Final Completion Report

Final Completion Report GSHP-1

FINAL COMPLETION REPORT
GSHP-1
Sarkhej to Viramgam
(km. 11+000 to km. 59+000)
Gujarat State Highway Phase - I
1-1
Louis Berger Int., Inc.

Table of Content
1 INTRODUCTION................................................................................................4
1.1 Description of Contract...............................................................................4
1.2 Project Summary........................................................................................4
1.3 Supervision Consultancy Contract Details..................................................4
2 PROGRESS SUMMARY....................................................................................5
2.1 Pre-Construction Activities..........................................................................5
2.1.1 Hand Over of Site..................................................................................5
2.1.2 Acquisition of Land................................................................................5
2.1.3 Utilities...................................................................................................5
2.1.4 Removal of Trees..................................................................................5
2.2 Work Programmes......................................................................................5
2.2.1 Submission of Programmes..................................................................5
2.2.2 Comparison of Progress against Programme.......................................6
2.3 Road Works................................................................................................6
2.3.1 Road Works - General...........................................................................6
2.3.2 Formation – Earthworks........................................................................7
2.3.3 Base Courses........................................................................................7
2.3.4 Asphalt Surfacing..................................................................................8
2.4 Structures................................................................................................... 8
2.4.1 General – Bridges.................................................................................8
2.4.2 Other Cross Drainage Structures..........................................................8
2.5 Drainage.....................................................................................................9
2.6 Socio Economic Development & Safety.....................................................9
2.7 Access Roads...........................................................................................10
2.8 Miscellaneous Items.................................................................................11
2.8.1 Site Offices..........................................................................................11
2.8.2 Highway Landscaping.........................................................................11
2.9 Extension of Time.....................................................................................11
2.10 Variation Orders....................................................................................... 11
2.11 Substantial Completion.............................................................................12
2.12 Maintenance.............................................................................................12
3 Quality Control................................................................................................12
3.1 General.....................................................................................................13
3.2 Details of the borrow areas & sources......................................................13
4 PROBLEMS AND THEIR RESOLUTION........................................................13
4.1 Key Events of Project...............................................................................14
4.2 Delays.......................................................................................................15
4.3 Technical Problems and their Resolution.................................................15
4.3.1 Over Toping of Water During Floods of 2003......................................15
4.3.2 Pavement Behavior.............................................................................15
5 PERFORMANCE OF CONTRACTOR.............................................................16
5.1 General.....................................................................................................16
5.2 Contractor’s Mobilisation..........................................................................17
5.3 Plant and Equipment................................................................................17
5.4 Staffing..................................................................................................... 18
6 Construction Supervision..............................................................................19
6.1 Consultancy Contract...............................................................................19
6.2 Supervision Team.....................................................................................19
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6.3 Procedures...............................................................................................20
7 Review of Design & Specification.................................................................20
8 Environment and Social Management..........................................................21
8.1 Training of contractor staff........................................................................21
8.2 Environmental Inspection.........................................................................21
8.3 Environmental Monitoring.........................................................................21
8.4 EMAP compliance....................................................................................21
8.4.1 Dust.....................................................................................................21
8.4.2 Air Pollution.........................................................................................22
8.4.3 Noise...................................................................................................22
8.4.4 Borrow area.........................................................................................22
8.4.5 Drainage..............................................................................................22
8.4.6 Contamination from Waste..................................................................22
8.4.7 Contamination from Fuel and Lubricants............................................22
8.4.8 Soil Erosion.........................................................................................22
8.4.9 Topsoil.................................................................................................22
8.4.10 Compaction Of Soil.............................................................................23
8.4.11 Loss of Trees.......................................................................................23
8.5 SOCIAL ENVIRONMENT.........................................................................23
8.5.1 Sanitation and Waste Disposal in Construction Camps......................23
8.5.2 Safety..................................................................................................23
8.5.3 Loss of Access....................................................................................23
8.5.4 Traffic Jams and Congestion...............................................................24
8.5.5 Cultural Remains.................................................................................24
8.6 Other.........................................................................................................24
9 Documentation................................................................................................25
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1 INTRODUCTION
1.1 Description of Contract
GSHP-1 is a part of Gujarat State Highways, Phase I. Contract Package of Loan

No.4577-IN comprises the strengthening and paving of shoulders of existing SH-
17 from Sarkhej to Viramgam covering 48 Km. the State highway is important link
to connect industrial hub, Sanand. This corridor is part of the shortest link to
Kachchh and western areas of Gujarat.
1.2 Project Summary
Project Name : Sarkhej to Viramgam

(km. 11+000 to km. 59+000)
Gujarat State Highway Project – 1
Under loan Assistance of World Bank
Contractor : Oriental Structural Engineers Ltd
Loan No. : 4577-IN
Date of Commencement of Works : 17th October 2000
Original Completion Date : 16th April 2003
Time Extension : 2 months (Sixty Calendars Day)
Revised Completion Date : 16th June 2003
Original Contract Period : 30 months
Revised Contract Period : 32 months
Contract Amount (Original) : Rs. 628,913,200.00
Final Completion Amount : Rs. 757,728,624.00
Escalation : Rs. 113,112,712.00
1.3 Design/Supervision Consultancy Contract Details
Design Consultants/Project Coordinating

