WY aarvee associates architects engineers & consultants pvt. Itd Indepencent Engineer for 4-Laning of Kundepur - Surathkal and Mangalore - Kerala border sections of NH-17 under NHDP Phase-Hl on DBFOT (Toll) bas 06" May, 2014 Our Ref, AA/KS/TL/2014/1819 To, M/s. Navayuga Udupi Tollway Private Limited Opp. Lions Public School, Nadsal (Village), Padubidri, Udupi District & Taluk, Karnataka ~ 574111 Kind Attn: The Project Manager Subject: Design, Engineering, Finance, Procurement, Construction, Operation and Maintenance of “ Four Laning of Kundapur ~ Surathkal Section of NH — 17 from km. 283+300 to km 358+080 (Section 1) and Mangalore ~ Kerala Border ( Km 375+300 to Km 376+700 (ie, Nantoor Circle to Mahaveer Circle) and km 3+700 to km 174200 (i.e. Mahaveer Circle to Kerala Border) (Section 2) in the State of Karnataka” — (Package No. NHDP-Ill/8OT/KNT/04) — Suggested Methodology for DLC & PQC (Toll Plaza area) for resubmission, Ref: 1) IE letter no. AA/KS/TL/2012/0751 dated: 03.02.2012 2) IE letter no. AA/KS/TL/2012/0915 dated: 04.05.2012 3) Your letter no. NUTPL/1233/SKS/936 date Dear Sir, We have gone through your submitted methodology for DLC vide above cited reference (3), wherein we have observed some missing link in the sequence of the works couple with the improper presentation of report layout. Consequent to the above observation, we herewith attach suggested methodology for DLC & PQC as guidelines for your re-submission of same. We have also attached sample check list for DLC which you can. adopt and use during submission of RFI You are kindly requested to incorporate the above suggestions and resubmit the methodology for DLC & POC without delay. ‘Thanking you. Yours sincerely, —_ een 5 am Leader Encl Suggested Methodology and Checklist for DLC. Ceto: The Project Director, NHAI-PIU Mangalore ~ for information. File. \ Project Office : —H.No. 7-48Q, Balaji Layout, 4th Right Cross, Kennarpady, Kadekai 516 a Tel: +91-820-2595956; Fax: +91-890-9599594; e-mail: aarveeudipi@smail.com Office Ravula Residency, Srinagar Colony Main Rd., Hyderabad - 500 089, India. Tel: +91-40-93737633; Fax: 93736977; e-naf IE suggested Methodology of Work for DLC & PQC (all Toll Plaza at ‘Scope of Work: Reach 1, 2 & 3) The work shall consist of construction of dry lean concrete sub-base (M10 grade) and pavernent quality concrete (M45 grade) in accordance with the requirements of MoSRT&H specifications and in conformity with the lines, grades and cross-sections shown on the drawings for rigid pavement at toll plaza. Reference Documents: ‘A. Concession agreement. B. MoSRT&H Fourth Revision IRC SP 49.1998 Guidelines for the use of Dry Lean Concrete as Sub-base for Rigid Pavement. ZOrms Materials: Concrete Dowel Bars Tie Bars Separation Membrane Plastic Sheath Joint Filler Joint Sealant Curing Compound Cement Sand Aggregate IRC 15-1981 Standard Specifications for Constructions of Concrete Roads. 15 383-1970 (Reaffirmed 2007) 15 12269-1987 (reaffirmed 2008) 15 10262 (guidelines for mix design) PPP Manual and other relevant code books (workability IS 1199). +: Ready Mix Concrete is sourced from Reach 1, 2 & 3 base camp for respective Toll Plazas. : 32mm dia grade Fe 250, plain mild steel bars as per IS 432 (yet to identify) ‘2mm dia grade Fe 415 as per IS 1786 (yet to identified) 125 micron thick Transparent / Non Transparent plastic sheet (yet to identified) :1.25mm thick plastic sheath (yet to identify) Compressible filler board (Polyethylene) as per IS 1838 (yet to identify) : Poly-sulphide type Sealant as per BS 5212, part 2 (yet to identify) + BS 7542 with 90% , (H20 — It shall meet the requirements stipulated in 1S. 456) retention efficiency Index (yet to identify) + 601.2.2 Preferably OPC as directed by IE & minimum cement context should be as MORTH (should confirm MORT&H sub clause 601.2.2) :t shall meet the requirements of MORT&H sub clause 602.2.4.3, OPC. It shall meet the requirements of MORT@H sub clause 602.2.4,24, Mix Design Proportions: Material Source iy fort cu. ‘Cement: Aggregate DIC Pac Proportion Proportion Qty fordcu. m. ‘OPC 20mm 12mm River Sand Moisture Content ‘WIC Ratio ‘Admixture 5. Equipment & Machinery: 1 Concrete Batching plant of Sufficient capacity Transit Mixers Roller for DLC compaction (8-10 Tons Roller required, ... Water Tanker Needle Vibrators Joint Cutting Machine (Make & Capacity to be provided by Structural Steel Forms for PAC panels construction Other tools & tackles as required Laying by only paver / slip from paver. 