SOMA-ISOLUX NH ONE

TOLLWAY PRIVATE LIMITED

SIX-LANING OF PANIPAT – JALANDHAR SECTION

OF NH-1 FROM KM96.00 TO KM 387.10 IN THE
STATE OF HARYANA AND PUNJAB TO BE
EXECUTED AS BOT (TOLL) ON DBFO PATTERN
UNDER NHDP – PHASE V

CONSTRUCTION METHODOLOGY
ICS Isolux Corsan India – Soma Construction
Joint Venture

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Confidentiality
This documents content is subject to confidentiality. Neither this document, nor its
contents, may be copied, transcribed or replicated in part or in full, without the written
permission of Soma-Isolux NH One Tollway Pvt Ltd.

Revision Grid
Rev No. Reason for Revision Revised Content
A Issued for Review

Approval Grid
Rev Date Author Signature Checked by Approved by
A 30-Nov-08 ASC BC JNC

Client Comment and Approval Table

Item No Comments

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TABLE OF CONTENTS

1. INTRODUCTION 4
2. SURVEYS AND SETTING OUT 5
3. SITE CLEARANCE AND DISMANTLING 6
4. EARTH WORKS 8
5. GRANULAR SUB BASE COURSE AND SUB BASE 11
6. WET MIX MACADAM 13
7. BITUMINOUS COURSES 15
8. EARTH, RETAINING WALL & DRAINAGE 17
9. JUNCTIONS 19
10. TRAFFIC SIGNS PAVEMENT MARKING & OTHER APPURTENANCES ETC. 21
11. MISCELLANEOUS 24
12. WORK AT TOLL PLAZA SITE 26
13. CULVERTS 29
14. MACHINERY REQUIRED 31
15. BRIDGES, FLYOVERS & ROBS (SUPERSTRUCTURE) 32
16. FOUNDATIONS, SUB STRUCTURE AND PROTECTIVE WORKS 35
17. REPAIR & REHABILITATION OF BRIDGES & ROBS ETC. 38

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1. INTRODUCTION

Upon receiving the notice to proceed with the work, we at the outset will
commence as follows:
i) Arrange for staff and labour.
ii) Identify and arrange stone quarry(s) and lay down area.
iii) Arrange the preliminary survey to demarcate the areas of site clearance.
iv) Arrange for Labour registration, various government regulations and
permission from the concerned Authorities.
v) Arrange for site offices, field laboratories, stores etc.
vi) Mobilise the equipment and materials required.
vii) Arrange for installation of Hot Mix plant, stone crusher, WMM plant, Concrete
batching plant, Compactors and allied equipments.
viii) Arrange for requisite gangs of labour.
ix) Prepare and submit detailed constructions schedule /work program.
x) Prepare and submit quality control plan.
xi) Plan and construct temporary approach /diversion roads.

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2. SURVEYS AND SETTING OUT

METHOD STATEMENT & BRIEF SCOPE

A Digital terrain model for the existing alignment as prepared by the Design Consultant
will be compared with the actual alignment on the ground and the project alignment set
out accordingly. The sections requiring field checks shall be identified. The field checks
shall be carried out using Total Station, auto/ digital level, dual frequency GPS etc. The
checks shall be carried out using close circuit method. The extent of field checks
exercised will be sufficient to authenticate the survey as carried out. The reference
Pillars/ Bench Marks will be checked using Total Stations/ Dual Frequency GPS. The
Bench Marks/ Reference Pillars, where found damaged/ displaced or missing will be
suitably repaired / restored.

In case any deviation is proposed in alignment standards in some sections by the

Design Review Consultants, such sections will be reviewed in detail to explore the
feasibility of avoiding/ reducing deviations as far as possible.

It shall be ensured that all the Control Stations are available along the road before
construction work is commenced. On completion of setting out, a survey file shall be
prepared showing X and Y co-ordinates and altitudes of Control Stations along the
project road. This information shall be used as a guide during construction and for
quality control check of various constructions activities as the work progresses.

Instrument required:
i) Dual Frequency GPS.
ii) Total Station
iii) Distomat.
iv) Digital/ Auto level.
v) 3 m Straight edge.
vi) Tape, Chain etc.

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3. SITE CLEARANCE AND DISMANTLING

METHOD STATEMENT & BRIEF SCOPE

A dozer with adequate capacity will be used for clearing and grubbing of the site. For
cutting trees of larger girth, mechanically operated saws will be used. For removal of
tree stumps, the Dozers Excavators, Cranes etc. will be used. All the trees, stumps etc.
will be cut to sufficient depth below ground level so that the roots do not fall within 500
mm of the sub-grade.

All excavation, subsequent to removal of trees etc. will be filled with approved materials
and compacted thoroughly so as to make the surface at these points conform to the
surrounding areas. All branches of trees extending into the roadway will be trimmed, as
required.

The material/ vegetation removed, as part of site clearance will be loaded on Tippers
and dumped into designated dumping areas. The dismantling and breaking of cross-
drainage structures, wherever required, will be done manually using Jack Hammers
taking sufficient care to see that no damage what so ever is caused to the receivable
materials to be salvaged and the part of the structures to be retained at the adjacent
structures/other properties. Tippers from the respective site of works will remove the
debris. No burning of felled trees or other deleterious material will be allowed.

DISMANTLING
The structures will be dismantled carefully and the dismantled material will be removed
in such a manner that no damage is caused to any serviceable material to be salvaged,
the part of the structure to be retained and other properties and structures in the vicinity/
close by.

Where necessary, superstructure portion of Culverts/Bridges shall be dismantled upto

ground level or as necessary depending upon the interference they cause to new
construction.

