summer internship aiims to digha By:-priyanshu kumar

1. MEDI-CAPS INSTITUTE OF SCIENCE & TECHNOLOGY
SUMMER INTERNSHIP PROJECT REPORT
GAMMON
Construction Of Elevated Road Corridor From AIIMS To Digha
In partial fulfillment of summer internship for the award of the degree of BACHELOR OF
ENGINEERING in CIVIL ENGINEERING
Submitted to:- Submitted by:-
Dr. Rajeev kumar Mr. Priyanshu kumar
(Hod- Civil dept.) 0876CE141113

2. ACKNOWLEDGEMENT
I would like to express my thanks and gratitude to my guide Mr.Sudeep kumar Verma, Mr. Vivek kumar,
Mr. Anand kumar and all the employee of GAMMON for their valuable knowledge, guidance and time. I
would also like to thank the HR&ES who gave me the golden opportunity to do this project in the wonderful
working atmosphere of GAMMON Patna, Construction Of Elevated Road Corridor From AIIMS To Digha
, which also helped me in doing a lot of Research and I came to know about so many new things.
I would like to express my Special thanks to Mr. Sandeep Sangwan Sir who guided me in this direction for
summer training.
Secondly I would also like to thank my parents, brother and friends who helped me a lot in finalizing this
project within the limited time frame.

3. Index
Title Page no.
1. Introduction about the project
2. Location and Satellite Images
3. Project information
4. Project on contract Data
5. Project alignment
4
5-7
8
9
10-11
6. Project Scope
7. Project Geometric Design
8. Project milestone
12-13
14-15
16
9. Health & Safety 17
10. Quality Control lab 18-20
11. Casting yard 21-22
12. Project design & Drawing
13. Batching plant
14. Pile foundation
15. Project Photographs Showing works
23
24-25
26-36
37-38

4. Introduction About The Project
India has a road network of over 4.7 Million km, the second largest in the world. Bihar being one of the
largest states has a various road network comprising of 29 National Highways with the total length of 2,910
km and State Highways with total length of 3,766 km. Bihar State Road Development Corporation
(BSRDC) conceived this prestigious Project of Elevated Road Corridor (11.9 km length) connecting
AIIMS and Digha. Hon’ble Chief Minister Shri Nitish Kumar laid foundation stone to kick start
commencement of construction work of India’s one of the Longest Elevated Corridor as his Dream Project.
The project involves construction of 2-lane semi-elevated and 4-lane elevated highway over Patna canal as
approach road of rail -cum-road project across the Ganga at Digha. With the above inauguration, yet
another glamorous project of BSRDC started taking shape.The elevated road project will have major
crossings at Bailey Road and Ashok Rajpath and will have connectivity with important places like Danapur
railway station, proposed Patliputra railway station and AIIMS. Besides, it will also have connectivity with
the Ganga Path and one Railway Bridge at Khagaul (Patna-Delhi) line. One minor bridge will also be linked
to this project Once completed, the road will provide much needed relief from the traffic congestion in the
city, particularly on the narrow Ashok Rajpath as it would be connected with the Ganga Path at Digha
end.This project would reduce journey time to AIIMS-Patna from the Digha locality. Even those coming
from outside Patna would be benefited, particularly once the Sonepur-Digha rail-cum-road bridge becomes
operational. Vehicles from north Bihar could use this bridge for a direct connectivity with the southern part
of the city.The project is being executed on the engineering procurement construction (EPC) mode. Under
the EPC mode, funds are provided by the government and the agency, which takes up the work, is paid as
per the work carried out by it. Even the ambitious Ganga Driveway project is being constructed on same
pattern.From the AIIMS-Patna side, the first 3km of the road would have two lanes on a semi-elevated
structure. It would culminate at the Bailey Road flyover between Jagdeo Path and Saguna Mor. The
remaining portion of the road would be elevated and would have four lanes.

