GAMMON INDIA LIMITED

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SUMMER INTERNSHIP AT THE NEW BRAHMAPUTRA BRIDGE

Ms. Baishali Choudhury Mr. Jehinder Singh Mr. Preetam Banerjee Mr. Angshuman M. Saharia Mr. P. Jarken Bui Mr. Azaz Ahmed

B.TECH ( 4th sem.) Tezpur University

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ACKNOWLEDGEMENT
We feel extremely satisfied presenting the report on the completion of the summer training program at GAMMON INDIA LIMITED from 7th June2011 to 25th June2011, for construction of the NEW BRAHMAPUTRA BRIDGE PROJECT at Guwahati on NH-31, Contract Package-EW-II (AS 28).

Expressing our heart full thanks and gratitude to GAMMON INDIA LIMITED, who has given this great opportunity and encouraged us to develop and expertise our knowledge, technical skills etc.

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Also we are great full to Associate Professor Atanu Kr.Dutta, HOD- Department of Civil Engineering, Tezpur University for being positive regarding the training program.

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The valuable time and support extended to us by the staff of GAMMON INDIA LIMITED, Mr. A.N.SINGH (Sr. Project Manager), Mr. D.K.DAS, Mr. S.CHARKRABORTY, Mr. R.K.VERMA, Mr. S. DUTTA, Mr. P.K.CHANDA, Mr. PAWAN, Mr. VISHAL and other engineers, technical and non-technical stuff helped us to learn a lot of new things and we are extremely grateful.

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INDEX

TOPIC INTRODUCTION CONTRACT WELL FOUNDATION HIGHWAY SUPERSTRUCTURES QUARRY STORE PLANNING AND BILLING

Page no. 1 2 3 4 5 6 7 8

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INTRODUCTION
In order to reduce traffic congestion on NH 31 (Near Guwahati, Assam), the NHAI (National Highway Authority of India) had decided to construct a new three lane bridge named New Brahmaputra bridge running parallel to the existing two lane bridge- The Saraighat.

PROJECT:

Construction of New Brahmaputra Bridge on NH 31, near the city of Guwahati, Assam. Contract package no. EW-(AS-28) National Highway Authority of India (NHAI), G5 & G6, sector-10, Dwarka, New Delhi -110075. Mott McDonald Private Ltd, A-20, Sector 2, Noida, Uttar Pradesh. Span Consultant Private Ltd, Span House, Gurudwara Road, Madangir, New Delhi110062. M/s Gammon India Ltd, Gammon house, Veer Savarkar marg, Prabhadevi, Mumbai-400025. IIT, Delhi Rs. 238.34 crores only 261045 N, 91450 E in the District of Kamrup, 40 m d/s of the existing Saraighat bridge.

CLIENT:

CONSULTANT: DESIGN CONSULTANT:

PROOF CONSULTANT: CONTRACT VALUE: LOCATION OF BRIDGE:

SALIENT FEATURES OF THE PROJECT:

Contract package: Contract period: Contract value: Date of Agreement:

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CONTRACTOR:

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EW-II (AS-28) 42 Month Rs. 238,44,25,881 4th August, 2006

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Date of commencement: Date of completion: Defect liability period: Retention money: Date of receipt of main bridge drawing: Extension of time:

22nd October, 2006 21st April, 2010 365 days after completion 6% of contract price 8th May, 2007 Up to 30th November, 2012

RIVER BRAHMAPUTRA:

High flood level: Lowest flood level: Maximum stream velocity: Maximum stream discharge: Mean annual discharge:

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MAIN BRIDGE:

Road level of the main bridge: Length of main bridge: Foundation type: No. of well: Size of well: Depth of well:

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49.88m 5m/s 11 no.s

Nature of the catchment:

Partly plain, mostly hilly.

29.696m

72400m3/s 46400m3/s

69.072m 1493.584m Double D type.

16m X 10m 48.400m (Average)

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Flow:

Perennial, high flood during monsoons.

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Nature of bed soil:

Alluvial.

