Presentation onDesign and Construction of Six Lane Highway

from Vasad to Bagodara

Industry Defined Project

byNIKUNJ PATEL (110170106055)BRIJESH PATEL (110170106050)

TEAM ID: 27947

DT. 29/05/2015

Vishwakarma Government Engineering College, Chandkheda Gujarat Technological University, Ahmedabad

INTRODUCTION

A project on Design and Construction of highway from Vasad to Bagodara

Six laning of existing three lanes road from Vasad to Bagodara (State Highway No.-8)Client Gujarat State Road Development Corp. (GSRDC), Govt. of Gujarat has planned to develop this project on Public Private Partnership (PPP) mode. M/s GVK Bagodara Vasad Expressway Pvt. Ltd. has been selected as concessionaire of this project on Build, Operate and Transfer (BOT) Basis.M/s Eagis India Ltd. is appointed as the Independent Consultant Engineers(ICE) for design checking and construction supervision of the project.As a part of fulfillment of final year project, this project is taken up as Industry Defined Project (IDP).

ABSTRACT The Project on “Design and Construction of six lane highway from Vasad to

Bagodara” includes the design and construction aspects of the highway project. This is an Industry Defined project (IDP). During 7th Semester first phase of the project work was completed, which includes design aspects, the study of design data such as CBR value, Traffic data, Drainage conditions, Rainfall data, Topography of the area, Alignment etc. It also includes design calculation based on Indian Road Congress (IRC) codes.

During 8th Semester, remaining part of the Industry Defined Project has been completed. Wherein, construction aspects and use of various construction methodology and machineries have been studied in detail. Construction aspects include the use of various Materials, Machines, and Manpower. Also Quality Assurance (QA) & Quality Control (QC), aspects incorporated in the construction procedure have been studied and these are included in the project report. Testing of various materials is required for Quality Assurance and Quality Control of the flexible pavement and significance of the same has been studied during project work and documented in the project report.

The construction of flexible pavement include construction of various activities viz. clearing and grubbing, excavation, embankment and sub-grade construction, granular sub-base, wet mix macadam, prime coat, dense bituminous macadam and bituminous concrete. Method statements of each of these activities are presented in the project report.

SCOPE OF WORK

To study design aspects of the flexible pavement of real life project.

To examine construction methods & techniques and various construction machineries used in the project

To review problems areas faced during design and construction related to drainage, overtopping, high flood etc.

OBJECTIVES

The main goal of this study is to get an insight of the design and construction aspects and problems faced in the expansion/widening of roads. To evaluate the various tasks, methodologies which are undertaken for the design and construction of a Highway pavement.

To study how to achieve a sound and economical engineering design considering the various factors viz. climate; quality of local materials, construction technology, environmental conditions etc.

To study the complex design process considering realistic assessment of subgrade strength, traffic loads & traffic projection, environmental factors and several other factors.

Contd/-

 

To study the general design procedure based on the design of new pavement structure as per IRC: 37(Guidelines for the design of flexible pavements).

To study the Impact of use of Construction machinery on the construction schedule. Examining of critical aspects of soil and material testing.

To study the various steps taken for completion of the work within estimated budget and time and also maintaining the quality of work as per required specifications

OBJECTIVES

PROJECT DETAILS

Client . Gujarat State Road Development Corporation Ltd.

Concessionaire M/s. GVK Bagodara Vasad Expressway Pvt. Ltd.

Design Consultant M/s. Neel Construction Links Pvt. Ltd.

EPC Contractor M/s. GVK Projects and Technical Services Ltd.

Principal Lender Axis Bank Limited

Lenders Engineer M/s. Frischmann Prabhu (I) Pvt. Ltd.

Independent Consultant Engineer M/s. Egis India Consulting Engineers

Pvt. Ltd.

Project Length 101.900 Km

Contd/-

PROJECT DETAILS

Total Project Cost (TPC) Rs.1189 Crores

Project Start Date: 15/11/2011

Original Scheduled Completion date : 16/5/2014

Revised Scheduled Completion date : 16/5/2016

Project delayed due to Land Acquisition Problem

and delay in forest clearance.

Present status: Work in progress and 45% work

completed.

CONSTRUCTION METHODS AND EQUIPMENTS

The construction of six lane highway from Vasad to Bagodara is being carried out by M/s GVKBVEPL. The project work in 7th Semester included survey, traffic forecast and design of flexible pavement. Whereas during 8th Semester project activities on construction methodologies and construction machineries have been covered. During project work site visits and interaction with project team has been carried out on several occasions. Based on actual project details, documentation of the project report has been finalized.

