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Ancient Caves
India has a very old history. Indus civilization is well known.
Tunnels had their own roles to play in every civilization and Indian civilization is no
exception. Tunneling dates back to prehistoric times. Primitive people dug cavities or
widened the natural caves for shelter against weather, enemies and wild life.
Archaeological research establishes that men even in the stone age excavated cavities.
Pre historic tunnels built a few thousand years ago have been discovered in India.
Tunnel construction in India dates back to Mahabharat period when Pandavas
excavated escape tunnel . History also reveals that many kings got constructed escape
tunnels from their forts to safer places to be used during emergencies. In India, number
of ancient caves are preserved even now and are well known through out the world. The
paintings found in these caves and the architecture of these caves while reflecting the
history of that period also indicates their expertise in excavating these caves. While the
caves of Ajanta, Ellora, Elephanta are the tourist attraction, there are other caves which
are equally fascinating and details of such 18 caves are given in this book.
Tunnels are important components of transportation networks, water conveyance
networks and communication networks. They could be in rocky environment or in softer
media and could be in various geometrical shapes depending on the functional utility.
Earlier tunnels were constructed manually. Man's insatiable passion to achieve more and
more progress and production to meet the ever increasing requirement of mankind has
driven him to design and improve upon the production of basic tunneling tools into more
efficient and productive ones.
Hydro Tunnels
Construction of tunnels received a big boost after independence in 1947 when large
programmes for exploitation of water resources were taken up which involved
construction of tunnels for water conveyance and other underground works. In the last
six decades large number of tunnels have been constructed in connection with
multipurpose and hydroelectric projects in the Himalayan region. Amongst the important
projects, where tunnels have been built include Chamera, Baira-suil, and Nathpa Jhakri
projects in Himachal Pradesh, Uri Stage-I, Dulhasti and, Salal projects in Jammu and
Kashmir, Dhauliganga project in Uttaranchal. In the North-East, important tunnel jobs
have been executed at Loktak and Teesta stage- V Projects. In the Peninsular India too,
there was spurt in tunneling activity connected with the execution of Koyna,
Nagarjunasagar, and Srisailam projects. Tunnels with bore diameter of as much as 9 m
and length up to over 25 km at Beas - Sutlej Link have been built in this period.
About 344 hydro-tunnels, small and big, totaling a length of about 659 km. have already
been completed while 126 tunnels having a length of about 220 km. are under
construction. About 567 tunnels having a total length of about 1200 km are planned to be
executed in recent future. Details of these projects are indicated in the chapter on Hydro
Tunnels Total lengths of tunnels in some projects are indicated in the table below.
Name of HE Project
Teesta Project
Tehari Project
17.32
16.39
Chamera I Project
10.72
90.17
Uri Project
19.40
Koyna Project
11.335
Kalinadi Project
17.21
Railway Tunnels
Apart from tunnels for hydroelectric works, another sector where tunnels have a
important role to play is Railway including Metros. Modern tunnel construction in India
has its origin mainly in the Nineteenth century when a number of railway tunnels were
constructed for extension of the rail network for crossing hill ranges in Western Ghats,
Vindhayas and in the foothills of Himalayas for connecting few hill resorts like Shimla.
Some of the 'Hill trains' connecting important hill stations passing through number of
tunnels have historical importance and some of them have been given World Heritage
Status by UNESCO. The hill train running on Kalka - Shimla section, built during the
period 1900-1903 has to pass through 107 tunnels of varying lengths. The longest
tunnel, the 'Barog Tunnel' is 1146m long. The expertise and equipments available at that
time in comparison to what we have today clearly reflects the difficulties which must
have been faced at that period to construct these memorable tunnels.
The new railway line, prestigious and the most challenging Jammu-Udhampur-SrinagarBaramulla (340km.) under construction in the Himalayan Mountains in Jammu and
Kashmir state passes through difficult terrain. The adverse geology enroute has led to
increase in tunnel length because it was not possible to locate bridges and tunnel portals
in slide zones and other unfavorable locations. The rocks range from loose
conglomerates and severly folded and crushed sand-clay- silt stones in KatraSangaldan region to slates, schist and phylites beyond Sangaldan. The line shall cut
across three major thrust zones, the Reasi thrust, the Muree thrust and the Pir Panjal
thrust. The rocks along the proposed alignment are heavily folded, over thrusted and
faulted at many places making the rocks highly jointed and crushed.
