Methodology

FOUR LANING (WITH PAVED SHOULDERS) OF VARANASI – SHAKTINAGAR ROAD
UPTO HATHINALA JUNCTION (SH – 05A) IN THE STATE OF UTTAR PRADESH ON

DBFOT BASIS
Four Laning (with Paved Shoulders) of Varanasi - Shaktinagar

Road up to Hathinala (SH-5A) from 0.000 to 117.650 in the State
of Uttar Pradesh on Design, Build, Finance, Operate and Transfer
(DBFOT) basis
METHODOLOGY STATEMENT
ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |1

DBFOT BASIS
FOR
HIGHWAY WORKS

DBFOT BASIS
A. METHODOLOGY FOR SETTING OUT
1. The setting out work will conform to MORTH specification clause no-109. In this job, working
benchmarks will be first established in the area soon after taking possession of the site.
These bench marks (WBM or TBM) will be tied with the reference bench mark (RBM) for the
area as indicated in the construction drawings.
2. TBM will be 5 nos per km and at or near all CD structures, Over-bridges and underpasses.
3. After establishing TBMs, setting out of the centre line of the project (PCL) will be accurately
established on the ground. This will be referenced at every 50m intervals. At all curve points
the referencing will be done at 20m intervals. Records of all co-ordinates and references as
set will be maintained in the survey Register.
4. At formation level stage, the centre line will be set out and referenced again. Referencing will
be done with lime powder and marker pegs. As per IRC-36 the reference pegs will be fixed
normal to the centre line on either side at a distance of 20-25m from PCL and in a position
away from the toe points. Reference pegs will consist of bamboo rods or other types of
pillar.
5. All dimensions and levels shown on the drawing along PCL will then be verified on the site.
After that a profile along the road centerline will be drawn both on plan and in L-section.
Simultaneously cross-section drawings will be prepared showing the FRL’s before clearing
grubbing and superimposing proposed pavement layers on it, at every 20m interval.
6. Total station equipment and precision auto-level instruments will be used in all setting out
and level recording jobs.
7. As a part of the setting out activity the old carriageway alignment is also to be referenced
and recorded on site plan drawing (strip plan). On this drawing, PCL will also be marked with
suitable co-ordinates/offsets. All existing features & fixtures like encroachments, pucca/
kuchha structures, poles, drains, bus-sheds, utilities etc. as lying in between the ROWs will
be referenced and marked on the strip plan.
8. All such activities of setting out will facilitate maintaining accuracy of work. This will also help
to have clear knowledge and record of all existing obstacles and hindrances. Kilometer
stones on existing carriageway will be checked and reset, if required, as a part of the setting
out activities. Similarly, all survey data given in the construction drawings regarding the
existing structures will also be verified.
9. Necessary steps for realigning the PCL if required as per site condition will be taken at the
initial stage. New Chainage as along the PCL will be marked near the edge of the existing

DBFOT BASIS
carriageway at every 20m interval. These markings will be constantly maintained & re-
written as & when erased out.
10. All TBM-Pillars & the X, Y & Z values on those will be checked every month. The values will
be recorded in the survey register monthly.
11. Toe points preliminarily determined from the X-Section drawings at 10m intervals will be first
plotted on a Toe-plan drawing duly referenced w.r.t. the PCL & ECL (Existing Road Center
Line) or other fixtures. At site these toe points will be located, Marked and joined to fix up
the limit of the work of embankment.
12. Boundary/ ROW pillars have been duly fixed after making confirmation from the PWD Land
Record. These will be helpful to avoid minor local disputes on land and related disturbances
in future.
13. For setting out of structures there centerline will be first laid on the ground as per drawings
and will be duly referenced w.r.t. Permanent fixtures, PCL, etc. These will also be recorded on
approved layout drawings. A pair of reference pillars will be constructed on either end of
structure along its centerline. Similarly pairs of reference pillars will be constructed on either
end of every foundation of structure. Record of these reference pillars will also be
maintained on approved drawings.
14. At the time of survey & measurement works on the existing carriageway due traffic control &
all safety arrangements will be made with the help of barricades, cones, flags, etc.

DBFOT BASIS
B. METHODOLOGY FOR CLEARING AND GRUBBING
1. This work shall consist of cutting, removing and disposing of all materials such as trees,
bushes, shrubs, stumps, roots, grass, weeds, top organic soil not exceeding 150 mm in
thickness, rubbish etc., which are unsuitable for incorporation in the permanent works, from
the area of road land containing road embankment, drains, cross-drainage structures, etc. It
shall include necessary excavation, backfilling of pits resulting from uprooting of trees and
stumps to required compaction, handing, salvaging and disposal of cleared materials etc.
Clearing and grubbing shall be performed in advance of earthwork operations and in
accordance with the MORTH Specification Clause No. 201.
2. Roadside trees, shrubs, and other plants, pole lines, fences, signs, monuments, buildings,
etc. within or adjacent to the highway which are not to be disturbed shall be protected from
injury or damage.
3. Ant-hills if any both above and below the ground shall be removed and their workings which
may extend to several meters shall be suitably treated.
4. All products of clearing and grubbing which cannot be used shall be cleared away from the
roadside. Care shall be taken to see that unsuitable waste materials are disposed of in such
manner that there is no likelihood of these getting mixed up with the materials meant for
road construction.
5. Dozer having ripper attachments/Excavator for removal of tree stumps will be used in
Clearing & Grubbing work.

DBFOT BASIS
C. METHODOLOGY FOR EARTHWORK IN EMBANKMENT
1. First of all setting out of the PCL will be done on the ground accurately with the
help of total station instrument. This will be duly referenced w.r.t. road nails and permanent
fixtures and documented with offset charts. Project linear chainages will be marked on the
existing black top surface at 20m intervals, which will be regularly checked & rewritten.
2. Clearing & grubbing activity will be commenced after completing the setting out
and documentation of setting out jobs.
3. As a parallel activity, suitable borrow areas will be selected as near as possible

from the proposed working stretch. Sampling & testing of soil will be conducted in the
meantime. Test results will be duly documented on individual formats.
4. Maximum Dry Density (proctor) and OMC will then be evaluated in the laboratory
to fix up the design density and target density at field as per specified compaction
requirement.
5. Dumped earth for the first layer will then be spread by Motor grader in already
determined loose thickness on the slope duly benched within the laid out boundaries and
predetermined length.
6. Moisture Content in the dumped earth will be verified with the help of a Rapid
Moisture Meter. As per requirement water will be sprinkled uniformly by a water tanker to
achieve OMC in the soil.
7. Vibratory roller will be deployed for compaction and compacted layer of

maximum 200mm thick will be laid.
8. Lines & levels (only at the top most layers) will be checked and FDD tests as per
required frequency will be conducted.
9. After complying with all above-mentioned activities and ensuring conformation

of all relevant technical specifications & test results, etc. the bed will be passed for receiving
material for the next higher layer in which similar operation will be repeated.