5. Location Mao and Satellite Images
Concept of Project to Develop Ring Road for Patna

6. PROJECT ALIGNMENT

7. PROPOSED ALIGNMENT CONNECTING NH-98 AT AIIMS to DIGHA BRIDGE
END OF THE PROJECT AT DIGHA

8. PROJECT INFORMATION
1 NAME OF PROJECT CONSTRUCTION OF ELEVATED ROAD
CORRIDOR FROM AIIMS (ON NH 98) TO DIGHA
(ON GANGA PATH) (11.90 KM) AT PATNA IN THE
STATE OF BIHAR
2 AUTHORITY BIHAR STATE ROAD DEVELOPMENT
CORPORATION LTD.
3 AUTHORITY’S ENGINEER M/S AECOM ASIA COMPANY LTD IN JV WITH M/S
RODIC CONSULTANT PVT. LTD.
4 DESIGN DIRECTOR MR. SHIRISH DESHPANDE
5 EPC CONTRACTOR M/S B&S ENGINEERING CONSULTANTS PVT.
LTD, NOIDA
6 EPC CONTRACTOR GAMMON INDIA LTD.
7 PROJECT IN CHARGE
(EPC CONTRACTOR)
MR. UMAKANT M KULKARNI, GM (PROJECTS)
8 TEAM LEADER
(AUTHORITY’S ENGINEER)
MR. N. K. SUMAN

9. PROJECT ON CONTRACT DATA
SL
NO.
PARTICULAR DETAILS
1 LOA NO. & DATE : BSRDCL-1131/2013/PART-II/257
DATED .09.2013
2 DATE OF SIGNING OF CONTRACT
AGREEMENT
: 11TH DAY OF OCTOBER 2013 AT PATNA,
STATE OF BIHAR
3 TOTAL CONTRACT PRICE : RS. 717.40 CR. (ORIGINAL VALUE)
: RS. 788.32 CR (AFTER APPROVAL OF COS-I)
: RS. 865.17 CR. (AFTER APPROVAL OF COS-2)
4 PROJECT DURATION : 36 MONTHS FROM APPOINTED DATE
(ORIGINAL DURATION)
: 46 MONTHS FROM APPOINTED DATE
(AFTER 10 MONTHS EXTENSION I.E. 300
DAYS)
5 APPOINTED DATE : 21.10.2013
6 COMPLETION DATE : 20.10.2016 (ORIGINAL)
: 16.08.2017 (REVISED)
7 PERFORMANCE SECURITY : CLAUSE 7.1.1 OF CONTRACT AGREEMENT
(VOL-I) “THE CONTRACTOR SHALL, FOR
THE PERFORMANCE OF ITS OBLIGATIONS
HEREUNDER DURING THE CONSTRUCTION
PERIOD, PROVIDE TO THE AUTHORITY,
WITHIN 15 (FIFTEEN) DAYS OF THE DATE
OF THIS AGREEMENT, AN IRREVOCABLE
AN UNCONDITIONAL GUARANTEE FOR AN
AMOUNT EQUAL TO 7.5% (SEVEN POINT
FIVE PERCENT) OF THE CONTRACT PRICE”

10. PROJECT OF ALIGNMENT
PROJECT ALIGNMENT (INCLUSIVE OF NON COS, COS-1)

11. PROJECT ALIGNMENT (INCLUSIVE OF NON COS, COS-I & COS-2)

12. PROJECT OF SCOPE
EXECUTIVE SUMMARY
Development of the Project Highway shall include construction of additional 2 lane (2.2km), 4 Lane
(8.9km) Elevated corridor over Patna canal, 4 Lane with 2 additional lanes (0.8km) along southern bank
of river Ganga and a rotary at Digha including allied facilities connecting AIIMS (on NH 98) and Digha
(on Ganga Path)
TOTAL PROJECT
LENGTH
11.90KM (KM 0+000 TO KM 11+900)
(AFTER APPROVAL OF COS-I)
12+270KM (AFTER APPROVAL OF COS-II)
NON-COS PORTION
Chainage Particular Remarks
Km 5+450 to Km 6+540 4 Lane (2 x 2 Lane) Shall be developed following
the canal bed upto Digha
The Elevated road corridor from chainage Km 5+450 to Km 6+540 will pass over the existing Bailey
road flyover instead of earlier proposal

13. Bailey Road Flyover Crossing Span
Harp Type Cable Stayed Bridge 25m + 40m +25m (continuous)
Chainage Particular Remarks
AshokRaj Path to Km
11+100
2x2 lane (separated) East side of canal (East
leg)
AshokRaj Path to Km
11+100
2x2 lane (separated) West Side near existing
PCC road (West leg)
Km 11+820 to Km 12+270 2 Lane Elevated Structure
44.609m with steel Girder
Minor Bridge 20m Span One minor bridge 20m
span to cross the canal.

