MUMBAI MONORAIL PROJECT

MUMBAI MONORAIL PROJECT

CONTENTS

Back Ground and History Introduction to Monorail Piling Work Reinforcement and Preparation of BBS Work Methodology of Concrete Production, Transportation, Placing and Curing

Block Work, Plastering, Floor and Wall Cladding

Casting yard
Methodology of Structural roofing.
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THE BACKGROUND

Considering the increase in population, increased travel demand and narrow road networks running through congested structures, there is a need of a system which will occupy less

space as well as reduce travel time.

Mono Rail system is proposed to be implemented by

MMRDA. It is supposed to carry close to 15000

PPHPD(passenger per hour per direction).
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HISTORY

Vilasrao Deshmukh, cleared the notification for construction of the first monorail system in India on August 13, 2008.

The two shortlisted consortia to build the line were Reliance Energy in association with Hitachi Monorail, and Larsen and Toubro with Scomi Rail of Malaysia.

On November 11, 2008, the winner was announced to be Larsen and Toubro along with Scomi, who received a INR 2460 crore contract to build and operate the monorail
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INTRODUCTION

Monorail is a single rail serving as a track

for

passenger or freight vehicles. Mostly elevated, monorails can also run at high curves and gradients or subway tunnels. This is first monorail project in

Mumbai , India.
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ADVANTAGES

The primary advantage of monorails over conventional rail systems is that they require minimal space. They are quieter, as modern monorails use rubber wheels on a concrete track. Whether they are of the straddle-beam or suspended variety, the nature of their design does not allow derailment. As monorail is elevated, accidents with surface traffic are impossible Monorail does not obstruct much sunlight Minimum use of land and save cost Less disruptive to road traffic Pre casting allows more off-site construction Add aesthetics to the city due to greenery along the road and appearance

DISADVANTAGES OF MONORAILS
Monorails have constraint of load carrying capacity as compared to other transit systems because they employ rubber tires instead of steel.

Maintenance cost are comparatively high.

SALIENT FEATURES OF MONORAIL

Client: MMRDA PMC: Louis Berger Group Inc. Contractor: L&T Scomi Engineering. Consortium Turnkey Built and Contract 3 years- Operation and Maintenance Date of Commencement: 14th November, 2008 No of stations: 17 numbers Depot: 1 number Journey time: 37min No of cars: 4 Passenger carrying capacity: 568 per train Average speed: 31 kmph Max speed: 80 kmph

Total alignment length: 19.2 km

Total alignment length- 19.2km

PILING WORK

Due to soft rock available at Bhakti Park between 12 to 20 m Pile is basically BORED CAST-IN-SITU PILES (Friction piles).

MATERIALS USED
a)

Reinforcement: Reinforcement steel shall be Fe500 deformed

bars .For properties and making cages.

b) c)

Concrete: Concrete shall be M35 grade.

MACHINE USED: HR-180 ROTARY DRILLING MACHINE

having Power 180hp
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HYDRAULIC RIG-180
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PROCEDURE
1.

Firstly Surveyor with the help of Total Stations gives centre point with the help of Northing and Easting bearings as per

Drawing and then gives two reference points 500mm apart from
the edge.
2.

The location of pile shall be marked on the ground using 6 to

8mm diameter steel rods of 150mm long.

3. 4.

The impression of boring tool shall be made Drilling shall start immediately and bore shall reach the required depth as shown in the drawings
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5) A Liner of inner diameter equal to the pile diameter, made of Mild

Steel of 12 to 16mm thick shall be pressed/driven in to the bore using the lifting and driving arrangements available in the rotary rig 6)The material inside the liner shall be removed using the attachment such as Various AUGERs or BUCKET tool available with the 13 rotary rig.

7) The Verticality of Drilling / bore shall be checked periodically with the help of SPIRIT LEVEL (vertical, horizontal, inclined 45 degree).
8) Sounding test is done to check the depth is as per drawing. 9) Prefabricated Reinforcement Cage

Concrete Cover blocks giving cover of 40mm to the reinforcement Helical Reinforcement of diameter 8mm. Main reinforcement of diameter 12mm,16mm,20mm and 25mm Master Ring of diameter 12mm Lifting Hook of diameter 16mm

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SPECIAL CASE:

In case of collapsing cleaning is done with the help of Cleaning Bucket and LINER is taken out and welding is done (electric arc welding) up to soft level.

