~ SCC SAI Consulting Engineers Pvt. Ltd.Independent Engineer Services for 4 Laning of Barhi-Hazaribagh Section

..,. Project Office: C/O Mr. Babban Gupta, Kashturi Niwas, Dewangana Chouk, Korra,..a. Hazaribagh - 825301 JharkhandTelefax: +91-06546-222760, E-mail: ichazaribagh@saiindia.com Web: www.saiindia.com

Ref. SAI/IC- HZB/NHAI/391/2014 Date: 11.06.2014

To,The Project Director,Regional Office/ PIU,National Highways Authority of India,B-402, Road No- 4-C, Ashok NagarRanchi 834 002 (Jharkhand)

Subject: Independent Engineering Services for 4 laning of Barhi -HazaribaghSection of NH-33 (Km 0.000. to 40.500) in the State of Jharkhandunder NHDP Phase-III on BOT (Toll) Basis-Inspection Report forthe Month of May,2014 - Reg.

Dear Sir,

'. -' As per clause 5.3 of TOR to our Consultancy Agreement, we submit herewith the"Inspection Report" for the month of May, 2014.This is for your kind perusal.

Thanking you and assuring you the best services of ours at all times.

Yours Sincerely,

For SAI CONSULTING ENGINEERS PVT. LTD.

(S~SEKAR)TEAM LEADER CUM SR. HIGHWAY ENGINEERINDEPENDENT ENGINEER

,

End: As above

Copy to:l.Mr. Sushant Gupta, Vice President (Projects), for kind information2.Mr. U. S. P. Singh, GM (Project), Abhijeet Hazaribag Toll Road Ltd, for kind information

Regd. Office: Block-A, SAI House, Sat yam Corporate Square, B/h. Rajpath Club, Bodakdev, AHMEDABAD - 380 054 INDIATel: +91-79-66142600, 66142700 Fax: +91-79-66142800 E-mail: mail@saiindia.com Web: www.saiindia.com

--Independent Engineer services for 41aning of Barhi -Hazartbagh section of INSPECTION REPORT

~1ay,2014NH-33 in the State of Jharkhand under NHDP Phase-Ill on DBFOTbasis

inspection Report

Introduction:

During the site Inspection, Team Leader with other key professionals and sub-professionals of Independent

Engineer, inspected the project corridor of NH-33 in which Concessionaire supervision staff. also

participated.

During inspection, site visits & meeting various issues as mentioned below have been discussed and

reviewed.

Overview of status

• Progress of Highway and Structure Works

• Design work

•• Constraint - Land acquisition status and Non availability of balance front, Utility shifting and if

any others

• Methodology

Materials

• Mobilization of plant, Machinery and resources

•• Quality Assurance

• Maintenance of ECW/Existing Structure

Lapses / defects or deficiencies

Safety Review has been made of background documents provided by concessionaires,

••

-c,

••••

Monthly Report

Various important correspondences issued by NHAI, the concessionaire and consultant

Plann ing .1

Quality Assurance Manual

Work methodology

Mix design/Job mix formula for DBM-Grading-II

Various Grades of Concrete mix design.

NHAI Page 1 of 8 SAt Consulting Engineers Pvt. Ltd.

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Independent Engineer services for 11 laning of Barhi -Hazaribagh section of

NH-33 in the State of Jharkhand under NHDP Phase-III on DIlFOT basis

INSPECTION REPORT

May, 2014

Details of Point Discussed and Review..._----_._._ ...._.__ ..._ ...__ ._-_.__ ._--_ .._._---- ··_·,_·__··_----·--1

i-~-C'-;::~;;;~~~;;I

o, 1_

~ ~ IIIf--------~---- L--- _

As on Date Construction time passed I 839 days--.-.-..--.-..-..--..-....-..---.------.----1-----------.-~

Remarks of Independent Engineer

Remaining Construction Time Nil,,Likely date of completion as per

Concessionaire Construction

Program

1ih Feb 2014

1 Overview ofStatus

Milestone from Date of Appointment

Milestone: 1 (202m! days)

.31.08.2012

Milestone: 2 (410(11 days)26.03.2013

Milestone: 3 (618!h days)

21.10.2013I ;

I ~'-~2 Progress Project Progress:

1st Milestoneachieved on31.08.2012.

Financial Progress 46.97 % NA

> Note: ..;Spending on base camp operation and Design & Drawing are on hiqhsr side

without any substantiation.