14. PROJECT GEOMETRIC DESIGN
PROJECT ALIGNMENT
The Project Highway shall follow the proposed alignment specified by the Authority and shown in the
alignment plans specified in Annex III of Schedule-A (EPC Contract Vol-1)
WIDTH OF CARRIAGEWAY
The Paved Carriageway shall be minimum 2 x 8.75m wide excluding the median for four lane divided
carriageway and 2 x 12m in Elevated Road Corridor portion. Except as otherwise provided in this
agreement the width of the Paved Carriageway shall conform to clause 1.2.1 above (EPC Contract Vol-
I)
DESIGN SPEED
Ruling 80/100 Km/hr
Minimum 60 Km/hr
RIGHT OF WAY
Sl. No From Chainage To Chainage Length Proposed ROW
1 Km 0+000 Km 2+700 2.7 Km. 30 m from canal
edge
2 Km 2+700 Km 10+600 7.9 Km. 35 to 45 m
3 Km 10+600 Km 10+950 0.35 Km. 45 m
4 Km 10+950 Km 11+900 0.95 Km. 60 m
TYPE OF SHOULDERS
Main Carriageway in Embankment Portion
1 Paved Shoulder 2X1.50=3.00m
2 Earthen Shoulder 2X2.00m
SERVICE ROAD
Service roads shall
be constructed at
the locations and for
the lengths indicated
below Sl.No.
From
Chainage
To Chainage Length Width Remarks
1 2+125 2+300 175m 5.5m LHS
2 2+175 2+400 225m 5.5m RHS

15. INTERSECTIONS AND GRADE SEPARATORS
Sl.No. Chainage Intersection
Type
Destination
(LHS)
Destination
(RHS)
1 Km 0+000 At Grade T
Junction
NH-98 Gangapath
2 Km 11+900 Interchange Sonepur Gangapath &
NH-19
The Carriageway width for proposed interchange will be as below-
TYPE OF PAVEMENT
The type of pavement for the main carriageway except Elevated portion has been considered as Flexible
Pavement.
DESIGN TRAFFIC
Notwithstanding anything to the contrary contained in this agreement or the manuals, the pavement shall
be designed for design traffic of 150 MSA.
MINOR BRIDGE
Sl.No.
Chainage Remarks
1 Km 2+080 Span (1x35m) Precast PSC
Girder with cast insitu RCC slab
ROB/ RUB
Details of
proposed ROB
is as
below.Sl.No.
Chainage Type of
Crossing
Structure type Span
Arrangement
Total Width of
Structure
1 2+975 BG Rail line Steel truss/
RCC Deck
1x70m 2x12m
Patna Elevated to Ganga Path 8.75m + 2.0m Earthen shoulder
Ganga Path to Patna elevated 8.75m + 2.0m Earthen shoulder
Other Ramps 7.25m
Ramp joining Rail cum road bridge 12m

16. PROJECT MILESTONE
ORIGINAL MILESTONE (PRIOR TO COS-1 & COS-2 ORDER)
Project Milestone As per EPC Agreement
Description(%of project cost) Days (From Appointed
date )
Date
PM - 1 10% 270th Day 18-July-14
PM - 2 30% 450th Day 14-Jan-15
PM - 3 70% 810th Day 9-Jan-16
PM - 4 Completion 1095th Day 20-Oct-16

17. HEALTH & SAFETY
SAFETY
Proper barricading and informatory sign boards are placed at working locations PPEs like
Helmets, safety shoes are being provided for workers engaged in structural works. Security
guards are provided at the camp, also deployed at working site, wherever necessary. Signal
marshal for traffic control has been deployed at site.
A separate dedicated team is working to provide proper safety measures all along the Project
corridor. Safety training and tool box talk has been conducted at regular basis.
DETAILS OF SAFETY ACTIVITIES IN THE MONTH
Sr. No Activity Numbers Attendant
01
02
3Q Meeting
Tool Box Talk
5 no’s
26 no’s
60 no’s
425 no’s
03 Induction training 12 no’s 38 no’s
04 Training on Working
at height
02 no’s 30 no’s
05 Training on Electrical
Safety
02 no’s 17 no’s
DETAILS OF PPE’S ISSUED FOR THE MONTH
Sr. No Item Issued
01 Safety Helmet 97nos.
02 Safety Shoe 38 pairs
03 Gum Boot 21 pairs
04 Hand Gloves 954 pairs
05 Safety Goggles (White &
Black)
37 nos.
06 Nose Mask 16 nos.
Sr. No Inspection No
01 Working at height 10 no’s
02 Electrical safety 04 no’s
03 Lifting tools and tackles 06 no’s
04 PPEs 04 no’s
05 Fire safety 04 no’s
06 Hot work (Welding & Gas
cutting)
16 no’s
07 Labour camp 02 no’s
08 Plant and Machineries 10 no’s

