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1. INTRODUCTION Soma Enterprise Ltd. is one of the fastest growing infrastructure developers in India focused on construction and development of core infrastructure projects in the transportation, hydel power and water resource sectors among others. An International Container Transshipment Terminal (ICTT) is being developed at Vallarpadam Island by the Cochin Port Trust. To cater to the huge additional transport requirements for cargo movements, Road and Rail connectivity to the ICTT are being taken up concurrently by Central government and State government to ensure smooth connectivity of Vallarpadam Island with the main land. The National Highways Authority of India (Ministry of Road and Surface Transport and Highways) has been entrusted with the work of Providing the Four Lane NH connectivity to ICTT at Vallarpadam, Cochin, Kerala. The project road provides the shortest path of access to NH-47 and NH-17 from ICTT without entering Ernakulam city. This new alignment connects several islands by bridging the backwaters and traverses through new reclaimed area for avoiding the traffic through city. The challenging Road connectivity project with a project outlay of Rs 329 crore has been awarded to ‘M/s Suncon-Soma Joint venture ‘on 18 th May 2007. The site camp office of soma enterprises is situated at Godown road Cheranelloor ernakulam. In this industrial training report a brief idea of the organisation setup, its functioning is done. Also a study 1
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Page 1: Report

1. INTRODUCTION

Soma Enterprise Ltd. is one of the fastest growing infrastructure developers in India focused on

construction and development of core infrastructure projects in the transportation, hydel power

and water resource sectors among others.

An International Container Transshipment Terminal (ICTT) is being developed at Vallarpadam

Island by the Cochin Port Trust. To cater to the huge additional transport requirements for cargo

movements, Road and Rail connectivity to the ICTT are being taken up concurrently by Central

government and State government to ensure smooth connectivity of Vallarpadam Island with the

main land. The National Highways Authority of India (Ministry of Road and Surface Transport

and Highways) has been entrusted with the work of ‘Providing the Four Lane NH connectivity to

ICTT at Vallarpadam, Cochin, Kerala. The project road provides the shortest path of access to

NH-47 and NH-17 from ICTT without entering Ernakulam city. This new alignment connects

several islands by bridging the backwaters and traverses through new reclaimed area for

avoiding the traffic through city. The challenging Road connectivity project with a project outlay of Rs

329 crore has been awarded to ‘M/s Suncon-Soma Joint venture ‘on 18th May 2007. The site camp

office of soma enterprises is situated at Godown road Cheranelloor ernakulam.

In this industrial training report a brief idea of the organisation setup, its functioning is done.

Also a study regarding store functioning, prestressing, quality control measures , girders

launching, various equipments used in construction, labour source, material source and ground

improvement techniques in highway work are included.

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2. SALIENT FEATURES OF PROJECT

The Project Road Length is 17.2 km and total length of bridges is 2.93 Km which includes 23

major bridges. A two lane Flyover at the starting chainage of the project road at Kalamassery

and eleven numbers of four lane bridges. The four lane bridges were designed with each two-

lane bridge resting on individual foundations.

LocationBridge Length(m)x no. of carriageway

Fly-Over 54.05x1Br-1 150x2Br-2 95x2Br-3 240x2

Combined bridges 4-5-6

420x2

Br-7 890x2Br-8 97x2Br-9 60x2Br-10 40x2Br-11 60x2Br-12 830x1

Total Length(m) 2936.05

Table1: Fly over and Bridge length details

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3. QUALITY ASSURANCE PLAN AMENDMENT RECORD

Quality assurance amendment plan (QAP) describes in brief about the project through a strategy

by placing quality as the priority. It also specifies the quality practices such as operating policies,

quality systems procedures, work instructions and method statements etc which is to be followed

in meeting the clients quality requirements. The QAP is prepared in pursuant to sub-clause 105.3

of MORT & H (Ministry of Road Transport and Highways) Technical specification. The quality

manual will be complying with IRC –SP-57 (Quality system for roads) and quality assurance

manual of NHAI.

