Station Maintenance Manual R2 PDF

Hyderabad Metro Rail STATION CIVIL MAINTENANCE MANUAL
HM-LE-PRWIDE-M0201-DOC-MA-STC-00-001
16-04-2015 2 (Issued for Approval) Sanjeev S C Y Sivaji RBK

DATE REVISION DESCRIPTION Prepared Checked Approved
CLIENT: CONSULTANT:
L&T METRO RAIL (HYDERABAD) LIMITED LARSEN & TOUBRO CONSTRUCTION LIMITED
Building & Factories
PROJECT:
HYDERABAD METRO RAIL PROJECT
SUPPLIER / CONTRACTOR:
LARSEN & TOUBRO CONSTRUCTION LIMITED
TITLE :
STATION CIVIL MAINTENANCE MANUAL

REV.
DOC. No. HM-LE-PRWIDE-M0201-DOC-MA-STC-00-001
02
TOTAL NO. OF PAGES 62
RELEASED FOR ☐ PRELIMINARY ☐ TENDER ☐ INFORMATION ☒ APPROVAL ☐ CONSTRUCTION
Page 1 of 62 Uncontrolled when Printed Revision 02

STATION CIVIL MAINTENANCE MANUAL
Document Control
Revision Submission Date Summary of Change Prepared by Reviewed by Approved by

Sanjeev Rajesh Kondle
01 18 Dec 2014 1st submission C Y Shivaji
Sharma V Moorthy
Comments received from LTM.
Redistribution of Manual in
Sanjeev Rajesh Kondle
02 08 April 2015 Volume I & II (Technical & C Y Shivaji
Sharma V Moorthy
Maintenance manual
respectively)

Table of Contents
VOLUME-I, Part-A ................................................................................................................................................ 7

INTRODUCTION ................................................................................................................................................... 7
Abbreviations ...................................................................................................................................................... 7
List of Reference, Standards and Codes .............................................................................................................. 8
VOLUME-I, Part-B ................................................................................................................................................ 9
1 Types of Station ........................................................................................................................................... 9
2 General Arrangement ................................................................................................................................ 10
VOLUME-I, Part-C .............................................................................................................................................. 12
3 Station General Block Diagram .................................................................................................................. 12
VOLUME – II, Part A ........................................................................................................................................... 15
4 MAINTENANCE AND INSPECTION ............................................................................................................. 15
4.1. Objectives .............................................................................................................................................. 15
4.2. Roles & Responsibilities......................................................................................................................... 15
4.3. Chief Station Maintenance Engineer ..................................................................................................... 16
4.4. Inspection Officer .................................................................................................................................. 16
4.5. Assistant Officer .................................................................................................................................... 16
4.6. Knowledge of rules and regulations ...................................................................................................... 16
4.7. Periodicity of Inspection ........................................................................................................................ 17
4.8. Type of Inspection ................................................................................................................................. 17
4.8.1. Routine Inspection............................................................................................................................. 17
4.8.2. Detailed Inspection............................................................................................................................ 17
4.8.3. Special Inspection .............................................................................................................................. 18
VOLUME – II, Part B ........................................................................................................................................... 19
5 STATION BUILDINGS STRUCTURES ............................................................................................................ 19
5.1. General .................................................................................................................................................. 19
5.2. Inspection and Repairs .......................................................................................................................... 20
5.3. Inspection of Station Areas ................................................................................................................... 20
5.4. Remedial Measures ............................................................................................................................... 21
5.5. Precautions during Maintenance .......................................................................................................... 21
5.6. Typical Traffic Management Plan .......................................................................................................... 22
5.6.1. Traffic management planning ........................................................................................................... 22
5.6.2. Traffic Management Practices ........................................................................................................... 25

5.6.3. Inspection/Maintenance on street level areas ................................................................................. 26
5.6.4. Traffic Management on Road Junction ............................................................................................. 26
5.6.5. Legal Permissions .............................................................................................................................. 27
6 STATION BOX STRUCTURE ......................................................................................................................... 29
6.1. Concourse Level..................................................................................................................................... 29
6.1.1. Spine & Wing ..................................................................................................................................... 29
6.1.2. Mezzanine Slab .................................................................................................................................. 31
6.1.3. Maintenance of Bearings................................................................................................................... 31
6.1.4. Expansion Joints ................................................................................................................................ 34
6.1.5. Cracks in Concrete Members............................................................................................................. 35
6.2. Platform Structure ................................................................................................................................. 36
6.2.1. PSC Precast Girders ........................................................................................................................... 36
6.2.2. Bearing............................................................................................................................................... 37
6.2.3. Expansion Joints ................................................................................................................................ 37
6.2.4. Wicket gate ........................................................................................................................................ 37
6.2.5. Gutter ................................................................................................................................................ 37
6.2.6. Tactile ................................................................................................................................................ 37
7 ROOF STRUCTURE...................................................................................................................................... 38
7.1. Inspection of Structural Steel ................................................................................................................ 38
7.2. Roof Sheeting ........................................................................................................................................ 38
7.2.1. Personal Safety .................................................................................................................................. 38
7.2.2. Maintenance of Roof ......................................................................................................................... 39
7.2.3. Maintenance of down take pipes ...................................................................................................... 39
7.2.4. Maintenance Guidelines.................................................................................................................... 40
8 STREET LEVEL STRUCTURE ......................................................................................................................... 41
8.1. Entry/Exit ............................................................................................................................................... 41
8.2. Signage................................................................................................................................................... 41
8.3. DG Foundations ..................................................................................................................................... 41
8.4. Hand railing............................................................................................................................................ 41
8.5. Lift Pit and Escalator Pit ......................................................................................................................... 42
9 COMMON DEFECTS ................................................................................................................................... 43
VOLUME – II, Part C ........................................................................................................................................... 44
ANNEXURE 1 Proforma for Inspection of Station.............................................................................................. 44
ANNEXURE 2 Proforma for Periodic Inspection Report of Bearings Inspection ............................................... 45
ANNEXURE 3 Proforma for Structural Steel Inspection Register ...................................................................... 47
ANNEXURE 4 Periodicity of Inspection and Maintenance................................................................................. 48
ANNEXURE 5 Routine Inspection Check List (for Typical Station) ..................................................................... 49
ANNEXURE 6 Detailed Inspection Check List ..................................................................................................... 53
ANNEXURE 7 List of tools for Routine, Detailed & Special Inspection .............................................................. 59
VOLUME – II, Part D ........................................................................................................................................... 60
ANNEXURE 8 Master Maintenance Schedule.................................................................................................... 60
List of Tables
Table 1: Reference, Standards & Codes .............................................................................................................. 8
Table 2: Station numbering ............................................................................................................................... 19
Table 3: Look At For ........................................................................................................................................... 21
Table 4: Minimum Sightline Distances and the Minimum Size of the Signs ..................................................... 23
Table 5: Sign boards during Maintenance ......................................................................................................... 24
Table 6 Maintenance Guidelines ....................................................................................................................... 40
Table 7: Common defects remedial measures .................................................................................................. 43
Table 8 Proforma for inspection of station ....................................................................................................... 44
Table 9 Proforma for Structural Steel Inspection Register ................................................................................ 47
Table 10: Maintenance periodicity .................................................................................................................... 48
List of Figures
Figure 1 Typical Station Cross Section ............................................................................................................... 10
Figure 2 Cross Sectional details of Stations Spine & Wing and Pier arm .......................................................... 11
Figure 3 General Block Diagram of Stations ...................................................................................................... 12
Figure 4: Street Level plan ................................................................................................................................. 13
Figure 5: Concourse level plan .......................................................................................................................... 13
Figure 6: Platform level plan ............................................................................................................................. 14
Figure 7: Organogram........................................................................................................................................ 15
Figure 8 Hand Signs ........................................................................................................................................... 25
Figure 9: Station traffic management ............................................................................................................... 27
Figure 10 Cross Section at Concourse level of Station ...................................................................................... 29
Figure 11: Spine end-sections near pier ............................................................................................................ 30
Figure 12: Spine section at centre ..................................................................................................................... 30
Figure 13: Spine & Wing cross section near pier ............................................................................................... 30
Figure 14: Spine 7 Wing cross section at Centre ............................................................................................... 30
Figure 15 Isometric view of elastomeric bearing .............................................................................................. 31
Figure 16: Bearing pedestal detail at Concourse level ...................................................................................... 32
Figure 17 Cross Section at Platform level of Stations........................................................................................ 36
Figure 18 General arrangement of station roof structure ................................................................................ 38
Figure 19 Typical Stations- Internal Staircase.................................................................................................... 41

The Station Civil Maintenance Manual is divided into 8 Chapters as mentioned below. Each Chapter has
specific information which makes a progressive link of information required for the Maintenance Activity of
the Station Civil for Hyderabad Metro Rail.
VOLUME – I. Technical Manual
Part-A Part-B
- INTRODUCTION - Types of Station
Abbreviations - General Arrangement
- List of Reference, Standards and Codes
Part-C
- Station General Block Diagram
VOLUME – II. Maintenance Manual
Part-A Part-B
- Objectives - STATION BUILDINGS STRUCTURES
- Roles & Responsibilities - STATION BOX STRUCTURE
- Chief Station Maintenance Engineer - ROOF STRUCTURE
- Inspection Officer - STREET LEVEL STRUCTURE
- Assistant Officer
- Knowledge of rules and regulations
Part-C Part–D
- ANNEXURE 1 Proforma for Inspection of Station ANNEXURE 8 Master Maintenance Schedule
- ANNEXURE 2 Proforma for Periodic Inspection
Report of Bearings Inspection
- ANNEXURE 3 Proforma for Structural Steel
Inspection Register
- ANNEXURE 4 Periodicity of Inspection and
Maintenance
- ANNEXURE 5 Routine Inspection Check List (for
Typical Station)
- ANNEXURE 6 Detailed Inspection Check List
- ANNEXURE 7 List of tools for Routine, Detailed &
Special Inspection

VOLUME-I, Part-A
INTRODUCTION
The Hyderabad Metro Rail Project (HMRP) envisaged by the Government of Telangana covers three high
density traffic corridors of Hyderabad. This project is structured as a Public Private Partnership (PPP) Project
on design, build, and finance, operate and transfer (DBFOT) basis. The Metro consists of 3-Corridors (Lines)
Corridor 1 Miyapur – LB Nagar (27 stations);

Corridor 2 Jubilee Bus Stand – Falaknuma (16 stations);
Corridor 3 Nagole – Shilparamam (23 stations).
A total of 66 stations are planned for Hyderabad Metro Rail Project.
The scope of work is operations and maintenance for the station civil that includes the station structures
which include Roof, Platform, Concourse, Entry & Exit staircases and retail areas based on ROW. This Manual
specifies the Technical Maintenance Plan (TMP) for different types of the station in HMRP. This Manual
covers the general construction issues and remedial measures and similarly the inspection maintenance of
the structures. It provides a general overview of the Station Structure as a System and includes essential
information relating to their maintenance.
Abbreviations
Abbreviations Description
AFC Automatic Fare System
ASS Auxiliary Sub Station
COM Communication
CSME Chief Station Maintenance Engineer
DB Distribution Board
DBFOT Design Build Finance Operate and Transfer
DG Diesel Generator
EFO Excess Fare Office
EPS Emergency Power Supply
FEA Fire Equipment Area
HMRP Hyderabad Metro Rail Project
IRS Indian Railway Standard
NDT Non Destructive Test
O&M Operation and Maintenance
PPP Public Private Partnership
PSS Power Supply and SCADA
PTFE Poly Tetra Fluoro Ethylene
S&TC Signalling and Train Control
SCR station control room
SER Signalling Equipment Room
SW Station Work
TER Telecom Equipment Room
UPS Uninterrupted Power supply

