Hindustan Construction Co. Limited - Infraline

Hindustan Construction Co. Limited 

(Building values since 1926) 

Hindustan Construction Co. Ltd July 07 Page 1

HCC - incorporated in 1926 

The first wholly Indian company entrusted with execution of 

large civil engineering projects in India. 

The Borghat Railway Tunnel [1928] – India’s first tunnel 

1 st contract to be awarded to an Indian company 


Over 600 large infrastructure construction projects …. 

Dams 

Barrages 

Tunnels 

Power 

Hydel 

Nuclear 

Thermal 

Transport 

Bridges 

MRTS 

Roads 

Industrial 

Environmental 

Ports 


HCC today 

Leading Infrastructure Construction Company in India 

Public Limited Company 

AA+ rating from CARE 

Manpower base > 2600 

Total ERP [SAP] enabled 

Specialists in execution of large / complex projects 


Landmarks in construction – Irrigation 

Then 

• World’s longest barrage as per 

Guinness book of structures [1971] 

Length – 2253 M 

Now 

• India’s largest barrage contract in 

recent times [1999] 

Length – 363.8 M 

Farakka Barrage, West Bengal 

Hathnikund Barrage, Haryana 


Landmarks in construction – Nuclear 

Then 

• India’s first indigenously built 

Atomic Power Project 

Units 1&2 – 1971 

Units 3&4 – 2000 

Units 5&6 - Ongoing 

Rajasthan Atomic Power Project 

Now 

• India’s largest, most modern & complex 

Nuclear Power Project - Ongoing 

Hemispherical IC & OC dome – first in India 

Steel liner for IC dome – first in India 

Russian collaboration – first time in India 

Kudankulam Nuclear Power Project, 

Units 1&2, Tamilnadu [ 2 x 1000 MW] 


Landmarks in construction – Water Supply 

Then 

• India’s largest Water Treatment 

Plant [1984] 

Capacity – 1910 MLD 

Now 

• India’s largest integrated water 

supply scheme on EPC basis [2006] 

Capacity – 185 MLD 

Bhandup WTP, Mumbai 

Tirupur Water Supply 

Scheme, Tamilnadu 


Landmarks in construction – Bridges 

Then 

• India’s first Rail cum Road Bridge 

[1965] 

Now 

• India’s first and only Bow String 

Arch Girder Bridge [1997] 

One amongst the longest in India 

Length = 1.854 KM 

First PSC rail bridge in India 

Length = 2.745 Km 

Mokameh Bridge, Bihar 

Godavari Bridge 

Andhra Pradesh 


Landmarks in construction – Marine works 

Then 

• One amongst India’s largest 

ntegrated multi berth port 

development projects [1975] 

Now 

• Asia’s largest Breakwaters [2000] 

Largest Port to be built in single contract 

Haldia Port Project 

West Bengal 

Ennore Port Project 

Tamilnadu 


Hydro Power Projects 

Technical Capability

Hydel Power …….. Our core competency 

India’s biggest 

“large hydro power” 

contractor 

Experience Expertise Diverse Capability 

ore than 5 decades 

1 dams 

8 barrages 

70 km of tunnels 

8 powerhouses 

• Himalayan projects with unforeseen 

problems / adverse geological 

occurrences. 

•Composite projects with all components 

in one contract 

•Surface / UG powerhouses 

•DBM / TBM tunnels 

•Dams / Barrages 

•Pressure shafts / Surge shaft 

•Intake / Desilting chamber 


Dams

Built 6 out of 11 highest concrete dams in India 

Himalayan 

Geology 

Experience 

Large 

Scale 

Construction 

Concrete 

Placement 

Techniques 

2007 

2001 

1988 

1982 

1977 

1976 

1966 

1965 

1954 

Tala HEP - 92 M high dam in the himalayan region 

Kurichu Dam - 55 M high dam in Bhutan – built in himalayan region 

Salal Dam-India’s first dam on rock pedestal, built in himalayan reg 

Idamalayar Dam - India’s eleventh highest concrete gravity dam 

Cheruthoni Dam - India’s fifth highest concrete gravity dam 

Idukki Dam - India’s first & only double curvature arch concrete dam 

Sabarigiri Dam - India’s third concrete gravity dam 

Rihand Dam - India’s second concrete gravity dam 

Vaitarna Dam - India’s first concrete gravity dam 


ndia’s first all concrete gravity dam [1954] 