18. QUALITY CONTROL AND MANAGEMENT
12.1 QUALITY MANAGEMENT PLAN
Quality Assurance Plan with Site Organization Chart and Test plan has been submitted to the
Authority vide letter no. Elevated/9211/camp/06 dated 15.11.13 for which approval has been
accorded vide letter no BSRDCL-1283/2013/3152 dated 28.11.2013. Base line Construction
Programme as per Cl no 10.1.3 of the contract Agreement, Monthly invoice Schedule and Monthly
cost curve has also been submitted vide letter Elevated/9211/camp/03-A dated 12.11.13 for which
approval has been accorded vide letter no BSRDCL-1283/2013/3151 dated 28.11.2013.
TESTING
 CTM MACHINE
 LOS ANGELES ABRASION APPARATUS
 HOT AIR OVEN
 CONCRETE FLOW TEST
 SLUMP CONE
 RAPID MOISTURE METER
 FLAKINESS & ELONGATION GAUAGE
 THIN FILM OVEN
 IS SIEVE
 PYCNOMETER
 DUCTILITY APPRATUS
 AIV APPARATUS
 CBR APPARATUS
 WATER BATH
 MARSHALL STABILITY APPARATUS
 MARSHAL MOULDS
 MARSHAL PEDESTAL BIG SIZE
 MARSHALL PEDESTAL SMALL SIZE
 BITUMEN EXTRACTOR APPARATUS

19. METHODOLOGY OF THE WORK
Working methodology of the items to be executed has been submitted to BSRDCL, Patna vide
letter no. Elevated/9211/camp/09 Dated 15.11.13 for kind review and the same has been
approved vide letter no BSRDCL-1283/2013/3153 dated 28.11.2013. Methodologies of the
following activities have been submitted:
Structure works : a) Piling b)Pile cap c)Pier d) Pier cap e) Casting of Girder f) Erection of Girder
g) Deck slab h) Crash barrier) Erection of super structure for Railway span (ROB) j) .Approaches.
APPROVAL OF SOURCE OF MAJOR MATERIALS
Sl. No. Material Source Approval date
1 Fine aggregate Koilwar 20.11.13
2 Coarse aggregate Chatarpur 20.11.13
3 Cement 43 Grade Ultra Tech 20.01.14
4 Cement 43 Grade Ambuja 24.01.14
5 Admixture BASF& SIKA 20.01.14
6 Admixture Kunal Conchem Pvt
Ltd
20.01.14
7 Bearing Grouting
Material
Fosroc Chemicals
(India Pvt. ltd)-
Conbextra GP-2
01.10.14
8 Bearing Grouting
Material
BASF India Pvt. Ltd.
– Master Flou 78
01.10.14
9 Bearing Grouting
Material
SIKA INDIA Pvt.
Ltd. – SIKA GROUT
214
01.10.14
10 Bearing Grouting
Material
CHRYSO-The
Structural Water
Proofing Company
Pvt.Ltd.-EXCEM VI
27.10.14
11 GSB Chatarpur 02.05.15
12 Wet Mix Macadam 40mm, 20mm, 10mm,
Stone dust from
Chattarpur in Palamu,
Jharkhand
30.09.15
13 DBM 40mm, 20mm, 10mm,
Stone dust from
Chattarpur in Palamu,
Jharkhand and
Bitumen (VG-30)
12.10.2015