List of Reference, Standards and Codes

Reference Description
IS 456-2000 Code of Practice for Plain and Reinforced Concrete.
IS 1343-1980 Code of Practice for Prestressed Concrete.
IS 800-2007 Code of Practice for General Construction in Steel.
IS: 2062 – 2006 Steel for General Structural Purposes.
IS: 1161 – 1998 Specification for Steel tubes for Structural Purposes.
IS: 2911(Part 1 Sec2) Code of practice for design and construction of pile foundations. Part 1 Concrete
– 1979 piles, Section 2 Bored cast-in-situ piles
IS 14593-1998 For pile Foundations.
IS: 432 (Part 2) – Specification for Mild Steel and Medium Tensile Steel Bars and Hard Drawn Steel
1982 Wire for Concrete Reinforcement – Hard Drawn Steel Wire.
IS 875 (Part 1) - 1987 Code of Practice for Design Loads (other than earthquake) for buildings and
structures – Unit weights of buildings materials and stored material.
IS 875 (Part 2) - 1987 Code of Practice for Design Loads (other than earthquake) for buildings and
structures – Imposed loads.
IS 875 (Part 3) – 1987 Code of Practice for Design Loads (other than earthquake) for buildings and
structures – Wind loads.
S 875 (Part 4) – 1987 I Code of Practice for Design Loads (other than earthquake) for buildings and
structures – Snow loads.
IS 875 (Part 5) – 1987 Code of Practice for Design Loads (other than earthquake) for buildings and
structures – Special loads and load combinations.
IS: 1786 – 2008 Specification for High Strength Deformed Steel Bars and Wires for Concrete
Reinforcement.
S: 1893 – 2002 Criteria for Earthquake resistant design of structures.
BS: 4447-1983 Specifications for the Performance of Prestressing Anchorages for Post-Tensioned
Construction.
BS: 4486 Specifications for High Tensile Steel bars used for Prestressing.
BS: 8004 Code of Practice for Foundations.
CEB-FIP For general guidance on prestressing concrete structures.
Delhi Metro Rail Corporation- Indian Railways
Indian Railway Bridge Manual- 1988
L&TMRHL/OE/STAGE Hyderabad metro rail stations Design Basis Report
1/D-2/1 Rev-H
Table 1: Reference, Standards & Codes

VOLUME-I, Part-B
1 Types of Station
Broadly stations can be classified into three types:
 Typical stations
 Special stations
 Interchange Stations
Typical station
There are 55 typical stations in this project. These consist of three levels – street level, concourse level and
platform level. Street level: There are total four entry-exits on both sides of each station for passengers to
enter station box from street level. All sump & pump rooms and DG are located at street level. Also there are
2 staircases at the street level and a lift on each side of station.
Concourse level: All technical rooms and retail areas are located in this level.
Platform level consists of DB, FEA shafts and the station roof. There are emergency exits at the four corners
of the Platform. The standard dimensions of the typical station:
 station Length– 138.85m
 station Width– 20.00m
 station Height (with respective to road level) – Varies with site condition, min. 21.75m
 Typical span of the station – 13.4m/17m
Interchange station
Interchange station connects two corridors. There are 3 interchange stations. Out of the three, 2 stations –
Ameerpet and MGBS stations consists of 2 platforms – lower platform and upper platform each connecting
one corridor.
Parade ground station consists of two independent stations (Corridor-2 & Corridor-3) connected through
sky-walk. Station in Corridor-2 is a multilevel station consisting of 3 levels namely Lower concourse, Upper
concourse and Platform level. Lower concourse further consists of 3 levels. Level 3 is the lower most level
and consists of toilets, food court, retail, auxiliary substation, emergency power supply and battery rooms.
Lower concourse level 2 and 1 consists of F&B outlet, retails, toilets and ticket office. Excess fare office is in
lower concourse level 2. Upper concourse level is similar to typical station except that the excess fare office
and ASS room are not at this level. Platform level is similar to typical station in all aspects.
Special station
There are 3 special stations in this project – Jubilee Check post, Punjagutta and Hi-tech city.
Jubilee Check post is a single level station with mezzanine covering part of the station. The technical rooms
like ASS, TER, SER, UPS, EPS and battery rooms are located at the mezzanine level. Ticket office, SCR and EFO
are located at platform level.
Punjagutta and Hi-tech city are multilevel stations. Hi-tech city station contains lower concourse covering
few spans of the total station. Punjagutta station contains lower concourse covering full station area. The
upper concourse and platform levels are similar to the typical stations.
Station consists of 2 level slabs:

 Concourse level structural system is of Spine and wings. Spine beam rests on Pier cap and Cantilever
wings are fixed to spine beams on either side
 Platform level structural system is of Pier arm fixed on top of pier cap and precast longitudinal girders
below platform slab supported on the pier arm. Composite slab (precast with cast-in-situ topping) is
used as floor Decking system.

2 General Arrangement
Roof
Platform
Concourse
Street Level
Figure 1 Typical Station Cross Section
Every typical station consists of Street level, Concourse level, Platform level and Roof.
 Street level: Houses the Sump & Pump room, DG set and Entry/Exit with Staircases, Elevators &
Escalators.
 Concourse level: Typically houses technical rooms of all contractors like SW, PSS, AFC, O&M, COM and
S&TC. It is segregated in to paid and unpaid areas with unpaid areas having retail outlets. The spine and
wing arrangements for the station are shown in Figure 2. The grade of the concrete shall be M50. The
cables shall be 19K15 low relaxation stress relieved HTS strands conforming to Class-2 of IS: 141628.
Sheathing shall be HDPE (ID. = 17mm). Spines are joined together by longitudinal stressing, whereas
wings are stitched to spines through transverse stressing.
 Platform level: Terminal stations / interchange stations have the train Crew room located in the platform
level. There are two DB closets at platform level which will house the electrical distribution boards and
earth terminals. There are 4 FEA shafts at the platform level of each station.
 Roofing system – Structural steel supported with roof sheet

Figure 2 Cross Sectional details of Stations Spine & Wing and Pier arm

VOLUME-I, Part-C
3 Station General Block Diagram
The following section breaks down different elements of a Station and also shows different architectural
plan viz. Street, Concourse and Platform.
STATIONS
Concourse Platform
Street Level Roof Level
Level Level
Prestressed
Entry Exit Spine & Wing Structural Steel
Precast Girder
Bearing
UG Sump & Pump Bearing Roof Sheeting
Corbel
DG Foundation Slab (Composite) Solar Panel
Expansion Joint
Signage Expansion Joint
Mezzanine Slab Roof walkway
Lift pit Wicket Gate
Stair Case Gutter
Escalator pit Elevator shaft Gutter

Sewage line / Escalator supports
Manholes Signage
Signage Fire & DB shafts
Technical Rooms Hand Rails
Toilets
Handrails
Gutter
Figure 3 General Block Diagram of Stations

Figure 4: Street Level plan
Figure 5: Concourse level plan

Figure 6: Platform level plan

VOLUME – II, Part A
4 MAINTENANCE AND INSPECTION
4.1. Objectives
The station inspection is done to ensure the safety and serviceability during the service life of the station civil
structures. The purpose of inspection of station can be classified as follows:
 To ensure that the structure is safe and fit for the designed purpose. This relates to the gradual
deterioration of the station structure with time or due to any accidental occurrence;
 To identify the actual and potential sources of trouble at the earliest possible stage;
 To record systematically and periodically the condition of the structure. This enables the concerned
authorities to identify any significant structural changes and defects;
 To provide necessary information on which decision can be taken for carrying out maintenance repairs,
strengthening and replacement of the structural components, if any;
 To keep close coordination with operations team to record any abnormalities during operation stage
leading to requirement of any need based inspection (other than periodical);
 Preventive maintenance of various elements of station/s.
4.2. Roles & Responsibilities

It is identified that there shall be 3 key staff identified for the implementation of this manual. The Chief
Station Maintenance Engineer (CSME), Inspection Officer and Assistant Officer, shall be appointed by the
Concessionaire. It may be noted that the designation may change during the course of maintenance of
Stations.
Chief Station
Maintenance Engineer
Over all responsibility of the maintenance of the
Station Civil
For different Stations
Inspection Officer Inspection Officer

Responsible for the thoroughness of the Responsible for the thoroughness of the
field inspection and the first level of field inspection and the first level of
analysis. analysis.
For different Stations
Assistant Officer Assistant Officer

To take up the activities related to To take up the activities related to
coordination of maintenance and coordination of maintenance and
inspection activities inspection activities
Figure 7: Organogram

4.3. Chief Station Maintenance Engineer
CSME is responsible for the overall station civil inspection and maintenance and should ensure that all
activities are carried out safely and periodically as per the schedule. As part of this team, there shall be an
Inspection Officer and Assistant Officer.
CSME shall be a competent, qualified Engineer not below the rank of a Senior Manager. CSME must be
thoroughly familiar with design and construction features of the station civil to interpret properly what is
observed and know what is to be reported. CSME must be able to recognise any structural deficiency, assess
its seriousness and take appropriate action necessary to keep the station civil in safe condition. CSME must
also recognise the areas of the station civil where a problem is identified so that preventive maintenance can
be properly programmed. CSME should have an overall idea of the interfaces of other systems with civil.
4.4. Inspection Officer

The Inspection Officer (IO) shall be responsible for the thoroughness of the field inspection, analysis of all
findings ascertained by the inspection and the subsequent recommendations for corrections of defects,
posting for restricted load and/or speed, any other recommendations deemed necessary. IO shall keep all
the structural components in observation at routine intervals specified by CSME. IO shall record all the
inspection details in the register maintained for this purpose
4.5. Assistant Officer

It is recommended that a dedicated Assistant Officer (AO) should be nominated for co-ordinating the
maintenance and inspection activities for a specific station. All relevant documents, tools/tackles and
accessories should be in the custody of this officer. AO shall maintain all the bearings including oiling and
greasing. AO should also arrange for the Inspection Officer’s visit and arrange for all the labour force and
assistance that is to be provided to the Inspection Officer.
4.6. Knowledge of rules and regulations

Station Civil Maintenance Team shall be well acquainted with the rules, regulations and procedures
concerning their work and duties. They shall keep in touch with the orders & circulars issued by higher
authorities from time to time and effectively act upon them. Inspection Officer/Assistant Officer shall ensure
that all the staff working in the team are well acquainted with the relevant rules, working methods &
efficiently perform their duties. They shall be periodically examined as specified on appointment. The
Inspector should keep close coordination with the staff for works with signalling, electrical, traction and
other departments when they are required to work jointly.
Every Inspection Officer/ Assistant Officer shall have copies of following updated revision.
 Schedule of Dimensions;
 Circulars issued by OCC and/or higher authorities.
All personnel and equipment who may intend to use this manual for the maintenance of the station civil
assets must be suitably qualified and certified to be able to operate on the HMRP. The Operator shall be
responsible for ensuring that personnel are operating under safe systems of works. Part of this may include
undertaking tests, prior to working, to determine if there are any hazardous materials that may affect
personnel. Utmost care and safe working practices shall be observed while performing any activity on the
station civil of the Hyderabad Metro system by all Station Civil Maintenance personnel, as follows:
 all personnel shall wear the appropriate Personal Protective Equipment (PPE) like safety shoes, high-
visibility vest, safety goggles, helmet, harness, gloves, mask etc. when working at site.;
 a trained and competent member shall be the Person In Charge (PIC) for the duration of the preventive
or corrective maintenance;
 coordinate with Roads Department and/or Traffic Police as necessary for works requiring lane closures
prior to commencement of work;

 the PIC shall ensure all safety equipment, maintenance tools, equipment and consumable to complete
the maintenance task are taken to site;
 all members of the workgroup shall use prescribed tools & equipment for any activity;
 the PIC shall ensure their own safety and the safety of the workgroup at all times (for example restriction
of mobile usage while working on heights);
 the PIC shall book-in according to the Permit To Work (PTW) System in place, especially when working
on the line side i.e. on the track or platform edge;
 The Person-In-Charge shall give a toolbox talk to the workgroup;
 all station civil line side inspections shall be conducted based on the available permit in the control areas
subjected to the Traffic block and/or Power block;
 all equipment shall be carried and secured on or across the neck, body and waist with equipment
hanging away from overhead electric lines;
 if any equipment is required to be manually handled, then this shall always be done from a stationary
position;
 Upon completing the inspection, the PIC shall book-out as per PTW System in place.
4.7. Periodicity of Inspection

For maintenance of the Station, regular and periodic inspection should be carried out for different elements
of the station. In general 3 types of inspection are required to be carried out:
 Routine inspection at close time intervals, once in every six months for the first year. Thereafter it
should be done yearly;
 Detailed inspection at longer time intervals, once in every five years;
 Special inspection should be done in the event of accidents, earthquake, and major weakness
noticed during routine or detailed inspection, unusual settlement of foundations, substantial
changes in traffic pattern, etc.
4.8. Type of Inspection
4.8.1. Routine Inspection

