Construction Work DMRC

PRESENTATION ON SUMMER By-
INTERNSHIP IN DMRC Sayyed Rubeel Bin Ali Naqvi

13-BCE-0060
CONSTRUCTION OF ELEVATED STABLING LINE FOR
KALINDI KUNJ DEPOT CC-90
Under the guidance of

Prof. Kafeel Ahmed
Under the supervision of
Executive Engineer
Azharuddin
CONTENT
 OVERVIEW
 CASTING YARD
 ORGANISATION CHART
 CASTING OF I GIRDER
 BATCHING PLANT
 REINFORCEMENT
 QUALITY CONTROL
 CONSTRUCTION OF PIER
 CONSTRUCTION OF DECK SLAB
 LAUNCHING
 MACHINES USED
 SAFETY
OVERVIEW OF CC-90
STABLING YARD
• Length of Stabling Yard – 1.3 km
• Located just near Kalindi Kunj Depot
where DMRC was facing space
constraints
• First of its kind elevated stabling deck
• 30 to 40m wide and 15m above
ground
• Capacity – 27 trains
CASTING YARD
• 3 Types of beams were casted
1. Longitudinal I girder
2. Secondary I girder
3. Transverse beam
• On an average, 10 sections casted

everyday.
• Maximum length of 15m sections can

be casted.
ORGANISATION HEIRARCHY
Project manager
QA/QC INCHARGE SECTION INCHARGE SAFETY MANAGER
QC ENGINEER SAFETY SUPERVISOR

SITE ENGINEER
LAB ASSISTANT SUPERVISOR

CASTING OF GIRDERS
• Bed is prepared for casting.
• Rebar cage is prepared and lifted up and

moved to casting bed using gantry crane.
• Buffing and oiling of shutter.
• Foam is provided at joints.

• Cover blocks are provided.
• M 50 concrete is poured by pump

or bucket.
• Shutters removed after one day.
• Curing for continuous atleast

14 days.
ILLUSTRATION OF CONCRETE PLACING IN
GIRDER MOULD WITH THE USE OF BUCKET
• CONCRETING TAKES USUALLY

10-15 MINUTES.
• COMPACTION IS ENSURED USING

NEEDLE VIBRATOR.
• SUPERVISOR’S PRESENCE IS MUST

AT THE TIME OF CONCRETING.
CONCRETE BATCHING PLANT
• AN EQUIPMENT THAT COMBINES VARIOUS INGREDIENTS TO FORM
CONCRETE. IT INTAKES WEIGHED AMOUNT OF SAND, GRAVELS,
CEMENT AND WATER.
• M10- M60 CONCRETES CAN BE PREPARED.
• 5 SILOS ARE PROVIDED FOR CEMENT IN

WHICH OPC IS FILLED.
• COMPUTER ORIENTED SYSTEM.
RECIPE MASTER
SCREEN
COARSE AGGREGATE AT CASTING YARD
CEMENT SILOS
TRANSIT MIXER
• 6 cubic metre capacity
• Slump test carried out at plant as

well as site.
• Reaches to CC 90 within 1 hour.

REINFORCEMENT
• Fe500 confirming to IS 1786 is used.
Reinforcement checklist-
• Correct bar sizes

• Correct bar spacig
• Covers checked
• Specified bar ties
• Correct lap length
• Bar bending schedule approved
QUALITY CONTROL
LAB TESTS
TESTS ON CEMENT
1. FINENESS TEST
• Cement is passed through 90 micron sieve.
• Percentage retained should be less than 10%.
• Average of three readings is taken.
2. INITIAL SETTING TIME
• Take 400g cement.

• Water conten taken 85% of consistency limit.
• Mix it for 5 minutes.
• Should not be less than 30 minutes.
3. FINAL SETTING TIME
• Should not be more than 10 hours.

• No impression of needle.
4. SOUNDNESS TEST
• 78% water of consistency limit used.
• Take 100g of cement sample.
• Le Chatelier’s apparatus used.
• Gap must not increase more than 10mm

TESTS ON AGGREGATES
• Sieve analysis is carried out.
• Only two types of aggregates

are used in DMRC.
• Conducted in the morning.
• Source- Pathankot & Kotputli

AN ILLUSTRATION OF CARRIED OUT
SIEVE ANALYSIS AT CASTING YARD
TESTS ON CONCRETE
1.Slump test
2.Cube testing
• 150 by 150 by 150mm cubes

• 6 cubes casted per cubic metre of concrete
• Loading rate- 14kN/sq.mm per sec
CONSTRUCTION OF PIER AND PIER CAP
• Layout of pier with the help of established

reference points.
• Fe500D is used.
• Rebar is fixed manually as approved by BBS.
• Temporary staging and working

platforms provided.
• Shuttering fabricated at pier location.
• Cover blocks checked.
• Slump checked at pouring location.
• M 40 concrete poured using boom

placer or concrete pump.
• Concrete compacted using needle vibrators.