Consultant : N. D. Lea, Canada & LASA, India
Construction Supervision Consultant : Louis Berger International Inc., USA
Domestic Associate Consultant : CES, ICT, ECI & SAI
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2 PROGRESS SUMMARY
2.1 Pre-Construction Activities
2.1.1 Hand Over of Site
The site was Handed Over on 17th October 2000 and mobilization started very
slowly.
2.1.2 Acquisition of Land
Apart from one or two locations, Acquisition of Land was not a problem to
construction progress. The road is constructed mainly parallel to the existing
railway line, which has required coordination between the R&BD and the
railways to resolve interface problems and minor land acquisition to improve
alignment and safety.
2.1.3 Utilities
The removal of utilities commenced in October 2000 and completed by August

2001. The utility shifting included removal of electric & telephone poles, trees
and shifting of high-tension line.
2.1.4 Removal of Trees
Generally removal of trees was not the problem in this package, tree cutting
started in 11th December ’00 and completed by August 2002.
2.2 Work Programme
The contractor produced an initial construction programme at the commencement

of work. This was subsequently upgraded to compensate for a slow start to the
project and acceleration towards the completion. When the contract was divided
from two to three working sections.
2.2.1 Submission of Programme
Contractor submitted a works programme in the form of a bar chart. This was
subsequently replaced during construction by 3 revised works programme
under General Conditions of Contract (FIDIC Clause 46.1).
1. Original Programme : October 2000

2. Revised Programme – 1 : January 2001
3. Revised Programme – 2 : August 2001
4. Revised Programme – 3 : November 2001
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2.2.2 Comparison of Progress against Programme
2.3 Road Works
2.3.1 Road Works - General
The work under contract consisted

of the strengthening of the existing
highway by direct overlaying the
original surface, with full depth
pavement widening if required,
and construction of a two lanes on
the existing. Improvement of
horizontal and vertical alignments
was incorporated where
appropriate. Four Lane Section Sanand
The improvement of Sarkhej and Sanand required that a dual carriageway with
parking facility and street lighting, a covered drain and paved walkways were
added to improve the town facilities. Total 5.7 km has been dualed in this
contract.
Start End
Mobilisation 17 Oct 00 Feb 02
Survey 17 Oct 00 16 June 03
Tree Cutting 11 Dec 00 Aug 02
Materials Testing 3 Jan 01 16 Jun 03
Clear & grubbing 14 Dec. 00 30 Sep 02
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Start End
Earth works 20 Dec 00 Trial Emb. 31 Dec 02
Selected Subgrade 16 Feb 01 01 Feb 03
GSB 25 Jan 02 09 Feb 03
Start End
WMM (Mechanical) 13 May 01 15 May 03
WMM (Paver) 29 May 01 30 May 03
DBM 11 Jun 01 10 Jun 03
AC 15 July 01 16 Jun 03
Diversions 8 Feb 01 16 Jun 03
Culvert construction Dec 01 16 Jun 03
2.3.2 Formation & Design

Changes – Earthworks
Local information related to the
hydrology of the area resulted in a
design change at some locations to
meet the anticipated flood level. The
list of borrow areas are shown in the
Chapter 3 Quality Control. The
contractor initially had three
earthworks groups and expanded to
five. The initial formation/earthworks GSB in Progress
was the excavation in three phases,
firstly along one side in order to
widen the formation to the full required width then the traffic was diverted out
same then to the other side was excavated including the area of existing road
that was required to be replaced. Finally the third phase was to return to the
area of road on the opposite side which had not been removed in the first
phase. This ensured sufficient room for traffic.
2.3.3 Base Courses
At many of the locations the existing road of the carriageway had shown signs
of distress, which could be a weak spot for the performance of the pavement
over its life. These locations were dismantled and replaced with selected sub
grade/granular sub base.
Materials were hauled from
Sabarmati River to stockpiles
located at strategic parts of the site
and blending with aggregates and
soil to make GSB for laying. Close
monitoring and testing was carried
out to ensure satisfactory GSB
materials. To ensure continuity of
GSB works during the disturbances
(February to June 2002), another
source and (55,000 m3) at Charia
near Limdi (in addition to Sabarmati Compaction in Progress
River) was approved temporarily
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between (Feb. 2002 to June 2002) were used to ensure continuity and avoid
stoppage.
WMM was manufactured at 4 pug mills located at Km 14, 20, 43 & 57. The
materials were strictly controlled for grading and optimum moisture while laying
to ensure a quality product. WMM was laid by both mechanical methods and
paver.
WMM Grader in Progress WMM Paver in Progress
2.3.4 Asphalt Surfacing

The laying of bituminous wearing concrete (AC) started on 12 th September
2002 and completed at the end of May 2003. The JMFs for DBM and AC were
approved and the asphalt works were carried out strictly in compliance with the
contract requirements.
BC Laying in Progress Compaction of BC in Progress
2.4 Structures
2.4.1 General – Bridges

No major bridges (Total Length
more than 60 m) are on this
highway.
2.4.2 Other Cross Drainage

Structures
New Culvert Parallel to Railway
72 culverts of various types and Culvert
sizes were constructed.
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Construction was carried out on 24 No Box culverts and on 43 No Pipe culverts

including 59/5 pipe culvert extension at Viramgam end.
One source of water at Khoda was approved for concrete works.
Box culverts and Minor bridges:
Construction carried out for 24 No box culverts – 15/1, 16/1, 19/1, 19/3, 24/1,
26/1, 27/1, 28/1, 28/2, 29/1, 30/2, 30/5, 33/1, 34/1, 35/1, 37/1, 38/1, 39/1, 42/1,
44/1, 46/1, 54/1, 54/2 & 58/3.
Near the end of the project

another culvert was constructed
over IOC pipeline at Km. 57 after
approval of the Employer In
October 2002.
Construction was also carried out