It is the periodic examination of the general condition of a structure. Each inspection is to be recorded in the
Station Routine Inspection checklist. It will be primarily a visual inspection supplemented by simple
instrumental aids available with the inspecting officials. The inspection should be such as to discover all
indications of deterioration/ damage such as texture or colour of concrete, exudation, cracks, spalling,
delamination, leaching, rust streaks, deformation, drainage system, bearing condition etc.
The periodicity of inspection should be once in every six months for the first year, there after on yearly basis
and preferably carried out prior to the onset of monsoon. This inspection should be carried out at the level
of Assistant Officer under the guidance or supervision of Inspection Officer. This inspection shall be carried
out as per the frequency mentioned in Volume-II, Part D, ANNEXURE 8 Master Maintenance Schedule of this
manual commencing from date of Commercial Operations.
4.8.2. Detailed Inspection

Detailed inspection involves close examination of the elements of the structure. This is more intensive and
thorough inspection than the routine inspection. All parts must be closely examined and if necessary, special
equipment should be made available to facilitate this inspection. First detailed inspection should be done
preferably before the defect liability period of the contract expires.
Inspection Officer under the guidance of CSME should conduct detailed inspection. The detailed inspection
should be planned in such a manner that Stations are inspected once in every five years. A fixed sequence of
inspection being observed to ensure that the period of detailed inspection for any part of the structure is not
more than five years. This inspection shall be carried out as per the frequency mentioned in Volume-II, Part

D, ANNEXURE 8 Master Maintenance Schedule of this manual commencing from date of Commercial
Operations.
4.8.3. Special Inspection

Special inspections are to be done in the event of unusual occurrences such as:
 Weaknesses are discovered during the routine or detailed inspection or by any other observation.
 Station loading is increased due to revised or increased loading standard.
 Settlement of foundation is noticed.
 Expectation events like earthquake, flood, storm, fire, accidents, etc. take place.
 Collision of road vehicle with the station pier, Entry/Exit column;
 Derailment of train / engineering vehicle in or around the platform area of station.
Special inspection is need based and should be carried out as and when required. However, special
inspection may require supplementary testing and structural analysis and may require detailed involvement
of CSME. It may be noted that the check list for Detailed Inspection can also be used for Special Inspections.

VOLUME – II, Part B
5 STATION BUILDINGS STRUCTURES
5.1. General
Maintenance of the buildings and other structures at station is undertaken to keep, restore or improve every
facility to a currently acceptable standard and to sustain the utility and value of the facility in an operational
condition. In order to achieve the above, the type of repairs as a follow up of inspection can be classified as:
 Day-to-Day repairs;
 Periodic repairs;
 Special repairs.
STATION LOCATIONS
CORRIDOR - 1 CORRIDOR - 2 CORRIDOR - 3
Code Station Names Code Station Names Code Station Names
R1 Miyapur G1 Parade Grounds B1 Nagole
R2 JNTU College G2 Secunderabad B2 Uppal
R3 KPHB Colony G3 Gandhi Hospital B3 Survey of India
R4 Kukatpally G4 Musheerabad B4 NGRI
R5 Balanagar G5 R.T.C Cross Roads B5 Habsiguda
R6 Moosapet G6 Chikkadapally B6 Tarnaka
R7 Bharat Nagar G7 Narayanguda B7 Mettuguda
R8 Erragadda G8 Sultan Bazar B8 Secunderabad
R9 G9 MG BUS Station B9
ESI hospital (Interchange station) Parade Grounds
R10 S.R Nagar G10 Salarjung Museum B10 Paradise
R11 Ameerpet (Interchange G11 B11
station) Charminar Rasool Pura
R12 Punjagutta G12 Shalibanda B12 Prakash Nagar
R13 Irrum Manzil G13 Shamshergunj B13 Begumpet
R14 G14 B14 Ameerpet (Interchange
Khairatabad Falaknuma station)
R15 Lakdi-Ka-Pul B15 Madhura Nagar
R16 Assembly B16 Yusufguda
R17 Nampally B17 Road No.5 Jubilee Hills
R18 Gandhi Bhavan B18 Jubilee Hills Check Post
R19 Osmania Medical College B19 Pedamma Temple
R20 MG BUS Station B20
(Interchange station) Madhapur
R21 Malakpet B21 Durgam Cheruvu
R22 New Market B22 Hi Tec City
R23 Moosarambagh B23 Shilparamam
R24 Dilsukhnagar
R25 Chaitanyapuri
R26 Victoria Memorial
R27 L B Nagar
Table 2: Station numbering

As the age of the structure goes up, deterioration occurs due to which repairs and replacement to the
facilities becomes inevitable. Every station should be numbered as instructed by the CSME so as to facilitate
reference in correspondence and making entries in the log book.
5.2. Inspection and Repairs

 All areas of Stations shall be systematically inspected by the Assistant Officer. The inspection will be
recorded in the inspection register as per Proforma given in Annexure 1.
 Assistant Officer should inspect all the areas, water supply installations, sewerage installations and
drainage arrangement twice a year after the first year. As an extra precaution inspections will be thrice
in the first year of Operation. Repairs requiring urgent attention should be carried out expeditiously.
 Inspection Officer should inspect as many station areas as possible particularly those requiring heavy
repairs and arrange for all repairs to be carried out in good time.
 Station areas should be inspected taking care of complaints of the concerned staff in the presence of or
with their prior consent.
 Valley gutters, vertical down take pipes in station areas and platform covers etc. should be attended
before monsoon to clear any blockages.
 Planning of repairs should be based on inspections carried out as mentioned above and completed well
in time to enable the repairs being done.
 It may be preferable to have annual contracts for maintenance.
5.3. Inspection of Station Areas

Structures such as platform roof sheets and roof trusses should be inspected by Assistant Officer once a year
during the prescribed months and once in five years on a programme basis by Inspection Officer.
Points to be noted during inspection of Structural steel are detailed out in section 7.1 of this Manual.
Maintenance of Concrete works and Architectural works are detailed out in the manual in sections 6 and 8
respectively.
LOOK
AT FOR
All over  General condition of the structure and pre-stressed components;
 Condition of concrete;
 Cracks;
 Corrosion signs;
 Scaling of concrete;
 Spalling of concrete;
 Efflorescence;
 Condition of construction joints.
Dampness  At all the external wall through visual inspection;
 During rainy season;
 Check for leaks due to rains;
 Leakage/crack in the PHE pipes;
False ceiling  check for sagging through visual inspection;
 fix the screws;
 Check for any loading at that area over the false ceiling and replace;
 For gypsum tile it should be replace with a new one;
 For the metallic tile, the same can be used;
 Inspection to be done by-yearly.
False floor  If tiles will come up re-fix the supports replace the same and place it properly;
 Inspection to be done 6 monthly.

LOOK
AT FOR
 Broken or loose skirting of false floor;
 Broken, bent or loose floor tile pedestal
Flooring  crack in the granite to be checked;
soundness  bulging of the tile;
 remove and refit the loosened or overlapping tiles;
 Inspection to be done quarterly.
Waterproofing  Comprehensive waterproofing at stations;
 Visual inspection from concourse to platform bottom;
 Visual inspection from street level to concourse bottom around toilet area;
 Remove the area identified and redo the water proofing is required after CSME's
recommendation;
 Water proofing vendor should be approached it happens within the warranty
period;
 Inspection to be done yearly.
Expansion Joint  Cracks or ruptures;
 Puncture that may allow water to flow;
 Accumulation of dust and debris.
Cladding  Sharp edges;
 Loose section of cladding;
 Cracks.
Roof sheeting  Loose sheets and/or connection;
 Missing sheets;
 Overlap or gaps in sheets’;
 Corrosion or discoloured sheet.
Structural Steel  Levels of corrosion;
 Loose nuts or broken welding;
 Bends in the section (columns or beams);
 Paint peeling off or change in colour.
Drainage  Free of dust and debris;
 No blockage in the path;
 No crack or bends or damage in the drain pipes.
Table 3: Look At For
5.4. Remedial Measures
This section covers general details of the possible remedial measures available for the various components
of the Stations. It is recommended that for any serious distress observed, a proper agency should be
appointed to determine the causes of the distress and to recommend suitable remedial measures. It is
suggested to follow the frequency of inspection/ time period for taking up regular maintenance. Safety of
Users - the public and operating personnel shall have the first priority.
5.5. Precautions during Maintenance

 The Assistant Officer / Inspection Officer shall arrange for lockout men equipped with hand signal flags
stationed on both sides for issuing caution orders to drivers.
 The Inspection Officer must personally be satisfied that no staging shall infringe standard moving
dimension. If this is not possible the work shall be done under block protection.
 Work shall be carried out under proper supervision near the overhead traction lines after obtaining
traffic and power blocks.

 All personnel and equipment who may intend to use this manual for the maintenance of the Station Civil
assets must be suitably qualified and certified to be able to operate on the HMRP;
 The Operator shall be responsible for ensuring that personnel are operating under safe systems of
works;
 Part of this may include undertaking tests like bad odour, accumulation of smoke, excessive dust, prior
to working, to determine if there are any hazardous materials that may affect personnel;
 Work near conductors carrying traction currents shall be done after obtaining traffic and power blocks
and under possible supervision; of Station civil personnel;
 When a maintenance or repair operation affects track, such work must invariably be done in
consultation with and in the presence of permanent way inspector;
 It is vital that everyone involved in working from a cherry picker can do their work safely. These lists
show the knowledge people in your workplace need to have if they use a cherry picker in their day-to-
day work. An elevated work platform (also known as a cherry picker, boom lift, man lift, basket crane or
hydra-ladder) is a type of aerial work platform that consists of a platform or bucket at the end of a
hydraulic lifting system shall be used for inspection of bearings. Check the wheels are in good condition
and the brakes are working properly. Check the working platform – is it in good condition? Check the
guard rails and the gate or barrier. Check the locking pins and joints for corrosion or damage. Check the
struts for corrosion and bends. Check the controls – make sure they work as expected. Check the fluid
and/or battery charge levels. Check the outriggers and feet. Check that the descent alarm and horn is
working. Check the emergency or ground controls are working properly.
5.6. Typical Traffic Management Plan

The basic objective of the following guidelines is to lay down procedures to be adopted by Maintenance
teams to ensure the safe and efficient movement of traffic and ensure the safety of staff. All staff shall be
provided with PPE, as most of station works or either above or under right-of-way. The Conspicuity of
workmen at all times shall be increased so as to protect from speeding vehicular traffic. The guiding
principles to be adopted for safety in maintenance zone are to
 Warn the road user clearly and sufficiently in advance.
 Provide safe and clearly marked lanes for guiding road users.
 Provide safe and clearly marked buffer and work zones.
 Provide adequate measures that control driver behaviour.
Hazards in street level maintenance works due to external traffic

 Construction workers hit by external vehicles while working.
 Injury to Pedestrians.
 Due to fall in excavated trenches.
 Hit by construction equipment / vehicle.
 As they use carriageway due to blockage / absence of footpath.
 Collision due to improper traffic management.
 Between external vehicle and construction equipment / vehicle.
 Between external vehicles.
 External vehicle with other stationery objects in the side of the road.
5.6.1. Traffic management planning

Traffic control plan
This plan gives the detailed guideline for traffic management in most of the common situations at our Road
Projects. Traffic Control Plan for a specific project shall be prepared based on this general guideline and
applying the following variables, which may vary from project to project. The variables are
 Average Vehicular Traffic Density in peak and non-peak hours.
 Maximum width of lane required for construction during various activities.
 Number and types of junctions in the road.
 Availability of standard footpath and its location and dimensions.
 Change in the lane width if any and its location.
 Regulatory and advisory speed limits etc. (like dump trucks, trailers, etc.) have proper license to ply on
public roads from the State Transport Authority. Drivers holding proper valid license as per the
requirements of Motor Vehicles Act shall drive these vehicles
Traffic Control Devices

Traffic control devices used to regulate the traffic in Road maintenance Zones include, Road Signs- are
classified in to three major categories. They are:
Mandatory / regulatory signs

These signs impose legal restriction on traffic and violation of these signs is an offence. These include all
signs, which give notice of special obligations, prohibitions or restrictions with which the road users must
comply. Regulatory signs are mostly circular in shape.
Average Distance of first sign in advance of Size of Warning Minimum no of signs in

Speed (Km/H) the first channelizing device (m) Sign (mm) advance of the hazard
Under 50 100 600 3
51-60 100-300 750 3
61-80 120-300 900 3 or 4
81-100 300-500 1200 4
Over 100 1000 1200 to 1500 4
Table 4: Minimum Sightline Distances and the Minimum Size of the Signs
Cautionary / warning signs

These signs are used to warn road users of the existence of certain hazardous conditions either on or
adjacent to the roadway, so that the motorists are cautious and take the desired action. Cautionary signs are
triangular with red border and black symbol or message on white background.
Information signs
These signs are used to guide road users along routes, inform them about destination and distance, identify
points of geographical and historical interest, and provide other information that will make the road travel
easier, safe, and pleasant. They are usually rectangular in shape.