Where existing culverts/ bridges are to be extended only, such part or parts of existing
structures shall be removed as necessary or directed by the Engineer to provide joint

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with the new work. Pipe culverts shall be carefully removed in such a manner as to
avoid any damage to the pipes forming part of the Contract.

The pavement shall be dismantled using special equipment like pavement cutters. Jack
Hammer and Compressor shall be used for dismantling as necessary.

Machinery required:
i) Dozers;
ii) Excavators;
iii) Front end loader;
iv) Tippers etc.;
v) Rippers;
vi) Cranes;
vii) Mechanically operated saws;
viii) Pavement cutter &
ix) Jack hammer & compressor.

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4. EARTH WORKS

METHOD STATEMENT & BRIEF SCOPE

Excavation:
Soil-cut:
All Earthwork excavation will be done by means of Excavators. Suitable excavated
material will be loaded on Tippers and deposited in embankment area. Wherever the
excavated earth is found unsuitable for use in embankment, it will be dumped in
designated dumping areas earmarked for unsuitable soil.

All debris and loose material occurring on the slopes and cutting will be removed, where
after the sides for the excavated area will be trimmed and the area contoured to
minimize erosion and ponding, allowing natural drainage to take place.

The required slopes as per drawings will be set out to assist proper slopes in
excavation. In addition, excavation works will proceed in such a manner that drainage
gradients are maintained. Access roads from cut to fill areas will be maintained
throughout. Water tankers with sprinkling arrangement will be provided frequently over
dry periods to keep the dust down minimum.

Rock cut / Blasting:

Nowhere in the project stretch from Panipat (Km 96) to Jalandhar (Km 387) envisaging
in the changing of 4- lane dual carriageway configuration to 6-lane configuration requires
rock cutting/blasting is required.

Embankment:
The top soil in embankment area will be removed up to a depth of 150 mm, levelled and
suitably compacted to facilitate placement of first layer of embankment which will be
scarified, mixed with water as necessary and then compacted using pneumatic/
vibratory rollers so as to achieve the necessary compaction.

The envisaged deficit in earth fill to be used for embankment will be brought in from
suitable borrow areas in Tippers and dumped in heaps which will be spread in layers
(maximum 30cm thick) by using Dozers. It will then be levelled, sprinkled with water and
graded with motor grader, finally rolling will be done using pneumatic/ vibratory rollers to

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obtain required density. The sub – grade material will be tested to ensure the necessary
CBR values as per contract, to be attained. Field density will be checked at site as per
provision of MORT&H specifications.

The blade of the grader will be adjusted initially with hydraulic control to achieve the
specific slope and grade. Each layer will be compacted thoroughly to the specified
requirement and finished approximately parallel to the final cross section of the
embankment before the succeeding layer is spread and only after the field density test
results have been obtained successfully.

While watering the layers, the tanker will be fitted with a sprinkler capable of applying
water uniformly with a controlled rate of flow to variable widths of surface but without
flooding until required moisture content is obtained throughout the depth of the layer.

When the excavated rock is used for filling in embankment, the materials will be tipped,
spread and levelled in layers extending to the full width of the embankment by a suitable
Dozer, and then compacted by minimum of 5 passes of 80 to 100 kN capacity Vibratory
Roller etc. where it is not possible to compact the fill due to inadequate space available
for movement of Compactors/ Rollers, Static rollers will be used.

Sub – grade Trimming:

Survey level pegs will be put at suitable intervals (say 10m) to facilitate dressing of
final embankment layer to required line, grade and density. The sub grade levels will be
properly graded and then compacted to within the sub-grade tolerances as per the
contract.

Machinery required:
i) Dozers,
ii) Motar Grader,
iii) Excavators,
iv) Trench Excavators/ JCB.
v) Tipper.
vi) Pneumatic/ Vibratory Rollers (80-100 KN),
vii) Bowser
viii) Rotavator,
ix) Disc Harrow,
x) Compressors with Jack hammer.

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xi) Static compactors.
xii) Front end loaders

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5. GRANULAR SUB BASE COURSE AND SUB BASE

METHOD STATEMENT & BRIEF SCOPE

This work will consist of laying and compacting well-graded material on prepared sub-
grade. The material shall be laid in two layers as lower sub base and upper sub base as
necessary according to lines, grades and cross section shown on the drawings or as
directed by the Engineer.

METERIAL
The physical requirements of the material will conform to the technical specifications
duly approved by the Engineer or his Representative.

CONSTRUCTION OPERATION
The sub grade already finished and tested will be prepared by removing all vegetation
and extraneous matter, lightly sprinkled with water, if necessary, and rolled.

The sub base material of specified grading already approved will be spread on the
prepared sub grade with the help of hydraulic motor grader having required controls.

Moisture content of loose material will be checked in accordance with the specifications
and suitably adjusted by sprinkling additional water from a water tanker when
necessary. Immediately there after, compaction will be done with the help of a Vibratory
Roller of 80-100 kN and Static Compactor as required.

Rolling will commence at the lower edge and proceed towards the upgrade longitudinally
for portions having unidirectional cross fall and super elevations and will commence at
the edges and progress towards the centre for portion having cross falls on both the
sides.

The rolling will be continued till the required field density as per MORT & H
specifications is achieved.

Machinery Required:
i) Wheel loader
ii) Grader
iii) Tippers
iv) Vibratory Roller- 80-100 kN
v) Smooth wheeled Roller 8 tonne.