DBFOT BASIS
D. METHODOLOGY FOR GRANULAR SUBBASE
1. The material will be Crusher run, Natural GSB or a combination thereof to meet MORTH
requirements for grading 1 or 2.
2. GSB layer will be provided on the sub grade top layer, which will be already constructed as
per MORT&H clause 305.
3. Calculated quantity of GSB material will be placed on the bed by tippers. If any segregation is
observed, the same is rectified by processing with the help of grader blade. GSB material
gradation will be checked at QC lab.
4. Material will be spread with the help of motor grader.
5. Required amount of water will be sprinkled, calculation based on OMC (+1% or -2%
tolerance limits). Material will be processed if required with the help of grader blade to
achieve uniform moisture.
6. Final grading will be done carefully as per required slope and level without segregation.
7. The graded material will be thoroughly compacted to the specified densities by a vibratory
roller having a static weight of 8-10 tons.
8. Rolling will be commence at the lower edge and will proceed towards the upper edge
longitudinally with overlapping of one third of roller drum width for each passes for areas of
unidirectional cross fall (camber) and super elevation.
9. The number of heavy vibratory passes will be established after doing trial stretch to achieve
required density i:e 98% of MDD. Speed of the roller will be uniformly maintained (not
exceeding 5km/hr.) during rolling.
10. All the depressions, high spots, segregated locations, cambers will be corrected during initial
rolling itself.
11. Finally one plain pass will be given on the entire length of the stretch.
12. After rolling compaction test will be carried out to check its degree of compaction by any
suitable method.
13. All the field density readings / results will be recorded in the specified as mentioned above.
14. Levels will be checked and recorded in the format no for the top layer.
E. METHODOLOGY FOR WETMIX MACADAM

DBFOT BASIS
1. WMM will be processed in pug mill of suitable capacity and having provision of maintaining
optimum water content as per IS:2720 (Part 8) and having forced/ positive mixing
arrangement.
2. WMM 1st layer will be constructed on the GSB top layer, which is already constructed as per
MORT&H clause 401.
3. Calculated quantity of WMM 1st layer material will be placed on the entire bed with the help
of paver/ grader. If any segregation is observed, the same is rectified by processing with the
help of grader blade. WMM material gradation will be checked at QC lab.
4. Required amount of water will be sprinkled, calculation based on OMC (+1% or – 2%
tolerance limits). Material will be processed if required with the help of grader blade to
achieve uniform moisture.
5. The graded / paved material will be thoroughly compacted to the specified densities by a
vibratory roller having a minimum static weight of 8-10 tons.
6. Rolling will be commence at the lower edge and proceeded towards the upper edge
longitudinally with overlapping of one third of roller drum width for each passes for areas of
unidirectional cross fall (camber) and super elevation.
7. The number of heavy vibratory passes will be established after conducting a trial stretch to
achieve required density i.e. 98% of MDD.
8. All the depressions, high spots, segregated locations will be made correct during initial rolling
itself.
9. Camber will be checked and corrected if required before final rolling.
10. Finally one plain pass will be given on the entire length of the stretch.
11. Speed of the roller will be maintained uniformly (not exceeding 5km/hr.) during rolling.
12. After compaction tests will be carried out to check its degree of compaction by any suitable
method.
13. All the field density readings / results will be recorded in the specified as mentioned above.
14. Levels will be checked and recorded in the format for the top layer
15. The 2nd layer will be laid on the 1 st layer by Paver/ Grader for which same procedure will be
followed from Step 3.
F. METHODOLOGY FOR KERB LAYING

DBFOT BASIS
1. Kerb shall be laid on WMM which shall have a projection of 50 mm beyond the kerb stone.
Before laying, the base shall be leveled and slightly watered to make it damp.
2. In the median portions or in the straight reaches, the kerb shall be cast in continuous
lengths. In the portions where footpath is provided and/ or the slope of the carriageway is
towards the median (as in the case of super-elevated portions), there shall be sufficient gap/
recess left in the kerb to facilitate drainage openings.
3. String/ guide wires for level control shall be fixed prior to kerb laying. Kerb alignment shall
be established and verified by the Engineer. The level will be maintained and checked in
reference to the finishing level of the roadwork with auto Level through sensor system of
machine.
4. Kerb machine shall be put in place and M-20 Grade concrete shall be fed into hopper by the
transit mixer. The machine shall be operated in accordance with control mechanisms and the
kerb shall be laid in accordance with the required cross sections, lines and levels as given in
the drawings that a well-compacted mass of concrete kerb which is free of voids and
honeycombs shall be produced. Quality of Concrete to be verified by taking cubes which
shall be tested for grade of concrete, After laying the kerb and just prior to hardening of the
concrete, saw cut grooves shall be provided at 10 m intervals or as directed by the Engineer
as soon as possible without damaging the concrete.
5. Curing shall be done by regular watering on the Kerb for 14 days, in hot weather hessian
cloth to be provided.
G. METHODOLOGY FOR PRIME COAT

DBFOT BASIS
1. This method statement for Prime Coat describes the systematic approach of laying on Wet
mix Macadam base conforming to MORTH specification
Sequential operation involved are explained here with the flow diagram
Selection of Primer as per MORTH
Cleaning of WMM base with Power

Broom and Air Compressor
Calibration of Bitumen Sprayer
Transporting primer by Bitumen

sprayer to the site and spraying the
primer on the prepared WMM surface
Check the spray rate as per specification
2. The work shall consist of laying of prime coat with approved primer on prepared Wet mix
macadam surface in accordance with the requirements of these Specifications as per
MORTH clause – 502.
3. Before commencing Prime coat laying, WMM approved top surface shall be thoroughly
swept clean by a mechanical broom and the dust removed by compressed air and care shall
be taken not to disturb the interlock aggregate. Priming shall be done on WMM surface by
approved primer (emulsion) with Bitumen pressure sprayer and rate of spray will be
measured as per specifications. The Bitumen sprayer spray rate shall be calibrated before
spraying on WMM surface.
4. The primed surface shall be allowed to cure as per the specifications of the primer used.
5. The bituminous primer shall not be applied on wet surface or when weather is foggy, rainy
or during a dust storm. The surface where the primer is to be applied should be moist until
the completion of the priming activity.
ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 10

DBFOT BASIS
6. The primer distributor shall be self-propelled, self-heating bitumen pressure sprayer.

DBFOT BASIS
H. METHODOLOGY FOR DENSE GRADED BITUMINOUS MACADAM (DBM) AND

BITUMINOUS CONCRETE (BC)
The Construction of Dense Graded Bituminous Macadam (DBM)/ Bituminous Concrete shall consist
of providing of DBM on a previously prepared base of WMM primed and BC on DBM surface to be
laid as per design thickness.
1. Setting Out:
Fixing pegs on both sides at regular intervals shall mark the limits of Dense Bituminous Macadam &
Bituminous Concrete layer. The chainage boards & Bench Marks shall be set outside the limits of
construction.
2. Equipment:
The following equipment shall be used for the production & construction of Dense Graded
Bituminous Macadam and Bituminous Concrete.
a) Loaders for feeding Aggregate
b) Dumpers for transporting of mix.
c) Hot Mix Batch type Automated Plant
d) Sensor Paver Finisher Capable of Paving 9.0 m Width
e) Water Tanker
f) Smooth wheeled Rollers/Double Drum Vibratory Roller.
g) Pneumatic Tyred roller
h) High Pressure Air Compressor
i) Mechanical Broomer
j) Asphalt Distributor with Spray Bar System
3. Bitumen will be procured from main refineries. Aggregate will be manufactured at the
company’s, crushing plant or procured from third party subject to meeting specifications.
Materials will be properly tested in the site laboratory.

DBFOT BASIS
4. Job Mix Formula for finalizing the mix ratio & gradation will be evaluated in the site
laboratory. Trial stretch will be laid and Marshall Moulds will be prepared for final approval
of the JMF and for fixing up the compaction factor.
5. Firstly, primed WMM for DBM course & DBM base for BC course will be prepared in specified
lines, levels, grades and cross-fall as per design. The surface will be thoroughly cleaned from
dust & foreign matters using mechanical broom & compressed air-jet. The base will be firm
and adequately compacted without any unevenness.
6. Tack coat of Bituminous Emulsion will be uniformly applied on the base by means of a
pressure sprayer. Quantities of bitumen & water will be previously decided as per Table 500-
2 of MORTH specification.
7. DBM/ BC mix will be prepared in a 200 TPH capacity Hot Mix Plant having centrally
computerized control, monitor & detailed batching record arrangement. Required quantities
of pre-heated bitumen, aggregates & filler will be automatically added for batch wise mixing.
Required temperatures of binder, aggregate & mix will be automatically maintained as per
specification.
8. A fleet of tippers will be deployed to transport the mix to the laying area. Number of tippers
will be determined on the basis of lead and optimum requirement for the paver. A brand
new paver with electronic sensing device for automatic leveling & profile control, extendable
screed, internal screed heating arrangement and one-man control will be deployed for
excellent spreading of mix. Mix not below 1200C temperatures will only be put in the paver.
9. Prior to start of laying, transverse joints at the starting point will be vertically cut to the full
thickness & the side surface will be painted with hot bitumen.
10. Rolling will be done by a group of rollers, two vibratory Tandem Rollers & one Pneumatic
Tyre Roller in that order. Rolling shall commence from the edge & proceed to the center.
Rolling without any vibration will be done during initial breakdown rolling and again during
final finish rolling. Each pass of the roller will overlap the adjacent track by ½ width of the
rear wheel.
11. Camber templates with levels will be used to check the required cross-fall continuously.
12. Constant watch of experienced eyes will be ensured to finish all operations before cooling of
mix. Local segregation, shortage of fines, unevenness etc. will be detected and rectified
immediately.
13. After completion of the operations, core densities will be checked and ensured for the
required value of minimum 98% of Marshall Density of specimens prepared of the mix on
that day.

