavation point, drop the bucket, and start
the cycle over. It is recommended that the operator curl up when the bucket is 75%
through the curl (digging motion of the machine) cycle.

16
The excavator should be position for digging so that the stick is vertical when the
bucket is full and curled with the load. The loading time is the time required by the
piece of equipment to load the hauling unit.
Loading time = Number of cycles required to load the truck (the estimated cycle
time).
𝐯𝐨𝐥𝐮𝐦𝐞 𝐨𝐟 𝐭𝐡𝐞 𝐭𝐫𝐮𝐜𝐤
Number of loader cycles to fill a truck =
𝐯𝐨𝐥𝐮𝐦𝐞 𝐨𝐟 𝐭𝐡𝐞 𝐥𝐨𝐚𝐝𝐞𝐫

Figure 3.1 a, b: Excavator and its parts

3.2.2. Travelling Gantry Formwork

It paces up the shuttering process. The gantry has to be assembled on site by workers
and inspected properly. The gantry works on the principal of hydraulics. It is used for
final tunnel lining. It is especially used for shuttering purpose.

17
Gantry runs on rails. The length of gantry is 12 m.

Figure 3.2: Traveling gantry formwork

3.2.3. Concrete pump

It is extremely important to have sufficient crew and equipment on hand to
successfully place and work the concrete. When the concrete truck arrives, the crew
member should be ready to discharge. The pump is a fairly simple machine. To work
properly, the pump must be fed concrete of uniform workability and consistency.
Perhaps one-fourth of all concrete is now placed by pumping. Pumps are available in
a variety of sizes, capable of delivering concrete at sustained rates of 10-150 cycles/hr.
There are two main configurations of a concrete pump:
1.Pumps with a separate pipeline
2.Pump and a boom combination
The latter is particularly effective and cost-effective in saving labor and eliminating
the need for pipelines to transport the concrete.

Figure 3.3a, b: Concrete pump with separate pipeline

18
3.2.4.Batching plant:
The batching plant is required for operation of large quantities of concrete. The stock-
piles prevent shortages caused by temporary production or transportation difficulties.

Figure 3.4: Batching Plant

3.2.5. Hydraulic Impact Breaker:

Simultaneous contour cutting and core extraction can be achieved if one or more
cutting units are moved while mounted on a portal corresponding to the tunnel outline
to produce a contour slot about 1 m deep. At the same time, a machine such as a breaker
mounted under the portal can break out the core. The muck pile is gathered by a loading
device and transported away. Rock is broken or fractured by an impact hammer usually
equipped with a chisel impact tool. Breaker hammering, as well as boom movements,
are carried out by hydraulic power. The hydraulic hammer works on the same principle
as hammer hitting a chisel.
The chisel receives energy from the blow of the hammer. The chisel of the impact
hammer receives energy from blows from the hammer.

Figure 3.5: The breaking point of Hydraulic Impact Breaker

19
The chisel of the impact hammer receives energy to break the rock from the movement
of the hydraulic piston in the impact hammer.

3.2.6. Concrete mixer

It is extremely important to have sufficient crew and equipment on hand to successfully
place and work on the concrete. When the concrete truck arrives, the crew should be
ready to discharge their loads as soon as possible. If a day occurs, do not let the truck
stand by without continuing

Figure 3.6: Concrete mixer

to rotate the mixer slowly. Prolonged mixing in hot weather increases the temperature
of concrete and causes faster hydration. The accelerated hydration rate will shorten the
time available for placing the concrete. If there is a problem at job site, placement of
the concrete should be delayed promptly notifying the ready-mix plant, to reschedule
batching. After surface finishing, apply a curing membrane to prevent rapid moisture
evaporation. The foundation must then be covered by polythene.

3.3. Time cycle of equipment

It is always good practices utilize equipment to the limit of its useful life on one
particular project. The average working condition in our country is:
1. Single shift operation: 1500 hrs.
2. Double shift operation: 2500 hrs.
3. Triple shift operation: 3200 hrs.
Thus, an equipment with an estimated economical life of 10,000 hours, when used for
4 years project should work for 2500 hours per year.

