PREFACE

This report has been prepared after getting different theoretical and
practical training in Construction of Bridge and Highway of Six Lane
Eastern Peripheral Expressway (NH No. NE-II) Package IV from 03-
06-2017 to 18-07-2017 Under ASHOKA BUILDICON PVT LTD. in
reference to my collage letter dated 30-05-2017 of Training &
Placement Officer for ALLENHOUSE INSTITUTE OF
TECHNOLOGY ROOMA, KANPUR (UP). The training was divided
in seven different sections of the Directorate.
• I- GIRDER
• VUP
• PUP
• BOX CULVERT
• ROB
• CONCRETEROAD
• DRAINAGE,
• INSPECTION UNIT
The process of training from my point of view was excellent for each
section was very useful for Civil Engineering Student with very
limited resources and time schedule. There are many things in the
Directorate on each subject which can be learnt from regular training
and proper guidance.
A little knowledge which I could get from this training, I am trying to
reproduce some of them in following pages. Any error in making
deliberations may please be ignored.
 INDEX
S. No CONTENT PAGE
NO.
1 Introduction
2 Detail of the project and its route
3 Project Status and update Water Treatment
Process
4 Methodology and its component
5 Scope of the Project
6 Major construction activity
7 Machine used for road construction
8 Methodology of carrying out structural concrete
in bridges and culverts
9 Transporting and placing of concrete
10 Major Components
• I-girder
• VUP
• PUP
• BOX CULVERT
• ROB
• CONCRETE ROAD
• DRAINAGE
11 Inspection Unit
INTRODUCTION ABOUT EASTERN
PERIPHERAL EXPRESSWAY:-

National Express way 2 or Eastern Peripheral Express way is an

under- construction expressway in the National Capital Region which
will bypass Delhi on the eastern side. The expressway will provide
connectivity between Delhi and the towns of Ghaziabad, Faridabad,
Greater Noida, Baghpat and Sonipat. The project involves
construction of a six-lane expressway with access control from
Faridabad to Sonipat. The expressway will be 135 km long and will
have two sections, the 56 km-long Faridabad-Ghaziabad section and
the 49 km-long Ghaziabad-Sonipat section. The completed
expressway will help relieve traffic congestion in the Faridabad
Ghaziabad
EPE will be the country's first and the smartest highway stretch
developed with most advanced intelligent traffic systems. The
highway bypassing Delhi on eastern side will enable the capital city to
have excellent connectivity to the towns of Ghaziabad, Faridabad,
Greater Noida and Sonipat.
The 135 km long EPE will be constructed in two sections, namely
Faridabad-Ghaziabad stretch and Ghaziabad-Sonipat section. The six-
laned corridor will have Variable Message Display System (VMS) to
guide drivers about the road conditions and traffic jams.
The EPE will merge with Yamuna Expressway near the Delhi-
Mumbai Industrial Corridor
(DMIC). The corridor will also link NH-91 near Beel Akbarpur. Cities
like Noida, Greater Noida, Dadri and locations in Ghaziabad like GT
Road, Dholana and Hapur will decongest once the EPE starts
operating.
DETAILS OF THE PROJECT AND ITS ROUTE:-
The Expressway passes through Sonepat, Baghpat, Ghaziabad,
Gautam Budh Nagar, Faridabad and Palwal in Haryana and Uttar
Pradesh. The proposed alignment crosses the Yamuna river at
Khurrampur/Khata in UP and Faizpur Khadar in Haryana and crosses
the river Hindon.

See also: NH 24: Wider highway set to unlock real estate potential in
the NCR
Numbers of structure in this project:-
"There are a total of 390 structures in this project, out of which
• 2 major bridges are on river Yamuna & 1 major bridge on river
Hindon and Agra
Canal.
• There are eight interchanges,
• four flyovers,
71 vehicle underpasses,
• Six road-over-bridges, etc.
The project work has been divided into six packages -