DBFOT BASIS
FLOW CHART FOR CONSTRUCTION

METHODOLOGY
(Attached as Appendix 1)

DBFOT BASIS
FOR
STRUCTURE WORKS

DBFOT BASIS
A. METHODOLOGY FOR HUME PIPE CULVERTS
The work shall consist of laying Hume Pipes of required diameter, preparation of bed for laying
pipe, construction of head wall, floor protection and slope pitching etc. as per drawing
reviewed by IE.
Selection of Materials
Cement : will be used from approved source
Sand : will be used from approved source
Aggregate : will be used from approved quarry source
Hume Pipe : Approved RCC Hume Pipe of Required Diameter and 2.5 m / required
Length will be used as per IS: 458 in conformation to the requirement of
section 1000 of MORTH specifications. Each consignment of RCC pipe shall be
inspected and tested.
Equipment
The following equipment shall be deployed in the construction work of pipe culverts:
a) Batch Mix Plant
b) Transit Mixer
c) Vibrator
d) Trailer
e) Water Tanker
f) Water Pump
g) Shuttering Plate and stays
Method of Operation
1. Layout and Excavation

After layout of the structure as per approved drawing, excavation of foundation for bed of
Pipe and Head walls will be done to proper lines, length, grade and level shown in the
working drawing on the natural ground. In case of old and existing embankment the trench
will be cut 150 mm in excess on both sides or one fourth of the diameter of the pipe
whichever is more to the founding level of pipe bed. The trench shall be made vertical.
During excavation, soft, spongy or other unstable soil, if any, will be removed and backfilled
with suitable material. The bed shall be compacted with approved granular material (as
shown in drawing). In case rock strata is encountered the excavation will be taken down to
minimum of 200 mm. below the bottom of pipe. Trench shall be kept free from water until
the pipes are installed and joints are hardened.

DBFOT BASIS
2. Bedding Concrete
Concrete/ Granular bedding will be provided as per drawing conforming to specification for
road & bridgework as per required thickness & compaction.
3. Laying of pipes
The arrangement for lifting, loading, unloading & lowering the pipes in the bed shall be done
by means of tripod, manual labor, cranes. Precaution shall be taken so that the pipes are
placed without damage.
The gap between two rows of pipes shall be at least minimum 450mm or half the diameter
of the pipe whichever is more. The laying of NP – 4 pipes will start from the outlet end and
will be completed at the inlet end to specified lines & grades.
4. Jointing
The pipe shall be jointed either by collar joint or by flush joint. In the former case, with
approved collars and then filled with cement mortar1:2 and kept damp for minimum 4 days.
5. Headwalls
After laying the pipe, surface reinforcement as per provision in the working drawing for
headwalls and reinforcement for catch pit as per section-1600 will be placed accurately.
Engineer will check the form works. Material for formwork shall confirm to section-1500 &
IRC – 87.
6. Cradle and Catch Pit

Concrete will be used as per approved mix design. Concrete will be produced with Batching
Plant and will be transported by means of Transit Mixer to the work site and will be laid to
required level as per working drawing. Curing with damp sacks will be done to the structure
for a minimum period of 14 days.
7. Backfilling
Backfilling material should not contain boulders, large roots. Backfilling up to 300mm above
the top of the pipe shall be carefully done & thoroughly rammed, tamped or vibrated in
layers not exceeding 150 mm. Particular cares shall be taken to thoroughly consolidate the
materials under the haunches of pipes. Filling of the haunch shall be carried out
simultaneously on both sides of the pipe in such a manner that unequal pressures do not
occur.
8. Apron & Stone Pitching

DBFOT BASIS
Apron will be done as per specification section-2500 after completion of pipe culvert.
Pitching will carried out as per working drawing along with other pitching work as per
specification section 2500 after doing earth work.
9. Safety
During construction work adequate safety and traffic signs shall be installed adjacent to the
road shoulders to protect the on-going work and prevent traffic hazard. All locations
adjacent to existing road where construction is in progress shall be provided with visible
safety and cautionary road signs. No machines or equipment shall be permitted on the
existing road or shoulder unattended at all times unless it is properly protected and secured
in a safe manner. The Safety Officer shall make frequent patrolling along the Highway to
ensure that the safety, equipment and signs are operational at all time.

DBFOT BASIS
B. METHODOLOGY FOR SLAB AND BOX CULVERTS
Equipment
a) Batch Mix Plant
b) Transit Mixer
c) Vibrator
d) Trailer
e) Water Tanker
f) Water Pump
Method of Operation
1. The location and level shall be as per approved drawing.

2. The reference points shall be staked out and layout marking shall be done as per approved
drawing.
3. The excavation shall be done with JCB/ Excavator upto 100mm above the required level. The
remaining excavation shall be done manually to obtain a hard surface. Unsuitable soil if any
to be removed and backfilled with suitable material.
4. Layout marking for widening, median and service road portion will be done with lime
powder as per approved drawing.
5. PCC leveling course will be provided as per approved drawing on damp surface.
6. Chipping of the existing exposed surface will be done with the help of chipping machine/
Chisel & Hammer/ Tractor compressor breaker as per requirement.
7. Dowel bars will be provided and grouted as per approved drawing for widening of existing
culverts.
8. Shuttering shall be fixed as per the approved drawings, levels, plumb and proper cover shall
be maintained.

DBFOT BASIS
9. Reinforcement tying as per diameter mentioned will be done as per approved drawing for
raft, wall, slab, parapet wall.
10. Concrete laying of grades specified will be done as per approved drawing for raft, wall, slab,
parapet wall with the help of either chute/ Boom Placer/ Pump.
11. Suitable arrangement for doing curing will be done as per the requirement at site.
12. Safety
During construction work adequate safety and traffic signs shall be installed adjacent to the
road shoulders to protect the on-going work and prevent traffic hazard. All locations
adjacent to existing road where construction is in progress shall be provided with visible
safety and cautionary road signs. No machines or equipment shall be permitted on the
existing road or shoulder unattended at all times unless it is properly protected and secured
in a safe manner. The Safety Officer shall make frequent patrolling along the Highway to
ensure that the safety, equipment and signs are operational at all time.
Signboards shall be placed along the right hand side on increasing chainage at every 500
meters i.e. “GO SLOW WORK IN PROGRESS”.