6. Construction of DLC (section clause 600 as per MORT&H): ‘The following are the sequences of activities involved in the construction of DLC 6a 62 Preparation of Subgrade: ‘The Subgrade should conform to the grades and cross sections as shown in the drawings and should be uniformly compacted to the required degree of compaction in accordance with the specifications. Surface defects if any, such as trenches and soft spots should be rectified by filling and compacting to avoid any soft or weak spots. A fine spray of water may be applied before laying sub base. Bate 1g, Mixing and Transportation of mix: Batching and mixing is done in a fully automatic controlled batching plant as per the design proportions. Mix is transported to the site in dumpers and mix is protected by covering with tarpaulin in case of any bad weather.6.3 Placing and Compaction: Laying and spreading should be done to the required levels in an even manner without segregation using paver to the full width of each lane. Compaction should be carried immediately after the material is laid and leveled with double drum 80 to 100kn static weight roller. The Final lean concrete surface on completion should be well closed, free from movement under roller, free from ridges, low spots, cracks, loose materials, pot holes, ruts or other defects. if any defects found, should be rectified using a lean mix of concrete with aggregates of size 10mm and below. 6.4 Joints Contraction joints and longitudinal joints should be provided as per the drawing. Unless vertical forms are used, the edge of compacted material should be cut back to a vertical face to the correct thickness of the compacted layer is obtained 65 Curing: Curing should be done as per MORT&H sub clause 601.5.7, preferably 601.5.7(a). 6.5.1 —Tolerances as per MORT&H sub clause 601.8, 6.5.2 —Trial length should be as per MORT&H 601.6. Construction of PQC (Clause 602 MORT&H): Construction of Pavement Quality Concrete construction involves the following sequences 7.1 Preparation of Sub Base: The base is made of roller compacted lean concrete to be to the grades, slopes and camber, If these are variable, it will affect the thickness. Loose debris on the base needs to be removed prior to paving. Any localized undulations / depressions to be rectified, sufficiently before panning the paving operations, since these may cause base restraint, which arrests the free movement of pavement slab, leading to cracking, 7.2 Spreading of membrane: Plastic sheet of 125 ym thickness, spread on the prepared base for 300mm excess on the either side of paving width. This basic function of this membrane is that it makes the concrete pavement independent of the base and allows it to move under traffic loads and thermal expansions and contraction and also does not allow the base to absorb water from concrete. 7.3 Setting of Formwork: ‘The forms shall be joined the required panel size of 5m x 5m neatly and shall be set with exactness to the required grade and alignment. Sufficiently rigidity is ensured to support tthe forms in position with the help of support anchor, runner beam and jacks during the entire operation of compaction and finishing of concrete. Following procedure shall be following:74 75 16 1 78 ‘Anchor bar shall be placed Runner beam shall be place with support of anchor bar Shuttering plate shal be placed in place with support of jack from runner bar ‘As we have proposed to lay concrete in alternative panel so dowel shall be supported at requisite level in panel where concrete has not to be placed 5. After concrete is laid then support and middle shuttering plate shall be removed before laying concrete in alternative panel awne ing of Dowel bars: Dowel bars of 500mm in length shall be positioned at mid depth of the slab within a tolerance of +20mm at spacing of 240mm within a tolerance of 25mm. Dowel bar shall be covered by a thin plastic sheath for atleast two-thirds of the length from one end for dowel bars in contraction joints or half the length plus 50mm for expansion joints. The sheath shall be tough, durable and of an average thickness not greater than 1.25mm. Fixing of Tie bars: Tie bars of length 580mm shall be positioned in longitudinal joints at spacing of 350mm. to remain within the middle third of the slab depth and approximately parallel to the surface and perpendicular to the line of the joint, with the centre of each bar on the indicated line of the joints within a tolerance of 50mm and with a minimum cover of 30mm below the joint groove. Batching, Mixing & Transportation: Batching and mixing is done in a fully automatic controlled batching plant as per the design proportions. The dosage of admixture is adjusted to have a workability of 30215mm at pouring site. The batched mix is transported to site by transit mixer. Placing and Compaction: Before placing concrete in the forms, the workability of the mix should be in the range of 60#15mm. Care shall be taken while placing the concrete no segregation occurs. ‘Compaction is done using 60mm needle vibrator. Texturing (should be as per MORT&H 602.9.8): While the concrete is still plastic, its surface shall be textured, 7.8.1 Once the “Broom” is fitted onto the handle the same is lifted off the slab and the Operator stands across the slab but very close to the edge holding out the broom to be placed on the edge on the opposite side. 7.8.2 Once the concrete surface is found to be “stiff” enough such that there is no Bleed Water / Excess-Mortar present over the freshly laid rod, it can be felt with a coin ‘whose impression slightly pushed should be just enough to sink the coin fat side7.8.3 The Bristles / Tines are held with slight pressure and the Handle is pulled towards the operator like pulling a rope, with the action being SLOW / JERK FREE and Continuous till the “broom” reaches towards the operator. 