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Valume : 9502 Oct - Dec. 2016 We are pleased to publish October-December, 2016 issue of Gammon Bulletin. We take pleasure in presenting some of our recent significant achievements, successes, learning and events from across the country to our Gammon family, our esteemed customers and other beloved stake holders. The lead article in the Bulletin is on Construction of Elevated Road at Patna for BSRDC. This is one of the flagship Projects of Bihar State Government. The Project has been executed on fast track basis and so far three Project Milestones have been achieved ahead of schedule. Record-breaking progress have been achieved on various activities like piling, casting of pre-cast girders, erection of girders etc. Achieving such consistent performance, month after month, was due to meticulous macro and micro planning, commensurate mobilization of matching resources duly line balanced, highest level of involvement from motivated team at site, positive attitude, team work, deep involvement of customer’s and consultant’s team etc. Site team has implemented several creative construction-friendly ideas and innovative construction methodologies while keeping an eye on cost-effectiveness and the same has been achieved without compromising on quality and safety considerations. The long list of innovations include innovative solution for movement of heavy launching gantry on compacted soil resting on soft ground and thereby avoiding normally adopted solution of providing piles, providing 2m long auger for pile boring in lieu of normally adopted 1 m long auger and thereby reducing boring time by 75 %, innovative pier formwork scheme for speedy erection and dismantling etc. The success story of this prestigious mega project, highlights the fact that if a project is mobilized in right earnest and initially execution is started on fast track basis without loss of time; a positive cycle is triggered which in turn results in improved progress unlike several projects where initial delays leads to triggering of vicious cycle. The second Article titled “Bid Stage Economical Proposals for Bridges– A Critical Study” by Mr. A. K. Chatterjee highlights the importance of preparation of technical proposal and competitive bidding based on such economical technical proposal. This is the stage at which the fate of Bid is sealed though outcome will become public only when bids of all bidders are opened by the Owner/Consultant. Few case studies of some classic success are worth noting. In our quest to continually improve the Bulletin, we will be glad to receive feedback and suggestions from our valued readers to make Gammon bulletin more and more interesting and informative for the readers. Your feedback and suggestions may please be sent to [email protected] We wish all our valued readers Merry X’mas and Happy and Prosperous New Year 2017.

Elevated Road Project, Patna 03 News Flash 20

Bid Stage Economical Proposals for 17 Company News 22 Bridges– A Critical Study

For Private Circulation Only Cover Photo: High Rise Residential Building at Runwal Greens, Mumbai 2 ELEVATED ROAD PROJECT, PATNA

(NH-98), Danapur Railway Station, AIIMS, Patliputra Railway Station, Ganga Driveway and surroundings on both sides of the project. The elevated road project will have major U.M. Kulkarni Maruti Jambagi crossings at Bailey Road and Ashok Rajpath and will have connectivity with 1. PREAMBLE important places like Danapur railway India has a road network of over 4.7 station, proposed Patliputra railway station P R O P O S E D A L I G N M E N T Million km, the second largest in the and AIIMS. Besides, it will also have CONNECTING NH-98 AT AIIMS to world. Bihar being one of the largest states connectivity with the Ganga Path and one DIGHA BRIDGE has a virtuous road network comprising of Railway Bridge at Khagaul (Patna-Delhi) 29National Highways with thetotal length line. One minor bridge will also be linked of 2,910 km and State Highways with total to this project length of 3,766 km. Once completed, the road will provide Bihar State Road Development much needed relief from the traffic Corporation (BSRDC) conceived this congestion in the city, particularly on the prestigious Project of Elevated Road narrow Ashok Rajpath as it would be Corridor (11.9 km length) connecting connected with the Ganga Path at Digha AIIMS and Digha. Hon’bleChief end. Minister,ShriNitish Kumar laid foundation 2. PROJECT DETAILS stone to kick start commencement of END OF THE PROJECT AT DIGHA 2.1 Location Map and Satellite Images. constrDeputy Managuctioner-Engineering work of India’s one of the LongestElevated Corridor as his Dream The Elevated Road Project is a part of Project. The projectinvolves construction prestigious Ring Road Project of city of of 2-lane semi-elevated and 4-lane elevated Patna. The layout of Elevated Road as part highway over Patna canal as approach road of Ring Road Project and its satellite of rail-cum-road project across the Ganga images are shown below: at Digha. With the above inauguration, yet another glamorous project of BSRDC Concept of Project to Develop Ring started taking shape. Road for Patna: Location Map

2.2 Scope of Work Deputy Manager-Engineering The scope of work encompasses design, e n g i n e e r i n g , p r o c u r e m e n t a n d construction of a highway with 3 km (2- lane) semi-elevated structure and 8.5 km (4-lane) of elevated structure with divided carriageway with Junction improvements After the Visit of Hon'ble Chief Minister from AIIMS to Digha over Patna Canal, of Bihar on 18th May, 2012; it was including construction of new pavement, envisaged to consider the 4-lane approach construction of major and minor bridges, road from Km 0.00 to Km 10.500 (starting culverts, road intersections, interchanges, point of Ganga Driveway) due to higher expected traffic flow from NH-84 ,NH-30 ROB, PUP,drains etc. and maintenance of (Bye Pass of Patna and part of Patna - the Project during the Defects Liability Buxur - NH-84), NH-98 (Patna- Period of five years. Aurangabad) , NH-19 (Chapra-Hajipur) The project proposal details are as below: and for the direct connectivity to AIIMS, Patna, and Ganga drive way.The approach • Km0+000 – Km2+100: RHS 2 road to Rail cum Road Bridge will get Lane road on Embankment overfilled due to induced / diverted traffic • Km2+100- Km2+300:- 4 Lane with projected traffic of 30000 PCU in the year 2016 between Km 3.000 to 10.500 approach road from 4-lane Patna-Buxur (NH-84), Patna- Concept of Project to Develop Ring • Km2+300 to Km10+750- 2x2 lane Bakhtiyarpur (NH-30), Patna-Aurangabad Road for Patna: Satellite Image Elevated Corridor

3 • Km10+750 to Km11+100 – 4 lane Eac h structure is supported by a pier and • Design of pile cap in ultimate limit state elevated on embankment / structure. pile foundation. The Pier is solid • Stress check of pile cap in serviceability • Km 11+100 to Km 11+820 - 4 rectangular in nature with a cantilever pier limit state Lane with 2 Additional Lane cap to support the superstructure. The Pier F o r c e s o n S t r u c t u r e f r o m Elevated on Embankment / Structure. is in turn supported on pile foundation and Superstructure The project involves major activities like a rigid pile cap. The piles are founded on • Dead load and footpath live load firm strata to transfer the vertical and Pile foundations, Piers & Pier caps, Casting • Wind load : as per IRC -6 horizontal loads from the structure. of Precast Pre-tensioned/ Post-tensioned • Bearing forces : as per IRC-6 clause 2.4 StructuralDesign- Overview I Girders, & Erection of the same using 211.5.2 suitable capacity of Crane / Gantry, Cast in The Load cases under consideration are • Water current forces : as per IRC-6 situ RCC Deck Slab Spans, Erection of Dead Load, Superimposed Dead Load, structural span over Railway track (ROB), Live Load, Footpath Live Load, braking • Seismic forces : as per IRC-6 for zone Fixing of Bearings, Installation of force, Wind Load, & Seismic Loads. The factor, importance factor and Expansion Joints, Cast in-situ Abutment, cer tain conditions which occur foundation strata Abutment caps & Dirt wall, construction simultaneously are taken together like, 2.5 Pavement design- Overview of Embankment, etc. braking and live load. Bearing friction is Pavement design basically aims at The site of the Four Lane Elevated and considered along with each individual determining the total thickness of the approach Road Corridor comprises the permanent load case and not as a separate pavement structure as well as the thickness section of Highway commencing from load case. These loads are combined as per o f t h e i n d i v i d u a l s t r u c t u r a l AIIMS Patna Km 0+00 (Km 6+800 of the recommendations of IRC 6 with components.Flexible Pavement is NH-98) to Km11+900 at proposed appropriate load factors. While preparing designed using Cement treated junction of Ganga Path, Digha in the state the load combinations the worst effects of base&Granular Sub-base by applying the of Bihar. The project highway from individual loads are taken to arrive at the mechanistic principles given in IRC: 37- Km0+00 to Km 2+125 will be developed design loads. 2012.Design inputs required for the on RHS parallel to proposed NHAI road. Bending moment in the pile is calculated by pavement design are established based on The proposed median will be developed spring constant analogyarrived from the site investigations. The Type of from NHAI BT edge and new 2 lane road horizontal & vertical subgrade reactions. Pavement for the Main carriageway (except will be developed as per proposed The geotechnical capacity of the pile is as Elevated Portion) has been designed as alignment plan. The approach road to new per the pile capacity calculation report. To Flexible Pavement with cemented base & 4 lane Elevated Road Corridor start after calculate the forces in the piles which sub-base.New Flexible pavement as well as crossing the minor bridge and end at depend on the stiffness of the substructure, widening and strengthening of the existing Km2+290 and 4 lane (2x2 lane) elevated the fixity is considered at the top of pile cap. pavement have been designed for a road shall be developed from Km2+290 to For the purpose of design the pile minimum design period of fifteen Km10+755 following the canal bed up to foundation is modeled in STAAD with years.The pavement has been designed for Digha. spring constant & horizontal forces applied traffic of 150 msa (million standard axles). The pavement has been designed 4lane elevated road on embankment at the pile cap bottom. For the distribution considering the CBR value of 9%.The /structure shall be developed from of forces in the piles, the pile cap is design exercise has been carried out using Km10+755 to Km11+100 and after that 4 considered as rigid. The pile cap is designed Mechanistic-Empirical principles with lane with 2 additional lanes elevated on as a flexural member for the critical load non-conventional material i.e. by using the embankment/structure shall be developed case. cemented base & sub-base. The from Km11+100 to Km11+820. For Design of Pile Foundation of this assumptions and procedure adopted for 2.3 Salient Technical Features. Elevated Road Corridor Project following aspects are taken in to consideration:- the ME design approach are briefly The Structure comprises of 25.0m two discussed below. • Dimensions of Structure continuous span (deck continuity) with Proposed pavement composition precast pretension I Girder sections resting • F o r c e s o n S t r u c t u r e f r o m Superstructure comprisesGSB, Cemented WMM base, on POT/PTFE bearing. The bridge is Aggregate Interlayer above cemented base divided into two separate structures Left & • Forces on Substructure • Geotechnical Aspects of Pile and bituminous layers.As the commercial Right carriageway separated by 3.50m – vehicles are more than 2000 per lane during each structure carrying the traffic in one • Evaluation of forces & moments at base of the pile cap the operation period and the design traffic direction in two lanes with 1.55m wide is more than 30 MSA, VG-40/PMB-40 or footpath. • Load combinations Ultimate limit state • Pile design by serviceability limit state modified bitumen of equivalent stiffness is

