Hello Friends Myself SHUBHAM RANA . I am pursuing B.Tech in Civil Engineering from IIT ROORKEE. This is the glimpse of my work and basic aspects which I learned while doing my Internship in Larsen and Toubro Heavy Civil Infra IC. Thank You :)

1. Summer Internship presentation
4/5/2015 – 13/6/2015
By : SHUBHAM RANA
12113104

2. Proposed Project
Lucknow Metro LKCC 01
Lucknow , Uttar Pradesh
Phase 1 Priority Corridor “Chaudhary Charan Singh
Airport to Charbagh Railway Station”
Total Stretch 8.5 Km

4. PROJECT DETAILS
 PROJECT - LUCKNOW METRO
 CLIENT -LUCKNOW METRO RAIL
CORPORATION
 CONSULTANT - SYSTRA MVA Consulting (I)
Pvt Ltd.
 CONTRACTOR–L&T CONSTRUCTION ,
HEAVY CIVIL INFRA IC
 TYPE OF CONTRACT – LUMPSUM
CONTRACT
 PROJECT COST - 4992 Crores
 CONSTRUCTION PERIOD = September
2014 – December 2016
 PROJECT COMPONENT–
Pre Cast Yard
U Girders
Beams
Piers
Pier Cap
Piles
Pile Cap
 PROJECT LOCATION –Near Domestic
Airport , Lucknow.

6. Salient Features
 Width of gauge : Standard (1435 mm)
 Axle Load: To be designed for 16T
 Max Acceleration: 1.0 m/s2 to 1.1 m/s2 ± 5%
 Max Deceleration: 1.1 m/s2 (Normal Brake)
>1.3m/s2 (Emergency Brake)
 Maximum Design Speed: 80 kmph
 Maximum Schedule Speed: 34 kmph

7. Why Metro ? Why is it needed ?
 It will provide speedy mass transport for the people
of Lucknow.
 Helps in reducing a traffic congestion on city roads.
 A better means of connectivity from Airport to
Railway Station for passengers travelling to and fro.

8. VARIOUS ASPECTS OF THE PROJECT
 ALLIGNMENT : Super elevation on curves is applied to counter the effect of
lateral force felt by passengers.
 CIRCULAR CURVES : The minimum length of the circular curves should not be
less than 25 m in order to accommodate full length of coach.
 VERTICAL CURVES : Vertical curves are to be provided when change in gradient
exceeds 0.4%
 TRACK : From considerations of maintainability, the complete track is proposed
to be joint-less and is made of LWR/CWR rails.
 RAIL SECTION : Keeping in view the proposed axle load , it is proposed to
adopt UIC-60 (60 kg. /m) rail section.

9. PRE – CAST YARD

10.  Pre Cast is Basically situated in the outskirts of City Region .
 This is a confined place where all the concrete Superstructure components for
this project are been casted here.
 Casting yard stores all the made units prior to erection in viaduct .
 It also contains a Fabrication and Scrap Yard Unit , Batching Plants , Storage of
Aggregate Fine and Coarse and Prestressing Units.
 Precast yard serves an economical and quality control way of constructing
components and hence beneficial in projects where mass production is done.
 Yard is spread in 27 acres.
 Place is suited so as to provide less hindrance to traffic movement while
transporting transit mixer and to avoid other nuisance to the public.

12.  Cement used to Mix Design is of OPC 43 grade.
 Before casting any Structure at Site mix design has to go through several
tests.
 7 days Compressive Strength of 6 concrete cube is determined . Strength
should come accordingly specified by the consultant , If not then the
whole structure is discarded .
 Slump test is also conducted at the spot so as to determine the workability
of Concrete .If it comes less ,then desired proportions of admixtures are
added (plasticizers/water reducer).

13. COMPONENTS FOR THE SUPERSTRUCTURE
1) U – GIRDER

14.  This is a specially designed U shaped Girder which basically provides a
track for the running of Metro Train .
 Design is maintained in a such a shape so as to provide an Aesthetic
attractiveness , Flexible shape to modify, A very Robust Cross Section.
 Twin U Girders are placed parallel to each other for the whole length of
Track , One for upgoing Train and other downgoing Train. Total of 478
U Girder are Required .

15. SPECIFICATION :
Length = 27000 mm Concrete Grade = M 55
Breadth = 5050 mm Concrete Quantity = 57m3
Height = 1870 mm Reinforcement = 10.076 MT
Dimension of Bars : 12 mm and 16 mm

16. Cleaning of Formworks
using Buffing Machine
Placing of Bars In Reinforcement Jigs

18.  Prestressing Strands are Introduced into
the U Girder from one end of the structure
to the other .
 Hoyer or Long Line Method is adopted , at
a time 6 U Girders are Prestressed
Simultaneously .
 For Prestressing work, low relaxation high
tensile steel strands conforming to
(IS:14268) 7 Ply Strands of 15.2 mm are
drawn through the Structure. Total Strands
72.
 Breaking Strength of each Strand 260.7 KN
conforming to IS :14268 - 1970.

