Final Report: Industrial Training

Project Name - Construction of 16

Bridges on Katra-Dharam section of
Udhampur-Srinagar-Baramulla Rail Link
Project.

Industrial Training report submitted in partial requirement of

B.E Civil Engineering

Submitted by
Akshay Deep Thakur
16BCE1041
Batch: 2016-2020
Contact No.: 9596843004
Department of Civil Engineering
Chandigarh University Gharuan, Mohali
 ACKNOWLEDGEMENT
The authoris highly grateful to the management of Chandigarh University Mohali, for
providing this opportunity to carry out the Industrial Training on the Project Construction of
16 Bridges on Katra-Dharam section of Udhampur-Srinagar-Baramulla Rail Link
Project in AFCONS Infrastructure Limited.

The author would like to express a deep sense of gratitude and thanks profusely to
<Supervisor/Senior Name>without whose wise counsel and able guidance, it would have
been impossible to complete the report in this manner.

The constant guidance and encouragement received from Prof. Sandeep Salhotra, Head,
Department of Civil Engineering & Er. Sandeep Nasier, Academic Coordinator, Department
of Civil Engineering, has been of great help in carrying out the Industrial Training and is
acknowledged with reverential thanks.

Sign

Name of Student: Akshay Deep Thakur

UID: 16BCE1041

Batch: 2016-2020

I have gone through the content of the report submitted by above mentioned student and
found it in order and fit to carry on the proposed studies.

Dated Signature of the Supervisor with stamp

Name:
Designation:
(For office use only)

The Viva–Voce Examination of above mentioned student was held on ____________ and
accepted.

Sign Sign
Name: Name:
Designation & E Code: Designation & E Code:
Department of Civil Engineering Department of Civil Engineering
TABLE OF CONTENTS
1) COMPANY PROFILE.
1.1 Introduction……………………………………………………….……………
1.2 Company Details………………………………………………………………
1.2.1 Company profile….…………………………………………………………..
1.2.3 Awards………………………………………………………………………..
1.2.4 Achèvements ……..…………………………………………………………..
1.3 Land Mark Projects…………………………………………………………….
2) ABOUT THE CONTRACT
2.1 Project Descriptions ……………………………………………………………..
2.2 Important Information in Contract Document ………………………………….
2.3Outcomes of this Project ………………………………………………………….
3) SITE EXECUTION
3.1 Brief Description of the Project………………………………………………..
3.2 Description of of Bridge no-39…………………………………………………
3.3Foundation in Abutment A-1….………………………………………………..
3.3(a)Hybrid Well Foundation(Micro-Piles)………………………………………
3.3.1Description of Hybrid Well Foundation………………………….
3.3.2Main Activities while the construction of Hybrid Pile Foundation….………..
3.3.2(a)Drilling of Boreholes including Grouting………………………………….
3.3.2(b)Fixing of Reinforcement Cage……………………………………………..
3.3.2(c)Cement grouting in place of Concrete……………………………………..
3.3.2(d)Excavation inside the Foundation………………………………………….
3.3.3Drawing of Hybrid Pile Foundation………………………………………….
3.3.4Overview of the Hybrid Pile Foundation for Abutment A-1…………………
3.3.5Precautions During the Construction (Technical Point of View)…………….
3.3.6Safety Precautions……………………………………………………………
3.4Foundation at Pier (P-1,P-2,P-6,P-7) of Bridge no.39……………………….
3.4.1Description of Raft Foundation at P-2………………………………………
3.4.2Activities Involved in Raft Construction……………………………………
3.4.3Machinery Used in Raft Construction………………………………………
3.5Foundation at Pier P-5 of Bridge no-39………………………………………
3.5.1Preliminary Activities………………………………………………………
3.5.2Main Activities……………………………………………………………..
3.5.3Machinery Used in Raft Construction……………………………………..
3.5.3(a)Approved Drawings for Pier P-5 Foundation…………………………..
3.5.4Risks Involved……………………………………………………………..
3.5.5Safety Precautions…………………………………………………………
3.5.6Concreting Arrangement as per site……………………………………….
3.6Excavation and slope protection works at Bridge-39 A2-P1 location………
3.6.1Major Equipments used while Excavation and Slope Protection work…..
3.6.2Major Materials used……………………………………………………..
3.6.3Method of Construction…………………………………………………..
3.6.3(a)Preliminary Activities Involved……………………………………….
3.6.3(b)Main Activities………………………………………………………..
3.6.4Risks Involved……………………………………………………………
3.6.5Safety Precautions……………………………………………………………
3.6.6Drawing of the Excavation Site………………………………………………
4 Roles and Responsibilities………………………………………………………
5 Summary………………………………………………………………………..
 1) Company Profile
1.1 Introduction
Originally incorporated as Asia Foundations and Constructions Private Limited, this
company came into existence in the year 1959 and began its operations as a mere civil
construction firm and gradually turned into a public limited company. Be it any civil
construction, heavy civil engineering marine work, bridges & flyovers, roads & highways,
power projects, LNG tanks, pipelines, tunnels or port developments, this organization is not
only a leader but also a specialist in offering the best of facilities to the citizens of the
country. Afcons Infrastructure Ltd Mumbai also takes up projects like jetties, breakwater,
docks, harbors, and cofferdams, special foundations like drilling and grouting, ground
anchors, micro piling, and soil exploration works. Further, this engineering, construction,
rehabilitation and infrastructure company does not only have its presence felt in India but is
well known internationally in countries like Iraq, Saudi Arabia, Oman, Qatar, Yemen,
Ethiopia, Sri Lanka, and Nepal.
With so much going into its product portfolio, Afcons Infrastructure LTD has majorly
contributed to the infrastructural development of the society at large.
The insatiable quest has led Afcons to pioneer Reinforced and Prestressed Concrete, Long
span bridges, Under water concreting using the Concrete process, thin shell structures,
Non–Shrinking concrete, Aluminium trusses for launching precast, prestressed beams and
many more. The project services of the Group include transportation engineering,
energy projects and high rise structures, hydraulic works and irrigation projects, tunnel
engineering, marine structures, water projects, pipeline projects and road projects.
The company has significant experience and strong track record in several infrastructure
segments:
• 180+ marine works.
• 140+ bridges/flyovers.
• 4,500+ lane kilometers of roads.
• 85+ Kilometers of Elevated Metro Rail.
• 6 LNG Tanks.
• 9 Tunnels and Hydro Works.
• 40 General Civil Engineering & Industrial Structure.

