Storm water Drain (SWD)

A storm water drain is designed to drain excess rain and ground water from impervious surfaces
such as paved streets, car parks, parking lots, footpaths, sidewalks and roofs. Even the gutters
from houses and buildings can be connected to stormwater drain.
A similar stormwater drain has been designed in Dholera SIR. The total length of the storm water
drainage system is 140.0 KM which includes 1250 nos of chambers. The entire work of storm
water drain is cast in situ.The storm water drain is being constructed along the side of road.
There are different sections of drain based on the chainage. The flow in the drain is open channel
flow and is gravity flow. Hence, steps have been provided at specific interval for rapid
movement of water. In order to prevent the effect of shear force across the edge of drain, haunch
has been provided in the inner side of the drain. Morever, inlets, manhole, desilting chamber
have been provided at specific interval.
Drawings

Reinforcement Detail of Storm water box drain

 S
chedule of Reinforcement
Steps for construction of drain:
Clearing and Grubbing: Clearing and grubbing shall consist of the removal and disposal of all
trees, stumps, roots, logs, shrubs, grass, weeds, fallen timber and other surface litter, wherever
they occur within the right-of-way and within such other areas as directed and staked out by the
Engineer.
OGL Layout: In this process, layout of drain is done by locating the point given by surveyor
through total station.
Excavation: The excavation is preliminary activity in the process. The excavation depth is taken
as 1.5m for the black cotton soil.
Laying out PCC: First of all the loose soil from surface is removed and then rolling is done.The
PCC is laid down after preparing the bed. The minimum depth of PCC shall be 100 mm. M20
grade concrete is used for PCC.
Construction of Raft & Haunch: After the PCC is prepared, raft and haunch are constructed
above it. The thickness of the raft varies as per the section. The reinforcement of raft is done as
per the drawing and proper spacing is maintained. All the shutters should be cleaned and oiled.
Cover blocks are applied to give cover of 50 mm. M40 grade concrete is used for raft and
haunch. The haunch plates shall be in the line in order to avoid offset. The plates and shutters are
removed after 10-12 hours of pouring the concrete.

Raft concreting Haunch concreting

Construction of wall: The wall is constructed above the haunch. The reinforcement is done as
per the drawing. The shutters used are either of wooden material or rolling shutter of plastic. The
line and level of the wall is checked before construction. The thickness of the wall is 175 mm.
The cover of 50 mm should be there. The plates should be in line with haunch to avoid the offset.
M40 grade concrete is used for wall. Curing compound should be applied after removing the
shutters with the help of auto sprayer.
Construction of slab: The slab is casted above the finished surface of wall. The slab is done
using conventional method and by deck plank method. The thickness of the slab varies and M40
grade concrete is used.
Defects in drain: There are possibilities of improper techniques used during construction which
can deteriorate the quality. Due to improper pouring of concrete or not using vibrators,
honeycomb is likely to occur. Offset occurs between different parts due to improper alignment of
shutters. Cracks often occurs in concrete due to excess water in concrete. The height of wall is
not maintained due to improper line and level.
Possible solutions to it: To avoid honeycomb, vibrator should be used properly. The admixture
should be used if the concrete is on the site for long time in order to prevent the setting. All the
shuttering material should be of same set to maintain uniformity. Proper cleaning and oiling of
all the shutters should be maintained.
Challenges on the site during construction:
The major obstacle on the site during construction is the dust or wind gust blowing at 25-30
kmph. Apart from that, the unavailability of skilled labour is major issue.

Shuttering Cube for Compression Test

Wall Concreting Slump Test

Applying curing compound Slab after completion
 POWEROL PHM-35-R 15kVA
Case Study:
Road: CPR-3
Chainage: 0+650 to 0+660 (LHS) Wall
Size of Drain: 2.01.6 m
Concrete used: 4.6 cum (approx.)
Vibrator: Needle Vibrator (60 mm)
Diesel Generator: 15 kVA
Contractor: Devendra Sahoo
Labours: 8 nos.
Shuttering used: 46 m2
Steel Used: 400 kg (approx.)
Slump of the concrete: 110mm

Machineries used in Storm water drain construction

BOOM PLACER LIFT & CARRY CRANE

SCHWING STETTER (S-36X) 90 cum/hr ACE FX120 12T

TRAILER TRANSIT MIXER

 TATA-3516 22T TATA LPK 2518 6 cum

Road Construction
General:
The road network in the Dholera SIR have been planned considering the industrial, residential
and all the other amenities. The total scope in roads & services has been divided into 2 groups
based on the construction sequence. All the services are designed along the road. The total length
of the roads and pavement is 72.3 km.

