1. MUMBAI METRO RAIL PROJECT
.
National Institute Of Construction Management And Research

2. CONTENTS
 Introduction.
 Project Details.
 Study Of Tender Documents.
 Time And Motion Study.
 Construction And Methodology.
 Resource Utilization.
2

4. Introduction
Present Traffic Scenario:-
1. Rail- 48% , Bus- 44% & Private Vehicles - 8%.
2. Inadequate road network.
3. Suburban rail traffic increased by 6 times while the capacity increased by
only 2.3 times.
4. 4500 passengers travel per train against the carrying capacity of 1750 resulting
an unbearable overcrowding
5. Vehicular growth Increased from 61,000 to over 1.02 Million in the last four
decades.
4

5. NEED
Existing suburban systems under extreme pressure
Existing bus system’s role limited to providing feeder services to
railways.
Bus system alone cannot meet the future demand
Constraints to expand the existing road network capacity
The Road & Rail improvements not adequate for future demand
Many pockets in Island city and suburbs not served by rail based
mass system.
Environmental deterioration due to growth in road traffic

6. WHY
• it has high-capacity
•...it is fast
•...it is environment-friendly
•...it is financially viable and economical
•...and is attractive to the commuters

7. ADVANTAGES
Carries same amount of traffic as 6 lane bus or 26 lane
Private cars (Either way).
Reliable, Comfortable and Safe
Reduces time by 50-75% as compared to road
No Air pollution and less noise levels
Energy efficient; Consumes 1/5th Energy per road passenger
km.
Occupies no road space if underground and only about 2m
width of road if elevated

8. Mumbai Metro Rail Master Plan:-
Phase I (2006 – 2011)
Versova-Andheri-Ghatkopar - 11.07Km
Colaba-Bandra-Charkop - 38.24Km
Bandra-Kurla-Mankhurd - 13.27Km
Total - 62.68 Km
Phase II (2011 – 2016)
Charkop-Dahisar - 7.5Km
Ghatkopat-Mulund - 12.4Km
Phase III(2016 – 2021)
BKC – Kanjur Marg via Airport - 19.5Km
Andheri (E)-Dahisar (E) - 18Km
Hutatma Chowk-Ghatkopar - 21.8Km
Sewri-Prabhadevi - 3.5Km
Total Length - 146.5Km 8

10. 10

11. SIGNIFICANCE (V-A-G)
Provides East-West rail based connectivity to Central and
Western suburbs.
Facilitates smooth and efficient interchange between
suburban rail system and MRT System at Andheri and
Ghatkopar stations.
Reduces the journey time from 71 minutes to 21 minutes,
between Versova and Ghatkopar .
Provides rail based access to the MIDC, SEEPZ and
commercial developments .

12. 12

13. 13

14. CAR DEPOT

15. VERSOVA CAR DEPOT (AREA 13.8 HA)
Stabling
Routine maintenance
Periodic maintenance
Workshop
Offices and storage

16. TECHNICAL DETAILS
Cab signaling with Automatic Train Protection.
Traction - 25 Kv Ac OHE
Rolling Stock with all advanced features
Train control With Driver
Ticketing system - Automatic Collection
Train Composition – Four/Six Coaches
No. of Classes - Single Class

17. TECHNICAL DETAILS
Environment - Air Conditioned
Max. Speed - 80 kmph
Average Speed - 33 kmph
Acceleration - 1.0 m/sec2
Deceleration - 1.2 m/sec2.
Frequency (2009)- 4 min ,(2031)- 3 min.
Carrying Capacity/rake -1500 Pax.
System Capacity – 60,000 pphd
Total Journey Time 21 min Approx

18. TECHNICAL DETAILS
Gauge (Nominal) 1435mm
Route Length (Elevated 31.87 Km
between dead ends)
Number of stations Elevated 27 Nos.
Rolling Stock
3.20 m wide & 22mts length modern rolling stock with stainless
steel body
Axle load 15 t
Seating arrangement Longitudinal
Capacity of 4 coach unit 1178 Passenger

19. PASSENGER SECURITY AND INFORMATION SYSTEM
 The passenger security and information system would manage the
MRTS passenger related functions.
 OPERATION CONTROL CENTRE (OCC)
To supervise the passenger areas and trains,
To provide visual information to passengers and at stations.
To provide one way communication from Operation Control Centre to the
passengers at stations through Public Announcement (PA) system.
 CLOSED CIRCUIT TELEVISION (CCTV)
System monitoring the stations and emergency call points on the stations.
 DYNAMIC VISUAL DISPLAYS AND LOUDSPEAKERS.
CCTV cameras, loudspeakers, and information displays will be provided.