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vi) Static Compactor
vii) Bowser

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6. WET MIX MACADAM

METHOD STATEMENT& BRIEF SCOPE

The work consists of mixing, laying and compaction of well-graded material as laid down
in the specification, premixed with water to required OMC forming a dense mass over
the prepared sub base. This material will be laid in layers to the necessary lines and
grades of cross sections shown in the approved drawing or as directed.

Construction Operations:
The finally approved materials will be mixed in the proportions as specified in the design
Mix in the WMM plant by adding water 3 to 5% more than the specified considering the
evaporation losses to reach to the required proportions of gradations of the materials as
approved in the Design Mix.

The Mixed materials received from the plant will be transported to the site by means of
the dumpers /tippers having capacity of 12 to 15 tons. This transported material brought
from the plant will be laid on the approved sub-base by means of the Paver /
hydraulically – controlled grader having the capacity to lay the material uniformly over
the approved surface.

Laying and compaction of the sub-grade material in the adjoining shoulders along with
the Wet Mix macadam together will fulfil the requirement of lateral confinement of Wet
Mix Material.

After the Mix has been laid to the required thickness, grade and cross fall / camber, the
same will be uniformly compacted to the full depth with the 80 to 100 KN Vibratory
Rollers with the speed of roller not more than 5 Km / hour.

The rolling shall begin at the edges with the Vibratory Roller rolling in forward and
backward direction and shall progress gradually towards the centreline parallel to the
centreline of the Road uniformly overlapping each of the proceeding track by at least
rd
1/3 of the width until the entire surface has been rolled.

In the portions of unidirectional cross fall / super elevation rolling shall commence from
lower edge and shall progress gradually towards upper edge. Thereafter rolling shall

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progress parallel to the centreline of the Road uniformly overlapping each proceeding
rd
track by at least 1/3 until the entire surface has been rolled.

Where the mechanical means cannot be used to lay and compact the Wet Mix material,
the same shall be laid by manual means or as directed and will be compacted by walk
behind Roller and Plate Compactors.

Along the walls of the CD works and other places not accessible to the Roller the Mix
shall be thoroughly compacted with Mechanical Tampers. Rolling shall be continued till
the desired density is achieved.

nd
Procedure for the 2 layer:
The same process as stated above will be followed. The Mix shall be laid on the
prepared surface and the top layer will be thoroughly checked and all high and low spots
will be remedied by removing or adding aggregate as may be required. After
compacting the surface, the density of the final compacted layer will be checked for
conformation to provisions of the Contract Agreement.

If wave like motion is formed on the surface, the area shall be removed at least 5 metres
in length and 2 metres in width and will be rectified with the fresh premixed material.

After the completion of the work of final layer, the area will be closed and will not be
allowed to movement of traffic. The area will be left for 24 hours at least to dry and no
vehicular traffic will be allowed to move over the damp surface of the finished layer.

Machinery required:
i) WMM Plant of capacity 60 TPH
ii) Loader for loading the hoppers of plant.
iii) Dumpers / Tippers having capacity to carry 12 to 15 tons of Mix.
iv) Paver finisher mechanical 100 TPH.
v) Vibratory Roller of 80-100kN.
vi) Smooth Wheeled Roller 8 tonne.
vii) Static rollers/ compactors.
viii) Bowsers.

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7. BITUMINOUS COURSES

METHOD STATEMENT & BRIEF SCOPE

A Hot Mix plant yard will be located centrally and will have the HM plant, equipped with
support machines inter-alia including Bitumen sprayer/spreader, Paver finisher, Belt
conveyors, Aggregate drying plant, Bitumen heating tank, Laboratory etc. To start with,
suitable job mix shall be designed for the bituminous course keeping in view the
provisions of the Contract Agreement.

The Hot Mix plant will produce the desired mix, which will be carried to the required
location by means of Tipper trucks. Bitumen sprayer will coat the surface in advance.
The hot mix will be discharged in the Paver, which will spread the mix on the surface.
The Paver will be set for desired thickness camber and profile.

The rolling will follow the Paver by using Tandem roller. Supervisors will continuously
monitor the temperature levels and profile. The road will not be opened to traffic at least
for 24 hours after rolling. Water tankers will be kept available to spray water in the
surrounding areas to avoid dust caused by movement of vehicle. Steel channels pegged
in the ground will restrain the edges. The edges of the previous day’s work will be cut by
means of mechanical cutter and work will be continued.

Appropriate trial mix for each course will be laid for the approval of the Engineer. Once
the right mix is approved, trial layer will be carried out to ensure the reproductibility of
the lab design criteria to be achieved in the field. Appropriate lab tests will be carried out
to ensure compliance with specifications.

Hot Mix bituminous work will be carried out following MORT&H specifications.

Methodology for each bituminous item of work covered in Bill of Quantities will be
submitted by the Contractor prior to execution of each item on site and shall be got
approved form the Engineer.

Material required: Bitumen of suitable penetration & grade and crushed stone of
required grading.

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Machinery required:
i) Mechanical broom
ii) Bitumen spreader/ distributor
iii) Paver finisher equipped with sensor unit.
iv) Hot mix plant with back up/ workshop facilities.
v) Belt Conveyor for feeding the plant.
vi) Bitumen heating tank
vii) Templates
viii) Tippers.
ix) Camber plate.
x) Bowser.
xi) Temperature gauges
xii) Tandem Road Roller
xiii) Vibratory Roller.
xiv) Pneumatic Road Roller.
xv) Static Compactor/ Tampers for small areas.
xvi) Aggregate Dryer.
xvii) Mechanical Cutter.