on the widening of 4 No existing
structures – 29/2, 43/1, 47/1 and
58/2.
Widened Structure
Pipe Culverts:
Construction carried out for 43 No pipe culverts on the main carriageway and
pipe culverts in accesses and/or access roads. Additional pipe culverts were
located and extended - 17/1, Km 16+080 (3 x 900 mm dia.); 18/2, Km 17 +840;
59/3 (2 x 900); 59/4 (3 x 900) & 59/5 (4 x 900).
Pipe culvert at Km 12+000 was moved to Km 12+420 and a new pipe culvert
44/2, Km 43 +460 (1 x 1000) was installed. Pipe culverts at 24/3 Km 22+400;
Km 23 +626; Km 23+900 and 56/1, Km 55 +998 (canal crossing) were
cancelled.
2.5 Drainage
A special covered drain was
provided in the urban areas of
Sarkhej and Sanand, in order that
the socio economic impact on the
area would be improved. In addition
to that a large outlet drain was
incorporated in the works at Sarkhej
to mitigate the monsoon affects.
Near Sanand village, lined drain
along with the footpath has been
constructed to improve the Social
environment and safety of bath Open Drain near Sanand
pedestrian and motorists.
Total Length of Covered Drain Km. 4.10

Total Length of Open Drain Km. 2.00
Total Length of Kaccha Drain Km. 89.50
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2.6 Socio Economic Development & Safety

In order that the socio economic impact on the area, a special covered drain and
asphalted shoulder allowing access to the commercial premises was constructed.
This has reduced the congestion problems in the town areas.
Sachhana Village km 47+000 Sanand Village km 22+550
At critical locations number of signboards, cat’s eyes and crash barriers are
installed as safety measures. Total 23 bus stands were constructed in Brick
masonry with covered RCC roof and sitting arrangements along the corridor.
Bus Shelter Sign Boards and Road Markings
In the area near km 47+000 (Sachhana village) the railways were persuaded to
give up land in order that a safer road alignment could be built and an improved
footpath compiled to a better safety barrier constructed.
The movement and improvement of 3 temples were carried out with the
assistance of the local people. In some cases, the alignment was adjusted to
avoid small temples and venerated trees.
Total Length of Four Lane Section Km. 6.30

Length of Footpath Section Km. 5.70
Total Length of Street Lighting Km. 5.00
Total Length of Kerb Km. 14.70
Crash Barriers Km. 5.30
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2.7 Access Roads
Total 234 access roads were constructed along the corridor. The category and
type of access roads are as follows:
Housing /
Type Villages Factory Fields Total
shops
Kaccha Roads (Earthen Roads) 7 4 6 16 33
Pakka Roads (BT) 81 54 60 6 201
2.8 Miscellaneous Items
2.8.1 Site Offices
The office of Resident Engineer (CSC) was established in Sanand at km 19.

The office of main contractor & Chief Project Manager are working from Sanand
office at Km. 20 (with all communication facilities) and other office established
km 43.
Contractor’s offices, labour quarters, Hot mix plant, pug mill for WMM, crusher
and concrete plants were located at km 43. The main laboratory at km 43 is
used for bituminous and concrete works. The contractor had also set up two
other laboratories; one at km 21 and the other at km 57.4.
2.8.2 Highway Landscaping
Generally the highway is passing from plain terrain. Running parallel to the
Railway line. Both the side slopes have been covered with turffing for stability
and protection of the slope. At some stretches the grass has not grown properly
due to lack of watering.
Turffing on Slope Turffing & Stone Pitching
2.9 Extension of Time
An extension of time for 2 months was granted for the earthquake of 26 th January
2001.
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2.10 Variation Orders
Total 7 variation orders have been submitted to the R&BD and they are as
follows:
Variation Order No 1 : Variation due to Stump Removal under BOQ item no.
2.01 (c)
Variation Order No 2 : Variation due to Extension of time due to Earthquake with
no additional cost
Variation Order No 3 : Variation due to use of Provisional sums
Variation Order No 4 : Variation due to re-assessment of BOQ items and
introduction of Granular Sub Base.
Variation Order No 5 : Variation due to additional testing on concrete structures
Variation Order No 6 : Variation due to Light scarification of the existing
bituminous road surface in accordance with Section 3 –
Bidding Data
Variation Order No 7 : Variation due to balancing quantities to the completion of
the contact
2.11 Substantial Completion
The takings over certificates were issued on following dates:

a) Km 20 to 46 on 31 March 2003 and
b) Km 13 to 20; Km 48 to 59+160 on 30 May 2003
c) Km 11 to 13 & Km 46 to 48 on 16 June 2003.
2.12 Maintenance
For maintenance guideline CSC will be submitting individual Maintenance Manual

for GSHP Phase-I.
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3 Quality Control
3.1 General
The Final Materials Report Volumes 1, 2 & 3 are submitted along the with the
final completion report for the reference. The detail report includes the works
carried out for earth works, sub grade, selected sub grade, culverts, minor
bridges, GSB, WMM, DBM, AC and miscellaneous items. The main laboratory at
km 43 is used for bituminous and concrete work. The batch type hot mix plant is
also functional at Km. 43.
Laboratory Setup
3.2 Details of the borrow areas & sources

