Badarpur – Faridabad Metro corridor near completion


The Badarpur – Faridabad extension of the Delhi Metro will take the Metro to the satellite city of Faridabad in Haryana for the first time. This line will be an extension of the currently operational violet line between Mandi House and Badarpur. The same section will expand up to Kashmere Gate on the other side from Mandi House.DMRC Line 6

Once fully operational, Line-6 will be running from Kashmere Gate to Escorts Mujesar having a length of 43.40 KM and 32 Metro stations. Of these, five will be interchange stations namely, Kashmere Gate, Mandi House, Central Secretariat, Lajpat Nagar and Kalkaji Mandir Metro Station.

Corridor Highlights:

  Route Length 13.875 Km

  Completely elevated corridor

  Number of Stations 9

  Names of stations: Sarai, NHPC Chowk, Mewala Maharajpur, Sector 28, Badkal Mor, Old Faridabad, Neelam Chowk Ajronda, Bata Chowk, Escorts Mujesar.

  • The Depot for this section has been constructed near Sector 20 A in Faridabad and will be called Ajronda Depot.
  • Two more stations NCB colony and Ballabhgarh will also be added in this line by 2017. The length of the line will be increased by 3.2 kms.

Present Status:

The construction work for the entire 13,875 km long elevated corridor has been completed and the finishing contractors are currently working on giving final touches to the nine stations on the section apart from the Ajronda depot. The trial runs of trains on this section are expected to begin within the month of April itself when all parameters of Metro functioning will be checked before the formal beginning of operations.

Construction Highlights:

  • The viaduct has been constructed using pre cast u-girders. These u-girders are 27 mtrs in length and were used because they allowed speedy construction as the pre cast girders could be brought to the site and launched in a short span of time. They also gave an aesthetic and sleek look to the entire viaduct.
  • I-girders have been used at the Old Faridabad station as a third line is also diverting from that station towards the Ajronda depot.
  • All the nine stations on the section have been provided with Foot Over Bridges (FOBs) so that commuters can easily reach the stations from the nearby areas. These FOBs are steel structures attached to the station buildings. All stations have been provided with lifts and escalators. Parking has been provided at stations depending upon the availability of land for station and property development areas as required.
  • Since the 27 mtr long pre cast u girders had to be carried to the site, giant 400 and 500 tonne cranes were employed at these corridors so that the work could be expeditiously executed.

Engineering Challenges:

Use of precast portal beams in Faridabad

  • Near the Badarpur toll plaza towards NHPC Chowk, Faridabad, the Metro alignment of the under construction Badarpur – Faridabad section moves from the right of the road (National Highway) to the left.
  • On this stretch, the alignment curves about five times on a 300 m length. To take the alignment through these curves, six portals have been built on the 15 m wide free way near the toll plaza that carries traffic which is not coming from the flyover. Construction of portals are generally done on site as they are generally very long and heavy in nature. In this case also, the initial plan was to construct the portal beams on site itself.
  • However, on close study, it was found that the onsite casting of the beams would severely hamper traffic on this free way of the National Highway as it has to be blocked for at least six months.
  • Therefore, for the first time in DMRC’s history, the decision to install precast portal beams was taken. These portal beams, each about 17 mtrs long and weighing between 205 to 225 mt were cast at the casting yard and brought on site for installation.
  • Five Extended Pier Caps (EPCs) were also used for the first time on which the beams rested. These extra long pier caps were used so that the portal beams could easily rest on them. The EPCs were about 7.5-8.5 metres in size. The girder between the EPCs were 36.5 metres long.
  • Two huge 500 mt cranes along with one 250 mt trailer were pressed into service for the installation of the six portal beams on 12 piers at a height of 12 mtrs. Had DMRC constructed cantilever piers instead of portal beams, it would have affected portions of the toll plaza, Foot Over Bridge and an NHAI building.
  • The work was done in close coordination with NHAI and Faridabad Traffic Police.

Shifting/modification of major electrical utilities including transmission lines

DMRC has shifted some major electrical lines and transformers to execute the construction work of the Faridabad corridor.

As part of this work, a 220 KV and a 66 KV Double Circuit transmission line were raised for the construction of viaduct and proposed NHPC Chowk station.

Another 66 KV Double Circuit transmission lines which is running along Escorts Mujeswar Station was converted into underground by laying about 12 Km single core cables.  Shifting of electrical utilities in this Metro Corridor was a major challenge for DMRC Engineers due to:-

  • Almost all the 517 piers were affected and were infringing with 2/3rd circuits of Over Head 11 KV Electrical Lines and Under Ground cables.
  • Space for shifting of electrical utilities was not available at number of locations. The electrical installations had to shifted after land was made available.
  • This was the first occasion in the history of DMRC when electrical lines were infringing throughout the corridor at all piers and station locations.

Construction along the busy National Highway 2

To carry out construction using heavy machinery on the busy National Highway 2 was a major challenge. Traffic marshals had to be put up at all crucial intersections to ensure that both Heavy trucks, buses as well as auto rickshaws could pass along without any inconvenience.

DMRC also had to ensure that the five flyovers running parallel to the Metro construction were not affected in any manner. The work was done in close coordination with the National Highway Authority of India (NHAI).

Depot Details

The following are the highlights of the new standard gauge depot at Ajronda:

  • 10 stabling lines and future provision for 8 more lines
  • Presently the depot has 5 open lines and five covered lines, 4 covered and 4 open lines may be added in future
  • 26 rain water harvesting pits
  • Auto wash plant on the ramp (only the second such facility after Sultanpur depot)
  • Test Tracks
  • Inspection Bay
  • Water Recycling facilities

Station Design

  • The alignment of metro corridor is along the 66 m wide on Mathura road.
  • As all the stations are off the road stations there is a scope of land available for Property development hence all the stations have provisions for Property development at Ground Level and Some area on Concourse Level. All necessary provisions like Separate Entry Exists, Fire Escape, Toilets and Water Supply and Electrical connections to PD area have been made in the station.
  • The stations are more visible from the Highway as compared to the typical metro stations constructed on the road. Therefore, utmost care has been taken to make the elevations of the stations to look good. The External Façade of the stations has been finished in combination of textured paint, ACP Cladding, Structural Glazing, Aluminum Windows and well crafted GRC Jalli work to give it vibrant look.
  • The stations will have state of the art signage system having Powder coated Aluminum extruded section box, polycarbonate sheets and vinyl pasted letters and graphic with LED light fixtures wherever it is illuminated.

Six coach trains on the violet line

  • Presently, out of 30 trains, only one six coach train is available on the Mandi House – Badarpur corridor, which will soon be extended upto Faridabad. All others (29) are four coach trains.
  • Now, out of those 29 trains, four more trains have already been converted into six coach trains and are ready to be inducted into service.
  • The rest 25 trains will be converted into six coaches for this corridor gradually. Thus, all trains operating on this corridor will be converted into six coach trains in the days to come.
  • The average ridership of the Mandi House – Badarpur section as on March, 2015 is 1.92 lakhs everyday.