There are 63 tunnels having a total length of about 120 km. along the alignment, the
longest being 6.574 km. Jammu-Udhampur Rail Link (53.4 km) forms a part of the
very busy roads of Kolkata, except in small stretches, where shield tunneling was
adopted. Cut & Cover method of construction was primarily adopted due to economical
consideration.
Kolkata Metro Railway is successfully running between Tollygunge & DumDum. Success
has further encouraged for further spread of a stretch of 18.65 km. between New Das
Nagar- Salt Lake City Sec- V , which is being planned and detailed project report has
been prepared.
Another hall mark is the 'Delhi Metro'. The city of Delhi with a population of around 16.0
million should have had an Mass Rapid Transit System (MRTS) network long back,
whereas actually it is still 65.10 kms at the take-off stage.
Delhi has experienced phenomenal growth in population in the last few decades. Its
population has increased from 57 lakhs in 1981 to 162 lakhs in 2006 and is poised to
reach 190 lakhs by the year 2011. For want of an efficient mass transport system, the
number of motor vehicles has increased from 5.4 lakhs in 1981 to 51 lakhs in 2007 and
is increasing at the rate of 6.21 lakhs per annum. The result is extreme congestion on
Delhi roads, ever slowing speeds, increase in road accidents, fuel wastage and
environmental pollution with motorized vehicles alone contributing to about two thirds of
the atmospheric pollution.
Government of India (GOI) and the Government of National Capital Territory of Delhi
(GNCTD), in equal partnership, have set up a company named Delhi Metro Rail
Corporation Ltd. in the year 1995 which has already commissioned a 65.10 kms route in
Phase-I and is proceeding ahead with another 125 kms in Phase - II. Phase II work is to
be completed by 2010 before the Common wealth games. The work is going on war
footing. Phase III and Phase IV covering length of about 112 km and 109 km
respectively are also envisaged in future and these Phases are likely to be completed by
2021 and total network of metro rail in Delhi would be about 414 km.
machines and engage best companies of the world for the tunnel work.
Another important highway having number of tunnels is the National Highway NH-4
which connects Mumbai earlier known as Bombay with the city of Rangalore via Poona
(Pune). This is a very old road constructed during British era. The road between Mumbai
& Pune is passing through precipitous mountain ranges of Sahyadri hills; the famous
Khandala Hill station is around midway enroute.
Due to increase in the traffic every year resulting In jams, accidents, increase in travel
time etc, it was necessary to build a new and independent expressway.
Government of Maharashtra planned a new Expressway by-passing the city of Panvel in
Raigad district upto outskirt of Pune city in 1990. In order to ease out the alignment and
reduce the steep gradient ;it few locations of the road in the hilly terrain, provision of the
tunnels was unavoidable. Therefore, twin tube tunnels have been constructed at five
locations i.e. Bhatan, Madap, Khandala, Kamshet I and Kamshet II ;md one single tube
tunnel at Adoshi for Mumbai bound traffic. Size of each tunnel is 17.6 m wide, 9.8 high,
to accommodate four lanes of traffic. Cross-sectional area of each tunnel is varying
between 148 m2 to 157 m2, which is considered to be a very large section, constructed
for the first time in India for any road project. The length of the tunnels varies between
168 m to 1086 m, totaling to 5762 m.
The tunnels on this expressway have been provided with modern facilities of ventilation,
lighting, communication system, fire fighting vehicles, computerized control room etc;
and would rank amongst the best in the world.
Construction Technology
A review of tunneling methods in India shows that the conventional drill-&-blast method
remains practically the dominant practice for excavation of tunnel in India.
