Six Lan Road Construction

INDEX

SERIAL NO.

CHAPTER NAME

PAGE NO.

1.

2.

3.

4.

5.

6.

7.

INTRODUCTION

SURVEY

CONSTRUCTION

LABORATORY

FEATURES

ADVANTAGES

PHOTOGRAPHS

4

7

8

22

23

24

25

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Chapter 1

INTRODUCTION

NHAI: The National Highways Authority of India was constituted by an act of Parliament, the National Highways Authority of India Act, 1988. It is responsible for the development, maintenance and management of National Highways entrusted to it and for matters connected or incidental thereto. The Authority is operational since Feb, 1995.

NHDP: National Highways Development Project is being implemented in 4 phases I, II, III & V at present. The present phases under Phase I, II & III envisages improving more than 32,754 km of arterial routes of NH Network to international standards.

About The Project: Six laning of the existing highway so as to cater to the rising traffic demand. Provision of service lanes on both side and necessary amenities.

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o The Project Details –Length of Road: 225.6 KmConcessionaire: Pink City Expressway Private LimitedIndependent Engineer: SNC Lavalin - Aarvee Associates

JVDate of Signing: 6th June 2008Appointed date: 3rd April 2009Completion Period: 912 days from the Appointed Date.Concession Period: 12 years from the Appointed Date.

o Project Technical Details –

Length of Project Highway: 225.600 Km. (Haryana – 64.40 Km, Rajasthan – 161.20 Km)

New Proposed Grade Separator/Flyover: 44 Locations. Grade Separator (Rehabilitation):2 Locations. Elevated Structure at Kotputli Urban area:1 Location (9 x 31m) Entry & Exit Ramp : 145 locations Proposed Service Road: 325.194 Kms Existing Service Road: 101.550 Kms Major Bridges:

Reconstruction (on RHS): 3 Nos.

Rehabilitation: 4 (2 + 2) Nos.

Minor Bridges: Reconstruction :7

New on both side Service Road :23

Widening with Rehabilitation: 24

Road Over Bridge (Widening): Length: 44.85m, Span Arrangement: (1x12.75) + (1x19.35) + (1x12.75)

At Grade Junction

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LHS: 05 Locations

RHS: 02 Locations

Both side : 06 Location

Cross Drainage and Structures Pipe Culvert +Box +Slab Culvert+ cattle pass to be widened :195

Culverts to be reconstructed : 11 New Culverts : 9 Pedestrian Underpasses: 38 Nos.

Toll Plazas: 3 nos. Toll Plaza No. 1: Km. 115+600 at Shahjanpur

Toll Plaza No. 2: Km. 211+000 at Manoharpur

Toll Plaza No. 3: Km. 241+000 at Daulatapur

Proposed Bus Lay Byes: LHS: 25 Locations

RHS: 26 Locations

Proposed Truck Lay Byes: LHS: 8 Locations.

RHS: 8 Locations.

Chapter 2

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SURVEY

Surveys for roads and streets involve both fieldwork and office work.  The  extent  of  each  type of  work  depends  on  the magnitude  and  complexity of the job. Some phases of the work may be done either  in  the  field  or  in  the  office,  and  the decision as to the exact procedures to be followed will  be influenced  by  the  number  of  personnel available and by the experience and capabilities of  the  individuals  involved.

Profile leveling and Cross sectioning is carried out along the length of the proposed road.

Chapter 3

CONSTRUCTION

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1. CLEANING AND GRUBBING

This work shall consist of cutting, removing and disposing of all materials such as trees, bushes, shrubs, stumps, roots, grass, weeds, top organic soil not exceeding 150 mm in thickness, rubbish etc., which in the opinion of the Engineer are unsuitable for incorporation in the works, from the area of road land containing and embankment, drains, cross-drainage structures and such other areas as may be specified on the drawings or by the Engineer. It shall include necessary excavation, back-filling of pits resulting from uprooting of trees and stumps to required compaction, handling, salvaging, and disposal of cleared materials. Clearing and grubbing shall be performed in advance of earthwork operations and in accordance with the requirements of these Specifications.