20
When the project duration is less than 3 years, the equipment should be used in triple
shifts so as to depreciate fully.
1. Concrete pump: It was used on an average 4 hours in 24 hours. The concrete
mixer’s time cycle depends upon concrete pump. Company used: Schwing. The
economic life of concrete pump is 12 years.
2. Batching plant: It was used for 8 hours in a period of 24 hours. Company used:
Akona.
3. Excavator: It was used for 18 hours in a period of 24 hours. Company used: Tata
Hitachi. Its economic life is 6 years or 9800 hours.
4. Hydraulic Impact Breaker: It was used for 4 hours out of 24 hours. Company
used: SRV. The economic life of breaker is 4-5 years.
5. Gantry: It was used for 36 rounds. 3 days for 1 round which involved 2 days for
steel, 1 day for concrete. Separate one day was for alignment. Company used: Aliba.
It was used only for one project.
6. Concrete Mixer: The economic life is 7-8 years.

3.4. Issues at site

The main issue was from the forest department for land clearance for cutting of trees.
There was an environmental issue due to this. The rainy season caused another
problem as it affected the mobilization of material.

Figure 3.7: Part of the mountain which wasn’t permitted to be

excavated.

21
3.5. Quality assurance
Despite the wealth of site experience accumulated throughout the decades, one in ten
building contracts still leads to client dissatisfaction and complaint against the
contractor.
In most cases, the defects are found to be the result of:
1. Misinterpretation of drawings and specifications;
2. Use of superseded drawings and specifications;
3. Poor communication with the architect/engineer, subcontractors and material
suppliers;
4. Poor coordination of subcontracted work;
5. Ambiguous instructions or unqualified operators;
6. Inadequate supervision and verification on site.
7. Defects arising in construction are mostly caused by poor management and
communication. It is preclusive to assume that mistakes appearing on site are actually
made on site. These mistakes may be traced back to the purchase of incorrect or
incompatible materials and the failure to retrieve the outdated drawings.
A quality system contains, among other things, a set of documented procedures for the
various processes carried out by the organization. Many government bodies
responsible for public works and housing have begun to insist on an effective (or even
certified) quality system as prerequisite for tendering. For a contracting company, a
well-established quality system is a marketing tool, especially when the company has
gone through third party certification. If a contractor does not want to be excluded
from bidding for available work, he should wait no more in establishing a quality
system in his organization.

3.6. Quality Control

According to IS: 9000, Quality control refers to the activities that are carried out on
the production line to prevent or eliminate causes of unsatisfactory performance. In
manufacturing industry, including production of ready mix concrete and fabrication of
pre-cast unit, the major functions of quality control are control of incoming materials,
monitoring of production processes and testing of the finished product.
Before production is commenced, an assurance is made of the minimum quality needed
to satisfy the stated requirements and how that quality can be consistently achieved.

22
We can establish the target mean strength of concrete on the basis of of specified
characteristic strength and the estimated variability. During production, the strength of
concrete is continuously monitored via routine testing and statistical analysis of the test
results, so as to detect at the earliest possible moment when either the mean strength or
the variability of strength shows a significant change. The control mechanism them goes
on to rectify the detected change, thereby preventing a problem from developing into a
real one. The stringent acceptance criteria are set and severe penalties for non-
compliance are imposed.
Despite the diversity of work handled by a construction company, the corporate
procedures apply to all projects in varying degrees. Typical examples are tendering,
procurement, document control and record keeping. This project was made in EPC
mode.

3.7.Safety at site:
Workers’ safety behavior, unsafe acts and attitudes affect the likelihood of accidents on
sites. An accident can be defined as an unplanned event that results in injury or ill health
of people, or damage to loss to property, plants, materials or the environment, or a loss
of business opportunity. From a nationwide perspective, industrial accident costs have
a significant impact on the national economy. Many of the accidents happen because of
construction structure and facilities’ problem in site. The poor working surfaces and
platforms cause accidents. Many of the accidents happen due to fall from elevation,
platform, ladder, roof and piled matter, fall on stairs and fall into openings. Most
significant indirect causes of falls include improper use of safety equipment, improper
use of personal protective equipment, lack of effective safety facilities, ineffective safety
equipment, unqualified safety nets, and the non-existence of safety devices. High
proportion of injuries are being struck against or by an object. The accidents due to
electrical shocks is 5 times more than the average accidents in the sector.
3.7.1. Significance of safety
Construction accidents often lead to huge costs in compensation. Hence, to know the
causes the accidents has become an important issue. The major loss being financially
due to the following reasons:
A. The financial loss of construction accidents:
1. Loss of injured persons