DBFOT BASIS
C. METHODOLOGY FOR MINOR BRIDGES
Equipment
a) Batch Mix Plant
b) Transit Mixer
c) Vibrator
d) Trailer
e) Water Tanker
f) Water Pump
Method of Operation
1. Layout
Electronic Total Station and Auto Levels shall be deployed to set out the exact alignment of
the bridge and to fix up location of the Abutments, Piers.
2. Excavation
Before commencement of excavation cofferdam, if required, shall be made all round the
excavation area for diverting of water has to be completed. Earthwork excavation shall be
carried out using Excavator taking all precautions to avoid soil slips. The foundation bed shall
be leveled manually at the required level i.e. bottom of PCC leveling course.
3. Leveling Course (PCC):

Leveling course of Plain Cement Concrete of M-15 grade, 150mm/ 100mm thick shall be laid
as per the approved mix design, duly controlling the water cement ratio and slump for
workability as indicated in the approved Design Mix Concrete.
4. Marking for Foundation Raft and placement of Reinforcement Steel

Before reinforcement is placed for raft, survey team will give centre point for the raft and
alignment will be fixed. Reinforcement will be placed as per drawing.
5. Foundation Raft Concrete

DBFOT BASIS
Upon checking for reinforcement is done, concrete will be placed using pump/ chute in the
raft.
6. Abutment/ Pier Concrete (Sub Structure)

Abutment/ Pier footing, marking on the leveling course shall be completed and
Reinforcement shall be tied with good quality binding wire. Form work with steel shuttering
shall be completed as per drawing and the concrete shall be poured in layers whether the
thickness of the concrete is more than 300 mm. Pre-fabricated steel shutters to be provided
up to required height and shape. In order to prevent concrete bulging due to buckling of the
form work, additional internal form ties will be provided along with adequate external
supports to maintain the alignment and verticality. Scaffolding will be provided around the
formwork with necessary ladders to reach the top wherein a platform provided with safety
railings around, for easy access to inspect and carrying out concreting works. Concreting will
be done in lifts of 1.0 to2.50 m till desired level is achieved. Cover will be maintained as per
drawing.
7. Abutment/ Pier Cap Concrete

Proper staging and shuttering arrangements will be made based on the size and shape of the
cap and concreting will be done using Boom Placer, Pump or Acrow Bucket.
8. Marking for Bearing Pedestals

Survey team will fix the point for placing bearings according to the required alignment and
bearing pedestals. Shuttering plates (small size) and concreting is done using bucket or
manual concreting.
9. Pedestal and Bearing Fixing

Clean the pedestal area and fix shuttering to its alignment and pour the concrete manually.
Utmost care shall be taken to maintain the levels while fixing the Bearing as per drawing.
10. Super Structure

Deck Slab concreting shall be done with balance lift and haunch of Abutment or Pier, if
required. The formwork for RCC slab will be erected as per section-1500 to the dimension
lines and levels. This shall be checked with respect to permanent reference lines and
permanent benchmark so that final product is in accordance with the drawings.
Reinforcement shall be placed as per section-1600 and structural concrete will conform to
the section 1700. The expansion boards shall be placed at appropriate position as per
working drawing. The whole slab shall be cast with reinforcement embedded for the road
kerb & railings.
Where wearing coat is required the surface of the slab shall be finished rough and put true
to line and levels as per drawing. Curing shall be carried out as per section-1700 by ponding.

DBFOT BASIS
The wearing coat shall be laid as per working drawing and true to the line grade & camber.
The road kerb and railing guard posts will be cast as per approved working drawing. The kerb
posts will be painted as per specifications.
11. Providing Filter Media/ Pitching Behind Abutment and Return Walls and Backfill
This work shall be taken up as per working drawing. The filter materials of specified grading
shall be placed from the base of abutment to the level of bed block in layers and compacted
to required thickness, backfilling shall be done with approved backfilling material compacted
in layers not exceeding 25cm layers at OMC by means of small vibratory roller, plate
compactor or power compactor with proper care to the structural member.
12. Stone Pitching on Slopes and Aprons

The stone should be sound and individual weight of stone should not be less than 40 Kg
conforming of IRC 89. The pitching and floor protection shall be taken up as shown on the
drawing. The heavy stones will be placed at the toe level layer and the voids will be packed
with smaller stone by means of ramming & wedging. The pitch work will be taken up on a
trimmed surface to proper line & camber as per working drawing.
13. Construction Joints:

Construction joints shall be avoided as far as possible and in no case the locations of such
joints shall be changed or increased from those shown on the drawings.
14. Test and Sampling Procedures

The material will be tested as per MORTH specification and relevant IS and IRC Codes will be
followed for the test procedures. Concrete produced will be sampled and tested as per
relevant codes.
15. Placing and compaction of concrete:

Concreting from Batching Plant will be transported by the Transit Mixers to the placement
site. Placing of concrete will be done by concrete pump or chute. When concrete is conveyed
by chute, slope of the chute shall be so adjusted that the concrete flows without the use of
excessive quantity of water and without any segregation of its ingredients. The delivery end
of the chute shall be as close as possible to the point of deposit. The chute shall be
thoroughly flushed with water before and after each working project and the water used for
this purpose.
All form work and reinforcement shall be cleaned and made free from standing water &
dust, immediately before placing of concrete which shall have a temperature of not less than
5oC and not more than 40oC. It shall be compacted in its final position within 30 minutes of
its discharge from the mixes. Concrete shall be thoroughly compacted by vibration and over
vibration shall be avoided to minimize the risk of forming a weak surface layer. Additional

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vibrators in serviceable condition shall be kept at site so that they can be used in the event
of breakdown.
The Concrete shall be placed and worked around the reinforcement, embedded fixtures
corners of the form work to produce a dense homogeneous void, free mass having the
required surface finish.
16. Arrangement of Traffic

Traffic will be opened on New Carriageway after completing the Back Filling, Deck Slab and
Approach Slab. After opening traffic on one side of carriageway the construction on the
other side of carriageway shall be taken up.
17. Safety
During construction adequate safety and traffic sign shall be installed adjacent to the road
shoulder to protect the ongoing work. All location adjacent to existing road where work is in
progress shall be provided with visible safety and road sign. No machine or equipment shall
be permitted to remain on existing road shoulder unattended at all times unless it is properly
protected and secured and in a safe manner. The Safety Officer shall be make frequent
patrols along highway to ensure that the safety equipment & sign or operational all time.

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D. METHODOLOGY FOR BORED CAST-IN SITU PILE
References:
1 IS:2911 1979 Part 1 Section 2 and IRC 78
2 IS: 2911 1985 Part 4&MORTH Specifications
(A) Concrete
 Grade of Concrete : M35
 Slump of Concrete : 150 to 175 mm
 The maximum size of Coarse aggregate shall not exceed 20mm
 The cement used for piling work as per IS: 455 specifications.
 Minimum cement content for design Mix shall not be less than 400 kg/ cum
 For Piling, quantity of cement shall be as per the Design Mix or the minimum cement
content whichever is greater.
 Concrete cube shall be tested as per specifications
(B) Reinforcement steel:

 TMT bars from approved source shall be used
 GI/ MS wire shall be used for binding reinforcement
 Bending of reinforcement shall be as per IS: 2502, 1963
 The reinforcement shall extend for the full length of the pile and shall project 60
times diameters above the cut-off level or as specified in the drawing.
 Circular cover blocks threaded on the helix of the pile cage to be used
Equipment
As per actual site condition, the number of equipment as mentioned below will be increased or
decreased. Any other equipment, machinery, tools and plants etc. whenever required to complete
the work successfully shall be deployed.
The following equipment shall be deployed for Piling:

a) Piling Rig
b) Tripod Winch
c) Crane
d) Tremie Pipe
e) Bentonite Pump and Agitator
f) Batch Mix Plant
g) Transit Mixer

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h) Vibrator
i) Trailer
j) Water Tanker
k) Water Pump
l) Welding Generator
Method of Operation
1. Setting Out
The work involves taking-over of survey reference point, establishment of control points,
triangulation points, bench marks, grid layout for all the piers and other structures
maintaining horizontal and vertical control within permissible limits, incorporating changes
(if any), tabulation of all data and survey drawings including setting and layout of various
works during the progress of work and matching of station area to track alignment with the
alignment of the approaches at station ends and incorporating the changes (if any).
2. Driving of Temporary Casing