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1.2 COMPANY DETAILS
1.2.1 COMPANY PROFILE:
* Year of Establishment : 1959
* Revenue :
* Corporate Address:Area No.16, Shah Industrial Estate, Afcons House, Veera Desai Road,
Azad Nagar-Andheri West, Mumbai - 400053, Post Box No 11978
* Management Details :
CHAIRMAN-Mr Shapoor Pallonji Mistry
EXECUTIVE VICE CHAIRMAN-Mr K Subramanian
MANAGING DIRECTOR-Mr S Paramasivan
• BOARD OF DIRECTORS
Mr Umesh Khanna
Mr Pradip N Kapadia
Mr ND Khurody
Mr RM Premkumar
Mr Pallon S Mistry
Ms Roshen Minocher Nentin
Mr R Giridhar
Mr Akhil Kumar Gupta
* Business Operation : Engineering – Construction
* Bankers : DBS Bank, ICICI Bank, IDBI Bank, Indian Bank, Karnataka Bank,
* Oriental Bank of Commerce, Punjab National Bank, Syndicate Bank, Union Bank
of India, UCO Bank, United Bank of India, Central Bank of India, Canara Bank,
* Business Operation : Engineering – Construction

1.2.3 AWARDS
Afcons has been honoured and recognised by the industry for its landmark achievements over
the years. Some select awards are as follows:
• Winner of Public Relations Council of India awards for corporate collaterals in 2017, 2018.
• Among India’s Leading Infrastructure Companies at Dun & Bradstreet Awards in 2017,
and, 2018.

• Three-time winner of British Safety Council’s International Safety Award.

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• Two-time Golden Peacock Award winner.
• Among Construction World’s Most Admired Companies for eight consecutive years.
• Construction Industry Award for Chennai Metro Project for two years in a row.
• Winner of Asian Banker’s Choice Award.
• Confederation of Indian Industry (CII) awards.
• Winner of Public Relations Council of India awards for corporate collaterals in 2017, 2018

• CIDC Vishwakarma Awards 2019 for Agra Lucknow Expressway project and Bharat
Mumbai Container Terminals project.
• MAKE Award in Global, Asia and India levels for two consecutive years (2016, 2017).
1.2.4 ACHIEVEMENTS
The name of Afcons is synonym to innovation, but their commensurate capability for
smoothly execution drives the company to success and galore. Afcons is the first Indian
company to construct an underground metro station without any foreign JV. It has built 4 out
of 6 LNG tanks in India, built India’s longest rail bridge of 4.62km (Vallarpadam Rail
Bridge). It has constructed the first underwater tunnel in India for Kolkata Metro, has also
constructed 8.8km long Rohtang pass tunnel, which is the longest road tunnel in the world at
an altitude of 13000 feet. The Chenab Bridge will stand out as the highest railway bridge post
its completion. Afcons is proud to have developed India’s largest dry dock at Pipavav, Gujrat.
1.3 LANDMARK PROJECTS:
Various landmark projects completed by Afcons. Infrastructure Limited are as follows:
1. 1) Cruise berth, Port Louis, Mauritius.
2. 2) Sulphur Expansion jerry, Abu Dhabi.
3. 3) LNG Jetty, Dahej, Gujrat.
4. 4) Cable Stayed Bridge over Mapusa River, Goa.
5. 5) Nad Al Sheba Development, Dubai.
6. 6) LNG Storage Tanks, Kochi.
7. 7) LNG Storage Tanks, Dahej.
8. 8) Jammu-Udhampur Highway Project.
9. 9) 3-Level Grade Separator at Ghazipur, New Delhi.
10. 10) Barakhamba Underground Station, New Delhi.

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 2) ABOUT THE CONTRACT

2.1 Project Descriptions:

Name of Work - Construction of Bridge no - 34, 38, 39, 40, 41, 42, 43, 53, 55, 56, 57, 58,
59, 85, 87 & 88 on Katra-Dharam section of Udhampur-Srinagar-Baramulla Rail Link Project
in state of Jammu & Kashmir.
Name of Client : Konkan Railway Corporation Ltd (KRCL), CBD Belapur, Navi Mumbai.
CONTRACTOR: AFCONS Infrastructure Limited.
Type of Contract : Item Rate Percentage Contract.
Location of Work: Katra-Dharam section of Udhampur-Srinagar-Baramulla Rail Link
project, J&K.
Total no of Bridges :16
Major Bridges: 11
Minor Bridges:5
Original Schedule Value: Rs. 1,101.27 Crs.
Quoted Rate Value: Rs. 1,219.76 Crs.
Currency of Payment: Indian Rupees.
Bid Submission Date: 01st February 2016.
Bid Opening Date: 29th February 2016.
Date of LOA: 16th March 2016.
Signing of Agreement: 28th March 2016.
Commencement Date:16th March 2016 i.e. date of LOA.
Project Duration: 30 Months from date of LOA. (i.e. Schedule completion date, 15th
September 2018).
Earnest Money Deposit: Rs. 1 crore Only (Rupees One Crore Only).
Security Deposit: Rs. 60,98,79,625 (5% of Quoted Contract Value).
Mobilization Advance: 10% of the Contract Value.
Maintenance/Defect Liability Period: 12 Months from Date of Issue of Completion
Certificate.