7.8.4 Here he lifts off the Texture brush, cleans with a wet cloth / tray filled with water and soft nylon brush off the mortar stuck to the tines and again repeat the process 781. 7.8.5 The Texture Broom MUST NEVER BE PUSHED! ALWAYS PULLED ONLY. 73 7.10 Curing: Soon after texturing as per MORT&H 602.9.9 & as per BS - 7542, resin based curing compound shall be applied as per the manufacture recommendations and further continues curing shall be done by water. J There are 3 types of joints as follows: ‘Transverse Contraction Joint: ‘There are the saw cut joints provided transversely at every 5m intervals. These joints control the location of uncontrolled cracking of pavement due to drying / shrinkage / thermal contraction and reduce the stresses due to slab curling and warping, These joints are saw cut after 12-14 hours after laying, when the concrete still in green condition and attain strength take the load of saw cutter. These are also provided with 32mm diameter dowel bars to transfer the loads. ‘These joints are saw cut for 1/3" of the pavement thickness as initial cut for a width of 4mm, filled with polythene / synthetic / rubber backer to avoid chocking of joint while curing or widening and further widened to 7mm after curing period is completed for a depth of 22mm and provide compressible deboning strip with paperback & Poly-sulphide sealant inserted. Transverse Expansion Joint: These are the construction joints provided transversely for thermal expansion / contraction and load transfer, generally provided at the end of days work or abutting structures or joining between flexible and rigid pavement. Compressible filler board (polyethylene) of 20mm thick shall be provided in these joints. Dowels bars of 32mm diameter MS round are provided as per the spacing shown in the drawings at the middle of the pavement thickness, with @ PVC cap. The compressible board is provided by leaving top 30mm space, which filled with 2mm de-bonding strip & 25mm poly-sulphide sealant after the curing period is completed. Longitudinal Joint: These are the saw cut construction joints provided longitudinally between two paving runs / lanes. These are provided to relieve early curling stresses otherwise longitudinal crack will develop. This joint is required to function as a permanenthinge and preservation i.e. opening of the crack also transfer the live loads in those zones adjacent to wheel path in order to reduce slab edge stresses. Trial length shall be as per MORT&H sub clause 602.10. 8, Anticipate Problem and Precautions: 10. The following are the precautions to be ensured during the an Ba 82 83 pated problems. Concrete during monsoon months: Concreting should be avoided during rainy season. However, when concrete is being placed during monsoon months and when it may be expected to rain, sufficient supply of tarpaulin or other waterproof cloth shall be provided along the line of the work, Concrete in hot weather: Besides, in adverse condition like high temperature, low relative humidity, excessive wind velocity, imminence of rains etc,, if so desired by the Engineer, tents on mobile trusses may be provided over the freshly laid concrete for a minimum period of 3 hours as directed by the Engineer. The temperature of the concrete mix on reaching the paving site shall not be more than 30°C. To bring down the temperature, if necessary, chilled water or ice flakes should be made use of, ‘Temperature should be measured at plant and site as per MORT&H 602.9.4.4 and documented. Also proper measure should be taken accordingly. Quality Control: ‘As per attached Inspection & Test Plan, also follow 3 level standards. Further strictly adhere to MORT&H clause 900. Health and Safety: 10.1 10.2 10.3 Working zone: The DLC / PQC laying area ete. at which workmen will be working, Working space: The space around the works area to store tools, equipment & Plant and Machinery. It is also the space to allow workmen, movement and operation of plant, (e.g. water tamker, tandem roller, DLC paver) to move around to do the job. Materials and equipment must not be placed in the zone either. Workmen will only need to enter the zone to maiiitain cones and other road sign. Safety zone: The zone provided to protect workmen from the traffic and construction machinery,10.10 House Keeping Flagmen should be equipped with yellow helmet with green reflective sticker fixed around and reflective jacket along with hand signaling devices such as flags and sign paddles. The typical specification is given below. Flagmen need to maintain the flow of traffic in the work zone at relatively reduced speeds by suitably regulating the traffic. He shall stop the traffic for a while whenever required (e.g. for entry and exit of construction eq 10 work zone). Flagman should be positioned in a place where he is clearly visible to approaching traffic and ata sufficient distance to enable the drivers to enable the drivers to respond for his flagging instructions. A flagman never leaves his post until properly relieved 1. An orderly arrangement of material and equipment will be maintained at all times. 