Nagpur Metro Project

Double Decker Integrated Road

Cum Metro Corridor

‘Railway span’

05.11.2022

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 Content
• Nagpur Metro Project Alignment

• Snaps of Works by AFCONS in Reach-03, Reach-01 & Depots

• Brief on Alignment in Reach-02

• Construction Sequence of Double Decker Viaduct

• Snaps of Reach-02 Double Decker Viaduct & Stations

• 80m Railway Span Construction

• Key Highlights & achievements on Railway Span

• Challenges & Solutions during construction of Railway Span

2
Nagpur Metro Project Alignment

Reach-4

Reach-1 , 330m critical

stretch of viaduct & 4
stations constructed by
AFCONS
Length of Nagpur Metro Viaduct = 38.215Km
Station & Depot works by AFCONS: Viaduct works by AFCONS:
Reach 1= 4 stations  Reach 1= 0.33 Km
Reach 2 = 4 stations  Reach 2 = 6.671Km
Reach 3 = 1 station (Sitabuldi)  Reach 3 = 10.8Km
Depot = 2 depots (Hingna & Mihan) Total Viaduct works by AFCONS =17.81Km i.e. 47%

AFCONS executed more than 51% value of Construction works in Nagpur Metro
3 Template V.07.18
 Works by AFCONS
In
Reach -03, Reach-01 & Depots

4
Reach - 03 : Viaduct

5
Reach - 03 : Sitabuldi Interchange Metro Station

Reach-02
Reach-03

Reach-01
Reach-04

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Reach - 01 : Metro Stations

Chattrapati Square Station

J P Nagar Station

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Depot works : Hingna & Mihan

Hingna Depot

Mihan Depot

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Reach – 02 / Viaduct

India’s longest double decker

Metro cum Road Corridor
Reach - 02

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Reach-02 - Alignment Brief

Located on North South Corridor between Sitabuldi Metro Station to

Automotive Metro Station on Nagpur – Jabalpur National Highway (NH-07)

 Length of alignment : 6.67 km

 Length of double decker Viaduct : 5.06 km

 Length of Metro Viaduct : 1.61 km

 Number of Elevated Metro Stations : 6 Nos (4 stations done by

AFCONS)

10 Template V.01.19
Viaduct : Scope of work

Sr. No. Activity Unit Total Scope

1 Pile Nos 1687

2 Pile Cap Nos 221
3 Pier Nos 386
4 Pier cap Nos 380
Portal Beam
5 Nos 6
(Railway span)
6 Pre-casting units : 7540
6.1 Metro : Segment Nos 2320
6.2 NHAI : Spine Nos 1740
6.3 NHAI : Wings Nos 3480
7 Erection :
7.1 Metro : Segment Spans 220
7.2 NHAI : Spine Spans 168
7.3 NHAI : Wings Spans 168
Railway span (80m) Fabrication &
8 MT 1650
Erection
9 Obligatory span (44m) - 275 MT Span 1 No.

11 Template V.07.18
Typical cross section – Double decker

Metro Segment

Pier Cap at
Metro level
Pier upto
Metro level
Spine Segment

Rib/Wing
Segment
Pier Cap at
Flyover level

Pier upto
Flyover level

Pile Cap

Pile

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Construction Sequence of
Double Decker Viaduct

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Construction Sequence of Double Decker Viaduct

Construction of pile Construction of

Construction of Pile
cap Flyover level Pier

Integrated Pier for

Metro level Pier cap Flyover Pier cap
Metro Viaduct

Erection of spine & Construction of

Erection of wing
Metro segments parapet at flyover,
segments on flyover
with launching expansion joints and
level
girder finishing works

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Construction Sequence of Double Decker Viaduct

Construction of Flyover
Level Pier
Metro Level
Pier Cap

Flyover Level
Pier Cap

Construction of Flyover
Level Pier Cap
Construction of Metro
Level Pier & Pier Cap

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Construction Sequence of Double Decker Viaduct

Spine Erection

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Construction Sequence of Double Decker Viaduct

Metro Segment Erection

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Wing Launcher for Rib segments erection

Cantilever Arms

Wing segments

Wing launcher for erection of Flyover wing

Spine elements elements

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 Reach -02
Double decker Viaduct
& Station
-- Photos --

19
Reach – 02 : Site Photos

Automotive Ramp –Start of Alignment

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Reach – 02 : Site Photos

Automotive Square

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Reach – 02 : Site Photos

Nari Road Station

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Reach – 02 : Site Photos

Indora Square to Nari Road Station

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Reach – 02 : Site Photos

Indora Square Station to Kadvi Chowk Station

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Reach – 02 : Site Photos

Kadvi Chowk Station

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Reach – 02 : Site Photos

Gaddigodam Station
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Reach – 02 : Site Photos

KCP Station
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Reach – 02 : Site Photos

44m Obligatory Span over Govari Flyover

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Finished structure

29 Template V.07.18
Asia Book of Records for Double decker on Wardha
Road

30 Template V.01.19
80m Railway Span Construction
India’s Most Iconic Four Layer
Multi Transport System
.

31
Scope of 80m Railway span - OWG

Salient Features of 80m Railway span

Type of Truss Double Decker Open Web Girder

Span Length 80m

Total Weight of Structure 1650MT

Total no. of HSFG bolts 80,000

Grade of Steel E – 350 B0

Bearing Type Spherical Bearings

Nos. of bearings Total = 06nos.