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Thickness of well staining: Thickness of false staining: Size of well cap: Pier type: Size of pier cap: Total width of main bridge deck:

2.5m 0.5m 16m X 10m X 3m Tapered hollow pier 12m X 8.5 X 4m 13.875m

APPROACHES/VIADUCTS:

Foundation type: Diameter of pile: Depth of pile: Substructure: Size: Height: Viaduct length:

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Total no of spans:

ROAD WORK:
Length: Carriage way: Retaining wall: Toe wall: 2087m 11m + 11m 1600RM 608.873RM

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10 no.s

Guwahati side:

1123+490 to 1123+600 Cast in situ RCC vertical bored pile. 1200mm Average of 25m RCC piers. 7m X 1.35m 3.8m to 5m 75+75+105m

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Amingaon side:

1121+850 to 1121+241

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Chainage in scope:

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Slip road:

2 X 1245RM

SEISMIC ZONE:

The project lies in zone-5 of seismic activity as per IRC-6. As such Gammon India Ltd had designed the bridged wherein a new technology is used. Shock Transmission Units (STU) are placed below the bridge at certain intervals which will resist any seismic force.

CLIMATE:

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The annual rainfall in the Brahmaputra valley varies between 30 to 34 during summer and 8 to 12 during winter. The humidity varies from 69% during January-February, to 80% during monsoons.

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CONTRACT
Contract defines the terms and conditions under which the employer and the contractor is bound into an agreement. It includes specifications, drawings, bill of quantities, the tender, the letter of acceptance, the contract agreement and other such related documents which may be incorporated in the letter of acceptance or the contract agreement. Overall, it is divided into 4 parts as given below-

Part 2 of 4: Technical Specifications.

Drawings Part 4 of 4: Technical bid

A brief summary of some of the documents:

AGREEMENT:
The Agreement was made on 4th of August, 2006 between NHAI (Employer), Plot No. G5 & G6, sector 10 dwarka, New Delhi and M/s Gammon India Ltd (Contractor), Gammon House, Veer Savarkar marg, Prabhadevi, Mumbai.

Part 3 of 4:

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1. Contract agreement. 2. Power of attorney. 3. Letter of acceptance. 4. Copy of bank guarantee along with confirmation letter. 5. Invitation of bid. 6. Instruction to bidders with classification of bidder. 7. General conditions of the contract. 8. Condition for particular application. 9. Appendix to bid. 10. Priced bill or quantity, standard form and schedule.

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Part 1 of 4:

POWER OF ATTORNEY:
Mr. Bhole, General Manager, Work survey was nominated by Gammon India Ltd to be their true and lawful attorney for them in their name and on their behalf to accept the letter of acceptance and to sign and execute the contract agreement between NHAI and Gammon India Ltd.

LETTER OF ACCEPTANCE:
It states that Gammon India Ltds bid for contruction of new Brahmaputra Bridge near Guwahati on NH 31 in the state of Assam, their civil package no. EW-II (AS-28) is accepted.

Includes Bid document.

QUALIFICATION OF BIDDERS:

1. 2. 3. 4. 5. 6. 7.

BIDDING DOCUMENT:

In order to qualify the bidders shallSubmit power of Attorney. Adequate experience of work. Financial capacity. Technical capacity Current contract commitment Annual audited turnover and financial data. Submit proposed methodology in sufficient detail and the program of construction backed with equipment planning and deployment duly supported by output calculation and quality assurance.

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INVITATION FOR BID:

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Canara banks guarantee no. 06BG1002, dated 20/06/2006 for Rs 23,84,00,000/- is issued in favor of NHAI on behalf of Gammon India Ltd.

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Performance security to NHAI on behalf of Gammon India for the project is provided by Canara Bank.

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PERFORMANCE SECURITY:

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Vol. 1 Set 1 1. Instruction to Bidders. 2. General conditions of Contract- part 1. 3. Conditions of particular applications- part 2. Vol. 2 Technical Specifications Vol. 3 1. 2. 3. 4. 5. Vol. 4 Drawing Form of Bid and Appendix. Bill of Quantity. Form of bill security. Schedule of supplementary information. Sample forms for qualification.

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Documents to be furnished by the bidder.

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Vol. 5

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FOUNDATIONS
Foundation types for the New Brahmaputra bridge: 1. A-1, P-1 P-6 and P-18 P-21, A2 - Pile foundations 2. P-7 P -17 - Well foundation

WELL FOUNDATIONS: DOUBLE D WELL FOUNDATION:

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Fig: Diagram showing parts of well foundation

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1. It is mostly used for the piers and abutments of bridges which are too long to be accommodated on circular well. 2. It provides lateral stability. 3. It has simple shape and easy to sink but requires greater effort than circular well. 4. Staining is relatively thick . 5. It is more prone to tilt and shift due to unsymmetrical shape and possible unequal dredging.