19.  After Providing Cables , Prestressing
strands are fixed against the abutment at
one side and at the other side it is fixed
to the Prestressing Jacks.
 6 Prestressing Jacks , with each jacks
connected to 12 strands are stretched to
provide required Prestressing before the
Concreting is being done .
 After Prestressing , strands are anchored
at both ends to restrain the prestress.

20. Concreting

21. Curing is done for around 7 Days in
Formwork itself by using Gunny Bags, so as
to maintain required moisture throughout
the day. After 7 days it is being transported by using
cranes and stacked above another U Girder
And cured for another 7 days.

22. Final Step of giving finish and checking tyre pressure before
transporting it through Trailors.

23. 2) Pier Cap
 The Upper or Bearing part of Bridge or Viaduct , Usually made of Concrete or
Hard Stone , which is designed to distribute concentrated loads evenly over
the area of the pier.
 No. Of Pier Caps Constructed for the project are around 230.

25. SPECIFICATIONS
 Length: 9200 mm
 Breadth : 2800 mm
 Height : 2000 mm
 Diameter of Bars : 16
and 25mm
 Concrete Grade : M 45
 Concrete Quantity: 27.3 m3
 Reinforcement: 3.491 MT

28. Pier Cap Installation

29. 3) Beams
 A beam is a structural element that is capable of withstanding load
primarily by resisting bending.
 For the purpose of this project beams are made to be placed before placing
of slabs for Stations and also I Shaped Girder are casted, which are used in
some places instead of U Girder because of Uneven span and curvilinear
portion .
 Beams of different dimensions are casted depending upon the requirement
as per drawing. Length of single beam varies from 10 m to 16 m.

31. SPECIFICATIONS :
 Length : 10 m to 16 m
 Breadth : 1000mm
 Height : 1000mm
 Bar Dimensions : 32mm in longitudinal
and 25 mm in Transverse.
 Concrete Grade : M 40
 Concrete Quantity: 16 to 20 m3
 Reinforcement :2.5 to 3 MT

36. VIADUCT

37. GEOTECHNICAL INVESTIGATION
 Geotechnical investigations have been carried out along the
proposed alignments to determine the strata, depth of foundation and safe
bearing capacity of foundations required.
 Subsurface explorations were carried out, 30m bore holes were done at
every 500m at the proposed corridor .
 Water level was found at a varying depth of about 18 to 27 m that to only in
some boreholes only.
 The subsoil strata at proposed site is generally homogeneous and comprises
of :
Silty Sand /Sandy Silt of Low Plasticity and (Classification as per
Clayey Silt of Low Plasticity IS 1498-1970)

38. PILES
 A pile is a vertical structural
element of a deep foundation,
driven deep into the ground at
the building site.
 Cast in situ bored Pile are made
below the ground level to
support all the structures above
the ground .

39. SPECIFICATIONS :
 Length of Pile = 30m deep below
ground level
 Diameter Of Pile = 1200 mm
 Capacity of one Pile (Design
Load) =400 MT
 Ultimate Load =1000 MT
 Concrete Grade = M 40
 Clear Cover to Any Reinforcement
in Pile = 75 mm
 Quantity of Concrete in one Pile =
36 m3
Reinforcement :
Circular bars = Outer one 16 mm dia. and Spacer bar 25 mm dia.
Longitudinal Bar = 8 mm – 16 mm dia. Bars

40. Construction Methodology of Piles
PREBORING
 It is suggested that all utilities such as
(cables, pipelines ,gaslines ,
sewerlines) falling within excavation
area are diverted away in advance to
avoid damage to such utilities during
the excavation/ construction phase.
 Initial hard strata of the ground is cut
by a “Drilling Bucket” , which is a box
like structure attached to Rig
machine and has a sharp toothed like
structure below it .

41.  Then a temporary Mild Steel casing for about 4 to 6 m (approx) length
from the ground level will be driven to protect loose soil from falling
in the bore hole.
 Then a Polymer Powder is added to form a slurry which provides a
clear, solid-free, viscous borehole stabilizing fluid till the excavation is
done for the piles. Polymer Slurry has a pH of 11 to 12, Specific
Gravity of 1-1.04 and Viscosity 65 to 140.
 After drilling borehole, reinforcement cage (with sonic tubes of
50mm dia. and 2.9 mm thick attached to the inner rebar cage)is
lowered into it . While lowering the cage care has to be taken to
install it in gap of 10 m and fillet weld of 6mm is to be provided to
join upper end of previous cage with lower end of cage to be
lowered.

42. Sonic Tubes

43.  After cage lowering , Tremie Pipe
generally of diameter 200mm
and 2-3 m length are lowered
one by one and tied to each
other . The gap between the
bottom of the bore to the end of
tremie pipe will be min 300mm.
 Upper end of the tremie pipe is
connecter to funnel shaped
“Hopper” , to which concrete mix
is poured .