20. Project Details
Type Of Design:-
1. SUB-STRUCTURE: Pier with pile foundation
2. SUPER-STRUCTURE: Pre-cast segmental girders
No. Of Piles: 1680 NOS.
1. DIA. OF PILES: 1000, 1200, 1500 mm
2. LENGTH: 12 TO 18 M
No. Of Pile Caps: 457 NOS.
1. LENGTH: 4.5 To 11.5 M
2. WITDH: 4.5 To 11.5 M
3. DEPTH: 1.8 To 2.5 M
20

21. NO. OF PIER: 457 NOS.
1. HEIGHT: 10 M
2. LENGTH – 2 M
3 WIDTH – 3 M
4 DIAMETER- 1.75 To 2.25 M
No. Pier Caps: 457 NOS.
No. Of “U” Girders: 747NOS. (PRECAST SEGMENTAL GIRDERS)
Bearing: Elastomeric Bearing.
21

22. Project Tender Documents
Requirement To Contractor:-
Passengers Per Day – 45000
Speed – 33Km/hr.
Time Interval – Less than 120sec.
Distance Of V-A-G Corridor – 11.4Km.
No. Of Stations – 12.
The total cost of the project will
be around Rs. 4,57,52,00,581.35 /-
22

23. Contractors For Work
Package Awarded to
Civil Works – Viaduct Simplex Infrastructure Ltd
Civil Works – Stations Sew Infrastructure Ltd
Civil Works – Special Bridges Sew Infrastructure Ltd
Civil Works – Depot Earthworks Shyam Narayan & Bros
Rolling Stock CSR Nanjing, China
Signaling System Siemens
Power Supply Traction & SCADA ABB
Communication System Thales
Track work VNC Rail One
Automatic Fare Collection Indra
E&M ABB
Escalators Schindler
Lifts OTIS
Depot Machinery & Plant Awarded to various suppliers
Depot Civil Works Ahluwalia Contracts (India) Ltd. 23

24. Funding Arrangement:-
% Share
Reliance Energe Ltd.
26%
Veolia
5% 69% Transport, SA, France
MMRDA
24

25. Basic Details:-
 The contract here is executed between MMOPL and SIMPLEX INFRASTRUCTURES
LTD.
 The contract was issued to SIMPLEX INFRASTRUCTURES LTD on 28/02/2008.
 Estimated value of the project by MMOPL was 457.52Cr. INR.
 Bid security was to be paid off, of amount 21Cr. approximately.
 The project has to be completed within the stipulated time period of 22 calendar months
or else the contractor has to pay the penalty.
 The total length of Viaduct under this project is 11.343 km.
25

26. SALIENT FEATURES
Name Of Project Construction of Viaduct VA & VB
Name Of Employer Mumbai Metro One Private Limited
Name Of Contractor Simplex Infrastructure Ltd.
Name Of Consultant PB – Systra
Name Of Designer PB – Systra
Tender Value Rs.457.52Cr
Project Value Rs.2356Cr
Type Of Contract Unit Rate Contract
Project Duration 22 Months.
Route Length - 11.07 km
Elevated Alignment- 100 %
Maximum Gradient- 4.0%
Minimum Curvature - 100 m
Minimum Ground Clearance - 5.5 m
No. Of Stations - 12
Platform Length - 135 m
Car Depot - D.N Nagar
Length Of Coach - 22 m. 26
Width Of Coach - 3.2 m.

27. LAYOUT OF WADALA CASTING YARD
27

28. WORK BREAKDOWN STRUCTURE
Mumbai Metro Rail Proj.
(Construction of VA & VB in
V-A-G corridore)
Foundation Sub Structure Superstructure
Open Anticrash
Pile Foundation Pier Pier Cap Bearing U-Girder
Foundation Barrier
28

29. PROJECT ORGANIZATION CHART
General Manager
Mr. Ajit Singh
Planning &
Casting Yard VA-Section Erection Survey
QA/QC VB Section Billing
Incharge Incharge Incharge Incharge
InchargeMr. Incharge Incharge
Mr. Umakant Mr. Dipak Mr. S. Mr. Karol
Suman Mr. I. Saha Ms. Vidya
Dube Tiku Adhikari Adak
Murugan
29