1. 21-km stretch in Sonipat-Baghpat,

2. 24.5-km stretch in Baghpat-Ghaziabad,
3. 24.5-km stretch in Ghaziabad-GB Nagar,
4. 22-km stretch in GN Nagar,
5. 21-km stretch in GN Nagar-Faridabad and
6. 22-km stretch in Faridabad-Palwal.
"Work on the project is being executed by Gayatri Projects,
Oriental Structural, Sadbhav Engineering, Jaiprakash Associates
and Ashoka Buildcon."
PROJECT STATUS UPDATE
1. 2015 Nov: Foundation stone of 135-km long expressway laid by
PM of India Shri
Narendra Modi.
2. 2016 Feb: Work started on expressway.
3. 2017 April: An estimated 60% of the work has been completed.
It is expected to be completed by August 2017.
4. 2017 July 26: An estimated 70% of the work has been
completed. It is expected to be completed by March 2018, three
months ahead of the deadline of July 2018 set by the Supreme
Court of India.
METHODOLOGY AND ITS COMPONENT:
The detailed data and information related to the design and
construction methodology of the projects of six lane Highway that
are necessary to carry out the study have been provided by the
Ashoka Buildcon Itd.
The works includes construction of following:-
 1. Road Works Viz: Site Clearance, Survey, Earthwork, Sub Base
& Base Course, and Bituminous Works.
2. Drainage & Protective Work
3. Traffic Signs, Markings and Road Accessories
4. Miscellaneous and Maintenance of Roads
The methodology includes the use of various equipments to carry
out the various procedures such as the Site clearance, Earthwork,
bituminous works etc. as per the required specifications.

SCOPE OF PROJECT

Various important surveys were carried out for the section

between Kundali to Palwal which are listed below:

1. Topography Survey
2. Traffic Surveys, which included Classified Weekly Volume Counts,
Turning Movement Counts, Origin - Destination Survey, Plate
Registration Survey, Axle Load Survey, Speed & Delay Survey.
3. Road & Bridge Inventory Survey
4. Pavement Condition Survey
5. Bridge Condition Survey
Environmental Survey, which included Vegetation and Fauna Survey

MAJOR CONSTRUCTION ACTIVTIES:

The construction work of six lane highway from Kundali to Palwal
includes following major areas:
• Construction of Flexible Pavement
• Construction of Major bridges
• Construction of Rail Over Bridges (ROBs)
• Construction of Culverts

1.) Construction of Flexible Pavement:

(1) Total new construction
(2) Widening of one side (Eccentric widening)
(3) Widening on both side (Concentric widening)

2.) Construction of Major bridges

There are 4 major bridges on the proposed six lane highway from
KUNDALI to
PALVAL
3.) Construction of Rail Over Bridges (ROBs)
There are 6 ROBs on the proposed six lane highway from KUNDALI
to PALVAL.
4.) Construction of Culverts
There are several box culverts on the proposed six lane highway from
KUNDALI to
PALVAL. The box culverts are provided depending upon local
discharge
calculations.
METHOD STATEMENTS
Method statements for various activities covered during construction
flexible pavement are as below:

Clearing and grubbing

Excavation
Embankment and sub-grade construction
Granular sub-base
Wet mix macadam
Prime coat
Dense bituminous macadam
Bituminous
concrete
METHODOLOGY OF CARRYING OUT STRUCTURAL
CONCRETE IN BRIDGES AND CULVERTS
The work shall consist of producing and placing the concrete of grade
M-40, M-35, M-30, M-25, M-20 & M-15 by weigh batching in
accordance with the specifications conforming to MORT&H, IS: 456
and the work specifications stipulated in the contract document.
Procedure:-
After completion of site preparation, alignment of structure of culverts
and or minor bridges is marked on the ground with lime and /or
string. With reference to its alignment other points of structures like
wing wall, abutment wall are pegged. For construction purpose
temporary bench marks (TBM) are also established near by the
location of structure. The place of TBM shall be chosen in a such a
way that it will not be disturbed by the construction activities and it
shall remain in position until all the works are completed in that
location.
Material
• Cement
Cement confirming to IS: 8112 & IS: 12269 shall be used only after
ensuring the minimum required design strength. Manufacturer's test
certificate shall be submitted to the engineer for every consignment of
cement. The certificate shall cover all the tests for physical, chemical
requirements and chloride content. Independent tests of samples
drawn from the consignment shall be carried out at the site laboratory
or in an independent laboratory approved by the Engineer,
immediately after delivery.
• Coarse aggregate
Coarse aggregate shall be produced from approved quarry in required
sizes. It shall consist of clean, hard, strong, dense, non-porous and
durable pieces of crushed stone or a suitable combination thereof as
specified. Maximum nominal size of aggregate for various structural
components shall confirm to the section 1700 MORT&H.
• Fine aggregate
Fine aggregate for structural concrete shall be clean, hard, strong and
durable pieces of crushed stone or suitable combination of natural
sand. They shall not contain dust, lumps, soft or flaky, materials,mica
or other deleterious materials in such a quantity to reduce the
durability and strength of concrete.
• Water
Water shall be free from injurious materials like oils, acids, alkalis,
salts, sugar, organic materials or other substances that may be
deleterious to the concrete or steel. Potable water is generally
considered satisfactory for construction purpose. Mixing and curing
with seawater shall not be permitted.
Reinforced steel
Reinforcement hall be thermo-mechanically treated (TMT) deformed
bars of grade Fe500 confirming to OS Code 1786. Only uncoated
steel shall be used as per shape and size shown on the drawing. It
confirms to the specification or as approved by engineer.
• Bending of reinforcement:
Bar bending schedule is prepared and submitted to get Engineer's
approval before start of work. Bar schedule shall include number,
shape and cutting length of bar and weight in respect of each type. A
separate bar bending schedule shall be prepared for auxiliary bars like
spacer, chairs etc.
• Placing of reinforcement:
Reinforcement shall be placed in accordance with the drawing and get
inspected and approved by Engineer. After approval from Engineer,
immediately pouring of concrete follows. Reinforcement shall be tied
with binding wire in such a way that it shouldn't be displaced while
pouring the concrete on it.
Cover block are made of cement mortar with the same durability of
surrounding concrete.
Layers of bar shall be separated by space bars kept at approximately
1m interval and min. size is 12mm, or maximum size of main
reinforcement, whichever is greater is used.
Horizontal reinforcement shall not be allowed to sag between
supports.
Proportioning Of Concrets
In proportioning concrete, the quetty of boch cemett and aggregate
shall be determined by weighe Cemere i weifed foen bulk sock at ste
and aggregates shul weigh separately.
Water shell citer te meaured by vodne in callon unky oe weifed. All
measuringequipment shall be in a clean and serviceable condition.
Their accuracy shall be periodicallychecked. Water comere noo le
minund consurt so is cocheting walke taking in to
accourt of monture consert of apregne. The amount of water to be
added shal be adseted to componate the varation in mosts coeke dae
so wonder oco/con
Trial mixes:
The tral macs of al grades of cocerole shat de pooparco by un samples
or approvee mucrish same as that as fmposod so use in the mods belie
commecacemans of work. The mial trial mes stel be peoparod at ste
bibornocy, la al cases complete testine of all tho contium matcriali
proposed in the devign mix shul be carriod out prior to muking trial
mees. Addtional trial mbus shal be cariod our befire the prodaction, in
case of substrial changes are made n the malcal or o le properton of
loe emines lo de lice
Equipment's
Korane n view of de eganet's of the work, eganmert monasad do carry
out is
as under:
1) For preduction of concests
> For outral bridge kegch of loss then 200 meters • booch ope
coocrete miver diesel orelectric operated, with a minimum size of 200
liters, automatic water measuringelectric operated, with a minimum
size of 200 liters, automatic water measuring system and internal
weighed (hydraulic/pneumatic type)
 • For overall bridge length of 200 meters or more - concrete batching
and mixing plant fully automatic with minimum capacity of 15 cu. m.
per hour.
2) For Concrete Transportation