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2.2 Important Information in Contract Document:
• Security Deposit - Security Deposit is 5% of Contract value, Bank Guarantee had been
submitted against this.This deposit will be released to the contractor after the
maintenance/defect liability and passing of final bill based on no claim certificate.
• Mobilization Advance - Mobilization Advance released against BG in two stages:
1) 1st Stage : Advance of 5% of Contract value on the signing of contract.
2) 2nd Stage : Advance on completion of the following activities
• 2 % on the establishment of camp site, mobilization of man power, machinery i,e. Batching
Plant (min 3 NO’s), Slipform shuttering, Excavation (min 3 NO’s).
• 1 % Laying of PCC for Foundation in at least 1 Pier location at Br 39&43.
• 1 % Laying of PCC for Foundation in at least 2 Pier location at Br 85&87.
• 1 % Completion of 100 MT Fabrication for Plate Girder.
Interest Rate on Mobilisation Advance at base rate of State Bank of India Plus 4.5 %.
• Recovery is after value of contract executed reaches 15 % of total value of contract and be
completed when value of work executed reaches 75 % of original value of contract.
• Payment of Bills : On Submission of On Account / RA Bills, payment to be, made by
client in 2 stages.
1st Stage - 75 % Payment of billed amount within 5 days after submission.
2nd Stage - 25 % balance amount payable after technical check.
After recovering Mobilization advance and Retention money.
• Performance Bank Guarantee: As per SCC, PBG is 5 % of contract value, submitted to
the client within 30 days after the issue of LOA.
• Taxes: As the contract was formed before the implementation of Goods and Services
Tax(GST), so the rate in bill of quantities were inclusive of Work Contract Tax (WCT).
Now WCT is deducted from the billing amount and GST are added. Along with GST,
Labour charges of 1 % of the billing amount and Income tax are also paid by the Contractor
to Client.
• Defect Liability Period : 12 month from the issue of substantial completion certificate.
• Insurance : Documentary evidence of a third party liability insurance cover in the joint
name of the contractor and the employer from reputed companies to be shown to the
Engineer-in-charge and it should be affected after 30 days of the commencement of work.
• Variation in Quantities : Varieties in Quantities excluding excavation up to 25% increase
would be subjected to no change in price,, and again if the quantities decrease than the

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 original amount then also no change in price. But for the increase in quantities from 25% to
40%, the incremental amount of quantities would be paid at a reduced rate of 2% for the
increase in quantity from 40% to 50%, the incremental amount of work will be paid at a
reduced rate of 4%. Any further increase, the rates would be manually agreed upon.
• Price Valuation : Adjustment to be made for the variation in prices for various compose ts
such as labour, fuel, cement, steel reinforcements and material except cement and steel
reinforcements. Calculations for such variations are made by the various formulae provide
in the contract document and separate bills on price variations are to be submitted to the
client.
2.3 OUTCOMES OF THIS PROJECT:
Socio-economic impact of the project
(i) The completion of this project will provide an all weather and reliable connectivity to the
J&K State through rest of the country by the railway network also provide connectivity by
rail to far flung areas of J&K.
(ii) Construction of Access Roads – Total about 262 kms of approach roads to work sites are
to be constructed. Out of which, 160 kms already constructed. With completion of approach
roads, more than 73 villages will get connected, which will provide road connectivity to
about 1,47,000 people, 29 villages already connected.
(iii) Employment generation – Direct employment to the local people (about 7000) and
indirect employment to thousands for day to day requirement of the project personnel. This
will help to mitigate militancy.
(iv) Permanent job in Railways to one of the family members, whose more than 75% of land
has been acquired. Job given to 343 persons so far.

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 3) SITE EXECUTION

3.1 Brief Description of the Project

Construction of Bridge 34,38,39,40,42,43,53,55,56,57,58,59,85,87 & 88 on Katra-Dharam

Section of Udhampur-Srinagar-Baramulla Rail Link Project in the State of Jammu &
Kashmir.
To connect the Kashmir Valley with the rest of the country, the Afcons Infrastructure LTD
have undertaken the project of KRCL-Construction of 16 Bridges on Katra-Dharma section
of USBRL project in J&K.
1. Br. No. 34- 1X24.4m Composite Steel Plate Girder
2. Br. No. 38 – 1x24.4+1X64+1X45.7m Composite Plate & Trussed Girder
3. Br. No. 39-1X 53.15 +6X64 +1X53.15 Continuous Composite Steel Plate girder
4. Br.No.40 – 1X4X3 RCC Box
5. Br.No.41 – 1X5X5 RCC Box
6. Br.No.42 – 3X5X5 RCC Box
7. Br.No.43- 1X35+1X53.15+10X64 continuous composite steel plate girder
8. Br.No. 53 -3X30.5m Composite Steel Plate girder
9. Br.No. 55 -1x24.4 m Composite Steel Plate girder
10 Br.No. 56 -1x24.4 m Composite Steel Plate girder
11 Br.No. 57 -1x24.4 m Composite Steel Plate girder
12. Br.No. 58 -3x30.5 m Composite Steel Plate girder
13. Br.No. 59 - 2X30.5+1X45.7+1X30.5 m Composite Steel Plate girder
14. Br.No. 85 – 1X45.7+3X61+1X45.7m Composite Steel truss
15. Br.No. 87 – 3X61+1X45.7m Composite Steel truss.
16. Br.No. 88 – 1X45.7m Composite Steel truss.

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 3.2 Description of of Bridge no-39 -
Bridge no 39 is amongst the major bridges comprising of 7 piers and 2 abutments.The whole
cost only for the construction of Bridge no 39 is estimated to be around 380 crores. The
bridge is an engineering marvel having very high rectangular, tapered hollow piers, spanning
490 meters. Bridge No 39 will be about 95 meters high and 22 meters taller than the Qutub
Minar of New Delhi.
Bridge 39 are having continuous composite steel superstructure. With span length as follow-
A1-P1- 1X53.15 m
P1-P7- 6X64 m
P7-A2 -1X53.15 m

• No of Abutment in Bridge no 39 - 2 (Having named as A1,A2).

• No. of Piers - 7 (Named as P1,P2,P3,P4,P5,P6,P7)
• Type of soil underneath foundation - Greyish white cherty dolomite.