20. FROM IOCL Haldia,
Emulsion (RS-1)
from MBD Industries
14 Bitumen VG-30 grade IOCL, Haldia 03.11.2015
15 Emulsion IONIC Products 4.12.2015
16 Reinforcement Steel M/S Electrosteel Steels
Ltd
11.04.2015
Sl.No. Design Mix Approval Date Source
1 M 40 for Piling
work
20.01.14 Coarse Aggregate -Chatarpur
quarry
Fine Aggregate- Koilwar
Cement- Ultratech&Ambuja
OPC-43 grade
Fly ash- Kahalgaon
2 M 40 for Pile cap 20.01.14 Coarse Aggregate -Chatarpur
quarry
Fine Aggregate –Koilwar
Cement- Ultratech OPC-43
grade
Fly ash- Kahalgaon
3 M 40 for Pile cap 20.01.14 Coarse Aggregate -Chatarpur
quarry
Fine Aggregate –Koilwar
Cement- Ambuja OPC-43
grade
Fly ash- Kahalgaon
4 M 40 for Pile &
Pile cap
20.01.14 Coarse Aggregate -Chatarpur
quarry
Fine Aggregate –Koilwar
Cement- Ultratech OPC-43
grade
Fly ash- Kahalgaon
Admixture SIKA KLD 045/3
5 M 50 for Pier &
Pier cap
20.01.14 Coarse Aggregate -Chatarpur
quarry
Fine Aggregate –Koilwar
Cement- Ultratech OPC-43
grade
Fly ash- Kahalgaon
6 M 50 for Pier &
Pier cap
20.01.14 Coarse Aggregate -Chatarpur
quarry

21. CASTING YARD
CASTING OF I-GIRDER
 STEP 1 : Cage is placed in the trough
 STEP 3 : Threading of HTS is done
 STEP 2 : Barell grip is fixed
 STEP 4 : HTS is sagged one by one under 50KN ( Sag removing process )
 STEP 5 : Citiring oil is poured on the bottom and enclosing surface of the citiring
 STEP 6 : First middle cage is fixed and then the remaining one
 STEP 7 : PVC pipe is inserted
 STEP 8 : Streaching is done by applying under 350KN
 STEP 9 : Again the pipe is adjusted to its original position
 STEP 10 : Centering of bearig plate
 STEP 11 : Diaphragm centering is placed
 STEP 12 : Concreting is done
 STEP 13 : Curing is done continuously for 72 hrs
 STEP 14 : Decitiring is done
 STEP 15 : Destreaching is done
P (m) Num ber
ing of HTS in

22. *Pre-Stressing of an I-Girder:
Pre-Stressing is a variant under which girders being casted having tension-ed struts inserted
inside the casting cage Before pouring the concrete on the reinforcement.After casting and
leaving the struts tension-ed for several days and after that we slowly remove the stress Thereby
transferring the stress to the girder.This thereby results in bending of the girder which helps in
generating an additional bending moment hence increasing the bearing capacity.
Fig: Supporting my above Explanation:

23. PROJECT DESIGN & DRAWING

24. BATCHING PLANT
There are two of the mixing plant involved in this project:
1.Compact plant:
This plant has an anticipated capacity of 0.5m3/min that is 30m3 per hour.
2.Mobile plant:
This plant has an anticipated capacity of 1m3/min that is 60m3 per hour.
In both the plants the type of of mix (i.e. all the proportion) has been feeded to the system, the
machine will automatically take that amount of raw material from their respective container and
mix it up in a hopper and when a transit mix truck arrives the mix is loaded on it.

26. PILE FOUNDATION
Pile Foundation
Preparatory work
After handing over encroachment free area, Survey will be carried out to find out the location of
pile. Pile coordinates will be marked with the help of Surveyor. Barricading will be carried out
with proper road signs & adequate lighting arrangement will be provided for night work. The initial
depth of excavation will be done manually / By JCB as per site feasibility to locate the utility lines
and services if any. If utility lines are found, it will be removed / shifted with the help of concerned
authority. Pile boring will be carried out with Integrated Hydraulic Piling Rig.
After completion of pile boring, service crane will lower the reinforcement cage and tremie pipe.
Then concreting for pile will be carried out. Transit Mixer will be used to transport the concrete
from batching plant to pile location. The work shall be done as per: IS 2911.
SUB SURFACE INVESTIGATION
The sub-surface investigation of strata in which pile foundations are proposed shall be carried out
in advance and by in-situ pile tests. Sufficient bore-hole for foundation of the bridge will be
executed. Borings would be carried up to sufficient depths so as to ascertain the nature of strata
around the pile shaft and below the pile founding level.
The investigation will also include location of ground water table and other parameters including
results of chemical tests showing sulphate and chloride content and any other deleterious chemical
content in soil and/or ground water, likely to affect durability.
TYPE OF PILES
The piles are RCC Bored cast in situ Piles.
METHODOLOGY
Survey/Setting Out: The location of pile is set out with respect to the control points (coordinates).
It is proposed to remove the top overburden manually for the pile cap group to identify the utility
lines and services. If any such utility service lines are seen then the same will be intimated to the
Engineer and will be removed with the help of concerned Authority. Once utilities are removed
then pile-driving activity will start.