Table 5: Sign boards during Maintenance
Delineators
The delineators are the elements of a total system of traffic control and have two distinct purposes:
 To delineate and guide the driver to and along a safe path
 As a taper to move traffic from one lane to another.
These channelizing devices such as cones, traffic cylinders, tapes and drums shall be placed in or adjacent to
the roadway to control the flow of traffic. These should normally be retro-reflectors complying with IRC: 79 -
Recommended Practice for Road Delineators.
Barricades
 Full height fence, barriers, barricades etc. shall be erected around the site in order to prevent the
working area from the risk of accidents due to speedy vehicular movement. Same the way barricades
protect the road users from the danger due to construction equipment and other temporary structures.
 All barricades shall be erected as per the requirements of the works being carried out and in line with
Traffic Management Plan and maintained in good condition.
 All barricades shall be conspicuously seen in the dark/night time by the road users so that no vehicle hits
the barricade. Conspicuity shall be ensured by affixing retro reflective stripes of required size and shape
at appropriate angle at the bottom and middle portion of the barricade at a minimum gap of 1000mm.
In addition adequate light or red light blinker shall be placed at the barricades.
Cones
Traffic cones of 500mm, 750mm and 1000mm high and 300mm to 500mm in diameter or in square shape at
base and are often made of plastic or rubber and normally have retro-reflectorized red and white band shall
be used wherever required.
Drums
Drums about 800mm to 1000mm high and 300mm in diameter can be used either as channelizing or
warning devices. These are highly visible, give the appearance of being formidable objects, and therefore
command the respect of drivers.

Pylons
Pavement markings
Flashing lights.
5.6.2. Traffic Management Practices

Working zone:
All Maintenance sites for e.g. excavation, chamber opening etc. at which workmen will be working is
considered as working zone.
Working space:
The space around the works area that will need to store tools, excavated material, equipment, and plant. It
is also the space to allow workmen, movement and operation of plant, (e.g. swing of jibs, excavator arms) to
move around to do the job. Materials and equipment must not be placed in the zone either. Workmen will
only need to enter the zone to maintain cones and other road sign.
Figure 8 Hand Signs
Safety zone:
The zone that is provided to protect workmen from the traffic and to protect from the hazards at that site.
Approach transition zone:

This will vary with the speed limit and the width of the works as given in (drag: Traffic control zone)
Longitudinal buffer zone:

This is the length between the end of the lead-in taper of cones (T) and the working space. It will vary with
the speed limit as given in table 4 (Traffic Control zone)
Lateral buffer zone:

This is the width between the working space and moving traffic. It will vary with the speed as given in table
(Traffic Control zone). The lateral buffer zone safety clearance is measured from the outside edge of the
working space to the bottom of conical sections of the cones on the side nearest to the traffic. Survey on
existing live divided carriageway

5.6.3. Inspection/Maintenance on street level areas
Special care is taken to regulate traffic while carrying out inspections / maintenance works during live traffic
at street level areas. The traffic for a stretch of 20m shall be blocked using signage and Marshalls for a period
of 2 mins for taking measurements / markings. The traffic should be diverted on service road if available.
Work to be carried out during night off-peak hours.
 The maintenance zone will be barricaded by red-reflectorized cones with white band and tying red cloth
or warning tape top of safety cone.
 Flagman (refer Figure 8 Hand Signs) will be appointed at both sides start and end of the transition zone.
 Gap between barriers (cones) shall be closed to redirect errant vehicles inside the safety zone.
 No personnel are allowed to come out of the safety zone, unless flagman guidance.
 First aid kit, water bag, communication service must be carried along with.
Live traffic lane management

 The traffic would continue to ply on the left or right hand lane (subjected to areas under maintenance)
of the carriageway; layout will be made by Give and take system or Priority signs.
 Flagman (refer Figure 8 Hand Signs) will be appointed at both sides start and end of the transition zone.
 The maintenance zone will be barricaded by red-reflectorized cones with white band.
 Gap between barriers (cones) shall be closed to redirect errant vehicles inside the safety zone.
 No personnel are allowed to come out of the safety zone, unless flagman guidance.
 First aid kit, water bag & communication service will be provided.
 Divert traffic to the slip road (if available) for the working during the off peak hours.
Material delivery management

 There are parking facilities at a few stations, which is different for different stations. All materials may be
supplied to the station during the off-peak hours. It there is a slip road, then it may be used for short
term parking and the goods may be transferred through stair-case.
5.6.4. Traffic Management on Road Junction

Construction traffic meets live traffic from quarry/plant/borrow pit
 Where vehicles are more to the approach junction from the side road, permission will be seek for
providing speed breaker at junction from local traffic police and road-authority
 Flag man will be kept in the peak time provided with the traffic circle painted with red and white at the
corner at a height of 500 mm, clearly visible to approaching traffic for a distance provided with while
gloves and STOP, GO Paddle. And night time flagman shall use LED Batons.
 All vehicles from approaching road shall be STOP, LOOK, and GO/PROCEED.
 Spillage of earth / Gravel / Aggregates / Bituminous mix from the tipper will be cleaned on routine basis,
if required 2 workmen will be permanently posted for brooming.
 All Construction vehicles must follow lane discipline and road signs.

Figure 9: Station traffic management
5.6.5. Legal Permissions

 In all cases, Maintenance Contractor shall employ proper precautions. Wherever operations undertaken
are likely to interfere with public traffic, specific traffic management plans shall be drawn up and
implemented by Maintenance Contractor in consultation with the approval of local police authorities
and/or the concerned metropolitan/civil authorities as the case may be. Such traffic management plans
shall include provision for traffic diversion and selection of alternative routes for transport of equipment.
 If found necessary by LTMRHL, the Maintenance Contractor shall carry out road widening before
commencement of works to accommodate the extra load. The primary traffic control devices used in
work zones shall include signs, delineators, barricades, cones, pylons, pavement markings, and flashing
lights.
 The road construction and maintenance signs which fall into the same three major categories as do
other traffic signs, that are Regulatory Signs, Warning Signs and Direction (or guidelines) Signs shall only
be used. The IRC: 67 (Code of Practice for Road Signs) provide a list of traffic signs. The size, colours, and
placement of sign shall confirm to IRC: 67.
Internal Traffic Management

 Maintenance Contractor shall ensure that internal traffic management schemes shall be in accordance
with the client requirement.
 Adequate and clear warning signs shall be displayed at appropriate distances before the commencement
of the site workings. In addition prior warning shall be given concerning the location of the approaching
site work, entry, and exit points.
 All traffic signs, barriers, cones, and lighting shall be kept maintained and clean at all times.

 Vehicles exiting the site shall observe caution at all times; if the vehicles are exiting directly onto the live
carriageway then they shall be directed by an identifiable Traffic Marshalls.
 Routine reviews of the traffic management schemes shall be conducted by Maintenance Contractor in
both the daytime and night time hours with the results of these inspections being recorded. These
records shall be kept available for inspection by L&TMRHL’s representative.
 Flagman shall be available for directing vehicles that are working in sites and especially at the turnings of
the site work, any vehicles entering the sites that are required to execute reversing manoeuvres shall do
so under the strict control of a trained and designated person.
Pedestrian Walkway
 Separate walk way will be identified at the site and barricaded on both the sides to avoid the traffic
incidents for the pedestrians, Lighting shall be provided adequately in pedestrians footpath frequent
monitoring shall be done through inspections.
Spoil Removal
 Only well maintained and licensed appropriate vehicles shall be allowed to be used for the removal of
excavated spoil from the sites.
 All drivers operating the appropriate spoil removal vehicles shall be medically fit and in possession of a
valid and current driving licence.
 No vehicles, which are overloaded, shall be allowed to leave the site.
 Any vehicles leaving the sites carrying loads which are liable to produce airborne contaminants shall
prior to leaving the site securely sheet the load over in order to effectively prevent disbursement during
transportation on the public highway.
 Vehicles exiting the site directly onto the live carriageway shall do so under the control of the clearly
identified Traffic Controller.
 Any vehicles that are required to reverse whilst on the site shall do so under the control of a trained
banks man.
 Any vehicles prior to leaving the site shall have their wheels washed and any loose material removed.
 Any spoil that is removed from the work-sites shall be disposed of only at authorised dumping sites.
General Note on deviation from Normal Condition:

Any deviation or distress found shall be referred to Chief Station Maintenance Engineer. He
shall investigate the cause of the distress and recommend for a detailed investigation. This is
in addition to the responsibilities mentioned in section 4.3

6 STATION BOX STRUCTURE
The Station box consists of:
 Concourse Level
 Platform Level
6.1. Concourse Level

The concourse level within the station complex can be segregated in to ‘paid’ and ‘unpaid areas’.
6.1.1. Spine & Wing

The concourse level consists of post tensioned spine beam with wings on either side ensuring the service
requirements like lift and escalator. The spine is a segmental posttensioned beam supported on bearings at
pier corbel. The precast wings are stitched to each other in longitudinal direction and also stitched with the
spine in the transverse direction. The segmental spine and wing is designed as per IRS Concrete Bridge
Codes.
Figure 10 Cross Section at Concourse level of Station
Maintenance of Spine and Wing:

The Spine & Wing shall be inspected for any crack/s on bottom of structure shall be monitored, and
compared to the design values. Graduated blades may be used to measure the width of these cracks.
Regular checks shall be carried out to see any further development in the existing cracks. Expansion of crack
to be monitored using tell-tales and gauges, further investigation and NDT (non-destructive test) may be
required. The epoxy joints between spine to spine and spine to wing segment joints shall be monitored. The
Spine & Wing Seating arrangement on top of the bearings shall be monitored; no gap should be there in
between the spine bottom to the bearing top. If there is a gap observed then the condition of bearing has to
be checked in accordance to section 6.1.3 of this manual.
Deflection checks to be carried out as per routine / detailed inspection schedules. The spine and wing shall
be inspected every six months and any excessive deflection more than L/250 for spine and L/150 for wing
(where L is length of span) due to live load, shall be recorded and monitored. For overall load any excessive
deflection more than 20mm shall be further investigated. Future prestressing ducts shall be used if any
prestressing is required. The root cause analysis shall be determined by thoroughly inspecting joints
between the spine and wings, corrosion of reinforcement, deterioration of concrete etc.
In case of excessive deflection, actual deflection shall be measured and compared with design values. The
deflection can be recorded by using a levelling instrument or theodolite. The points where the camber is
measured should be clearly marked on the underside of the girders so that the reading taken on different
years are comparable.

Prestressing system
Before taking up stressing operation it is to be ensured that the jack and pump are properly calibrated. All
cables shall be stressed from one end only. At any point of time there shall not be residual transverse
eccentric force of more than one cable. The reading pertaining to both force and elongation at every stage
shall be recorded at regular intervals. Jacking force per cable shall be equal to 76.5% of UTS.
Figure 11: Spine end-sections near pier
Figure 12: Spine section at centre
Normally, stressing can proceed on the indication elongation. In case elongation is reached and
corresponding jack pressure is not reached, stressing shall be continued up to 5% in excess of prescribed
elongation. In case jack pressured is reached and elongation in snot reached, stressing can be continued up
to a maximum jack pressure of 1.05 times the calculated pressure. Even in case of variation more than the
prescribed limits, then the matter shall be referred to the
Grouting of strands shall be carried out as per Appendix 5 of IRC-18-2000, thoroughly flushing the sheathing
with water.
Figure 13: Spine & Wing cross section near pier
Figure 14: Spine 7 Wing cross section at Centre
Anchorages: any corrosion and cracks and ducts seating arrangement shall be monitored.

