NATIONAL INSTITUTE OF TECHNOLOGY

PUDUCHERRY
(An institute of National importance under MHRD,
Govt. of India)
KARAIKAL- 609609

Summer Internship Report

May 06 - May 20, 2024

A report submitted in partial fulfilment of the requirement for the award of degree of

BACHELOR OF TECHNOLOGY
IN
CIVIL ENGINEERING

By
KIRTHIKA. P
(CE22B1016)

UNDER SUPERVISION OF

ER. K. PRATHEEBAN
(JGM CONSTRUCTION)
IN
CHENNAI METRO RAIL LIMITED
 Acknowledgement

Gratitude is the hardest of all emotions to express. There is no word capable to express
everything one feels. Until I reach the world, where thoughts can be adequately expressed in
words, "Thank you" will have to do.

I express our heartfelt gratitude to Mr. ER. K. Pratheeban, JGM Constructions and Mr. S.
Rajaram, Assistant Manager-Admin for extending their exemplary guidance and constant
support throughout the internship.

I also reveal our sincere thanks to the staff members and technical support staff, whose
suggestions and guidance has helped me to complete this internship. I thank my parents and
my friends who helped me and guided me directly or indirectly in many ways, during the
tenure of my internship.

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 Table of contents

About CMRL……………………………………………………………………………...4

Bar bending schedule .....................................…………………………………………….9

Shapes of bars . …………………………………………………………………………..11

Casting yard elevated ……………………………………………………………………12

Steps for casting concrete U- girder . ……………………………………………………15

Pile foundation ...... ………………………………………………………………………18

Pier cap…………………………………………………………………………………..19

Surveying………………………………………………………………………………...21

Safety ……………………………………………………………………………………26

Conclusion ………………………………………………………………………………26

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Chennai Metro Rail Limited (CMRL):
➢ The Government of Tamil Nadu created a Special Purpose Vehicle (SPV) for
implementing the Chennai Metro Rail Project. This SPV named as “Chennai Metro
Rail Limited” was incorporated on 03.12.2007 under the Companies Act.
➢ Special Purpose Vehicle - is a legal entity that allows multiple investors to pool
their capital and make an investment in a single company.
➢ It has now been converted into a Joint Venture of Government of India and
Government of Tamil Nadu with equal equity holding.

Objective:
This project aims at providing the people of Chennai with a fast, reliable, convenient, efficient,
modern and economical mode of public transport, which is properly integrated with other
forms of public and private transport including buses, sub-urban trains and MRTS.

PHASE I:
o The Phase I of Chennai Metro Rail project length - 45.046 km
o Corridor-I - Washermenpet to Airport (23.085 Km),
o Corridor -2 -Chennai Central to St. Thomas Mount (21.961 km)
o Elevated stations – 13/32
o U.G Stations – 19/32

COMMERCIAL OPERATION:

The Phase I was commissioned in stage wise.

➢ Alandur to Koyambedu -29th June, 2015
➢ The first Underground line Thirumangalam Metro Station to Nehru Park Metro
Station - 14th May, 2017
➢ The Underground stretches – Nehru Park Metro Station to Chennai Central Metro
Station and Saidapet Metro Station to AG-DMS Metro Station - 25th May, 2018
➢ The Underground stretch from AG-DMS to Washermenpet - 10th February, 2019.

PHASE I EXTENSION:

Phase I Extension covers a length of 9.05 Km from Washermenpet to Wimco Nagar.

COMMERCIAL OPERATION:

The Phase I Extension from Washermenpet to Wimco Nagar was commissioned and opened
for Public on 14th February, 2021 except ThiruvottriyurTheradi Station, Wimco Nagar Depot
station.

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PHASE II:

o Phase II expansion length - 118.9 Km

o Corridor -3 - Madhavaram to SIPCOT (45.8 Km),
o Corridor -4 - Lighthouse to Poonamalle Bypass (26.1 Km),
o Corridor-5 - Madhavaram to Sholinganallur (47 Km).
o The estimated cost of the project is 63246/- Cr

Corridors Elevated UG Total Stations

C-3 Madhavaram to SIPCOT 20 30 50

C-4 Lighthouse to Poonamallee Bypass 18 12 30

C-5 Madhavaram to Sholinganallur 41+1(at Grade) 6 48

Total Stations 128

PHASE II FUNDING DETAILS:

o Funding for a portion of Chennai Metro Rail in Phase II (i.e. 52.01 Km, i.e.
Madhavaram Sholinganallur of Corridor 3 and Madhavaram CMBT of Corridor 5) has
been tied up with JICA as State Sector Project.

o Balance portion of Funding (66.89 Km): The Screening Committee of DEA has
accorded in principle approval for funding of entire Corridor-4 and balance section of
Corridor 3 &5 and posed for funding from Multilateral Banks i.e., ADB, AIIB &NDB..