The bridge length will be 490.3 m.

The Superstructure had a reinforced concrete deck slab, which is joint by shear studs with the
top flange of superstructure.

Figure:1- Drawing showing the side profile of the Bridge no.39

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3.3 FOUNDATION IN Abutment A1:-
After working out on the soil bearing capacity and assessing of the geological conditions on
which the pier was to be erected ,the engineers decided to lay a particularly new type of
foundation namely HYBRID WELL FOUNDATION.

3.3(a) HYBRID WELL FOUNDATION (Micro-Piles)— A hybrid foundation

consists of both a soil-supported mat and piles and is used principally to support an axial
load. In Europe it is commonly called a piled raft because engineers conceived the idea of
designing the foundation for high-rise buildings using a mat (raft) resting on the ground with
piles supporting the mat The concept was that the combined foundation would be adequate to
support the applied axial loading with an appropriate factor of safety and that the settlement
of the combined foundation at working load would be acceptable.The settlement of a mat
foundation is dish-shaped, with the largest settlement at the center of the mat. To achieve a
more uniform settlement of a structure, it has been suggested that the piles be clustered near
the center of the mat.
The settlement of a mat foundation is dish-shaped, with the largest settlement at the center of
the mat. To achieve a more uniform settlement of a structure, it has been suggested that the
piles be clustered near the center of the mat.The analysis of such a system is complicated
because the settlement of the raft is affected by the presence of the piles and because a piled
raft foundation consists of conventional piles and a rigid raft. Considering each of these
foundation elements separately leads to the conclusion that interaction is inevitable. The mat
alone is certainly affected by the presence of the piles because the foundation is much stiffer
than with the soil alone. The piles alone are affected by the earth pressure from the raft
because the increased lateral stresses on the piles affect the capacity for side resistance.The
problem can be solved by using the finite-element method,
where appropriate plate or solid elements can be used for modeling the raft. Beam elements
can be used for modeling piles.The soil around the piled raft system can be conveniently
modeled as solid elements. Modeling the problem by the finite-element method, which is
widely available, was found to be practical and yielded reasonable agreement between results
from analyses and from experiments.

9
3.3.1 DESCRIPTION OF HYBRID WELL FOUNDATION (Micro-Piles) -
The Hybrid pilling work was executed using drilling machine which works on rotation plus
hammering function. Compressed air was flushed to blow out the crushed rock or soil from
the bottom.
Micro Piles are to be carried out with M40 grade concrete.To reduce the risk of potential
voiding, 10 mm Aggregates.

Diameter of Pile Area :- 14 meters.

Outer Ring :- 98 no’s of pile with 350mm diameter and having height of 22 m.
Inner Ring :-
1st Circle :- 23 no’s of pile with 350mm diameter and having height of 11m.
2nd Circle :-17 no’s of pile with 350mm diameter and having height of 11m.
3rd Circle :- 11 no’s of pile with 350mm diameter and having height of 11m.
4th Circle :- 4 no’s of pile with 350mm diameter and having height of 11 m.

Figure:2- Plan of Hybrid Well Foundation showing Micro Piles.

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3.3.2 MAIN ACTIVITIES INVOLVED DURING THE CONSTRUCTION
OF HYBRID PILE FOUNDATION:
1) Drilling of Boreholes including Grouting.
2) Fixing of Reinforcement Cage.
3) Cement Grouting in place of Concrete.
4) Excavation inside foundation.
Above activities are explained in details as below:
3.3.2(a) Drilling of Boreholes including Grouting:- Points are marked with the
help of Total Station, Reference point is marked nearby about 2 m from the pile point.
After preparation of access, survey works etc; drilling rigs were be deployed at site.Generally
drilling method is selected on the basis of causing minimal disturbance to the ground or
nearby structures.In this case, looking at the site condition, Micro pile was carried out with
the help of DTH type drilling rigs.

• STEP 1- Positioning of Drilling rig on the top of the survey point. Verticality of first drill
rod and mast is checked using spirit level. In addition to this, a plate of cylindrical shape
was be attached to the drilling bit, generally at 5-7m c/c.There was an additional precaution
to avoid any deflection or movement of drilling bit.

Figure:2- Piling with compressed air.

• STEP 2- In soil condition only, temporary liner was be placed, approx. for a depth of 3-5
m

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 Drilling was done with reamer attachment to enlarge the holes for placing of liner.
Air compressor was be attached to the drilling rig with hydraulic hose.
All the loose strata was be removed with the help of air and drilling was continued.

• STEP 3- During the drilling in Rock, if there is an air loss, the portion of the air lost was
grouted with sand-cement grout.Drilling was continued only after 1 day waiting period for
setting of the grout. Same process will be continued till termination of the pile.
In this case, since the outer piles were closely spaced, drilling sequence was arranged in such
a way that the time gap between adjacent piles was to be 2 days.
In order to drill the pile without any disturbance to the adjacent piles and based on the space
availability, total foundation was distributed in four sections.
3.3.2(b) Fixing of Reinforcement Cage: As per drawing and approved BBS,
reinforcement cage was fabricated at site.
After the completion of drilling, reinforcement cage was inserted in the drilled hole.

Figure:3- Reinforcement Cage lowering

In case of higher depths, cage was to be welded and inserted inside the drilled hole one after
the other.
It was to be made sure that, welded spots are coated again with inhibitor solution.

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3.3.2(c) Cement Grouting in place of concrete- The pile is now ready for
concreting which is done using tremie pipe technique (150mm dia).
The steps involved are :

• Lowering of pipes with the help of small telescopic crane / hydra into the piles to be
concreted .

• Fixing the hooper at the top of the tremie pipe.

• Once the concreting is begun, the tremie pipe is lifted so as the bottom of the pipe is
submerged at a distance of 1.5 m meters from the top of the current concrete level.

• Concrete is allowed to flush for sufficient, a minimum overflow of 1 meter above pile cut-
off is suggested.