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CHARACTERISTICS:

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In this type of well foundation, the dredge hole is in the form of a D-shape. It consists of 2 Dshaped dredge holes, therefore it is called double D well foundations.

PARTS OF THE WELL: 1. CUTTING EDGE: It is the lower most tapering edge of the well made of steel which
facilitates cutting through soil for the sinking of the well. 2. WELL CURB: The cutting edge has to be strengthened suitably to take up the heavy loading and this portion is called the well curb. It is usually made of heavily reinforced rich concrete.

6. WELL CAP: The well cap is a R.C.C slab laid at the top of the well staining and is usually cast monolithically with the staining. It transmits the load of the superstructure to the staining.

CAISSONS:
Caisson is a box-like structure usually round or rectangular which is sunk from the surface of either land or water to some desired depth. It is pre-cast at the bank with the bottom which is generally provided with opening which are plugged and toed to the required positions by tugs and then plugs are removed to permit the caisson to reach the bottom of the river bed.

5. REINFORCEMENT: It provides required strength to the structure during sinking and service.

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4. BOTTOM PLUG: The bottom of the well is mass concreted to prevent further sinking of the well in future and is known as the bottom plug. It is done by means of pipes inserted through the Ds of the well. After mass concreting the plug is tested for cracks.

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3. STAINING: The well staining is the main body of the well which transfers load to free sub-soil. It also acts as a cofferdam during sinking and provides the weight for sinking.

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Fig: Cutting edge

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After the caisson rests in its final position, concrete blocks are normally dumped in to the hollow portion to increase its lateral stability.

COMPONENTS OF CAISSONS:
1. 2. 3. 4. Cutting edge A-frame B-frame Extension

CONSTRUCTION OF ISLANDS:
An island, if necessary, is constructed enclosing the construction site to facilitate the construction of the well foundation in dry condition, if depth of water is not more than 4.5 to 6.0 m. In case, where the velocity of water in the river is sufficiently high making it difficult to construct either an island or cofferdam to construct a well, caisson type construction has been used. SITE: P-7, P-8, P-9 ,P-16 and P-17 are planned to be constructed using islands.

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Fig: Island for pitching the well curb

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Fig: An island for pitching a well curb

TILT:
Tilt is the angle by which the central axis ( both X and Y ) of the well gets rotated. Maximum tilt allowed is 1:80. CALCULATION OF TILT1) R.L of the points are taken on all 4 sides using total station. 2) For e.g. => G/s = 20.170 A/s = 20.120 D/s = 20.100 U/s = 20.150

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Fig: Well sinking using crane and grab

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TILT IS CALCULATED USING THE FOLLOWING FORMULA: TILT = difference in RL / length Thus, tilt along X-X = 1 : 200 Amingaon side tilt along Y-Y = 1 : 320 downstream side SHIFT DUE TO TILT = diff in RL * height of well / length Thus ,shift => X-X = 100 mm Amingaon side Y-Y = 62.5 mm downstream side SITE VISIT:

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The dredging process was going on in P-12 by means of a crane and a grab.

HIGHWAY
In the planning for New Brahmaputra Bridge Project, highway is provided measuring 700m in Amingaon side and 1200m along the Guwahati side with retaining walls measuring 3.8m -5 m in height. The highway is designed to be of flexible pavement with 3 lanes for smooth movement of the traffic. Moreover it is designed to manage a volume of traffic 3 times than that of todays. While designing and constructing the highway IRC recommended CBR values, frictional coefficient, etc. are considered. The flexible pavement highway involves the distance between the viaduct of the bridge and the point where it joins the existing highway. LAYERS OF FLEXIBLE PAVEMENT:

LENGTH OF HIGHWAY

Amingaon side : 700m

HEIGHT OF RETAINING WALL: 3.8m - 5 m COST OF HIGHWAY PROJECT: 130 cr PROJECT COMPLETION TIME: DECEMBER, 2012 (conditions apply)

The materials used in embankment, subgrades, earthen shoulders and miscellaneous backfills shall be soil, moorum, gravel, sand, excavated material.