APPOINTMENT OF GENERAL CONSULTANTS:

o Consortium of Nippon Koei India Pvt. Ltd., Aarvee Associates Architects Engineers
& Consultants Pvt. Ltd. and Balaji Railroad Systems Pvt. Ltd were awarded a General
Consultancy contract (GC1) for the 52.01 km JICA Corridor (Line-3 & Line-5) of
Chennai Metro Phase II project.

o JV of AECOM India Pvt Ltd., Oriental Consultants Global Co Ltd (OCG) & Nippon
Koei Co. Ltd (NK) were awarded a General Consultancy contract (GC2) for the
balance section of 66.89 km (C4, Part of C3 & C5 Corridors) of Chennai Metro Rail
Project under Phase II.

Major contractors involved in Phase 1:

- Afcons Infrastructure Limited: Afcons was responsible for the construction of tunnels,

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stations, and other civil works for several stretches of both the Blue and Green Lines.

- L&T (Larsen & Toubro): L&T played a significant role in the construction of
underground tunnels, stations, and related infrastructure.

Consultants and Design Teams:

Consulting agencies such as RITES (Rail India Technical and Economic Services),
AECOM, and SYSTRA were involved in various aspects of project management, design,
and planning for Phase 1.

CMRL Phase 1

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CMRL Phase

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8
BAR BENDING SCHEDULE(BBS):
A broad list that outlines the type, location, length, mark, size and number, and bending details of each
bar in a Reinforcement drawing of a structure is called a Bar Bending Schedule or “BBS”.

This process of listing the location, type and size, number of and all other details is called
“Scheduling”. Bar Scheduling is the same thing in context of Bars. Detailed reinforcement
requirements are provided for each structural unit.

Importance of BBS:
o It serves as a control document for structural engineers, detailers etc. on reinforcement.
o It helps quantity surveyor with measurement of materials during pre and post contract
operations.
o It helps assist the steel bender and fixer.
o It becomes very useful in helping detect inconsistencies.
o Fast tracks construction and supervision.
o It can help save cost by handling reinforcement.

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Bar Bending area

10
Shapes of Bars:

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Casting Yard Elevated:

Casting Yard is a confined place where all the concrete structures like segments, parapets, I-
girders/beams, boundary wall panels, cable troughs etc. Re-casted/manufactured, shifted to their stack
yard, cured for the specific period/days and then shifted to the working site/viaduct after they gain their
required strength.

Requirements of Casting Yard:

o Site for any Casting Yard should be easily accessible from all site locations.
o Land should be available from 25 Acres to 40 Acres for establishing a casting yard.
o Approach Road leading to Casting Yard should be easily identified.
o Good Environmental conditions.
o It should not more than 3 to 4 kms from working site.
o Proper Drinking Water facilities for Engineers, Supervisors & Labours.

Casting Method:

o Long Line Method

o Short Line Method

U-girder (pre-tensioned, precast U-shaped girder )

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Stressing End

Anchorage End

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 Two Lane Track U-Girder

This major milestone of the 116.1 km Chennai Metro Phase 2 project was recorded between
Okkiyampet and Karapakkam on Old Mahabalipuram Road (OMR) using a 30 meter long U-girder.

This is the longest ever U-girder to be erected in India for building a metro line’s viaduct.

Grade M55.
Cover 50mm.
Width of U-girder is 4.8m.
Height of U-girder is 2m.
Thickness of U-girder is 300mm.

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Steps for casting concrete U-girders:

1.Prepare

o Prepare a casting yard

o Spread and compact a 150 mm layer of GSB
o Fabricate a reinforcement cage
o Prepare a pour card

2. Cast

o Lift the pre-fabricated cage onto the casting bed

o Vibrate the concrete
o Start de-moulding after 12–48 hours

3. Other procedures

o Recheck the profile of sheathing

o Finish the concrete surface
o Stage prestressing
o Apply anticorrosive paint
o Fill the end face with concrete

Vibrator
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Vibrating concrete helps to:

Increase strength: Vibration can increase concrete's compressive strength by 3–5% for each 1% of air
removed. Vibration removes air pockets and packs aggregate particles together, which increases
density and strength.

Prevent segregation: Vibration prevents mortar and aggregates from separating.

Improve workability: Vibration helps move concrete around forms and reinforcement.
Create a smoother finish: Vibration mixes aggregates better and compacts concrete, resulting in a
smoother finish.