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10) Concreting done by TREMIE METHOD

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FIELD TESTS:
1) SLUMP TEST

2) Temperature Test 3) Sounding Chain Test

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BBS PREPARED FOR PILE CAGE

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BAR BENDING SCHEDULE

Dia(mm ) 20 25 No. per membe r 6 6 No. of membe r 1 1 Total no.s 6 6 Shape of bar Straight Straight Cutting length (m) 12 12 Total length (m) 72 72 Total weight (kg) 177.84 277.2

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12 12 16

1
8 8 2

1
1 1 1

1
8 8 2

Helix
Lap in helix Master ring Lifting hook

90.913
.480 1.264 .6

90.913
3.84 10.112 1.2

80.731
3.41 8.979 1.89
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REINFORCEMENT STEEL AND FORMWORK

For plain or reinforcement cement concrete or pre-stressed concrete, the reinforcement shall be grade Fe500 HYSD bars.

Use of stirrups mainly of 8mm Spacer bars or Chairs at approx. 1m intervals shall separate layers

of the reinforcement .

Use of Cover blocks .

Cover for Slab = 30mm

Cover for beams = 30mm Cover for columns =40mm

Use of screwed couplers and electric arc welding.

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Bars with cranks are provided in beams for overlapping and proper
cover.

Main Reinforcement HYSD 500 Bars For slabs = 8mm bars

For Beams 25mm and 32mm bars

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For columns = 40mm and 32mm bars

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ANTI-CORROSIVE TREATMENT TO REINFORCEMENT BY INHIBITOR CEMENT SLURRY COATING (CPCC)

3 steps:
a)
b)

Sand Blasting
Primer coating Seal coating

c)

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TOLERANCES:

Overall depth +- 10mm for depth<200mm and 15mm for depth>200mm

Cover to reinforcement Least of 1/3rd of specified cover

or 5mm

Centre-to-centre distance +- 10mm

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CONCRETE PRODUCTION

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SWING STETTER

Transportation of concrete: The concrete shall be supplied in continuously agitating transit mixers. Placing of concrete: The placing shall not commence until the reinforcement is tied properly, insert plates placed, the formwork is to the lines, shapes, and dimensions given in the approved drawings.
Placing Tremie concrete
Pumped Concrete Crane Bucket or Manual

Slump(mm) 175+-25
100-150 100+-25
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PLACING BY PUMP IN SLABS OF STATION BUILDINGS:

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COMPACTION:

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BLOCK WORK
Concrete Blocks: Precast solid cement concrete blocks should be from an approved source. Length tolerance = 5mm Width and Height tolerance = 3mm Density > 1800kg/m3 Compressive Strength > 5N/mm2 Water absorption < 10% by mass Cement: Ordinary Portland cement, 53 Grade Masonry Mortar: Grade of masonry mortar MM5 (1 Cement : 4 Sand)
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Laying of Block work Block wall thickness: 200mm and 100mm as per architectural drawings. Size of block for all inner walls = 390 x190 x 90 mm Size of block for all outer walls = 390 x140 x 190 mm

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PROPER RACKING

1) There should be proper hacking 2) There should be proper racking and proper horizontal and vertical leveling.
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Galvanized steel chicken wire mesh shall be used where masonry

face comes flush with a concrete beam or column face. The purpose is to avoid shrinkage cracks in the plaster.

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MULLIONS AND LINTELS

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PLASTERING OF WALLS:
Equipments:

Scaffolding

Mixing tray
Float, Trowel Plumb bob, Leveling tube

Materials:

Water Water confirming to IS: 456 shall be used and of one

source.

K-95 READYPLAST FIBER having Fibre reinforced Ready Mix plaster.