Rotary Drilling Rig/ Winch fitted with suitable tool (soil or rock boring tool) to be positioned
at the pre-marked pile point. After necessary checks for verticality of the mast, boring will be
started. On completion of boring up to about 2m on top, temporary steel casing pipe will be
installed in position using second wire of Hydraulic Rig/ lowered by crane. The casing pipe
will be gradually pushed to the required depth in advance of boring ensuring verticality.
Casing shall be driven preferably in one piece. The diameter of cutting tool shall in no case
be less than the diameter of the pile minus 75 mm. The working level should be 0.3m to
0.5m above ground level. The centre line of the casing pipe is then checked with respect to
the reference points. After concreting the casing is extracted.
3. Boring
Boring will be done by Hydraulic Rig/ Winch upto founding level/ hard rock. If rock level is
relatively high, dry boring will be done after installing temporary casing. If length of bore
upto rock surface is more or if soil collapses in this extra length, fresh bentonite slurry will be
poured. In hard rock, boring will be done by Chisel (i.e. Tripod Method) and cleaning will be
done by Bailer after pouring 3m fresh bentonite slurry.
Initial Boring of about 1.5/2.5 m is done by using Auger. Further boring will be continued
using suitable boring tools. Auger boring may be continued till water table is reached.
However, when boring is required to be done below ground water table and bored muck is
not getting collected in the auger, bucket tools (soil/ rock bucket) will be used for boring.
Once the bore has reached the desired depth the bottom of the bore will be cleaned.
4. Checking

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After achieving initial founding/ rock level, quality of rock is checked by Engineer. Further
boring in rock is then started by using Hydraulic Rig in soft and medium hard rock and Tripod
Winch in hard rock.
5. Chiseling By Tripod Winch

Chiseling by using Tripod Winch is done upto desired depth in rock as per approved drawings
by using suitable capacity chisel and fresh Bentonite solution.
6. Reinforcement Cage Lowering

The bar bending schedule is based on approved drawing. Reinforcement is cut and bend to
required size and shape. Reinforcement cage shall be fabricated at fabrication yard and
transported to location or fabricated at site as may be convenient. Specified cover blocks
shall be provided to reinforcement cage for the pile. Reinforcement cage shall be lowered in
1 piece or more depending on the available length of steel bars and length of pile. Bottom
cage is lowered inside the borehole and temporarily supported on the casing pipe top,
keeping the dowel length projecting above and second cage is lifted and lapped as per
approved drawings. Helical/ rings are tied and main reinforcement laps are tack welded to
provide more rigidity to the cage. The cage is further lowered in the borehole. Alternatively,
the cages will be lapped and welded on ground and the entire cage will be lowered inside
the bore. The reinforcement shall project 60 times bar diameters above the cut off level.
7. Reinforcement Cover Block

Circular cover block of 150mm dia. shall be made with the same grade of concrete as that of
pile concrete and fixed to either the main bar or to helical as mentioned in drawings. The
cover block shall be provided at approximately 2 meters intervals and suitably staggered.
8. Flushing Operation
Before the concreting starts the bore shall be flushed with bentonite solution. Immediately
after lowering of the cage, Tremie pipes of minimum 200 mm dia. of length 1.5 m are joined
together and lowered into the bore. During flushing, contaminated muck from the bottom of
the pile is collected in a ground level tank through the Tremie outlet. Flushing shall be
continued till the density of return mud is less than 1.2 gm/cc.
If the bore is cleaned by Bailer, contaminated particles will be relatively less and more
flushing will not be required. Bore will be filled by fresh bentonite slurry before concreting.
During concreting return bentonite solution with muck will be stored in small pits and
disposed of by movable tanker or will be returned to 2nd tank for re-use.
9. Concreting

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Once the flushing operation is complete, funnel shall be attached on top of the Tremie pipe
for pouring of concrete. The concrete shall be placed in the bore through the Tremie. The
bottom of the Tremie shall be 300 mm above the bottom of the bore. During concreting care
has to be taken so that the Tremie pipe is always embedded in concrete by 1 to 1.5 m.
If Cut-off Level is less than 1.0 m below the ground level, concrete shall be cast at top of the
piling platform level and overflow the concrete. In case COL of Pile is more than 1.0m below
working level then concrete shall be cast to a minimum of one meter above COL.
On completion of concreting to the required elevation, temporary casing will be withdrawn

either by tripod rig or the drilling rig. Lowering of Reinforcement Cage, lowering of Tremie
pipe, pouring of concrete and extraction of Tremie will be done by Hydraulic Rig/ Tripod.
Tripod rig then will be shifted to next pile location.
10. Safety
Barricade having suitable width and length shall be erected at construction work location.
Suitable reflectors, blinkers, diversion board, proper illumination, painting of barricade etc.
shall be provided to caution the road users and their safety. All site personnel will wear all
personal protective including high visibility vests.
Proper precautions and safety devices shall be used for activities like excavation, fabrication,
handling of electrically operated equipment etc.

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E. METHODOLOGY FOR PILE CAP CASTING
Equipment
The following equipment shall be deployed for Pile Cap casting:
a) Excavator
b) Dumper
c) Batch Mix Plant
d) Transit Mixer
e) Vibrator
f) Trailer
g) Water Tanker
h) Water Pump
i) Welding Generator
j) Jack Hammer and Compressor
k) Shuttering Plate and stays
Method of Operation
1. Setting Out
Before commencing excavation, the pile cap area shall be marked on the ground after
carrying out survey with reference to control points. After excavation the levels of the pit
shall be checked for correctness to the drawings and recorded. Longitudinal and transverse
centerlines shall be marked outside the pit for reference for cross checking the pile. The shift
of pile shall be recorded by marking the theoretical coordinates of pile on ground and circle
of 1500 mm diameter shall be drawn and shift of actual pile will be measured from
theoretical edges of pile. PCC layout shall be marked to ensure minimum 225 mm gap
between outer edge of pile and the pile Cap. After laying of PCC, the layout of the pile cap
shall be marked on it with reference to the reference points to facilitate tying of rebar and
erection of shuttering.
2. Excavation
Approved shoring shall be provided depending upon the stability of the soil found in the
area. Shoring shall be done with the help of old steel plates and props. At A road locations
the pit shall be excavated to the dimensions providing working space all around the pile
cap, to facilitate fixing of Reinforcement Steel and erection of shuttering as detailed in the

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drawings. The last 200mm excavation shall be carried out manually and leveling course shall
be laid down within 36 hours after completing excavation of last 200 mm depth. Provision
for sump shall be made at the corner of the pit to pump out underground water of about
750 mm deep from PCC bottom. Also a drain of about 300 mm width shall be provided all
around pile cap dimension and it shall be connected with sump to drain off excess rain
water/ seepage water to ensure that the water table will at least 300 mm below the lowest
level of the excavation before laying PCC. The excavated earth shall then dispose-off in
covered trucks to approved dumping yards provided by local authorities.
3. Removal of Laitance
After excavation the laitance of the piles shall be removed by using Pneumatic Jack Hammers
7 days after casting of pile or manually 3 days after casting of pile. The top of pile after
striping shall project above Cut-off Level (COL) 50 mm into the pile cap. The debris shall be
removed from the pit and disposed-off to dumping site. Exposed bars shall be cleaned
properly with wire brush.
4. PCC
After leveling the bottom, the pit shall be watered to keep the soil moist. PCC from Batching
Plant will be transported to site in Transit Mixers. The concrete shall be directly poured by
chute, shall be spread and leveled manually to the minimum specified thickness shown in
the drawing.
5. Reinforcement
a) Fabrication: For fabrication of Reinforcement, BBS shall be prepared as per the drawings.
The Reinforcement shall be cut using cutting machines or manually as required and bend.
b) Fixing of Rebar: The Reinforcement shall be manually fixed into its position as shown in
the drawing. Cover blocks of same grade of concrete in which these are to be embedded
shall be provided at spacing of 2 m c/c to ensure uniform cover of minimum 75 mm and tied
together with binding wire. After fixing the pile cap rebar, pedestal rebar, pier shaft rebar
shall be erected. This rebar shall be supported by erecting a suitable staging frame across the
width of the pile cap. Suitable laps, chairs and spacers as required shall be provided and
balance shuttering work will be taken up. Pier rebar shall be hold in position rigidly to
prevent it from buckling.
6. Shuttering
Shuttering fabricated as per approved drawings shall be placed at locations as per the pile
cap dimensions shown in the drawing and shuttering shall be placed in two stages. In first