6.1.2. Mezzanine Slab
The mezzanine slab shall be inspected for the cracks, spalling, long term deflections in line with the
periodicity mentioned in the Routine inspection and Detailed inspection.
6.1.3. Maintenance of Bearings

The following types of bearings are generally used. (Check with CWP and also vendor catalogues for
manufacturer’s recommendations.)
 Elastomeric bearing permitting rotation and translation.
Maintenance of Elastomeric Bearings

Elastomeric bearings are made of natural or synthetic rubber of hardness of approximately 60 to 70shore A.
These bearings require periodic cleaning. They may require replacement in service depending on the
condition and usage.
Figure 15 Isometric view of elastomeric bearing

Figure 16: Bearing pedestal detail at Concourse level
Proper inspection of the bearing in terms of measurement of dimensions, physical condition and inspection
of the adjacent structure help to determine the condition of the bearing. It should be ensured that the
bearing is free of dust and any other deposits or any foreign debris. The bearing may be cleaned with clean
water. Tools like brush and lenin cloth may be used for cleaning of the elastomeric bearing.
 The bearings shall be subjected to well planned maintenance;
 The exposed bearing surface shall be maintained clean and free from contamination like grease, oil and
other dirt;
 Damaged bearing shall be replaced immediately to avoid difference in stiffness. All adjacent bearings on
the same line of support shall also be inspected for uniform seating of the main girders over all the
bearings. The decision for replacement of other bearing shall be taken by CSME;
 Routine annual maintenance inspection or special maintenance inspection for all bearings shall be made
to check for any surface cracking or signs of damage, deterioration or distress;
Following are some points which indicate that the bearing is not functioning properly either due to damage
in the bearing or inadequacy in design etc.:
 Peeling of Skin of the Elastomer
 Steel Laminate Exposure
 Separation of Cover
 Back Lift of Contact Edge
 Bulging Overlap
 Evidence of Cracks/Splits
 Partial Loss of Contact
 Evidence of Creep Walk
The condition and replaceability of a bearing can be best ascertained by Professional Inspection of bearings.
Procedure for bearing replacement

 No live load i.e. Passengers and station operation (i.e. lifts and escalators) should be stopped during
replacing the bearings;
 Jacking shall be done on the prescribed location (As per the concourse level corbel drawing reference
HM-LE-HSGHSG-M0201-DWG-NU-STC-08-077 &108). The jacks should be placed on the top of the pier
bracket, for the concourse level bearings. For platform level bearings the jacks should be placed on the
top of pier arm;
 Bearing plate size should be more than the bearing size while jacking up the segments;
 The minimum capacity of each jack = 500 T shall be used for lifting the segments;
 Jack should be low in height since gap between concourse level corbel top to spine bottom is 100 mm;
 The maximum height shall be raised the segments 5 to 10 mm only;
 During jacking up block wall support should be made flexible to facilitate the lifting;
 After lifting the structure, remove the old bearings and grind to clear the bearing contact surface;
 The span are to be jacked UP and temporarily supported during replacement of bearing;
 Grout the top from the side of the bearing;
 Replace the bearing with the new one on a grout bed;
 Release the pressure uniformly and simultaneously in both of the jacks after the grout are set;
 After grout is set, the packers to be removed and jacks brought DOWN; Speed restriction or single line
working shall be implemented until the grout is fully set;
 During releasing the pressure the top level of the concourse should be maintained level and monitoring
should be done by placing gauges;
 After replacing the bearing expansion joint levels and escalator seating arrangements and staircase
levels need to be checked.
Note-1: At most care should be taken while bearing replacement+ to avoid any compounded effect on the
station block wall. The block walls have expansion joint in line with concourse level deck to nullify the effect
of lifting during bearing replacement.
Note-2: The Elastomeric bearings are tested as per the IRC83 Part-1 and IS3400 Part-1 and Part-2.
Cleaning
The inspection should be preceded by thorough and careful cleaning of the bearings, depending on the
actual condition surrounding the bearings e.g. deposit of salt, debris, dust or any other foreign material.
Elements of Inspection
The following are recommended inspection elements and actions, which are considered necessary to
monitor and maintain the bearing:
a. Functioning properly
During inspection at site, it should be checked whether all the components of the bearings are functioning
satisfactorily. This check is more a judgment than measurement and requires an experienced eye. However
the overall malfunctioning may be easily detected by any unusual characteristic or physical property of the
bearing such as excessive movement, leakage/ damage of the elastomer, excessive rotation etc.
b. Measurement of dimensions
Overall dimensions of the bearings are required to be measured and compared with the actual dimensions
to ascertain any excessive stress or strain on the bearing.
c. Condition of the adjacent structures
The adjacent structure of the bearings is also required to be inspected for any damage and if found,
necessary actions to repair the same should be taken immediately.
Maintenance
 Bearings are maintenance free due to its unique features and supporting quality assurance system and
thereby eliminate undesirable effects caused by extreme atmospheric or adverse environmental
condition and/or unforeseen events.
 The surrounding area of the bearings should be kept clean and dry to avoid damage to the bearings.
 The bearings should be thoroughly and carefully cleaned at least once in every year to ensure that there
is no deposit of salt and accumulation of debris, dust or any other foreign material on or adjacent to the
bearings. If the grout is damaged and/or cracked it should be replaced.

6.1.4. Expansion Joints
The maintenance of expansion joints comprises regular inspection, repair, and housekeeping to keep the
structure functional to its intended users. It is recommended that the expansion joints and surrounding area
to be inspected quarterly for general functionality, damage and moisture leakage.
The following checks should be carried out for the expansion joints
 Check if the joints are free of stones and any other debris.
 Are there tears or separation to the continuous water barrier?
 Are there any leaks or cohesive failure of the expansion joint system?
 Are there loose cover plates, hardware or components?
 Is there evidence of underlying substrata failure?
 Are cracks present in the base concrete?
 Check the gap and compare the movement with design values. Movement should not be more than
±20mm. Procedure of replacement & supplier details can be traced from the Station AMS. It may be
noted that the supplier of Expansion Joint for the station is M/s. Construction Speciality for the station
box and M/s. Mageba for Station Entry/Exit.
 Replacement of Expansion Joint

A work procedure in understanding the procedure replaced to replacement of EJ is given in this section. List
of material required to carry out this work is as follows: Aluminium Extruded Sections, Glue/Adhesive (Dr
Fixit), EPDM Water Barrier, Anchor fastener, GP 2 Cementitious Grout, Coarse Aggregate (10 mm), Plastic
Sheet.
The sequence of works shall be as follows:
 Getting approval from interface departments (like live equipments below the area wherein the EJ is
being replaced). Station manager shall intimate all interface department regarding on going
rectification and take concurrence prior to start rectification process.
 Precautions: As a precautionary measure make bund on both sides of expansion joint. To prevent
water seepage in expansion joint always Keep plastic sheet nearby to cover from rain water as safe
side. As per MSDS recommended for glue
 Removing Expansion joint aluminium profile: Remove expansion joint aluminium profile without
damaging adjacent granite flooring
 Saw cutting GP2 till EPDM sheet: From the edge of granite stone make a saw cut a grove entire
length. Chip off GP2 with chisel till end of the EPDM sheet. Care shall be taken while chipping near
granite stones. Remove puncher EPDM sheet carefully
 Remove the puncher EPDM sheet
 Surface preparation: Remove existing glue material from both sides of slabs using grinder on the
mother slab. Any damage or edge broke to the slab shall be rectified using GP2 grout. Expansion
joint surface should be cleaned with air blower or air compressor to remove all loose materials, dust
etc. Expansion joint should be free from oil, grease or fuel etc.
 Application of Glue/Adhesive: Application location/area shall be free from dust, dirt, oil & grease,
mould release agent and other contaminants. Surface must be completely dry condition. Before
applying glue/adhesive, stir it in the container to achieve a uniform mix with no sediment at the
bottom of container. Apply the glue/adhesive uniformly on both (Concrete and EPDM) the
substrates to be bonded by brush. If porous observed in substrata, second coat of glue/adhesive
application is required, this can be applied after 5 to 10 minutes of first coat. Allow the applied
glue/adhesive to dry 15 to 20 minutes at room temperature. The glue/adhesive after drying exhibits
tack. The finger test has proven itself to be a reliable method of judging the OPEN-TIME, whereas
this time only serves as rough indication, drying time variation may occur due to temperature,
relative humidity, type of substrata etc. In the finger test the adhesive must feel dry but tacky. The
substrates bonded after prolonged open time & in the absence of tack may result in inferior

coalescence & bond strength. After appropriate OPEN-TIME (span between Drying time & Tack
retention Time) bring both the substrates together and align them properly and press firmly. The
bonded components need to be pressed firmly to have complete bond by using rollers, but not to be
kept under pressure fixture.
 Installation of New EPDM sheet: The approved make and materials shall be only used for
installation. The required size of water barrier shall be cut and kept ready as per manufacturer
recommendations. Thickness of EPDM water barrier shall be as per approved specification or
GFC/scheme drawing. Expansion joint portion and either side of joint surface shall be free from
dampness, loose material, dust oil, grease and any other foreign materials. Once the application of
Glue/adhesive to the concrete surface along with expansion joint a width of 35 to 40 mm on both
sides completed fix the EPDM as per drawing. Glue/adhesive shall be applied to the EPDM and allow
touch drying. EPDM water barrier shall be laid along the expansion joint. Fix the EPDM water barrier
sheet along with glue by using with expansion joint by leaving loose/flexible at joint portion. EPDM
water barrier top surface shall be gently rolled with rubber roller and the edges shall be gently
pressed, so that it gets proper bonding with concrete surface
 Water pond test for 48 hours: Allow dry curing of fixed EPDM water barrier for 12 hours. Make bund
with blocks for water pond test and offer client inspection before starting. Pour water up to required
level inside the bund and make a mark on top level. After 48 hours check water level which has to
match with previous level and also check for any leakages below the expansion joint. If any leakages
remove water and repeat the process for fixing of New EPDM sheet
 Laying/ Filling of GP2 Grout with 10 MM Aggregate
o Mixing: The 10 mm single sized aggregates shall be washed properly without any debris,
dust and other any foreign materials. Aggregates shall be added to GP 2 grout is 1:1 ratio.
Weigh the 10 mm aggregate equal to GP2 grout materials (full bag or partially) and put in
mechanical mixer. Mix the both aggregates and GP 2 materials in dry condition before
adding water. Add the water 4.125 to 4.5 liters per bag in to mixer gradually and mix till it
get smooth even consistency. Mixing shall be done minimum 5 minutes.
o Laying/filling of grout: Once the grout materials mixing are ready, mixed grout materials
shall be poured and consumed within 20 minutes after final mixing. By leaving Expansion
joint gap 50 mm over EPDM water barrier, GP2 Grout shall be laid on both the sides of
expansion joint. The GP2 grout shall be laid 25 mm below the finished floor level. Thickness
of grout shall be 50 or 75 mm as per floor thickness. Top level of GP2 grout shall be uniform
level. Gp2 grout shall be cured for minimum 7 days or maximum 14 days to gain strength.
Curing shall be done either portable water or with approved curing compound. After gaining
and conformation of strength of grout only the expansion joint system shall be installed
 Installation of Expansion Joint System(Floor to Floor): Install aluminium cover plates
6.1.5. Cracks in Concrete Members

Cracks may occur due to loss of strength of masonry/ concrete because of age, excessive dynamic impact
and settlement or any other damage to foundations. Any shrinkage cracks can be sealed with low viscous
epoxy grout.
 Vertical Cracks
Vertical cracks may occur due to differential settlement of the foundation or excessive shearing stresses in
the sub structure. The crack should be monitored regularly. If these show sign of propagation, a detailed
study should be made to identify the cause before taking remedial measures.
 Horizontal Cracks
These are more serious and could be due to inadequacy of section, defect in construction, failure of back fill
drainage or excessive horizontal loads etc. the remedial measure should be decided after identifying the

cause, based on results of analytical study and field observation. Generally grouting with cement or epoxy
mortar and jacketing are used as remedial measures
The following actions shall be taken when the crack is detected.