4 considered for bituminous layers (BC and Major Quantities DBM).Cemented base layer consist of Total Item of Work Unit aggregates stabilized with cement Quantity containing 4 to 6 % Ordinary Portland or Pozzolanic cement which are required to Pile No 2965 give a minimum UCS Strength of 4.5 to Pile Cap No 692 7MPa in 7 days determined by test on Pierand Pier 150mm size cubes. Though the initial A cemented layer normally develops No 692 Cap modulus of the cemented base is in the transverse and longitudinal cracks due to Casting of I No 4080 range of 10000 to 15000 MPa, the long shrinkage and thermal stresses during girder term modulus of the cemented layer shall hydration and during the service life. A Erection of I No 4080 be taken as fifty per cent of initial modulus crack relief layer of wet mix macadam of girder due to shrinkage cracks and effect of thickness 100mm sandwiched between Deck Slab Span 688 construction traffic. A Design value of bituminous layer & cemented base layer is 5000 MPa has been considered here for more effective in arresting the propagation 3. FAST TRACK EXECUTION OF cement stabilized WMM. Curing of of cracks from cemented WMM to the PROJECT cemented bases after construction is very bituminous layer. The modulus of Immediately upon receipt of Letter of important for achieving the required aggregate interlayer varies from 250 to Award from BSRDC,field survey work, strength. Curing should start immediately 1000 MPa and a typical value of 450 MPa geotechnical Soil Investigation work, by periodical mist spray of water. The has been used in the analysis of pavement. preparation of designs and drawings, relevant design parameter for bound bases As per IRC: 37-2012, the elastic modulus detailed planning of the Project etc. was is the Elastic Modulus E, which can be of subgrade is estimated as given below diligently taken up. determined from the unconfined Also site mobilization was started in right compressive strength of the material. In ESG in MPa = 10 * CBR for CBR ≤ 5% earnest for undertaking expeditious and case of cementitious granular base, the =17.6 * CBR0.64 for CBR > 5% fast track implementation of the Projec. A laboratory based E value is given by Poisson’s ratio 0.50, 0.35 and 0.25 are camp with full-fledged establishment following equation: considered for bituminous, unbound including field office, mechanical E = 1000* UCS granular material and cement treated layers workshops, field laboratories, staff and Where UCS = 28 days strength of the respectively. labourquarters etc. was established. A cementitious granular material. A reliability of 90% has been considered state-of-art Casting yard for casting precast Granular Sub-Base material confirming to for design traffic more than 30 MSA as per RCC girders was established with multiple MORTH Specification grading given in IRC: 37-2012. casting beds and Gantry Crane for table 400-1 & physical requirements given 2.6 Major Quantities of Prime handling girders. Similarly fabrication yard in table 400-2 are recommended for use. Activities with required facilities for fabrication work The specifications suggest close & coarse Major Components:- was also established. Huge investment was made for procuring fleet of Plant and graded granular material and specifies that Ø Road work - Including culvert, Minor Equipment and all Plant and Equipment the material passing 425 micron sieve when Bridge,Pedestrian underpass, Railway were mobilized expeditiously for tested as per IS: 2720 (Part 5) should have Over Bridge, Major Bridge/structure accelerated implementation of the Project. liquid limit and plasticity index of not more (Excluding service Road) than 25 and 6 respectively. Grading III & Stand by Plant and Equipment were also Ø Structure - Elevated Road corridor IV shall preferably be used in lower sub- provided for critical category of Plant and Ø base. Grading V & VI shall be used as a Other Work - Road side Drain, Slope Equipment so as to continue with the work drainage layer. Protection work, Road sign marking and uninterruptedly even if there are break- safety device. The relevant design parameter for granular downs of some Plant and Equipment. sub-base is Resilient Modulus (MR), which Project Facilities Because of the above actionson fast track is given by the following equation: Ø Road Side Furniture basis, it was possible to commence physical MR GSB = 0.2 h0.45 x MR Subgrade Ø Pedestrian Facilities activities at Project Site immediately on award of the work which helped in Where h = thickness of sub-base layer Ø Traffic and Medical Aid Post achieving Project Mile stones ahead of in mm. Ø Street Lightening schedule as shown below: Ø Rescue Lane Ø Noise Barrier

5 Milestones as per Contract and Exploration Plan removed with the assistance of concerned achievements A complete soil, rock and ground water Authority. Once utilities are removed then PROJECT MILESTONE

Project % of Cumulative Target days Remarks investigation should encompass the pile-driving activity will start. Milestone Project Value Cost Rs. Cr. following activities: Temporary Casing / Permanent Liner: st Achieved on 31 May Achieved 48 days PM - 1 10% 78.8 2014 Before Schedule Ø Review of available information, both Initial boring up to required depth is th Achieved on 28 Feb Achieved 78 days PM - 2 30% 236.5 2015 Before Schedule regional and local, on the geological carried out for lowering the temporary Achieved on 07th Achieved 10 days PM - 3 70% 605.61 Aug - 16 Before Schedule history, rock, soil and ground water guide casing / Permanent liner (as per

1395days from the PM - 4 100% 865.17 16-Aug-2017 Appointed date conditions occurring at the proposed approved drawings). It is proposed to use location and in the immediate vicinity of the 10mm thick MS plate for the Site Conditions and exter nal the site. temporary guide casing. The 10mm thick constraints. Ø Field reconnaissance for identification MS plate will be rolled in the plate-bending Still some portion of our Project stretch is of surficial geological conditions and machine. The temporary / permanent yet to be handed over due to examination of performance of existing liners of required diameter will be encroachments made by Indira Aawas surface fabricated in the casting yard and will be building, Irrigational Structure and other Ø On site investigation of the surface transported to the piling location with the reasons. and sub-surface materials by carrying help of trailers. Integrated hydraulic piling Design Approval for the Railways over boreholes. rig will be used to drive the casing. The Bridge which is a part of this existing center line of guide casing will be checked Ø Sequence and extent of each soil and project isexpected shortly from Railways with reference to guide points / reference rock stratum in the region likely to be Design Department. points before continuing further boring. affected by the proposed structure. 4.CONSTRUCTION METHOD The verticality will be checked with the Ø Nature of each stratum and S TA T E M E N T S O F M A J O R help of plumb and correction if required, engineering properties of soil and rock ACTIVITIES. will be made. For side stabilization of bore which may affect design and mode of For all major activities, detailed Method hole, use of bentonite will resorted to as construction of proposed structures and Statements were prepared in advance per site conditions. their foundations. taking in to consideration site conditions Pile boring: Ø and practical aspects apart from Technical Field testing and recovery of On completing the lowering of temporary Specifications and relevant Codes of representative samples of the soils and / permanent casing, pile boring will be Practice and the work at site was executed rocks for laboratory tests. continued with the help of Integrated as per such Method Statements. Few Ø Identification of the position of Hydraulic Piling Rig. The boring in soil is Method Statements of major activities are ground water table. continued till the founding level is reached. reproduced below: Ø Obtaining general information on Pile termination level will be finalized as 4.1 Soil Investigation geology, seismicity of the area, surface per approved drawings & as instructed by Introduction drainage, etc. the Engineer. Muck / excavated materials Ø will be transported with the help of tippers This include Geotechnical investigation for Identification and assessment of the and disposed as directed by the Engineer. subsurface investigation and submission location of suitable foundation material- of a detailed Geo-technical report. either bed rock or satisfactory load bearing Piles shall be installed as accurately as soils. possible as per the approved drawings. Scope of Investigation 4.2 Pile Foundation Since Piles in this Project are having The entire field as well as laboratory diameter more than 600 mm, Piles should Piling was the major activity at site as nearly investigation work will be supervised by not deviate from their designed positions 2900 RCC Bored cast in situ Piles were experienced Geotechnical Engineer. The more than 75 mm or D/10 whichever is involved in this Project. . positions of bore holes will be marked as more & tilt should not exceed 1 in 150. per the drawings and the Reduced Levels Survey/Setting Out: Reinforcement cage – Preparation & (RLs) at these locations determined with The location of pile is set out with respect Lowering: respect to the single Bench Mark (BM), to the control points (coordinates). It is Based on approved drawing, a bar bending indicated by the Engineer. All the field and proposed to remove the top overburden schedule will be prepared and got laboratory data will be recorded in the manually for the piles coming in any approved from the Engineer / Client. The standard format in the relevant Indian particular pile cap group to identify the reinforcement is cut and bent to the Standard Codes. The investigationshall be utility lines and services. If any such utility required length / size and shape according carried out without causing any detrimental service lines are seen then the same will be to the approved BBS. Reinforcement cage effects to the nearby existing structures. intimated to the Engineer and will be

6 will be fabricated in casting yard and Concrete is built above the cut off level by 4.3 Cast-in-Situ Pile Cap transported to site using trailers. The about 600 mm and is confirmed by The area around the work location was reinforcement cage will be lowered with sounding chain. If borehole is left un- barricaded as per traffic management plan the help of service crane. The concreted for more than 6 hours after and excavation for pile cap was started reinforcement cage is to be lowered boring then it will be cleaned thoroughly after pile concrete attains sufficient immediately after the pile boring is before placing the concrete. In case, under strength. Excavation is carried out up to completed and the bore is flushed. the unavoidable circumstances, the the bed level with the help of excavator. Cleaning of Pile bore: concreting operation is to suspend for a Bed will then be prepared with leveling Ø After completion of the pile bore up period of 2 hours (maximum), the tremie course (PCC) of required thickness (75 to the required depth the pile bore - shall not be taken out of concrete. Instead, mm or 100 mm as per drawing). especially the bottom of the pile bore, will it shall be raised and lowered slowly from Subsequently reinforcementis fixed and be cleaned by three stage flushing of slurry time to time which would prevent the shuttering is placed as per approved using airlift technique. concrete around the tremie from setting. drawings. Concreting of pile cap is done in Concreting shall be resumed by Ø Cleaning will ensure that the pile bore layers of 500mm ensuring proper introducing a little richer concrete with a is completely free from sludge / bored compaction with needle vibrator. higher slump for easy displacement of material, debris of rock / boulders etc. 4.4 Pile Load Test (Initial / Routine) partly set concrete. After completion of Ø Initial Pile Load Tests - Pile bore will also be cleaned by fresh Pile concreting, fresh concrete will be drilling mud through tremie pipe before removed above the cut of level by using Ø For scope of piles less than 1000 and after placing the reinforcement and bucket. Only 150 mm concrete will be kept numbers - A minimum of two tests. just before the start of concreting. above the cut of level. Ø For scope of piles more than 1000 Concreting: numbers - A minimum of two tests for first Immediately after lowering the 1000 piles and additional one test for every reinforcement cage, tremie pipe of 200mm additional 1000 piles and part thereof. dia. and in segments of 1.2m to 2 m will be Routine Pile Load Tests - 0.5 percent of joined together and lowered into the pile the total number of piles, subject to a and concrete funnel of approx. 1.5 cum minimum of one test. capacity to the tremie pipe at the pile top Anchorage Pile Load Test level. Provide the gap/clearance of Preparatory Works: 300mm between the tremie pipe bottom and founding level. Once the concrete is a. Removal of laitance: After casting of built up to say 4 m and it is confirmed by pile, the additional built up portion shall be sounding, the tremie pipe with funnel will hacked up to the design cutoff level / or till be lifted up and the top tremie pipe will be sound concrete is reached whichever is removed, during this operation it should be lower. ensured that the bottom of the tremie pipe is always embedded in the concrete for a depth of minimum 1000 mm. During the course of concreting, if tremiecomes out " I am sorry, Sir. I absented from site for 10 days of concrete either accidentally or taken out without prior intimation to you. Ten days ago I was to remove a choke in the tremie, the tremie defending quality of water pipe is re-introduced into the old concrete added in concrete mixer. I strongly argued with the with small penetration. A vermiculate ball Consultant that our Company is very particular plug is introduced in the tremie, fresh about quality and that water concrete of slump between 150mm to we use for concreting is undoubtedly 100% potable. 180mm is filled in the tremie which will go He took random sample and made me to drink two on pushing the plug forward and emerge glasses of this potable out of the tremie. After this the tremie is water. Next day ...... " pushed further in steps making fresh concrete displace the earlier concrete layer. When the tremie is buried about 0.6 m to 1.0 m in the concrete then the concreting is resumed / continued.

