6-LANING OF PANIPAT-JALANDHAR SECTION OF

NH-1 FROM KM 96.00 TO KM 387.100 IN THE

STATE OF HARYANA & PUNJAB TO BE
EXECUTED AS BOT(TOLL)ON DBFO PATTERN
UNDER NHDP PHASE V

Organization Details:

SOMA ENTERPRISE LIMITED

Bhullarai Village,
Hoshiarpur Road, Phagwara
Distt. Kapurthala, Punjab 144401.

Trainee Details

Dr. B.R. Ambedkar NIT Jalandhar

Name: Sorav Mehton
Roll No.: 08102064
Discipline: Civil Engineering

INTRODUCTION TO
PROJECT
NHAI launched an ambitious program
in 1999. The National Highway
Development Project (NHDP) was
initially introduced in two phases at a
cost of $14 billion. Since then, it has
been greatly expanded.
Initially the two phases were setup
but now it aims at completing seven
phases.

INTRODUCTION TO
PROJECT
Regarding seven phases:
Phase I covers the golden quadrilateral linking the four metropolises of
IndiaDelhi, Mumbai, Kolkata, and Chennaithrough a four-lane
highway (5,846 km).
Phase II includes the northsouth corridor (about 4,000 km) connecting
Srinagar to Kanyakumari, and the eastwest corridor (about 3,300 km)
connecting Silchar to Porbandar. This phase also covers port
connectivity.
Phase III (10,000 km) covers national highways carrying high volumes
of traffic connects state capitals with the network established in the first
two phases and provides connectivity to places of economic,
commercial, and tourist importance.
Phase IV (20,000 km) envisages upgrading of existing single-lane and
two-lane national highways across the country to high-quality two-lane
national highways.

INTRODUCTION TO
PROJECT
Regarding seven phases:
Phase V (6,500 km) provides for expansion to six lanes of the four-lane highways,
comprising the golden quadrilateral and certain other high-density stretches. The
Project is part of this phase.

Phase VI (1,000 km) includes the development of 1,000 km of expressways on a

buildoperatetransfer (BOT) basis to serve the growing urban centers, particularly
those located within a few hundred kilometers of each other.
Phase VII provides for building of ring roads, bypasses, grade separators, and
service roads to utilize the enhanced capacity of the national highways fully

INTRODUCTION TO
PROJECT
In a BOT modality, the private party is responsible for
constructing, maintaining, and operating the road during the
concession period. At the end of the concession period, the
road is transferred to NHAI. In a BOT toll modality, the private
party recovers its investment by collecting the toll over the
life of the concession.
In January 2008, the Soma Isolux Consortium emerged as the
winning bidder. The concession agreement was signed
between NHAI and Soma Isolux (concessionaire) on 9 May
2008. The consortium ownership comprised Isolux Corsn
Concesiones (51%) and CorsnCorviam Construccin (10%),
both part of the Group Isolux Corsn, and Soma Enterprises
(39%).

INTRODUCTION TO
PROJECT
The Project consists of retrofitting the existing four-lane highway
to a six-lane highway, and building flyovers or overpasses and
vehicular underpasses on all existing intersections to allow
continuous flow of traffic.
This has to be undertaken with the minimum possible
inconvenience to existing traffic, and with no major
deterioration in current levels of service.
The concessionaire will also be responsible for the O&M of the
road during the concession period. At present, NHAI is collecting
tolls on the existing four-lane sections. This will continue until
financial close. Thereafter, including during the construction
period, the concessionaire will be entitled to collect all tolls.
At the end of the 15-year concession period, the road will be
transferred back to NHAI.

PROJECT SETUP
6-LANING OF PANIPAT-JALANDHAR PROJECT
The Rs. 45182.00 M project aims at increasing the capacity of the
Panipat Jalandhar section of NH-1 from 96 kms. to 387.10 kms. to
six lanes in the state of Haryana/Punjab on BOT (Toll) basis.
Employer: National Highways Authority of India
Concession Period: 15 years
Construction Period: 2.5 years

Reach
I

Reach
II

Reach
III

Reach
IV

Reach V
(KM 329 - KM387.1)

Highway

Structural
VNCPL

1. Flyover
2. V.U.P.
3. P.U.P.

SOM
A

VSoL

SOM
A

SCJC

1. Retaining Wall
2. Drains
3. Spladed Wingwall

Retaining
Earth Panel

Upto
Embankment

Rest like GSB,

WMM, DBM

ABOUT CONSTRUCTION
SITES
1. Reach 357KM Phagwara Gol Market Flyover,
Kapurthala
GPS Address: 3113'3.19"N 7546'10.79"E, Elev. 246m
Abutment-Pier system flyover at
Shaheed Bhagat Singh Chowk, Gol
Market (Phagwara) is being constructed
as a part Phase V NHDP. It aims at
facilitating:
Fast moving traffic to pass over
without being interrupted by pauses
at intersections.
Fast moving traffic to move without
interruption due to nearby bus stand.
Fast moving traffic to avoid being
disturbed by local Gol market
consumers.