Group 1
Road Name PROW(m) Length(m)
G-6 55 3068
G-7 55 3401
G-4 65 5479
H-1 80,70 4657
H-2 70 1987
F3A 45 1598
K1 48 693
K2 48 1986

Group 2
Road Name PROW(m) Length(m)
A6 12 228
B40 18 547
 B41 18 2132
B42 18 3375
B43 18 1329
B44 18 151
B48 18 257
B53 18 695
B54 18 696
B55 18 697
B56 18 2791
B57 18 2525
B58 18 85
B59 18 1421
C7 21 3107
C9 20 2772
C10 20 3624
C16 20 1198
CPR1 20 1280
CPR2 20 1921
CPR3 20 1110
CPR4 20 1009
CPR5 20 290
CPR6 20 600
CPR7 20 600
CPR8 20 600
CPR9 20 1987
CPR10 20 600
CPR11 20 600
CPR12 20 400
E1 30 2665
E2 30 3258
E3 30 2282
D7 24 199
D9 24 180
J1 25 1291
 Clearing and
Fig: Key Plan of Road Network
Grubbing

Clearing and Grubbing

Emb/SWD PD/Sewer

MPCS/Emb/B.
SG Fill Sewer/PD

CSTB
SWD/Emb
PW/RW/ICT

WMM/KERB
ICT/SG
SG
Asphalt
GSB/CTSB
GSB
St. Lighting
WMM
CC blocks &
Finishing
Finishing
Works Asphalt
works

St. Lighting
Group 1
Finishing Works

Group 2
 Figure: Sequence for procedure of road construction

Typical Cross Section of Road:

The typical cross section of the road shows all the details. All the required facilities are provided
along the right of way. Separate cycle track and MPC has been provided. The SWD lies below
the carriageway. The power duct, ICT duct, potable water, recycled water, and all other utilities
have been provided below the ground.

Machineries used in road construction

VIBRATORY ROLLER DUMPER
 L
&T-CASE (W1107D) -11.3T AMW-2012 17 MT
MOTOR GRADER WATER TANKER
KOMATSU GD555-3A 13T
POWER DUCT
General:
The RCC ducts are being constructed along the edge of right of way in Dholera SIR for power
supply network. The precast technique is used in the duct construction. The total length of the
power duct is 120 km. Two agencies i.e. Megalaxmi and KK Spun are given contract to construct
the precast power duct at precast yard. Total three class of power ducts are there.
Class Size
A 1.71.8
B 2.21.8
C 2.71.8

Drawings of Power Duct:

 Fig: Reinforcement Details of Precast Box

Construction Methodology
 Fig: Methodology Flowchart

Construction Sequence
A) Bulk material stacking and loading: The bulk material like aggregates and
cementitious materials are stored and handled by batching plant manufacturer at precast
site. Coarse aggregate, fine aggregate, cement, fly ash, etc are not mixed before use.
B) Placement of reinforcement cage, Mould, Concreting, De-moulding by
machine:
Bottom mould and reinforcement cage after preparing are placed on vibrator platform
table. PVC cover blocks are used to maintain the clear cover as per drawings. MS insert
plate is tied with cage as per the approved drawings. Inner core is fitted permanently on
vibrator table which is underground. Steel cage is placed on base ring; mould is placed
over it with help of EOT crane on base ring and locked and moved to center of pit.Outer
assembly is placed on the inner mould and concrete feeding is done.

Steel Cage Placing in mould

Vibrator inside inner core settles and compacts the concrete. After concreting, conveyor feed
moves out. Outer mould is lift up with the base plate & formed structure with help of EOT
crane. The structure is demoulded and sent for curing.