27. I. Temporary Casing / Permanent Liner: Initial boring up to required depth is carried out for
lowering the temporary guide casing / Permanent liner (as per approved drawings). It is proposed
to use the 10mm thick plate for the temporary guide casing. The 10mm thick MS plate will be
rolled in the plate-bending machine. The temporary / permanent liners of required diameter will
be fabricated in the casting yard and will be transported to the piling location with the help of
trailers. Integrated hydraulic piling rig will be used to drive the casing. The center line of guide
casing will be checked with reference to guide points / reference points before continuing further
boring. The verticality will be checked with the help of plumb and correction if required, will be
made. If required then bentonite will be used for side stabilization of bore hole.
II. Pile boring: On completing the lowering of temporary / permanent casing, pile boring will be
continued with the help of Integrated Hydraulic Piling Rig. The boring in soil is continued till the
founding level is reached. Pile termination level will be finalized as per approved drawings & as
instructed by the Engineer. Boring in soil will be carried out to specific depth as mentioned in the
GFC drawings. Muck / excavated materials will be transported with the help of tippers and
disposed as directed by the Engineer.
Piles shall be installed as accurately as possible as per the approved drawings. Piles should not
deviate more than 75 mm or D/10 whichever is more in case of piles having diameter more than
600 mm from their designed positions at the working level of the Piling Rig & tilt should not
exceed 1 in 150.
III. Reinforcement cage – Preparation & Lowering: Based on approved drawing, a bar bending
schedule will be prepared and got approved from the Engineer / Client. The reinforcement is cut
and bent to the required length / size and shape according to the approved BBS. Reinforcement
cage will be fabricated in casting yard and transported to site using trailors. The reinforcement
cage will be lowered with the help of service crane. The reinforcement cage is to be lowered
immediately after the pile boring is completed.
IV. Cleaning of Pile bore:
 After completion of the pile bore up to the required depth the pile bore will be cleaned by
three stages flushing of slurry using airlift technique.
 The bottom of the pile bore will be thoroughly cleaned by airlift technique.
 Cleaning will ensure that the pile bore is completely free from sludge / bored material, debris
of rock / boulders etc.

28.  Pile bore will be cleaned by fresh drilling mud through tremie pipe before and after placing
the reinforcement and just before the start of concreting.
V. Concreting: Immediately after lowering the reinforcement cage, tremie pipe of 200mm dia.
and length of 1.2m to 2 m will be joined together and lowered into the pile. Attach concrete funnel
of approx. 1.5 cum capacity to the tremie pipe at the pile top level. Provide the gap/clearance of
300mm between the tremie pipe bottom and founding level. Once the concrete is built up to say 4
meters and it is confirmed by sounding, the tremie pipe with funnel will be lifted up and the top
tremie pipe will be removed, during this operation it should be ensured that the bottom of the
tremie pipe is always embedded in the concrete for the depth of minimum 1000 mm. During the
course of concreting, if tremie is withdrawn out of concrete either accidentally or to remove a
choke in the tremie, the tremie pipe is re-introduced into the old concrete with little penetration. A
vermiculate ball plug is introduced in the tremie, fresh concrete of slump between 150mm to
180mm is filled in the tremie which will go on pushing the plug forward and emerge out of the
tremie. After this the tremie is pushed further in steps making fresh concrete displace the lean
concrete. When the tremie is buried about 0.6 m to 1.0 m in the concrete then the concreting is
resumed / continued.
Concrete is built above the cut off level (600mm above cut off level) and is confirmed by sounding
chain. If borehole is left un-concreted for more than 6 hours after boring then it will be cleaned
thoroughly before placing the concrete. In case, under the unavoidable circumstances, the
operation is to suspend for a period of 2 hours (maximum), the tremie shall not be taken out of
concrete. Instead, it shall be raised and lowered slowly from time to time which would prevent the
concrete around the tremie from setting. Concreting shall be resumed by introducing a little richer
concrete with a higher slump for easy displacement of partly set concrete. After completion of Pile
concreting, fresh concrete will be removed above the cut of level by using bucket. Only 15cm
concrete will be kept above the cut of level.