Image from Google map(map vie

ABOUT CONSTRUCTION
SITES
2. Reach 371KM P.A.P. Flyover, Jalandhar
GPS Address: 3118'35.38"N 7536'43.00"E, Elev. 236m
The main objectives of the built-up which
will facilitate the localities are:
Allow Bye-Pass Road traffic to proceed
toward Rama Mandi Chowk without
being interrupted at P.A.P. traffic signals.
Separate the traffic wishing to proceed
either Jalandhar City or Out of Jalandhar
City.
Allowing the out of Jalandhar traffic to
cross P.A.P. Chowk without any
stoppage.
Decreasing traffic burden on P.A.P.
Chowk. Reach 379KM Focal Point
Flyover, Jalandhar

Image from Google map(map vie

ABOUT CONSTRUCTION
SITES
3. Reach 379KM Focal Point Flyover, Jalandhar
GPS Address: : 3121'29.27"N 7534'51.73"E, Elev. 238m

Flyover: 1. Facilitate slow moving traffic to enter Transport Nagar, near Focal Point,
Jalandhar,
without being interrupted by fast moving traffic.
2. Avoiding the fast moving bye-passing traffic from road jams due to Sarb Multiplex.
V.U.P:
1. Allow people and vehicle to change direction of travelling.
2. Facilitate peope on othe side to move toward Focal Point.
Image from Google Earth

ABOUT CONSTRUCTION
SITES
4. Reach 384KM Suranussi Flyover, Jalandhar
GPS Address: 3123'00.68"N 7532'29.51"E, Elev. 238m
The facility is made so as to help
people from village like Nussi, Lidhran
and surrounding to get access to G.T.
Road, on the other side of suranussi, as
point A and B shown in pic are the only
point where traffic from these villages
and surrounding intersect Bye-pass
traffic.
It will also facilitate those concerned
with:
Dr. B. R. Ambedkar N. I. T. Jalandhar
St. Soldier Collage.
Central Reserve Police Force Camp

Image from Google Earth.

TRAINING SESSION
The training session starts from 26th
May 2011 and ends on 16th July 2011
with duration of 7 weeks and 3 days.
Entire training session undergoes at
construction zones on actualization
sites.
Different training activities are covered
at different construction sites as per the
active works and as guided by trainer.

TRAINING SESSION
VARIOUS CONSTRUCTION PROCESS ENTERTAINED DURING
TRAINING SESSION ARE:
Layout
Excavation
Leveling
P.C.C.
Reinforcement framework
Formwork or shuttering
Casting of form or concreting
Removal of shutters and curing

STRUCTURAL ELEMENT ACTIVITIES CARRIED OUT DURING

TRAINING SESSION ARE:
Abutment/Pier
Divider
Drainage
Elastomeric and Pedestal Bearing
Expansion Joint

Retaining Earth Panel

Retaining Earth Wall
Piling
Soil Bed
Survey Leveling

TRAINING SETUP
Under the training there are various sites where the training program is being carried
out. Training session of 26-June-2011 to 5-July-2011 is carried out in Jalandhar and of 6July-2011 to 16-July-2011 is carried out in Phagwara (Kapurthala Distt.) under the same
project. The site and training particulars are as explained below:
Reach V (KM 329 KM387.1)

Reach 357KM
Phagwara Gol
Market
Flyover,
Kapurthala

Reach 371KM
P.A.P. Flyover,
Jalandhar

Reach 384KM
Suranussi
Flyover,
Jalandhar

Topics under training:

Topics under training:

Piling, Raft-pile
coupling,
Abutment/Pier
Cap, Elastomeric
& Pedestal
Bearing

Reach 379KM
Focal Point
Flyover,
Jalandhar

Topic under training:

Abutment/Pier
framework,
formwork, casting

Crash Barrier,
Drainage,
Frictional Belts,
Retaining Earth
Panel,Retaining
Earth Wall, Soil
Bed, Cross Wall,
P.C.C., P.U.P., V.U.P.