QAP is reviewed every 6 months with incorporation of relevant updating or changes. It includes

contract information such as contract title, contract sum, date of possession, contract documents,

project description, project organisation, project admistration, statutory and regulatory

requirements, occupational safety, health and environment safeguard details, method statement

for site clearing, grubbing and demolition works, machinery and equipment, laboratory testing

details etc. Organisation chart of ICTT Project is given below:-

Figure: 1 Organisation chart of ICTT Project

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SITE MANAGEMENT

Rock Processing Department

Finance Department

Administration/ Human Resource

PROJECT MANAGER

Quality Control Department

Safety Department

DY.PROJECT MANAGER

IPC & Billing

Fabrication Department

Plant & Machinery Department

Store/ Procurement

Planning / Contracts

Surveying DepartmentHighway Department BridgesStructural Department

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Project main operating policies and related Quality management system procedures includes:-

Control of documents, Control of quality records, plant and equipment, safety health and

environment policy, internal communication, infrastructure(site camp), work methodology,

planning of project realization, control of test laboratory, approval of materials, management

review, Quality audits, control of non conformity product, monitoring and measurement of

product, control of key personal selection, contractor quality control etc. Type and Frequencies

of meetings at construction stage are given below:-

SLNo: TYPE FREQUENCY CHAIR PERSON ATTENDEES

1. Monthly progress meeting

MonthlyProject Director

(NHAI)

- Project Director

- Team Leader

- Project manager

2.

Contractors internal

coordination meeting

WeeklyProject Manager

- All Section Heads

Table 2: Type and Frequency of meeting at construction stage

Figure 2:- Organisation Chart of key persons linking with consultant staff

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Project Manager

Material Engineer

Surveyor

Q C Engineer

Bridge Engineer

Field Engineer

Highway Engineer

Field Engineer

Quantity Surveyor

Surveyor

Quantity Surveyor

Field Engineer

Sr. Highway Engineer

Field Engineer

Bridge Engineer

Lab Technicians

Sr. Material Engineer

Team leader – CSC (LASA)

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4. DEPARTMENT WISE DETAILS

4.1 QUALITY DEPARTMENT

The chief person in charge of quality department is the material engineer. The quality department

conducts test on soil, aggregates, bitumen, prestressing strands etc. All materials to be used, all

methods adopted and all works performed shall be strictly in accordance with the requirements

of MORTH technical specifications. The field laboratory at camp is approved by the consultant

Engineer in order to carry out all required tests and Quality Control work as per Specifications.

The field laboratory should be as per section 100:121 given in technical specification manuel.

Quality control for road work is as per section 900 given in technical specification. In quality

control lab sample tests are carried out as per specifications and a report is made. Based on the

report, approval for material is sanctioned by the material engineer. Third party test are

conducted in some of the external labs (engineering colleges) of CUSAT, MA College, Govt

Engg College Thrisur. Some materials like bitumen, mild steel, prestressing strands, admixtures

etc manufactures test certificate (MTC) and external labs test certificate are considered.

Calibration of gauges is done once in 6 months from Bangalore University. After conducting

tests RFI (Request For Inspection) is made to the consultant engineer for approval. Organisation

chart of Quality department is shown below.

Figure 3: Organisation chart of Quality control department

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PROJECT MANAGER

MATERIAL ENGINEER

QUALITY ENGINEER IIQUALITY ENGINEER I

QUALITY ASSISTANTSQUALITY ASSISTANTS

LAB ASSISTANTSLAB ASSISTANTS

HELPERS HELPERS

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The consultant (LEA Associate) official has an office in the quality department. It is for close

inspection and approval for RFI. The office lay out is as given below:-

LEA ASSOCIATES STAFF SETUP

Figure 4: Organisation Chart of LEA Associates

Approval for quarry source and materials are given by consultant engineer. In some case

purchase records are checked for usage assurance. For soil Grain size analysis, Atterbergs limit,

Modified proctors compaction test, Free Swell Index, California bearing ratio, CBR Value V/s

Density graph etc are carried out and approved by contactor representative as well as consultant

representative. Samples of concrete cubes are taken from site for compressive test and slum test

are also conducted for workability. Sand replacement test is conducted at road site and report is

submitted to QC department. Non destructive test such as Ultra sonic pulse velocity are

conducted as third party test in case of any major surface damage.