C) Curing:
The curing is done for at least 10 hours after demoulding. The curing is done with the
help of plastic membrane which prevents the loss of water. After removal of membrane,
curing compound is applied over it before taking it to site.
 Concreted power duct Plastic curing membrane

D) Transfer of precast structure from precast yard to site:

All the precast power ducts are lifted with sling, loaded on low bed trailer and transferred
to site with utmost handle and care. Four cross hook cavities are provided for it.

Laying out PCC

Placing Power Duct
 E) Process of laying out Power Ducts:
After laying the PCC, the first duct is placed in straight line. Then, second one is placed
adjacent to first pre cast duct. The joint between them is filled with GP2 or non shrinkage
compound.

List of machineries used during precast:

 Gantry Crane Automatic welding machine

Automatic steel bending machine Inner Vibrator

 Tilting Machine Conveyor Batch

EHS Department
Objective
1. The main objective of EHS department is to determine the broad parameters of
EHS management at site.
2. It also aims to establish and define line of command for resolution of all hazard
prevention issues.
3. To define individual responsibilities hazard prevention and safety promotion
responsibility at each level of the construction team.
4. To identify the highly hazardous operations within the scope of the work and
specify integrated preventive measures to mitigate the same.
5. To ensure compliance with relevant applicable legislation.
6. Continual EHS performance improvement by directing focus on the key areas for
improvement in a consistent manner.

GENERAL EHS RULES & REGULATIONS

The following are the general EHS Rules & Regulations to be adopted in the site
for the following areas:
a. Use of Personal protective Equipment and safety devices relevant to site
activities.
b. General housekeeping, stacking of materials.
c. Road safety inside project.
d. Access, Egress & workstation safety.
e. Safe use of construction power supply and upkeep / maintenance of installations.
 f. Use, maintenance & Inspection of Plant & Machinery.
g. Scaffold & Formwork norms.
h. Use of safe material & personnel handling devices as per requirement.
i. Fire prevention, protection & preparedness.
j. Others

Beside all these general rules and regulations, there are various general information
provided to the workmen at the site by giving them PEP talks and training.

PEP Talk: Before starting the operation, description is given to the workmen for the safe work
procedure on particular operations such as welding, concreting, height work, grinding, manual
and mechanical material handling.

Fig: PEP Talk

TRAINING
To achieve the EHS objectives and to meet the Zero Accident Targets, EHS training are regularly
organized for all personnel working on the project. All managerial, supervisory staff and
workmen attend the EHS Training Courses, organized time to time.
Training programs listed below are organized to make the people aware of the hazards & dangers
at work site but not limited to the following.
 Working at Height
- Safe working practices
- Safe access and egress
Demolition
- Safe working procedures
- Control of access / egress
Safe storage of fuels, oils and lubricant.
Prevention of oil spillage. Provision of dip trays below machinery to collect oil and
grease. Disposal of used oil and lubricants.

Fig: Training
Waste Management Collection, storage & disposal
Use of PPEs
Housekeeping, Hygiene and sanitation.
EHS systems of Company as applicable on Project.
Safe Execution Card: Its like checklist of all the concerned parameter regarding safety before
starting the operation and it is to be filled by the respective safety engineer.
Permit System: It is the legal documents required before starting any critical activity (welding,
material handling, and work at height).
FIRST AID & MEDICAL SERVICES
L&T provides and maintain first aid stations complete with all first aid equipment necessary for
the initial care of any of the contractors personnel who is injured and ensures that the first aid
equipment at each first aid station is complete in all respects at all times. At each first aid station
the names of the contractors staff that are trained to render first aid shall be displayed. List of
first aid trained personnel shall be available at sites and is circulated the same among all
concerned for easy identification. Equipped first aid boxes are provided at convenient locations
under the charge of a trained person. First aid case register is maintained at every location in the
site.

Personal Protective Equipment: PPE is equipment that will protect the workmen against
health or safety risks at work. It includes items such as safety helmets, gloves, eye protection,
high-visibility clothing, safety shoes and safety harnesses. It also includes respiratory protective
equipment (RPE). It is important for making the workplace safe and to encourage people to work
safely and responsibly.

Fig: PPE model

Thus, EHS department plays an important role to maintain good environmental controls during
every activity and at all time L&T requires employees, at all levels, to support and strictly
implement the EHS Policy to which end this plan is site-specific guidance to aid in achieving the
set objectives and targets.