7 b. Pile head: To distribute the applied load pile parameters, important of these are force, displacement and velocity. uniformly on the entire cross-section of mentioned below: Immediate field results in the form of the the pile a suitable pile head as per detailed Ø Static capacity of the pile at the time of capacity of the pile, pile top settlement, drawing should be cast at the pile cutoff testing integrity and stresses developed in the pile level. The pile head shall be provided with etc. are obtained. Ø Static load test curve reinforcement mesh as detailed in the Reporting Ø Total skin friction and end bearing of drawing and shall be cast true in level. M.S. On completion of all field work, a final the pile plate of 25mm thickness shall be placed report covering all aspects of the pile Ø Skin friction variation along the length for uniform distribution of load on the pile monitoring and analysis work will be of the pile head. prepared and presented within a period of Ø c. Datum bar: The datum bar of size as Compressive and tensile stresses ten days. detailed in the drawing shall be positioned developed in the pile during testing 4.5 Pier / Abutment Wall over concrete blocks. Ø Net and total displacement of the pile. Introduction d.Placement of reaction frame: Ø Pile integrity and changes in cross- It is planned to constr uct the Reaction frames shall be placed in position section, if any. Pier/Abutment Wall for full height / as per detailed drawings. Pile monitoring and preparation suitable Lifts as per site feasibility at each e. Placement of jacks: A jack of desired Ø High-Strain Dynamic Testing of piles location & Pier Cap/Abutment Cap with capacity shall be placed with steel packing is conducted by attaching strain suitable staging and shuttering between the reaction pile and the top transducers and accelerometers to the arrangement as per approved drawings and frame. sides of the pile approximately 1 to 1.5 specifications. Concrete Pumps / Placer Application of Load: times pile dia. below the pile top. These will be used to place the concrete. 300 t / 500 t capacity jack shall be pairs of gauges are fixed onto opposite Construction joints, if any will be planned connected to the power pack. The pile shall sides of the pile so as to detect bending in at locations as shown in the drawings only. be tested for 2.5 times the working load the pile, if any during testing. Suitable treatment will be given to the capacity for Initial Pile Load Test & 1.5 Ø These transducers are then connected construction joint before pouring fresh times for Routine Pile Load Test. Thus for through the main cable to a Pile Driving concrete. Curing will be carried out as per Design load of 300 t, the initial pile load Analyzer, which is a state-of-art Pentium specifications. Access arrangement for and routine pile load work out to 750 t and Computer System with ability to record inspection and safe working of labor 450 t respectively. The increment for strain and acceleration measurements and during fabrication, erection of loading shall be 20% of the safe design convert them from analog to digital form reinforcement, shuttering and placing of load. The increment of load for test shall concrete will be done as per specifications. Ø The signals are then triggered by the be maintained till the rate of displacement impact of a ram falling from a pre- Concrete may be brushed with a stiff of pile top is near to 0.1mm per 30 determined height. The ram weight and fall b r u s h s o o n a f t e r c a s t i n g o f minutes. Displacement shall be read using height is determined in advance. As a Pier/Abutment Wall while the concrete is four calibrated dial gauges of 0.01mm thumb rule, the ram weight shall be 1% to still fresh. If the concrete has partially sensitivity. 1.5% of the testing capacity of the pile. hardened, it shall be cleaned by wire Release of Load: Thus for measuring a 500 ton load, the ram brushing immediately. Before further After taking observations, once the final weight shall be approximately 5 t. concrete of Pier Cap/Abutment Cap is load is attained, loading shall be released in cast, the surface should be thoroughly Ø Upon impact, the strain transducers the units of 20 % of the total safe load at a cleaned to remove debris and accumulated measure strains whereas accelerations are time. Observations may be discontinued rubbish. Care will be taken to remove all measured by accelerometers connected on as soon as the rate of displacement is zero. loose materials around reinforcements. either sides of the pile. These signals are The concrete of required grade will be then converted to digital form by the Pile produced as per the approved design mix Driving Analyzer and then converted to at the centralized batching plant at the force and velocity respectively by casting yard and transported by transit integration. mixers to the pouring location. Before Ø The capacity mobilized under the blow pouring concrete slump will be checked at is then obtained from the force and pouring location. Before starting of velocity values. The PDA has an in-built Dynamic Pile Load Test concrete the pipeline will be pumped with program which calculates and generates cement grout. The concrete will be placed The test can be used to evaluate various over 30 pile variables based on pile top by concrete pump / Concrete Placer with

8 flexible hose or crane and bucket. Once the tack welded girder is placed on Check on the Completed Weld: Sufficient dia. tremmie pipe & hoppers will the welding fixture, the stiffener rods of Ø No visible defects like cracks, pinholes be used in the case of crane used for side-1 shall be removed and c-clamp & or incomplete fusions. pouring of concrete. Initial 2 m height of wedges shall be used to hold the upper Ø The weld surface must be sufficiently concrete will be compacted by using surface of the flange plate of side-1 with free of coarse ripples, grooves, overlap, shutter vibrator, if required. The plate in order to minimize distortion of the abrupt ridges and valleys, visible slag concreting of pier will be done in one go. flange plate during and after welding. inclusion, porosity adjacent starts and The drop height of the concrete should Ø The joints to be welded are ground stops. not be more than 1.5m. The concrete will smoothly with grinder machine; edge shall Ø There shall be no overlaps. The faces be vibrated using 60mm diameter needle be prepared as per requirement. vibrators. Concrete cubes will be taken for of filled welds are not excessively convex Ø Remove the slag of tack weld. testing of compressive strength as per IS: or concave and the weld legs are of the Ø 456-2000 at pouring location. Concreting If the moisture content in the proper length. should be done continuously in one pour. atmosphere is more, then preheat the Ø NDT test to be carried out like DPT, Proper care will be taken to see that girder by using Oxy-acetylene flame or any RT, UT etc. 0 suitable method. concrete temperature will not exceed 40 C. Sand blasting: Ø Set the track for SAW machine at the This procedure describes the minimum girder side. Mount the SAW machine on requirements and essential particulars of the track. Fix the filler wire in the bobbin cleaning by sand blasting of IS: 9954 and and pass it through nozzle. Fill the flux in Swedish Standard. the hopper and set the flux. Equipment: Ø Remove the girder from the jig. Rotate Ø Sand blasting hopper with blasting the girder upside down in cross section. hose and Nozzle. CONCRETING FOR PIER Ø Again fix the girder on track of jig then Ø Air compressor with its accessories 4.6 Fabrication and Erection of Steel carry out the welding of 3 and 4 similarto like calibrated pressure gauge and safety Super Structure as in case of 1 and 2. valve. Weld Fit-Up Inspection: General Requirements for Welding: Ø Sand and screening mesh. Ø The surface to be welded shall be Ø Ensure that the components to be Ø Wire brushes. smooth and free from deep notches, welded arein accordance with the contract Ø irregularities, scale, rust, oil, grease and drawing, welding schedule and other Safety equipment like boiler suite / other foreign material. relevant documents. goggles / safety shoes/hand gloves etc. Ø The fit-up components to be welded Ø The condition of welded surfaces to Sand Blasting Process: shall not show an appreciable off-set or be inspected must be clean & dry. Fabricated Steel structural items etc. will be misalignment when viewed from position Ø There shall be sufficient lighting to sand blasted A Sa 2-1/2 standard using apart. allow proper interpretation of visual River Sand as abrasive medium- size Ø The root opening of components to inspection as well as NDT. ranging from 600 micron to1700 micron. Air compressor engaged will be of be joined shall be adequate to provide Checks during Welding Operation: 300CFM and above capacity and can acceptable penetration. Ø Ensure the required minimum preheat produce a pressure more than 6 bar. Ø In fillet welds the parts to be joined temperature (if required) is applied and The surface shall be thoroughly cleaned shall be brought as close to contact as established during welding. and roughened by compressed air blasting practical, although in most instances a Ø Ensure correct electrode/filler metal using suitable abrasive sand. The sand shall small opening between the parts is used for welding. be loaded into a suitable direct pressure desirable. Ø Examining tack welding by the welder type blasting hopper. From the mixing Ø Weld area should be protected from before they are incorporated in the final chamber, at the bottom of the hopper, the drafts and wind to maintain inert gas weld. mixture is injected through the blasting shield. Ø Ensure proper drying/holding of nozzle at a very high velocity. Saw Welding electrodes prior to use. This jet is directed on to the surface to be Ø Welding of I-Girder: Ensure correct inter-pass temperature cleaned traversing the nozzle each Tack welded girder is placed on a welding is maintained. succeeding pass overlapping the preceding fixture which is 45 degree inclined from the Ø Ensure proper cleaning of the weld one by about 10% and exposing clean floor. between beads. white metal. 9 Surface to nozzle distance shall be about Ø Elcometer. arrangement or remove the wooden blocks 350 to 450 mm, with the nozzle inclination Ø Paint mixing arrangement. placed between the Deck girder & ISMB of about 30 degrees to the vertical. The Ø Safety arrangement i.e. safety goggles girders. diameter of nozzle orifice to be used shall and nose mask. Ø Trestle (supporting arrangement) is be 4 to 8 mm. This process shall be carried now free from the Deck girders. out to cover the entire surface. The entire 4.7 Erection of steel girder – structural Ø surface shall be free from rust, scale, spans Lift G1, G2, G3& G4 Girders and previous paint, grease, oil and any other Ø Place the Pre-cast Footing at required place the Bearings underneath. foreign material. location as shown in Annexure-I. Ø Cast the Deck slab over complete Precautions: Ø Erect the temporary supporting assembly of Deck girders as per the approved Design & Drawing. Ø Sand used should be dry and of fairly arrangement like trestle and temporary uniform grain size. Girders on both the sides of the span as 4.8 Cast-in-situ DeckSlab shown in Annexure-I. Ø Ø If sand gets moistened in high Corrugated sheet will be placed in- Ø humidity weather then it should be baked Brace the vertical trestles and the between of erected girders to support as a to remove the moisture before blasting temporary girders as shown in Annexure-I. bottom shuttering for cast in situ deck slab operation. Ø Place wooden blocks on top of the or bottom shuttering will be fixed as per approved drawings. Ø Blasting should not be done if ISMB Girders or place screw jack on both Ø humidity is more than 80%. the sides of ISMB girder so as to rest the Reinforcement will be tied for deck Deck girders. slab. Ø Sand blasting shall be done in an Ø Ø enclosed area open from one side only. Assembled Diaphragm shall be The concrete of required grade will be erected with proper support at both the produced as per the approved design mix Ø Sand blasting shall be done by an side of Pier cap using crane of suitable at the centralized batching plant at the experienced blaster. capacity and the alignment will be checked. casting yard and transported by transit Ø Blaster should use safety device and Ø Place the crane of suitable capacity in mixers to the pouring location. Concrete clear vision spraying helmet. position as shown in Annexure-I for lifting will be placed by concrete pump / Placer Ø The person near the blasting operation the Deck girder “D1”. with flexible hose. The drop height of the shall wear safety goggles. concrete should not be more than 1.5m. Ø Deck Girder “D1” (G1 & G2) shall be Ø The concrete will be vibrated using 60mm Care shall be taken to protect the lifted and placed between the two supports diameter needle vibrators. Concrete cubes adjacent machinery, electrical equipment as shown in Annexure-I. will be taken for testing of compressive etc. Ø Place the crane of suitable capacity in strength as per IS: 456-2000 at pouring Ø No hammering or any other type of position for lifting the Deck girder “D2”. location. blows should be given to shot blasting Ø Deck girder “D2” shall then be lifted Ø machine while it is under pressure. After the deck slab is cast, the top and placed between the supports as shown surface of the slab shall be finished rough Ø Calibrated Pressure gauge shall be in Annexure-I. for proper bonding with the wearing coat. provided. Ø Deck girder “D3” shall then be lifted Adequate care shall be taken for Ø Blasted surface must be coated within and placed between the supports and Pier maintaining proper lines and levels of the 2-4 hours with primer. as shown in Annexure-I. surface as per drawings. Metal spraying/ metalizing procedure: Ø Tight all the bolts of Splice joint Ø Proper curing arrangement will be Spraying shall be done with metal spraying location as per approved drawings. made for curing of Deck Slab. Necessary gun. Spraying gun used shall be the gas or Ø Similarly, erect the Deck girder “D1”, pipeline arrangement shall be provided for flame type wire spraying gun. Clean sand “D2”, “D3” parts of G3 & G4 by crane of carrying water for curing the structures. blasted area is to be metal coated/sprayed suitable capacity over the trestle. Curing of concrete shall be done by water within 2 hours from the completion of Ø ponding method. blasting. Tight all the bolts of Splice joint location. Equipment: Ø Fix / connect the Deck girders to Ø Connecting hoses with spray gun. Diaphragm with suitable Nut & Bolt as per Ø Air compressor with its accessories approved drawings. like calibrated pressure gauge and safety Ø After fixing all the Deck girders to the valve. Diaphragm, release the screw jacks placed Ø Brushes. between the Deck girder & trestle