CONSTRUCTION OPERATION 1. Compacting ground supporting embankment/ subgrade

Guwahati side : 1200m

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SPECIFICATIONS AND DETAILS

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Fig: layers of flexible pavement

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2. Compaction: Vibratory roller of not less than 100 KN weight with plain or pad foot drum or pneumatic roller of 300 KN static weight shall be used for compaction. Subgrade strength: The subgrade should have a minimum design CBR value of 5%

MATERIALS Cement for use shall comply with the requirement of IS : 269, 455, 1489 or 8112. Water to be used shall be clean and free from injurious salts

WEATHER LIMITATIONS:

The soil before addition of cement shall be pulverized

5.6 mm

Moisture content for compaction: The mix shall be compacted at OMC or not more than +2% of OMC

ROLLING:

Compaction of mix is completed within two hours of its mixing

CURING: The subgrade shall be suitably cured preferably for 7 days but at least min. of 3 days by sprinkling water in every 4 hours.

STRENGTH: Soaked CBR after 7 days at density shall not be less than 10% in laboratory.

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80

26.5 mm

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100

IS SIEVEMINIMUM % BY WEIGHT PASSING THE IS SIEVE

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Cement soil construction shall not be done when the air temperature in the shade is less than 10C.

Surface finish and quality control of works, arrangement of traffic, measurement of payment, soil erosion and sedimentation control.

TEST FOR BITUMINOUS CONSTRUCTIONS Dense bituminous macadam/ semi dense bituminous concrete/ bituminous concrete 1. Sand equivalent test 2. Polished stone value (PSV) 3. Density of compacted layer.

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SUPERSTRUCTURE
A superstructure is an upward extension of an existing structure above a baseline. The bridge deck is to be constructed by the cast in situ Cantilever Segmental Construction method. Formwork for the in situ cast parts shall be made by steel.

PCC: The mixture of cement, sand and aggregate is called Plain Cement Concrete (PCC).

PIER:

PIER CAP:

Pier Caps are designed to be placed on top of pillars or columns. They protect brick or stone work from weather and corrosion and add beauty to the work. They usually needed to be slightly larger than the dimensions of the pillar itself so that they overhang.

BOX GIRDER: A box girder or Tubular girder is a girder that forms an enclosed tube with multiple walls, rather than I or H-beam. The advantage of a box girder is that it better resists torsion. Having multiple vertical webs, it can also carry more load than an I beam of equal height.

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A pier is a raised structure, including bridge and building supports and walkways, over water, typically supported by widely spread piles or pillars. Piers can range in size and complexity from a simple light-weight wooden structure to major structures extended over a mile out to sea.

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Pre-stressing tendons (high tensile steel cable or rods) are used to provide a clamping load which produces a compressive stress that balances the tensile stress that the concrete compression member would otherwise experience due to bending load.

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Pre-stressed Concrete is a method for overcoming concretes natural weakness in tension. It can use to produce longer span in bridges than is practical with ordinary reinforced concrete.

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PRE-SRTESSED CONCRETE:

DETAILS OF SUPERSTRUCTURE OF MAIN BRIDGE (P7 to P17):

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Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Location P-7 P-8 P-9 P-10 P-11 P-12 P-13 P-14 P-15 P-16 P-17

Part of Structure Pier Pier Cap Pier Pier Cap Pier Pier Cap Pier Pier Cap Pier Pier Cap Pier Pier Cap Pier Pier Cap Pier Pier Cap Pier Pier Cap Pier Pier Cap Pier Pier Cap

Height (m) 7.31 4 16.31 4 17.81 4 17.81 4 17.81 4 17.81 4 17.81 4 17.81 4 10.31 4 10.31 4 3 4

of

Structure

Fig: P-17

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QUARRY
A quarry is a type of open-pit mine from which rock or minerals are extracted. Quarries are generally used for extracting building materials such as dimension stone, construction aggregate, sand and gravel.

BATCHING PLANT:

The process of weighing out or measuring out the ingredients for a batch of concrete is called batching. In this plant mixing is done by machine, the size of the batch depends upon the rated capacity of the mixer.

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Fig: Quarry

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Fig: Batching Plant

AGGREGATES USED: 10mm and 20mm.

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. Fig: Transit Mixer

ADMIXTURES USED: 1. Eastern Setcrete- Waterproofing Admixture 2. SWC 3. BASF-Superplasticizer

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Mixing is done by Transit mixer. They are truck mounted having a capacity of 6m3. Mixed concrete is transported to site by keeping it agitated all along at a speed varying between 2 to 6 rpm

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BASIS OF MIXING:

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IS CODES: Following IS codes are followed 1. 2. 3. 4. 5. Cement (general)- IS-4031 OPC 53 grade cement- IS-12269 OPC 43 grade cement- IS-8112 Concrete mix- IS-10262 Coarse and Fine aggregate-IS-383

1. 2. 3. 4. 5.