}> Since the concessoanire has not submitted any Work Plan I Construction Program

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Independent Engineer services for 4 laning of Barhi -Hazarlbagh section of

. NH-33 in the State of Jharkhand under NHDP phase-ilion DBFOTbasis

INSPECTIONREPORT

May, 20141Q'WiP'-;;;;-1_···.2:_· - ...--- ...-._-.- .. - ....- ...-_ ...I . Proqrass of Road work:

iI

Remarks of Independent Engineer

2 i Embankment/ 41.314I Excavation •

-3----r-SU b~~~de __--l-4-1-.3-1-4-+-2-0-.-1---Li8~65% - 2o-:2o-----r48-:-89~4 GSB 41.314 17.50

1 41.314

5 WMM 40.614 15.20..__ ._----

6 Prime Coat 40.614 11.60---- ..--------------- ---------- --7 DBM Top layer 40.614 11.60

Completed

8 BC 40.614

20.30 49.14%20.30 49.14%

1----,42.36% 20.10 48.65%37.43%

28.56%'--------28.56%

15.810 38.93%

1~.7~ __ J~.40%10.72 26.40%

I- .. - -----·----1....-.-"--.-.-.-..-..---rOJJ8S--" 0.21% provisional I

i approval INo--1PQC 0.7009

Progress of Structure:fi

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i

I2 No. 1 No/Nil.I

1 No. Nil/2 Nos. I

I! •

1 No. 1 f\ios./Nil

LHS 3 Nos.MajorBridges

13 Nos.RHS

J

3Nos.

1 No.

LHS 2 Nos.~--l-------I-------+-------f-'--------:

RHS I 2 Nos. 1 No. Nil I 1 No./1 No.I

I----+-S-Ia-b-a-n-d- --I-l:Hsi--6-0-N-O-S-. - +--45-N-o-s.--+--4-2-NOS. ! 3 Nos./16 Nos.

3 Box I i 1-·------·Culverts r-;IISi 60 Nos. 37 NOS." 34 Nos. I 3 Nos./23 Nos.i - I

I-------il

, LHSPipe

4 I Culverts

2MinorBridges

9 Nos.

2 Nos.9 Nos.RHS

NHAI Page30f8

2 Nos.

9 Nos. 9 Nos.

1 No /7 Nos.'

Nil/Nil

I 1 Nos.

r------------ ------------ ..-....---.-.-..--.--...-.-....- ._----_ ....- ...- --

I' Sl. DescriptionNo.

I ),

I3~ " Design

\I

I Commented and r!01 I. GFCissuedI Compliance Awaited

--j The concessionaire )lad been MOEF ApprovalI commented to revise vertical ReceivedonI profile as per Wild' Life Area 18.12.13 and, .

and. NHAI has01

I requirements

I observation of the Safety informed theI Consultant. Compliance of Concessionaire ~I the concessionaire in this on 19.12.13

regard is awaited I'

I Commented andGFCissued01 I Compliance Awaited

Commented and compliance GFCDrawings01

received Issued

Reviewed and found in order·01 Reviewed by I.E

and it is in use

Independent Engineer services for 41aning of Barhi -Hazaribagh section of INSPECTION REPORT

NH-33 in the State of Jharkhand under NHDP Phase-ilion DBFOT basis May, 2014

Remarks of Independent Engineer

- i

IIssued i

Minor Bridge 02 02 ~:~m~~t:: I GFC draWings'l

f-3-+-

1

-=B-ox--=-i -=S""'Ia""C"b-=C=-u""'!v-e-:rU""H":":P::"".-i------+----+---- ---+·-GF~~~:~ingsjI

69 69 Commented ,., !culvert Issued

2

02Major Bridges Commented03

CommentedGFC drawings

Issued-------.~----------.

1

01a). From km % to 15/0

b). From krn 15/0 to 24/0 01

f 0'1c). From krn 24/0 to 30/0I

d). From km 30/0 to 41/0 01

Pavement Design for New2 01

Carriageway

I• Pavement design submitted after fresh traffic survey by HAKS has been reviewed, and found I

satisfactory for implementation in work. I

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Independent Engineer services for 4 laning of Barhi -Hazaribagh section of INSPECTION REPORT

NH-33 in the State of Jharkhand under NHDP Phase-Ill on DBFOT basis May,2014

~~-"esoripUo~ __ R~mar~s of Independent Engin__oo_,r _

4, ~ethodology 11. The concessionaire has been requested to submit the work rnetbodcloqy to I.E for

! review/approval well in advance.

12. The Concessionaire followed the system of collecting Earth from designated borrow areas,! 'I spreading, grading, mixing water and leveling. The vibratory roller I compactor is deployed for

II 3. The concessionaire has not yet submitted the work methodology for laying Mastic asphalt on

I the deck slab of Bridges, Plant trial and Field tria! patch laying for f3C work.has not been'

I

compaction of Embankment and Sub grade layers,

carried out by the Concessionaire till date for getting Final Approval of BC work as per

MoRTH specification Clause No. 509,3.4 & 509.3,5.