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8. EARTH, RETAINING WALL & DRAINAGE

METHOD STATEMENT & BRIEF SCOPE

The Concessionaire may adopt any type of earth retaining structure keeping in view the
site conditions. The earth retaining wall shall be designed for lateral earth pressure
including surcharge and hydrostatic pressure, if any. System provider shall provide the
basic design of the structure and the design shall conform to BS 8006 in respect of limit
state of collapse and serviceability.

SPECIFICATION
The reinforcing element shall generally consist of geo-textile, aluminium alloy strips,
carbon steel strips mats of metal or synthetic geo-grid or any other proprietary material
approved by Engineer/ stipulated in the Contract. Complete design calculation and
drawings showing ground improvement, foundations, facia reinforcement drawings
showing friction slab crash barrier etc. shall be provided by system provider.

FACIA MATERIAL
The facia shall conform to one of the following: -
i) Reinforced concrete (cast at site or pre cast) slab.
ii) Plain cement concrete hollow blocks.
iii) Masonry construction (gabion facia)
iv) Other proprietary and patent provision systems.

The facia shall be sufficiently flexible to withstand any deformation on account of fill.

EARTH FILL
The fill material for reinforced earth structures shall have an angle of interface friction
0
between the compacted and the reinforcing element of not less than 25 C measured in
accordance with IS: 13326 (Part-I). The soil shall be predominantly coarse ground, not
less than 10% of the particles shall pass 75-micron sieve. The soil should have
proportion such that the salt in the soil does not react electrically or chemically, the
reinforcing elements and affect in an adverse manner.

CONSTRUCTION DETAILS

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The plan area of reinforced earth structure shall be excavated to provide nominally level
base, which may be prepared to receive horizontal reinforcement element grid. The
orientation of reinforcement element facing batter and drainage arrangement shall
conform to the approved design and the structure shall be constructed according to
section 3100 of MORT & H specification.

DRAINAGE SYSTEM
The design of drainage system such as surface and sub-surface drainage for pavement,
median, shoulder, high embankment shall be carried out in accordance with IRC: SP: 42
and IRC: SP: 50. Surface runoff from the main highway, embankment slopes and the
service roads shall be discharged through longitudinal drains/ chutes, which shall be
designed for adequate cross section, bed slopes, invert levels and the outfalls. If
necessary, the wall of the drains shall be designed to retain the adjoining earth. Where
drains are required to be covered, the cover of the drain shall be designed for carrying
the maximum expected wheel load. The covered drains shall be provided with iron
gratings, strong enough to withstand the expected loading.

Item covered in checklist:

i) Protection works

MACHINERY REQUIRED:
This shall depend upon the design/ specification provided by the system provider out of
the following items:
i) Excavator
ii) Trench Excavator
iii) Loader
iv) Grader
v) Tippers
vi) Bowser.
vii) Mini Concrete plant
viii) Transit mixer.
ix) Compactor 80-100 Kn
x) Static Compactor

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9. JUNCTIONS

METHOD STATEMENT & BRIEF SCOPE

According to IRC-92, interchanges are necessary at all crossings of a highway, which is
to be developed to completely access controlled standards. Similarly interchange is also
required at all major crossings of Highways developed to expressway standards. There
will be no At Grade intersection of any road with the main highway, except only with
service roads. The intersection of the Project Highway with another National Highway
(NH), State Highway (SH) or Major District Road (MDR) shall be grade separated. The
existing direct intersections shall be closed and remodelled accordingly. The intersecting
road, other than those stated above, shall be designed to facilitate all movement in the
following manner:

Through a diamond shaped grade separated intersection for cross roads, or

Through underpass/ overpass for crossing the Project Highway and then right turn
through a ramp to merge with the Project Highway or service road where provided or
Through merging with service road and crossing through the next available vehicular
underpass.

There shall be no direct access to the main highway and all accesses shall be from
service roads, which shall be provided on both sides of the main highway. All traffic
without exception, needing access to the main highway shall first come on to the service
road and then join the main highway through an acceleration lane. Similarly, all traffic
exiting the main highway shall first come on the service road through an exit ramp from
where it would divert to the local road network for various destinations. The existing
direct access to the highway shall be closed and alternative access through service
roads only shall be provided. The service roads on both sides shall be continuous
(except where discontinuity is permitted) and have widths as specified in the Contract.

There shall be interconnection between the service roads of both sides through under
passes which will facilitate cross movement of local traffic from one side to the other
side to facilitate change of direction of through traffic. Accordingly, the intersections on
the service road including those at underpasses shall be designed for safe movements
for all turnings. There shall be pedestrian crossing facility through the underpasses, and
exclusive pedestrian underpasses as required.

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The service roads shall be connected to the main highway through properly designed
entry/ exit ramps. The service roads, the ramps and the underpasses/ flyovers shall take
care of the local/ access traffic and ensure that no right or U turn is required to be
provided on the main highway. At the ends, the service roads shall be provided with end
treatment so that the local traffic is able to merge the highway in a safe and efficient
manner.

Acceleration/ deceleration lanes:

Each entry and exit ramp shall have acceleration/ deceleration lane for the main
highway. The length of the acceleration/ deceleration lanes shall be decided on the
basis of speed differentials of the main highway traffic and the speed permitted on the
ramps.

Vehicular Underpasses:
Vehicular underpass shall be provided as specified and to connect service roads on
both sides of the Project Highway in such a manner that no vehicle is required to travel
more than 2 Km on service road to approach an underpass.

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10. TRAFFIC SIGNS PAVEMENT MARKING & OTHER
APPURTENANCES ETC.

