DIAL PROJECT 

DIAL Project- World class Airport and a National asset

The DIAL Project is the Largest Airport Privatization effort in India to upgrade the busiest Airport of the country – The Indira Gandhi International Airport, New Delhi.

Gateway for all International travelers and to showcase India for visitors during 2010 common wealth games @ New Delhi.

Unprecedented task of building this Airport infrastructure to handle over 30 million passengers per annum in a short period of 36 months for complete Engineering, Procurement & Construction has been given to L&T.

DIAL Project- L&T’s another definition of “Imagineering”

Design & Engineering

1. Single point responsibility for-

1. Architectural and concept designs, meeting world class performance specifications of OMDA (Operation Maintenance and Development Agreement between DIAL & Govt. of India).

2. Detail designs of Asia’s longest runway and new sophisticated Terminal T3 capable to serve even Airbus-380.

3. Preparation of Technical specifications, Design Basis Report for all MEP and Airport Systems works.

4. Evaluation and review of detail designs of 26 specialist vendors from different countries for performance compliance & endorsement for implementation.

5. 8,500  design  man-months spent in producing, reviewing, endorsing 137,173 drawings and 63,666 design related specification documents with 400 design experts with 100 being expatriate along with supporting staff of draftsmen and CADD experts.

Procurement of Specialist Vendors    

Complete responsibility for-

1. Preparation of NEC3 based tender documents.

2. Floating and evaluating bids for 35 specialized works packages from both indigenous and international contractors.

3. Participating International contractors from all parts of world- European Union, Singapore, China, Japan, USA, Australia, and Canada.

4. Contract Execution & Administration involving 21 International and 44 Indigenous vendors for 65 different specialized work packages.

Project Management

Implementation of standardized, uniform project management system for all 65 subcontractors by setting up Project Control Cell responsible for -

1. Time Planning and scheduling using Primavera P-6 software.

2. Progress and Time Monitoring using weightage based ‘S’ curve.

3. Document management System through Aconex.

4. Daily, Weekly, Monthly reporting for accurate status updates and proactive identification of Project critical issues.

5. Resource requirement, sequential workflow, and identifying non performing activities challenging Project timelines.

Separate Planning teams for every package assigned working out details related to sequence, logistics, progress, site interface on the broader targets set by top management through project control.

Construction Implementation

Dedicated 1,100 staff deployed to turn the Engineering Challenge into reality -

1. Airside Works:

a. 4.43km of Runway along with 20km of taxiways completed in 20 months with 24.52 Lac cum of earthwork, 4.61Lac Cum of CTB ,70,651 Cum of Pavement Quality Concrete and 5.8 Lac MT of Asphalt ,5,100 AGL lights.

b. 6.3 Lac Sqm of Apron area with 57 stands and capacity to park 115 different types of Aircrafts involving 3 Lac Cum of Pavement Quality Concrete.

c. 11 km of Perimeter Roads, 11.2 km of precast elements Boundary Wall

d. 12.5 km of Drains and 5.5 km of Culverts

 

2. Terminal Building Works

i. Building Civil Structural Works

a. Structural works for 5.5 Lac Sqm area Terminal Building completed in record 18 months duration involving 5.32 Lac cum of concrete, 1.0 Lac MT steel, 10.6 Lac sqm of shuttering.

ii. Building Envelope Works

b. Terminal Building Structural roof having 16,000 MT structural steel fabricated & erected in span of 6 months.

c. 1.92 Lac Sqm of 7 layer roof sheeting system.

d. 1.8 Lac Sqm of Façade with 3,100 MT structural steel as transoms and mullions

iii. Building Services and Utilities

e. 2.5 Lac sqm ducting, 735 AHU installations,48 km of chilled water pipeline, 8 chillers with cumulative capacity of 20,000TR 

f. 1 Lac light fixtures with 880 kms conduiting, 565 panels, 5,000 kms wiring

g. 1.12 L kms piping works for plumbing, 15,000 sanitary fixtures.

h. Fire protection system for the building with 320 km piping, 500 km of Fire Alarm cabling and 85,000 sprinklers and nozzles.