4.2 SAFTEY DEPARTMENT

Safety department at camp office reports site accidents to head office if fatal accident it is

reported to district collector by HR department. Safety department organisation structure consists

of 5 personals as given below:-

Figure 5: Organisation chart of safety department

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MATERIAL MANAGER

QUALITY ENGINEER

LAB TECHNICIAN LAB TECHNICIAN

SAFETY ENGINEER

SAFETY ASSISTANT - I

SAFETY SUPERVISOR

SAFETY ASSISTANT - II

SAFETY SUPERVISOR

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Monthly health, safety and environment report is kept as record, it includes number of fatalities,

loss time accidents (LTA), loss time injuries(LTI),non loss time accidents, first aid case, near

miss incidents, boat barge accident, man days lost due to accident, compensation case resolved

and paid to workmen etc. Safety manuel for company includes site letter, sign boards,

barrications. Checklists are made for laboratory, cranes and machinenary. Tool box

meetings(TBM) are conducted per week. Medical camps are organized at nearby hospitals and

health centers. National Safety Day is celebrated on march 4 th every year. Mock drills are

conducted, training programs, poster competition, safety quiz, awareness camps, Awards are

given for best safety practice engineer, supervisor, worker at site, good construction site and

good housekeeping site. Penalty slips are given for those personals, who violate the safety norms

and their records are kept at safety department and accounts.

Some of the special safety materials include landing mats, safety net, reflective jackets, safety

nets, fire extinguishers mainly used is DPC (Dry chemical powder). Electrical accidents are

recorded more at site, electrical inspection comes under one the important safety measures taken

on behalf of safety department.

4.3 STORE AND PURCHASE DEPARTMENT

Store and purchase department keeps records of material intend quantity, stock at store, balance

to procure. The store department purchase major item under ERP(enterprise resource planning)

through regional office at banglore. Enquiry, getting quotations, price comparison statement etc,

are made before purchase order of a material. Item receipt such as material receipt note(MRN)

and Goods receipt note (GRN) are received and bills are send to accounts department. The store

department follows weighted average system which is calculated by dividing amount to total

quantity. International suppliers are for bauer machines and band drain. The local tax for material

purchase is 12.5%. Identification tags are provided for each items on each rack in an alphabetic

order.

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Figure 6: Organisation chart of stores

The job responsibility of senior associates are keeping receipts of Steel Structural Material, HSD

verification, Bill Verification , reconciliation, weigh Bridge In charge & Preparation of Day

Book. The job responsibility of junior associates are issue of Civil Materials, issue of Spare and

ERP Entery, issue of HSD (Diesel Tanker) Night & day, bill Cheking.ERP Entry etc (Receipts

& Issue), issue Shuttering Material Weigh Bridge Operator, ERP Entery & Aggregate B/P,

weigh Bridge , night Shift, aggregate, receipts of Civil, Cement, steel etc, and Verification &

ERP Entery, to collect Quotation, vendor selection communication, Comparison of quotations,

making P.O. in ERP.

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Procurement Asst. Manager Issues - Civil & HSD etc

Receipts with verification of Materials

Asst. Manager & Sr. Associate

Issues - 'A' Class materials

Sr. AssociateJr. Associate

Manager

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4.4 HUMAN RESOURCE AND ADMISTRATION DEPARTMENT

Figure 7: Organisation chart of HR department

The total strength of site camp is around 1300. As in other organisation, the public related issues,

salary- bonus, office management, training facility, labour food and accommodation etc comes

under HR Department.

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HR MANAGER & ADMISTRATOR

Asst Manager HR & Admistration Receptionist

SupervisorsSenior Assistant I

Public Relation

Senior Assistant II

Pay sheet, Salary sheet

ERP, Bonus etc.H R Trainees

Mess both North Indian and keraliteAccommodation

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4.5 MECHANICAL DEPARTMENT

Mechanical department is headed by soma mechanical department vice president at head office

Delhi. The general manager is the responsible head for ERP (enterprise resource planning). The

information source is from daily log sheets, trip sheets, DPR (Daily progress report) etc.