METHOD STATEMENT & BRIEF SCOPE

The configuration, size and location of all traffic signs shall be as per IRC 67. The road
signs not covered by IRC-67 would be as per BIS/ British standard/ AASHTO/ASTM. All
road signs shall consist of retro-reflective sheeting of high intensity grade with in-
capsulated lens fixed over aluminium base plate as per clause 801 of MORT& H
specifications.

Kerb mounted signs shall be supported on GI pipes. Overhead signs shall be placed on
a structurally sound gantry or cantilever structure made of GI pipes. Its height, lateral
clearance and installation shall be as per MORT & H specifications. The pedestal
supporting the gantry or cantilever structure of the overhead signs shall be flushed at the
ground level and in no case shall protrude more than 15 cm above the ground level.

It shall be ensured that any sign, signal or any other devise erected for traffic control,
traffic guidance and / or traffic information shall not obscure any other traffic sign and
shall not carry any advertisement.

Each exit ramp shall have signs mounted on posts indicating the name of the place and
the important roads it would lead to.

For toll plaza(s) advance direction signs shall be provided at 1 km and 500 m ahead of
toll plaza. These signs shall be rectangular in shape, bilingual, gantry and cantilever
mounted. Wherever the local language is other than Hindi, local language instead of
Hindi shall be used for sign at 500 m.

It is necessary that user be informed before using the road that a section of National
Highway is a Toll Road. Similarly the user be also informed of the end of the Toll Road.

At the start of flare of the toll plaza, a sign displaying the fee rates shall be erected. It
shall be ensured that any sign, signal or any other device erected for traffic control,
traffic guidance and or traffic information shall not obscure/ contradict any other traffic
sign.

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PAVEMENT MARKING
Pavement markings on the project highway shall be in accordance with IRC: 35. These
markings shall be applied to road centre line, edge line, continuity line,. Stop line, give
way lines, diagonal / chevron markings, zebra crossing and at parking areas by mean of
an approved self propelled machine which has a satisfactory cut off value capable of
applying broken line automatically.

Road markings shall be of hot applied thermoplastic paints with reflect rising glass
beads as per relevant clauses of section 803 of MORT&H specifications.

At toll plazas, transverse bar lines be used across the flared approach to toll gate to
reduce the speed of approaching traffic. The width of these lines shall be 300 mm.

EQUIPMENTS
i) Pothole auger.
ii) Road marking machine
iii) Welding machine
iv) Mini Concrete plant/ mixer
v) Static compactor
vi) Scaffolding arrangement/ gantries.
vii) DG set.

TRAFFIC CONTROL
In order to ensure safety of traffic, all necessary measures such as erecting and
maintaining signboards, barricades, speed breakers and diversions, etc. will be provided
as per requirement. The letters and signs on the signboards and other markings will be
painted in fluorescent paint so as to be clearly visible during the night. Lights and flags
will also be provided at all important junctions. Flagmen will be employed, wherever, it is
considered to be essential.

The Barricades to be erected will be sufficiently strong to resist any untoward violation
and painted with alternate black and white strips. Wherever required, warning lights will
be mounted on the barricades all through the night and kept lit through out the period
from Sun-set to Sunrise.

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Wherever existing traffic needs to take a diversion, the channel for traffic will be marked
distinctly using pavement marking or painted drums. At night, these passages will be
delineated with lanterns or other suitable lighting. On both sides, minimum two signs, (in
reflective paint) one close to the point where the diversion begins and the other about
120m away will be fixed. At all crucial junctions, flagmen equipped with red and green
flags and lanterns/ lights will be employed for regulating the Traffic.

Supervisors acting, as traffic enforcers will be employed to ensure all the necessary
traffic safety guidelines required for road construction works are strictly carried out and
followed.

MACHINERY REQUIRED
i) Barricades
ii) Warning lights
iii) Traffic signs

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11. MISCELLANEOUS

METHOD STATEMENT & BRIEF SCOPE

This generally includes roadside facilities like Rest Areas, Bus Bays pickup Bus stops,
Pedestrian Crossing, Lighting system, Safety Barrier and other similar facilities. The
method statement only covers the facilities as stated above.

REST AREAS
The Rest Area shall be planned to cater for traffic moving in both directions such that
there is no need for the vehicles on one carriageway to cross over to the other
carriageway. The entry to the Rest Areas would be through deceleration lane and exit
through Acceleration lane. The minimum width of these lanes shall be 5.5 mm. The Rest
Areas shall be planned such that they are spaced at intervals of 90 minutes to one hour
driving time between two important cities/ town. They would not be located between 5
km of town or city or near interchanges and would be designed for peak time traffic and
provides facilities like Parking, Cafeteria, Toilets, Phones, Shops selling eatables and
other items as required during travelling. The whole area shall be landscaped to provide
the pleasing environment.

BUS BAYS
The Bus Shelter shall be located at least 1.0 m form edges of the Bus Bay which shall
generally be 30 m long. The plinth height of the Bus Stop shall be 0.3 m form the Bus
Bay level and shall be two risers high. The minimum ceiling height of the structure shall
be 2.1 m and the height of seating shall be 0.4 m form floor level.

The Bay shall be designed following IRC: 80 considered for 6-lane dual carriageway
highway. The barrier fencing/ pedestrian safety guardrail shall be erected between Bus
loading Areas and through lanes to prevent pedestrian crossing.

PICK UP BUS STOPS

The Bus Stops are invariably designed to cater for the actual peak hour demand. The
stop shall be located along service road only on one side and on both sides of the
project Highway for either direction travel. The stop would provide safe entry and exit of
Buses and safe movement of passengers. The shelter structure shall be aesthetically

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pleasing, structurally safe and functional so as to protect the waiting passengers
adequately from sun and rains.