Patented process of pre-cooling 

ggregates for concrete 

Vaitarna Dam, Mumbai – 555 m x 82 m 

First time fully mechanized 

onstruction activity 

Concrete Placement – 

5.6 lakh cum 


ndia’s second concrete gravity dam [1965] 

• India’s 10 th highest concrete gravity 

dam 

Rihand Dam, U.P –935m x 92 m 

• HCC secured dam contract without 

any foreign collaboration 

n global tendering process 

• Biggest single contract ever 

assigned to a single private enterprise 

n India. 

•Concrete placement - 16.3 lakh cum 

placed by 900 M long cableways, 

reputed to be then the world’s longest 


ndia’s second concrete gravity dam [1965] 

Rihand Dam – 2 nos 20.32 T & 2 nos 10.16 T cableways placing cooled concrete 


India’s first & only Double Curvature Arch Dam [1976] 

India’s second highest 

oncrete gravity dam 

Concrete placement - 

4.6 lakh cum 

Special feeding arrangement for 

Crushing plant, by ropeway 

assing through a specially made 

unnel. 

Idukki Dam, Kerala – 366 m x 167.5 m 


First Dam in India on a rock pedestal [1988] 

•6 th highest concrete dam in India 

Salal Dam, J&K – 450 m x 113 m 

• Built in himalayan region – very 

complex geology & poor rock 

conditions 

• Concrete – 14.76 lakh cum 

• Heavy foundation treatment 

measures were undertaken 


Other major Dams built by HCC …….. 

ABARIGIRI DAM, Kerala 

966] – 336 m x 110 m 

dia’s seventh highest 

ncrete dam 

oncrete Placement – 

85 lakh cum 

CHERUTHONI DAM [1977] – 651 M X 133 M 

India’s fifth highest concrete dam 

Concrete Placement – 17 lakh cum 

AMALAYAR DAM, KERALA [1982] – 382 M X 91 M 

ndia’s Eleventh highest concrete dam 

Concrete placement – 17.3 lakh cum 

TALA HEP, BHUTAN [2007] – 128 M X 92.5 M 

Concrete Placement – 2.4 lakh cum 


Powerhouses & Tunnels 

Underground Construction

HCC’s contribution > 20% of India’s hydel Power 

Roadheaders 

DRESS method 

unnel Boring Machines 

Full Face / Shield 

NATM method 

Rock support systems 

Alimac Raise Climber 

DBM 

Fullly mechanised 

Hand held rock drills 

2007 

2000 

2000 

1994 

1988 

1975 

1965 

1962 

1956 

1928 

India’s longest railway tunnel being built across younger 

Himalayas with complex geology 

Nathpa Jhakri HEP - India’s 2 nd longest power tunnel pkg, 

Amidst AGO - shear zones, soft ground conditions etc 

Mumbai tunnels - tunnel construction in congested conditio 

Chamera HEP, Stage I – 5th largest UG powerhouse 

Kadamparai HEP - India’s first pumped storage project 

Yamuna HEP - India’s 3 rd UG powerhouse & first in himala 

Koyna HEP, Stage I&II-India’s first “steep pressure shafts “ 

Koyna HEP, Stage I&II - India’s 2nd underground powerho 

India’s first underground powerhouse @ Maithon, Bihar 

Borghat Tunnel - India’s first railway tunnel 


ndia’s second largest UG hydro power station 

Koyna Hydel Power Project, Maharashtra 

Largest Hydro power station in Western India 

HCC has been associated with all four stages of this project 

Stage I 

Stage II 

Stage III 

Stage IV 

1962 

1965 

1976 

2000 

260 MW 

300 MW 

320 MW 

1000 MW 

Underground 

Inclined 

Concrete 

Underground 

powerhouse 

Pressure 

Dam 

powerhouse 

shafts 


Koyna HEP, Stage I & II - 560 MW [1965] 

Machine hall cavern here is the 6th widest cavern built in India so far. 