30. 3.1.3 CAST-IN-SITU PILE CAP
PREPARATORY WORKS
It is proposed to barricade around the work location as per traffic management plan and start the
excavation for pile cap after pile concrete attains sufficient strength. It is proposed to start pile cap
wherever work front is available without any hindrances. The area will be surveyed and barricaded
as per plan. Clearing and marking of area will be done to start excavation. Excavation is carried
out up to the bed level with the help of excavator. Bed will then be prepared with leveling course
(PCC) of required thickness (75 mm or 100 mm as per drawing). Successively reinforcement cage
will be fixed and shuttering will be placed as per approved drawings. Concreting of pile cap will
be done in layers of 500mm ensuring proper compaction with needle vibrator.
CONSTRUCTION METHODOLOGY
 Survey and barricading
 Clear area for excavation and marking
 Excavation up to pile cap bottom level
 Simultaneously chipping of pile
 Preparation of bed with PCC
 Cutting and bending and fixing of reinforcement for Pile cap.
 Shuttering for pile cap
 Concreting
 Backfilling
1. Survey and Barricading: Do survey and barricade around the work location to the required
width. Proper road / traffic signs as per contract will be marked on the barricading for the free flow
of traffic.
2. Clear area for excavation, survey and marking: As the pile cap is located below formation
level clearing the area for excavation and marking will be done as per the dimensions of the pit to
be excavated. Surveyor will give the markings. The dimensions of the pit will be more in addition
to the pile cap dimensions in all over the periphery for working area during the side shuttering
work of Pile cap.

31. 3. Excavation up to pile cap bottom level: Excavation in soft soil will be done with the help of
excavator to the extent possible. The remaining portion between the piles will be excavated
manually. The excavation in soil will be having dimensions as of the pile cap plus 0.5 m clearance
all around. Excavation will be done up to the bottom level of PCC.
4. Chipping of pile: Chipping of piles will be carried out after a minimum of 7 days after pile
concreting. Pile chipping will be done up to the cut off level with the help of Pneumatic Breaker.
The reinforcement of the pile will be cut / bent leaving the anchorage length for the reinforcement
bars as per specifications.
5. Preparation of bed with PCC: PCC will be laid up to required depth as leveling course for bed
preparation for pile cap. This will also support the formwork to be fixed for concreting.
6. Reinforcement Tying: Bar bending schedule will be prepared and get it approved from the
Engineer / client. Cutting and bending of reinforcement will be done in reinforcement yard. Tying
of reinforcement for preparing cage will be done in the excavated pit itself after shifting of
reinforcement steel from yard to location.
7. Shuttering for pile cap: Ensuring complete checking of reinforcement as per approved shop
drawing, shuttering will be placed as per the scheme and will be fixed after placing all the inserts
and cover blocks, which will be having same strength of pile cap concrete. Cover will be provided
as per specifications. Adequate supports will be given to the shutters to ensure fixity. Before fixing
of side shutters, cleaning of inside surface of shutters will be done with wire brush & emery paper.
8. Concreting of pile cap: After placing and fixing shuttering with proper number of cover blocks
and inserts, concreting will be done with client’s approval. Concrete of specified design mix will
be prepared in the batching plant located in the casting yard. And then it will be transported to the
concreting location in transit mixer. Transit mixer will be placed at appropriate location near the
pile cap and concrete chute / concrete pump will be fixed to pour the concrete. De-shuttering will
be done after concrete gets adequate strength
9. BACKFILLING: Immediately after de-shuttering, concrete surface shall be checked jointly
and coal tar Epoxy Paint (as approved by Engineer) will be applied to concrete surface and
backfilling will be done. Curing of top surface of the Pile cap will be done by pond making.