23
2. Loss due to inefficiency of the workers who have recovered from injury and resumed
work
3. Loss due to medical expenses
4. Loss of productivity of other employees
5. Loss due to damaged equipment or plant
6. Loss due to damaged materials or finished work
7. Loss due to idle machinery or equipment
8. Social cost of construction accident:
9. Based on the severity of accidents
10. The age of the injured person
11. The type of condition and other related situations and conditions

B. Human pain and suffering costs of construction accidents: Employees can

compensate claims due to the following reasons:
1. Loss of earning of employee
2. Loss of earning capacity
3. Loss of personal property
4. Medical expenses
5. Miscellaneous expenses
6. Pain, suffering or loss of amenities
7. Loss of societyLoss of dependency
8. Loss of accumulation of wealth
9. Loss of personal property
10. Funeral expenses
11. Loss of service
12. Bereavement

3.7.2.Modes used for safety

Safety induction (initial safety in basics of safety) and training (routine training)
exercises, medical screening of personnel for working inside tunnels, systems of permits
for simultaneous operations in various locations, pep talks (regular talks to the workmen
before they commence work on importance of safety and how necessary it is for them
to observe safety regulations.

24
3.7.3. Accessories of safety
1.Hard-shell helmets.
2.Well-illuminated sign boards are placed at required locations to inform people of the
safety hazards inside the tunnel and the precautions to be taken.
3.The electrical installations should be carefully designed and executed and regular tests
should be carried out to ensure safe conditions and emergency cut-off procedures.
Design and installation of appropriate supports within the stand-up time for the
particular type of rock is the most important steps to ensure proper safety for all personal
inside the tunnels.

25
 Chapter-4
Concepts and Technology used
4.1. Excavation:
Excavation work was done by Hydraulic Impact Breaker and not by blasting or by
using Tunnel Boring Machine as the soil found in the terrain is Sandy gravel. Blasting
is done where there is hard soil found. Tunnel Boring Machine is chosen where the
tunnel height is greater than 7.5 m. The design height of the tunnel was 6 m. The
machine used for this in this project was Excavator.
Excavation is done by two methods:
4.1.1. Heading: The top portion cross-section of the tunnel is known as heading.
The top heading is excavated first. It can extend to full length of tunnel or can be
short as single round length. Heading depends upon the time required to install
necessary support or reinforcements for the arch. The complete excavation was done
on 14th of January, 2018.
4.1.2. Benching: The bottom portion cross-section of the tunnel is known as
benching. Once the roof is secured, the bench can be excavated. After benching, raft
is laid out.

Figure 4.1: Benching

4.2. Tunnel lining:

Tracks are laid in line and leveled. Trolley and shutters which are already assembled
outside are rolled into position and aligned.

26
Shutter is fully deployed for concrete placement. Concrete placement between tunnel
wall and shutter is completed. Shutter is collapsed to proceed further. Shutter moves
to next location and all operations are repeated. In this manner the entire tunnel lining
is completed.
There are various reasons for lining a tunnel:
1.To maintain the tunnel shape, that is, to support the ground;
2.To keep fluids in or keep fluids out of the tunnel;
3.To provide a certain friction coefficient for the flow of fluids.
4.2.1. Primary Support (initial):
The primary lining is the ground support that is installed immediately after
excavation and provides a temporary structure for safety and to maintain tunneling
operations. The function of the primary lining is purely to stabilize the tunnel
following excavation and avoid loose material falling on the workforce. The primary
lining was of steel ribs held together by bolts. 200 mm thickness layer of M15 grade
concrete lining is spread between the ribs. The outer layer is installed as the tunnel
advances and serves, as a composite with the load-bearing capacity of the rock mass
on its own, to secure the cavity until the final concrete lining is installed. Shutters are
used to hold the cement in place till the time it sets.

Figure 4.2: Primary lining

4.2.1.1. Ribs installation

ISMB steel ribs of dimensions (200*100) mm are used. Support systems based on
steel ribs have been used for many decades. This technique involves rolled steel
sections being placed around the circumference of the excavated tunnel profile at
specified intervals. It has high bending and tensile bursting resistance.

