GROUND ENGINEERING: TUNNEL SYSTEM
Construction of a Cross-Passage for a Twin
Tunnel System for Delhi Metro’s CC-27 Project
R.G. Saini1, Ishaan Uniyal2
Project Director, DMRC,L&T-SUCG JV CC-27, New Delhi, India
1
Student, Dept. of Civil Engineering, Thapar University, Punjab, India
2
Abstract: In this paper, construction of cross-passage for a twin CP-12, CP-13, CP-14 and CP-15 are being constructed be-
tunnel system has been discussed along with problem encoun- tween the two stations with average gap of 400m between
tered and solution adopted, by using a case history of cross pas- the cross passages. Soil type found in this region is called
sage in R.K Puram Station, being constructed by L&T-SUCG JV for ‘Delhi Silt’which contains silt and sand in varying proportions
CC27 of Delhi Metro. Work for the cross-passage commenced from 35% to 80%. It is lightly compacted, has only an insig-
after the completion of the twin tunnel on account of ease and nificant proportion of clay and is largely non-plastic although
efficiency. Method employed for construction of the cross-pas- its behavior is transitional. Absence of rocks and stones
sage and specifications of materials used have been reported in lends this soil easily to efficient utilization of Okumura TBM.
this paper. The paper also reports a solution adopted for mitiga- Construction of the cross-passages is taken up only after
tion of a major problem of water-logging encountered during the completion of the tunnels on account of ease of working and
construction. Approach adopted to address the problem has also efficiency. Following steps were followed for construction of
been reported in the paper. Efficacy of the procedure utilized and CP-15, the cross passage under study:-
applicable conditions for same along with possible contributing
factors have been also indicated. (i) Marking up of the survey lines (for excavation purpose)
with the help of total station.
Introduction (ii) Ring girder erection, which consisted of I-sections being
fixed in the form of a polygon.
Cross-passages are reinforced concrete structures built
in between either two tunnels (as in case of twin tunnel sys- (iii) Packing of the ring girder with wooden wedges so as to
tems) or a tunnel and the ground surface. They are provided fill the void spaces between the tunnel segment and the
to serve two primary purposes namely, emergency escape ring members thereby increasing the contact area and
and maintenance work. In this paper, design, construction thus the overall strength of the system.
methodology and problem encountered during construction (iv) Core cutting with the help of a 150mm diameter core cutter.
of one such structure has been described by analyzing case (v) Excavation work is carried out after core cutting. In the
of a cross-passage being constructed by L&T-SUCG JV for course of excavation, structural steel member ISMB 125
twin tunnels between R.K Puram and Munirka underground or ISMB 150, as per the design considerations, is placed
stations for project CC27 of ‘Delhi MRTS Project of Phase-III’. near the main tunnel segment to support the excavated
soil strata, where in the load gets transferred by ‘arch
Project Background effect’.
The project consists of five underground metro stations The excavation work is further divided into two parts
(Hauz Khas, Vasant Vihar, Munirka, IIT and RK Puram), un-
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derground ramp at Shankar Vihar metro station (part of CC- - Heading: The upper half of the excavation is known as
27) and tunnel from end of this underground ramp to Hauz Heading. Here it was kept at a height of 1.8m. After exca-
Khas metro station connecting the five underground stations vating for every heading, of 750mm in length, arch-shaped
listed above. Total tunnel drive length is 4.49 Km. Keeping ribs are fixed followed by fixing of wire mesh between
strata of the soil in mind and time constraints, five Tunnel two consecutive ribs, as shown in figure 1. After this, shot-cre-
Boring Machines (TBM’s) namely Okumura TBM, THI-1 ting using M30 grade concrete mix was done to prevent
TBM, Herrenknecht TBM, THI-2 TBM and Mitsubishi TBM were collapsing of roof & side wall soil and strengthen these
used for construction of the tunnels. Out of these, Okumura surfaces. 50mm thickness of shot-crete layer was main-
TBM is particularly suitable for tunneling in soft soil. tained throughout the procedure. The shot-crete mix
Of the total tunnel length under construction, part of the contained a chemical named ‘Master ROCS 540’ for
tunnel connecting R.K Puram station to Munirka station, is the early setting of the mix (approximately 3-4 hours).
the subject of consideration in this paper. The tunnel extends Any further excavation was done only after checking the
1.32km in length and has an internal diameter of 5.80m and strength of the shot-crete mix, sprayed over the soil sur-
external diameter of 6.35m. face, which should be more than 10kN/mm2 per 750mm
As a standard practice, during construction of a tunnel mesh layer.
system, depending upon length of the tunnel and soil char- - Benching: The lower half of the excavation is known as
acteristics, a pre-calculated number of cross-passages are Benching. It was kept at a depth of 2.2m below heading.
planned. In the instant case, four cross passages numbered Benching can be done up to a length short of heading i.e.