i. Power station having 200MVA Capacity and 42 MVA DG back up with 14 DG set, 4  66/11kV Transformer

j. 13 MLD capacity Sewage Treatment Plant and Under Ground reservoir

3. Airport Systems

a. 12,400 Bags per hour capacity Baggage Handling System with 6.4km conveyor, 12 km belt, 2,100MT steel, 3,500 sensors, 41 X-ray machines.

b. 63 Nos elevators, 31 Nos escalators and 88 travelators

c. 78 Numbers PBB’s  capable to serve A-380

d. 40,500 Network Data points, 3,300 CCTV, 8,500 speakers, 2,500 access control entries, 2,500 km of Optical fiber cabling,729 FIDS display screens,  168 check in counters. equipped with Common Usage Terminal Equipment CUTE Self Check in and Boarding pass generation. IT Integrated CMS system of MEP services to IBMS for fast and effective control.

Building Interior Finishes

e. 4.6 Lac Sqm of Flooring with 1.10 lac Sqm of Granite from Saudi and remaining area with Vitrified, Kota, carpet and Granolithic screed flooring.

f. 3.60 Lac Sqm of false ceiling with 2.84 Lac Sqm of Metal Panels being imported from Germany and China.

g. 1.5 Lac Sqm of Internal ACP works, 15,462 Sqm of Corian Cladding.

 

Mechanization of Construction

1. Mobilization of Plant and Machinery worth 150 Crore in short span of 5 months.

2. 960 Cum/hr Concrete production capacity set up.

3. 600 MT/hr production capacity Hot mix plants.

4. 8,000 MT/month capacity steel service center established at site.

5. Pre casting yards for Boundary wall and Drain and Culverts elements.

6. Establishment for Horizontal and Vertical Precast Hume pipe production at site.

7. 62 Lac Tons of High quality aggregates procured. Critical part of 10 Lac ton for pavement works produced at L&T’s own crushing plant at Pichani.

8. 8 Lac MT of cement procured at site with cement storage capacity built up for 45,000MT.

9. 65,000 Sqm/Month duct production capacity factory set up at site for HVAC works.

10. Pipe fabrication factory with capacity of producing 88km of pipes/ month set up at site.

11. Laser Leveling machines with racker for precision in levels upto +-3mm and spreading capacity of 1,000 sqm in 8 hours  

 

Sustainability and Social Responsibility towards Environment and

Human resource

1. Adopting Green Building Concepts at Design stage itself:

a. Reduced cooling loads due to insulated roof and efficient glass.

b. Double glazing all along the building envelope for heat insulation.

c. Variable frequency drives on AHU fans to vary air supply as per demand conserving energy.

d. CO2 sensor based outdoor air control in public areas & SO2 sensors in vehicular movement areas.

e. Free cooling for public areas during favorable weather conditions that is 100 % outside air is used directly to cool the space when outside air temperature is low thus saving on chiller energy use.

f. CFC free refrigerants for Chillers (R134A)

g. Minimum electric lighting use during daytime. Lighting Control and Monitoring System for the whole PTB & Piers with all the associated Presence detectors, Occupancy sensors, Daylight sensor, and Brightness sensor modules to adjust the lighting levels as required.

h. Water-efficient landscaping using recycled water.

i. Over 400 Nos. rainwater recharging Pit installed to conserve & replenish Ground water

j. STP (Sewage treatment plant) water for complete Air Conditioning system

k. No use of potable water for landscaping – completely recycled water.

l. Use of sensors in taps etc, effectively reducing the wastage of water by 20%

m. Baggage handling system uses sophisticated mechanism that ensures the system runs as per load, so if there is no movement of bags then the conveying equipment shall go on power save mode or sleep mode.

2.   At Execution Stage

n. Accommodation capacity of Labour colony at site - 30, 000

o. Workmen Training Institute set up at Site itself.

p. Waste Water utilization by Sewage treatment plant at Labour colony.

q. Taking up tree plantation, dust control and zero emission provisions at HMP.