10 Laying of Profile sheet at COS-II Ø Dismantle the entire shuttering and ensured throughout the construction at 4.9 Cast-in-situ box girder staging arrangement after stressing. site. Traffic control devices such as cones, Casting Of Box Girder Stressing Operation signs, flashing lights, barricades flagmen etc. will be provided as specified or Sequence of construction will be as Ø Suitable Pre-stressing System shall be directed. follows. adopted as per approval by Engineer for Ø Place the pre-cast footings at the stressing of Box Girders. location as shown in drawing. Ø Stressing will be done after 7 days of Grouting Operation Ø Erect the trestle and lock in position concrete or after concrete achieves Grouting shall be carried out within 2 over the footing. required strength as specified in Drawing. weeks of stressing of cables. Number of cables to be stressed, will be as Ø Ø Erect the trestle heads over each trestle Ducts shall be flushed with clean water mentioned in Drawing. and fix. for cleaning as well as for wetting the Ø Extension at each end during stressing surfaces of the duct walls. Water used for Ø Provide bracings between the trestles. operation should be equal as far as flushing should be of same quality as used Ø Place the main longitudinal girders possible, max. Difference should not for grouting. over trestle heads and fix in position. exceed 5% of the prescribed extensions at Ø After cleaning all water shall be Ø Place the cross members over the main each end. In case the required extensions drained thoroughly by vent pipe or by girders. The spacing will be as per the are not obtained at the specified pressure, blowing compressed air through duct. drawing. stressing should be continued till the Ø During and after 3 to 4 hours of Ø required extensions are obtained subjected Place the soffit formwork over the grouting other non-stressed cables (if any) to jack pressures not exceeding the cross member. shall be checked manually for free prescribed limits. Ø Erect the supporting truss at the given movements. Ø Difference between calculated and spacing for outer side & cantilever Ø All outlet points including vent observed tension and elongations during formwork supporting. openings should be kept open before to the pre-stressing operations shall be Ø Erect longitudinal member and outer commencement of grouting. regulated as per MORTH sec. 1807 under formwork over external truss and fix in Ø Injection of Grout. position. post tensioning head as per point a, b, c, d. Ø After mixing grout should be kept in Ø Safety during stressing and casting Mark profile for sheathing ducts. continuous movement and injection of Ø Use hydraulic equipment supplied Ø Tie the reinforcement bars for soffit grout must be continuous without any with a relief valve. Place safely valve in and web. interruptions. between jacks and connection high- Ø Fix pre-stressed ducts and inserts. Ø pressure hose. Grouting shall be commenced initially Ø Fix internal shuttering for web. with a low pressure of injection of up to Ø Use hosepipes in good conditions and Ø 0.3MPa increasing it until the grout come Concrete soffit and web. avoid using worn out hosepipes. out through the other end with same  De-shutter the internal formwork of Ø Check the concrete around bearing consistency as that of the grout @ webs after concrete attains required plate and anchorage to see whether there injection end. strength. are any voids / honeycombing. Ø Full injection pressure (approx. Ø Erect the bottom shutters for deck Ø Do not allow anybody behind 0.5MPa) shall be maintained for a slab and fix in position. stressing devices, in line with tendon, or minimum of 1 minute before closing the Ø Tie reinforcement for deck slab. near hydraulic hoses. injection pipe. Ø Ø Concrete the entire deck slab. When the stressing works are in Ø Grouting records shall be maintained Conventional curing will be done. progress no other work should continue in as per format conforming to MORTH, Ø Immediately after de-shuttering, the vicinity. Appendix 1800/IV. Ø concrete surface shall be checked jointly Health of safety systems incorporated 4.10 Road Works and curing of top surface of the structure in the stressing equipment shall be Material selection and mix design will be done by pond making & side faces ascertained once a week. Provide safety Ø The field laboratory will be established by using hessian cloth & by sprinkling barriers during stressing operations. in stages, to meet the testing requirement continuous water. Ø Display a clearly visible sign schedule and the specifications indicated in Ø Stressing will be done after concrete “ D A N G E R … P R E S T R E S S I N G contract till site laboratory is established, attains required strength as per approved WORKS IN PROGRESS” testing will be carried out at an approved drawings. Ø Safety of workmen and public will be laboratory.

11 Ø Borrow areas will be prospected for Methodology Ø The bin will be adjusted to feed the sampling materials for use in embankment. The sub-grade surface will be watered & plant of defined quantities as per the Based on the test results of such samples the compacted as per MORTH specification. requirement. approval of the Engineer’s representatives The material to be used for the work will be Ø The mix will be brought to the site by for the material for use in embankment fill crushed aggregate, natural sand, gravel or dumpers. The surface will be prepared by will be obtained. Similarly, based on the test combination thereof depending upon the wetting. results, the suitability of the material for use grading requirement. Gravel or any other Ø Wet mix macadam will be loaded in in sub-grade will be determined and material having dimension in any one ready mixed condition; water will be added approval obtained accordingly. direction exceeding 75mm shall be at the mixing point of batching plant as to Ø removed. The material proposed for use in ensure that additional water will not be Granular Sub-base / Drainage layer is The selected source from quarry will be free necessary during the compaction of the crushed aggregate material or natural from organic matters and other deleterious layer. materials. The material will be also crushed constituents. The material will confirm the Ø The surface of the sub-base to receive aggregate, natural sand, gravel or IS specification and will be got approved by the WMM will be prepared to the specified combination, depending upon the grading the Engineer prior to use. The spreading will lines & cross falls and made free of dust and requirement. Quarries will be identified for be done with the grader. Each compacted other extraneous materials. natural GSB. The crushed material directly layer will not be more than 225mm thick Ø from the crusher with required gradation after compaction. The mix will be spread with the motor grader to the required width and thickness will be used. The mix will be transported to All tests to be done as per MORTH & IS so that no supplementary spreading, the grader location in dumpers and graded requirement. to required line and levels using a motor shaping or finishing will be required to When the sub-base materials consist of a grader and thereafter bringing the material obtain tolerance, requirement after combination of materials, mixing will be to required OMC levels by water sprinkling, compaction. done mechanically by mix-in-place method. if required. The material will subsequently Ø Rolling will be continued with vibratory Compaction will be done with a vibratory be compacted to the required density as per compactor at speed not exceeding 5Km/hr. roller of minimum 80-100 KN static weight. specifications. Rolling will commence at the lower edge and DenseBituminousMacadam and Ø The crushed aggregate to be procured proceed towards upper edge longitudinally Bituminous Concrete from the local market initially will be tested for portions having unidirectional cross fall Scope for suitability for use in the works and the and super-elevation and will commence at The work involves of preparing an existing test results will be submitted for the the edges and progress towards the center black topped surface of specified lines, approval of the Engineer. of portions having cross fall on both sides. grades and cross sections in advance of Ø The mix design for various grades of Wet Mix Macadam (WMM) laying a bituminous surface. concrete will be carried out once the Scope Methodology materials namely cement, sand (Natural or The work will consist of laying and Ø The aggregates and the binder that Crushed or blend of Natural &Crushed) compacting crushed, graded aggregate and make up the mix will be checked for their and crushed aggregates are selected. The granular material, premixed with water to physical properties. mix designs found complying with the dense mass on a prepared sub base in Ø The mix design will be prepared ahead requirements will be submitted for accordance with details given in Typical of commencement of work and got approval. Upon erection of the Concrete Cross Section of Road. approved by the Engineer. Batching Plant and the mobilization of the Concreting team, trials will be commenced Methodology Ø The course aggregate will consist of for production of concrete mix complying Ø The constituents of the aggregates will crushed rock, crushed gravel or any other with the approved mix design requirements. be produced by a multiple stage crushing / hard material produced from integrated crushing plant. Fine aggregate will consist Ø The mix design will be carried out with screening plant and will be carried out at- of crushed or naturally occurring material Engineers representative to ensure least in two stages. Ø or a combination of two. achievement of required strength. Grading requirement of aggregates is as per specification. Ø GranularSub-base (GSB) The mix will be prepared in the hot-mix Ø The Physical properties of the plant of adequate capacity & capable of Scope aggregates that make the mix will be yielding a mix of proper and uniform quality The work will consist of laying and checked for their adequacy as per with thoroughly coated aggregates. The compacting well graded material on specifications. system shall have arrangement of accurate prepared sub-grade in accordance with the Ø The percentage of the various weighing at cold aggregate feed system, details given in Typical Cross Section of ingredients that make up the mix will be as shifting of ingredients of different Road. per specifications. quantities conveying to the hopper, heating 12 storing and heating the bitumen, mixing of Ÿ Dynamic Cone Penetration Test DCPT/ Site Infrastructure and Layout bitumen and aggregate to the requisite Field CBR Test. Site Office – Total Built-up Area (30 m x temperature of 150-163 0C. 5. RESOURCES DEPLOYED 20m) Ø The tippers will carry the mix to the The fast track execution of the Project was Casting yard - 110 m x 60 m required locations. It will be transported in possible because of timely mobilization of Central Store - 44 m x 8 m clean vehicles and will be covered while in ample resources. Major deployment of transit. The rate of delivery of the material resources is as below: Central Workshop - 30 m x 10 m to the paver will be regulated to enable paver Manpower Deployment Stock yard - 39 m x 53 m to operate continuously. Description Numbers Batching Plant - 56 m x 40 m Ø The surface to receive will be primed GM/DGM/Managers and Engineers 45 Material arrangement and Logistic. with bituminous emulsion as laid down in Officers 8 Cement contact and the primed surface will be left to Surveyor/ Technicians 6 Cement Store – 2 Nos. be cured for 24 hr. Sr. Accountant/Accountant/Store keeper 8 Ø The spraying will be done uniformly Foreman/Supervisors 63 Size- 40 M X 12 M & 25 M X 12 M with nozzles with temperature as desired by Drivers/Operators/Helpers 170 Total Capacity-3000 t the Engineer in charge. Skilled & Unskilled workers 450 Source /Approved Vendor – Ultra Tech Total 750 Ø The laying will be done with approved Lead / Lead time – 500 K.M / 1week paving machine. The thickness of Plant and Equipment Deployment Means of Transportation– Rail DBM/BC will be as per specification and Reinforcement Steel drawing. Sr. Description Quantity Storage – Steel yard Ø The rolling will be done with vibratory 1 Concrete batching Plant 2 2 Hydraulic piling Rig 2 Capacity -1500 t roller. 3 Excavator 9 Ø In case of BC additionally pneumatic 4 Crane 8 Source / Approved Vendor - TATA, SAIL, tyre roller will be used to give a uniform and 5 Tippers / Dumper 6 JINDAL , EELCTROSTEEL 6 Vibro compactor 2 smooth finished surface. Lead / Lead Time - 60 K.M, (4 to 6 Hr.) 7 H M Loader 2