Figure 8: Organisation chart of mechanical department

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SENIOR MANAGER

MANAGER –I IMANAGER- I

ERP

(Enterprise resource planning)

DEPUTY MANAGER II

DEPUTY MANAGER I

MACHINERY PLANT DIVISION

GENERAL MANAGER

SMDVP

(Soma Mechanical Division Vice President)

MECHANIC MECHANIC ELECTRICIAN

MARINE DIVISION

BATCHING PLANTS

TRANSPORT DIVISION

GARRAGE

OPERATOR

DRIVERS & MECHANIC

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4.5.1 LIST OF EQUIPMENTS DIVISIONWISE

4.5.1.1 TRANSPORT DIVISION:

SL

NoVEHICLES NO: PURPOSE

1. Four Wheelers 24 Staff transportation

2. Ten Tyre Tipper 55 Material movement

3. Six Tyre Tipper 7 Material, Labour, machinery movement

4. Water Tanker 10 Water supply

5. Transit Mixer 12 Shifting of concrete

Table 3: Transport division Vehicles details

4.5.1.2 PLANT DIVISION

SL No

EQUIPMENT NO: PURPOSE

1.Hot Mix Plant (124tps

capacity)1 Asphalt aggregate mixing

2. Dense Bitumen Plant 1 Producing bitumen concrete

3. Wet Mix Macadam Plant 1 Producing wet mix macadam

4. Batching Plant 3 Concrete production

5.Boom Placer (concrete

pumps)7 Concrete placing

Table 4: Plant equipment details

4.5.1.3 MARINE DIVISION

SL No

EQUIPMENT NO: PURPOSE

1.Barges (250 ton capacity)

Barges (75 ton capacity)28

Precast member transportConcrete transit mixer transport

2. Tug Boats 4 Pulling

3. Speed boats 4 Pulling / transport

Table 5: Marine division equipment details

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4.5.1.4 CRANES

SL No

EQUIPMENT NO: PURPOSE

1. 85 Ton crane 2 Precast spliced girder erection

2. 30 Ton crane 2 hoisting

3. 12 Ton crane 2 Member hoisting

4. Mobile tower crane 60 ton 3 hoisting

Table 6: Crane types

Engine maintenance for machines are done after 250 hours. Maintenance is usually done after specific kilometers or at the time of breakdown, for major problems nearby local garages are depended.

4.5.1.5 EXCAVATORS

SL No

EXCAVATORS NO: PURPOSE

1. Girder launching 5 launching

2. Bull Dozer 4 Earth moving

3. Roller 10 rolling

4. Paver 2 paving

5. Back hole Loader 2 loading

6. Wheel Loader 5 loading

Table 7 : Excavators details

4.5.1.6 GENERATORS

SL No

GENERATORS NO: PURPOSE

1. 500 KV 1

Power supply

2. 250 KV 1

3. 160 KV 1

4. 125 KV 1

5. 62.5 KV 1

Table 8: Power source details

5. SOURCE OF MATERIAL

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SL. No:

Source of material Source

1. Aggregates / Sand M/s Vijaya crusher, Malayattoor

2. G S BM/s Cochin Granites – Vengola perumbavoor

3. Cement-Ultra tech OPC 53 grade –Andrapradesh-Dalmia OPC 53 grade dalmia-Ramco OPC 53 grade

4. TMT Steel ,CRS Fe 415 / Fe

500

-SAIL - Durgapur-RINL - Vizag-SRMK- Steel Rolling Mills Kolkatta

5. RCC PipesAswathy Spum pipes -Aroor

6. Prestressing cable TATA Steel ltd Madhya Pradesh

7. BearingMetcogroup Engineering pvt .Kolkatta

8. Expansion joint Metcogroup Engineering pvt.

Kolkatta

Table 9: Material source details

6. SITE VISIT REPORT

6.1 HIGHWAY WORK

Highway work starts from site clearance, earthwork erosion control, sub base, base (non

bituminous), surface course (bituminous layer). Details regarding these operations are mentioned

in the MORTH specification. In highway road construction first step after site clearance is to

make the embankment layer the maximum dry density of this layer is 95%. Above embankment

layer sub grade layer is made, total depth of this layer is 500 mm which include two 200 mm

layer and one 100 mm layer. Next layer is the granular sub base layer this layer is also called

drainage layer having maximum plasticity index 6 and CBR value of 30. Then WMM(wet mix

macadam) layer is laid, this is called cationic emulsion prime coat.WMM layer should be

compacted up to 98%.The layer given over WMM is DBM (dense bituminous macadam) layer,

this layer act as a stress absorbing membrane. The final coating is with BC (bituminous concrete)

it is also called modifier bitumen layer.