 Location of the crack should be marked for an easy identification, for reference and subsequent
inspection;
 Ends of the crack shall be marked and observed if there is any crack propagation;
 Length and orientation of crack should be recorded. Sketch should be prepared indicating the location
and details of crack. If necessary, photographs may be taken;
 If necessary, crack should be examined in detail using non-destructive testing methods like ultrasonic
test to know the depth of crack. Expansion of crack to be monitored using tell tail or measuring gauge;
 If more identical cracks exist on girder, these should also be inspected in detail;
 Significance and severity of crack shall be studied with reference to load carrying capacity of the girder.
6.2. Platform Structure

The platform Structure comprises number of Cast–in-situ prestressed balanced cantilever Pier arm at Pier
location. The precast prestressed longitudinal girders rest on the pier arm which in turn support the whole
platform composite slab (consists of precast members with cast-in-situ topping). The general arrangement of
Slab and Beams at Platform level is shown below
Figure 17 Cross Section at Platform level of Stations
6.2.1. PSC Precast Girders

Common defect and repair/strengthening techniques:
 Signs of hollow spots in concrete components and spalling;
 Dormant cracks;
 Active crack whose cause of cracking has been determined and remedial action has been taken.
Strengthening techniques as detailed below could be also adopted:

 Strengthening measure. Vertical prestressing may be adopted to prevent separation of deck slabs which
are generally cast-in-situ over precast girders. Longitudinal prestressing may be adopted to strengthen
the girder and to increase its flexural strength. Longitudinal prestressing may be resorted in cases where
girders are required to carry increased load or the existing prestressed cables were deteriorate;
 Established techniques such as external bonding steel plates etc. can also be adopted in consultation
with specialists;
 In case of distress in prestressed and reinforced cement concrete girder, the cause should be thoroughly
investigated. External prestressing, epoxy grouting depending on the nature of distress can be adopted.

6.2.2. Bearing
Please refer the maintenance of bearings which is covered in section 6.1.3 of this Manual.
6.2.3. Expansion Joints

Please refer the same in section 6.1.4 of this Manual.
6.2.4. Wicket gate

Wicket gate is access controlled for the platform end stair case at platform level. Wicket gate should be
maintained and inspected periodically, so that it can be opened during emergency.
6.2.5. Gutter
Gutter is a narrow channel, or trough, forming the component of a roof system which collects and diverts
rainwater shed by the roof at platform level. Roof gutters in stations are fabricated from Galvalume colour
coated plain sheet with 4mm thick FRP coated, which collects water from roof and diverts it through a PHE
pipe on to the street level sewer manhole.
Routine inspection should be carried out as per routine inspection regime, preferably including the end of
autumn, end of spring and extreme weather conditions. In the case of extreme events, inspection should be
carried out and abnormal maintenance carried out as required. All gutters are to be inspected for the
deposition of any debris, dust, pollutants or organic growth. In particular, care is to be taken in the
inspection of gutters for these points.
 Staining of gutter at possible ponding locations;
 Built up of dust and debris at the high end of gutter;
 Built up of debris at rain heads, water spouts, and overflow locations and in general around the down
pipe entry;
 Metallic staining of the gutter surface rust.
Twigs, dust, leaves and fungal matter (debris) should be removed using the following recommended
procedure, taking care to ensure no damage occurs to the gutter during debris removal. We recommended
that the following procedure be adopted to remove the dust, debris and fungal matter
 Sweep debris into a pile using a stiff , soft bristled brush (shovels or hard tools should not be used;
 Place debris into a receptacle and lower to the ground;
 The Gutter should then be washed down with a hose, including high ends of gutters, possibly protected
by overhangs, rain heads, water spouts and overflow locations.
6.2.6. Tactile
Tactile at station box are provided to assist visually impaired people to find their way to train door, lift etc.
Tactile should be checked regularly for any damage. Tactile shall be replaced just like replacing a floor tile.
Supplier details of tactile are H & R Johnson (India), (A Division of Prism Cement Limited), Hyderabad.

7 ROOF STRUCTURE
The parabolic shape structural steel roof supporting on platform beams and the roof has covered with
standing seam metal roof system.
Figure 18 General arrangement of station roof structure
7.1. Inspection of Structural Steel

During inspection of structural steel works, the following points should be examined.
 The condition and tightness of foundation bolts.
 The condition and tightness of the fixing bolts;
 The condition of steel work in roof girders, purlins, wind bracing etc.
 The condition of welds in welded connection.
 The condition of roof gutters and their fittings.
 The conditions of roof sheets/transparent polycarbonate sheet and their fittings.
7.2. Roof Sheeting

Galvalume standing seam metal roof system is generally fabricated and installed to meet the rated wind up-
lift resistance requirement. This roof sheeting is a puncture-less, which are held together with halter. The
halters are fixed with Galvanised Iron self-driven screws. If the screws are found rusted, then they should be
replaced with a similar ones.
It should be noted that solar panel are installed on the roof of station from Stage-2 onwards. As part of
maintenance of the solar panel, a water supply arrangement through fixed pipe is provided. It should be
ensured that the water pipe is not chocked and flow if water is regular or not obstructed. There is a walkway
provided on the roof sheet to access each solar panel. It should be ensured that the walkway is in good
working condition.
7.2.1. Personal Safety

Walking on any roof structure is dangerous. Safety must always be top priority when performing
maintenance on the roof system. Always use all fall protection and personal safety equipment required by
OSHA and other regulatory agencies. Failure to follow these regulations can result in serious injury or death.
Insure that all maintenance personnel are adequately trained in safety procedures and that all safety
equipment is in proper working condition. When walking on unprotected roofing, soft soled shoes should be
worn and walking on at least two ribs, as close to supports as possible is recommended. Point heel and toe

loads should be avoided. Avoid dragging and hard materials across the surface of the cladding as this may
result in scratching.
The area where the curving of sheets will take place, the curved sheets will be temporarily stacked and the
current fixing locations on the roof will be barricaded at platform level, by providing crash barriers the
barricades and placing them wherever required. Only Authorized personnel will be carrying / moving in the
area for erection of the building. The phase / area which are to be erected will be barricaded for movement
/personnel at the site.
Full body harness will be Double Lanyard (2.5m) will be fixed to the life line. A second line of protection is
safety net will be installed below while working on the roofs. After the above safety precautions are taken
the sheets will be laid from the eave to ridge bay wise and then continue to move on.
7.2.2. Maintenance of Roof

 The roof should be inspected at least once a year;
 Any exposed metal that shows signs of rust or has rusted should be painted 280 microns in line with the
Technical Specification of Station for structural steel Section 7.4.3.1;
 With a little care and attention during service, pre-painting Galvalume sheet will provide an extended
service life;
 Roof should be cleaned thoroughly on a routine basis whenever the finish is not washed by rain.
Applications where the paint finish is automatically washed by rain, such as roofing, do not require this
maintenance;
 Use fall protection and other safety equipment as required. Do not walk on roof flashings such as gutter,
rake, hip or ridge flash;
 The access to the roof is from the outer edges of the roof end in Stage-1, which can be done only
through a boom lifter. In Stage-2 to Stage 6, an access hatch has been provided in the roof to gain entry
to the roof for maintenance;
 Don’t allow debris of any kind to collect on roof;
 After a hail storm, check roof for punctures, damaged, trim and loose fasteners. After abnormally heavy
rains, check roof and gutters for ponding water.
When a leakage is observed, cordon the areas underneath and at the next given opportunity access the roof
and observe the type of opening on the sheet. The likely causes of the roof leakage are through the
expansion joint locations between the sheets. The remedial measure is sealant and mastic tape to be
checked for the water tightness.
7.2.3. Maintenance of down take pipes

 The downpipes and storm water disposal pipes are to be inspected for cleanliness and free flow of
water.
 Growth of fungus and other matter and collected debris at the inlet and outlet locations is to be noted.
 Any noted blockages should be removed immediately to avoid water back-up in the gutters.

7.2.4. Maintenance Guidelines
DOS DON’TS
 Inspect roof regularly.  Allow roof to be neglected
 Always walk in the flat of the panels near the  Walk on the panel ribs or on flashings.
structural supports.  Allow debris of all kind to collect on roof.
 Keep roof, gutters and downspouts free of debris.  Allow damage from storms to go undetected
 Inspect roof for damage after heavy storms. and cause ancillary damage.
 Caution workers on roof to protect against roof  Drop sharp or heavy objects on roof.
punctures.  Use metal shovels or other tools that can
 Inspect and reseal as necessary all roof curbs and scratch the paint or Galvalume coating on the
other penetrations with urethane sealant. panels.
 Always use long life fasteners and stainless steel  Use plastic roof cement or butyl or silicone
rivets on the roof and trim. caulks anywhere on the roof.
 Always get manufacturer approval before making  Assume that minor additions or modifications
any modifications to the roof. will not cause any problems.
 Repaint any areas that are susceptible to rust as  Use zinc plated fasteners or carbon steel
required. rivets.
 Allow rust or rust stains to build up on roof.
Table 6 Maintenance Guidelines

8 STREET LEVEL STRUCTURE
8.1. Entry/Exit
Figure 19 Typical Stations- Internal Staircase
The rolling shutter, doors and locks at staircases are to be maintained regularly for comfortable operation.
Check regularly for cracks, debris or any damages in the staircase. It is always recommended to treat any
cracks on the staircase, major or minor, as soon as they occur to minimize accidents.
8.2. Signage
Signage plays a vital role in the efficient operation of the metro stations. The metal which is used for signage
shall be free from rust, scale and any other defects, the various shapes and sections shall be clearly rolled or
otherwise formed to uniform sections. All non-metal shall have uniform finished surface, machined and
buffed, free from defects and conform to the sizes and shapes required. This is further detailed in MEP
manual.
8.3. DG Foundations
DG foundation is located at street level of the station. Inspection needs to be carried out on regular basis to
check whether any differential settlement has happened. Observe the cracks formed on the pedestal and
rectify before it develops. And the same applies for entry/ exit.
The following steps shall be carried our as part of Maintenance of DG foundation:

 Regular cleaning of DG foundation to ensure cleanliness;
 Regular checking of cracks and settlement;
 The DG machine frequency acceptable to the Operator of the machine and its foundation;
 Tightening of the foundation bolts.
8.4. Hand railing

Regular cleaning of the hand rail shall be carried out. Check for oily marks or grease that could be due to
passengers. Check for corrosion levels of the exposed metallic part of the hand rails. Check for any hand rails
which are loose and swaying. Thought it is mentioned in this section, but this is applicable for all three levels
i.e. Entry/Exit, concourse level and platform level.

8.5. Lift Pit and Escalator Pit

Lift pit to be inspection as per the maintenance schedule for any blockage of drain-out pipes and debris. The
drain-out pipes to be cleared and cleaned. It should be ensured that all accumulated debris is cleared from
the pit. Check for any cracks and dampness in the pit walls. The same shall be maintained as per the section
4.1.5
The Escalator pit may be inspection once in 3 months. The main issues to be looked into are the
accumulation of water and/or debris. The water may be pumped out immediately, especially during the
rainy seasons. Check for cracks and dampness in the walls and followed the instruction mentioned in table
below.