Ø After completion of Dense Bituminous 8 JCB backhoe 2 Means of Transportation–Trucks/Trailer

Macadam layer and Bituminous Concrete 9 Transit Mixer 11 Sand/Aggregates/Minerals 10 Hydra 7 layers, grid point levels will be jointly 11 Service van 1 Storage Capacity -30000 t measured to ensure any level differences to 12 1 Weigh Bridge Lead / Lead time - 195 Km / 8-10 Hr. be within acceptable limits. This will also be 13 LMV 13 used for measurement of layer thickness for 14 D.G. Set 17 Means of Transportation – Truck payment as applicable. 15 Tower Light 1 6. Productivity 16 Low bed Trailer 5 Tests (For Design) – Actual Cycle Time and Productivity 17 Welding DG 3 Following Field & Laboratory test needs to 18 Welding Transformer 29 Chart. be initiated at site for Flexible pavement 19 Bar bending machine 7 S. Time Target 20 Bar cutting machine 6 Activity Unit Unit design No. Cycle Qty/Month 21 Plate bending machine 1 a) Lab Test - 22 Concrete Pump 1 1 Pile Nos. 3 Nos. /Day/Rig 150 23 Boom placer 2 Ÿ Physical Test on Borrowed Soil Sieve 2 Pile Cap Nos. 4 Days/Set 40 24 Gantry–60 t 3 3 Pier Nos. 5 Days/Set 35 Analysis, LL, PL, Modified Proctor Test. 25 Compressor 1 Ÿ 4- days soaked CBR Test on borrowed soil. 26 Motor Grader 2 4 Pier Cap Nos. 4 Days/Set 35 I-Girder Ÿ Nos. Test on Aggregate Sieve Analysis, Enabling Structures deployed at site. 5 Casting 4 Days/Set 200 Nos. Flakiness & Elongation Index, Sp. Gravity 6 I-Girder Nos. 4 /Day/Gantry 220 Sr. Erection & Water Absorption, Los Angeles Abrasion Item Unit Quantity Precast No. Value, Impact Value Test, Stripping & Panels 1 Pile Cap Sets 12 7 Casting Nos. 1.5 Days/Set 1350

Coating test etc. 2 Pier Sets 8 Precast Panels Nos. 1350 Ÿ Bituminous mixes will be as per IRC37- 3 Pier Cap Sets 11 8 Erection Nos. 45 /Day/Gantry 4 I- Bays 8 Deck 2012 Girder Casting 9 Slab Span 12 Days/Span 30 b) Field Test - 5 I-Girder Erection Sets 2 Parapet 10 Casting Nos. 1 Day/Set 720 Ÿ 6 Precast Panels Casting Sets 100 Field Density (by Core Cutter Method) & Parapet Field Moisture Content by Rapid Moisture 7 Deck Slab Sets 8 11 Erection Span 2.5 Days/Span 35 meter. 8 Crash Barrier Casting Sets 35

13 7. Quality Assurance and Quality Control Summary of Concrete Mix / Pavement Design

PAVEMENT MIX DESIGN SUMMARY

Table 400-1 : Grading :-1 for Granular Sub-Base Material (GSB-1) Source of MDD OMC Aggregate 2.4 Chattarpur gm/cc 5.26% Table 400-13 :Grading Requirement of Aggregates for Wet Mix Macadam (WMM )

40 mm 20 mm 10 mm Stone Source of Aggregate Aggregate Aggregate Dust MDD OMC Remarks Aggregate Blending Blending Blending Blending Proportion Proportion Proportion Proportion

2.380 Chattarpur 5.20% 35% 16% 19% 30% gm/cc Table 500-10 : Composition of Dense Graded Bituminous Macadam -I (DBM-I)

Density 40 mm 20 mm 10 mm Stone Filler Source of of Aggregate Aggregate Aggregate Dust Bitumen Blending Aggregate compact Blending Blending Blending Blending Proportion Mix Proportion Proportion Proportion Proportion

2.515 Chattarpur 4.10% 18% 19% 22% 39% 2% g/cc Table 500-10 : Composition of Dense Graded Bituminous Macadam -II (DBM-II)

Density 40 mm 20 mm 10 mm Stone Filler Source of of Aggregate Aggregate Aggregate Dust Bitumen Blending Aggregate compact Blending Blending Blending Blending Proportion Mix Proportion Proportion Proportion Proportion

2.484 Chattarpur 4.55% 0% 39% 20% 39% 2% g/cc Table 500-17 : Composition of Bituminous Concrete-I (BC-I)

Density 40 mm 20 mm 10 mm Stone Filler Source of of Aggregate Aggregate Aggregate Dust Bitumen Blending Aggregate compact Blending Blending Blending Blending Proportion Mix Proportion Proportion Proportion Proportion

2.469 Chattarpur g/cc 5.23% 0% 33% 23% 42% 2%

WEEKLY TEST SCHEDULE AS PER FREQUENCY OF TESTING

DAYS TEST TO BE CONDUCTED MONDAY 40MM &20MM GRADATION ,CUBE TESTING

TUESDAY 10MM & SAND GRADATION ,CUBE TESTING

WEDNESDAY FLAKINESS ,AGGREGATE IMPACT VALUE & CUBE TESTING

THURSDAY 40MM &20MM GRADATION,COMBINED GRADATION, CUBE TESTING

FRIDAY 10MM & SAND GRADATION,ALL IN AGGREGATE,CUBE TESTING

SATURDAY FLAKINESS ,AGGREGATE IMPACT VALUE & CUBE TESTING

SUNDAY WEEK-1=40MM & 20MM GRADATION WEEK-2=10MM & SAND GRADATION WEEK-3=FLAKINESS INDEX WEEK-4=AIV

14 8. CHALLENGES ENCOUNTERED approach road at intermediate level boring in lieu of normally adopted 1m long AND ITS REMEDIAL MEASURES. throughout the Project alignment which auger and thereby reducing boring time by 8.1 Launching of I Girder on Rising then provided us clear passage for the 75%. Pier Cap. Transportation of 25 m span I Girder. 9.EXEMPLARY AND RECORD- Launching of I-Girder on 24m height Pier 8.4 Unpredicted high Tension BREAKING ACHIEVEMENTS Cap was a puzzling task for Site Team. It underground Electric Cable We have achieved our First Millstone-48 was a complex situation where telescopic Along the seven kilometer of project days ahead of schedule, Second Milestone- boom cranes could not complete the task alignment, we have encountered the 132 78 days ahead of schedule and Third as I-Girder of 35 t was to be lifted and KVA Underground Electric cablesfor Milestone-18 days ahead of schedule. In erected at the height of 24 m. So, it was which no prior information was available addition to this, several exemplary record- decided that the height of Goliath Gantry to us due to which we have to change our breaking achievements have been recorded having load carrying capacity of 70 t (Main pile/Pile cap Design. Places where Change on this Project few of which are: Hoist) to be increased up to 27 m Height. of design was not possible, the utility Ø Erection works of 32 no steel plate But still the task seemed to be next to shifting has been done. girder for 8 no of spans (44.6 m lengths impossible due to progressive increase in 8.5 Innovation/R&D. each) in 58 days only. height of pier. Finally, it was decided by the Ø Erecting work for Steel span of Bailey Ø Erection work for I-Girder having site team that the approach path along the Road Crossing (Cos-I Portion) is a height up to 24 m through Gantry Crane. direction of Gantry to be raised stimulating task for the reason that our Ø Concreting for 8 m Pier Height having progressively by earth filling after which elevated portion is intersecting an existing dia of 2.4 m in a single pour. we have installed the rising Gantry track flyover which is in operation and carrying As regards Quality Assurance and Quality for launching of Girder on Pier cap . heavy traffic. Control, Site established Quality Award 8.2 Erecting of Steel Girder Ø In COS-II where each steel span system that recognizes the commitment Our COS-II portion (Elevated Structure) having the length of 44.6 m which is very and dedication to the standards our comprises 356.8 m of total length with rare in Elevated structure; concreting deck organization has set for maintaining eight steel spans of 44.6 m each. It was slab was a real challenge. In order to resolve quality. This is an excellent way to show our indeed a challenging task to erect the steel this, profile sheet over girder was provided. site team that the corporate management girder of 140 t over 53 m tall pier in very Main objective behind provision of profile team values our efforts. Such recognition limited time period. We have placed the sheet is to replace shuttering arrangement, was given when a team has consistently Pre-cast Footing at required location. to reduce cycle time and to provide extra met a series of quality standards fixed by Subsequently we have erected the safety. the site or when a team has exceeded the temporary supporting arrangement like Ø Concrete work of Pier and Pier cap up level fixed by the site , or when team has trestle and temporary Girders on both the to 25 m of height was carried out by met the level for a certain length of time sides.We also positioned wooden blocks on making net type standing platform over the schedule. The criteria included reductions top of the ISMB Girders or placed screw work zone and thereby staging was in errors while execution of task on site, jack on both the sides of ISMB girder so as avoided which lessens our cycle time and and other such metrics that determine to rest the Deck girders keeping in mind supplementary possessions. quality levels for the organization. that assembled diaphragm shall be erected Ø A special arrangement of liner driving Awards were often given for successfully with proper support at both the side of which pledge the verticality at the time of realizing ISO Certification for stores, Site Pier cap using crane of suitable capacity driving, resultant into lessening of Cycle execution team, workshops andfield and the alignmen.t time up to 2 hrs. Laboratory during periodical surveillance 8.3 Transportation of Pre-Casted I Ø Railways approach spans of Digha end audit by certifying agency. girder had limited access for working in addition VIP Site-Visits Transportation of Pre-caste I Girders to the problem of lateral and vertical Hon’ble ChiefMinister of Bihar, from casting yard to their launching point clearances with the running railways track ShriNitishKumar, Deputy Chief Minister is a big challenging task for Execution team with road. ShriTejashviPrasadYadav and Secretaries due unavailability of suitable road and high Ø Innovative solution for movement of of various departments visited our Project density of composite traffic on existing heavy launching gantry on compacted soil site on few occasions and appreciated the road. As our Project construction work is resting on soft ground and thereby site progress. going on canal bank, no approach road was avoiding normally adopted solution of available. We collected data for Maximum providing piles. Water flow level of canal and developed Ø Providing 2m long auger for pile