32. SHUTTERING FOR PILE CAP

33. REINFORCEMENT FIXING FOR PILE CAP
CONCRETING FOR PILE CAP

34. 3.1.4 PILE LOAD TEST (INITIAL/ ROUTINE)
Pile Load Test will be done by using Anchorage system or by Dynamic Pile Load Test system
Initial Pile Load Tests - The number of initial tests may be selected as given below depending
upon the nature of sub-strata & number of piles.
 For scope of piles less than 1000 numbers - A minimum of two tests.
 For scope of piles more than 1000 numbers - A minimum of two tests for first 1000 piles
and additional one test for every additional 1000 piles and part thereof.
Routine Pile Load Tests - The number of tests shall be 0.5 percent of the total number of piles,
subject to a minimum of one (1) test.
3.1.4.1 ANCHORAGE PILE LOAD TEST
PREPARTORY WORKS:
a. Removal of laitance: After casting of pile, the additional built up portion shall be hacked up to
the design cutoff level / or till sound concrete is reached whichever is lower.
b. Pile head: To distribute the applied load uniformly on the circular side of the pile a suitable pile
head as per detailed drawing should be cast at the pile cutoff level. The pile head shall be provided
with reinforcement mesh as detailed in the drawing and shall be cast true in level. Before placing
the jack on the pile head a M.S. plate of 25mm thickness shall be placed for uniform distribution
of load on the pile head.
c. Datum bar: The datum bar of size as detailed in the drawing shall be positioned over concrete
blocks.
d. Placement of reaction frame: Reaction frames shall be placed in position as per detailed
drawings.
e. Placement of jacks: A jack of desired capacity shall be placed with steel packing between the
reaction pile and the top frame.
APPLICATION OF LOAD:
300 T / 500 T capacity jack shall be connected to the power pack. The pile shall be tested for two
and half times the working load capacity for Initial Pile Load Test & 1.5 times for Routine Pile

35. Load Test (ie. Test Load 750 MT for Design load of 300 MT for Initial Pile Load Test & 450 MT
Test Load for Routine Pile Load Test). The increment for loading shall be 20% of the safe design
load. The increment of load for test shall be maintained till the rate of displacement of pile top is
near to 0.1mm per 30 minutes. Displacement shall be read using four dial gauge of 0.01mm
sensitivity.
RELEASE OF LOAD:
After taking observations, once the final load is attained, loading shall be released in the units of
20 % of the total safe load. Observations shall be discontinued as soon as the rate of displacement
is zero.
3.1.4.2 DYNAMIC PILE LOAD TEST
The test can be used to evaluate various pile parameters, important of these are mentioned below.
 Static capacity of the pile at the time of testing.

36.  Static load test curve
 Total skin friction and end bearing of the pile
 Skin friction variation along the length of the pile
 Compressive and tensile stresses developed in the pile during testing
 Net and total displacement of the pile.
 Pile integrity and changes in cross-section if any.
PILE MONITORING AND PREPARATION
 High-Strain Dynamic Testing of piles is conducted by attaching strain transducers and
accelerometers to the sides of the pile approximately 1 to 1.5 times pile dia. below the pile top.
These pairs of gauges are fixed onto opposite sides of the pile so as to detect bending in the
pile if any during testing.
 These transducers are then connected through the main cable to a Pile Driving Analyzer, which
is a State of Art Pentium Computer System with ability to record strain and acceleration
measurements and convert them from analog to digital form
 The signals are then triggered by the impact of a ram falling from a pre-determined height. The
ram weight and fall height is determined in advance. As a thumb rule, the ram weight shall be
1% to 1.5% of the testing capacity of the pile. Thus for measuring a 500 ton load, the ram
weight shall be approximately 5 tons.
 Upon impact, the strain transducers measure strains whereas accelerations are measured by
accelerometers connected on either sides of the pile. These signals are then converted to digital
form by the Pile Driving Analyzer and then converted to force and velocity respectively by
integration.
 The capacity mobilized under the blow is then obtained from the force and velocity values.
The PDA has an in-built program which calculates and generates over 30 pile variables based
on pile top force, displacement and velocity. Immediate field results in the form of the capacity
of the pile, pile top settlement etc, integrity and stresses developed in the pile etc. are obtained.

37. PROJECT PHOTOGRAPHS SHOWING WORK PROGRESS
Steel Girder Erection in progress at COS-II
Erection of Girders

38. Embankment at CH:10+950
Reinforcement of Box Culvert