 

Unique Design and Construction Technology

1. HVAC:

  8 chillers of 2,500 TR capacity each, first time in India.

  APS (Air Purification system) is installed within Air Handling Units (AHU’s) to maintain the required air quality of circulating air.

  Full compliance to NBC-2005 for outdoor air requirements.

  Dedicated smoke extraction fans to flush out the smoke formed in case of fire.

  Lift lobby, lift well and staircase pressurization fans to provide safe passage to public and fire personnel’s.

  To maintain the uniform temperature, the areas having more temperature, especially glazing areas are fed from separate dedicated AHU’s.

  Considering energy efficient design, the Chillers installed are having very low KW/TR (kilowatt/Tones) ratio of 0.55 at 100% load, which means reduced power consumption.

  Main substation building/rooms are temperature cooled for better monitoring and equipment operations.

  State of art HVAC- CMS (Central Monitoring system) to operate, monitor and Control HVAC system.

 

Electrical:

  Additional levels of reliability to prevent power failure by creating multiple banks for transformers.

  Separate lighting CMS system for better monitoring and control.

  Routing of 11 KV cables from Main substation to Passenger Terminal Building through underground tunnels.

  Way finding design is incorporated in the lighting design.

Fire:

  Gas suppression system uses a unique gas- NOVAC 123, which is environmental friendly having 0.0% ozone depletion effect and atmospheric lifetime of 5 days only.       

  All designs as per NFPA norms (National Fire Protection Association – American Society)

BHS:

  Sophisticated in- line Baggage Handling system, no queues to stand in to have luggage system go through X-Ray system thereby saving time and offering comfort and convenience to passengers

  All Check in counters to use CUTE (Common user Terminal Equipment), which facilitates airlines to use any counter during peak hours.

  Foolproof security system with 5 levels of baggage screening. The baggage shall go through level one of screening through X-ray machine. If suspicious article is found the baggage will proceed to level 2 workstations with dual monitors. If the baggage is not cleared, it proceeds to level 3 of screening. At level 4 screening passenger will be called and asked to open the luggage and if there are any explosives, baggage is sent to level 5 which has designated Threat bag disposal area.  

  Baggage handling system running with 1,200 motors that are controlled with fully automated Programmed Logic Controls (PLC’s) that will ensure conservation and optimum utilization of energy.

  Apart from dedicated 5 carousels for domestic arrivals and another 5 for international arrivals, another 2 inter changeable carousels are also provided which can be used either for international or domestic arrivals during peak loads as per the requirement.    

 

Major Software used:

  Building Information Management(BIM) for 3D modeling for Design Interface and Clash free execution.

  Tekla 3D –used for structural steel and Apron Interface

  TERRA model for Bulk earthwork calculation

  LIDAR survey for existing Fuel Farm of BPCL to create the exact 3D model of our Aviation Fuel Connection designs.

 

Unique Achievements and Interesting facts:

  Greenfield Runway- 4.43 kms long, second longest in world which caters to Code F aircraft requirements and is CAT III enabled was Design, Built and commissioned in a short span of 20 months

  Use of Stabilized sub grade (CTSG - Cement treated sub-grade) to reduce the thickness/ quantities of the more expensive layers above, thereby making it more cost effective and reducing the haulage resulting in lesser environment pollution during construction.

  13 kms long, India’s largest Aviation fuel system designed to cater demand till year 2036.

  The peak piled up stock of aggregates went up to 12. 0 Lac MT.

  In a month the Concrete qty poured went up to 148,725 cum.

  Peak Labour mobilization strength-27,000

  Launching of Roof structure structural steel by using Pressure Pumps for lifting-Erecting 600 MT steel up to 15 m height in a time span of 3 hours.

  Inclined travelators being used for the first time.

  One of the largest IT-Control centre for Centralized Monitoring of Airport operations.

  Thermal cameras for CCTV provision, first time used in India for strategic locations of T-3.

  CUTE and CUSS equipped check in system avoiding congestion.

  4300 car parking MLCP being separately built with skywalk connection to Terminal Building.