Emb. & Sub grade - 24 Nos. borrow areas
Hansalpur I & II (km 57), Haripura (km. 54), Jakhwada (km 51), Sachana I, II & III
Sachana village (km. 47) & Ogan village (46), Virochanagar (Km. 42), borrow
areas ID Mark SV-I to SV-V (Km 43+700 to 38), Khoda (km 32), Iyava (Km. 30),
Madhavpura (Km. 26), Telav (Km.18), Dhakadi.
Sub base - Sabarmati River (80%), crushed Agg. (10%), local soil
(10%).
- Charia near Limdi used as a temporary source during
riots of 2001.
Selected sub-grade - Dhakdi (km 59), borrow area ID Mark
SV-III, and Sabarmati sand+30% Local
Soil.
Aggregate - 2 sources – Sayla.
All materials used were in accordance with the requirements of the specifications
together with the relevant IRC and IS codes. The frequency of sampling and
testing of various materials are as per Clause 900 of the specifications.
Samples of the materials used for embankments, Subgrade and selected

Subgrade were collected from the identified borrow areas and tested for
suitability. The following tests were conducted:
MDD, OMC, LL, PL, PI
Free Swell Index , Grain Analysis, CBR
Based on test results, borrow areas were approved for using the materials in
embankment, sub grade and selected Subgrade.
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4 PROBLEMS AND THEIR RESOLUTION
4.1 Key Events of Project

 17 Oct 00 date of commencement of the works
 Oct to Dec 00 planned mobilisation by Contractor, which actually extended till
February/March 2002.
 10 Dec 00 Louis Berger International Inc appointed as Engineer.
 26 Jan 01 Earthquake in Gujarat, Contractor granted 2 months extension of
time.
 From Mar 01 to date (as surveys were supplied by Contractor), the vertical
profile was adjusted ahead of the works to optimize on the profile corrective
quantities.
 Jun 01 high sub grade shoulders lowered to existing road level.
 Mid Jun to Sep 01 monsoon period -- no work could be carried out on any
works (earthworks, WMM, DBM) until the site had dried up.
 17 to 23 Oct 01, work was stopped on WMM until pavement design changed.
 23 Oct 01 change in pavement design following PCC’s review of the design
and Contractor’s submission of letter under Clause 8.1 absolving him from
costs of failure due to defect in the design. The use of granular sub base
(GSB) was introduced in the pavement.
 Oct 01 to Feb 02 Site reorganization by Contractor.
 Dec 01 Jan 02, 5 No small bridges in poor condition added to be replaced by
box culverts.
 28 Feb - Jun 02 Communal disturbances in Gujarat. Contractor off 28 Feb –
3 Mar 02.
 Sept. 02 approval for the construction of a box culvert 24/1 in Sanand
 Oct. 02 approval for a slab culvert over IOC pipeline, Km 57+820.
 Monsoon approx. 13 June 01 – 17 Aug 01 & 25 Jun – 31 Aug 02
st
 31 March 03- Stretch from km 20 to km 46 substantially completed and
taken over.
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4.2 Delays
Programme and progress Ref: RE/GSHP1/C1/0211 dated 5 June

5 June 2001 :
2001
Lack of Progress and Remob. Clause 46.1 Ref:
13 Sept. 2001 :
TL/Gen/015/C1/10731
18 Sept. 2001 : Progress on Contract I Ref: RE/GSHP1/C1/0362.
Minutes of Progress Review Meeting between CSC and
21 Sept. 2001 :
Contractor.
24 Sept. 2001 : Progress of work Ref: RE/GSHP1/C1/0379.
Progress on Contract 1 Ref: RE/GSHP1/C1/0410 dated 5 October
5 Oct 2001 :
2001.
Lack of Progress and Remob. Cl. 46.1 Ref:
29 Oct. 2001 :
TL/C1/Gen/019/RE1/10843.
30 Oct 2001 : Minutes of R&BD/CSC meeting with Contractor
26 Nov. 2001 : Lack of Progress Ref: TL/C 1/Gen/022/C 1/10916
Lack of Production by Sub contractor Ref:
12 Dec. 2001 :
TL/C1/Gen/023/C1/10949
28 Dec. 2001 : Revised Work Programme Ref: OSE/W3/1626
11 Jan. 2002 : Progress and Equipment on Contract 1 Ref: RE/GSHP1/C1/0616
Minutes of Progress Review Meeting between R&BD/PCC/CSC
24 Jan. 2002 :
and Contractor
4.3 Technical Problems and their Resolution
4.3.1 Over Toping of Water during Floods of 2003
At some locations near km 42, water had passed over the road and LHS
shoulders were washed out in August ‘03. The contractor has been instructed
to backfill both areas with graded rock fill as a preliminary to save any further
damage. The real cause is that there is no culvert opposite the present railway
culvert and this has increased the volume. The road is also lower than the
railway at this location and as such acts as a weir during the worst of the flood.
4.3.2 Pavement Behavior
During June 2003, at km 35 to km 38 some cracking has been observed and it

has been repaired during dry periods. These patches have been observed on
RHS, which will be inspected and attended during dry spell.
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5 PERFORMANCE OF CONTRACTOR
5.1 General
The initial progress of he contractor was very slow but once the project manager
was changed and the principal contractor took over the sections work
progresses, the contractors work was on schedule.
At the commencement of the works