MAJOR CONSTRUCTION ACTIVTIES:The construction work of six lane highway from Vasad to Bagodara includes following major areas:

Construction of Flexible Pavement Construction of Major bridges Construction of Rail Over Bridges (ROBs) Construction of underpasses & Culverts

CONSTRUCTION OF FLEXIBLE PAVEMENT

Construction of flexible pavement include following activities:

Site Clearing and grubbing, Excavation

Preparation of subgrade – scrubbing, rolling & compaction

Construction of sub base layers- Laying and compaction of Granular sub base in layers

Construction of base course- Laying and compaction of Wet Mix Macadam layer

Construction of wearing course- Laying and compaction of Bituminous layers

CONSTRUCTION OF MAJOR BRIDGES There are 3 major bridges on the proposed six lane highway from Vasad to Bagodara viz. (1) River Sabarmati, (2) River Andheri and (3) River Salvo

  CONSTRUCTION OF RAIL OVER BRIDGES (ROBS)

There are 3 ROBs on the proposed six lane highway from Vasad to Bagodara.

CONSTRUCTION OF UNDERPASS & CULVERTSThere are several box culverts and around 35 underpasses on the proposed six lane highway from Vasad to Bagodara. The box culverts are provided depending upon local discharge calculations.

CONSTRUCTION MACHINERIES

Site clearing - Back Hoe cum Loader Dozer Grader Roller Water Tanker Tipper Trucks

Preparation of subgrade – Excavator, Dozer, Tipper Truck, Motor Grader, Vibro Roller, Water Tanker Tractor.

Construction of sub base layers- Excavator Dozer, Tipper Truck, Vibro Roller, Water Tanker

Construction of base course-Wet Mix Plant Paver, Grader Vibratory Rollers, dumpers Water tanker, Back Hoe cum Loader.

Construction of wearing course- Hot Mix Plant Paver Vibratory Rollers Pneumatic Roller Bitumen Sprayer Dumpers

MATERIAL INVESTIGATION SURVEY

Road pavement component comprises of subgrade, sub base, base course and bituminous wearing course. Soil and aggregate are the prime material, which are available naturally and therefore its characteristics vary from place to place. In order to familiarize with the resources, properties and characteristics of these basic items, material survey is undertaken.

  Testing procedures being followed are in accordance with Indian

Standards, Association of American State Highways and Transportation Officials, and British Standards (IS/AASHTO/BS) wherever applicable to determine their suitability in accordance with MORT&H specifications, including those for stripping value and 10% fine value of aggregates.

Contd/-

The samples of soil from borrow area, sand from river and aggregate from crusher are collected and tested to determine its suitability in construction of various component of pavement. Soil samples collected from borrow area were tested for Gradation, Atterberg limit, Free Swell Index, Modified Proctor test, CBR. Parameters like Crushing strength, Impact value, Water Absorption, Specific gravity, Stripping value test and coating were carried out on the aggregate

The site was surveyed and various samples of soil, sand, aggregate etc. from carriageway, side shoulders, nearby quarry, and borrow area were collected and necessary tests have been carried out. The report of testing and suitability of materials are enclosed. The general terrain is plain along the proposed alignment. The detailed survey work for the materials have been carried out and borrow material was found suitable.

List of Test carried out for Soils and Aggregate

Sr. No. DescriptionA. Soil & Borrow Area

1 Natural Moisture Content2 Sieve Analysis of Granular Material3 Free Swell Index4 Atterbergs Limit5 Modified Compaction Test6 California Bearing Ratio

B. Granular material1 Sieve Analysis2 Atterberg limit3 Ten percent fine value Test4 Modified Proctor Test5 California bearing ratio Test

C. Aggregates1 Water Absorption2 Flakiness Index & Elongation Index3 Aggregate Impact Value4 Specific gravity test

FINE AGGREGATE REPORT  

The Gradation Test conducted as per I.S. 2386 part I and results of the same areas under:

 SAMPLE TAKEN: 1000 gm.