9 COMMON DEFECTS
The following section is dedicated to commonly occurring defects that can be found across different sub-
section of a station. Along with every identified defect, the possible remedial measure is mention for the
maintenance team to take appropriate guidance and actions.
# Common Defect Remedial measures

1 Shrinkage cracks in concrete exceeding Grouting with low viscous epoxy grout
permissible limits.
2 Sagging of false ceiling Check the support frame for any abnormality. Else
replace the specific panel.
3 Cracks in gypsum ceiling Replace the gypsum ceiling.
4 Uneven settlement in false flooring If tiles will come up re-fix the supports replace the
same and place it properly;
5 Gaps between false floor tiling Check for any broken, bent or loose floor tile pedestal
for the rigidity of the supports, replace the same and
place the tile properly;
6 False floor skirting coming off the wall Broken or loose skirting of false floor to be replaced
7 Door handles and door organiser not working Tighten the door holding unit so that the handle is
rigidly connected to the door. It the unit is still not
working then replace the door handle;
Fix the door organiser so that it is rigidly connected to
the door and door frame. If it is still not working then
replace the unit.
8 Plaster cracks on walls Grouting with low viscous epoxy grout
9 Leakage through roof sheeting Check for the spot or origin of leakage. Check if there is
gap in the sheeting on the roof. Adjust the sheets if the
gap is noticed. Look for any punctured sheet/s. Replace
the specific sheet which is punctured.
10 Leakages in toilets, or room ceiling Identify the source of leakage.
If it is due to the cracks in the wall or ceiling, then
grouting with low viscous epoxy grout shall be done.
In toilets check the drainage after exposing it through
flooring and seal the opening. It the drain pipes is
found cracked, then replace it.
11 Waterproofing Carry out a pre-monsoon check for the expansion joint
in viaduct deck, platform slab in the station areas like
cracks, punctures, etc.
Origin of leakage to be identified;
Replace the seal or barrier material of expansion joint.
All cracks identified in the leakage area/s to be sealed
Table 7: Common defects remedial measures

VOLUME – II, Part C
ANNEXURE 1 Proforma for Inspection of Station
Name of Inspector Signature
Designation of the Inspector Date of inspection
# Condition of Building Nature of repair Details of repair Initial of Building In- Remarks
Roof Doors/ Flooring/ Others to be done done with date charge/ occupant
windows plastering
Table 8 Proforma for inspection of station

ANNEXURE 2 Proforma for Periodic Inspection Report of Bearings Inspection
Location of the Station
Date and Time of Inspection
Last inspection carried out on
Pier /Abutment Marked
Bearing Location
Type / Name of Bearing
Atmospheric Temperature
Elements of Inspection Observations Remarks

a. Functioning Properly
(Yes/No) If no, explain in
detail
b. Measurement of Dimension Theoretical Actual Variance Tolerance
dimension Dimension
Length
Breadth
c. Measurement of Dimension Design Height of the Bearing (mm):

Actual Height of the Bearing (mm):
The overall height of the
H1 H2 H3 H4
bearing shall be measured at
the four extreme corners of
the bearing from the seating
level of the base plate.
d. Check for movement or Design distance of Actual distance of Variance
displacement of bearing to bearing centre bearing centre
check the eccentricity of from pier cap edge from pier cap edge
load transfer point
e. Check the physical condition

of the bearing for any
deformation
f. Check any accumulation of
dirt / debris around the
bearing
g. Check for any gap in the
horizontal bearing to ensure
proper seating of structure
h. Check for any gap or
displacement of vertical
bearings of seismic arrestor
i. Check for any cracks on the
exposed surface of the
bearing
j. Check for any exposed
reinforcement of the bearing
k. Check the condition of the Superstructure Substructure
adjacent structure in case
any damage to the structure
is observed, specify suitable

Elements of Inspection Observations Remarks
recommendation for repair.
Name of Inspector Signature
Designation of the Inspector Date

ANNEXURE 3 Proforma for Structural Steel Inspection Register
Name of Station
Name of Inspection Officer
# Description of the sub-system Details

1 Description of structure
2 Type of truss/column
3 Span/Height
4 Type of bed block/pedestal with details of fixture
5 Connection details(Bolts/Welds)
The following points (but not limited to) may be inspected as part of structural steel inspection:
Elements of structure Date of Condition of Action taken Initial of Detail of repair

checked Inspection structure Inspection done with date
Officer
(1) (2) (3) (4) (5) (6)
Welded connections
Bolted connections
(torque);
Dry Film Thickness of
paint coating
Levels of corrosion
Conditions of the sheets
Condition of the fixtures
Condition of fastenings
Table 9 Proforma for Structural Steel Inspection Register

ANNEXURE 4 Periodicity of Inspection and Maintenance
# Inspection for Periodicity

1 Bolts/Welds Once in a year
2 Water leakage Regularly
3 Drain pipes (Debris) Regularly
4 Cracks Regularly
5 Bearings As per routine inspection mentioned in MMS.
6 Expansion joints Every quarterly
7 Gutters Once in a year
8 Steel structure Once a year
9 Roof At least once a year
Table 10: Maintenance periodicity

ANNEXURE 5 Routine Inspection Check List (for Typical Station)
# Description OK Remarks
(Yes/No)
STREET LEVEL
1 Entry/Exit
(a) Monitor any deep excavations in vicinity of columns.
(b) Check for cracks in the beams, columns & slab.
(c) Check for corrosion and peeling of paint in:
Roof
Hand rails
(d) Check for any loose or swaying member of structure in:
Roof
Hand rails
(e) Door
Door key is locking properly;
Handle is rigidly connected to the door;
The door organiser is smoothly working.
(f) Rolling shutters
Check for corrosion;
The shutter movement is smooth;
Check for any loose or swaying member.
(g) Flooring, tactile
- Check for breakage, cracks;
- Check for stain marks.
2 UG Sump and Pump

(a) Crack in walls
(b) Seepage/Dampness in the walls
3 DG Foundation
(a) Monitor for any deep excavations in vicinity.
4 Lift & Escalator Pit

(a) Crack in walls
5 Sewage line / Manholes

(a) Water stagnation
6 Check for cracks and dampness in:

(a) Concrete of rain water harvest pit
(b) Block work of DG room
(c) Crash barrier of entry/exit columns
CONCOURSE LEVEL
7 Spine and Wing
(a) Check for cracks, spalls and scaling
(b) Check the condition of recess filling at end anchorages

(Yes/No)
8 Bearing
Please refer Annexure 2
9 RCC Corbel
10 Expansion Joint
(a) Check if the joints are free of stones and debris
11 Other Concourse level members:

- Check for cracks, dampness, spalls and scaling in:
o Mezzanine slab in Grid AB / BC / HJ
o Stair Case-1 / 2 /3 / 4
o Elevator Shaft-1 / 2
o Escalator Support-1 / 2 / 3/ 4
12 Concourse Level rooms:

(a) Check for cracks and dampness in the block work in:
Signalling Equipment Room
Telecom Equipment Room
Station Control Room
Emergency Fare Office
Aux Sub-station room
UPS & Battery Room
EPS & Battery Room
Clean Gas Room
Ticket Office 1 and 2
Ante Room
Cash Room
Staff Room
Security Room
First aid Room
Station Manager/Maintenance Room
Retail Area
Toilets
(b) Flooring (including False floor), tactile, skirting and
False ceiling
- Check for bulges in the tiles;
- Check for stain marks;

(Yes/No)
UPS & Battery Room
EPS & Battery Room
Clean Gas Room
Ante Room
Cash Room
Staff Room
Security Room
First aid Room
Retail Area
Toilets
Common areas
Paid areas
Unpaid areas
(c) Cladding:
- Loose cladding;
- Crack in the cladding material;
- Sharp edges and stain marks
Outside SCR
EFO
Ticket Office
Pier Arm
Pier
(d) Door
(e ) Glass:
Check for cracks, sharp edges or breakages
13 Structural steel elements:

- Check for corrosion and peeling of paint;
- Check for any loose member or swaying of
structure including nuts & bolts;
(a) Signage support
(b) Handrails
(c) Gutter
(d) Rolling shutter
(e) Bottom access hatch
PLATFORM LEVEL
14 Prestressed precast girder
15 Bearing

(Yes/No)
16 Slab (composite)
Check for cracks, spalls and scaling
17 Expansion Joint
18 Fire & DB shaft

(a) Check for cracks and dampness

- Check for any loose member or swaying of
structure including nuts & bolts;
(a) Signage support
(b) Handrails
(c) Gutter
(d) Wicket Gate
(e ) Steel egress steps (Platform end stair-case)
20 Others
(a) Door
(b) Check for cracks and dampness in the block work
(c) Check for cracks and dampness in the RCC upstand wall
(d) Flooring, coping stone, tactile and skirting
(e ) Cladding:
- Loose cladding;
ROOF LEVEL
- Check for any loose member including nuts & bolts
or swaying of structure;
(a) Structural Steel roof member
(b) Roof sheeting
(c) Solar Panel
(d) Gutter

ANNEXURE 6 Detailed Inspection Check List
(Yes/No)
STREET LEVEL
1 Entry/Exit
(a) Monitor any deep excavations in vicinity of columns.
(b) Check for cracks in the beams, columns & slab.
(c) Check for corrosion and peeling of paint in:
Roof
Hand rails
(d) Check for any loose or swaying member of structure in
(including nuts & bolts):
Roof
Hand rails
(e) Door
Door is rigidly connected to the frame;
Door is not skewed;
The door organiser is smoothly working;
Door glass panel is not cracked or smoky.
(f) Rolling shutters
Check for corrosion;
The shutter movement is smooth;
Check for any loose or swaying member;
Ensure the moving parts are free of debris and oiled.
(g) Flooring, tactile
- Check for stain marks.
2 UG Sump and Pump

(a) Crack in walls
3 DG Foundation
(a) Check for settlement wrt floor levels
(b) Monitor any deep excavations in the vicinity
4 Lift & Escalator Pit

(a) Crack in walls
© Check for settlement wrt floor levels
5 Sewage line / Manholes

(a) Water stagnation
6 Check for cracks and dampness in:

(a) Concrete of rain water harvest pit

(Yes/No)
(b) Block work of DG room
(c ) Crash barrier of entry/exit columns
CONCOURSE LEVEL
7 Spine and Wing
(c) Monitor the propagation and expansion of cracks by
using Tell-tale pads or by measuring gauges (if any)
(d) Take floor levels & compare with actual readings
(e) Check for deflection for excessive deflection more than
L/250 for spine and L/150 for wing (where L is length of
span) due to live load, shall be recorded & monitored.
(For spine check at mid of span; whereas for wings
check at free ends)
8 Bearing
9 RCC Corbel
(b) Monitor the propagation and expansion of cracks by
10 Expansion Joint
(b) Check the width of Gap at expansion joint with respect
to the tolerance limits (50mm + 20mm) preferably
during extreme weather conditions
(c ) Check for acts of vandalism
(d) Check for any missing parts
11 Other Concourse level members:

- Check for cracks, dampness, spalls and scaling
(Monitor the propagation and expansion of cracks
by using Tell-tale pads or by measuring gauges);
o Mezzanine slab in Grid AB / BC / HJ
o Stair Case-1 / 2 /3 / 4
o Elevator Shaft-1 / 2
o Escalator Support-1 / 2 / 3/ 4

(Yes/No)
12 Concourse Level rooms:

(a) Check for cracks and dampness in the block work
(Monitor the propagation and expansion of cracks by
using Tell-tale pads or by measuring gauges. (if any))
UPS & Battery Room
EPS & Battery Room
Clean Gas Room
Ante Room
Cash Room
Staff Room
Security Room
First aid Room
Retail Area
Toilets
(b) Flooring (including False floor), tactile, skirting and
False ceiling
UPS & Battery Room
EPS & Battery Room
Clean Gas Room
Ante Room
Cash Room
Staff Room
Security Room
First aid Room
Retail Area
Toilets
Common areas
Paid areas
Unpaid areas
(c ) Cladding:
(Yes/No)
- Loose cladding;
Outside SCR
EFO
Ticket Office
Pier Arm
Pier
(d) Door, Door stopper, Door locks:
 Door key is locking properly;
 Handle is rigidly connected to the door;
 The door organiser is smoothly working;
 Door is rigidly connected to the frame;
 Door is not skewed;
 Door glass panel is not cracked or smoky.
(e ) Glass:
Check for cracks, sharp edges or breakages

(a) Signage support
(b) Handrails
(c) Gutter
(d) Rolling shutter
(e) Bottom access hatch
14 Others
(a) Windows:
 Ensure the window frame is rigidly fixed to the
wall;
 Ensure the glass of window is not cracked;
 Ensure there are not protruding sharp edges;
 Ensure the window organiser is working smoothly;
(b) Ventilators
 Check the louvers are free of dust and rigidly
connected with its frame;
 Ensure there are not protruding sharp edges;
 Replace any broken louver.
PLATFORM LEVEL
15 Prestressed precast girder
(c) Take platform levels and compare with actual readings
(d) Monitor the propagation and expansion of cracks by