(17 October 2000), the project was
divided equally in two by the main
Contractor and let out to 2 Non
approved subcontractors (B. Patel
and B.A. Patel) to carry out the
early works (earthworks, WMM
etc.). Although part of the early
period (covering about 6 to 8
months) was taken up with Initial Setup for Contractors Camp
mobilisation, monsoon, earthquake
and design changes, it soon
became clear that Contractor was not achieving the progress on site as he had
shown in his works programme. The reasons being -- the lack of equipment,
planning and manpower on site. R&BD, PCC and CSC closely monitored the
progress situation and accordingly issued various contractual letters at various
times to try and speed up progress.
Then in August 2001, the main Contractor (after his own assessments) began the
change process towards re-organisation of the site activities. The re-organisation
and remobilization of more resources took place from the end of October 2001 to
March 2002. The main Contractor took over all of the asphalt works along with
sections of work Km 21 to 25; Km 25 to 30; 35 to 43 and the 2 No subcontractors
also increased their equipment. The progress and quality in the second half can
be considered as good.
Asphalt Plant WMM Plant
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5.2 Contractor’s Mobilisation
Contractor’s offices, labour quarters, HMP, WMM, crusher and concrete plants
were located at km 43. The production of aggregates at km 43 from imported
site boulders was carried out from 15 February 2002 to 28 February 2003.
Oriental’s staffs headed by the Chief Project Manager are worked from both the
established Sanand office (with all communication facilities) and km 43 new
offices.
The contractor also set up two other laboratories; one at km 21 and the other at
km 57.4. At each of these locations, Contractor had also installed a wet mix
Macadam Plant (Pug-mill type). The laboratories at these locations are well
equipped for soil, granular sub-base and wet mix macadam. The Subcontractors’
crushers were located (120 km away from the project road) at Sayla. In summer
2002, the sub contractor erected another wet mix macadam plant (pug-mill type)
at Km 14.
5.3 Plant and Equipment
Equipment Type Horse Power As Per Bid Mobilised

Remarks
Or capacity Documents No.
Dozers 325 cum/Hr 3 1 Idle
Loader 1.5 cum. 2 3 1 broken
Tippers 5/8cum per trips 30 32
Tractors 6
Excavators 75/100 cum/Hr 1 1 Idle, 1broken
PTR 1
Static/Tandem Vibrator Roller 4 5 3 in camp
JCB 100 cum/Hr 7
Water Tanker 235 cum/Hr 3 8
Crusher 60 TPH 2 3
Motor Grader 200 cum/Hr 4 2
WMM Plant Pug mill Type 100 TPH 2 4
Hot Mix Plant 160 THP 1 1
Vibratory Roller 162.5 cum/Hr 6 2 1 broken
Vibratory Roller 2-4 tons static 3
Paver Finisher Sensor Type 3.5 – 5 m wide 2 1
Paver Finisher Mechanical 3.5 – 5m wide 2 Not
required
Bitumen Bouzer 1 2
WMM Paver (Sensor) 2 1
Concrete mixer with W/B 2 7
DG sets 6 6
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5.4 Staffing
Name Position From To

Narendra Mohan 16 Oct 00 13 April 01
Lt Col Singh 14 Apr 01 2 Nov 01
S. Gupta Chief Project Manager 3 Nov 01 16 June 03
S. K. Ayappa Junior Project Manager 1 Oct 01 2 June 03
S. Majumdar Planning Engineer 7 June 03 31 Aug 03
Susheel Kumar Comp. Operator 16 Oct 00 31 Aug 03
Part – 1 (11 – 35)

S.S.Chakraborty Project Engineer 16 Oct 00 31 Aug 03
P. K. Shriwastava Sr. Engineer 1 Oct 01 15 May 03
B. K. Ramappa Sr. Engineer 1 Nov 01 30 May 03
Dhaval CAD operator 1 Jan 01 31 Aug 03
Mushir Khan Mech. Foreman 1 Nov 01 20 June 03
Chandrabali Foreman (3) 1 Nov 01 30 April 03
Part – 2 (35 – 43)

Pritam Singh Material Engineer 1 Oct 01 2 Aug 03
Assistant Engineer (4) 1 Oct 01 2 Aug 03
Som Dutt Asst. Engineer 1 Nov 01 31 Aug 03
Part 3 (43 – 59)
Rajeev Panth (OSE) Sr. Engineer 01 Feb 01 07 Aug 03
6 No Site Engineers 01 Oct 01 31 July 03
Ashish Patel Project Engineer 16 Oct 00 31 Aug 03
Mukesh Patel Material Engineer 16 Oct 00 31 Aug 03
K. K. Verma Assistant Engineer 16 Oct 01 30 June 03
Junior Engineer (6) 01 Oct 01 31 Aug 01
Supervisor (6) 01 Oct 01 31 Aug 01
Saurin Mehta Junior Engineer 01 April 02 31 Aug 01
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6 Construction Supervision
6.1 Consultancy Contract
The consultancy contract has been finalised by R&BD, as per International

competitive bidding. The consultant’s staff started mobilizing in December 2000
and RE was mobilized in February 2001.
6.2 Supervision Team
Consultant’s office from 1 Jan 2001- 30 June 2003 functioned with the following
staff:
S.No. Name Position From To