27
It has High shear resistance and is readily available. Steel ribs are commonly used
for tunnel support system. If there are no ribs installed as support system there is a
possibility of inadvertent voids left behind the lining. Steel support ribs are made of
rolled profiles, U profiles, special mining profiles or composite sections, as closed
arches or open at the bottom. To prevent steel ribs from rust, PCC layer is spread to
prevent the direct contact with soil.
4.2.1.2. Primary lining
200 mm thickness layer of M15 grade concrete lining is spread between the ribs. The
outer layer is installed as the tunnel advances and serves, as a composite with the
load-bearing capacity of the rock mass on its own, to secure the cavity until the final
concrete lining is installed.

4.2.2. Final Support (final):

The final lining is of concrete. Poor ground conditions could result in additional,
unexpected loading on the lining. Hence, this lining is important as it helps distribute
load. It is 80 mm in dimensions. Traveling Gantry formwork is used as shutters. This
helps save time in the construction of the overall project.
The tunnel lining, whether it is temporary or permanent, must be capable of
withstanding all the influences.

4.2.2.1. Steel Reinforcement

Steel has been increasingly used instead of timber since the middle of the 20th
century, since steel enables standardization of support elements and prefabrication
of the support. It provides high tensile strength when combined with concrete. Steel
is high in tension. When combined with concrete which has high compressive force,
there is a proper balance of bending moment, hence imparting more strength to the
structure. It provides very high tolerance control to the structure. It is lighter than
equivalent concrete sections. Using steel as a reinforcement, its only disadvantage is
that it is prone to corrosion and it’s expensive. The dimensions of the bar used for
steel reinforcement is:
1.Distribution bar: 16 mm
4.2.2.2. Main bar: 25 mm;

28
4.2.2.2. Final Concrete Lining
A tunnel is commonly a composite structure made up of the tunnel lining and the
surrounding material. The surrounding material not only has a loading function, but
also is the medium in which a void is created with the help of the supporting role of
the surrounding material. 800 mm thick concrete lining is used of grade M35.

4.3.Water proofing
A waterproofing system, consisting of watertight PVC membrane with a geotextile
mechanical protective layer, is applied over the full section between the final tunnel
lining and primary support. Waterproofing is important in tunnel lining construction
to prevent excessive water flow into the tunnel.

4.4.Shuttering
For columns, walls and vertical form works the de-shuttering time is 16-24 hours.
Greasing is done on the shutter plates to ease the removal of shutter plates after the
concrete sets. The shutter plates are secured in place by nuts and bolts. Shutter is the
process of putting steel plates (shutter) after concrete has been filled to prevent the
backfill from sliding. These steel plates prevent concrete from falling down and are
attached to their place with the help of bolts. The ribs have pre-fabricated holes that
allow the connection of HSF nuts and bolts and to be stronger.
For columns, walls and vertical form works the de-shuttering time is 16-24 hour.
Greasing is done on the shutter plate to ease removing shutter plates after the concrete
sets. The shutter plates are secured in plates by nuts and bolts. The ribs have pre-
fabricated holes, which allow better connection of nut and bolt.

Figure 4.3: Shuttering of primary lining

29
 Figure 4.4: Shutter plate

4.5.Drains
Drainage of the backfill is essential to keep the wall from being subjected to water
pressure and to prevent frost action. When the backfill is composed of clean, easily
drained materials, it is customary to provide for drainage by making weep holes
through the wall. The width of the drainage is 1.10 m.

Figure 4.5: Detail of drain at outfall

4.6. Crash Barrier

They help keep the vehicles within their roadways and prevent them from colliding
with dangerous obstacles such as boulders, sign supports, trees, bridge abutments,
building, walls and large storm drains. Vehicle crash barrier have been in use in some
form almost since the inception of the highway itself.

30
Over the years many accepted types of crash barrier have become obsolete because
of the increasing demands of traffic and the need for more in-built safety in
their design.

Figure 4.6: Crash Barrier

4.7.Weep Holes
Weep holes are commonly made by embedding pipes 4-6 inches in diameter into the
wall. These holes are spaced 5-10 feet center to center both horizontally and
vertically.

Figure 4.7: Weep Hole

A filter of granular material should be provided around the entrance to prevent the
soil from washing out or the drain to become clogged.