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stage, the bottom channel of the shuttering shall be fixed as per the layout marked on the
PCC. Balance shuttering shall be erected after completing the fixing of rebar cage of pile cap.
Before placing the shuttering, shuttering oil shall be applied on shutter face in contact with
the concrete face to ensure easy removal of shuttering & proper form finish. For preventing
leakages from joints, rubber strip/ foam strip shall be provided at the joints of shuttering
plates.
7. Concreting
The concrete required shall be produced as per the approved design mix at the Batching
Plant and transported by Transit Mixers to the pouring location. Before pouring concrete,
slump of 75mm to 100 mm shall be checked at pouring location. The concrete shall be placed
by Chute/ Boom Placer. Concrete placing commences from one end to another in cascading
manner till completion. The drop height of the concrete should not be more than 1.5m. The
concrete shall be vibrated using 60mm/ 40mm diameter needle vibrators. Concrete cubes
shall be taken for testing of compressive strength as per IS: 456-2000 at pouring location.
Concreting should be done in such a way that next layer of concrete should be laid before
initial set of concrete of previous layer to avoid cold joints. Regular tamping shall be done
during and after concreting operation. Proper care shall be taken to see that concrete
temperature shall not exceed 40°C.
8. Curing
The concrete shall be cured by ponding method. Bunds of cement mortar of lean mix shall
be built after the concrete attains final time after casting of concrete, these bunds shall be
filled with water from approved source. The sides of the pile cap shall be covered with
Hessian cloth till back filling is started. Further curing is ensured by keeping the backfill moist
with water.
9. Backfilling
Backfilling shall commence immediately after de-shuttering. Back filling with excavated
material as shown in drawings shall be carried in layers of 200 mm and compacted by plate
vibrator with sprinkling of water to achieve 98% density.

DBFOT BASIS
F. METHODOLOGY OF ABUTMENT/ PIER CONCRETE
Equipment
The following equipment shall be deployed for Abutment/ Pier casting:
a) Batch Mix Plant
b) Transit Mixer
c) Vibrator
d) Water Tanker
e) Water Pump
f) Welding Generator
Method of Operation
1. Setting Out
The location of piers and their layout shall be checked once again with respect to the
reference points already established during open and pile foundation works of respective
pier.
2. Reinforcements and Embedding of Fixtures

The bar bending schedule shall be prepared as per working drawing. The bar length shall be
cut as per length given in approved B.B.S. either manually or in cutting machine and then
those shall be bent as per requirement shown in approved B.B.S. The cutting and bending
operation shall be done in the reinforcement yard or site. Reinforcement shall be placed and
fixed in position manually.
Concrete cover block shall be made for providing 50 mm clear cover to the outermost
reinforcements with same grade of concrete as provided for pier shaft with a spacing of 1 to
1.2 m. The reinforcement bars shall be tied with Binding wires and wherever required tack
welding shall be provided for handling purposes. After fixing of reinforcements in position, it
shall be got checked from Site representative for getting clearance for further work.
3. Formwork

DBFOT BASIS
Formwork shall be fabricated in the fabrication yard as per the approved drawing and a trial
assembly shall be made at casting yard to check for any defect. If any defect is found that
shall be rectified. Starter form work shall have standard height of 1 m and each board of
formwork shall have standard height of 1.2 m except one piece which shall have height less
than 1.2 m to cover the remaining height of pier not covered by standard piece. Form work
shall have 2 to 4 quadrants to cover entire periphery. The board shall be put one above other
till it goes upto cap bottom. All the joints shall be connected by bolts and rubber/ foam strips
shall be used in all joints to prevent leakage during concreting. Marking shall be made on all
the segments of formwork during trial assembly at fabrication yard for easy and quick fixing
at site.
The surface of all formwork board shall be thoroughly cleaned and shutter oiled before
fixing in position and shall receive green concrete .For adjusting verticality, anchoring shall
be made by using wire ropes from top of shutters to suitable anchor points on and around
ground surface. Turn buckles/ chain pulleys shall be attached to the above wire ropes to pull
the formwork for ensuring its verticality and thus tightening them for fixing at the position.
The formwork shall be removed after 24 Hrs. of concreting.
4. Concreting
The concrete of required strength shall be prepared in the Batching Plant as per approved
mix design. The concrete shall be transported in Transit Mixers to the pouring location.
Slump in concrete shall be kept between 100 mm to 150 mm at pouring location and the
slump shall be checked regularly at the pouring location.
The concreting shall be done using concrete pump with flexible hose and fall height of
concrete shall be limited to 1.50 m. The compaction of concrete shall be done using needle
type vibrators with 60 mm/ 40 mm diameter needles and further compaction will be done
by the self-weight of concrete poured in the shaft. To check the quality of concrete, cubes
shall be taken for testing compressive strength as per IS: 456-2000 at pouring locations.
After de-shuttering, if there is any irregularity in the surface, the same shall be immediately
rubbed with carborundum stone and brought to their true shapes, sizes and locations.
The Pier portion in open foundation/ pile cap will have rough surface and shear key will be
provided for further bonding of concrete. Before placing the concrete, the joints shall be
cleaned for any loose material and shall be made moist.
5. Curing

DBFOT BASIS
Wet curing will be adopted by putting hessian cloth over the entire surface of pier shaft
except the top surface of pier. The hessian cloth shall be kept moist by sprinkling water and
for pier top surface water shall be poured directly on the surface to keep it wet.
6. Safety
Barricading shall be barricaded along the road for the purpose of construction of piers. This
can be increased at specific locations with prior approval of the Engineer. Suitable reflectors,
blinkers, diversion board, etc. shall be done to caution the road users and for their safety.
Working space shall be well illuminated during work at night.
Proper precautions and safety arrangements shall be used for activities like welding,
handling of reinforcement, fixing of formwork, electrically operated equipment etc.

DBFOT BASIS
G. METHODOLOGY FOR CASTING YARD, CASTING OF GIRDER, PRE-STRESSING,

LAUNCHING OF GIRDER, BEARING FIXING, CASTING OF DIAPHRAGM AND
DECK SLAB
Equipment
The following equipment shall be deployed for Abutment/ Pier casting:
a) Batch Mix Plant
b) Transit Mixer
c) Concrete Pump
d) Pre-stressing Equipment
e) Grouting Equipment
f) Crane
g) Trailer
h) Vibrator
i) Water Tanker
j) Water Pump
k) Welding Generator
l) Shuttering Plate and stays
Method of Operation
Establishment and Construction of Casting Yard
1. Base Preparation for Casting Bed

After setting out the layout, initial site clearance will be carried out. Proper leveling and
compaction of soil will be carried out to avoid post settlement of soil in the casting yard.
2. Construction of Casting Beds

After setting out the layout for casting beds, 100 mm thick PCC layer will be laid over the
compacted soil. Then side shutters will be erected and properly supported. Concreting will
be done with proper compaction. Top level of casting bed shall be maintained properly. Side
shuttering will be removed after 24 hours of concreting. Concrete will be properly cured.
Casting of Pre-cast Girder