1. W.J.Hutchinson RE 23-02-01 30-05-03
2. V.K.Shriwastava ARE 02-12-00 21-04-02
3. M PS. Sethi ARE 22-04-02 07-07-03
4. G.R.Sharma QME 13-03-02 14-03-02
5. G. Gujja QME 17-06-02 30-04-03
6. R.C.Mathor QME 02-12-00 19-12-00
7. M.P.Ashathan QME 11-04-01 31-12-01
8. S. Segor JE (Survey) 14-12-00 20-04-02
9. Sidheshwara JE (Survey) 21-04-02 30-09-02
10. Dilip. B. Tumar JE (Survey) 17-05-01 31-12-02
11. Hiran Patel JE (Survey) 22-10-02 30-04-03
12. Ashish Sinha Inspector Roads 10-09-01 31-12-01
13. Yogananda Reddy Inspector Roads 10-01-02 28-02-03
14. H. Sandhu Inspector Roads 17-04-01 30-06-03
15. Nikhil Singh Inspector Roads 02-12-00 14-05-01
16. Neeraj Chaudhary Inspector Roads 12-06-01 08-09-01
17. Jigar K. Shah Inspector Structure 14-04-01 19-08-02
18. Bhushan Tuplondhe Inspector Structure 28-08-02 07-02-03
19. Nitin Rathod Inspector Structure 07-02-03 31-03-03
20. Amarjeet Singh Jr. Material Engineer 01-01-01 31-01-03
21. H. R. Padaya Jr. Material Engineer 09-07-01 08-02-02
22. S. K. Singh Jr. Material Engineer 09-02-02 30-06-03
23. Tony Mathew Jr. Quantity Surveyor 01-05-01 30-06-03
24. H. R. Padaya Jr. Quantity Surveyor 02-04-01 08-07-01
25. Paras Shah Jr. Quantity Surveyor 09-07-01 30-04-03
26. Rakesh Kumar Secretary/accountant 15-02-01 31-08-01
27. Ajit Kumar Secretary/accountant 01-09-02 31-07-03
28. Jasmin Patel Computer Operator 15-02-01 21-05-02
29. Bharati Trivedi Computer Operator 01-06-02 31-07-03
1-20

6.3 Procedures
A Construction Supervision Manual with quality control procedure was produce

and used on the job.
In house training on materials and construction methods have been made during
the course of the Project for contractor staff and R&BD Engineers as part of
technology transfer.
Results of quality testing and quantity measurements have been filed

systematically and details are available in the
7 Review of Design & Specification
Works were carried out on 76 No structures (25 No box culverts, 4 No widened

bridges, 40 No pipe extensions and 4 No new pipe culverts).
From 2 June to 23 October 2001, the Subgrade top in the shoulder-widened portion
was being adjusted to the same level as that of the existing road asphalt in order to
facilitate the drainage. However, after 23 October 2001, Contractor was instructed to
follow the revised pavement design -- following PCC’s review of the design and
Contractor’s submission of letter under Clause 8.1 absolving him from costs of failure
due to defect in the design. Accordingly revised finished road levels and areas of failed
existing road requiring treatment were issued to the Contractor. The use of granular
sub base (GSB) was introduced in the pavement.
The re-adjustment of the vertical profile for improvement of the vertical alignment was
carried out to minimize the quantity of profile corrective course (PCC) in sub base.
Following the issue of the modified pavement design, materials from the nearby
Sabarmati river were hauled to various parts of the site for blending into granular sub
base materials (GSB). Contractor following discussions with R&BD and CSC Engineer
reached agreement of a rate for GSB.
During the disturbances (February to June 2002), another source (55,000 m3) at
Charia near Limdi (in addition to Sabarmati River) was approved temporarily (February
to June 2002) to accelerate the works on GSB and avoid the idling of equipment.
At many of the locations the existing road extension of the carriageway had shown
signs of distress, which could be a weak spot for the performance of the pavement
over its life. These locations were dismantled and replaced with selected sub
grade/granular sub base.
Near the end of the project another additional culvert was constructed over IOC
pipeline at Km. 57 after approval of the Employer In October 2002.
1-21

8 Environment and Social Management
In GSHP, a new initiative towards environmental protection and management has been
taken. To make this initiative work, special focus has been given to two strategies.
One - adopting a structure in which compliance with the environmental clauses
becomes mandatory. This is achieved by making the EMAP a part of the contract
between the employer, R&BD, and the contractors, thus empowering the Engineer with
the monitoring powers. The second, and more important, is the recognition that “good”
engineering practices to take care of a number of environmental issues. The process
of environment management in the project started with following steps.
8.1 Training of contractor staff
The staffs of the contractor were trained to make understand the need for
environment management and the contractual obligation on the part of the
contractor in complying the same. The process followed both classroom and on
the site training.
8.2 Environmental Inspection
Environmental compliance inspection of EMAP has been a regular feature of the

project. The inspection team normally consist of CSC environment officer, EMU
environment expert, PIU staff, PCC environment officer and the local R&BD staff.
In addition to this, the contractor has submitted monthly environmental
compliance report to the CSC and CSC certified the same before submitting to
EMU.
8.3 Environmental Monitoring
Regular environmental monitoring of following parameters was conducted during

the construction.
 Ambient air quality: parameters monitored are RPM, SPM, CO, NOx, HC, SO2
and Pb.
 Water quality: parameters monitored are pH, total solids, total dissolved
solids, total suspended solids, oil & grease, COD, chloride, lead, zinc and
cadmium by Standard Methods
 Ambient noise quality: Twenty-four hours of sound pressure levels on an
hourly basis was monitored with intervals of two minutes at a “A” weighted
frequency using a “slow time response mode” of the measuring instrument.
8.4 EMAP compliance
The environmental and social issue that has been successfully complied as per
EMAP requirement is detailed out below:
1-22

8.4.1 Dust
 Water sprinkling was done at regular intervals to prevent dust
nuisance at the crushing and aggregate processing sites, and temporary roads,
during construction.
 Access roads and any unpaved construction roads were watered to
prevent excessive dust nuisance.
 Vehicles delivering materials were covered to reduce spills.
 Asphalt mixing plants were located over one km away from
communities/residences.
 Mixing equipments were well sealed and operators were provided with
dust masks, eye and ear protection aids.
8.4.2 Air Pollution

 Vehicles and machinery were regularly maintained so that emissions
conform to the National and State Standards.
8.4.3 Noise
 Workers in vicinity of strong noise were provided with earplugs and
helmets and their working time were limited.
 Maintenance of machinery and vehicles was regularly maintained to
keep their noise at a minimum.
8.4.4 Borrow area

