Industrial Training/Visit Report 2013- 17

INDUSTRIAL TRAINING REPORT

AT

DELHI METRO RAIL CORPORATION LTD

ERNAKULAM

DONE BY: REYA GRACE JACOB

SCMS SCHOOL OF ENGINEERING AND TECHNOLOGY

KARUKUTTY

DURATION: 12-16 JANUARY 2016

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

CERTIFICATE

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

ACKNOWLEDGEMENT
I feel indented to Mr. G. Kesava Chandran, Chief Engineer, DMRC Kochi, for giving me an
opportunity to do internship.
I would also like to express my gratitude to Mr. M Madhavan (SSET Principal), Dr.Anitha G
Pillai (Head of Department, Civil) for granting me the permission for the training.
I also thank my family members and friends for their support.

REYA GRACE JACOB

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

1. CONSTRUCTION OF METRO SYSTEM AT KOCHI

1.1 Study area

Our proposed site is the metro station at Maharaja’s College, Ernakulam and casting yard at
Muttam, Kalamassery.

1.2 Aim of the project

The aim of the project is to study the structure of the Metro system.

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

2. INTRODUCTION
Kochi Metro is an under-construction metro system for the city of Kochi in Kerala, India. The
first phase is being set up at an estimated cost of ₹51.81 billion (US$800 million), A 13.4 km
section of the line from Aluva to Palarivattom will open in May 2017. A second 5 km section
from Palarivattom up to Maharaja's College will be made operational by August 2017.

Former Prime Minister Manmohan Singh laid the foundation stone for the project on 13
September 2012. Construction work on the Kochi Metro rail project began on 7 June
2013, with the piling works for the viaducts near Changampuzha Park, after an official launch
ceremony held at the Jawaharlal Nehru Stadium at 10:30am on the same day. At the
inauguration ceremony, the State Government announced that the metro would be extended a
kilometre-and-a-half from Pettah to Tripunithura, Construction work on metro's first station, at
Kaloor, began at 10:30am IST on 30 September 2013, when Soma Constructions began
piling. The next station were piling work was carried out was Aluva.

Several companies (Era Infra Engineering, Larsen & Toubro, and Soma Constructions) were
contracted to build viaducts and stations. Larsen and Toubro (L&T) was awarded the contract
to construct the viaduct and 6 stations on the Kalamassery-Stadium stretch in April 2013 at an
estimated cost of ₹4 billion (US$62 million).

The original cost of the Kochi Metro project was ₹51.46 billion (US$800 million), but this later
increased to ₹55.373 billion (US$860 million). Taxes on the project will come to about ₹2.373
billion (US$37 million) which will be borne by the Kerala Government along with any
escalations. JICA has agreed to offer loan at an interest rate of 1.50%. The total estimated cost
of land acquisition is ₹11.1 billion (US$170 million), higher than the ₹6.72
billion (US$100 million) estimated as per the original plan. The total external borrowing
requirement for the metro rail project is nearly ₹21.7 billion (US$340 million).

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

SITE DETAILS
KMRL has proposed an elevated route spanning 25.253 km (15.691 mi) from Aluva to Petta
with 23 stations. All platforms will be 70 metres (230 ft) long. There will be 17 sharp curves
along the route; the sharpest curve will have a radius of 120 metres (390 ft).

The Route Map of Proposed Phase 1 of Kochi Metro Rail Network

Construction Methodology: Elevated viaduct carried over pre-stressed concrete ‘U/I’ shaped
girders with pile / open foundations.

Elevated Viaduct

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

GEO TECHNICAL INVESTIGATIONS

A total of 51 bore holes have been drilled at an average distance of about 500 m each along the
corridor.

Geotechnical investigations were carried out along the corridor upto a depth varying from 13m
and 50m. Soil and rock samples were collected and tested in laboratory.

The soils in and around the Kochi City vary from lateritic soils on the Northern part to the
Marine clays on the Southern part of the city. From Kochi towards Alwaye, the lateritic soils
in the top layers changing to granitic rocks in the lower strata. Kochi being a city on the coast,
we have marine clays, loose to stiff in nature for greater depth with dense sand layers
underlying these clay layers. There are locations where this sand layer varies occurring from
40 – 60m.

For the elevated section 0.8m dia pile foundation is recommended. Bearing capacity is not
likely to cause any problem for the foundations.

GRADE OF CONCRETE

It is proposed to carry out construction work with design mix concrete through computerized
automatic Batching Plants with following grade of concrete for various members as per design
requirement/durability considerations.

i) Pile cap and open foundation - M -30

ii) Piers - M –40/M-50
iii) All pre-cast element for viaduct and station - M -45
iv) Cantilever piers and portals - M -45 - M -60
v) Other miscellaneous structure - M - 30
vi) For all the main structures, permeability test on concrete sample is recommended to
ensure impermeable concrete.

REINFORCEMENT AND PRE-STRESSED STEEL

It is proposed to use HYSD 415 or TMT steel as reinforcement bars.

For pre-stressing work, low relaxation high tensile steel strands with the configuration 12 T
13 and or 19 K 15 is recommended (confirming to IS:14268).

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

FOUNDATION
Based on available geotechnical reports, it is anticipated that all foundations will be piled
foundations.

Bored cast in-situ pile foundations are provided. Pile diameters are 1m, 1.2m and 1.5m.

Reinforcement details: length of steel bars used is 12m. Lapping length is 58D.

Center to center distance between piles is 3D. 50 cm of pile should be inside the pile cap.
100mm gap is provided between soil and cage to resist corrosion.

Pile Cap:

Rectangular and trapezoidal caps are provided.

PSC ( Portland slag cement) is used in piles.

Piling works
PIERS
The viaduct superstructure is typically supported on single cast in site RC pier. The shape of
the pier has be chosen to follow the flow of forces and both economy and aesthetics.

Cantilever piers and portal piers are also provided. Circular, rectangular and capsule type pier
are also provided.
To prevent the direct collision of vehicle to pier, a Jersey Shaped crash barrier of 1.0m height
above existing road level has been provided all around the pier. A gap of 25mm has been also
provided in between the crash barrier and outer face of pier

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

Circular Pier Portal Pier

PIER CAPS
It is the upper or bearing part of pier. They are precast pre-stressed members.
Types of pier caps used are:
i) Normal
ii) Transition
iii) Interchanging
iv) Cantilever
v) Portal
vi) Extended
If the span of the girder is restricted, the width of pier caps are increased. It is usually done at
junctions and where there is underground restrictions.
Above pier cap pedestals, wedge plates and bearings are provided. Wedge plates maintain the
slopes.

Cantilever Pier Cap Normal Pier Cap

GIRDERS
The superstructure of the viaduct comprises of simply supported precast pretensioned twin U
girders span.

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

U girders are lifted and placed over pier caps. When height of piers are more it is not safe to
raise the U girders using crane due to its heaviness. So I girders are provided. In I girders the
parapet and slabs are extra casted.

U girder casting cage I girgers

U girder
STATION
The stations contain two levels. Platform level and concourse level.

Railway track and platforms are provided at the platform level. Ticket counters and other
important offices are provided at concourse level.

An entry exit building which carries lifts, escalators, stairs, shops etc. are provided near to the
station.

The station carries concourse slab, track slabs and beams, longitudinal beams and transverse
beams.

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

Metro station

Entry exit building

Kochi metro train approaching Muttam yard

Department of Civil Engineering SSET

Industrial Training/Visit Report 2013- 17

CONCLUSION

Department of Civil Engineering SSET