Cube testing 7th day Cube testing 28th day Concreting Cement Cube testing Aggregate testing

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EXPERIMENTS:

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Fig: Various Admixtures.

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1. 2. 3. 4. 5.

Aggregate Crushing Machine UTM (Universal Testing Machine): 2000kN (limit). Aggregate Impact Value Apparatus. Set of Sieves. Thickness Gauge (for determination of Flakiness index)

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MACHINES USED:

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The tests for concrete have done at 150 mm cube to determine the compressive strength in N/mm2.

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Fig: Cube testing area

STORE
The efficient handling and storing of materials are vital to industry. In addition to raw materials, these operations provide a continuous flow of parts and assemblies through the workplace and ensure that the materials are available when needed. The improper handling and storing of materials often result in costly injuries. Its main purpose is for housekeeping of materials, issuing of materials and check on the availability of materials.

MAIN STORE: Main store is used for storage and efficient distribution of materials. It contains all sort of materials required for construction like diesel, petrol, hydraulic oil, TMT bars, ropes, hammers, nuts, bolts steel, iron, machine parts, tyres, welding equipments etc and including safety equipments like safety helmets, safety nets etc.

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PLANNING AND BILLING

Planning involves optimal utilization of all the available resources for maximum output. Its the prime requisite for any project to proceed. It aims to achieve a desirable target in a cost effective way and at scheduled time. Following reports are made and maintained by the planning department: 1. Daily Progress Report or the DPR. 2. Bridge Progress Report (Weekly). 3. Monthly turnover. 4. Day to day program for next month (Monthly). 5. Standard deviation (Monthly). 6. R.A. bill (Monthly). 7. Reconciliation statement (Monthly). 8. Client billing and collection statement (Monthly). 9. Safety report (Monthly) 10. Monthly Progress Report. 11. Weekly Progress Report.

QUALITY ASSURANCE PLAN:

WORK ORDER:

It comes under module execution & sub contractor of ERP which deals with the various details of the job as well as the involved costs.

ITEN RECEIPT NOTE or the IRN: IRN contains info regarding costs, quality, quantity, source and testing criteria.

CONTROL ESTIMATE:

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Provides a systematic approach to managers, engineers and supervisory staff connected with the project for correct implementation of the project specifications and codes as well as application of sound engineering practices so as to minimise human errors and enslaves stability, soundness and durability.

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The reports are made under the supervision of the planning head, and are sent to the Head Office and Project manager.

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It is prepared for providing a skeletal plan incorporating the changes after the tendering stage till date, based on the inputs received from the project site. It attempts a plan to monitor overall progress, turnover and expenditure at site and at the corporate office level. It includes all the monetary aspects of the project like inflation.

TURNOVER: It is the total money involved in the project including escalation as well as the total work done.

INTERIM PAYMENT CERTIFICATE: Interim payment certificate or the IPC is similar to a running account bill and is the bill given to the client for claiming money after a certain amount of work done at certain period of time as specified in the BOQ is completed. In includes the calculation of escalation etc.

PRICE ADJUSTMENT:

MOBILIZATION ADVANCE:

RETENTION MONEY: IT is the amount deposited by the contractor (Gammon India Ltd) to the employer (NHAI) as a security deposit.

LIQUIDATED DAMAGES: It is the amount the contractor (Gammon India Ltd) is liable to pay the client (NHAI) for delay in the project completion.

DEFECT LIABILITY PERIOD:

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It is the sum of money given by the client- NHAI to the contractor- Gammon India Ltd for mobilization and utilization of resources at a rate of interest. The contractor can decide whether it requires the advance or not.

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It gives the difference in the base price index (BPI) and the current price index (CPI). Price adjustment is done for increase in labour, materials, fuels and lubricants in accordance with certain formulae.

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It is the guarantee period which mentions that the contractor is liable to rectify and maintain the job, from the date of handling over of the works.

ENTERPRISE RESOURCE PLANNING (ERP): It is an automated management information system having different modules through which the database of all the records related to the project is managed. The main server is located at Head Office, Mumbai. The modules of ERP are as: 1. 2. 3. 4. 5. Accounts. Client Billing. Control Estimate. International Standardization of Organization (ISO). Planning.

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It is the total quantity of work done under the project as given in the tender without the inclusion of costs. The rates of the various items in the BOQ are finalized by the company during the time of tender estimation.

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BILL OF QUANTITIES (BOQ):

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