Topics under training:

Divider, Expansion
Joint

Various construction processes carried

out during training are as follow
Note: The process (current, predecessor or successor) listed below, in relation to one-another, may or
may not be associated to one particular place, site, structure, structural element, engineer, junior
engineer, supervisor or company.

LAYOUTTING
For this particular project, NATIONAL
HIGHWAY SURVEY OF INDIA is responsible
for carrying out plane, leveling surveys.
The proof of work can be seen on the
service roads (at 20m interval), national
highway and either sides of road which
looks like as follow:
The points
+1802 on the
service road at KM379 signifies
180m advance from KM379 and 2m
from outer edge of drainage.

LAYOUTTING

Layout for the excavation process of the

retaining wall section (3mX30m) at site

LAYOUTTING

For section (20000 X 3950) , point +1802 is used. From point

Distance from outer edge of drainage = 2m
Total Width of drainage = 2m
Thus, total distance to the outer edge of stem of retaining wall =
4m
Thus a point at 4m (A) is marked, and one point left at 2350(toe
side, B) another at right side 1400(heel side, C) are also marked.
Sometimes when the ground surface level differs, stone falling
method to get vertical point below measurement tape marks is

EXCAVATION

Excavator is run parallel to layout line (longitudinally) and

excavation continues until required depth level is not achieved.
Since the adjoining soil is hard enough, falling of soil was minimum
and no need of bracing was expected. Excavated land afterwards is
treated with rollers for getting uniform plane surface.

LEVELING

PLAIN CEMENT
CONCRETING

REINFORCEMENT FRAMEWORK

For retaining wall sec.

(20000 X 3950), the
base dimensions and
reinforcement details
are

REINFORCEMENT FRAMEWORK
REINFORCEMENT DETAIL FOR RETAINING WALL (Fe500 TMT to be used)

The cutting lengths are to be

calculated and provided to
reinforcement contractor or concerned
body. The cutting lengths are
calculated considering clear cover and
diameter of bar.

REINFORCEMENT
FRAMEWORK
For example bar cutting dimension are as:

Total Length = 3750

Clear Cover from bottom & rest = 80
& 40
The vertical bend length specified =
150
Horizontal Length = 3750 40 40 =
Bending3670
Bar Schedule(BBS) is prepared
Similarly all the lengths can be
accordingly
and given to the contractor.
calculated.

FORMWORK OR SHUTTERING
Forming boundaries using shutters around the place where concrete is to be pour,
may be reinforcement or plain, which gives desirable shape to concrete on casting.

CASTING OF FORM OR
CONCRETING
During pouring of concrete one must take care of following
things:
The height of fall of concrete can cause segregation.
Uniform distribution of concrete to cast uniform strength
section. specification of concrete used in the project are:
Different
Grade of
Concrete
M15
M30
M35
M40
M50

Area of application
Plain Concreting, Leveling
Retaining wall
Foundation and Approach Slab
Pedestals and Crash Barrier
Deck Slab, Elastomeric and Pedestal Bearing,
Abutment & Pier and their cap

CASTING OF FORM OR
CONCRETING
Concrete
Delivery Ticket
from Driver

REMOVAL OF SHUTTERING

1-1.5 Days after the concreting, shuttering is removed manually.

Nut and bolts are loosened and shutters are removed.
During removal care should be taken. Shutters should not be
removed by pulling, instead jerks should be given in longitudinal
direction and removed smoothly.
Afterwards the polythene covering drainage pipes are removed
and checked and cleaned.
Immediately afterwards curing procedure is started. Curing is
the process of supplying water to concrete for hydrolysis
reaction from external.

CURING
Immediately afterwards curing procedure is started. Curing is the
process of supplying water to concrete for hydrolysis reaction from
external. Two methods used are:
Method used

Application area

Ponding

Approach slab, Flyover slab

Using Jute Bags

Crash Barrier, Abutment/Pier Cap, Drainage,

Retaining wall

Curing of approach slab by means of ponding of water at site 384:

STRUCTURAL ELEMENT
ACTIVITIES
ABUTMENT/PIER
Vertical member
that transfers load
from the deck slab
to the foundation
system is known
so. If the vertical
member is at the
ends it is known
as an Abutment or
if
it
is
intermediate it is
termed as a Pier.
Different types of
combinations are
as follow:
1) Abutment system
2) Abutment-Pier
system

The abutments and piers used under Reach 357, 371, 379, 384
are of same lateral dimensions 4m X 1m,

DIVIDER

Important highway
element that are built
in order to distinguish
between the
difference in passage
directions of traffic on
a road. The
specifications of
divider are as:
Width = 12.5cm,
Height from WM =
41.5cm, Height from
Final Wearing Coat =
22.5cm
The casting of dividers
is done by fully
automatic machine
called Slipformer
provided by Arrow
Machinery, Australia.