EQUIPMENTS REQUIRED:- Grader

Excavator/ J.C.B.

Tipper

Rollers

Water Tankers

Survey kit

Dozer with tipper attachment

2. EMBANKMENT AND SUBGRADE CONSTRUCTION

The work shall consist of construction of embankment with approved and specified material obtained from approved borrow areas or suitable material obtained from roadway excavation and

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drain excavation and in accordance with clause no305 of MORTH specification. The materials used in embankments, subgrades, earthen shoulders and miscellaneous backfills shall be soil, moorum, gravel, a mixture of these or any other material approved by the Engineer. Such materials shall be free of logs, stumps, roots, rubbish or any other ingredient likely to deteriorate or affect the stability of the embankment/subgrade.

EQUIPMENTS REQUIRED

Hydraulic Excavator Dozer Dumper Motor Grader Vibratory Roller Water tankers Survey kit

QUALITY CONTROL

Following are the list of control tests to be carried out in the laboratory for Embankment and sub-grade construction.

TESTS MINIMUM DESIRABLE FREQUENCY

Sand content /Gradation test 2 test / 3000 cumAtterberg’s limits 2 test / 3000 cumModified proctor test 2 test / 3000 cumMoisture content 1 test / 250 cumDensity of compacted layer (soaked

1 test / 1000 sq.m

3. GRANULAR SUB BASE(GSB)

This work shall consist of laying and compacting well-graded material on prepared sub-grade in accordance with the requirements of these Specifications. The material shall be laid in one or more layers as sub-base lower sub-base and upper sub-

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base (termed as sub-base hereinafter) as necessary according to lines, grades and cross-sections shown on the drawing or as directed by the Engineer. The Material to be used for the work shall be natural sand, moorum, gravel, crushed stone, or combination thereof depending upon the grading required. Materials like crushed slag, crushed concrete, brick metal and kankar may be allowed only with the specific approval of the Engineer. The material shall be free from organic or other deleterious constitute.The Material shall have a 10 per cent fines value of 50 KN or more (for sample in soaked condition) when tested in compliance with BS: 812 (Part 111). The water absorption value of the coarse aggregate shall be determined as per IS: 2386 (Part 3); if this value is greater than 2 per cent, the soundness test shall be carried out on the material delivered to site.

EQUIPMENTS REQUIRED Hydraulic Excavator

Dozer

Dumper

Motor Grader

Vibratory Roller(80 to 100 KN)

Water tankers

Survey kit

QUALITY CONTROL

Following are the list of control tests to be carried out in the laboratory for Granular Sub Base construction.

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TESTS MIN. DESIRABLE FREQUENCY

Gradation 1 test / 200 cumAtterberg’s limit 1 test / 200 cumMoisture content prior to compaction

1 test / 250 cum

Field density of compacted layer 1 test / 500 sq.mDeleterious content test As requiredCBR Test As required

Control test for GSB: Post construction Tolerance in surface level : +10mm, -20 mm

Max. permissible undulation(with 3 m straight edge): 8mm

Max. no. of undulations permitted in any 300 m length exceeding 16mm: 20

4. WET MIX MACADAM

This work shall consist of clean, crushed aggregates mechanically interlocked by rolling and bonding together with screening binding material where necessary and water laid on a

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properly prepared sub-grade/sub-base/base or existing pavement, as the case may be and finished in accordance with the requirements of these Specifications and in close conformity with the lines, grades, cross-sections and thickness as per approved plans or as directed by the Engineer.Coarse aggregates shall be either crushed or broken stone, crushed slag, overburnt (Jhama) brick aggregates or any other naturally occurring aggregates such as kankar and laterite of suitable quality. Materials other than crushed or broken stone and crushed slag shall be used in sub-base courses only. If crushed gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. If the water absorption value of the coarse aggregate is greater than 2 per cent, the soundness test shall be carried out on the material delivered to site.Binding material to be used for water bound macadam as a filler material meant for preventing ravelling, shall comprise of a suitable material approved by the Engineer having a Plasticity Index (PI) value of less than 6. The quantity of binding material where it is to be used will depend on the type of screening. Generally, the quantity required for 75 mm compacted thickness of water bound macadam will be 0.06-0.09 m3/10m2 and 0.08-0.010 m3/10m2 for 100 mm compacted thickness.