Construction Equipments
Attempts have been made in the past on some projects to use Roadheaders and Tunnel
Boring Machines (TBMs) with success in some and failure in others. A beginning was
made using the TBM's for the construction of a water supply tunnel in Bombay called the
Malabar Hill Tunnel and Dulhasti Project in J&K. and Parbati Project Stage -II in
Himachal Pradesh. Road headers are being used for quite sometime in the mining
sector particularly in the Singareni Collieries Co. Ltd. A road header was used for the
excavation of the Loktak tunnel in Manipur in late Seventies.
Till recently, barring a few cases, the use of steel ribs with backfilling by tunnel muck or
lean concrete was practically the only method of supporting in India. This being a
passive support system, a considerable damage is done to the rock mass before the ribs
interact with it. The combination of the drill-&-blast method of excavation and steel rib
support system delays the supporting action, allows opening of the existing joints,
creates new fractures, permits loosening of the rock mass in the roof, mobilizes higher
tunnel closures and greater rock loads which require larger excavation and thicker
support. All these problems result in increased cost and completion period.
Lately, there has been considerable increase in the use of shotcrete as a support
system, particularly for large underground cavities. The use of steel fibre reinforced
shotcrete (SFRS) has also been made at a few projects, such as, Uri (J & K) and Koyna
Project (Maharashtra).
Compared with the great advances made in methodology for tunnelling all around the
globe, it is obvious that we have still a long way to go to catch up with modern tunnel
construction technologies. With new tunnelling techniques, extensive developments
have taken place in the field of special excavation equipment -hydraulic jumbos, Tunnel
Borers, Road Headers, explosives, methods of ground stabilization, methods for rock
support, special equipment for concrete lining, which enable realization of tunnel
construction at rates hitherto unimaginable.
Construction industry in India is growing at a faster pace. About 1200 km of tunnels
including adits are proposed to be constructed for number of projects which are planned
to be taken up in near future. Keeping in view the execution of large number of projects
for accelerated development of tunnel projects, sufficient and competent agencies are
not available in the country. To enable more construction companies to enter in the field,
policies and procedures have been simplified by Government of India. With the change
in policies and procedures, some international reputed companies have already started
operation in India in the recent past and many more are expected to join shortly.
Geological Investigation
Almost every aspect of a tunneling project, from its conception to commissioning, is
influenced by the geology of the area. Reliability of the predicted geology, therefore,
plays an important role in the success of the project. Inadequate geological investigation
and poor anticipation of the nature and the magnitude of problems catch the tunneling
engineers unawares, resulting in delays and higher cost of construction. Inadequate
investigations could be attributed to financial, technical and site constraints etc .
The nature of major construction problems which have been experienced in the past due
to inadequate investigations are:
(i)
(ii)
(iii)
(iv)
(v)
In view of the above, adequate investigations needs no emphasis. Keeping in mind that
huge tunneling activity is likely to be involved while executing many proposed
hydroelectric, railway, and road projects in Himalayan region where challenges are
more, attempts are being made to induct modern techniques of engineering geological
investigations in order to unravel geological complexities and adversities well in
advance, so that geological surprises are minimized during construction. The other
means of investigations such as satellite image analysis and geophysical methods need
to be explored. Geological investigations and these methods of investigations could
definitely provide additional information which shall be useful during boring of tunnels.
Besides, numerical modelling for design considerations and fast tunneling technology
using Tunnel Boring Machine (TBM) are being adopted to reduce time and cost over run
and ensure safety and stability of the structures.
Contractual Practices
For successful and timely completion of a tunnel project, correct contracting practices
are very important. Essential contracting practices' include all operations and procedures
involved from fixing up an agency for execution of the work, getting a contract
agreement signed and effective follow up and monitoring the progress of works till
completion of the job.
Practically, all the tunneling projects in the country are executed through contractors only
and it has been experienced that there are invariably time and/or cost overruns on
almost every such project due, among other things, to deficiencies in the contracting
practices which are generally found to be indifferent to the project needs. Inadequate
finances, delay in decision making, inadequate geological exploration often lead to
contractual problems.
in the state of Jammu and Kashmir. The Jammu- Udhampur sector having 21 tunnels
has already been completed while the work in the remaining sector having 42 tunnels
with total length of 108 km. is in progress. In other sectors also there is a good future
role for underground works.