15 Achievers Award Consultant’s teams and integration and We also wish to place on record our Hon’ble Chief Minister felicitated Mr. co-ordination among these teams. Better appreciation of guidance, mentoring and understanding and co-ordination goes a U.M.Kulkarni with “ACHIEVER relentless 24X7 follow-up of Dr. N.V. long way in fast track execution of the Nayak apart from excellent support AWARD” on behalf of BSRDC for for Project. received from Design, Procurement, Plant, outstanding progress of the Project. Ø Together with leadership skills, we HR, Finance and other teams from need to be aware of the strengths and Corporate office. weaknesses of our team, so that the talents are harnessed and the shortfalls, if any, are The entire Team at site put substantial downplayed for the benefit of the project. extra efforts in fast track execution of this Ø We need to know who the real decision Project and made this Project a success. makers are. Such individuals may not The Key Members of the site team always be readily visible or may not be in includes:- MEDIA COVERAGE limelight but they may be calling the shots. Mr. Shashi Ranjan (D.G.M. -Projects) A good leader will spot such members Mr. P.S Rao (D.G.M-Plant) The Telegraph 29th December, 2015 from the team and develop a strong line of flashed article titled 'Elevated path for communication with such members which Mr. R.N Tiwari (Senior Manager/ cool drive' by Amit Bhelari will reap benefits in the long run. Incharge –Execution) Mr. Sudeep Verma (Senior Manager Ø If we have the knowledge, experience and judgmental skill to take a decision and –Administration ) implement the same right up to result Mr. SashiKushwaha (Manager/Incharge- stage, no matter what are the difficulties COS II -Execution) and hardships en-route, then we should go Mr. D.K Roy (Incharge –Casting yard) ahead and do so, without expecting top Mr. Suman Jha (Incharge QA/QC) management to spoon feed us every now Mr. Mithilesh Ray (Incharge-Stores) and then. Mr. Rajeev Kr (Accounts Incharge) Ø Do not be afraid of taking calculated risks. After all, as the famous adage from Credits are also due to our partnering Mr. William G.T. Shedd goes, “A ship is Subcontractors including Arti Infra, safe in the harbor, but that is not what ships Amhara Construction, Meccaferi, are built for.” Siddharth Tanks and Vessels, Sarenes Heavy Lift India Pvt. Ltd and others and 1 1 . C R E D I T S A N D various PRWs. ACKNOWLEDGEMENTS

Fast track execution of such mega Project MISSION IMPOSSIBLE?!!!! would not have been possible without - M. U. Shah "Commuters will have another reason to whole-hearted and positive support from One Project Manager working at construction site cheer with a part of the AIIMS-Digha BSRDC officers. We wish to place on stumbled upon a bottle and a magic Genie came elevated road will be becoming functional. record our sincere appreciation of entire out. The construction of this stretch would team of BSRDC officers and in particular The Genie told to Project Manager, Gentleman, “I provide a direct road connection between Mr. Vijay Shanker, Chief General Manager am impressed by your dedication, hard work and AIIMS in south Patna and Rupaspur point under whose dynamic stewardship the loyalty to your organisation. You ask any one wish. I will fulfill your wish.” at Ashok Rajpath in west Patna." Project is executed. Credits are also due to 10. CONCLUSIONS entire Project Supervision Team Project Manager thought for a while and said, “I have built many Roads and Highways in my State, Lessons learnt comprising of Shri Sanjay Kumar (General in my country and abroad also. Having achieved Manager-Tech), Shri Arun Kumar (Deputy Ø The success of a project is largely everything in my career and having reached a pinnacle, I now want to build Road from Earth to dependent on the knowledge, knowledge- General Manger),Shri Sanjeev Kr Moon for yet another zenith in my career. ” application skills and strengths of the (Manager-Tech), ShriRajnath Singh people involved. Therefore, a project (Manager-Tech) and others. “Impossible, my child, impossible” said the Genie; “Ask something else, something which is possible.” needs to have competent, talented and Creditts are also due to team of BSRDC dedicated set of individuals working appointed consultants – M/s AECOM- “ OK. In that case, get my claims passed from the Authority.” said the Project Manager. towards a common goal with killing RODIC (JV) who are having the valuable instinct. standing in consultancy services having “ What will be the width of the Road you wish to Ø build from Earth to Moon. ? Will it be a four- Also the success of a Project is executed number of prestigious project in dependent not only on Contractor’s teams laned Road or six-laned !!!? ” was the instant the world. response from the Genie. but also depends upon the Owner and

16 Bid Stage Economical Proposals for Bridges– A Critical Study A. K. Chatterjee

3. Types of bridges to support the foundations. The foundations system that would occupy the waterway in such Bridges can be normally categorized as cases are very expensive and the usual layout to i) Overland/ Land based bridges. e.g. choose for economy is with long spans, Flyovers, RoB’s. RuB’s, elevated roadways and minimizing the number of such expensive A. K. Chatterjee similar such overland crossings. foundations as much as practically possible. ii) Bridges across waterways: River bridges, 4) For waterways which are mostly dry in the 1. Preamble bridges over creeks or sea or canals, hill streams, dry season and rock is available at shallow depths deep valleys etc. of the bed, foundations will not be very For any bridge construction contract, the phase expensive (usually simple open foundations will of preparation of technical proposal and 3.1 Land based bridges do) and here simply supported or continuous competitive bidding based on such economical spans ranging from 25 to 40 m may prove to be technical proposal is of vital importance. This is Land based bridges can be again sub categorized as below: economical for the superstructure as well as for the stage at which the fate of Bid is sealed though the bridge itself. outcome will become public only when bids of Flyovers, RoB’s etc. of maximum height of 8 to all bidders are opened by the Owner/Consultant. 10 m where spanning over railway tracks, 5) Also there are other types of crossings A bid stage proposal which is not economical or obligatory spans etc. are involved. The where overall bridging length is not much, but the which is not based on efficient and creative foundation medium could be reasonably hard site characteristics are peculiar and challenging conceptualization will be automatically out soil or could be an over burden of very poor soil and the solutions are very limited. This is priced at the hands of efficient competitor. underlain by rocky strata. particularly true of hill bridges. e.g. Lubha Bridge Naturally, to stay in business, no company wants in Meghalaya and Jadukata Bridge, also in to be a loser. Hence it puts in the best efforts at Elevated roadways are usually concrete bridges Meghalaya, which necessitated providing a large the bid stage for preparing an efficient and of considerable length with relatively tall piers. central span covering the waterway and counter economical technical proposal for winning a These could also have hard soil or poor soil as weight arms on either side of the main span over contract, some of them, very prized ones, for the founding medium as for flyovers, RoB etc. as hilly banks for providing stability. Both the above growth and reputation of the company. mentioned above. bridges were constructed by Gammon by cantilever construction method. 2. Two types of Bids 3.2 River Bridges While in case of Lubha bridge, the bed between 1) In the case of the first type of bid, the Usually the design and the construction engineer will encounter many complex problems when the banks were very deep and velocity of flow Owner/Employer appoints a Consultant who was extremely high, in the case of Jadukata prepares technical proposal, carries out the dealing with river crossings. The various types of crossing for bridging waterways are as below: Bridge (Fig. No1) the waterway was a type of designs and estimates quantities of various deep ponding, associated with a velocity of flow items and prepares Bill of Quantities. The bid is 1) Bridges of appreciable lengths across not very small. This was really a challenging job, then invited based on such BOQ prepared by the rivers flowing through alluvial plains e.g. Ganga, as, for stability, counterweight arms had to be Consultant. In such cases superiority of Brahmaputra, Sone, Godavari, Narmada. These provided, being partly located inside tunnels on construction techniques, good planning, a bridges, because of the soil composing the bed either side because of limitations in length on the proper appreciation of the site, use of state-of- and high water current velocities, display very banks. It currently has the largest single span in art Plant and equipment will enable a particular deep scours due to obstruction to flow created by prestressed concrete box girder construction construction company to have and edge over his piers and their foundations. Usually such rivers with a span of about 140 m. competitors, which will most likely enable him to have large water depths in their channels secure the work. This type of bidding is usually sometimes even during dry season. 6) Then there are crossings where the river known as Item Rate bidding with pricing based bed is composed of boulders but with large on the aforesaid BOQ. 2) Bridges of large lengths but having rocky velocity of flow (12 to 13m /sec) causing strata, hard or soft as the case may be, below a moderate scours, but still requiring costly well 2) There is however another type of bid of manageable depth of overburden soil, formed of foundations and therefore warranting the use of the ‘Design and Build’ type, where the silt sand and clay. In such cases usually the scour is long spans to bridge for economy. An example is construction agency bids a lump sum price considered up to the surfaces of the rock, Passighat Bridge over river Siang at Passighat, (wherever stipulated in the tender by the depending on the rock quality. Arunchal Pradesh, the river being a tributary of Employer to do so) based on quantities arising river Brahmaputra and descending from China. out of its own design, which could be either 3) The type of waterway crossings that need special attention particularly are for those The author was deeply involved in the design of prepared by its in-house design team or could be this bridge, and the bridge saw the light of the day based on the design of a consultant engaged by it. waterways which are associated with large scours, large perennial depths of water and no bedrock after almost 16 years from commencement of While in case of Item Rate bidding all bidders are construction as there was intense differences in on the same platform as far as BOQ is concerned, the bidding is more complex in nature for a construction company who bids for Design and Build types of contracts. Here the construction company not only must have superiority in matters that factor the construction itself to its advantage, but his technical proposal and design also has to be very competitive as also easily constructible vis-à-vis possible technical proposal and design of competitors, is superior. Here the skill of a design engineer, his experience, his creativity and alertness will have a significant influence on the bid if the bid has to be a winning one. It is important to analyse and study the considerations that dictate the selection of economically viable proposals for various types of bridges that may not necessarily need to use complex techniques of construction, except for a few special type of bridges.