30. TIME AND MOTION STUDY
Pile Boring:-
Sr. No. Work Description Number of Number of days Equipment/
labour Machinery used
1 Pavement quality concrete breaking 2 1 Diamond cutter
2 Excavation up to 2.5 m 8 2 Back hoe loader,
Dumper
3 Utility checking 2 1
4 If utility found then utility shifting 2 1
5 Marking pile location 3 1/2 Auto level/ Total
station
6 Initial boring with soil auger 2 2 hr Pile boring rig,
7 Temporary Pile case/linear insertion 2 1 hr Pile boring rig,
8 Soil/Rock auger boring 2 1 Pile boring rig,
9 Muck removal 2 1 Back hoe loader,
Dumper
30

31. Soil Auger
Hydraulic Boring Rig Machine Rock Cutter 31

32. Pile Reinforcement Work:-
Sr. Work Description Number Number of Equipment/
No. of labour days Machinery
used
1 Reinforcement cutting and 3 2 Bar bending
bending and Bar
cutting
machine
2 Reinforcement anti- 3 1/2
corrosive treatment
3 Reinforcement cage 4 1
preparation
32

33. Pile Concreting:-
Sr. Work Description Number of Number of Equipment/
No. labour days Machinery
used
1 Reinforcement cage shifting 4 3 hr Hydraulic
crane and
truck
2 Reinforcement cage 4 1 hr Crane
insertion in bore hole
3 Pile concreting with tremie 4 1 Tremie pipe,
pipe Transit mixer
33

34. Pile Cut-Off Level:-
Sr. Work Description Number of Number of Equipment/
No. labour days Machinery used
1 Extraction of temporary pile 2 1/2 Crane
casing
2 Temporary backfilling with 3 1/2
approved material
3 Cutting off pile heads 8 3 Hammer and chisel
(manually)
4 Disposal of excavated 4 1 Back hoe loader,
material Dumper
5 P.C.C. up to pile cut off level 4 1 Transit mixer and
needle vibrator
34

35. Pile Cap:-
Sr. Work Description Number Number of Equipment/
No. of days Machinery
labour used
1 Reinforcement cutting and 4 2 Bar bending &
bending cutting machine
2 Reinforcement anti-corrosive 3 1/2
treatment
3 Reinforcement cage preparation 6 3
4 Shuttering work for pile cap 4 2
5 Concreting of pile cap 8 1 Transit mixer
and needle
vibrator
6 Deshuttering of pile cap after 2 4 1
days
35
7 Curing of pile cap for 7 days 1 7

36. PILE CAP REINFORCEMENT BINDING
PILE CAP SHUTTERING WORK
36

37. Pier Starter:-
Sr. Work Description Number of Number of Equipment/
No. labour days Machinery used
1 Reinforcement cage 5 1
preparation
2 Shuttering work for pier 4 1/2 Hydraulic crane
starter
3 Concreting of pier starter with 4 3Hrs Transit mixer,
the help concrete pump Needle vibrator,
Concrete pump
4 Deshuttering of pier starter 2 2 Hrs Hydraulic crane
after 2 days
5 Curing of pier starter for 7 1 7
days 37

38. Shuttering Of Pier Starter
38

39. Pier CONSTRUCTION:-
Sr. Work Description Number of Number of Equipment/
No. labour days Machinery used
1 Reinforcement cage 8 1.5
preparation
2 Shuttering work for pier 6 1 Hydraulic crane
3 Concreting of pier with the 4 1 Transit mixer,
help concrete pump Needle vibrator,
Concrete pump
4 Deshuttering of pier after 2 2 2 Hrs Hydraulic crane
days
5 Curing of pier starter for 7 1 7
days 39

40. 40

41. Anti-Crash Barrier:-
Sr. Work Description Number of Number of Equipment/
No. labour days Machinery used
1 Reinforcement cage 3 1
preparation
2 Shuttering work for Anti – 3 2Hrs Hydraulic crane
crash barrier
3 Concreting of Anti – crash 2 1/2 Transit mixer,
barrier Needle vibrator
4 Deshuttering of Anti – crash 2 2 Hrs Hydraulic crane
barrier after 2 days
5 Curing of Anti – crash barrier 1 7
for 7 days
41