Tunnels are generally located in difficult environments- in various types of softer mediaand the alignment may traverse zones of various complexities. It is important that such
engineering projects are properly conceptualized and planned systematically to ensure
smooth implementation. Since one of the fundamental measures to ensure fast track
construction is the choice of a safe alignment, careful consideration is required to be
given to avoid all types of hazards as far as possible and these include treacherous soil
conditions, subterranean water streams, strata bearing hazardous gases such as
methane, etc. In addition, it is also to be ensured that adequate investigations have been
done, proper selection of tunneling equipment has been made, appropriate contracting
practices are available, environment and forest clearances have been taken, competent
construction agencies are available, social issues have been taken care of and similar
other issues are duly considered. If these are not properly accounted, the
implementation will not be smooth and many problems are likely to arise from various
affected agencies during the construction leaving to delay and cost over-runs.
FUTURE TUNNELING AND UNDERGROUND WORKS
Underground works in Infrastructural development - Power, roads and railway are very
vital for prosperity & growth of a Nation. Underground works are key corridors for
connectivity, transportation, Water Conveyance and communication.
Indeed in the Asian region, construction of underground works for hydro power
development, road and rail links have been taken up on a large scale. In India alone, in
the next two decades, about 50000 MW of hydro power is planned to be developed
involving over 1200 km of tunneling for conveying water and number of large size
Cavern to accommodate desilting chambers, generating units & transformers. The
mountainous/Hilly regions are adopting Tunnels for connectivity, where as mega cities
and major towns are adopting underground routes to over come congestions and
improve transportation. It is a sector which is expected to attract considerably large
investment in the coming two decades. With the comparatively easier sites already
exploited, the future development involves projects located in complex geotechnical and
topographical conditions posing challenges for investigation, design, planning and
construction. An even greater challenge is to accelerate this construction with improving
sustainability and maintaining quality and safety.
Name of Project
Pare HE Project (110 MW)
Length in km
3.483
8.895
16.40
12.034
2.7
2.665
6.385
16.179
19.226
12.235
Dibang (3000MW)
8.904
8.785
Naba(1000 MW)
24.12
27.84
25.3
9.12
18.6
Tato ll (700MW)
10.8
4.43
9.15
5.58
Etabue(165MW)
12.463
Utung(110MW)
2,67
9.38
Pakke(110MW)
3.34
3.32
8.7
2.247
4.47
34.94
1.12
3.6
10.15
24.325
12.75
Elango(150MW)
8.215
5.815
6.547
4.851
11.785
20.81
9.5
5.909
6.584
6.9
Kotri(150MW)
2.04
4.626
Khab ll (186MW)
12.161
10.226
Gondhla
11.432
Jhangi Thopan - II
7.0
7.286
8.703
8.672
9.474
4.0
15.81
10.87
Tropal Power I
7.53
89.996
17.05
21.57
12.065
17.05
8.76
2.5
.85
2.0
17.66
0.9
0.9
0.9
2.426
18.79
5.65
11.41
17.53
2.80
14.186
6.6
15.865
11.543
15
Nongham (50MW)
4.005
Nongkolait (120MW)
6.52
Umjaut (69MW)
2.9
Umangi (54MW)
6.772
Mawblei (140MW)
7.585
Sushen (65MW)
1.492
Boinu
34.982
Mawhli
11.82
Umduna (57MW)
7.945
Mawput(21MW)
2.587
Selim (170MW)
4.965
Rangmaw (65MW)
3.06
Twang
2.515
Yangnyu(80 MW)
4.137
5.648
5.789
1.127
Teesta-IV (495MW)
18.435
5.816
17.6
18.95
19.975
17.79
10.05
6.05
5.81
Lingza(120MW)
4.69
10.525
6.81
Vyasi(120MW)
3.07
KotlibhelStage-IA (195MW)
1.616
KotlibhelStage-IB (320MW)
3.983
KotlibhelStage-ll (530MW)
3.36
14.29
1.925
4.222
Sub Total
It is also planned to develop 31000 MW in the 13,h plan ending 2022 and remaining
about 36500 MW by end of 14th plan ending 2027. All these developments would
provide scope for tunnel construction in a big way.