17 the opinion about the scour level provided by the pier (double plate piers) formed the foundation founding possible at shallow depths and no scour client at the tender stage, an over conservative system. The longitudinal seismic forces were is encountered, repetitive short spans e.g. 20 m to one, which took many years to resolve and client resisted by two stiff trestle piers in prestressed 25 m will display economy. At the opposite end, finally accepted the foundation level proposed by concrete (space frame) one at either end of the the designers will encounter large, turbulent and GIL, following numerous deliberations, side spans and supported on shallow wells. high velocity water ways with associated deep bed dialogues etc. between the client and GIL. scours etc warranting adoption of long span The successful construction of Barak Bridge, an superstructure units for economy. Apart from This is a fine example where long spans (about economically competitive structure, paved the the range of basic span configurations suitable 117m) were found suitable for economic way for many more cantilever bridges in the under various site conditions and site considerations. country later when many contracts were won due peculiarities, the important factors that mostly to these competitive designs e.g. Ganga Bridge at While dwelling on construction of long span govern the economy in pricing of bridge Patna (which is the longest river bridge), Buxar proposals are : systems a few important things must be kept in Bridge , Bihar, Narmada Bridge in Gujarat, mind. The questions that are usually posed to Pamban Bridge, Tamil Nadu. 1) The material content e.g. cement , coarse the engineers are: and fine aggregate, steel rebars, structural steel, 4. Study of Site i) Do we have the necessary design expertise high tensile steel etc.. to design a long span? The designers before making a proposal for a 2) The Labor component. bridge layout, must make a good study of the site ii) Do we have necessary resources i.e. plant to consider a few alternatives which would at a 3) The plant & machinery that would be and machinery to construct a long span? first glance furnish possible economical suitable for the implementation of the proposal iii) Do we have skilled and trained solutions. Thereafter with preliminary at site, practically and swiftly. construction engineers to meet the challenge? calculations (simple ones) the designer will be able to pick up a satisfactory and economically It may be noted that under the prevailing market iv) Do we have the necessary interfacing viable alternative for selecting the final proposal. situations in India the material component in a coordination between the design engineer and bridge structure is perhaps the costliest construction personnel to discuss and resolve 5. Applications of long spans bridges component. In India, the labor costs are still cheaper when compared to developed countries. the problems that might encounter during In terms of economy long span bridges find their construction? application in With the advent of the arrival in the scene of Most of the times, in mid 20th century in India, many manufacturers for cranes, excavation 1) Very wide waterways where foundations equipment, batching plants, concrete pumps etc. the answers would have been difficult to provide, have to be deep due to considerable bed scours, in context of the prevailing times, then. and other related bridge construction plant and large water depths at HFL and considerable machinery, an increase in speed of construction Thus, in the earlier periods (early sixties) of current velocities. has resulted and the overall cost is showing Gammon’s history of bridge construction, there 2) On tidal creeks of large lengths e.g. Thane trends of improved economics in bridge were limitations in going for long spans. The Creek, Vasai Creek near Mumbai, Pamban construction than earlier, referred however to designers had to be satisfied with provision of 35 bridge, Tamilnadu etc. equivalent prices, accounting for inflation etc. to 40 m simply supported spans formed with But the material costs are the heaviest. precast concrete girders and launched into 3) Crossing over deep gorges encountered in position by aluminum launching trusses which hill rivers e.g. Mandi River, Himachal Pradesh & In the U.S.A and other advanced countries in the were not easy to handle and considerable care Teesta bridge in Sikkim, West Bengal. They are world, the material component is much cheaper, had to be taken during launching. Thus economy usually the only solutions for economy. labor expensive and plant costs reasonable. had to be sacrificed in many cases. Some Hence proposals which are economically viable improvement in achieving longer spans came 4) Crossings near deeply ponded waterways in U.S.A may not be necessarily be so in our later by using cantilever pier heads also known as e.g. Jadukata Bridge country because of reasons explained above. ‘Hammer Heads’ with prestressed concrete 5) Elevated roadways in deep valleys with Now the question is how do we assess the simply supported spans supported on the very tall piers material component in a decking. The simple Hammer Heads with articulated supports e.g. 2 2 6) With peculiar site characteristics that formula for bending wl /8, wl /12 (continuous) first Thane Creek Bridge, Maharashtra, Kosi 2 bridge at Kursela, Bihar (Fig no.2), Dorighat render construction of multiple piers at relatively & wl /2 (cantilever) will give us an idea. These Bridge in U P etc. close intervals uneconomical and time formulae will indicate the mass content. The consuming. longer the span the heavier the mass and that will The breakthrough in long span construction in therefore guide the designer to set up a proposal prestressed concrete came in early sixties when 6. The Initial Approach for targeting the in which he can optimize the proportions of Gammon developed the cantilever construction most economical proposal mass in the superstructure and substructure and system in house and indeed it was a very good As a thumb rule a bridge proposal will generally foundations with some preliminary calculations development which won Gammon contracts for approach an economical one when the for assessing the material content. many long span of bridges later. With this superstructure cost and the cost of foundation development Gammon successfully completed Base on this preliminary guidance, the designer and substructure will tend to be equal in cost i.e. can then think of a few alternative proposals Barak Bridge at Silchar (Fig no 3), Assam, using each will be 50 % of the total cost. This perhaps is the cantilever construction method for the first closely fitting the site characteristics for fine an ideal situation, which can never be realised in tuning and with the process of elimination select time in India. This bridge has a central span of practice, because of many other influencing 120 m with side spans of about 56 m, covering the most optimized structure involving the least factors governing the design. Hence where material content, leading to economy. the waterway of the river. Twin wells under each foundation medium is generally good with

18 Surajbari Creek (fig no 4) near Kutch is a fine between 8 m to 12 m. Beyond this height, piers was soft rock with an allowable bearing capacity example where Gammon won a large contract categorized as tall piers with heights reaching of the order of 40 t/m2, a large footing diameter for a simple bridge, just by introducing a slight above 30 m, circular annular piers or rectangular was required which in turn led to a solid RCC innovation whereby it was possible to reduce the box shaped piers in concrete are very effective footing, extremely heavy rendering it very net span length by providing integral short both structurally and economically. uneconomical . As the author recalls, the cantilevers to the precast girders. diameter of footing was around 30 m and solid 1) Where rocky strata is easily available at RCC footing of depth of over 6 m was required. 6.1 Superstructure: relatively shallow depths in the bed, open The large diameter of the footing was required to foundation are usually fine for medium simply Transverse arrangements cater to the codal provision of not to exceed a supported spans if the excavation is generally in certain percentage of the overall footing area 1) RCC/Prestressed concrete I or T sections the dry requiring relatively small dewatering. coming under tension (i.e. no contact) under the are very suitable for land based structures with 2) The size of open foundations will increase action of critical forces & moments. After a short spans and will give economy when when the founding medium displays soft rock careful study an alternative was thought of, foundations soil is good and scouring is absent. with allowable bearing capacities of the order of instead of providing a solid footing, a ring 2) Box girder (single or multiple as the 40 to 50 t/m2. Hence under high seismic forces foundation was examined which had a diameter requirement may be) in situations as in item 1 the depth of footing will become considerable of about 26m and a depth of 2.5m (Fig no.5). above will be highly uneconomical unless the and not only bending but punching shears will Although the design of the foundation and the spans are in sharp curvature. dictate which will increase footing depths pier shell became very complex in absence & considerably. In these cases rectangular footing digital computers & software in those days but 3) Box Girders are very suitable for long with RCC wall piers can be used, effectively the problem was solved with success based on spans because of their high flexural & torsional proportioned in such a way that from both manually prepared calculations for this complex rigidity, for right bridges, as also for skewed and bending and punching shear considerations the design. The economy achieved in both concrete curved bridges. footing could be designed economically without and steel was considerable and substantial saving 4) Cable stayed decking is most suitable for providing large depths for span ranging between in costs was achieved. Fig no 5 shows the general spans beyond 180 to 600 m and that too for 30 to 35 metres. shape of the pier and the ring foundation. waterways with deep scour. However under certain situations, for aesthetic 7. Conclusions : 5) The cable stayed decking is not considerations and where considerably high The concept of an economical proposal is economical for land based bridges with small velocity of flow exists, circular piers are many a normally difficult for a young designer to ingest, heights of piers albeit they are many times time adopted, particularly when high depths of as this requires experience. However with careful constructed in city areas also mostly for aesthetic water are encountered in the waterway. If study of the site condition and with experience considerations rather than economic resultingly, the piers are high and high seismic the designer can develop the skills of identifying considerations. forces are associated, large footings circular in an economical proposal, gradually. The author shape would be required, leading to considerably 6.2 Foundations: had the good fortune to have had the large footing depths. Thus for tall piers, cellular opportunity to be deeply involved with the 1) The most economical are those with open annular circular piers in concrete flared to a larger design of many of the bridges mentioned herein foundations if the site conditions and soil quality diameter at the base will help in reduction of and thus could gather valuable experience for will permit. footing depth, by controlling both flexure and identifying economical proposals. punching shear in the footing, for economy. 2) Well foundations supporting long spans The key is to examine a few alternatives (may be give a balanced cost of the proposal itself when The author was faced with a vexing problem two or three), prepare simple preliminary very deep foundations are necessitated due to during the design execution of an elegant bridge calculations; assess the quantities of each very deep scours, high seismicity, tall piers etc. constructed in the nineties by Gammon namely proposal for arriving at the most economically Although piles have been and are being used as Kaladan Bridge, Mizoram constructed for viable proposal. Although easier said than done, deep foundations in many cases, presently, in Border Roads Organisation. the designer, with application, can gradually cases with deep scour, well foundations are For superstructure this bridge had a central span develop a maturity which will enable him to easily economical under certain compelling situations. of 122m with 71m side spans on either side in the recognize an economical proposal amongst 3) Pile foundations display economy when continuous system with one fixed bearing in C.S several others, with confidence. sandy/clayey soils are met as the medium for at one pier location and C.S roller bearing at the 8. Acknowledgements: founding for land based bridges with nominal or other supports. The piers were about 33m in no scour but may not be economical in cases of height with a seismic acceleration of G/10 as was 1) Gammon India Ltd specified those days. There was no response deep bed scour, large water depths and intense 2) i) To my senior colleagues for their seismicity. reduction factor for use. The river also had a high velocity of flow about 12m/sec and considerable valuable guidance, at those times when the 6.3 Piers: water depth at HFL. bridges were designed. Usually for good aesthetics, solid circular piers Hence an annular circular pier with gradually ii) To my junior colleagues at those times who are economical and pleasing to the eye, these increasing diameter towards base was initially with their dedication and hard work kindly however display economy when supporting thought of. However, as the foundation strata assisted me in contributing to the successful short to medium spans and up to a pier height completion of these projects by Gammon.

19 NEWS FLASH

1. HON’BLE PRIME MINISTER Gammon is the only civil construction developed for public use by constructing a DEDICATES THREE FLAGSHIP company who has the unique distinction cycle track, a jogging track, walking track, HYDRO POWER PROJECTS TO of working on all the three projects stated kids play area and facility of toilet, potable NATION above. Gammon is proud to be associated water and parking at every 500 m. Hon’ble Prime Minister, Shri Narendra with these flagship Projects namely Commuting in the water-way has also been Modiji dedicated three flagship Hydro Koldam, Parvati and Rampur and thereby arranged through a water bus, which Power Projects on 18th October, 2016 to contributing our bit in development of would start plying from December. Under the nation at a function in Mandi, Himachal Pradesh and other parts of the the project, a lake has also been developed Himachal Pradesh. The Projects include nation. which would have a musical fountain, place 800MW Koldam Project of NTPC, 520 for yoga, wedding ground, 2000-person MW Parvati Project of NHPC and 412 2. DEDICATION OF GOMTI RIVER capacity amphitheater and stadium for MW Rampur Hydro Station of SJVNL. FRONT TO PUBLIC playing football and cricket. Shri Acharya Devvrat, Governor of Gammon has executed the above Project Himachal Pradesh, Shri Vir Bhadra Singh, Hon’ble Chief Minister Shri Akhilesh Yadav, on 16th November, 2016 said that on fast track basis ahead of schedule Chief Minister, Himachal Pradesh, Shri registering a record breaking progress in Jagat Prakash Nadda, Union Minister of the U.P. Government had set an example for balanced development and timely construction of Diaphragm Wallsun Health and Family Welfare; Shri Piyush paralled in the country. Goyal, Union Minister of State ( IC) for completion of projects for other states. Power, Coal , New & Renewable Energy CM was speaking at a function to dedicate Hindustan Times Dated 17th November, and Mines and eminent dignitaries were the Gomti Riverfront Development 2016 flashed the above news prominently. present on the occasion. Project to public in the state capital. 3. SITE VISIT BY HON’BLE “The Gomti Riverfront is one of the MINISTER OF STATE MoRTH largest eco-friendly projects and has no Shri. Pon. Radhakrishnan Hon’ble parallel anywhere else in the country. It will Minister of State MoRTH, Mr. Anand not only be a tourist attraction but also Kumar, the first Managing Director of the generate business and employment National Highways and Infrastructure opportunities,” CM said. Development Cor poration Ltd. (NHIDCL) and other NHIDCL officers visited New Brahmaputra Bridge & Road Work Project on 27th October, 2016.