• After concreting , Casing is removed and rebars are left exposed.

• No pile which is located within 1.5 m clear distance from a newly concreted pile shall be
bored or driven until 48 hours completion of concreting.

• Newly concreted piles shall not be loaded by any sort of machinery used , until a minimum
of 24 hours elapse following the completion of the concreting.

• The tremie should be designed so it is able to pass within the reinforcing cages without
causing damage. No vibration is allowed and there shall be no segregation.
As per the drawing issued, Micro piles were to be carried out with M40 grade of
concrete.Considering the congestion i,e. Cover of 50mm, Reinforcement steel of 12mm and
20mm did, the space available for placing the tremie was only 126mm.Considering the tremie
of 100mm, Free flowing of concrete was not possible and it could have ended up with the
voids.
Looking at this scenario, it was proposed to use cement grout in place of concrete.
A grouting plant (MS) was installed at the site location with a maximum capacity of 2 cum. A
cement grout was prepared at the site in the mixing tank and same was poured with the help
of grouting pump.
3.3.2(d) Excavation inside the Foundation/ Shotcrete / Pile cap -Excavation
inside the foundation was carried with the help of Long boom excavator/ Crane & Grab.

13
 Figure.4: Construction of hybrid pile foundation during initial stages.
Stage wise sequences for the same are as follows-

• STAGE 1 - Excavation inside the well up-to the Bottom of Level 1 ring beam was carried
out with the help of excavator.The depth of excavation was 750 mm.After the excavation,
Level 1 ring beam was casted.

• STAGE 2 - After the completion of Ring beam and curing period of 7-14 days depending
on the achieved strength , further excavation till bottom of level 2 ring beam was
completed and subsequently Ring beam 2 was casted. After the completion of Ring Beam
2, shotcreting was carried out between Level 1 & 2. Shotcreting was to be carried out with
the hose having a reach of 20 m by keeping the machine at the ground.

• STAGE 3 - Same procedure adopted between Level 1 & 2 was repeated between Level 2
& 3.

• STAGE 4 - After completion of excavation, inner piles were chipped to the required level
and bottom cap was casted.

• STAGE 5 - After completion of the Bottom pier Cap , inner filling with concrete was
carried out by directly from transit mixture.

• STAGE 6 -After the completion of inner fill and required curing period, Top pile cap was
constructed.

14
3.3.3 DRAWING OF HYBRID PILE FOUNDATION:

Fig.5- Plan of Hybrid pile foundation for Abutment A1.

15
3.3.4 OVER VIEW OF THE HYBRID PILE FOUNDATION
CONSTRUCTED FOR ABUTMENT A-1:
• No of Bores Casted in-situ Outer piles - 98.

• Depth of Bores Casted in-situ Outer piles - 21.750m.

• Diameter of Bores Casted in-situ Outer piles - 350mm.

• Diameter of Bored Cast in-situ Outer piles Ring (c/c) - 13500mm.

• No of Bores Casted in 2nd in-situ piles and Dia. of bores - 23 bores, 350mm dia.

• Centre to Centre Distance b/w Bored Cast in 2nd in-situ piles- 11000mm.

• No of Bores Casted in 3rd in-situ piles and Dia. of bores - 17 bores, 350mm dia.

• Centre to Centre Distance b/w Bore Casted in 3rd in-situ pile ring - 8000mm.

• No of Bores Casted in 4th in-situ piles and Dia. of bores - 11 bores, 350mm dia.

• Centre to Centre Distance b/w Bore Casted in 4th in-situ pile ring - 5000mm.

• No of Bores Casted in 5th in-situ piles and Dia. of bores - 4 bores, 350mm dia.

• Centre to Centre Distance b/w Bore Casted in 5th in-situ pile ring - 2000mm.

• R.L of Pile Founding Level - 771m.

• Bottom of Pile Cap Level - 793m.

• R.L of Level-1 Ring Beam - 792.250m.

3.3.5 PRECAUTIONS DURING CONSTRUCTION (Technical point if

view)
• In case of duplex drilling , maximum of 0.5 m shall be drilled beyond temporary liner.

• Temporary liner shall be removed such that reinforcement is not disturbed.

• Drilled holes shall be plugged or covered.

• Proper monitoring of drilling works to avoid loss of drilling fluid, sudden drop of drill tools
etc.

• Adjacent piles shall be drilled after an interval of at least 1-2 days.

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3.3.6 SAFTEY PRECAUTIONS
• Prior to starting the excavation, the area will be barricaded and suitable signboards shall be
placed.

• Proper PPE and Ear plugs were to be provided for the persons working near the pile driving
location.

• Proper Ingress and egress to be provided.

• For inspection of works, if feasible, stair case were erected at site.

• Proper lighting arrangement was made during night works.

• It was ensured that all the equipments were properly maintained prior to the
commencement of works.

• All other precautions were taken as per AFCONS safety and HSE manual.

3.4 Foundation at Pier (P-1, P-2, P-6,P-7) of Bridge No.39

Raft Foundation :
3.4.1 Description of Raft Foundation at P2
Clear Cover - 75mm
Grade of Concrete - M35
Grade of R/f Steel - 50d (Good Bond) & 72d (Bad Bond)
Anchorage Length - 36d (Good Bond) & 52d (Bad Bond)
Bending of Reinforcement shall conform to IS:2502.

Figure:6- Dimensions of Raft Foundation P2.

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 Figure:7- Plan of top view of Raft Foundation P2.

Figure:8- Plan of side view of Raft Foundation P2.

3.4.2 Activities involved in Raft Construction :

1. Marking of position with the help of Total Station.
2. Excavating and leveling the ground surface.
3. Laying and leveling PCC (M10) 100mm thick.
4. Cutting, Bending, Placing of Reinforcement Steel according to the drawing provided.
5. Cleaning of shuttering plate with the help of grinder wire mesh attachment.
6. Installation of the shuttering along the periphery of the raft foundation.
7. Installation of the concrete pumps, concrete pump pipes (125mm dia ).
8. Cleaning with the Air compressor and sprinkling water over PCC.
9. Pouring of Concrete in 300mm layers with the help of Needle Vibrators.
10. Smearing curing compound once the concrete is set and shuttering is removed at last.