i. Concrete dumpers
ii. Powered hoists
iii. Chutes
iv. Buckets handled by cranes
v. Transit truck mixer
vi. Concrete pump
vii. Concrete distributor booms
viii. Belt conveyor
ix. Cranes with skips
x. Tremies
TRANSPORTING, PLACING & COMPACTION OF
CONCRETE
Transportation of concrete is carried by pumps. Pipe lines from the
pump and to the placing area should be laid out with minimum bends.
Concrete at the time of pouring should have temperature in between 5
to 40 degree Celsius. It shall be compacted to its final position within
30 minutes of its discharge from the mixture. Concrete shall be
poured in horizontal layer of compacted thickness of 300 mm. Fresh
concrete shall not be placed against concrete which has been in
position for 30 minutes unless appropriate construction joints are
provided.
Placement of concrete shall not be carried out when the day
temperature exceeds 40 deg.
Celsius.
A. Formwork
Only steel formwork shall be used. All bolts shall be countersunk. The
use of approved internal ties or plastic spacer shall be used. Structural
steel tubes are used as support for forms and form shall have
minimum thickness of 4mm ply.
(B) Construction Joints
Construction joints shall be provided as minimum as possible and
shall be as per drawings. Laitance shall be removed before fresh
concrete is cast. The surface shall be roughed enough not to dislodge
the coarse aggregate. Concrete may be brushed with stiff brush in its
green stage at the location of construction joint. Fully hardened
concrete shall be treated with mechanical tools to remove the laitance.
(C) Curing
Water curing shall be done with water specified in section 1000 of
MORT&H exposed surface of concrete shall be kept continuously in a
damp or wet condition by pending or by covering with a layer of
sacks, canvas, Hessian or similar materials and shall be kept
constantly wet for a period of not less than 14 days from the date of
placing the concrete.
MAJOR COMPONENTS:-
• I-GIRDER:-
The I girder is a I shaped girder which is used where used in the place
where the u girder cannot be placed due to curve radius or the
unavailability to put the u girder in place. The I girder can be upto
30meters in length different height as desired. The height varies as 1
1.2 and 2 meters. Also the numbers of stands vary as per the height.
The number of strands vary from 14 in 1 meter,, 29 in 1.2 meter and
45 in 2 meter height girder. The casting procedure is given in the
below paragraphs: first of all the reinforcement caging is prepared the
reinforcement is of high strength steel (FeSOO) the casing is done in
three zones namely zone a,b,c. the different zones have different
spacing and different diameter of bars are used.
Second the reinforcements are tied together with the help of steel
wires. Each bar is tied to its proximity bars so that the bars are not
loose.
Third the sheathing pipe is introduced in the between the
reinforcement layers and the stands are passed in them. A stand is a
group of cables twisted together to provide greater strength.
Each strand consists of 6 cables twisted together. Concreting process
in which ready mix concrete is poured in the reinforced cage which is
fitted in the casing. The concrete is made available from the nearby
batching plant which has two plants of 60 and 30 cubic meter
capacity. The mixture is transferred from the transit mixture truck of 6
cubic meter capacity to the u girder casting area.
After concreting the mixture is left for setting so that the mixture can
attain its desired strength in the specified number of days. The mix is
of MS5 strength. Also some admixtures are used in the mix
proportional (2% of the total weight of mix). After the setting process
is completed and desired setting time is over the girders are
transferred to the desired place for placing.

Fig: - I-girder
Process of I- Girder
1. Label alignment
2. Cleaning of bed
3. Shuttering oil
4. Reinforcement cage & lowering
5. Sithing pipe fixing (cable duck profile fixing)
6. Outer (vertical shuttering fixing)
7. Plumb and alignment

VUP: - Vehicule underpass sal be providod as spovided in Schedule B

and to coroct senice roads on both sides of the Project Ilghway in soch
a manner that no vehick i roquirod to travel mee then 2 km es senice
road do appeach an underpass for crossing over to the oser side. The
design shef de in acondine wie IRC:103. Al the crossingpoints drop in
the curve shall be provided to facilitate crossing of physically
challeng users. Similarly, the gaps in the channeliser shall be provided
so as to avoid the need fo frequent climbing and getting down from
the channelisers.

• PUP: - Podestrian under Pass shul be provided with sule crossing

facilies for the podestrians Facities for safe and untindarod movement
of poletrins and cycles shal be provided on the projoct highway
sherever i passes through urban bull-up areas and at gade sporaton
These Soldies shall be parmad in accondance
wàh the relevant
provaces cortanod n IXC-10, 1x0-17 aod 1x4-109, Facines shal abo
be parnod and
provided ie crossing of podestriars and cycles