Appreciating the contribution of Public sector companies in country’s growth, Prime Minister, Shri Narendra Modiji said that these hydro projects will bring prosperity to the State of Himachal and other parts of the nation. With commencement of generation from four 200 MW units, NTPC’s Koldam Project has achieved capacity of 800 MW and provides peaking capacity to the Northern grid. It shall annually generate 3054 GWh electricity at 90% dependable year basis. NHPC’s Parbati-III Power Station is a run of the river scheme having a 43 m high rock fill dam, underground Power House CM congratulated the Officials and and 10.58 km long water conductor Engineers of the Irrigation Department system. A net head of 326 m is utilized to and Gammon team for completion of the run four vertical Francis turbines with an project ahead of schedule. installed capacity of 520 MW (4x130 MW). Under this prestigious River front The power plant is designed to generate Development Project, RCC Diaphragm Hon’ble Minister and the team inspected 1963.29 Million Units annually. Walls have been constructed on both the entire site and also crossed the river in the SJVN’s Rampur Project (412MW) in Kullu banks of Gomti river, channelizing the project site boat and appreciated the district will be operated in tandem with water-way. The land between the water- progress achieved so far. Nathpa Jhakri Hydro Power Station. way and the embankment has been

20 4. VIP VIST : SABARMAT BRIDGE The Signature Bridge will connect Outer Mr. Aadesh Sharma, MD, DFCCIL along Ring Road (National Highway 1) on the with other DFCCIL Executives visited the western side and Marginal Bund Road at Sabarmati Bridge site on 11th November, KhajuriKhas intersection on the eastern 2016 and reviewed site progress. side. It will serve as a vital link for commuters travelling between north Delhi Also present during site visit were and northeastern part of the city and JV Lead members ( JFE Engineering – Ghaziabad. Udhampur Ramban Road Project Japan) and Executives of Nippon Koi 7. SAFETY AWARD Consultants who are PMC for this project. VallurThemalPowe Plant site has received Safety Award from NTECL on 28th October, 2016 for having achieved 2 million safe man hours. The Award was received by the GIL representatives(PM and site safety In-charge ) from the Project Head/AGM (P), NTECL

RVNL Kolkata Metro Project

5. VIP VISIT : BRAHAMPUTRA BRIDGE AT TEZPUR S r i . S h a m s h e r S i n g h , D e p u t y Commissioner of Nagaon District Assam visited New Brahamputra Bridge at Tezpur 8. SAFETY MONTH CELEBRATION on 4th October, 2016 Like every year, this year also Gammon decided to celebrates the month of November as “Safety Month”. The entire gamut of Gammon including all Projects, Bajoli Holi Hydro Project Regional Offices, Workshops and HO are actively involved and encouraged to participate in the celebration of the Safety Month with various safety programmes for awareness, motivation, propagation and enhancing Safety Culture as a whole. The 6. SIGNATURE BRIDGE theme of the Safety Month for year 2016 was “Focused Supervision and effective Hindustan Times dated 13th October, participation for Safety”. 2016 carried the news of Signature Bridge Nathani Heights Building Project across Yamuna River. The celebration of Safety Month is to ensure full participation by all concerned The Signature Bridge at Wazirabad is on with zeal and enthusiasm for continual the verge of completion. The construction development of Safety Culture in the of the bridge is in its final phase and may be company. completed by April Various activities aimed to enhance Safety When the project was first conceptualized awareness and build sound Safety Culture in 2004, it was decided that the space close were planned during the month. to the bridge would also be developed as a picnic destination. As per a proposal, the Delhi Tourism and Transportation Patna Elevated Road Project Development Corporation (DTTDC) was to initiate revamp on areas surrounding the bridge. The previous Government had planned recreational facilities such as water sports, boating, open-air theatre, food plazas with promenades and winding walkways at Yamuna bank to attract a larger number of tourists. The area is also to be rejuvenated as a habitat for avian and aquatic life. Opening ceremony at Corporate office Gomti River Front Project

21 9. DEVELOPMENT OF GATES Reservoir ) project with First lift at FOR INUNDATION BINS Regumangadda of Kollapur Mandal of Taloja Workshop conceived, designed and Mahabubnagar District. developed Water Tight Gates for The Scheme envisaged to irrigate 3.40 Lakh inundation bins of Vyasi Hydro Project. acres at a cost of Rs. 2990 cores utilizing 25 These gates are developed in-house by TMC of water by series of 3 lifts located as Gammon team for the first time in the follows: country. Lift-1 ( Stage-1) at Regumangadda with static The puja of 2nd Pump commissioning was done by Mr. lift of 95 m. 10. COMMISSIONING OF 2nd Penta Reddy, Advisor Lift Irrigation Schemes, Govt. of P U M P I N G U N I T A T Telangana. KALWAKURTHY Lift-2( Stage-2) at Jonnalaboguda with static harvesting season . It is planned to lift of 86 m. Having successfully commissioned 1st commission the 3rd, 4th and 5th units Pumping unit in September, 2016, now progressively in coming months. 2nd Pumping unit of 30 MW capacity has Lift-3 ( Stage-3) at Gudipalli Gattu with static Kalwakurthy Mahatma Gandhi Kalwakurthy lift of 117 m. been successfully commissioned at Lift Irrigation Scheme is designed to provide Kalwakurthy on 16th November, 2016. irrigation and drinking water facility to the The above 3 lifts are interconnected with With this achievement, now 1300 Cusecs chronically draught affected, upland areas in series of balancing reservoirs, gravity canals water is being discharged which is providing Mahabubnagar District by lifting water from and tunnels along with other relevant irrigation for 1.50 Lakh acres apart from the river Krishna from the foreshore of the components. filling about 200 Village Tanks in this Nilam Sanjeeva Reddy Sagar ( Srisailam

COMPANY NEWS

THANKS TO AWARDS ESTEEMED S. A. Reddi CUSTOMERS Mr. S. A. Reddi, Ex-Dy. Managing Director, Gammon India Limited has been conferred with the Life Time Achievement Award by the Indian Roads Congress (IRC) during 77th Annual Turnkey Design and Construction Session held at Hyderabad on 17th December, 2016. of Well Foundation at River The Award is in recognition of his outstanding achievements and personal commitment to Brahmaputra for Guwahati Highway Engineering profession. Ropeway Project, Assam

C.V. Rs. 12. 24 Crores

WELCOME TO GAMMON FAMILY

Pradeep Kumar Kulshrestha Nilesh Pundalikrao Vaidya Soubhagya Panda Arun Vasudev Panchal Gaurav Dilip Jadhav Jitendra Sanjay Jambhale Navneet Dhiman Md Jasim . Nayan Kumar Harshit Kumar Dwivedi Mahesh Kumar Prem Prakash \ Bikkina Sivannarayana Ravish Kumar Bhardwaj The Award was presented by the Honourable Minister of Road Transport and Highways, Mr. Khem Raj Malhotra Nitin Gadkari and was received by his son Mr. Ashok Reddi on behalf of Mr. S. A. Reddi. Nadeem A Sanadi Parikshit Singh This is an indeed great honour conferred on Mr. Reddi and speaks a volume about the Yurendra Yadav contributions made by Mr. Reddi in various IRC committees and other activities of this august Harihara Pani Awadhesh Sharma body in the country. Prasenjit Kumar Kundu Mr. Reddi has been a role model and source of inspiration for all Engineers not only in private Vishal Nivas Kachare Shruti Brat Shukla sector but in PSUs and Government organisations also. Yarrabothula Malleswararao Angshu Lahiri We extend hearty congratulations to Mr. Reddi on this honour bestowed on him by IRC. . Brajesh Kumar Patel ...... contd. It is indeed a proud moment for all of us in Gammon. 22 V. N. Heggade Conferred Maharashtra PWD Medal PHD EVALUATION GIL instituted for the Best Paper on Dr. N V Nayak PARTICIPATION Construction for his Paper “ Evolution of Precast Segmental Technology for Bridges 3rd November, 2016 IN SEMINAR in India” Evaluated Research work of PhD Hon’ble Minister Shri Nitin Gadkari Candidate at VJTI. Dr. N.V. Nayak presented the Medal during 77th IRC 15th October, 2016 Annual Session at Hyderabad on 17th LECTURES December, 2016. DELIVERED Workshop on “Outstanding Steel Structures” at VJTI PUBLICATION OF BOOK P.Y.Manjure 19th November,2016 Book titled 'HANDBOOK OF 4th October,2016 Attended a Technical Lecture on Concrete arranged by ICI at Bandra Kurla Complex, ENGINEERING GEOLOGY' authored Mr. P.Y. Manjure, Director, Freyssinet Mumbai by Dr Vinay Kumar Pandey, Manager- Prestressed Concrete Company Geology, Udhampur-Ramban Highway V. N. Heggade & P. S. Raizada Project has been accepted for publication Limited delivered a Key Note Address in by CBS publication, New Delhi. Technical Session No.4, during the 15th -18th December, 2016 conference organized by Ministry of Attended Annual Session of IRC at Surface Transport and IDDC Ltd on Hyderabad ‘Bridge Management System’ at New Delhi on 04th and 05th October, 2016. In appreciation he was felicitated by an STUDY TOUR IBMS Momento by the Chairman. Mr. M.V. Jatkar and Mr. V. N. Heggade visited China on invitation to study cable supported technologies in China on 13th to 14th and 17th to 18th October,2016 BEREAVEMENT

...... contd. from page 22 Ravirala Srinivasulu Jayanta Samanta Taj Ahmad Ravindra Kumar The Ministry of Surface Transport has Rana Ranjeet Singh Bhim Patar launched an ambitious project on Bridge Mangal Singh Management System in 2014. The project Prasanta kumar Barik envisages identification of all bridges on Amit kumar Sharma Chandra Narayan Das National Highways. It includes collection Bhavusingh Bhukya of various particulars of the bridge, Ajay Kumar V technical parameters and structural details Ajay Kumar Singh Nihal Tripathi of the bridge. Besides, the project will Manish Srivastava bring out the conditions of the bridge and Gudiwada Gopikrishna would identify the bridges which need Sujeet Kumar Sunil Kumar Mishra strengthening measures to maintain their Jeet Kumar service life. Avinash Karshanbhai Santoki With deep regret, we inform the sad and Lanka Venkata Sivarama Krishna The Ministry has appointed IDDC Ltd and sudden demise of Sh. Rahul Srivastava, Shivayya A Hinemath 18 other consultants to inspect all these Senior Manager – WSS, located at Kolkata Kartheek Chava bridges and collect the necessary Kartik Tiwari Office. Mr. Rahul Srivastava passed away Sourav Chatterjee information. on 21st October, 2016 at the age of 63 Siva Sankar years. Nishant Kumar Also biennial conference was held under Sachin Rewachand Indulkar the aegis of Ministry of Surface Transport He worked with Gammon for nearly two Dibyendu Maiti and IDDC Ltd to discuss various aspects decades. Mr. Srivastava was known for his Dhrubajyoti Thakuria of the Bridge Management System in the Harsh Kumar Singh positive attitude & helping nature. Mr. Amit Kumar Patra light of information collected during the Srivastava is survived by his wife, daughter Vikash Mehta last two years. The Ministry and and son. A Rakesh Organizers invited Mr. P.Y. Manjure to Manoj Biswakarma We offer our deepest condolences to his Amirul Hoque address the conference and speak on Jitendra Giri ‘Challenges in Rehabilitation of Bridge family and pray almighty God that his soul Anshumaan . Structures’. rests in peace. Sandeep Kumar Singh

23 - THE ACROSS YAMUNA RIVER AT DELHI

India’s first “Signature Bridge” being constructed by Gammon across Yamuna river at Wazirabad, promises to be a great tourist attraction of Delhi, the Capital of India. This cable-stayed bridge will link NH-1 at Wazirabad on Western bank and at Khajuri Khas on eastern bank of the river Yamuna, connecting North Delhi with East Delhi. With a length of about 575 m (main bridge) +100 m extension and a height of 154 m, with glass facade at top part, the proposed Signature Bridge would have a bow-shaped steel pylon in the middle. Two high towers will provide double cable support in the inner periphery of the carriageway. The deck will be composite (steel and concrete) while the pylon will be in steel. Equipped with four lanes, this engineering masterpiece will have a 1.2 m wide central verge, space for anchoring cables, maintenance walkway and crash barrier on either side of the central verge. Once operational the Signature Bridge will dramatically improve access between North and East Delhi reducing present congestion and traffic jams and will become the identity of Capital City – the way Taj Mahal is to Agra