Stop bleeding: Vibration creates an even material distribution, which helps to stop bleeding.

U-Girder used in Stations (17m)

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 I- girder

I-girders are used in the superstructure of metro viaducts, especially in cantilever corridors. In
cantilever corridors, the concourse and platform levels are supported by an I-girder that stands on a
single row of columns.

I-girders are used in Chennai Metro Rail Limited (CMRL) for elevated corridors and cantilever
corridors. I-girders are pre-cast, "I" shaped structures that are placed on corridors using cranes. They
are used instead of U-girders to create space for track crossing and platform switching. I-girders are
also used in cantilever corridors, where they support the platform and concourse levels on a single row
of columns.

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Pile Foundation:

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Pier Cap:

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Pier caps transfer the loads from the superstructure to the piers. They hold the bridge girders on bearing
pads and disperse the loads from the bearings to the piers. Bridges with piers will all have pier caps to
transfer the load from the superstructure

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 Surveying

Control point

The device in the image is called a Global Navigation Satellite System (GNSS) receiver, which can
receive and process signals from GPS satellites. In land surveying, GNSS receivers are used to
determine the precise position of points on the Earth's surface.

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 o The Global Navigation Satellite System (GNSS) uses trilateration to determine a receiver's
location on Earth by measuring the distance from multiple satellites. The GNSS system has
three parts:
o Space segment
o A network of satellites called constellations that orbit 20,000 kilometers above the Earth
o Control segment
o An earth-based network of ground control stations that analyze signals from the satellites and
transmit corrections
o Receiver
o Uses the time difference between when it receives a signal and when it was broadcast to
calculate the distance to the satellite

Control point second point

The distance between control point to second point is 200m.

For bridge work 1.5km to 2km once the survey has been taken for sharp alllignment.

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 ` Recevier:

Contoler (antenna):

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Global Navigation Satellite Systems (GNSS) have revolutionized surveying and mapping by providing
accurate positioning data. GNSS surveying methods employ satellite signals to determine precise
coordinates, enabling professionals in various industries to carry out accurate measurements. In this
article, we will delve into the different methods of GNSS measurement, compare their accuracy,
explore surveying techniques, highlight the advantages of Real-Time Kinematic (RTK) over
Differential Global Positioning System (DGPS), and identify the most accurate surveying tools.

Different methods of GNSS measurement:

Single Point Positioning(SPP)

Single Point Positioning is the most basic form of GNSS surveying, where a single receiver collects
satellite signals to determine its position. However, SPP has limitations in terms of accuracy, typically
within a few meters due to factors like atmospheric interference and satellite geometry.

Differential Positioning (DGPS)

Differential Positioning improves accuracy by using a reference station with known coordinates. By
comparing the reference station’s position with the receiver’s measurements, DGPS can eliminate
errors caused by atmospheric disturbances, clock inaccuracies, and satellite orbit errors, achieving sub-
meter to decimeter accuracy.

Real-Time Kinematic (RTK)

RTK is a surveying method that provides high-precision real-time positioning. It employs a base station
and one or more rovers to receive GNSS signals. The base station receives signals from satellites and
transmits correction data to the rovers, allowing them to compute precise coordinates. RTK can achieve
centimeter-level accuracy, making it suitable for applications that demand high precision.

Post-Processing Kinematic (PPK)

PPK involves recording raw GNSS data during the survey and processing it after data collection. By
using a base station or virtual reference station data, PPK calculates the precise coordinates of the
survey points. PPK can achieve similar accuracy to RTK, but it requires additional post-processing
time.

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 Water permeability test

The water permeability test involve measuring the depth of water penetration into concrete samples
under specific hydrostatic pressure for a set period. The water permeability testing process includes:
Casting and curing concrete samples for 28 days.

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Safety:
o Always wear PPE.
o Be mindful and follow signs.
o Provide clear instructions.
o Keep the construction site tidy.
o Organize and store tools properly.
o Use the right equipment for each task.
o Prepare an emergency response plan.

CONCLUSION:
Chennai Metropolis has been growing rapidly and the traffic volumes on the roads have also been
increasing enormously.
Hence the need for a new rail-based rapid transport system has been felt and towards this objective, the
Government of Tamil Nadu have decided to implement the Chennai Metro Rail Project.

The Metro Railway should complement the existing transportation network, a passenger will have the
freedom to interchange other modes of transportation with metro travel.

This project aims to provide the people of Chennai with a fast, reliable, convenient, efficient, modern
and economical mode of public transport, which is properly integrated with other forms of public
And private transport including buses, sub-urban trains and MRTS.

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