SAFETY BARRIER
The crash barrier shall be provided along the Highway to provide safety to road users.
Safety barrier shall be of rigid, flexible, or semi rigid type in accordance with MORT & H
guidelines.

Barrier shall be provided at following locations:

i) Where heights of embankment is 3 m or more.

ii) Where embankment is retained by a retaining structure.
iii) Where median is depressed, flushed or having the width less than 4.5 m. The
barriers shall be for both directions of travel.
iv) On valley side of Highway in mountainous and steep terrain.
v) Between main carriageway and footpath in bridges.
vi) At hazardous locations as identified.

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12. WORK AT TOLL PLAZA SITE

METHOD STATEMENT & BRIEF SCOPE

The location of Toll Plaza shall be decided keeping in view the following:
i) Land availability
ii) Streams of traffic at Toll plaza.
iii) Visibility for appropriate traffic.
iv) Reasonably away from road intersections and / or road crossing.
v) Risk of flooding/ sub- mergence of road.

The toll plaza shall be designed for projected peak hour traffic of 20 years. The total
number of Toll Booths and lanes shall be such so as to ensure the service time of not
more than 10 second/ vehicles at peak flow regardless of methodology adopted for fee
collection.

The following norms are generally adopted for design of a Toll plaza.

i) Semi automatic toll lane - 240 vehicle/ hour

ii) Automatic toll lanes.
(Automatic vehicle identification and money - 360 vehicle/ hour
transaction –smart card)
iii) Electronic toll collection (ETC lanes) - 1200 vehicle/ hour
(Toll collection through on board unit and no
stoppage of vehicles)

Two toll lanes in each direction of travel shall be provided with the system of payment
through smart card and their configuration would be such that one lane in each direction
could be upgraded in future to the system of Electronic Toll Collection (ETC). Not less
than 2 middle toll lanes shall be capable of being used as reversible lane to meet the
demand of tidal flow.

The width of each toll lane shall be 3.2 meters, except for the lane for over dimensional
vehicles, where it shall be 4.5 m or more depending upon size of over size vehicles.

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Between each toll lane of the toll plaza, traffic islands are required to accommodate toll
booth. These islands shall be of minimum 25 m length and 1.8 m width. Protective
barriers of reinforced concrete shall be placed at the front of each island to prevent out
of control approaching vehicles crashing into the Tollbooth. They would be painted with
reflective chevron markings.

Toll booth shall be placed at the centre of each traffic island with dimensions to
accommodate toll collector’s task for toll equipment such as key board and console,
video screen, card reader, note and coin storage, telephone and environmental control
system. The toll booth shall have large glass window to provide the toll collector with
good visibility of approaching vehicles. The bottom of the toll window should be placed
at such a height (0.9 m) above ground level so as to provide convenience of operation.
The Tollbooths shall be chronologically designed and shall be vandal proof. There shall
be CCTV camera installed at each booth.

For the movement between toll office and Tollbooth in each toll lane, an underground
tunnel across all toll lanes shall be provided. Its dimensions would be sufficient to
accommodate the required wiring/ cable system and for convenient movement of
personnel. It should also be provided with lighting and ventilation system so that the
movement is convenient.

The area of toll plaza covering the flared portion shall be provided with concrete
pavement. All the toll lanes and tollbooths shall be covered with a canopy. The canopy
shall be wide enough to provide weather protection to toll operators, drivers and
facilities. The canopy shall be of aesthetically pleasing design with cylindrical support
columns located at traffic island so that there is no restriction on visibility and traffic
movement. The vertical clearance shall, however, conform to IRC standards.

Toll plaza shall have a separate office building so as to provide comfortable office space
for manager, cashier & other staff. There shall be separate rooms for T.V. monitors,
meetings, toilets, and for the sale of passes, smart cards, on board units and public
interaction. The building shall have a strong room for keeping the money and a garage
to accommodate the security van (during operation of loading the collected revenue).
There shall be parking space in the same campus for vehicles for the staff and workers
and other vehicles engaged in the operation of the Project Highway.

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The toll plaza shall have toll audit system and fraud protection measures. The
operations for toll collection, supervision, auditing and money handling shall be done
through the qualified personnel so that each operation is efficiently handled.

MACHINERY REQUIRED:
Toll equipment with accessories.

i) Concrete barriers.
ii) Video screen.
iii) Card reader.
iv) Cable system.
v) CCTV cameras.

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13. CULVERTS

METHOD STATEMENT & BRIEF SCOPE

The culverts requiring reconstruction, widening and repair generally consist of RCC slab
deck with either RCC or Brick masonry abutments. Consequently the culverts are
proposed to be up-graded as under:

RCC Culverts
• Construction of new culverts on Service roads.
• Widening of the existing Culverts on both the Carriageways.

The design of new RCC slab or box culverts on the proposed service roads shall
generally conform to IRC-SP: 13. The widening of culverts shall generally follow the
present configuration and be in RCC construction. To begin with, the Contractor shall
identify the Bench Marks/ Reference Pillars in the vicinity of culvert and further check to
setting out of the structure w.r.t centre line of approved/ existing cross section of the
road. It shall be inter-alia ensured that layout of the culvert conforms to ‘Good for
Construction’ drawings approved by the Engineer.

Existing foundation design shall be adapted to build new abutment (adjacent to the
existing one) except that the substructures shall be in RCC. The deck slab of uniform
depth shall be widened by joining the steel reinforcements of existing culvert and new
slab culvert by mechanical splicing (after demolition of parapets) where feasible and
work completed as per drawings otherwise box culverts would be added adjacent to the
old slab culverts.