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6.1.1GROUND IMPROVEMENT

Extensive ground improvement activities have been necessitated due to very poor subsoil

conditions prevailing over the alignment, most of which were additional works. Ground

improvement works In the entire 6.7kms of reclaimed area are carried out by advanced

engineering techniques of installing Prefabricated Vertical Drain (PVD) treatment and by

Stone Column method in order to ensure the proper consolidation of the reclaimed areas , prior

to commencing of highway works. This project is the first NHAI project to introduce Stone

column method for ground improvement.

6.1.2 PVD (Prefabricated Vertical Drain) TREATMENT

The ground improvement technique using prefabricated vertical drains (PVD) is one of the most

suitable methods to avoid settlement in week sub soil areas. The sole purpose of vertical drain

system is to shorten the drainage path of the pore water from a low permeable layer to free water

surface or to pre-installed drainage layer, thereby accelerating the rate of primary consolidation

or the process of settlement. Application of ground improvement method using pre fabricated

vertical drains (PVD) coupled with surcharge or preloading can significantly shorten the period

of primary settlement.

6.1.3 CHARACTERISTICS OF PVD

PVD is a prefabricated material consisting of a plastic core covered by synthetic geotextile “filter

jacket”. Two main components of PVD are core and the filter jacket. The core serves as a

longitudinal flow path along the drain and the filter jacket allows water to pass into the core

while restricting intrusion of soil particles.

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Photo 1: PVD equipment Photo 2: PVD bands at site

Position equipment and Mandrel driving Mandrel extraction PVD cuttinganchor plate installation

Figure 8: Different stages of PVD installation

6.1.4 PVD EQUIPMENT

PVD installation equipment can be developed to suit the soil condition, installation depth,

specified scope of work and required production rate. Technical data of typical medium-sized

PVD installation equipment and accessories are shown below.

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Installation Rig

Type of Base Machine: Excavator of suitable model CAT EL200B or larger model

Size (CAT EL200B): 3.18m x 4.45m

Weight (CAT EL200B): 20 ton

Pushing Force: 5.5 – 20 ton

Mandrel Lifting and Pushing: Hydraulic gear drive

Mast Height: 8m

Typical Mandrel Dimensions

Weight of Guide and Mandrel: 1.5 to 4 ton

Length of Mandrel: 12 to 20m

Cross-sectional Area of Mandrel: 60 to 70 cm2

Maximum Installation Depth: 11 to 19

Figure 9 :Typical Time V/s settlement graph

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0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.40

0.5

1

1.5

2

2.5

3

3.5

4

PVD with surchargePVD without surchargewithout PVDrequired settlement

SETTLEMEN

TIME

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A typical Time settlement curve of soft clay showing significant time reduction achieved by

applying PVD with surcharge loading.

6.1.5 QUALITY CONTROL IN PVD INSTALLATION

Quality control in installation of PVD can be achieved by below methods:-

Use appropriate size of Mandrel and anchor plate to minimize soil disturbance

Use Mandrel with adequate stiffness to maintain verticality

Applying appropriate penetration rate to avoid significant bending

Checking verticality during installation

PVDs are installed in either square or triangular patterns. A square pattern is simpler for setting out in the

field. Triangular pattern however provides more uniform consolidation between drains. Triangular pattern

is adopted for present project site conditions.

6.1.6 QUALITY CONTROL TEST FOR PVD MATERIAL

Various quality control test for PVD material are Apparent opening size test, Puncture resistance test ,

Burst strength test, Trapezoidal tear strength test, Grab tensile strength test, Discharge capacity (plain and

triaxial) test, Density of filter fabric test etc.

Figure 10: Pattern of PVD installation

6.2 BRIDGE NO: 7

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Bridge no.7 comprises of two parallel two-lane bridges, each having 33 spans, connecting the

islands of Kothadu and Mullampilly. The length of each bridge is 882.6m. It is the longest and

most challenging bridge of the ICTT-Vallarpadam port connectivity project. The bridge is being

constructed partially on water and balance on land. Most of the areas (low lying areas) are

immersed in water during high tide and the soil is marshy. Available means for transportation of

man, machineries and materials to the island was through barge and boat only.