EMERGENCY VALVE PUMP 

MACHINE HALL- 184 m * 14.6 m * 31.5 m 

TRANSFORMER HALL 

- 200 m x 12.95 m x 16 m 

4 nos Pressure Shafts each of dia 

3.05 m to 2.6 m and length - 616 m, 

inclined @ 45 deg. to horizontal 

. 

48 

VALVE HOUSE 

BUS BARS 

PRESSURE SHAFT 4 Nos. 

TURBINE PIT 

TAIL RACE 

eel lined pressure shafts inclined at 45 deg were the first of their kind in Indi 

First time use of Alimac raise climber for pressure shaft construction in INDIA 



Machine hall cavern here is the 6 th 

widest cavern built in India so far. 

nos Pressure Shafts each of dia 3.05 m to 2.6 m and length - 616 m, inclined @ 45 deg. to horizontal 

Steel lined pressure shafts inclined at 45 deg were the first of their kind in India. 

First time use of Alimac raise climber for pressure shaft construction in INDIA 



Machine Hall - 184 m * 14.6 m * 31.5 m 

Transformer Hall - 200 m * 12.95 m * 16 m 




Koyna HEP, Stage 4 - 1000 MW [2000] 

EMERGENCY VALVE TUNNEL 

. 

58 

HEAD RACE TUNNEL 

INTER ADIT 

KOLKEWADI LAKE 

TAIL RACE PORTAL 

POWER CABLE TUNNEL 

VENTILLATION TUNNEL 

4 Nos. PRESSURE SHAFTS 

- 3.75 m DIA TO 3.90 M dia, 571 m LO 

COLLECTION GALLERY 

MACHINE HALL 

- 144 M X 20 M X 50 M 

TAIL RACE CHANNEL 

TRANSFORMER HALL - 173 M X 20 M X 18.5 M 


Koyna HEP, Stage 4 - 1000 MW [2000] 

Machine Hall Cavern 

Alimac raise climber 

Pressure shafts 


ndia’s first Underground powerhouse in himalayas [1975] 

Yamuna HEP, Uttar Pradesh - 228 MW 

A trend setter in rock support systems in himalayan region 

EXPANSION GALLERY 

HEAD RACE TUNNEL 

GATE SHAFT 

INSPECTION GALLERY 

DRAFT TUBE 

GATE 

GALLERY 

INTAKE STRUCTURE 

MACHINE HALL- 113 M X 18.2 M X 32 M 

PRESSURE SHAFT 

COLLECTION 

GALLERY 

DRAFT TUBE TUNNEL 


Yamuna HEP, Uttar Pradesh - 228 MW [1975] 

Powerhouse Complex : 

– Complex Geology – Poor rock 

conditions 

– Presence of several shear zones 

– Heavy rock collapses 

• Heavy system of PSC steel cable anchors. 

• Cavern roof supported by steel sections & 

backfilled with concrete 

•Excavation done stage-wise 

Power Tunnel : 

– Complex geology – thinly 

bedded soft rocks charged with 

water and heavy stresses 

– Soft ground conditions 

– Heavy ingress of water 

– Heavy rock collapses 

• Shotcreting 

• Heavy steel supports with concrete backing. 

• Extensive rockbolting 

• Pilot heading was driven. 

• Widening to full section done. 


Stage-wise excavation in Powerhouse 

Text (Font Arial 16, Color Black, Line Spacing 30 points). 



Powerhouse – Excavation in progress 



Anchor head 


Head Race Tunnel–Pilot tunnel method 

Perfo bolt anchors provided beyond full section 




Adit to HRT with heavy steel supports to roof 




Yamuna HEP, Uttar Pradesh - 228 MW [1975] 

This is one of the largest projects to be have been built in a composite contract. 

This is also the third underground powerhouse to be built in India. 


ndia’s first Pumped Storage Project [1988] 

Kadamparai HEP, Tamilnadu - 400 MW 

INTAKE 

CONTROL SHAFT 

HEAD RACE SURGE SHAFT 

KADAMPARAI 

FORE BAY DAM 

FRL +1149M 

POWER TUNNEL 

INTERMEDIATE ADIT 

PRESSURE SHAFT 

- 2 nos, 5 M dia, 516 M long 

POWER 

HOUSE 

- 113 M X 18.2 M X 32.5M 

SWITCH 

YARD 

CABLE 

TUNNEL 

ACCESS 

TUNNEL 

TAIL RACE 

SURGE SHAFT 

TAIL RACE 

TUNNEL 

GATE SHAFT 

TRASH 

RACK 

FRL +769.62M 


Chamera HEP Stage I – 540 MW [1994] 

• India’s fifth largest operating underground hydropower station. 