Height of Truss 12.3m

Truss above from ground level 28m

Part Pulling and
Erection Methodology
erection with multiple cranes
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Construction sequence & erection method

.
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Site Photos – Four Level multi transport crossing
Gaddigodam Automotive

At 4th Level
Metro Rail

At 3rd Level
NHAI Flyover

At 2nd Level
Indian Railway

At 1st Level
RUB

Completed view of Railway Span

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DAY 01/22.12.2021
Erection of 1st member (PART-B ) Node -6 LHS
DAY 10/31.12.2021
Erection of Node 6 & 7R , 7-6, 6-5 & 5-4 R BC of (PART-B )
DAY 18/08.01.2022
Erection of Flyover Cross girder 5BH & 7-6 RHS diagonal of (PART-B )
DAY 28/18.01.2022
Erection of 5, 4 TH, 7-4 LHS TC, 5-4 LHS & RHS diagonals, 5-4 BB & FSB of (PART-B )
DAY 34/24.01.2022
Erection of PART – A & PART – B in progress
Construction of 80m Railway span - OWG

Pulley

Pulling direction

Hillman Roller
Part-2 Part-1

Restraining Winch
Pulling Winch

Part erection of Steel truss Part 1 (Right of Rail Track), Part – 2 on Left
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DAY 44/ 03.02.2022
Erection of PART – A & PART – B
DAY 44/03.02.2022
Erection of PART – A & PULLING OF PART – B
DAY 47/06.02.2022
Erection of PART – A & PART – C
DAY 55/14.02.2022
Erection of PART – A & PART – C
DAY 63/22.02.2022
Complete erection of PART – A & PART – C
Construction of 80m Railway span - OWG
Part-1 Part-2 Part-3

Lowering arrangement

Completion of member erection of Steel Truss

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Construction of 80m Railway span - OWG

Deck Slab Construction of Steel Truss

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Construction of 2nd level Portal of 80m Railway span
- OWG

Prefab cage placing over shutters Balance reinf. Fixing and side shuttering

Key Features of Portal

1. Reinf. Quantity = 40T
2. Concrete volume = 190cum
3. Grade of concrete = M60
4. Clear height above ground = 24m
5. Time duration to complete = 11days

Completion of portal
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Construction of 80m Railway span - OWG

Test load for NH level = 443.62T Material used for test load
Test load for Metro level = 464.6T 1. Concrete blocks
Total test load = 908.22T 2. Sand bags
3. Metro bogie

Span load test at 80m Railway span

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Site Photos

80m Railway Span

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Key Highlights & achievements
during construction
of
Railway Span
.
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Asia Book of Records for Railway Span

 Record Titles approved by Limca Book of Records and expected to be awarded

shortly
 Record Titles approved by Guinness World Records and expected to be awarded
shortly
52 Template V.01.19
Key Highlights & achievements of Railway Span

Located at Railway crossing where average train movement is 5 numbers per

hour and peak movement is 8 numbers per hour

 Railway span facilitates Four Level multi-transport junction

 Fabrication completed in 80 days (Total 9140 members & 2700 splice plates)

 Trial assembly of entire span completed in 48 days

 Transportation of all the members sequentially done in 96 trailer trips

 Erection done in 3 parts due to area/location constraints. Erection done with 3 erection

work fronts and completed in 63 days.

 Pulling of truss across Railway line done in 3.5 hours, distance travelled is 27m. Accuracy

of joining Part 2 with Part 1 was within +/- 3 mm.

53 Template V.01.19
Key Highlights & achievements of Railway Span

 Total erection done in 436 lifts (Average weight of each lift – 24 T and maximum weight was

42 T)

 300 number of workforce worked round the clock, 80,000 HSFG bolts fixed with 28 number of

torque wrenches

 Dismantling of Temporary Structure completed in 5 days

 Lowering of entire span (4.5m height) done in 2.5 days, 8 number of Single acting hydraulic

jacks used for lowering. Lowering done with each layer of 150mm (Lowering rate – 15 minutes

per layer)

 Camber was measured upon lowering the span duly resting on four points. Theoretical camber

at the centre of span was 83mm and actual value observed was 86mm

 Adjacent spans completed within 19 days after completion of 2nd Level portals of Railway

Span
54 Template V.01.19
Challenges & Solutions during
construction of Railway Span
.

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Challenges & Solutions

FINALISATION OF METHOD STATEMENT OF ERECTION :

 Presence of Railway hospital, Railway workshop, School, Gurudwara on one

side of Railway boundary and on other side residential zone, workshops,
garages, shops, curved alignment etc. Narrow road width near Railway
boundary.