 All the borrow areas in use were village ponds except couple of them
were in private agriculture field where the land owners wanted to develop a
pond for storage of water for the dry season. In other cases the panchyat ponds
were used and deepen for retention of water for longer period. All necessary
measures have been taken such as slope protection; access and fencing
(where necessary) have been done as per the EMAP.
8.4.5 Drainage
 All necessary measures were taken to prevent earthworks and stone
works from impeding the rivers and water causes or existing irrigation and
drainage system.
8.4.6 Contamination from Waste

 All necessary measures were taken to prevent the wastewater
produced in construction from entering directly into watercourse, rivers and
irrigation system
8.4.7 Contamination from Fuel and Lubricants

 Vehicle maintenance and re-fuelling was confined to areas in
construction camps designed to trap discarded lubricants and fuel spills. The
discarded lubricants and fuel was stored in drums and latter sold to the agency
certified by the Pollution Control Board for recycling.
8.4.8 Soil Erosion

 To prevent soil erosion grass has been planted and on sections with
high filling slopes has been covered by stone pitching and planted with grass,
etc.
1-23

8.4.9 Topsoil
 Preservation of topsoil was a highlight of the project. The process of
topsoil preservation was done at construction camp, agriculture land used for
earth borrowing etc. At the end of the project the topsoil was relayed to
minimize the impact on productive lands.
8.4.10 Compaction of Agricultural Soil

 To avoid compaction of field soil and damage to soil property the
construction vehicles were allowed to move in designated road and parked in
designated place.
8.4.11 Loss of Trees

 Tree clearing within ROW was limited to only those required for
construction activities and or to reduce accidents.
8.5 SOCIAL ENVIRONMENT
8.5.1 Sanitation and Waste Disposal in Construction Camps

 Sufficient measures were taken in the construction camps i.e.
provision of garbage tanks and sanitation facilities. Waste in septic tanks was
cleared periodically. Garbage were collected in dustbin and disposed of daily.
 Potable drinking water provision was made at each camp
 Camps were located at a minimum distance of 200m from any water
sources and away from settlement.
8.5.2 Safety
 Safety of workers by providing safety gear such as helmets, gloves,
masks, ear plugs, safety jackets etc.
 Road user’s safety was met by providing sign boards at regular
intervals including retro reflective sign boards for night traffic. In addition to this,
delineators, sand bags, painted drums, safety tapes etc were used.
 All the construction vehicle had red flags on them in order that they
could be noticed from distance
 In case of emergency the provision of a first aid box at each camp
location and the display of important telephone numbers were incorporated.
 Speed of construction vehicles was controlled to avoid mishaps.
 To avoid accidental risks from blasting in quarries the project use the
material from existing quarry.
Construction Safety Safe Construction
1-24

8.5.3 Loss of Access

 Temporary access has been built at the interchange of the highway
and other roads.
8.5.4 Traffic Jams and Congestion

 During construction temporary access were maintained until
permanent accesses could be constructed.
8.5.5 Cultural and Temples

 All the cultural issues have been settled in amicable manner through
the process of community consultation in restoration of shrines and temples.
 Or the road way was adjusted to avoid temples
8.6 Other
 The public were informed through large signboard at both end of the
project giving details such as scope, timeframe, consultant, and contractor of
the project.
1-25

9 Documentation
The various correspondence and files are compiled and packed in the boxes for your
reference.
Box No – 1 Re Files Record
1. Re to Contractor 1 to 10
2. MPR CSC 1 to 3
RE Total Files: 1 To 2 13nos Files
1. OSE To RE 1 to 6
2. RE To Team Leader 1 to 6
3. From Team Leader 1 to 3
4. MPR OSE 1 to 3
RE Total Files: 3 To 6 18 Nos. Files
1. CSC Manual 1
2. OSE Delhi 1
3. PCC 1
4. R&BD 1
5. FRL’s 1
6. Guide Rail 1
7. As Built Structure 1
8. As Built Road 1
9. Access Road OSE 1 to 2
10. Access Road CSC 1
11. Environment 1 to 2
12. Vo’s 1
13. Work Methodology 1
14. Final Est. Cost 1
15. Work File Re 1
16. Delay Claim 1
Total RE Files: 7 to 22 19 Nos. Files
1. Claim 1
2. Initial Levels 1
3. Contractor Equipment 1
4. Structures 1
5. CBR 1
6. Daily Progress Record 1 to 3
7. CSC Manual Record 1
8. CSC Manual 1
9. Agreement Office 1
1-26

10. Survey 1
11. Widening Slab Culverts 1
12. Weekly Progress Report 1
13. Progress 1
14. Work Shops 1
15. Diversion 1
16. Miscellaneous 1
Box No –5 Re Files Record
1. Letter Summary 1
2. Work Programme 1
3. Staff Memo 1
4. Staff CSC 1
5. Survey CD 1
6. General 1
7. Attendance Sheladia 1
8. Sheladia Memo 1
9. TBM 1
10. Bus Shelters 1
11. Public Shelters 1
12. Guide Rail 1
Box No – 6 Structures Files Record
15/1 Box Culvert

16/1 Box Culvert
19/1 Box Culvert
19/3 Box Culvert
24/1 Box Culvert
26/1 (25+002) Box Culvert
29/2 Box Culvert
Structures (15/1 to 38/1)

Total: S1 to S18 18 Nos. Files
Box No – 7 Structures Files Record

1-27

43/1 Bridge Widening

44/1 Box Culvert
47/1 Box Culvert
54/1 Box Culvert
54/2 Box Culvert
58/2 Box Culvert
58/3 Box Culvert
58/4 Box Culvert
12/1 to 24/2 Pipe Culverts
29/3 to 31/3 Pipe Culverts
32/1 to 51/1 Pipe Culvert
52/2 to 60/1 Pipe Culvert
Access Road Pipe Culverts
Structures (39/1 to 60/1) Box Culvert & Pipe Culverts

Total: S 19 to S34 Files 16 Nos. Files
Box – 8 Structures Files Record
RCC Drain (Sanand) 1 to 5 Nos.