 

Sieve Size

Wt. of Soil Retained

Weight of Soil retained (%)

Cumulative% massretained

% of passing

Limit as perI.S. – 383ZONE – II

4.75 mm 104 10.4 10.4 89.6 90-1002.36 mm 81 8.1 18.5 81.5 75-1001.18 mm 216 21.6 40.1 59.9 55-90

600µ 224 22.4 62.5 37.5 35-59300µ 242 24.2 86.7 13.3 8-30150μ 88 8.8 95.5 4.5 0-10PAN 28Total 983

OTHER PROPERTIES

Sr.no Description Result I.S Requirement as per I.S 383

1 Zone classification: The above sample falls in

Zone –II --

2 Fineness Modulus 3.14 --

3 Uniformity co-efficient

from the semi log graphCu = D60/D10

2.340 --

4 Curvature co-efficient

Cc = D302 / (D10 x D60)

0.833 --

5 Bulk Density in gm/cc 1.520 --

6 Specific Gravity 2.578 --

SIEVE ANALYSIS OF GRANULAR MATERIALIS: 2720 (Part: 28)

Type of Sample Granular

Total Wt. Of the sample: 30015 g

I.S. Sieve Size

WeightRetained

PercentageRetained

Cumulative% Retained

% Passing SpecificationLimit

75 mm Nil Nil Nil 100 100 100

26.5 mm 7920 26.39 26.39 73.61 55 - 75

4.75 mm 14005 46.66 73.05 26.95 10 - 30

75 µ ` 6995 23.31 96.36 3.64 < 10 %

LIQUID LIMIT AND PLASTICITY INDEX(I.S: 2720 part – v)

Sr.No

No. of

Blows /

Penetration

CanNo.

Wt. of

can gmW1

Wt. of

can

& wet

Soil. gmW2

Wt. of

can

& dry

Soil.gm W3

Wt. of

water

gm(W2-W3)

Wt. of

Dry Soil

gm (W3-W1)

Moisture

content

%

(W2-W3)*100

(W3-W1)

1 18 10 22.30 46.84 43.32 3.52 21.02 16.74

2 21 23 26.15 51.52 46.98 4.54 20.83 21.79

3 23 13 24.81 55.98 50.02 5.96 25.21 23.64

4 26 14 28.50 59.10 52.83 6.27 24.33 25.77

Liquid Limit : 18.80%Plastic limit : -%Plasticity index : N.P. %

CALIFORNIA BEARING RATIO TEST (IS: 2720 (PART – XVI)

PENETRATION mm

DIAL GUAGE READING

LOAD kg CORRECTED LOAD kg

0.0 -- --

0.5 27 96.79

1.0 46 164.91

1.5 66 236.61

2.0 85 304.72

2.5 103 369.25

3.0 122 437.27

4.0 154 552.09

5.0 184 659.64

6.0 217 777.94

7.5 297 1064.74Proving Ring Factor: 3.585

CBR (Penetration At 2.5mm) : 26.95 % No. Blows – 56 Per LayerCBR (Penetration At. 5.0mm) : 32.09 % Volume of Mould – 2250 cc CBR For Tested Sample : 32.09 % Surcharge Weight Used = 5000 gm

ELONGATION & FLAKINESS INDEXI.S. 2386 (Part – I)

Fraction Sample

Weight

taken

(A)gm

Wt.

Retained

on

flakiness

gauge(B) gm

Wt.

Passing

flakiness

gauge

(A– B)

gm

Wt.

Taken(B)

Wt.

Retained

on

elongation

gauge

(C)gm

Wt.

Passing

on

Elongation

gauge(B – C)

Passing

IS Sieve,mm

Retained

IS Sievemm

1 2 3 4 5 6 7 863 5050 4040 31.5 742 667 75 667 627 40

31.5 25 946 885 61 885 820 6525 20 390 345 45 345 310 3520 16 300 273 27 273 244 2916 12.5 497 412 85 412 363 49

12.5 10 485 399 86 399 298 10110 6.3 434 296 138 296 216 80

Total 3794 517 3277 399Flakiness Index-: 517/3784= 0.136= 13.6% Elongation Index-: 399/3277= 0.1281= 12.81%

AGGREGATE IMPACT VALUEI.S. 2386 (Part – IV)

DESCRIPTION SAMPLE – 1

SAMPLE – 2

Total Weight of oven dry sample passing

12.5 mm sieve and retained on 10 mmSieve (W1),gm

342 356

Weight of portion passing 2.36 mm sieve,(W2)gm

60 57.5

Weight of portion retained 2.36 mm

sieve,(W3)gm

282 298.5

Aggregate Impact Value = (W2/W1)x100 %

17.54 16.15

Aggregate Impact Mean Value = (1+2) / 2 %

Average 16.85

Acceptance Criteria Specified: 30% Max.