31
Weep holes have the disadvantage of discharging the water that seeps through the
backfill at the toe of the wall, where the soil pressure is the greatest. The water may
weaken the soil at this point and can cause the wall to fail. A more effective solution,
which is more expensive, is to provide longitudinal bac drain along the base of the
wall.

4.8.Retaining Wall
A retaining structure is usually required to protect and stabilize steep slopes. Low
retaining structures at the toe of a slope make it possible to grade the slope back to a
more stable angle. Structures are generally capable of resisting much higher lateral
earth pressures and shear stresses than vegetation alone. The image below is of the
forces acting on the retaining structure.
A retaining wall is a wall constructed to support vertical or nearly vertical earth bank
that, in turn, may support vertical loads. Generally, retaining wall are classified into
the following five types:
1. Gravity Retaining Wall
2. Cantilever Retaining Wall
3. Counter-fort Retaining Wall
4. Buttressed Retaining Wall
5. Crib Retaining Wall
The retaining wall used here is Cantilever retaining wall. Cantilever retaining wall
has a tapering wall height design. At base the dimension of stem is 500 mm and on
advancing to a height the thickness reduces to 200 mm gradually. Cantilever can bear
more weight than a counter-fort retaining wall. The reason for tapered design is that
there is more weight of soil at the bottom. The vertical stem resists pressure from one
side and the slab bends like a cantilever. The slab is thicker at the bottom and
gradually decreases in pressure while going up as there is a decline in soil pressure.
The retaining wall rotates with toe as the center of rotation.
Retaining wall structure is used in a highway to permit the use of a steep slope and
avoid excessive amounts of excavation. For the excavation of land area, permission
from the Forest Department has to be taken. Retaining walls are used on the
embankment side of hill sections to avoid excessive volumes of fill.
Retaining walls are used to provide support for the side of deep and permanent
excavations.
32
Permanent retaining walls are generally constructed from plain or reinforced
concrete.
Backfilling behind the retaining wall shall be carried out only after the ground floor
slab is cast and has attained design strength.

Figure 4.8: Retaining wall

Figure 4.9: Parts of Retaining Wall

4.9.Raft
Since the bearing capacity of sand increases with the size of the foundation and since
rafts are usually of large dimensions, a bearing capacity failure of raft on sand is
practically ruled out. As a raft bridges over loose pockets and eliminates their
influence, the differential settlements are much smaller than those of a footing under
the same pressure. Hence, higher allowable soil pressures may be used for design of
rafts on sands. It is usually laid after the benching is complete. A raft or mat
foundation is a combined footing that covers the entire area beneath the structure and
supports all the walls and the columns.
33
It is more economical than footing. The weight of raft is not considered a part of the
structural design as it is assumed to be directly carried by the sub-soil. The depth at
which the raft is established is sometimes made so great that the weight of the
structure plus of the raft is completely compensated by the excavated soil.

Figure 4.10: Laying of Raft

34
 Chapter-5
RESULTS, ANALYSIS AND DISCUSSION

5.1. Aggregate Gradation Test (IS: 383):

Aggregates are the materials basically used as filler with binding material in the
production of mortar and concrete. Aggregates form the body of the concrete, reduce
the shrinkage and effect economy. They occupy 70-80 per cent of the volume and
have considerable influence on the properties of the concrete.

Sample weight= 1000 gm

Type: Fine aggregates
Number of sieves used= 7

Table 5.1: Observation table of Gradation Test for fine aggregates

290.40
Fineness modulus (FM) = = 2.90
100

The fineness modulus (F.M.) varies between 2.0 and 3.5 for fine
aggregate, between 5.5 and 8.0 for coarse aggregate, and from (3.5 to 6.5) for all-in
aggregate. The object of finding F.M. is to grade the given aggregate for the required
strength and workability of concrete mix with minimum cement. Higher F.M.
aggregate result in harsh concrete mixes and lower F.M. result in uneconomical
concrete mixes.