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AFTER PLASTERING OF WALLS

Internal plaster thickness- 12-15mm External plaster thickness- 20mm in two coats

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PLASTERING OF CEILING:

Plastering of ceiling is done with the BIRLA PUTTY.

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VITRIFIED TILE WALL CLADDING

Materials Vitrified Tiles - 600x600x8mm Adhesive - Laticrete 111Crete powder + Laticrete 73 latex admixture

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VITRIFIED TILE FLOORING

Material

Size: 600 x 600mm Thickness: 10mm Mixing Ratio: (1 Cement: 6 Sand)

Bedding Mortar thickness:

30-40mm

Jointing width: 2mm jointing

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PRECASTING YARD WORK SEQUENCE:

Rebar Yard Casting Yard Curing & Stressing Stacking Yard

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Vertical post act as a template to held the cage in position

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CPCC coated Fe 500 HYSD bars are used Bottom rebar tying Placing of sheathing for pre stressing cables

Top rebar tying

Placing of inserts for electrical work Cover of 50 mm to reinforcement using concrete cover blocks Main reinforcement is of two 16mm dia bars coupled together Horizontal stirrups are of 12mm and vertical stirrups of 16mm dia

Use of steel wire of dia 1.5mm to tie bars with each other

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ALIGNMENT OF SOFFIT

Alignment is done as per the points given by the surveyor

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with the help of spirit level and plumb bob

LIFTING OF CAGE

Use of TRUSS is to lift the cage One end of the Truss is attached with HOOKS which is further attached with cage and other end is attached with the GANTRY GIRDER Reinforcement cage which is initially straight is put on the soffit and with the help of two GANTRY GIRDERS Reinforcement is aligned according to soffit

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End Shutter is of Steel and certain Provisions are there Provision for development bars

Provision for sheathing

Provision for cables

Use of SPRING
Sheathing is attached to the cone

End Shutter is fixed

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CONCRETING BAY OR CASTING BAY:

Oiling of shuttering
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SHIFTING OF TROLLEY ON WHICH CAGE IS PLACED TO THE CONCRETING BAY:

TURN BUCKLES are used to align the shuttering

Final alignment is checked with the help of TOTAL STATION. If it is correct then Concreting is done
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CONCRETING IS DONE WITH THE HELP OF BOOM PLACER (PUMPED CONCRETE)

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TESTS PERFORMED

Temperature test Slum test Cube testing -12 cubes are casted and put it in water for

curing for 28days and are tested for7 days and 28 days

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During concreting

After casting
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CURING YARD
After 1 day shuttering is removed and trolley is moved to the Curing Yard for the curing purpose. MEMBRANE CURING

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FINISHING AND WATER PROOFING

Finishing is done with (1/2 acrylic base amrocrate solution + 1/2 cement -opc53)

This is done because so that surface becomes smooth and

outer water will not effect in the future. After Curing

Trolley is shifted to Pre-stressing Yard.

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STRESSING YARD

Firstly the Sheathing Ducts shall be cleaned using water

jet or blowing air

A 12-16 gauge GI wire (High tensile steel strands) have large diameter coils, so that Tendon retain its physical properties.
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At one end of GI wire the strands shall be clamped and

the other end of the GI wire shall be connected to a chain pulley block

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GROUTING OF CABLES/ DUCTS:

MIX:

The mix for grouting cables/ducts is OPC53 mixed with water to obtain water-cement ratio of not more than .45.

The mix shall be added with FLOW CABLE-50 OF BASF.

Grout shall be pumped into the duct

by means pump and allowed to flow freely from the outlet end until the consistency is same as that of inlet end.
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STACKING YARD

With the help of gantry girders having 75MT capacity beams lifted and stacked into the stacking yard
Beam shift Shift trolley along with soffit using gantry

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METHODOLOGY OF ROOFING STRUCTURE:

FIXING OF PIPES AND TEMPLATES

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FIXING OF 50MM THICK BASE PLATE AND BOLTS

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Painting of Structural steel column will be done and thickness is measured by ALCOMETER

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 Erection

of Column
Arc welding

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Erection of Main portal beam, secondary beam, purlin and bracings

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Thank you
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