 Erection of full span on any of the side of Railway track was not possible due to
above constraints. Using nose for erection of the span was also examined but
was not possible due to space constraint

56 Template V.01.19
Challenges & Solutions

FINALISATION OF METHOD STATEMENT OF ERECTION : …..Contd

 To overcome above constraints, method of erection of entire span in 3 parts over
temporary support system was explored and finallised.

 Part-2 structure erected on other side of railway track to pull across the tracks to
match with erected part – 1 structure followed by erection of balance part - 3
structure.
 The method was deliberated at various levels at AFCONS, GC, Maha metro,
Railways,CRS and advisory technical experts and frozen.

 Design of all temporary structures were reviewed and approved by DDC

and 3rd party of Mahametro, Railways and CRS including construction
stage

57 Template V.01.19
Challenges & Solutions

TEMPORARY FOOTING & STRUCTURE OVER RAILWAY EMBANKMENT:

 Temporary footings & supports were required to rest over Railway
embankment to reduce the weight of temporary track beams due to radius &
space constraint. The span of temporary structure was 25m

 Joint discussions with Railway officials for finallisation of method with full
support & active involvement of Maha Metro, Railways gave permission to
rest foundations over embankment with strengthening of embankment toes,
additional temporary supports for retaining walls of RUB

 Plate load tests were conducted at all 14 temp foundation locations to

ensure SBC.

 Method adopted was 1m X 1m X 1m concrete blocks along with structural

steel structure retaining walls was adopted to retain embankment slopes.

58 Template V.01.19
Challenges & Solutions

TEMPORARY FOOTING & STRUCTURE OVER RAILWAY EMBANKMENT:

Conc. Blocks

59 Template V.01.19
Challenges & Solutions

TEMPORARY FOOTING & STRUCTURE OVER RAILWAY EMBANKMENT :

Str. Steel Retaining Wall

60 Template V.01.19
Challenges & Solutions
PULLING OF ‘PART – B’ OVER RAILWAY TRACKS:
 Entire pulling operation across Railway tracks under one block of four hours,
maintaining the alignment to mm accuracy was most critical

 Most sophisticated & safe Hillman rollers, each of capacity 350T, (8 numbers)
were used for pulling of truss in place of conventional wheel & trolly system.

 Guide rollers & full proof pulling arrangement with synchronised electric winches
were deployed including stand by winches/guide rollers.

61 Template V.01.19
Challenges & Solutions
OBTAINING RAILWAY TRAFFIC BLOCKS:
 The entire construction was completed with minimum of 5 Railway traffic blocks

 Total 4 traffic blocks, each of 1 hour, was taken during erection of temporary track
girders across railway line & the removal of the same.

 One large time traffic block, 4 hours, was taken during pulling operations of
truss across Railway line

 Maha Metro continuously was engaging even with Railway Board for obtaining
timely traffic blocks

62 Template V.01.19
Challenges & Solutions
SAFE LOWERING OPERATION OF ENTIRE TRUSS FOR 4.5MTS:
 Safe Lowering of the assembled truss on to temporary bearings from a height of
4.5m was most critical

 8nos of 600T hydraulic jacks were used for lowering operation at the initial stage,
2 nos. at each corner bearing points.

 It was lowered in 30 increments of 150mm each and was completed in 2.5 days
as against envisaged 6days.

 1200T hydraulic jacks were used for final lowering after deck slab construction
and bearing installation works.

63 Template V.01.19
Challenges & Solutions
SAFE LOWERING OPERATION OF ENTIRE TRUSS FOR 4.5MTS:

Steel Packing

600T Jack

64 Template V.01.19
Challenges & Solutions
CREATION OF MULTIPLE ERECTION WORK FRONTS:
 3 work fronts were created for erection of structural members. 1st from Gurudwara side, 2nd
from Itarasi end of Railway line, 3rd from Nagpur end of Railway line
 Approach road of 250m constructed in 5 days time
 Assembly area developed for daily stacking & assembly of elements.Two locations
developed for day to day assembly of elements.
 12 Trailers used to transport fabricated materials from 40 km away fabrication shop. Entire
transportation done in the night between 11:00 pm to 06;00 am
 28 torque wrenches used to cater torquing requirement of average 2200 number of HSFG
bolts per day

500T Crane with

super lift
300T Crane

Assembly area

400T Crane

65 Template V.01.19
Challenges & Solutions
COLLABORATIVE & SYNCHRONISED WORKING BY STAKEHOLDERS:
 Various Task Force were formed from AFCONS, GC & Maha Metro for various activities
and stringent deadlines were given to respective Task Leaders.
 Daily tele conferences were held chaired by MD/Maha Metro without singly break during
entire completion period.
 Round the clock monitoring was done by at the Level of Directors of Maha Metro, GC and
AFCONS
 Detailed macro level transportation and erection sequence was prepared in advance and
monitored continuously.
 Successful Liasoning with all stakeholders such Traffic Police, Railway Authorities, Local
Authorities, Gurudwara Committee, Schools etc by Maha Metro & AFCONS was most
crucial & critical for smooth execution under most stringent time lines

66 Template V.01.19
Thank You…!

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