• Concrete pouring is to be done in two stages
for peir height more than 6m.
• Deshuttering after 24 hours of concreting.
• Curing carried out for 14 days using water pump.
• Hessian cloth to sustain moisture.

CASTING OF INSITU DECK SLAB
• Stitch beam
• Deck sheet placed between

longitudinal beams.
• Reinforcement fixing carried out

confirming to IS:2502.
• Proper buffing and oiling of shutter.
• Fixing of cover block by GI wire.

• Rubber/ foam provided at shuttering joints.
• M 35 concrete poured by concrete pump.
• Curing using wet hessian cloth for 14 days.
• Deck sheet may not be removed.
SHUTTERING DECK SHEET

LAUNCHING OF I GIRDERS
• 10-15 minutes process.
• 10mm error allowed.
• Using prestressed 25mm diameter cables.
• Each cable’s capacity- 20 tonnes
• Levelled ground.
AN ILLUSTRATION OF GIRDER LAUNCHING AT CC 90 STABLING YARD
MACHINES USED
CRAWLER CRANE
• Working capacity 187 tonnes
• Boom length 120 ft
• Counter weight 90 tonnes
GROOVE CRANE
Maximum capacity
60 tonnes
 TRUCK TRAILER
Capacity- 40 Tonnes
One more crane is deployed.
 MAN LIFT CRANE

• To be used by engineers
and technicians.
• For miscellaneous activities.
SAFETY CONSIDERATIONS
POTENTIAL RISKS AT SITE
 Binding wire may cut hand.

 Shutter may topple or fall and hit the person.
 Wire may slip from stressing jack.
 Lifting hook or wire may fail.
 EOT may hit workers.
 EOT wheel may off track.
 Sudden fall of rebar cage or shutter.
 Fall of worker from scaffolding.
WORKING AT HEIGHT
PRECAUTIONS
 Area below barricaded.
 Safety net should be provided.
 Proper ladder and handrails should be provided
 Anchoring of body harness to nearby handrails.

THANKING YOU….

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PRESENTATION ON SUMMER By-

INTERNSHIP IN DMRC Sayyed Rubeel Bin Ali Naqvi

Under the guidance of

• On an average, 10 sections casted

• Maximum length of 15m sections can

QA/QC INCHARGE SECTION INCHARGE SAFETY MANAGER

QC ENGINEER SAFETY SUPERVISOR

LAB ASSISTANT SUPERVISOR

• Rebar cage is prepared and lifted up and

• Buffing and oiling of shutter.

• Foam is provided at joints.

• M 50 concrete is poured by pump

• Shutters removed after one day.

• Curing for continuous atleast

• CONCRETING TAKES USUALLY

• COMPACTION IS ENSURED USING

• SUPERVISOR’S PRESENCE IS MUST

• 5 SILOS ARE PROVIDED FOR CEMENT IN

• COMPUTER ORIENTED SYSTEM.

• 6 cubic metre capacity

• Slump test carried out at plant as

• Reaches to CC 90 within 1 hour.

• Correct bar sizes

• Take 400g cement.

3. FINAL SETTING TIME

• Should not be more than 10 hours.

• 78% water of consistency limit used.

• Take 100g of cement sample.

• Le Chatelier’s apparatus used.

• Gap must not increase more than 10mm

• Only two types of aggregates

• Conducted in the morning.

• Source- Pathankot & Kotputli

• 150 by 150 by 150mm cubes

• Layout of pier with the help of established

• Rebar is fixed manually as approved by BBS.

• Temporary staging and working

• Cover blocks checked.

• Slump checked at pouring location.

• M 40 concrete poured using boom

• Concrete compacted using needle vibrators.

• Deshuttering after 24 hours of concreting.

• Curing carried out for 14 days using water pump.

• Hessian cloth to sustain moisture.

• Deck sheet placed between

• Reinforcement fixing carried out

• Proper buffing and oiling of shutter.

• Fixing of cover block by GI wire.

• M 35 concrete poured by concrete pump.

• Curing using wet hessian cloth for 14 days.

• Deck sheet may not be removed.

SHUTTERING DECK SHEET

• 10mm error allowed.

• Using prestressed 25mm diameter cables.

• Each cable’s capacity- 20 tonnes

One more crane is deployed.

 MAN LIFT CRANE

 Binding wire may cut hand.