2. Construction areas will be cleaned and arranged by safe means on a daily basis, to preclude the creation of tripping, slipping and fire hazards, 3. Appropriate trash containers will be placed strategically on the project and used for disposal of scrap materials and other construction-generated debris. 4. Liquids (such as paints, solvents, thinners, oils and greases) and any other material or containers that have contained chemicals will be disposed of in accordance with project hazardous waste procedures and regulatory requirements. 5. All scrap lumber, waste material and rubbish will be removed from the immediate work area as the work progresses. 6. All solvent waste, oily boxes and flammable liquids will be kept in fire-resistant covered containers until removed from the project. 7. Rubbish, waste and other trash shall be disposed as per norms. 10.11 Portable Fire Extinguisher: Hand-held portable fire extinguishers are basically first aid firefighting equipment for Use against small fires. It is important for every employee to know how to identify fire extinguishers and how to use them, Fire extinguishers should be installed in plain view, in an accessible spot.10.4 10.5 10.6 10.7 10.8 10.9 Approach Transition zone: This will vary with the speed limit and the width of the works as given in (please refers fig. 1 and table 1. Source IRC:SP:55-2001 at page no. 41840}, Longitudinal buffer zone: This is the length between the end of the lead-in taper of cones (T) and the working space. It will vary with the speed limit as given in table (please refer fig. 1 and table 1. Source IRC:SP:55:2001 at page no. 41840). Lateral buffer zone: This is the width between the working space and moving traffic. It will vary with the speed as given in table (please refer fig. 1 and table 1. Source IRC:SP:55-2001 at page no, 41842). The lateral buffer zone safety clearance is measured from the outside edge of the working space to the bottom of conical sections of the cones on the side nearest to the traffic. DLC / PAC Layi Certified Operators are only allowed to operate Paver, Roller & Vehicles. Planning is done for blocking the areas for road work such that they do not hinder other works and vice versa. > The road construction area is cordoned off. > Nominated signal men hall regulate the vehicle movements. They should wear a fluorescent jacket and have a red & green flag and a whistle > The signals applied for regulating the vehicle should be made aware to all. > The Employees working with DLC / PQC shall wear the appropriate Personnel Protective Equipment. > Employees should be informed to be careful while DLC / POC laying is done. > First Aid kit should be provided. > Appropriate and adequate warning and caution boards should be displayed, PPE Requir All personnel engaged on work with hot DLC / PQC should wear complete clothing covering the entire body, shoes with sound soles and heavy socks. Wear Safety helmet with chin strap, gloves and goggles during work. All construction personnel must wear minimum requirements of PPE helmet, safety shoe, gloves ete. 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Ts the previous GSB layer approved and ready for DLC laying? Ts weather condition favorable? ‘Are Grader, trucks and compactors clean and {free of any residual soil? ‘Are equipments in good working condition? 70 Concrete batching plant no. & Lacation 7 ‘Are there ascharge sips7batching plant dockets (with name of project, discharge time and arrival time, discharge temperature and arrival temperature, weight of the load, truck number, type of mix, slip! docket ‘number and location of laying) ? D7 ‘Are joints of previously laid DLC on the other side trimmed! eut vertleal. iB Ts staré up Joint properly formed and checked with 3m straight edge for irregularity/bump? Uncompacted thickness Tam] 5 Ts there segregation of aggregates? 6 Te there contaminatTon by foreign substances (spilled gasoline, kerosene, oll, rags, paper, trash, dirt etc.)? 7 “Ambient air temperature Page 1 of 2 1CHECKLIST DRY LEAN CONCRETE 18] Concrete temperature at site Cl 19_| Are rolling operations (commence from lower side and progress towards higher side paraltet to the centre line of the pavement) os. specified? 20 | Are rollers speeds as specified? 72i__| Are manually lad strips where grader can nat operate compacted properly? ‘2 __| Are irregularities checked and corrected before final compaction? 73 | Are longitudinal Joints and transverse jomnts ‘made and compacted properly? 74 | Ts Flshed width checKed and found as per drawing? 5_| Have representative concrete samples been taken for cubes? 26 | Ts newly finished wrk protected from traffic? ‘27 | Ts the area covered with moist gunny bags for curing and continuously watered? 28 | Ts the area left neat and clean? 29 __| Has the area been checked by CST with checklist? Description of noncompliance: For Construction contractor For Concesionaire Perle Name Name Name stenature sisnotore Signature ate ate bate Page 2 of 2