3.4.3 Machinery used in Raft Construction :

1. Telescopic Crane RT 60 Ton.
2. Flat Bed Truck 25 Ton.
3. Bar Bending Machine.
4. Bar Cutting Machine.
5. Total Station.
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6. Batching Plant CP30 and M1.
7. Air Compressor (Having pressure of 300CFM).
8. Concrete pump 32cum/hr , 46 cum/hr and 72 cum/hr.
9. Concrete Pipe (125mm).
10. Transit Mixture.
11. Needle Vibrator.
12. Grinder with wire meat attachment.

3.4.4 There are some conditions in the scope relevant to this work :
1. Hooper with chutes are provided as height is more than 1.5m, reducing the chances of
segregation .
2. Temperature of concrete is needed to be maintained , use of at ice at batching plant.
3. Concreting is done in the layers of 300mm.
4. Finishing on the trapezoidal section of the raft can be done by reducing the slump to be
just able to pump.

Fig: 9 - Reinforcement Fixing of Raft at P2.

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Fig:10 - Complete Plan for of Raft P2 (which is similar to that for Pier 1,2,6 and 7).

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Fig.11 :- Plan of Foundation of Pier P-5 (Top View).

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3.5 Foundation at Pier P-5 of Bridge No.39
3.5.1 PRELIMINARY ACTIVITIES :-
A) Design & Drawing
The latest GFC (Good for Construction) drawing was used at site. In case of change or
revisions, it was notified to all the key personnel immediately.

B) Survey and Layout

The foundation layout as per approved drawing was marked at site over the PCC laid
surface.

3.5.2 MAIN ACTIVITIES :-

• Casting RCC Foundation-

A) Placing of Reinforcement:
1. High strength deformed (HYSD) bars of grade Fe 500/500D conforming to I.S 1786-1985
were used as reinforcement with the minimum yield strength of 500N/mm sq.
2. Clear Cover to outer most steel was 75mm for footing.
3. Approved Bar Bending Schedule was used on basis of approved drawing and actual length
of bars available indicating the positions of laps and splices.

4. All the reinforcement bars were accurately placed in an exact position as shown in the
drawings and were securely held in position during placing of concrete by galvanized still
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 binding wire not less than 18 SWG in diameter and conforming to IS 280 and by using
stays, blocks or metal chairs, spacers, metal hangers, supporting wires or other approved
devices at sufficiently close intervals.
5. To protect reinforcement bars from corrosion shall be coated with inhabited cement
slurry coating as per IRS and IRC specifications.

B) Formwork :-
1. The formwork conformed to the shape , lines and dimensions as shown in the drawings in
order to achieve the relevant tolerances of finished concrete as specified.
2. The formwork was so constructed and supported as to remain sufficiently rigid during the
placement and compaction of concrete and were tightly closed in order to curb the loss of
water or mortar from concrete.
3. Forms for finished surfaces were smooth and mortar tight.
4. Where the wood forms are used, the boards were uniform in the thickness, tongued and
grooved, smoothly finished on the surface next to the concrete evenly matched and
tightly placed, except where the desired surface or appearance requires special treatment.

Fig:-13. Drawing of top view of foundation showing the dumping yard along with other features.

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C) Concreting :-
1. The concrete as per approved design mix designed was placed before setting has
commenced and not be subsequently disturbed.
5. Concrete was placed as to avoid segregation of the materials and the displacement of
reinforcement. To achieve this, concrete was to be lowered vertically in the forms and
horizontal movement of concrete inside the forms should as far as practicable be brought
to a minimum.
6. Under no circumstances concrete was dropped freely from a height of more than 1.50
meters.
7. A record was kept of the time and date of placing the concrete in position. Slump of
concrete was maintained and checked to maintain proper workability of concrete.
8. No concrete was allowed without the vibration except under water concreting. To achieve
proper compaction mechanical vibrators were used. The use of vibrators complying with
I.S: 2505, I.S: 2514 and I.S: 4656 for compacting concrete is recommend. Over vibration
and under vibration of concrete is harmful and thereby was avoided.
9. The concrete was kept constantly wet for a minimum period of 14 days. Water was to be
applied uniformly on the surfaces as soon as it can be done without marring the surface
and on formed surfaces immediately after the forms were skipped.

3.5.3 Machinery used in Raft Construction :

1. Telescopic Crane RT 60 Ton.
10. Flat Bed Truck 25 Ton.
11. Bar Bending Machine.
12. Bar Cutting Machine.
13. Total Station.
14. Batching Plant CP30 and M1.
15. Air Compressor (Having pressure of 300CFM).
16. Concrete pump 32cum/hr , 46 cum/hr and 72 cum/hr.
17. Concrete Pipe (125mm).
18. Transit Mixture.
19. Needle Vibrator.

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20. Grinder with wire meat attachment.

3.5.3(a) Approved Drawings for the Foundation of Pier P-5:

Fig.14:- Drawing showing the Foundation of Pier P-5 (Incorporates all the views).

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Fig.15:- Side view of the Foundation of Pier P-5.

Fig.16:- Drawing of Reinforcement for Foundation at Pier P-5 (1 OF 2)-Br39.

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 Fig.17:- Drawing of Reinforcement for Foundation at Pier P-5 (2 OF 2)-Br39.

3.5.4 Risks Involved

1. Working at height / deep.
21. Falling of object.
22. Sliding of loose soil.
23. Heavy equipment movements.
24. Running traffic.
25. Dewatering.