Delhi Metro rail Corporation Ltd. has already commissioned a 65.10 km route in phase I
and is proceeding ahead with another 125 km in phase II.
Phase-Ill
After the completion of Phase II of Delhi Motm Project by 2010, work on Phase III
covering 112.17km:. is likely to be taken up. Some of the corridors that art likely to be
included in Phase III are Mukundpur- Snrnl Kalenkhan ISBT, CS-Gokulpuri borderNawada, Rithala Barwala, Airport Link Sushanlok-T junction Soctor 47&48, Bahadurgarh
Extn. and Ghaziabad Extn. to Bus depot. These corridors are tentative and subject to
change.
Phase-IV
This would be the final phase of Delhi Metro. By adding another 108.50 kms, it would
completely link Delhi & the National Capital Region (NCR) with a total network of around
414 kms. Both these phases would also involve construction of tunnels and underground
stations. After completion Delhi Metro Rail work shall be amongst one of the longest
Metro network in the world.
Rail Network
For Jammu-Udhampur- Srinagar Baramulla Rail Link, between Katra-Quazigund section
(142 km), there are 42 nos. of tunnels with total length of 107.96 km are to be executed
in short span of next five years.
Road Tunnels
Under programmes for development of infrastructure, road links to remote regions of the
country are also planned to be strengthened and improved. National Highways Authority
of India and Border Road Organization (BRO) are preparing plans for development of
road tunnels.
s. Name of the
No. city
1
Bangalore
Line
Kms
18.1 Kms
14.9 Kms
Airport Link
City Airport Terminal at Police Ground
(NH-7) New International Airport (Phase-I) 33.65 Kms
2
Hyderabad
26.27 Kms
13.18 Kms
21.74 Kms
Airport Link
Begampet Airport - Hyderabad
International Airport at Shamsabad (Phase-I) 42.35 Kms
3
Ahmedabad
Metro System
Line-I Akshardham - APMC Vasana
32.65 Kms
10.90 Kms
Mumbai
44.85 Kms
9.85 Kms
11.07 Kms
38.24 Kms
13.18 Kms
Kochi
25.253 Kms
Chennai
23.05 Kms
23.44 Kms
Kolkata
18.65 Kms
Ghaziabad
9.41 Kms
Badarpur
13.875 Kms
3. Standardise the size of tunnels for optimizing the use of tunnelling machines. A
number of smaller tunnels can be preferred over a large tunnel.
4. Identify the level of machine excavation techniques and the machine types suitable
for working conditions of the country.
5. Import tunnelling machines from the developed countries with a package including
spares, training and transfer of technology for indigenous production.
6. Create a production base for tunnelling machines in the country.
7. Use controlled blasting technique instead of conventional blasting method where
machine excavation is not possible.
8. Use shotcrete and rock bolt support instead of the steel-rib support system, wherever
possible.
9. Adopt purposeful tunnel instrumentation programmes.
10. Adopt air-borne surveys and geophysical techniques for faster, quicker and reliable
geological investigation.
11. Incorporate modern management systems to enforce time and cost schedule.
12. provide adequate ventilation system wherevor required.
Specific Project Based Policy
The project-based remedial measures am necessary to plan tunnelling operations in
case of a specific tunnel for timely execution of a project. Following i could be
considered.
1. Collect reasonably reliable geological information with increased use of air-borne
surveys and geophysical techniques.
2. Prepare an assessment of the expected ground behavior with the help of a
geotechnical expert. This should include:
(i)
(ii)
(iii)
(iv)
3. Prepare tentative tunnel designs along all possible alignments on the basis of the
advice of the geotechnical expert.
4. Prepare time and cost estimates along all possible tunnel alignments and select a
time and cost effective alignment.
ensure safety and stability of the structures. At last, in future no user industry can flourish
without having an easy apd quick access to cost effective and good quality equipments,
therefore, there is a need for creating an equipments manufacturing base in the country.