Water Absorption TestI.S. 2386 (Part – III)

Sr.no Description Unit TestA Weight of Saturated Surface Dry

Sample(After 24 hrs. immersed in water)

Gm 600

B Weight of Surface Dry Sample(After 24 hrs. dried in oven)

Gm 594.5

C Water Absorption(A – B) / B * 100

% 0.925

Name of Sample: 18 MM

Source: SevaliaInitial weight of Sample taken: 600 grams

PROBLEMS FACED DURING CONSTRUCTION

Some of the construction issues include workforce considerations, safety, time constraints, and the changing nature of the work. Non-construction challenges that Construction Managers face that are part of the business landscape include legal issues, government regulations, environmental concerns, and socio-political pressures.

  The Bagodara-Vasad Highway passes through flood plain of river Sabarmati.

The flood plain of the river Sabarmati gets inundated in a stretch of more than 10 km during high flood event of 100 year return period. This high flood level poses several problems for deciding formation level of the highway, provision of appropriate drainage, provision of cross-drainage work etc.

  Flexible pavement is more susceptible under overtopping during heavy rain.

Also embankment for providing formation width is equally susceptible to overtopping during heavy rain. Rutting and erosion of embankment virtually lead to failure of road formation work.

The existing pavement has riding surface fair to poor because it has a various surface defects such as cracking, bleeding, potholes, edge erosion etc. thus strengthening of existing pavement is needed for required design period.

  Overtopping of the carriageway caused by the rain water during monsoon

season causes damage to the road and vehicles are stranded and it leads to long spells of traffic.

  Other problems include the significant negative, environmental impacts if any

on account of the implementation of the project. There are certain benefits to the human and natural environment as a result of improvement of Bagodara – Wataman – Tarapur – Vasad road. The traffic currently using this section of SH-8 comprises of local transportation and long distance through traffic. These create traffic congestion leading to increase in travel time; higher vehicle operating costs and affects road safety. Improvement of this section will mitigate all these problems and will provide comfortable and efficient road transportation in the area.

Following were the possible solution given for the above mentioned problems:  

For the water logged area Longitudinal & transverse drains will be cut to dewater the area through sumps, for identification of artesian holes & to facilitate removal of unsuitable materials.

After dewatering, all rotten vegetation, marsh etc. will be removed grid wise which will be disposed off away from the site by tippers. When the area will be satisfactorily cleaned of the unsuitable soil, excavated ground levels will be jointly recorded.

Water will then be allowed to raise upto its maximum head so that a standstill condition is achieved. Rate of rise of water will be recorded regularly until zero rises is observed.

The boundary of the fully flooded area will then be measured and the water level will be recorded

Crushed GSB granular mix will then be filled-up (without any stone dust / filler) by side tipping & dozing.

After filling every layer, compaction will be done by running excavator crawlers and then by vibratory compactors depending upon the firmness of the ground.

 Granular filling will be continued upto the above mentioned water level upto maximum head ignoring afflux (raised water level), whatsoever.

After compact granular filling, dewatering of the area will be done through drains & sumps.

The top surface will then be made in proper level & grade & also in required compaction, dry & firm so that it becomes ready to receive the next higher layer of embankment in dry condition.

For the strengthening of base the filling of cracks and bituminous spray grout proposed to complete the required base before overlay.

To restore the area washed off during flood it is proposed that the section of road will be dug out and rebuilt with new crust layers.

PROBLEMS FACED DURING PROJECT EXECUTION

Delay in handing over of required land for ROW due to Land Acquisition Problem

Delay in Forest clearance for the project

Delay in finalization of High Flood Level in Flood Plane portion of Sabarmati River has resulted in delay of adjoining road construction.

So far 45% work is completed. But work is suspended due to financial problem of GVKBVEPL.

PROBLEMS FACED DURING PROJECT EXECUTION

GSRDC is planning to provide financial support to GVKBVEPL to overcome financial crisis.

Presently only maintenance of the completed road work is being carried out GVKBVEPL.

FIELD VISITSFIELD VISITS

Field visits have been carried out during different phases of the project.

During the visit interacted with technical wings of M/s GVKBVEPL Ltd.

Study of design report, design drawings and method statements.