3.5.5 Safety Precautions

1. For working at height / deep, all the necessary safety measures were provided.
26. No personnel were allowed inside the working area / swing radius of the equipments.
27. Equipments working in the narrow width were well planned.
28. Highly skilled workers, operators and drivers were engaged in this construction
work.They were educated and trained as per the guidelines of safety regulations, about
the procedures of the job and high degree of risks involved in this job.
29. Working area was barricaded properly to prevent ingress of the other unauthorized
workers.
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30. Work methodology of the activity was explained to all the key personnel and workmen
involved in that activity and standing instruction were also given.
31. Site first aid facilities were made available.

3.5.6 Concreting arrangement as per site :

1. Three concrete pups and two chute were used at the site.
32. Elephant horse pipe was used for concreting through pumps to prevent free flow of
concrete from more than 1.5 m height.
33. Concreting was done completing from one side to the other side.

3.6 Excavation and Slope Protection works at Bridge no-39/A2-

P1 Location.

Reason Behind the Evaluation & Rendition of Excavation and Slope Protection
Activity:

Slope failures are the most common natural hazards and are mainly caused due to the
additional forces due to foundations of the structures on them or rainfall induced or
earthquake induced ground shaking and associated inertial forces. Earthquakes of even a very
small magnitude may trigger failure in slopes in jointed rock masses which are perfectly
stable otherwise.

• Geological structure of the rock often govern the stability of slopes in jointed rock masses.
The Slope or the rock mass at the vicinity of Piers and Abutments of Bridge no-39 consists
of highly crushed dolomite rock which has severely low cohesion value or C value.

• Since the Platform of the Reasi Railway station is going to lie over these piers and
abutments, therefore it becomes imperative upon the engineers to provide slope protection
work.

• The geographical location of Reasi lies in the Seismic Zone-V, which is highly susceptible
to Earthquake tremors, therefore backing this fact it becomes necessary to impart adequate
slope protection.
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Thus, the evaluation and protection of stability of the natural rock slopes becomes very
essential for the safe design especially when the slopes are situated close to structures which
are built on these slopes. The stability of a natural slope becomes more critical if the slope is
situated in earthquake prone areas.

3.6.1 Major Equipments involved during the excavation and slope

protection work :

1. Excavators.

Fig.18- Excavator

2. Rock Breakers.

Fig.19:- Rock breaker

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3. Dumpers and Tippers.

Fig.20:- Tipper carrying excavated earth.

4. Shotcrete Machine.

Fig.21:- Shotcrete machine.

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 3.6.2 Major Materials:

The materials listed below will be used for slope protection works:

• SFRS (Steel Fibre Reinforced Shotcreting).

• SN 32mm x 6m & SN 32mm x 4m.

Fig .22:- SN rockbolts coated with water repellent Admixtures

• Base plate and Nuts.

Fig.23: - Base plate.

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3.6.3 METHOD OF CONSTRUCTION:
3.6.3(a) PRELIMINARY ACTIVITIES :
a) Design Drawing :
The Latest GFC (Good For Construction) drawing is usually used at site.If there is any
change or revisions, it will be notified to key personal immediately.

b) Survey and Layout :

The layout was plotted at site jointly after approval of the layout from the KRCL.

3.6.3(b) MAIN ACTIVITIES :

The below activities are the major activities involved in excavation and slope protection of
bridge no 39 A2-P7.

a) Clearance of site :

The site will be cleared from obstructions to enable the setting out to be done.

Necessary labour, pegs, string will be used for the proper setting out of work.

b) Construction of approach road :

To carry out the excavation and protection works the construction of approach road unto the
required area which is to be excavated was carried out.

Fig.24: - Approach Road for the excavation site

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c) Survey Marking :

As per the site requirement, the survey points were marked at ground for excavation by
considering the excavation margin for subsequent works involved in the construction and
protection works for slope on the left side of foundation alignment.

Fig.25:- Figure showing survey marking.

d) Excavation and Disposal :

The excavation at the site is being executed to the depth as shown in the drawings.

Original ground levels were recorded for claim.Excavators or breakers were used to remove
the excess soil and dumpers is being used to transport the soil from working area to the
designated dumping area.Dewatering pumps were used when there was the requirement for
the removal of seepage water from the excavation pit.Sloping and benching is required to be
maintained as per the site conditions to avoid the side collapse during excavation.

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 Fig.26:- Excavator while excavation.

e) Shotcreting to stabilize the sides of excavation pit :

After completion of the excavation at respective stages, the slope surface will be prepared for
shotcreting works. SFRS of 50mm thick will be sprayed in 2 layers.

Fig.27 :- First layer of Shotcrete done after excavation of slope.

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 What is Shotcrete?
• Shotcrete is concrete shot from a hose and pneumatically projected at high velocity onto a
surface, as a construction technique.
• Shotcrete undergoes placement and compaction at the same time due to the force with
which it is projected from the nozzle. It can be impacted onto any type or shape of surface,
including vertical or overhead areas.
• Shotcrete is applied in thin layers.
• Shotcrete is usually reinforced by wire-mesh or steel fibres.
• Shotcrete is being used widely around the world as underground support.
Shotcrete consist of Cement, Sand, Coarse Aggregates, Water as the basic shotcrete mix and
the additives which are added to improve shotcrete properties. These are mixed in pre-
determined proportions to produce a Dry-mix or a Wet-mix shotcrete.

Shotcrete- History :

Shotcrete, then known as Gunite, was invented in early 1900s in America used to fill plaster
model of animals. Development further for Engineering applications is as under:

• 1907- First Device to spray dry materials invented by Carl Ethan to spray materials on to
wire frames to make Animal models.

• 1910- First Cement Gun was introduced at New York Concrete Show. The Design
developed by Cement Gun Company (Now- Allentown Shotcrete Technology).

• 1920 Dry-mix process patented in Germany.

• 1930 Generic name shotcrete introduced by the American Railway Engineering

Association to describe the dry-mix process.

• 1940 Initial use of coarse aggregate in dry-mix shotcrete.

• 1950 American Concrete Institute ACI Committee 506, Shotcreting, formed.

• 1952 Development of the rotary style dry-mix gun in Michigan and Illinois, USA.

• 1955 Introduction of the wet-mix shotcrete process.