42. 42

43. Pier Cap:-
Activity Name No. Of No. Of Days Equipment Or Tools
Labour Req.
Reinforcement Cutting Bending 11 2 Days Bar bending & Bar
cutting machine
Reinforcement Cage Preparation 11 2 Days
Shuttering Soffit Leveling (Base) 5 1 Days
Shutter Alignment 4 1 Days
Cage Shifting Over The Shutter 3 ½ Hour Gantry
Shutter Fixing 4 1 Day
Gangway Preparation On Slab Of 2 ½ Day
Girder For Concreting
Concreting 6 3 Hours Transit Mixer, Boom
Pressure & Vibrator
43
Curing 1 21 Days

44. PIER CAP STACKING YARD
REINFORCEMENT CAGEPREPARATION
44

45. SHIFTING & FIXING OF PIER CAP ON PIER
NECK
45

46. U-Shaped Girder:-
Activity Name No. Of Labour No. Of Days Equipment Or
Tools Req.
Reinforcement Cutting Bending 30 2 Days Bar bending and Bar
cutting machine
Reinforcement Cage Preparation 30 3 Days
Shuttering Soffit Leveling (Base) 12 1 Days
Outer Shutter Alignment 12 1 Days
Cage Shifting Over The Shutter 4 lab.& 2 gantry opt. ½ Hour Gantry and truss to
hold cage
Inner Shutter Fixing 10 1 Day
Strand Cutting & Fixing(Threading) 20 2 Days
Slackness Removal Of Strand 5 lab. & 1 opt. 1 Hour Stressing jack
Prestressing Of Strands 3 lab. & 1 opt. 2 Hours Stressing jack
Gangway Preparation On Slab Of Girder For 6 ½ Day
Concreting
Concreting 16 lab. & 4 meson 6 Hours Transit Mixer, Boom
Pressure & Vibrator
46
Curing 2 21 Days

47. LIFTING OF REINFORCEMENT CAGE
PRE-STRESSING OF
“U” GIRDER
47

48. CONCRETING OF “U‟ GIRDER HEAVING OF CONCRETE
LIFTONG AND SHIFTING OF „U‟ GIRDER TO STACKING YARD 48

49. Construction Methodology Of Piling:-
49

50. Construction Methodology Of
Pile cap
50

51. Construction Methodology Of
Pier
51

52. Construction Methodology Of Pier
Cap
Reinforcement Cutting &
Bending
Anti corrosive treatment
Reinforcement Cage
Preparation
Shutter Leveling(Base)
Side Shutter Alignment
Cage Shifting Over The
Shutter
Fixing Pipes for post
tensioning
Checking of reinforcement &
shuttering
Concreting
Curing on casting bed
52
Deshuttering

53. Construction Methodology Of
U-Shaped Girder
Reinforcement Cutting & Bending Anti corrosive treatment
Reinforcement Cage Preparation
Shuttering Sofit Leveling(Base)
Outer Shutter Alignment
Cage Shifting Over The Shutter
Fitting Inner Shutter
Strand Cutting & Threading
Slackness removal of Strand
Pre stressing
Concreting
Deshuttering
53
Curing Shifting Girder to Stacking Yard

54. RESOURCE UTILIZATION
Consumption of Concrete in May-2009
1700
1591.5 Cum
1600
1500
1400
1300
1200
1100 Grade of Concrete
1000
900
465.25 Cum
800
700
561 Cum
600
500
400
300 246.25 Cum
200 155.5 Cum
52.5 Cum 14 Cum
100
0
Cement Slurry M15 M25 M35 M40 M45 M55
54

55. Consumption of Concrete in June up to 09/06/2009
500
485.25 Cum
450
400
350
300
250
Concrete in Cum
200
150
100 93.5 Cum
71 Cum
50 39 Cum
23 Cum
5 Cum 0 Cum
0
Cement Slurry M15 M25 M35 M40 M45 M55
55

56. Utilization Of Steel:-
Utilization of Steel in May
80
70.736MT
70
62.914MT
60.167MT
60
47.948MT
50
40
Steel Utilization
29.252MT
30 25.031MT
20
10 5.343MT
0
8mm Steel 10mm Steel 12mm Steel 16mm Steel 20mm Steel 25mm Steel 32mm Steel
56

57. Utilization of Manpower
Utilization of Manpower from 07/05/2009 to 06/06/2009
10000
9000 8685
8000
7000 6707
6000
5000 4676 Manpower Utilization
4000
3000
2000
1000
0
Casting Yard JB Nagar Varsova
57

58. Daily Utilization of Manpower
400
350
300
250
200 Casting Yard
150 Versova
100
JB Nagar
50
0
58

59. 59