Major Bridges
There are total 6 major bridge to be constructed in activation area namely E-2, A-6, E-3, G-4, G-
7, and F-1A. All the bridges are box type which consists of unit of cells. The drain water will be
diverted to the bridge through cut-out provided from where it will be discharged into the sea. The
construction procedure consists of excavation followed by PCC construction. After PCC, raft and
haunch are constructed above it. The wall is constructed in 2 lifts followed by slab. The fly return
wall has been provided at the end of slab. Duraboard is the material used in expansion joint.
Inside the wing wall floor apron has been provided for the easy flow of water.

Drawings of Bridge
 Fig: Plan and section details
Progress pictures of bridges:

Slab Reinforcement for E-2 bridge Cut-out for drain

 Staging for the support Fly return wall of A-6 bridge

PCC for G-4 bridge Slab shuttering for E-2 bridge

Major Plants
General
As the scale of the ongoing work is large, requirements of the materials are also huge. There is
huge requirement of the steel for reinforcement, concrete, shuttering materials, and other
miscellaneous things. These requirements are fulfilled by batching plant, steel yard and doka
yard. This chapter describes the above plants.

Batching Plant
 Fig: Batching Plant
There are two batching plant established; one for Transportation Infrastructure and other for
Water Effluent & Treatment at the site. The batching plant is of Schwing Stetter model CP-30
and CP-60. The maximum output of the CP-30 is 30 cum/hr and CP-60 is 60 cum/hr. There are
three silos out of which one contains GGBS and rest cement. It produces M20 and M40 grade
concrete. The basic ingredients of concrete are cement, water, coarse and fine aggregate,
admixture and GGBS.
Their proportions are calculated as per the mix design and is shown in Table

Table-3.1 Mix Design for M20

M20 Nominal Mix M20 Nominal Mix

With Sanghi With Ambuja
S.No Ingredients
Cement Cement
(Kg) (Kg)
1 Cement(Ultratech OPC 53 Grade) 50 50
2 Water(GWIL, Pipli Reservoir) 25 25
3 CA 20mm(Shreeji Quarry) 100.2 100.2
4 CA10mm (Shreeji Quarry) 66.8 66.8
 5 Fine Aggregate Natural(Bhogava river) 41.5 41.5
6 Fine Aggregate Crushed(Shreeji Quarry) 41.5 41.5

Table-3.2 Mix Design for M20

M40RCC
M40 RCC M40 Pile
S.No Ingredients Precast Qty
Qty (Kg/m3) Qty (Kg/m3)
(Kg/m3)
1 Cement(Ultratech OPC 53Grade) 225 225 225
2 GGBS(JSW) 225 225 225
3 Water(GWIL, Pipli Reservoir) 144 148.5 148.5
4 CA 20mm(Shreeji Quarry) 730 726 726
5 CA10mm (Shreeji Quarry) 483 480 480
6 Fine Aggregate Natural(Bhogava river) 357 355 355
7 Fine Aggregate Crushed(Shreeji Quarry) 348 346 346
8 Admixture (PC 20R- YAHSKA) 4.05 4.05 4.05

Steel Yard
The steel yard has been provided near the batching plant for fulfilling the steel requirement. All
types of steel based on the bar bending schedule are cut here.

Fig: Steel yard

Various operations like cutting, decoiling and bending of steel is done here. The list of
machineries used in the steel yard is given as follow:
1) Cutting Machine: It is mainly used for cutting the cutting the large steel in small pieces
used as extra bar and other bar.
 Cutting machine
2) Decoiling Machine: This machine decoils the large rings of the steel into straight bars of
12 mt. It also maintains the uniformity in the steel bars.

Decoiling machine
3) Bending Machine: This machine is used for bending the steel as per the requirements
and is effective as it reduces the time. There are two such bending machine operating at
the steel yard.
 Fig: Decoiling machine
Dokayard
This section of the project mainly is provided for making the shuttering materials. All the
required shutters, plates, formwork, channel section, fitting materials, ply are made here and
supplied as per the requirement. H beams and staging materials required in the bridge are
supplied from here. It provides a proper arrangement of all the materials and safety also.