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 • 1970 First use of steel fiber-reinforced shotcrete by U.S. Army Corps of Engineer.

• 1975 First use of silica fume in shotcrete in Norway. 1980 First use of silica fume in
shotcrete in North America in Vancouver, BC, Canada.

• 1985 First use of air entrainment in dry-mix shotcrete process in Quebec, Canada.

• 1988 First practical use of high-volume synthetic macrofibers in wet-mix shotcrete in

Alberta, Canada.

• 1998 Formation of the American Shotcrete Association (ASA).

• 2000 ACI Shotcrete Nozzleman Certification Program established.

Shotcrete- History in India

In India Shotcreting has been in use since 1970s. Initially small capacity dry shotcrete
machines were used. Later in Chamera-I hydroelectric project Dry Shotcreting with Aliva-
280 and Teledyne Robo-arm was used. Later Nathpa Jhakri was another major Hydro Project
using similar technologies. Further Wet shotcreting and Steel Fibre Reinforced Shotcrete was
done at Uri HE Project in 1990s. Wet Shotcrete has now taken over from Dry shotcrete is
being regularly used especially in underground works i.e. tunnels, caverns etc.

• How Does Shotcrete Stabilise Rock Mass?

Shotcrete stabilises the excavated or exposed rock mass as it maintains the existing
stability. Fines are squeezed into cracks and joints which produce a wedge effect like
mortar between bricks in a wall. Transfer of load in a weak zone to adjacent stable
rock mass is through shear or adhesion. Shotcrete layer acts as a membrane in
bending or tension thus preventing exposure of rock to changes of moisture, effect of
air & temperature, washing effect of running water.

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f) Rock Bolting :

Rock Bolts SN of 32mm dia and 12m long will be installed.

The spacing between rock bolts will be 1.50m c/c in horizontal lines and in vertical lines as
staggered pattern.

For these, suitable drilling machines R0C crawler drill machine is used by making ramp from
one side to install the rock bolts.

Fig.28 :- Rock Bolts SN of 32mm dia and 12m long.

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g) Grouting :

Each rock bolts will be grouted to stabilize the soil/rock and anchor bolts using grouting
pump. Grouting is done till the grout returns from the hole.

After the grouting is completed the SN/SDA’s are finally anchored with base plates which
are tightened with nuts.

The above sequence will be repeated until founding level has reached.

Thus the slopes are stabilized by spraying of SFRS and anchoring with rock bolts and
Grouting.

Fig.29 :- Grouting Pump.

h) Weep Holes:

Pressure relief holes of 100mm dia, 5m long and at 3m centre to centre spacing as mentioned
in the approved drawing is to provided. PVC pipes with 50mm geotextil wrapping is
provided in the weep holes.

j) Drainage :

Drain of 0.75m x 0.75m will be provided on each berm as shown in the diagram.

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3.6.4 RISK INVOLVED :

a) Working at height.

b) Falling of object.

c) Sliding of loose soil.

d) Heavy equipment movements.

e) Dewatering.

3.6.5 SAFTEY PRECAUTIONS :

a) For working at height, all the necessary safety measures were be provided.

b) No personnel were allowed inside the working area / swing radius of the equipments.

c) Equipments working in the narrow width were planned.

d) Highly skilled workers, operators and drivers were engaged in the construction work. They
were be educated and trained as per the guidelines of safety regulations, about the procedures
of job and high degree of risks involved in the job.

e) Working area was be barricaded properly to prevent ingress of the other unauthorized
workers.

f) Work methodology of the activity was explained to all key personnel and workmen
involved in that activity and standing instructions was given.

g) Site first aid facilities were made available at the site.

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3.6.6 DRAWINGS OF THE EXCAVATION SITE

FIGURE.30 :- Reasi Station Yard Open Cut plan

FIGURE.31:- Reasi Station Yard Open Cut plan with R.L

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 FIGURE.32 :- PLAN OF SLOPE PROTECTION WORK.

FIGURE.33 :- PLAN OF SLOPE PROTECTION WORK

FIGURE.34 :- DETAILS OF SLOPE PROTECTION WORK

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 4) Roles and Responsibilities:

I have been asked to observe the work going on site along with my mentor. He was an
Engineer from Development Authority for Surveillance of the work done by various
departments. As there were number of sites allotted to Company for Construction of these
sites are categorised as Bridge no - 34, 38, 39, 40, 41, 42, 43, 53, 55, 56, 57, 58, 59, 85, 87 &
88 on Katra-Dharam section of Udhampur-Srinagar-Baramulla Rail Link Project in state of
Jammu & Kashmir.
The work schedule of each zone was same i.e. construction of bridges on different sites. The
perfection of each and everything was according to the company’s plans and safety of
workers and trainee engineers. Work done by me individually is as follows:

I was appointed on site as Trainee Engineer, so on site my duty was to learn and supervise

the work going on site my Duties on site are as follows:

• Monitoring quantity like cement, sand, aggregates, & quality of materials.

• Observing the assembling & checking of reinforcement as per drawing.

• Supervise concreting work.

• Studying all types of drawings & layout of concrete work.

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 5) SUMMARY
It was indeed a privileged moment for me to be a part of a project of such magnitude and
brilliance. Even 6 weeks seemed a minuscule of a time to learn the vast array of technology
and skill on display for the project. AFCONS uses state of art technology with the Innovation
never heard of hybrid pile well foundation and many other technology that were new for my
knowledge. The attitude of the team here is credible and they are so much devoted towards
their work.
ICRA has reaffirmed the long term rating of A1+ which reflects highest credit quality. Dun
and Bradstreet has assigned rating of 5A2 which states overall status of the company is good.
Afcons is developing a niche for itself in the infrastructure sector with projects that no one
else plans to venture into. It has already associated itself amidst some of the renowned
projects in the country. With the modest roots and committed employee base AFCONS is
taking giant strides to become one of the best in the business among Infra companies.
A thank you would be an understatement for the vast foray of skills I was imbibed with.

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