• Project has been built in the geologically complex himalayan region. 

• Major geological problems were faced and were overcome with use of modern 

construction techniques. 

• New Austrian Tunnelling method was used for the first time in India in this 

project. 

• Project has won “Sarvamangala Award for Excellence in Construction” in 1994. 


Chamera HEP, Stage I - 540 MW [1994] 

• Powerhouse Complex : Wall cracking 

occurred despite provision of 300 nos 

10.5 m long, 51 mm dia tensioned bolts. 

10 m – 18 m long, 36 mm dia rock 

anchors were provided to control the 

collapses 

• Draft tube & transformer gallery : 

47 m deep huge cavity formation happened 

during excavation. 

Cavity filling with Concrete. 

Loose rock mass grouted with cement. 

Multi drift excavation method used. 

• Power Tunnel : Collapse in tunnel & heavy 

water ingress eroding tunnel invert resulting in 

huge cavity formation. 

Eroded portions filled with concrete. 

18 m long rock anchors used. 

• Pressure shaft : Heavy rock collapses & 

presence of shear zone throughout the height. 

Rock support with steel ribs placed @ 

500 mm c/c. Strengthening with 

rockbolt, shotcrete & grouting. 


Chamera HEP, Stage I - 540 MW [1994] 

Powerhouse – rock reinforcement 

Drilling & installing anchors 


Chamera HEP Stage I – Power tunnel geology 


Chamera HEP Stage I – Power tunnel 

Typical deformed shape of rib 

Convergence measurement in 

carbonaceous phyllite 


IIIA Water Supply Tunnel Project, Mumbai 

• Employer : Brihanmumbai Municipal Corporation 

• Contract Sum - Rs. 166.15 Crores 

• Total length of tunnel- 12.03 Kms. 

• Finished diameter : 3.0 M 

• This tunnel has been built as a part of IIIA Mumbai water supply project. 

• This tunnel has been constructed by using by 2 nos full face open TBM’s. 

• Tunnel boring method has been selected due to the following reasons : 

• The location of the tunnel is one of the most congested areas in Mumbai. 

• Drill /Blast method would have created problem to the safety of the structures overground. 

• Condition of rock was good. Geology along tunnel was hard rock. 

• This tunnel is one amongst the longest water supply tunnels which have been built in 

India so far. 


IIIA Water Supply Tunnel Project, Mumbai 

Indicates TBM movement 


View of TBM cutters & Lowering of TBM Kelly 




Probe Hole Drilling &Tunnel Boring By TBM 




Mine car with hydraulic jacks & Laser for tunnel 

alignment 




Nathpa Jhakri HEP – 1500 MW [2002] 

• HCC’s scope of work : 

– 11332 M long HRT with a finished dia of 10.15 M. 

– 294 M deep surge shaft – reputed to be one amongst the deepest in the world. 

• Built for India’s largest operating hydel power project. 

294 m 

HCC’s scope of 

work 


Major problems encountered 

• Change in Geology : 

– Substantial variation in rock classes 

– Substantial increase in poorer classes of rock 

10 m – 18 m long, 36 mm dia rock 

anchors were provided to control the 

collapses 

• Presence of shear zones : 

– about 60 m wide 

– fractured / shattered rockmasses 

– multiple shears 

– flowing ground conditions 

Cavity filling with Concrete. 

Loose rock mass grouted with cement. 

Multi drift excavation method used. 

• Extreme hot water conditions : 

– Temperatures > 65 deg C 

– Length > 2.8 Km 

Installation of additional ventilator 

boosts / water chillers / enhancement of 

dewatering system. 


Geological changes 

VARIATION IN ROCK CLASSES 

• Change in Geology 

– Substantial length in poorer classes 

of rock. 