45.  As the Concreting Proceeds Concrete mix being denser replaces the Polymer slurry and
slurry comes out of the borehole and is diverted away from the hole.
 A very high Slump Concrete 150 – 200 mm is needed for piling ,regular compaction to be
provided by Hydraulic Drilling Machine so as to ensure proper lowering of concrete .
 After Few days of setting sonic tubes are filled with water and then in one tube ultrasonic
wave emitter probe and in other receiver probes are inserted, knowing the distance
between the two tubes , Relative energy, waveform and differential time are recorded and
mapped. This is called “Cross Hole Sonic Logging”.
 This gives qualitative idea of the structural soundness of the concrete throughout the pile
and hence structural integrity of pile can be verified by this method.

46. PILE CAP
 A pile cap is a thick concrete mat that rests on concrete or timber
piles that have been driven into soft or unstable ground to provide
a suitable stable foundation.
 It usually forms part of the foundation of a piers and above
superstructure and support base for heavy equipment.
 Pile cap is constructed over Piles after they acquire the desired
strength , Pile cut off level extends to about 75 mm in the Pile Cap
as per the drawing of the site.

47. SPECIFICATIONS :
 Generally for 4 Piles Dimension of Pile Cap is 5300mm x 5300 mm
For 6 piles 5300 x 8900 mm
For 8 piles 5300 x 12500 mm
 Height of Pile Cap 1800 mm
 Clear cover to Reinforcement 75 mm
 Concrete Grade : M 40
Pile Cap Concrete Volume : pile cap with 4 piles 50.5 m3.
For pile cap with 6 piles 85 m3 and so on.
Reinforcement :
 Top Reinforcement : 16 mm dia. bars on both axis
 Bottom Reinforcement : 32 & 25 mm dia. bars.
 Stirrups : 12 mm Dia.

49. • ,

50.  Pile Cap Cut off level should be at least 500mm below ground level .
 After Concreting and few days of curing , Over Pile cap a layer of PCC
(Plain Cement Concrete) of 75 mm height is laid , having Compressive
Strength of M 15. PCC provides even surface for Pier formation.
 After 7 days of continuous curing Pier construction activities are
started.

51. PIER
 A pier is a raised structure typically supported by well-spaced piles or
pillars.
 Pier casted at the viaduct starts from the 0.5 m below the ground level.
 Piers are made of varying height giving a slope of about 0.3 for
effective flow of Rainwater . Height varies as per the drawing.
 Through the piers a 15cm diameter drainage pipe HDPE is inserted to
reach to the ground.

53. SPECIFICATIONS :
 Diameter = 1700 mm
 Height = 12 m average
 Concrete Grade for Pier = M 45 to M 60
as per drawing .
 Clear Cover = 50 mm
Reinforcement :
 Outer Circular Bar 16 mm dia.
 Spacer Bar = 32 mm
 Longitudinal Bar = 20 mm - 32 mm depending upon drawings.
 Starter Bar should start from atleast 300 mm from edge of pier.

56. CRASH BARRIER
 To prevent Pier from wear and Tear due to Crashing of vehicles, a
protective Concrete Structure is made around Pier to a height of about
1.5 m from ground level.
 It works as a shock absorber and protect pier from Road Accidents.
 It has a dimension of 2200 mm diameter.
 Concrete Grade = M 30
 Clear Cover = 40mm
 Gap between the Pier and Crash Barrier boundary is around 250 mm.

58. BATCHING PLANT
 It is a machine that combines various ingredients to form concrete.
Some of these inputs include sand, water, aggregate (rocks, gravel,
etc.), fly ash, potash, and cement.
 At this site there were 2 Batching Plants.
 CP 30 = which generates 30m3 of concrete in 1hour.
 CP 60 = which generates 60m3 of concrete in 1 hour.

60. TRANSIT MIXER
 Special concrete transport trucks (in–transit mixers) are made to transport and
mix concrete up to the construction site.
 One Transit Mixer has the capacity of loading 6m3 of Concrete at a time to the
site.
 The concrete mixing transport truck maintains the material's liquid state
through agitation, or turning of the drum, until delivery.

62. BOOM PLACER
A concrete pump is a machine used for transferring liquid concrete by pumping.
It is known as a trailer-mounted boom concrete pump because it uses a remote
controlled articulating robotic arm (called a boom) to place concrete accurate.

64. GANTRY
 Gantry cranes are a type of crane built atop a gantry, which is a structure used
to straddle an object or workspace.
 These Gantry cranes run over the rail track which are laid in the precast yard.
 At the project location they were 4 in Nos. with 3 having capacity of 100 MT
for lifting (U-Girders, Pier Cap , Beam , I-Girder), while 1 is of 25 MT for ( Steel
Yard).

66. Thank You