DBFOT BASIS
1. Preparation of Bed:
The extra concrete on the surface on the bed shall be stripped and checked, if any
irregularity is found, it would be rectified by grinding, rubbing, applying metal putty, etc.
3mm thick ply wood will be placed over prepared bed and girder layout shall be marked over
it.
2. Reinforcement Cage: Cutting and bending of reinforcement will be done according to the
bar bending schedule near the casting bed. Then the reinforcement will be tied over the
prepared bed. Cover blocks are fixed at suitable intervals to maintain the cover to
reinforcement as per design.
3. Profiling of Sheathing Pipe: The Sheathing will be profiled with the help of Jigs or tendon
support. The Jigs will be prepared of 12mm dia. Reinforcing bars and shall be fixed at 1m c/c
by welding firmly with the reinforcement. The Sheathing can be threaded together outside
and then installed in one piece or assembled in one place, section by section. The sheathing
has to be checked for damage. The coupler when threaded should also be taped. Cutting of
Sheathing has to be done at site with hacksaw to prevent tearing off. Fixing of bursting
reinforcement (Spiral Rings) at the ends of cables will be done along with the tying of
reinforcement.
4. Erection of Form Work: Erection of side shutter plates is done as per marked layout and end
block shutter is erected on both the ends after checking line and alignment.
5. Cutting of Strands: The uncoiled strands will be laid on the elevated platform and cut to the
required length as given in the drawings including the jacking length require at the time of
stressing. Keeping (min. 800mm length for stressing) the cutting of the strands will be done
by abrasive cutter only. The cables will be marked/ identified by suitable tags according to
the coil number of strands so as to calculate the modified elongation.
6. Threading of Cables: The cables will be prepared on the platform and then brought to the
site with due care. The cable end from, which the threading is done, will be taped properly
to ensure the ends don’t damage the duct. Binding wire should be removed before inserting
the cables into the sheathing. Both the ends should be closed after strands installation &
strands wrapped suitably to prevent any entry of material inside the ducts or damage to the
end of strands.
7. Fixing of Tube Unit: The Tube Unit will be fixed to the end block shuttering plate with the
grout hole on the top. The fixing will be done by using 8 mm threaded bolt with the head
out side. The cable profile will be maintained while fixing the tube units. The Sheathing will
be properly fixed into the mouth of the tube unit and sealed/ taped so that it is leak proof &

DBFOT BASIS
no slurry will enter the sheathing during the concreting. Reinforcement behind the tube unit
with proper helix of 16mm Dia. has to be ensured.
8. Concreting of Girder: Placing and fixing of concrete pipe lines will be done above the girder
on working platform. After complete checking of reinforcement and shuttering arrangement,
concreting shall be done. Concrete of specified design mix will be produced in the batching
plant and transported from the batching plant to the casting yard in the transit mixer. The
concrete is poured into the concrete pump and pumped through the concrete pipe line to
the required location. During concreting precaution should be taken to prevent the duct
damage by use of needle vibrator. The strands should be continuously moved on both the
ends to ensure that they are free all the time in case of cement slurry getting into the duct &
subsequent blocking it.
9. De-shuttering: De-shuttering will be done after 24hrs of concreting.
10. Threading of Bearing Plate: The identification on the bearing plate will be aligned so that it
is on the top of the bearing plate. Only after this alignment the bearing plate will be
threaded into position. The bearing plate should be cleaned with petrol before threading.
Keeping the tapered holes on the front side for inserting the wedges during stressing.
11. Fixing of Anchorage Wedges: The wedges are three segments supplied with wire circlips
holding it together. The wedges must be cleaned with petrol & ensured that they are not
rusted. The circlips should not be removed. The wedges will be threaded to the strand with
the help of long MS pipe without disturbing the circlips.
12. Threading of Jacks: The Jacks will be threaded in to the cables with the help of a supporting
frame to which is fitted a chain pulley block capable of moving the jack in vertical &
horizontal direction. The jack will be suspended on to the supporting structure & the moved
along & fixed to the cable, which is to be stressed.
13. Fixing of Master Wedges: The master wedge which is made of special alloy steel metal be
cleaned properly with petrol & the outer surface should be applied with wax, to ensure that
they don’t get jammed during release of stress. The master wedges should be fixed to the
pulling plate inside the jack with the help of M.S Pipe. This ensures that the wedges are not
loose during the actual stressing operations.
14. Connecting the Hose Pipe: The hose pipe should be connected to the power pack and then
to the jack. It should be ensured that the hose pipe is connected properly in the position
before stressing to the required ports as indicated on the jack and power pack. Check should
be made that all the connection are tight to prevent any leakage.
15. Stressing Operation: The stressing operation to commence after 14days of casting of girder

DBFOT BASIS
or when girder attains a compressive strength of 40 mpa. All the necessary calculations
required should be done prior to the stressing operations. Modified pressure gauge reading
& modified elongations should be calculated & noted down in stressing report enclosed.
After this the stressing operations can be started & the cables will be stressed to the
required force & also the elongations will be measured at pressure intervals as mentioned in
stressing sheet. Once the stressing operation is started the supporting chain should be
slackened & the jack made self-supporting. This chain should be again tightened during
retracting.
16. Measuring of Extensions: Normally this extension should be achieved at the specified
jacking forces. In case the required extension is not achieved at the specified jacking force
the stressing should be continued till the required extension is obtained, subject to the
jacking force not exceeding 75% of ultimate tensile value (2618KN for 19T13 cable & 1653KN
for 12T13 cable). Under no circumstances this pressure gauge should be exceeded. If the
required extension is obtained at jacking force lower than the specified jacking force, then
the stressing should be continued till the specified jacking force is reached, provided the
additional extension is not more than 5% of the specified extension.
17. Blocking of Wedges (Locking): Cables satisfying the jacking force and extensions should be
locked at a locking pressure of 75% of stressing pressure of the cable. The multiple jacks
have a hydraulic locking system by which the Anchorage wedges are locked into the bearing
plates grips the strands firmly by their threads inside.
18. Transfer of Pre-stress: After locking is ensured the pressure is released from the master
wedges to the Anchorage wedges. This process should be done very slowly so as to retain a
minimum slip. This is done by releasing the pressure release valve of the pump very slowly
to reduce the pressure to initial pressure at which the slip is noted.
19. Slip: During the transfer of pre-stress from the master wedges to the Anchorage wedges
some pre-stress is being lost & this is called as slip. Normally this slip achieved is between 6
to 8mm at the jacking end. Slip is mentioned on the extension ram of the jack.
20. Jack Removal: After the stressing operation the jack is released and retracted and master
wedges should be removed out. The Jack is now shifted for the next stressing operation. Slip
after 24 hours is also noted on to the Strand by marking the Strand with a reference mark.
21. Grouting: After stressing all the cables, grouting should be taken up at the earliest. Strands
are cut to min. length keeping about 1 inch from the bearing plate. The grout cap is to be
fitted prior to the grouting operation.
a) Remove loose material/ dirt etc. from cable duct by passing water through the
threaded grout hole of the tube unit. A ball valve & a threaded pipe is fitted to this
grout hole of the tube unit.

DBFOT BASIS
b) After flushing the duct with water and it has to be ensured that clean water comes
out from the other end. Compressed air may also be used to remove traces of water
in the duct.
c) Ball valves should be fixed at inlet location and it is connected to the grouting pump
with high pressure hose pipe.
d) Dual piston electrically operated grouting pump developing a pressure of minimum
10 Kg/cm2 and a delivery of 20 lit/ minute will be used.
e) Grout should be made in a drum of 200 lit capacity and a grout agitated by grout
agitator to make colloidal mix. First water should be added to the drum. Cement bags
to be emptied in the drum. This mix should be agitated by keeping the electrically
agitator on the top of the drum. A non-shrink additive generally FOSROC Cebex – 100
or equivalent is used in proportionate of 0.5% by the weight of cement. The Water
Cement ratio of the mix is between 0.40 to 0.45. The temperature of the grout should
be controlled in case of hot atmosphere by using ice water. The agitated grout should
be passed to the small drum sieving to remove lumps or minor unwanted particles.
f) The properties of grout like compressive strength are to be checked on a 100mm
cube. The minimum strength at days is to be 17 mpa.
g) The grout shall be made just before the grouting operation and shall be kept agitated
unit it is pumped. Grout once made shall be consumed within 30-45 minutes.
h) Grouting shall be carried out in one continuous operation. The grout should be
pumped from one end of the girder. The grout should allow to pass through the other
end with same consistency before closing the grout hole opening. The bolt fitted to
the grout cap also should be loosened or refitted on the other end to ensure air be
expelled out.
i) After a consistent grout starts coming out of the outlet, it shall be closed and the
pressure maintained at 5 Kg/m2 for at least 30 seconds. Once the grouting operation
is complete, the inlet ball valve should be passed to remove the pressure at the pump
end. Shift the pump for next grouting operation.
Girder Launching
1. Erection of Staging: Erection of staging near piers and abutments to true level & line for
placing girders as per staging drawing.
2. Shifting of Girders: Girder shall be loaded in the modular hydraulic trailer with the help of