6000 

– Heavy rock support system 

• Change in nature of each rock 

class 

• Major changes in rock support 

system 

Metres 

5000 

4000 

3000 

2,655 

5,265 

4,620 

3,604 

3,280 

– Change in rockbolt pattern 

2000 

1,062 

1,598 

– Increased length & spacing of steel 

ribs 

– Overall increase of excavation time 

cycle 

1000 

0 

I 

0 

0 

II 

III 

IV 

0 

V 

442 

60 

VI / EGO 

Encountere 

Foreseen 

Foreseen 

Encountered 

Classes of Rock 


Major rock collapse causing cavity formation 




Drainage-Reinforcement-Excavation-Support-Solution 

DRESS method] 

Drainage in advance of rockmass ahead of the face with long drainage holes. 

Reinforcement of rockmass by installation of long forepoles of 12–15 M 

length followed by intensive grouting to create an umbrella arch as 

pre excavation support 

Excavation of tunnel with varying diameter in parts to make space for 

installation of one rib at a time 

Support system by installation of steel ribs of varying diameter and other 

rock support like shotcrete, concrete, self drilling MAI anchors etc. 


Drainage-Reinforcement-Excavation-Support-Solution 

DRESS method] 


Nathpa Jhakri HEP – Head Race Tunnel 


Nathpa Jhakri HEP – World’s deepest Surge Shaft 


One amongst Asia’s largest Hydel Power Projects 

Tala Hydel Power Project, Bhutan [1020 MW] 

HCC has executed two different contracts in this project 

Contract Package C1 

Contract Package C4 

• 92 M high concrete dam 

•Intake 

•Desilting Chamber 

•6.48 Km long HRT 

7.18 Km long HRT 


Major problems encountered 

• Poor rock conditions 

– More than 70% of the tunnel passed through 

poor to squeezing conditions 

Heavy rock support system consisting 

of Rockbolt, SFRS, Forepoles & 

steelribs was provided 

• Presence of shear zones : 

– about 100 m wide 

– fractured / shattered rockmass 

– multiple shears 

Heavy rock support system consisting 

of Rockbolt, SFRS, Forepoles & 

steelribs was provided 

• Adverse Geological Occurrence over 

a stretch of 329 M 

– 102 M of tunnel portion abandoned 

– tunnel alignment diverted by 45 deg. 

DRESS method 


ace Map of the rockmass 


Heavy seepage of water 


Shear Zone 

484 

607.00 

Ago 

Portion 

Mirchingchu d/s 

1730.00 

1592.00 

102 M 

RD 1589.50 (Div) 

Abandoned Portion 

Mirchingchu Adit (320 m) 

Kalikhola Adit (520.30 m) 


Rock collapse along shear zone 


Adverse Geological Occurrence 


Collapse on diverted tunnel alignment 


orepoling and Drainage holes 


Tala Hydel Power Project, Bhutan [1020 MW] 

Desilting Chamber Dam HRT 

Intake 

HRT 

Dam 


Hydel Power / Tunnel Projects 

Current Portfolio

Current Portfolio of Hydel Power / Tunnel projects 

JAMMU & KASHMIR 

1. NIMOO-BAZGO HEP – (3x15 MW) 

value: Rs. 384 Crores 

2. CHUTAK HEP – (4x11 MW) 

value : Rs 411 Crores 

3. URI HEP – STAGE II - 240 MW 


4. PIR PANJAL TUNNEL, J&K 

value : Rs 379 crores 

HIMACHAL PRADESH 

WEST BENGAL 

7. TEESTA LOW DAM HEP – 160MW 


8. Purulia Pumped Storage Project 

900 MW 


5. CHAMERA – STAGE III - 231 MW 

Value: Rs. 505 Crores 

UTTARANCHAL 

6. LOHARINAG PALA HEP 

(4X150MW) BARRAGE & 

DESILTING CHAMBER. 

Value: Rs. 246 Crores 


Pir Panjal Tunnel, J&K - Project layout 

his tunnel is being built across Pir Panjal range, the longest & most complex zone in younger himalayas 

India’s longest railway tunnel. Length = 10.3 km 


Pir Panjal Tunnel, J&K - Road headers deployed 

oad headers are being used for tunnel excavation here due to following reasons : 

• Complex himalayan geology 

• Faster excavation progress. Tunnel construction to be completed in 44 months. 




Chutak HEP & Nimmo Bazgo HEP, J&K 

Climatic Conditions & Logistic Problems Faced 

• Inaccessibility of project site during 

winter. 