35
Table 5.2: Mix Proportions according to I.S. Code

(118 gm ∗ 100)
Weight retained in pan= = 11.8 gm
1000

Total number of sieves used= 7

𝑫
Cu = 𝑫𝟔𝟎= Uniformity co − efficient
𝟏𝟎

Uniformity co-efficient= Cu
1.𝐃𝟏𝟎 : 10% of the particles are finer than this size = 6 mm
2.𝐃𝟔𝟎 : 60% of the particles are finer than this size = 0.42 mm
3.𝐃𝟑𝟎 : 30% of the particles are finer than this size = 2 mm
Applying formula:

𝑫𝟑𝟎 𝟐
𝑫𝐮 =
𝑫𝟏𝟎 ∗ 𝑫𝟔𝟎
2∗2
𝐷𝑢 = = 1.587 mm
0.42∗6

Ideal size according to Indian Standard Classification of soil:

1.Gravel (10 mm – 2 mm)
2.Sand (2 mm – 0.50 mm)
3.Silt (0.50 mm – 0.002 mm)
4.Clay (0.002 mm – 0.001 mm)

Result: Hence, the texture found of soil is sandy. The type of aggregates that should
be used for making a cement paste should be angular, as they have better adhesive
properties due to sharp edges. Round aggregates should be avoided.

36
 Figure 5.1: Graph showing the relationship between particle size
and percentage by weight

5.2. Sieve Analysis of Coarse Aggregates

Sieve analysis is conducted to classify soil into sands, silts, and clays. Sieves are used
to separate soil particles and group them based on their size. This test is used for the
purpose of classification of soil in general.
Any particle greater than a no. 4 sieve is considered to be gravel.
Sands are defined as falling in the range of no. 4 to no. 200 sieves. Silts and clays are
particles smaller than no. 200 sieve.
Weight of the sample taken= 1000 g

Figure 5.2: Textural classification of soil

37
The soil is sand gravel, according to I.S. Classification, as maximum weight retained
on Sieve No. 10 is 99.7%

Table 5.3: Observation Table for Sieve Analysis of Coarse Aggregates

Figure 5.3: Sieves

5.3. Slump Test

This test is done according to IS code 1199 (1959).
The slump in the range of 50 mm to 100 mm has medium workability whereas the
slump in the range of (75 mm to 100 mm) has high workability. According to IS
456:2000, M15 lies in the group of Ordinary Concrete and M30 lies in the group of
Standard Concrete. M30 concrete is used for severe conditions. The maximum water
kg
to cement ratio should be 0.45 and maximum cement content in should be 320
m3
for M30.
If there is less water than 0.4 (ratio of cement and water), honeycombing of structure
occurs. Honeycombing is also caused due to poor compaction of concrete mix.

38
The recommended slump values are:
1.Heavily reinforced structures: 75- 100 mm
2.Lightly reinforced structure: 25-75 mm

Table 5.4: Slump Test values

5.4. Compression Cube Test

One of the important property of concrete in hardened state is ‘Compression
strength’. The compressive strength of concrete is given in terms of the characteristic
compressive strength of 150 mm size cubes tested at 28 days. The characteristic
strength is defined as the strength of the concrete below which not more than 5% of
the test results are expected to fall.
For casting the cement concrete cubes, measure the dry proportions of the ingredients
as per the design requirements. As per the Indian Standards Code book 456: 2000
the proportions are (1:0.5:0.66).
For testing the compressive strength, the cube is simply placed in the loading unit.
The compression testing equipment used was manual in nature with a lever arm
pulley to impose load on the cubes. Its market price is 50,000 INR and is cheaper
according to automatic compression testing machine worth 1,00,000 INR. The
maximum weight at which the specimen breaks is taken as the compressive load.

Figure 5.4: Compression Testing Machine

39
 𝐌𝐚𝐱 𝐜𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐯𝐞 𝐥𝐨𝐚𝐝/𝐀𝐫𝐞𝐚 𝐨𝐟 𝐜𝐮𝐛𝐞
Compressive Strength =
𝐀𝐫𝐞𝐚 𝐨𝐟 𝐜𝐮𝐛𝐞

Cross−sectional area of cube: (150*150) mm2

Date of casting: 24th February, 2018
Date of reading: 25th March, 2018
1 kg= 9.81 N

After 7 days, 65% strength is occupied by the cube and after 28 days the strength
occupied by the concrete is 100%
Hence, the strength of cube of concrete of grade M25, after 28 days is 32 MPa
which is above the characteristic strength. Hence, the concrete cube casted is of
good strength.