The crossing facilities can be either in conjunction with at grade

intersections or through underpasses. The crossing facilities shall be
provided through underpasses such that unless otherwise specified in
schedule B, pedestrians do not have to walk for more than 0.5 km. to
reach the crossing point. The existing slab culverts and minor bridges
with span length equal to or more than 5m, a vertical clearance of
more than 2.5m and not catering to perennial flow, can also be used
for pedestrians and cycle crossings by providing necessary flooring.
In rural stretches, pedestrian/cycle underpasses shall be provided at
the locations of existing crossing points.
Box culvert: - Box culverts are in rectangular shape and generally
constructed by concrete. Reinforcement is also provided in the
construction of box culvert. These are used to dispose rain water. So,
these are not useful in the dry period. They can also be used as
passages to cross the rail or roadway during dry periods for animals
etc. Because of sharp corners these are not suitable for larger velocity.
Box culverts can also be provided in multiple numbers. The box
culvert can be specifically engineered to provide the required
foundation strength under the road pavement. As the base of the box
is the floor of the underpass, boxes provides some construction
savings by eliminating the need to pour as in situ base.
• ASTM C 1433 - Box culverts, for conveyance of storm water,
industrial wastes and sewage.
• ASTM C 1504 - Three-sided structures, for storm water conveyance
and culverts.
Applications of box culvert:-
• Short-span bridges (over highways, waterways, railways, for golf
courses, etc.)
• Conveyance of storm water, sewage or industrial wastes (storm
drains)
• Tunnels (to house conveyers, utilities, etc; to provide access, escape
routes, etc.)
• Detention
Benefits: -
• Box culverts can be made in large sizes to accommodate increased
flow rates and capacities.
• Boxes can be set with 0 feet to 100 feet of cover.
• ROB: -Normally, Railway undertakes the construction of Railway
portion of ROB/RUB where as approaches are being constructed by
the State Government. Proposals for construction of ROBs/RUBs in
lieu of Level Crossings (LCs) are received at various levels in Zonal
Railways from State Government and other Statutory Authorities.
• CONCRETE ROAD:- Concrete surfaces (specifically, Portland
cement concrete) are created using a concrete mix of Portland cement,
coarse aggregate, sand and water. In virtually all modern mixes there
will also be various admixtures added to increase workability, reduce
the required amount of water, mitigate harmful chemical reactions and
for other beneficial purposes. The material is applied in a freshly
mixed slurry, and worked mechanically to compact the interior and
force some of the cement slurry to the surface to produce a smoother,
denser surface free from honeycombing. The water allows the mix to
combine molecularly in a chemical reaction called hydration.
Concrete surfaces have been refined into three common types:
• Jointed plain concrete pavement (JPCP),
• Jointed reinforced concrete pavement (JRCP) and
• Continuously reinforced concrete pavement (CRCP).
• Pre-stressed concrete pavement (PCP) The one item that
distinguishes each type is the jointing system used to control crack
development.

Basic Component of a Concrete Pavement.

This cost can typically be offset through the long life cycle of the
pavement. Concrete pavement can be maintained over time utilizing a
series of methods known as concrete pavement restoration which
include diamond grinding, dowel bar retrofits, joint and crack sealing,
cross-stitching, etc. Diamond grinding is also useful in reducing noise
and restoring skid resistance in older concrete pavement.
Fig: - Placing of concrete

Advantages of concrete pavements:-

 They are typically stronger and more durable than asphalt
roadways.
 They also can be grooved to provide a durable skid-resistant
surface.
Disadvantage of concrete pavements:-
They typically can have a higher initial cost, and can be more time-
consuming to construct.
• Drainage: - Drainage is the natural or artificial removal of a surface's
water and subsurface water from an area. The internal drainage of
most agricultural soils is good enough to prevent severe water logging
(anaerobic conditions that harm root growth), but many soils need
artificial drainage to improve production or to manage water supplies.
The design of drainage system such as surface and sub-surface
drainage for pavement, median, shoulder, high embankment shall be
carried out in accordance with IRC: SP: 42 and IRC: SP: 50. Surface
runoff from the main highway, embankment slopes and the service
roads shall be discharged through longitudinal drains, which shall be
designed for adequate cross section, bed slopes, invert levels and the
outfalls. If necessary, the walls of the drains shall be designed to
retain the adjoining earth. Where drains are required to be the
covered, the cover of the drain shall be designed for carrying the
maximum expected wheel load. The covered drains shall be provided
with iron gratings, strong enough to withstand expected loading.
• The ancient Indus of sewerage and drainage that were developed and
used in cities throughout the civilization were far more advanced than
any found in contemporary urban cities in the Middle East and even
more efficient than those in some areas of the Indian Subcontinent
today. All houses in the major cities of Harappa and Mohenjo-Daro
had access to water and drainage facilities. Waste water was directed
to covered gravity sewers, which lined the major streets.
Conclusion:-