DRAINAGE
Built along the road side, on both sides, the drainage facilitates highway and
traffic by eliminating the surface run off water to the major drainage facility.
Sectional view of drainage along with dimension and reinforcement details:

ELASTOMERIC AND PEDESTAL

BEARING

Reasons for the introduction of these members are:

To provide a jack to hold deck slab.
To facilitate provision of camber because the height of bearing
pedestals uniformly varies.
To counteract the large shear forces.

Details of
Elastomeric
and Pedestal
Bearing built
at location 3
on
Abutment-1
Cap at Reach

EXPANSION JOINT
Special joint that has the ability to expand and contract due to
temperature effects on concrete are used in spans either longer than or
equal to 30m. Since the flyover at reach 384(Suranussi Flyover, in front of
Lidhran Vill. Gate) spans 30m, expansion joint are made using edge beam
and sealing material.

Z-Tech Expansion Joint used for reach 384

RETAINING EARTH PANELS

Despite fulfilling the functioning of retaining earth walls, RE panels

add pleasant visual effect in the structure.
These are mostly used in situation when the height of retaining wall
above the ground is more than 4m which becomes uneconomical.
These are simply put one over another using crane aided by skilled
labor and clamped together with simple material insert locking.
Since all the four sides of RE panel are grooved, better interlocking is
achieved that prevent auto fall even in the absence of frictional belts.
Afterwards frictional belts are inserted through RE panel hooks and
held by bars at other end. Zigzag spreading of frictional belts is
adopted with friction length = 6m.

RETAINING EARTH
PANELS

PILING
For this particular project, cast-in-situ piles are used using M30 grade concrete.
Firstly the centre point of pile is located on the ground in terms of lateral
displacement and reduced level.
Then the process of drilling starts.
It should be noted that all the piles at Reach 357KMs are of = 1200mm. The
only difference is in the length and number as explained below:

Abutment(A)/Pie
r(P) No.

No. of Piles

Length of Pile
Group

Diameter of
Pile

A1
P1
P2
A2

4
6
6
4

24m
27m
27m
24m

1.2m
1.2m
1.2m
1.2m

NOTE: Abutment/Pier numbering is as starting from Panipat and proceeds to

Jalandhar. Length of pile group is the height measured from the abutment/pier
base.

PILING
Reinforcement Framework: The reinforcement framework is done
at site using Fe500 TMT steel bars. A minimum lap of 2m is
provided.
Drilling:Drilling is carried out by ordinary drilling machine aided
with water as lubricant and soil removing liquid. Drilling depth is
measure from the machine level and the number of torque arms
joined.
Chemical known as Bentonite is also added in water during
drilling. The function of bentonite is that it prevents the falling of
drill boundry soil by increasing viscosity of water-soil solution.
For the Pier-2a, drilling of one pile consumed 3.5 days (the one
used at Reach 384, cost Rs. 4 crores, drilled for one pile in one
day).
R.L.out
of top
of pile
(by
R.L.
of top of raft
Concreting was carried
during
night
VNCPL.
Width of raft + 1m)
Cutting of Pile:

PILING

Cutting is carried out by 10kg hammer and cutting tool.

Photos of installation of steel framework

in the drill.
Photos of process of cutting of piles.

SOIL BED
The soil bed need to prepared for:
For formation of approaches.
For frictional belt installation.

Formation steps:
1.
2.
3.
4.

Land on which soil bed is to be form, is temporarily marked.

Soil in the form of dumps is stacked on the land using dumping trucks.
Using JCB bulldozer, the dumps are distributed all over the land.
Using crater the soil level is made even on the land. Depth of non-compacted soil
is not to be more than 250mm otherwise chances of lump formation are there.
5. Firstly a roller compacts the soil, then the water sprinkling truck sprinkles water
over the compacted soil.
6. Finally again the roller compacts the soil.