In the water span area operation sequence of splice girder are:- a) Casting of segments in the

camp casting yard, b) transportation of segments through barges, c) Placing of girder segments in

position over plate girders, d) Stitching of 5 splice segments, e) Plate girder shifting.

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Quantity Concrete(m3) Steel(MT):Weight(MT):

End splice : 9.77 0.838 25

Middle splice : 12.00 1.000 30

Intermediate splice : 9.775 1.041 25

Grade of concrete: M-50

Figure 11: Splice girder details

Time cycle for pre casting of spliced segments:

i. Reinforcement works…………………….12 hrs

ii. Cable profiling……………………………4 hrs

iii. Shuttering…………………………………4 hrs

iv. Concreting………………………………..2 hrs

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v. Waiting period……………………………24 hrs

Total : 46 hrs, say 2 days

6.2.1 PRE STRESSING

Concrete reinforced by either pre tensioning or post tensioning, allowing it to carry a greater load

or span a greater distance than ordinary reinforced concrete. In pre tensioning, lengths of steel

wire or cables are laid in the empty mold and stretched. The concrete is placed and allowed to

set, and the cables are released, placing the concrete into compression as the steel shrinks back to

its original length. In post tensioning, the steel in the concrete is stretched after the curing

process. Prestressing places a concrete member in compression; these compressive stresses

counteract the tensile bending stresses of an applied load. The process was developed by the

French engineer Eugène Fressinet in the early 20th century. Post tensioning is carried out at

bridge no:7 as per given in the good for working drawings. Section 1800 of MORTH also gives

all information regarding prestressing operations. First stage stressing is done after 7 th day of

casting of girders and second stage is done after 28 days. A stressing report is made by engineer

showing the calculations of elongation of prestressing strands and submits it to consultant

engineer for cross checking.

Photo 3: Multi pull Jack operating Photo 4: Girder on stressing

7. DISCUSSION

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From the initial stage of this infrastructure project soma enterprise has encountered many

challenges both technical point of view as well as construction management point of view. If we

take the list of technical obstructions faced the re engineering proposal of bridge no:7 is the

major example. In the contract drawings, the bridge superstructure was designed as 2x26 spans

of RCC Voided slabs and 2x8 spans of M-40 PSC Box girder. Considering the site conditions

the planning engineers put forward re-engineering proposal for super-structure of Bridge no: 7 to

use precast I-girders in 33x2 spans(one span reduced) in place of cast-in-situ RCC Voided slab

and PSC box girders. This technique is being adopted to facilitate faster construction and lesser

problems to NHAI as the closure of this navigational channel leads to non-passage of passenger

boats/vessels. In case of cast-in-situ construction, as proposed in DPR, all the activities are

sequential and cannot be done in parallel which many lead to delay. Some of the challenges

faced in management part are delays in obtaining sanction to operate the crusher and quarry,

restrictions by the district administration, preventing movement of our vehicles and machinery

during day time through road, so maximum transportation is being done during night, frequent

hindrances to work by the strong labour unions and the local people who were affected during

land acquisition. Logistics across islands is one among the other challenges of the project. The

access to the islands was through water only. To facilitate land access, number of temporary

bridges including one Bailey bridge and 6 kms of temporary approach roads, incurring huge cost.

Disputes so far in project is regarding utility shifts pre construction activities minor disputes in

sub contracting and local labour union issues occur often but all those are negligible.

8. CONCLUSION

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During this training period overall project big picture and minute details that go in to make it a

reality study was aimed, but time restrictions mentioned in academic curriculum is not enough

for such a challenging project. In this short period of training a rough idea about planning,

various departments, new materials, labour source, construction equipments, method of work

execution etc are obtained.

9. REFERENCE

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1. Quality assurance plan amendment record.

2. Ministry of Road Transport and Highways published by the Indian Roads Congress on behalf

of the Govt. of India, Ministry of Road Transport and Highways

3. Good for working drawings.

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