EQUIPMENTS REQUIRED Wet Mix Macadam Plant

Dumper

Vibro Roller(80 to 100 KN)

Paver capable of paving more than 9 m width

Survey kit

QUALITY CONTROL :Following are the list of control tests to be carried out in the laboratory for Wet Mix Macadam construction.

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TESTS MINIMUM DESIRABLE FREQUENCY

A.I.V. / LAV Test 1 test / 200 cumGradation test 1 test / 100 cumFlakiness & Elongation Index 1 test / 200 cumAtterberg’s limit 1 test /100 cumField density of compacted layer 1 test / 500 sq.m

Control test for WMM: Post construction Tolerance in surface level : +10mm, -20 mm

Max. permissible undulation(with 3 m straight edge): 8mm

Max. no. of undulations permitted in any 300 m length exceeding 16mm: 20

5. PRIME COAT

The work shall consist of application of single coat of low viscosity liquid bituminous material over prepared wet mix

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macadam surface. The prime coat shall be applied on the top most WMM layer over which DBM/BC layer is to be laid. The priming will not be applied when the WMM surface is wet or the weather is foggy, rainy, windy etc. or temp. In shade is less than 10degree centigrade. The primer used for prime coat shall be bituminous emulsion.

EQUIPMENT REQUIRED Air compressor

Mechanical Broom

QUALITY CONTROLFollowing are the list of control tests to be carried out in the laboratory for Prime coat.

TESTS MINIMUM DESIRABLE FREQUENCY

Quality of Binder 2 sample per lotBinder Temperature At regular intervalRate of spread of Binder 1 test / 500 sqm

6. DENSE GRADE BITUMINOUS MACADAM

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The work shall consist of laying in single course a 50 to 100 mm thick layer of DBM on a previously primed and approved WMM layer. BITUMIN- Bitumin shall be paving of penetration grade

60/70.

COARSE AGGREGATE- The coarse aggregate should be cubical/ angular type so that FI and EI indices are contained within the specified limit.

FINE AGGREGATE- Fine aggregate shall be of the fraction passing 2.36 mm sieve and retained on 75 micron sieve.

PREPARATION AND TRANSPORTATION OF MIX- DBM shall be prepared in batch in Hot Mix Plant. The mixing will be done in twin shaft pug-mill which will produce a homogeneous mixture. The mix shall be transported from the batching plant in tippers covered with tarpaulin so as to maintain the temperature and dust. The temp. should be greater than 150 deg. Celsius at the hot mix plant and 120 -140 deg. Celsius at the site.

EQUIPMENTS REQUIRED :- Crusher of required capacity

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HOT MIX PLANT

Paver with sensor arrangement & capable of paving 9 m width of material

Steel tandem rollers with required weight

Pneumatic roller with required weight

Bitumin sprayer

Dumper

Air compressor

Pegs for putting level

Mechanical Broom

Straight edge

Camber plate

Thermometer

Gauge for checking thickness

Surveying kit

QUALITY CONTROL :-Following are the list of control tests to be carried out in the laboratory for DBM construction.

Pre construction tests for aggregates -

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TESTS SPECIFICATIONA.I.V. TEST Max 27%Grading of aggregate and screening test

Grading 2 of table500-10

Flakiness & Elongation Index of aggr.(combined)

Max 30%

L.A.A. Max 35%Soundness test- sodium sulphateSoundness test-magnisium sulphate

Max 12%Max 18%

Water absorption Max 2%Stripping value of aggr. Minimum retained 95%

Frequency of test to be performed during construction of DBM :-

TESTS MINIMUM DESIRABLE FREQUENCY

Quality of Binder No of sample per lotLos angels abrasion test/ A.I.V. Test

1 test per 50 cum

Stripping value of aggr. Initially 1 set of 3representative specimens for each source of supply