If the deck slab of existing culvert cannot be attached to the proposed new one, RCC
box culvert shall be provided for widening works. RCC pre-cast elements shall
preferably be used for box culverts

The widened culverts shall have the same overall width as the approach road. Overall
width of the structure shall be such that outer face of parapet shall be in line with outer
edge of shoulder.

Pipe Culverts

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 • Widening on one side by additional length of pipes, if the existing pipe culvert is
in good condition
The dia of pipe for widening shall be the same as existing ones. If the vents are choked,
the existing pipe culvert shall be replaced by either slab culvert or box culvert in RCC,
with an overall width suitable to 2 x 3 lane carriageway. The depth of earth cushion shall
be adjusted keeping conditions at site.

The culvert shall preferably be widened on outer side of carriageways as per

geometrical requirement.

Under Passes
• Construction of new underpasses for the main carriageways.
• Lengthening of both pedestrian and vehicular underpasses to cater for 2 x 3 lane
carriageway.

The cross section of Pedestrian Underpass (PIJP) and Vehicular Underpass (VUP) shall
cater to the headroom requirement of each. While the PUP is proposed to be built of
pre-cast elements, the VUP shall be of pre-cast / cast in Situ Construction. For
lengthening of existing PUP/ VUP the same cross section shall be adopted, except
where masonry arch/ steel concrete composite spans exist.

For lengthening existing PUP, open excavation shall be carried out followed by
installation/ construction of box section with new staircases and roof structure. The
existing staircases shall be closed and buried for the widened carriageways.

The existing VUPs shall get lengthened together with the widening of ROBs / Flyovers
as per the span requirements. The setting out of the underpasses shall be similar to that
of culverts.

However, the quality control requirements in respect of excavations, retaining the earth,
precast elements in Situ Construction etc shall follow checklists.

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14. MACHINERY REQUIRED

i) Excavator.
ii) Tipper.
iii) Loader.
iv) Vibratory/ Static Compactor.
v) Non-tilt Mixers- 2 nos. or RMC.
vi) Transit mixer if RMC is used.
vii) Needle and screed vibrator.
viii) Bar bending machine.
ix) Mechanical splicing equipment.
x) DG sets.
xi) Equipment for handing and lowering pre cast elements.
xii) Dewatering pup sets.

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15. BRIDGES, FLYOVERS & ROBS (SUPERSTRUCTURE)

METHOD STATEMENT & BRIEF SCOPE

Most the minor and major bridges generally consist of either 15m or 20m individual span
lengths and built of prestressed concrete solid slabs. The exceptions are Augmentation
Canal (AC) & West Jamuna Canal (WJC) bridges near Karnal single span box girder
bridges on SYL canal and the bridges on Bhakra main canal near Sirhind. In addition the
major bridges across Markanda, Ghaggar and Sutlej river have varying span
arrangement. The 10 nos. of flyovers proposed shall be built of precast elements as per
required width. The new bridges on service roads and ROBs for widening shall have
similar configuration as on main carriageway, except that they shall be of 2-lane
capacity.

For widening as well as for construction of new bridges, the superstructure shall be built
using pre-cast pre-tensioned elements (Beams/ Slabs). Occasionally post tensioned
concrete technology shall be used. The beam and slab elements so cast shall be made
monolithic (for composition action) by in-situ concreting.

PSC Solid Slab Bridges

• Enhancing the capacity of carriageways, by construction of additional 2-lane
bridges adjacent to existing ones, by pre-cast elements; thus making 4 x 2
lane bridges with divided carriageways.
• Construction of 2-lane bridges on service roads with pre-cast elements.

River Bridges
• There is no proposal for widening of these bridges at present.

Canal Bridges
• Construction of 2-lane bridges on service roads with pre-cast elements of 15m/
20m length, instead of widening of existing bridges.

New Flyovers
• Construction of 2 x 3 lane flyovers with footpaths, adopting pre-cast elements of
15m/ 20m length.
• There is no proposal as yet on widening of flyovers in urban areas.

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ROBs
• Construction of 2-lane new ROBs adjacent to existing ones by adopting pre-cast
element (beams / slabs) supported on RCC substructures as per
requirements of Railways.

For all the bridges, flyovers and ROBs both open and pile foundations shall be used as
per site conditions. The per-cast elements shall be produced under stringent quality
control conditions in a factory.

The design of bridges, flyovers, ROBs shall generally conform to IRC:18., IRC:SP:71,
Indian Railway Codes and International Codes of practice and specialist literature on the
subject(s).

The widening work shall preferably be done on the outer side so as to increase the
carriageway widths as stated above.

To begin with, the Contractor shall identify the Bench marks/ Reference Pillars in the
vicinity of existing structures and/ or with respect to the centre line of approved cross
section of the widened road. It shall be inter-alia ensured that the layout of the structures
conforms to ‘Good for Construction’ drawings approved by the Engineer.

The checklist of pre-cast elements and post tensioned concrete besides others related
to concrete and formwork shall be followed for Quality Control

Machinery required
i) Excavator
ii) Tipper
iii) Loader
iv) Vibratory/ Static compactor
v) Concrete batching plant
vi) Concrete compaction equipment (needle/ form and screed vibrators)
vii) Prestressing bed with bulkheads
viii) Forms for casting pre-cast girders
ix) Prestressing jacks (for factory site)

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x) Mobile crane for lifting/ placement of pre-cast girders
xi) Trailers for transportation of pre-cast girder up to 30m length
xii) DG sets

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16. FOUNDATIONS, SUB STRUCTURE AND PROTECTIVE
WORKS

METHOD STATEMENT & BRIEF SCOPE

The culverts, bridges, flyover and ROBs required adoption of appropriate type of
foundation, substructure and protection works as the case may be, for both widening
and new construction. Both open and pile foundations shall be used for difference work.
Their design shall in general conform to IS: 2911 (Section 2), IRC: 78, IRC: 6 and IRC:
89 besides MOSRT&H specification for road and Bridge works. The PUP and VUP shall
be designed separately as per current practice.