RCC Drain (Sarkhej) 1 to 3 Nos.
Independent Test Reports
Guide Rail
Footpath
Brick Open Drain
Expansion Joints
Median Opening
Kerb Levels
Geo Textiles
OGL Structures
SPT Report
Total Files: (S35 to S52) 18 Nos. Files
Box No –9 Structure Files Record
Inspector Diary 6 Nos.

Methodology Structures
Pipe Culvert Access Roads
NGL Structures
Bus Shelters
Road Marking
Cube Test Results 11 - 30
Cube Test Results Copy 11 - 59
Cube Test Results Copy 11 - 59
Drain Cube Results 11 - 59
Inspector Record 2 Nos.
Total Files: (S53 to S70) 19 Nos. Files
1-28

Box – 10 Quality Control Files
Embankment Field Density 1, 1a, 1b & 1c

Subgrade Field Density 2 & 2a
Selected Subgrade Field Density 3 & 3a
Granular Sub Base Field Density 4 & 4a
Wet Mix Macdam 5 & 5a
DBM Field Core Density 6
Prime Coat Over WMM 7
Tack Coat on Prime & DBM Surface 8
Access Road Field Density 9 & 9a
Shoulder Field Density 10
Total Files: 1 to 10 18 Nos. Files
Box No – 11 Quality Control Files
All Miscellaneous Item Field Density 11

All Miscellaneous Tack Coat/Prime Coat 12
Embankment Frequency Test 13
Subgrade Frequency Test 14
Selected Sub. Frequency Test 15
Granular Sub Base Frequency Test 16, 16a, 16b & 16c
Wet Mix Macdam Frequency Test (Grader)17, 17a, 17b & 17c
DBM Frequency Test 18, 18a, 18b & 18c
Box No –12 Quality Control Files
DBM Frequency Test 19&19a

BC Frequency Test 20&20a
Prime Coat Viscosity Test 21&20a
Concrete Cube Test Structures 22, 22a, & 22b
Concrete Cube Test Miscellaneous 23
Concrete Cube Test Drain 24
Concrete Frequency Test 25
Aggregate 10 mm & 20 mm Test 26
Bricks Frequency Test 27
Boulder for Pitching Test 27
GSB Miscellaneous Frequency 28
WMM Miscellaneous Frequency 29
BC & DBM Miscellaneous Frequency 30
Box No – 13 To 23
Road Work
1-29

Final Completion Report - GSHP-1

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Final Completion Report - GSHP-1

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Final Completion Report GSHP-1

Gujarat State Highway Phase - I

Louis Berger Int., Inc.

Louis Berger Int., Inc.

Louis Berger Int., Inc.

1.1 Description of Contract

GSHP-1 is a part of Gujarat State Highways, Phase I. Contract Package of Loan

1.2 Project Summary

Project Name : Sarkhej to Viramgam

Contractor : Oriental Structural Engineers Ltd

Loan No. : 4577-IN

Date of Commencement of Works : 17th October 2000

Original Completion Date : 16th April 2003

Time Extension : 2 months (Sixty Calendars Day)

Revised Completion Date : 16th June 2003

Original Contract Period : 30 months

Revised Contract Period : 32 months

Contract Amount (Original) : Rs. 628,913,200.00

Final Completion Amount : Rs. 757,728,624.00

Escalation : Rs. 113,112,712.00

1.3 Design/Supervision Consultancy Contract Details

Design Consultants/Project Coordinating

Louis Berger Int., Inc.

2.1 Pre-Construction Activities

2.1.1 Hand Over of Site

2.1.2 Acquisition of Land

The removal of utilities commenced in October 2000 and completed by August

2.1.4 Removal of Trees

2.2 Work Programme

The contractor produced an initial construction programme at the commencement

2.2.1 Submission of Programme

1. Original Programme : October 2000

Louis Berger Int., Inc.

2.2.2 Comparison of Progress against Programme

2.3 Road Works

2.3.1 Road Works - General

The work under contract consisted

Louis Berger Int., Inc.

2.3.2 Formation & Design

2.3.3 Base Courses

Louis Berger Int., Inc.

WMM Grader in Progress WMM Paver in Progress

2.3.4 Asphalt Surfacing

BC Laying in Progress Compaction of BC in Progress

2.4.1 General – Bridges

2.4.2 Other Cross Drainage

Louis Berger Int., Inc.

Construction was carried out on 24 No Box culverts and on 43 No Pipe culverts

One source of water at Khoda was approved for concrete works.

Box culverts and Minor bridges:

Near the end of the project

Construction was also carried out

Total Length of Covered Drain Km. 4.10

Louis Berger Int., Inc.

Louis Berger Int., Inc.

2.6 Socio Economic Development & Safety

Sachhana Village km 47+000 Sanand Village km 22+550

Bus Shelter Sign Boards and Road Markings

Total Length of Four Lane Section Km. 6.30

Crash Barriers Km. 5.30

Louis Berger Int., Inc.

2.7 Access Roads