(Yes/No)
16 Bearing
17 Slab (composite)
Check for cracks, spalls and scaling
Monitor the propagation and expansion of cracks by
18 Expansion Joint
(a) Check the width of Gap at expansion joint with respect
to the tolerance limits (50mm + 20mm) preferably
during extreme weather conditions
(b) Check for acts of vandalism
(c) Check for any missing parts
(d) Check if the joints are free of stones and debris
19 Fire & DB shaft

(a) Check for cracks and dampness
(b) Monitor the propagation and expansion of cracks by

 Check for corrosion and peeling of paint;
 Check for any loose member including nuts & bolts
(a) Signage support
(b) Handrails
(c) Gutter
(d) Wicket Gate
(e) Steel egress steps (Platform end staircase)
21 Others
(a) Door
(b) Check for cracks and dampness in the block work
(c) Check for cracks and dampness in the RCC upstand wall
(d) Flooring, coping stone, tactile and skirting
(e ) Cladding:
- Loose cladding;
ROOF LEVEL

(Yes/No)
(a) Structural Steel roof member
(b) Roof sheeting
(c) Solar Panel
(d) Gutter

ANNEXURE 7 List of tools for Routine, Detailed & Special Inspection
Tools required for aforesaid inspections are as under:

i. Auto level with levelling staff;
ii. Chisel, hammer;
iii. Clip boards, chalks, markers;
iv. Cover / crack meter;
v. Feeler gauge, Calliper;
vi. Graduated blades to measure crack width;
vii. Inspection cum chipping hammer;
viii. Inspection mirror;
ix. Magnifying glass;
x. Non Metallic ladders;
xi. Plastic jars and bags for sampling;
xii. Pocket knife, wire brush;
xiii. Rebound Hammer;
xiv. Scrapper and emery paper;
xv. Screw drivers, pliers, torque wrench;
xvi. Straight edge, plumb bob, spirit level;
xvii. Tapes 3m, 5m, 30m;
xviii. Tell-Tales;
xix. Thermometer;
xx. Torch light, camera, binoculars etc.;
xxi. Total station with prism.

VOLUME – II, Part D
ANNEXURE 8 Master Maintenance Schedule
Master Maintenance Schedule & Maintenance Task Matrix
Maintenance W ork Instruction Routine Inspection Total Sample Required Man-hours per unit or per m Total Man-hours for
Detailed Special Tolerance
Title 1st 2nd Year Sample Basis of (1 = 60 minutes, 0.5 = 30 minutes) (1 cycle of Inspection) Personnel Source of
Inspection Inspection Maintenance Unit of Units / of
# Name Reference for Year onwards Number Length Area size Required category Tools Data [Hazard
Action Codes measure Length / Inspection Routine Detailed Special Routine Detailed Special
Inspection Item Routine Detailed Action Half Unusual of units (m) (m2) (%) Manhours (G, M.E) Analysis]
Area (± days) Inspection Inspection Inspection Inspection Inspection Inspection
Inspection Inspection Required year ly Year ly 5 Year s occur r ence
Annexure-5, item- Annexure-6,

1 Entry/exits foundation Record P P P Visual/Detailed Number of units 396 - - 10 40 15 E 0.5 1 - 20 40 - G
1a item-1 a
Entry/exits slabs,
2 beams (Stair case Record P P P Visual/Detailed Length - 1320 - 10 132 15 E 0.25 0.5 - 33 66 - G
1b item-1 b
steps), column.
Hand railings for Annexure-5, item- Annexure-6,

3 Record P P P Visual/Detailed Length - 74910 - 10 7491 15 E 0.25 0.5 - 1873 3746 - G
entry/exits 1c, d item-1c, d
Details are mentioned in separate document for tools and plants (Annexure 7)
4 DG foundation Record P P P Visual/Detailed Number of units 66 - - 10 7 15 E 0.25 0.5 - 2 4 - G
3 item-3

5 UG sump & pump Record P P P Visual/Detailed Number of units 132 - - 10 14 15 E 0.25 0.5 - 4 7 - G
2 item-2

6 Tactile Record P P P Visual/Detailed Area - - 8910 10 891 15 E 0.25 0.5 - 223 446 - G
1g item-1 g
Street Level

7 Lift & escalator pits Record P P P Visual/Detailed Number of units 264 - - 10 27 15 E 0.25 0.5 - 7 14 - G
4 item-4
Doors (inculding locks,

8 stoppers, organiser & Record P P P Visual/Detailed Number of units 660 - - 10 66 15 E 0.25 0.5 - 17 33 - G
1e item-1 e
handle)
Crash barrier for Annexure-5, item- Annexure-6,

9 Record P P P Visual/Detailed Number of units 264 - - 10 27 15 E 0.25 0.5 - 7 14 - G
entry/exit columns 6c item-6 c

10 Blockwork Record P P P Visual/Detailed Area - - 155760 10 15576 15 E 0.25 0.5 - 3894 7788 - G
6b item-6 b
Flooring (Granite/ Annexure-5, item- Annexure-6,

11 Record P P P Visual/Detailed Area - - 179916 10 17992 15 E 0.25 0.5 - 4498 8996 - G
Vitrified/ IPS/ Kota) 1g item-1 g
Sewage line including Annexure-5, item- Annexure-6,

man holes 5 item-5

13 Rolling steel shutter Record P P P Visual/Detailed Number of units 330 - - 10 33 15 E 0.25 0.5 - 9 17 - G
1f item-1 f
Rain water harvesting Annexure-5, item- Annexure-6,

14 Record P P P Visual/Detailed Area 132 - - 10 14 15 E 0.25 0.5 - 4 7 - G
pit 6a item-6 a

RCC corbel (concourse Annexure-5, item- Annexure-6,

15 Record P P P Visual/Detailed Number of units 660 - - 10 66 15 E 0.5 1 - 33 66 - G
level) 9 item-9
PSC box girder spans Annexure-5, item- Annexure-6,

(Spine & wing) 7 item-7
PSC Pier arm (cast-in- Refer Annexure- Refer Annexure-

situ) 5, item-14 6, item-14
Elastomeric bearings, Annexure-5, item- Annexure-6,

bearing pedestal & grout 8 item-8
Concourse Level (including lower concourse level if any)

12 a item-12 a

12 d item-12 d
handle)
21 Hand railings Record P P P Visual/Detailed Length - 11220 - 10 1122 15 E 0.25 0.5 - 281 561 - G
13 b item-13 b

22 Expansion joints Record P P P Visual/Detailed Length - 28261.2 - 10 2827 15 E 0.25 0.5 - 707 1414 - G
10 item-11

Vitrified/ IPS/ Kota) 12 b item-12 b
False flooring (raised Annexure-5, item- Annexure-6,

flooring) 12 b item-12 b

25 False Celling Record P P P Visual/Detailed Area - - 28578 10 2858 15 E 0.25 0.5 - 715 1429 - G
12 b item-12 b

12 b item-12 b

27 Skirting Record P P P Visual/Detailed Area - - 25410 10 2541 15 E 0.25 0.5 - 636 1271 - G
12 b item-12 b

28 Rolling steel shutter Record P P P Visual/Detailed Number of units 396 - - 10 40 15 E 0.25 0.5 - 10 20 - G
13 d item-13 d

29 Glass Record P P P Visual/Detailed Area - - 2970 10 297 15 E 0.25 0.5 - 75 149 - G
12 e item-12 e
HBL Cladding (on pier & Annexure-5, item- Annexure-6,

pier arm) 12 c item-12 c
Calicium Silicate Annexure-5, item- Annexure-6,

Cladding 12 c item-12 c
Access hatch of viaduct Annexure-5, item- Annexure-6,

deck 13 e item-13 e
Gutters (for discharge of Refer Annexure- Refer Annexure-

drainage) 5, item-13(c) 6, item-13(c)

34 Granite Coping Record P P P Visual/Detailed Length - 13200 - 10 1320 15 E 0.25 0.5 - 330 660 - G
12 b item-12 b

PSC girders (precast) Annexure-5, item- Annexure-6,

at platform level 14 item-14
Elastomeric bearings, Annexure-5, item- Annexure-6,

bearing pedestal & grout 15 item-15

37 Platform level slab Record P P P Visual/Detailed Length - 17820 - 10 1782 15 E 0.25 0.5 - 446 891 - G
16 item-17
Upstand wall on viaduct Annexure-5, item- Annexure-6,
deck 20 c item-21 c

20 b item-21 b

Platform Level
Vitrified/ IPS/ Kota) 20 d item-21 d

20 a item-21 a
handle)

20 d item-21 d

43 Hand railings Record P P P Visual/Detailed Length - 18876 - 10 1888 15 E 0.25 0.5 - 472 944 - G
19 b item-20 b
Annexure-5, item- Refer Annexure-

44 Expansion joints Record P P P Visual/Detailed Length - 28261.2 - 10 2827 15 E 0.25 0.5 - 707 1414 - G
17 6, item-18
Steel egress steps

45 (platform end stair Record P P P Visual/Detailed Number of units 264 - - 10 27 15 E 0.25 0.5 - 7 14 - G
19 e item-20 e
case)

46 Cladding Record P P P Visual/Detailed Area - - 6600 10 660 15 E 0.25 0.5 - 165 330 - G
20 e item-21 e
Coping stone for Annexure-5, item- Annexure-6,

platform 20 d item-21 d

48 Skirting Record P P P Visual/Detailed Area - - 25410 10 2541 15 E 0.25 0.5 - 636 1271 - G
20 d item-21 d
document for tools and plants (Annexure 7)

Structural steel for Annexure-5, item- Annexure-6,
49 Record P P P Visual/Detailed Area - - 198000 10 19800 15 E 0.5 1 - 9900 19800 - G
roofing 21 a item-22 a
Details are mentioned in separate

Roof Level
Annexure-5, item- Refer Annexure-

50 Roof sheeting Record P P P Visual/Detailed Area - - 250272 10 25028 15 E 0.25 0.5 - 6257 12514 - G
21 b 6, item-22 b

51 Gutters Record P P P Visual/Detailed Length - 17820 - 10 1782 15 E 0.25 0.5 - 446 891 - G
21 d item-22 d

52 Solar panel structure Record P P P Visual/Detailed Number of units 28230 - - 10 2823 15 E 0.25 0.5 - 706 1412 - G
21 c item-22 c

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Hyderabad Metro Rail STATION CIVIL MAINTENANCE MANUAL

16-04-2015 2 (Issued for Approval) Sanjeev S C Y Sivaji RBK

STATION CIVIL MAINTENANCE MANUAL

RELEASED FOR ☐ PRELIMINARY ☐ TENDER ☐ INFORMATION ☒ APPROVAL ☐ CONSTRUCTION

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STATION CIVIL MAINTENANCE MANUAL

Revision Submission Date Summary of Change Prepared by Reviewed by Approved by

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VOLUME-I, Part-A ................................................................................................................................................ 7

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VOLUME – I. Technical Manual

VOLUME – II. Maintenance Manual

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Corridor 1 Miyapur – LB Nagar (27 stations);

A total of 66 stations are planned for Hyderabad Metro Rail Project.

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List of Reference, Standards and Codes

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Station consists of 2 level slabs:

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Figure 1 Typical Station Cross Section

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Escalator pit Elevator shaft Gutter

Figure 3 General Block Diagram of Stations

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Figure 4: Street Level plan

Figure 5: Concourse level plan

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Figure 6: Platform level plan

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4 MAINTENANCE AND INSPECTION

4.2. Roles & Responsibilities

For different Stations

Inspection Officer Inspection Officer

For different Stations

Assistant Officer Assistant Officer

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4.4. Inspection Officer

4.5. Assistant Officer

4.6. Knowledge of rules and regulations

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4.7. Periodicity of Inspection

4.8. Type of Inspection

4.8.1. Routine Inspection

4.8.2. Detailed Inspection

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4.8.3. Special Inspection

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5 STATION BUILDINGS STRUCTURES

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5.2. Inspection and Repairs

5.3. Inspection of Station Areas

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5.5. Precautions during Maintenance

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5.6. Typical Traffic Management Plan

Hazards in street level maintenance works due to external traffic

5.6.1. Traffic management planning

Traffic Control Devices

Mandatory / regulatory signs

Average Distance of first sign in advance of Size of Warning Minimum no of signs in