SPECIFICATION

The section of a particular type of foundations depends on bearing capacity of soil,

consideration of scour and the loads transmitted from superstructure.

A. Open foundation.
This type of foundation is chosen mostly for culverts and minor bridges. It
consists of open excavation of ground to the required depth, dewatering and
construction of a footing in RCC as per drawings. Open excavation shall be
chosen for both PUP and VUP.

B. Pile Foundation
Bored cast in-situ pile foundation conforming to IS: 2911 (Part-2) shall be chosen
for bridge, flyover and ROB works. The piles are built by boring a hole in the
ground by percussive or rotary method by the use of temporary/ permanent
casing or drilling mud and subsequently filling the hole with reinforced concrete.
The length, dia meter and spacing of a group of piles shall be as per drawings.

A test pile for load testing (by applying a load of 1½ times the safe load) may
form a working pile itself. Otherwise it may be cast separately.

C. SUB STRUCTURES
The substructure shall be built in RCC. A pile bent, wall type of abutment and
pier shall be built complete with pedestals for placement of bearings with a dirt
wall on abutment. They shall invariably built monolithic with footing or pile cap.

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 The gravity type of wing walls shall be built as retaining walls (of varying height)
on open foundations.

Weep holes shall be provided for earth retaining elements.

D. PROTECTION WORKS
The type of protection work such as apron for stream bed, slope protection
depend hydraulic considerations and requirements at different sites.

Either boulders or pre-cast concrete blocks weighing 40 kg and above are

chosen for protection works. They may or may not be set in cement mortar
depending on the velocity of stream and flood / flow level. Boulders set in wire
crates (gabions) are also employed for bridges across rivers and major canals,
whenever they are taken up.

The columns /piers of flyovers are protected against collision of vehicles passing
underneath by different methods. Such works are usually executed in RCC.

E. EMBANKMENT REQUIRED
(i) Excavator
(ii) Trench excavator
(iii) Loader
(iv) Weigh-batcher
(v) Transit mixers
(vi) Bar bending machine
(vii) Vibrators for compaction of concrete.
(viii) Tippers (for boulders/ pre-cast blocks)
(ix) Percussion / rotary type rig.
(x) Pump for direct/ reverse mud (bentonite) circulation.
(xi) Standard auger
(xii) Pile rig for placing/lifting casing
(xiii) Hopper for tremie concreting

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(xiv) Kentledge arrangement for pile test
(xv) Truck mounted crane

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17. REPAIR & REHABILITATION OF BRIDGES & ROBS ETC.

METHOD STATEMENT & BRIEF SCOPE

Most of the culverts and bridges do not require any major rehabilitation. The
deterioration/ damage if any is confined to railings/ parapets, parts of expansion joints
and delamination of concrete at some locations. The ROBs of carriageways need
rehabilitation of footpaths and repairs to local spalling of concrete, besides resetting/
replacement of railings. the presence of cracks and voids / honey comb in concrete
members is also limited.

Consequently the structures are proposed to be repaired / rehabilitated as follows:

Culverts
Repairs to delaminated concrete in RCC slab and damaged parapets are to be done on
inner side by dismantling of affected portions. Guniting or Cement mortar repair shall
follow as per requirement. Cracks shall be filled by epoxy injection.

The RCC parapets on outer side are likely to be replaced in the widening scheme. The
brick masonry parapets shall be demolished in the widening schemes and new parapets
shall be built in RCC.

Bridges
RCC parapets (where retained) and delaminated portions in RCC deck slab (6m to 10m
length) in the affected areas shall be dismantled. Guniting or Cement mortar repair shall
follow as per requirement. Cracks if any shall be filled by epoxy injection and voids shall
be filled by cement grout.

In addition resetting/ replacement of damaged lengths of expansion joints shall be

carried out as per manufacturer’s specifications. The bearings in general are functioning
satisfactory.

ROBs
The old multi-span Steel Concrete composite ROBs (LHS carriageway) on brick
masonry substructures are proposed to be retained. Their repair/ rehabilitation
comprises of Removal of steel railings, reconstruction of RCC kerb or footpath and
provision of new vertical anchor arrangement in the kerbs. For attaching new parapets

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construction of new RCC parapets shall be done by taking advantage of anchor
arrangement. Repairs to portions of delaminated, concrete, by dismantling, followed by
Guniting or Cement mortar/ grouting shall be done as per requirement. Similar repairs
shall be carried out to the ROBs as well on RHS as per the need.

The checklist for repair and rehabilitation shall be followed in implementation.

Items covered in checklist:

(i) Repair to concrete elements.

(ii) Repairs to Appurtenances

MACHINERY REQUIRED
(i) Chipping tools for dismantling concrete
(ii) Concrete mixer (for footpath/ kerb repairs)
(iii) Guniting equipment (for concrete repairs) if needed
(iv) Form vibrator for kerb/ footpath rehabilitation
(v) Bar bending machine (for steel reinforcements)
(vi) Equipment for epoxy injection of cracks.
(vii)Grouting pump
(viii) DG sets.

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