Flakiness index of aggregate 1 test per 50 cumWater absorption of aggregate Initially 1 set of 3representative

specimens for each source of supply

Grading of all in aggregate One set of test on individual constituents and mixed aggregate from the dryer for each 400 tonnes of mix subjected to a minimum of 2 tests per day per plant

Temperature of binder of laying and rolling

Regularly

Binder content 1 test for each 400 tonnes of mix subjected to a minimum of 2 test of per day per plant

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Rate of spread of premix Regular control through checks on material and thickness

Density of compacted layer 1 test per 250 sqm

Control test for DBM: Post construction Tolerance in surface level : +6mm, -6 mm

Max. permissible undulation(with 3 m straight edge): 6mm

Max. no. of undulations permitted in any 300 m length exceeding 10 mm: 20

7. BITUMINOUS COURSE :-

The work shall consist of laying in single course a 30 to 50 mm thick layer of BC on a previously approved DBM layer.

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EQUIPMENTS REQUIRED :-

Crusher of required capacity

HOT MIX PLANT

Paver with sensor arrangement & capable of paving 9 m width of material

Steel tandem rollers with required weight

Pneumatic roller with required weight

Bitumin sprayer

Dumper

Air compressor

Pegs for putting level

Mechanical Broom

Straight edge

Camber plate

Thermometer

Gauge for checking thickness

Surveying kit

Core cutting assembly

QUALITY CONTROL:-Following are the list of control tests to be carried out in the laboratory for BC construction.

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Pre construction tests for aggregates -

TESTS SPECIFICATIONA.I.V. TEST Max 24%Grading of aggregate and screening test

Grading 2 of table500-18

Flakiness & Elongation Index of aggr.(combined)

Max 30%

L.A.A. Max 30%Soundness test- sodium sulphateSoundness test-magnisium sulphate

Max 12%Max 18%

Water absorption Max 2%Stripping value of aggr. Minimum retained 95%

Frequency of test to be performed during construction of DBM :-

TESTS MINIMUM DESIRABLE FREQUENCY

Quality of Binder No of sample per lotLos angels abrasion test/ A.I.V. Test

1 test per 50 cum

Stripping value of aggr. Initially 1 set of 3representative specimens for each source of supply

Flakiness index of aggregate 1 test per 50 cumWater absorption of aggregate Initially 1 set of 3representative

specimens for each source of supply

Grading of all in aggregate One set of test on individual constituents and mixed aggregate from the dryer for each 400 tonnes of mix subjected to a minimum of 2 tests per day per plant

Temperature of binder of laying and rolling

Regularly

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Binder content 1 test for each 400 tonnes of mix subjected to a minimum of 2 test of per day per plant

Rate of spread of premix Regular control through checks on material and thickness

Density of compacted layer 1 test per 250 sqm

Control test for BC: Post construction Tolerance in surface level : +6mm, -6 mm

Max. permissible undulation(with 3 m straight edge): 6mm

Max. no. of undulations permitted in any 300 m length exceeding 10 mm: 20

Chapter 4

LABORATORY

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Every section of the project has its own lab. The following instruments and apparatus were installed at the NKC lab:

1. Marshall Machine2. Equipment to determine the Sp Gravity3. Vibrating Table4. Compression Testing Machine5. Sieve Shaker6. AIV Apparatus7. CBR Machine8. Marsh Cone9. Saybolt Viscometer10. Redwood Viscometer11. Vacuum Pump12. Moulds of various dimensions and sizes

Chapter 5

FEATURES

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Enhanced safety features  Better Riding Surface. Better Road Geometry Better Traffic Management and Noticeable Signage. Divided carriageways and Service roads Grade separators Flyovers Bypasses Wayside amenities

Chapter 6

ADVANTAGES

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Savings in vehicle operating costs Faster, comfortable journeys Reduced fuel consumption Safer travel Benefits to trade especially in movement of perishable1

matr Reduced maintenance costs Safer travel All round development of areas

Chapter 7

PHOTOGRAPHS

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Construction of service road (BC)

Hot mix plant at NKC

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Batching plant at NKC

Pipeline

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Drain along the road

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