Table 5.5: Observation table of Compression Cube Test

40
 Chapter-6
SUMMARY AND CONCLUSIONS

This Tunnel is being constructed to ease out traffic congestion especially in cities and
is called as transportation tunnel. For transportation tunnel we need proper alignment
and size. The size and depends on the size of the natural obstacle. In hilly areas, less
number of tunnels are required to pass through the hills. In railway transport tunnels
are required as there are smooth bends but in road there are sharp hairpin turns.
Tunnel construction is governed by the ground and hence site investigation is vital
to obtain ground characteristics and geotechnical parameters. Knowledge of the
ground conditions plays a key role in the choice of construction technique, and hence
the success of a tunnel project. The money available to spend on site investigation is
usually between 1 to 3% of the total tunneling project costs.
1. The Slump Test determines the workability of concrete. Since we obtained true
slump of value 60 mm, which is the ideal slump shape for the experiment, the quality
of concrete in terms of workability is good. The quality is determined by proper use
of mix proportions of the mix design.
2. Compression Cube Test helps determine the strength the concrete cement after it
sets after a period of 7 days and 28 days. Concrete compressive strength for general
construction is 15 MPa - 30 MPa and higher in commercial and industrial structures.
The average reading of the test came out to be 33.36 MPa. Hence, the quality of
concrete in terms of strength is good.
3. Sieve Analysis of Coarse Aggregate helps determine the particle size distribution
of a granular material. The soil is coarse sand based upon grain-size according to
Textural Classification, as maximum sand particles move through Sieve No 10
(98.99%). 4. Estimation of Retaining wall gave a rough idea of expenditure in the
material used in the project specifically cement bags and steel bars. Hence, valuation
became easier.
4.Gradation Test of Fine Aggregates determines the texture of the soil which is
found to be sandy. The type of aggregates that should be used for making a cement
paste should be angular, as they have better adhesive properties due to sharp edges.
Round aggregates should be avoided. Gradation test helps determine the location
from where the soil should be selected for mix design.

41
 Chapter 7
FUTURE SCOPE AND LIMITATIONS
The city of Dehradun is planning to construct a new road around the city. The current
planning phase of the project includes study of the road tunnels for shorter route near
Dat Kali temple at Km 33-34.
The total cost of the tunnel is 57 crores. The time scale of the project is 2 years from
17th May, 2017 to 19th May, 2019. The traditional view is that the more one pays
for site investigation the more likely one is to reduce additional costs resulting from
unforeseen circumstances.
Tunnel Boring Machine was opted out from being used in this project and instead
Hydraulic Impact Breaker was used as:
1. The minimum height of the tunnel for excavation should be 7.5 m to use this
equipment.
2. Since the budget was low as compared to other government projects. The cost of
one TBM is 200 crore and the length is 550 m. Since, the tunnel design length is 340
m using TBM is not practically feasible.
They were equally effective in the project, with the only setback being that this
equipment was time consuming in nature. Though plenty of time is saved on
assembling of Hydraulic Impact breaker, the overall time in the excavation process
was more.
Since the soil had some significant amount of water content in it, but it was sandy in
consistency, blasting was prohibited as it is generally used for hard strata. This
prevented the loose rock mass from collapsing immediately and being beyond
engineering limits.

42
REFERENCES

Reference / Hand Books

[1] Patrick X. W. Zou; Riaz Yosia Sunindijo, “Strategic Safety Management in

Construction and Engineering,” Wiley Black, 2015, ISBN: 9781118839379
[2] S.C. Sharma, “Construction, Engineering & Management of Projects [For
Infrastructure and Civil Works],” Khanna Publishers, 2008, ISBN: 9788174092722
[3] H.W. Chung “Understanding Quality Assurance in Construction,” E & F.N.
Spon, ISBN: 0-419-2495
[4] Applied Geotechnics, “Introduction to Tunnel Construction,” Spon Press,
Volume 3, ISBN 0-203-89515-0
[5] Hemphill, Gary B. “Practical Tunnel Construction,” John Wiley & Sons, ISBN
978-1-118-33000-5
[6] Douglas D. Gransberg, “Construction Equipment Management for Engineers,
Estimators and Owners,” Taylor & Francis.
[7] Dr. B.C. Punmia, Er. Ashok K. Jain, Dr. Arun K. Jain, “Soil Mechanics and
Foundations,” Lakshmi Publications, ISBN 81-7008-791-0

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ANNEXURES
1. Proposed drawing

44
2. Proposed alignment of the Datkali Tunnel

3. AutoCAD Structural Drawing of Tunnel Portal

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