Field tests, laboratory tests of various materials have been witnessed during site visit

Use of construction machinery have been observed during visit

WMM Top Laying and spreading using paver finisher Dt: 13/3/2015

USE OF CONSTRUCTION MACHINERIES

Compaction of WMM layer Dt: 13/3/2015

HOTMIX PLANT Dt: 13/3/2015

USE OF CONSTRUCTION MACHINERIES

USE OF CONSTRUCTION MACHINERIES

Spreading of Bituminous layer using PaverDt: 13/3/2015

USE OF CONSTRUCTION MACHINERIES

Finished road surfaceDt: 13/3/2015

Compaction of DBM layer using rollerDt: 13/3/2015

Staging work under progress9/9/2014

BRIDGE UNDER CONSTRUCTION

Bridge Superstructure completed9/9/2014

BRIDGE APPROACH CONSTRUCTION

RE Wall ConstructionDt: 13/3/2015

Precast Friction Slab & Crash BarrierDt: 13/3/2015

UNDERPASS CONSTRUCTION

Dt: 13/3/2015

BOX CULVERTCONSTRUCTION

5 cells box culvert construction9/9/2014

CONCLUSIONS The Bagodara Vasad highway is a part of SH-8, which provides key

connectivity to two National Highways (NH), viz., NH-8A (Ahmedabad-Rajkot-Probandar), and NH-8 (Mumbai-Delhi).

Gujarat State is a highly industrialized state in India and has vast industrial developed area spread over the whole of the state. The project highway caters to commercial traffic from industrial clusters in Bhavnagar, Savli, Sanand, Anand and ports in Saurashtra region (Pipavav, Porbandar, Mundra and Kandla).

Also, it is the shortest link connecting Saurashtra/Kutch region to the highly industrialised regions of Surat, Vadodara, Ankleshwar and Mumbai.

Six laning of Bagodara Vasad Highway Project will reduce travel time and vehicle operating cost significantly.

The potential for progress will be a result because the transportation of goods from one place to another will be good and will lead to a booming economy and higher income for the government.• Accessibility to remote areas will not become a major problem.• It would become easy for people to migrate from one place to another.• There is faster transportation of goods• Labor employment will rise when highways are being built giving

people more jobs meaning more income.

INDEX

TITLE Page No.

Acknowledgement 3

Abstract `4

List Of Figures 5

List Of Table 5

Table Of Contents 6

List Of Figures

Figure 1 13

Figure 2 14

Figure 3 14

Figure 4 36

Figure 5 36

Figure 6 36

Figure 7 36

Figure 8 36

Figure 9 36

List Of Tables

Table 1 44

Table 2 45

Table 3 46

Table 4 46

Table 5 47

Table 6 48

Table 7 49

Table 8 50

Table 9 50

INDEX

TABLE OF CONTENTTABLE OF CONTENT

TITLEPage

NoCHAPTER 1: INTRODUCTION 8

1.1 General Background 8

1.2 Objectives of the project 9

1.3 Main components of methodology 10CHAPTER 2: DETAILS OF PROJECT 112.1 General 112.2 Project corridor 122.3 Project scope 14

CHAPTER 3: CONSTRUCTION METHOD AND EQUIPMENTS 15

3.1 Major Construction Activities 15 3.1.1 Construction of Flexible Pavement 15

3.1.2 Construction of Major bridges 15 3.1.3 Construction of Rail Over Bridges (ROBs) 16 3.1.4 Construction of Culverts 16

3.2 Method Statements 16

3.2.1 Method Statement For Clearing And Grubbing 16

3.2.2 Method Statement For Excavation 18

3.2.3 Method Statement For Embankment And Sub-Grade Construction 19

3.2.4 Method Statement For Granular Sub-Base 21

3.2.5 Method Statement For Wet Mix Macadam 22

3.2.6 Method Statement For Laying Of Prime Coat 25

3.2.7 Method Statement For Dense Bituminous Macadam 26

3.2.8 Method Statement For Bituminous Concrete 30

3.2.9 Method Statement For Road Markings 33

3.2.10 Machinery used for Road Construction 35

3.3 Methodology Of Carrying Out Structural Concrete In Bridges And Culverts 36

3.3.1Transporting, Placing & Compaction Of Concrete 39

CHAPTER 4: MATERIAL INVESTIGATION SURVEY 40

4.1 Introduction 40

4.2 Material Survey 40

4.3 Lead for materials 41

4.4 Soil from borrow area 41

CHAPTER 5: PROBLEMS FACED DURING CONSTRUCTION 50

5.1 Problems Faced 50

5.2 Possible Solutions 51

CHAPTER 6: CONCLUSIONS 52

REFERENCES 53

THANK YOUTHANK YOU