DBFOT BASIS
cranes of suitable capacity at casting yard. Girders shall be transported in an upright

position. It shall be tied with the safety belts or chains throughout the periphery of the
girder. Rubber padding shall be provided at the edges to prevent any damage to the girder.
Care shall be taken during the transportation of the girders to prevent their cracking or being
damaged. The transportation of the Girders shall be done carefully.
3. Erection of Girders: Girder shall be lifted from the trailer by using cranes of suitable capacity.
The area where the cranes are to be placed shall be leveled properly and shall be compacted
using suitable vibratory rollers to avoid any undulation of the surface and to ascertain a firm
base. The location of the cranes shall be finalized after considering the maximum working
radius and the capacity at that radius for each crane. The cranes shall be placed in such a
way that they do not touch/ damage the Girders already erected (if any).
4. The Girders shall be lifted with the help of wire ropes. A team of lifting supervisor, riggers
and banks men shall be deployed to ensure proper lifting of the girder. The banks men shall
be placed at each of the crane to give the signals to the crane operators. Lifting Supervisor
shall be placed at the centre of the span to supervise the lifting operations and to give
instructions to the banks men placed at each crane. Suitable training shall be conducted for
the lifting coordinator, riggers and banks men. Synchronization of both the cranes is of
utmost importance and shall be ensured.
5. Due care shall be taken while placing the Girders so as to maintain the alignment accurately.
A surveyor shall be deployed at the time of lifting and placing the girder and shall be
responsible for the alignment of the girder. Once the girder is placed in its final position over
the staging, the rope attached to the girder shall be detached.
Bearing Fixing
1. Installation of bearings on the pedestal:

Correct alignment shall be marked on the bearings pedestals, such that the geometric centre
line of the bearings, when placed matches with the marked alignment. The level of the top
of the bearing plate shall be checked before grouting. To ensure the seating of bearing in
perfect line and level, the pedestal shall be casted 25 mm lower than its specified top and

DBFOT BASIS
this 25 mm gap shall be filled with grout when the anchors are grouted. This will not only
ensure proper level of the bearing but also ensure proper grip of the backing plate with the
pedestal. The bearing shall be placed on the pedestal with the anchorage system properly in
the pockets/recesses left in the concrete pedestals. Since the recesses would be wider and
deeper than the anchorage, any fine adjustment of the bearing to bring in perfect alignment
shall be done manually. Since the pedestal is cast 25 mm lower than the required top level,
the bearing is adjusted to the level and line by proper packing and shall be restrained in
position before and during grouting. Once the alignment of the bearing matches with that of
the girder, the bearing is placed perfectly and fixing shall proceed.
2. Grouting:
For grouting of the anchorages inside the recesses after the bearing is placed, suitable
cement based non-shrink grout with air releasing additive and epoxy based grout shall be
used. For preparing the grout mix, manufacturer’s literature shall be referred. The grout shall
be poured in the recesses/pockets manually. Care shall be taken that while grouting, due to
any leakage /breakage of pipeline, grout does not spill on the bearing. In case of an
accidental spillage it shall be immediately cleaned with water/ thinner before it hardens.
Casting of Diaphragms
1. Bottom shuttering shall be erected as per required level. Cutting and bending of
reinforcement will be done according to the approved bar bending schedule. The
reinforcement will be tied over the bottom shutter then the side shuttering shall be erected
as per marked line. After complete checking of reinforcement and shuttering, concreting of
diaphragms shall be done over permanent bearings.
Casting of Deck Slab
1. Shuttering for Deck Slab:

For Shuttering and concreting purposes temporary platform will be made by the help of
bracket fixing on the either sides of I-Girders. The brackets are fabricated in the fabrication
yard with proper dimension and are shifted by the shifting barges to the deck slab. These
brackets are fixed and are fastened with tie bolts. Then slab bottom shuttering plates were
placed on the channels.
2. Reinforcement for Deck Slab:

Cutting, bending and tying of reinforcement for deck slab will be done as per approved BBS
and GFC drawing. Proper lap length has to be given in the case of where the bar length is
less than the required length as per drawings. Cover blocks of required thickness shall be
provided in adequate numbers.

DBFOT BASIS
3. Concreting of Deck Slab:

After placing and fixing side shutters with proper number of cover blocks and inserts,
concreting will be done by pumping through concrete pipe line. Concrete of specified design
mix will be produced in the batching plant and it will be conveyed to the concrete pump
location in transit mixer. Deck slab shall be cured properly. Shuttering of deck slab to be
released after 14 days of casting of deck slab.
Safety
1. Employing safe working practices.
2. All workers would be made aware regarding the methods of work and safety awareness
through toolbox talks.
3. The crane will be operated within the safe working radius and no person will be allowed in
the area of working /swing radius of the crane.
4. Proper signaling facilities would be provided during the movement of cranes.
5. Proper lighting facilities would be provided to ensure safe working during night shifts.
6. First Aid Facilities should be available on site.

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Methodology

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FOUR LANING (WITH PAVED SHOULDERS) OF VARANASI – SHAKTINAGAR ROAD

UPTO HATHINALA JUNCTION (SH – 05A) IN THE STATE OF UTTAR PRADESH ON

Four Laning (with Paved Shoulders) of Varanasi - Shaktinagar

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |1

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |2

A. METHODOLOGY FOR SETTING OUT

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |3

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |4

B. METHODOLOGY FOR CLEARING AND GRUBBING

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |5

C. METHODOLOGY FOR EARTHWORK IN EMBANKMENT

3. As a parallel activity, suitable borrow areas will be selected as near as possible

7. Vibratory roller will be deployed for compaction and compacted layer of

9. After complying with all above-mentioned activities and ensuring conformation

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |6

D. METHODOLOGY FOR GRANULAR SUBBASE

4. Material will be spread with the help of motor grader.

E. METHODOLOGY FOR WETMIX MACADAM

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |7

F. METHODOLOGY FOR KERB LAYING

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |8

G. METHODOLOGY FOR PRIME COAT

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A Page |9

Selection of Primer as per MORTH

Cleaning of WMM base with Power

Calibration of Bitumen Sprayer

Transporting primer by Bitumen

Check the spray rate as per specification

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 10

6. The primer distributor shall be self-propelled, self-heating bitumen pressure sprayer.

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 11

H. METHODOLOGY FOR DENSE GRADED BITUMINOUS MACADAM (DBM) AND

a) Loaders for feeding Aggregate

b) Dumpers for transporting of mix.

c) Hot Mix Batch type Automated Plant

d) Sensor Paver Finisher Capable of Paving 9.0 m Width

f) Smooth wheeled Rollers/Double Drum Vibratory Roller.

g) Pneumatic Tyred roller

h) High Pressure Air Compressor

j) Asphalt Distributor with Spray Bar System

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 12

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 13

FLOW CHART FOR CONSTRUCTION

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 14

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 15

A. METHODOLOGY FOR HUME PIPE CULVERTS

1. Layout and Excavation

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 16

6. Cradle and Catch Pit

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 17

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 18

B. METHODOLOGY FOR SLAB AND BOX CULVERTS

1. The location and level shall be as per approved drawing.

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 19

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 20

C. METHODOLOGY FOR MINOR BRIDGES

3. Leveling Course (PCC):

4. Marking for Foundation Raft and placement of Reinforcement Steel

5. Foundation Raft Concrete

ACP TOLLWAYS PVT LTD.VARANASI-SHAKTINAGAR ROAD PROJECT SH-05A P a g e | 21

6. Abutment/ Pier Concrete (Sub Structure)

7. Abutment/ Pier Cap Concrete

8. Marking for Bearing Pedestals

9. Pedestal and Bearing Fixing