– Road blockage on the nearest routes 

Travel by alternative / longer distances 

• Extreme cold conditions 

– Temperature range : 40 deg C in summer to - 

25 deg C in winter 

– Freezing of Diesel, lubricants 

– Difficulty in concrete production & placement 

1. Negative temp. kit fitted in 

equipments 

2. Special concreting 

arrangements made. 

• Acclimatisation to local climatic 

conditions 

24 hour acclimatisation period 


Snowfall on Access Road 


Snowfall at Workshop area on 03.12.06 


Snowfall at Project Office on 04.12.06 


Financial Capability

Key Financial Information 

One amongst the fastest growing construction companies in India in terms of 

Construction turnover 

Turnover for last 5 years 

CAGR = 33% 

789 

1171 

1576 

2028 

2395 

2002- 

03 

2003- 

04 

2004- 

05 

2005- 

06 

2006- 

07 

All values are as of 31 st March of each FY & in Rs Crore 


Key Financial Information 

Well diversified order backlog – most challenging & complex projects 

Order backlog for last 5 years 

CAGR = 33% 

5381 

9800 

9315 

3346 

3975 

2002- 

03 

2003- 

04 

2004- 

05 

2005- 

06 

2006- 

07 

All values are as of 31 st March of each FY & in Rs Crores 


Current Portfolio of hydel power projects 

Order Backlog - Segment wise breakup 

March 31, 2007 - Rs 9315 crores 

Others 

53% 

Hydel 

Power 

47% 


Organisational Capability

quipment Investment (Gross Block Vs Turnover ) 

35% of the total investment is in Hydel Power Projects 

2500 

2395 

2000 

1577 

2028 

1500 

1000 

500 

302 

566 

380 

618 

436 

789 

488 

1171 

556 

674 

1159 

0 

00-01 01-02 02-03 03-04 04-05 05-06 06-07 

Note: All values are in Crores. 

& 06-07 Values are projected Values 

Years 


ost modern & youngest fleet of equipments 

Road Header 

Wirth T3.20Q 

Tunnel Excavator 

STE-280 

250 TPH Crushing Plant 

Fore Poling rig 

Cassagrande PG 175 

Computer Based 

Rocket Boomer 


One stop Integrated Equipment management solutions 

To ensure better maintenance and productivity of equipments 

Spread over 100acres 

Our Equipment workshop 

State of art hydraulic 

overhaul shop, engine 

overhaul, reclamation 

facility for rebuilding. 

Automated Equipment 

Management System 

Fabrication support to 

construction activity 


Our Manpower base 

Experience, Commitment and Knowledge 

Total strength > 2600 

Hydel 

Power 

22% 

 

Specialists 

Concrete dams 

UG works in himalayas 

TBM tunnels 

Geologists 

Project Engineers 

Contract Managers 

Others 

78% 

Others 

36% 

Civil 

40% 

Elec 

8% 

Mech 

16% 


Integrated Management Systems 

Compliance with Global standards for Quality / Safety / Environment 

Quality systems 

(ISO 9001-2000) 

Environment Mgt Systems 

(ISO 14001-2004) 

Occupational Health &Safety 

(OHSAS 18001-1999) 




mphasis on Innovative construction materials / technique 

R&D Centre : 

To facilitate quality construction at economical prices 

Recognition from Ministry of Science & 

Technology, GOI 

Affiliations – Fly Ash mission, GOI; 

NCCBM & CANMET, Canada 

Mission 2010: To develop and adopt ecofriendly 

concrete technology to reduce 

one million tons of greenhouse gas 

(GHG) emissions 

Training Centre : 

Approved by City & Guilds 

International , UK. 

 

Infrastructure setup to impart training of 

various skills & trades to construction 

workmen 


HCC brings to you …. 

• Experience 

• Engineering Innovation 

• Technological Leadership 

•Timely completion 

• Quality construction 

• Skilled and specialist manpower base 

• Modern equipment 

• Sound financial capability 

Corporate Vision 

To be the Industry Leader and a 

Market driven 

engineering construction company 

renowned for 

Excellence 

Quality 

Performance 

and reliability 

in all types of construction. 


THANK YOU

Hindustan Construction Co. Limited - Infraline

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