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GROUND ENGINEERING: TUNNEL SYSTEM
Figure 2: Shows the fixing of main reinforcements
contains a hydrophilic strip at the entry and exit, so as to pre-
Figure 1: Shows the fixing of ribs and wire mesh vent seepage from entering in the construction joint formed
between the tunnels and the doors of the cross-passage.
there should always be one extra heading than benching The cross-passage was 10.5m in length, 1.31m in width and
till the last part. Rib-fixing and shot-crating etc. follows 2.493m in height. The total number of ribs used was 14.
benching as mentioned above. During the construction of the cross-passage, a major
After this stage, permanent lining is constructed by using problem was encountered due to leakage of a water supply
M40 grade Water Proofing Course concrete. Method of con- pipelocated above the cross passage resulting in extensive-
struction is similar to any RCC structure. Rebars are fixed seepage of water from top strata of the soil into the cross
first, as shown in Figure 2, followed by shuttering form-work passage itself. Same delayed the work being undertaken in
before pouring of the concrete mix. Note that the main rein- the cross passage as it affected the shot-crating which was not
forcement has to be provided as per the design, considering setting in the given time frame and lumps started formingon
the overburden and lateral earth pressures of the location the surface. Although the leaking pipeline was fixed post haste,
being considered. but in order to prevent further leakage and possible failure
As per the drawing shown in figure 3, the cross-passage of the shot-creted soil surface, pressure grouting-using a
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Figure 3: Shows the Plan and Cross-section of CP-15
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GROUND ENGINEERING: TUNNEL SYSTEM
grout-mix having a composition as 3:3:2; cement (OPC 53), Conclusions
sand, water, was done using grouting packers, along with
pumping out of excess water. This filled up the voids and - This project is being undertakensilty silty-clay type soil,
prevented any further seepage into the cross passage. which is a type of soft soil, which limits the construction
The final settlement value as measured with the help of procedure to the one applicable only for soft soils. The
a Total Station came out to be 7mm. Since this value is much construction method utilized in this case wouldn’t have
lesser than the danger-level value (13.5mm), specified by L&T been suitable for undertaking similar work in hard soil
and Delhi Metro Rail Corporation, the construction and de- since the overburden pressure due to above strata would
sign were deemed safe. Reduction in the level of vertical de- have been extremely large exceeding the retaining limits
formation was achieved due to high rigidity caused by the arch- of the ribs-mesh arrangement. However, in this project, the
ing action of the ribs-mesh arrangement. Also, the depth of soil characteristics lent itself to the ribs-mesh method of
excavation which was nearly 11m, offered well compacted construction.
soil. - The method used to prevent failures due to seepage as
The entire construction process was done following the encountered in this case can only be applied to situations
necessary safety measures. The measures taken were as where the water discharge is in limited quantity and can
follows: be easily pumped out in short duration of time. If quantity
of water is large (say) due to a nearby water body, excessive
- All the workers were cladded with proper safety equipment. weight of the water may cause excessive settlements
- Regular checking of gaseous release from the soil. As the and, in worst case scenario, may lead to collapsing of the
soil contained minor portions of lime, daily checks for cross-passage, resulting in fatalities.
‘carbon mono-oxide’ were carried out so as to prevent any
mishap. Acknowledgements
- Lighting was provided in the tunnels, with illumination at The authors would like to thank the team of engineers of
the work area (in cross-passage) being 100 lux and else- L&T-SUCG JV who were involved in the construction of CP-
where 50 lux. Emergency lighting units were also provided 15 for providing us the valuable data and the chance to have
so as facilitate safe egress in the event of power failure. the on-site experience.
- The processes of heading and benching were carried out
alternately, with one benching after one heading. If more References
than one heading or benching were to be done, there was a - Usmani, A; Ramana, G.V; Sharma, K.G. (2010):”Experimental evalua-
chance that the soil may have settled due to lack of binding tion of shear strength behaviour of plastic and non-plastic silts.” Geome-
force. chanics and Geoengineering, 10.1080/17486025.2014.921336,174-
- While shot-crating, gas masks, rubber gloves and boots, 181. (ASCE)Online publication date: 3-Jul-2015.
eye-gear and ear-protecting gear were used so as to - L&T-SUCG JV.CC27 DELHI: “Method of statement for the construc-
prevent any fatalities due to inhaling of pressured fumes tion of cross-passage”.
coming out with concrete and damage to eyes and ears
- IS 456 (2000):Plain and Reinforced Concrete-Code of Practice. w
and body parts in contact with the shot-crating equipment.
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