4. Tile concessionaire has been instructed to followthe RFI system and now there is 'no site

activity & hence no RFl's are being received,

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Materials: 11.

II·

All construction materials used in construction are procured from the approved sources

which are tested by the concessionaire in-house Field QC-Iaboratory and Third party

independent laboratory. IE has reviewed the test results of materials proposed for use in

permanent work before deployment.

Test results of Borrow Areas have been reviewed and approved by I.E. There was no earth,work carried out at Bypass locations in the month of April,2014.

Tests on materials from Quarries for procurement of aggregates for wet Mix Macadam,

Bituminous work and Concrete have been reviewed. The materials are conforming to the

requirements of specifications and standards.

Crushed stone aggregates are being used for GSB and WMM materials..'

WMf\(l aggregates are procured from Adrar quarry,

Aggregates for Bituminous Work are procured from Adrar quarry.

Aggregates for Concrete work are procured from Adrar Quarry.

The material from Quarries is meeting the requirements of specifications.

.RCC Np4 class 1200 mm dia Hurne pipe source-was reviewed/approved by IE

Procurement of materials: Bitumen-VG-30, Steel & Cement have been done but exact

quanlities of materials procured are not yet provided to I.E for our review, inspection and

monitoring third party testing of materials and it is not reported in their MPRs aslo.

Submitted Q'AP/QA manual was reviewed and approved by IE.

3.

4,

5.

6.

7,

8,

9.

10.

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Pvt. ltd.NHAI Page 5 of 8

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Independent Engineer services for 4 laning of Bar hi -Hazaribagh section of

NH-33 in the State of Jharkhand under NHDP Phase-ilion DBFOT basis

INSPECTION REPORT

May, 2014

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SI. Description I Remarks of Independent Engineer INo. ..__ ..._...__._.._-1- ... _ ..... _ ..... _ ... __ ._ ..... _ .. -:----:-~-:-----;--"7."--:--;----;--;-;-~,---;---:-:--:-::::::::::---;-;

I 12. The concessionaire has been directed and advised to submit MTC (~A~lnufacturer Test II Certificates) for steel-TMT bars, Cement, and Bitumen regularfy to I.E. '

. .~. , i 13. Source of Water used has already been tested, reviewed and approved by IE.

11::. ~~--30 Bitumen is being used for Asphalt/bituminous work and it is procured from I! ~L.Haldia refinery-·-~--I-:~~~~~~onI Main OffiC:~-::::~ibagh town ..-.- ..- ....-....-..-.-.- .....-.-..-- ....-...-.. --.----.

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I Base Camp- @ Kill 16+000 RHS (ltakhori) where HM Plant, Crushinq.Plant, WfvlM Plant, !I Concrete Batching plant and Field Laboratory has been set up. No activity there & kept locked. IMobilized Equipments and laboratory equipments are enclosed as Annexure - I I

Quality Laboratory tests were not c::~cte~ and witnessed in the field Q.C labora-tory during the -.Assurance of MaY,2014 for checking/verification of stock of materials being used in the works.

I

1. Test on Compressive strength of the Cubes of various grades of concrete for structures and Itest for coarse & fine aggregate/Sand for concrete work were not done in the Lab. I

2. All the plants such as HMP-hot mix plant, Wet mix plant and concrete Batching plant were Ifound not calibrated when inspected at Camp site. I

I

IiI !,r-- ------.----- .--------.-.----------- ..---...-....-.-..; 8 Lapses! IE Key Personnel and Sub Professionals are checking regularly wherr work is in progress the

II defects or quality control tests at Lab/Field density tests for earthwork, sub-grade. (;S8, WMM works anddeficiencies

I also for various concreting work in Structures.

II

The concessionaire has been instructed to submit the following report jointly which is still pending i

1. Neither Cross Sections of road nor OGL records furnished to I.E to check/verify the Toe I. ~.I I "-

Iline marking of road construction or cross section executed. . ,

2. Checkin~~~~BM;S not done jointly fo~.~ast~~~ months. J_ .._.__._--+------- !

9 MaintenanceECW

• Some maintenance work was done on existing carriaqeway during the first week ofOctober 2013. Potholesl Patches damaged were still there on existing road. Hence,NHA/ has taken up maintenance' by MIs Narayan Constraction, other agency from2nd week of November 2013 and SDBC laid from km 0+000 to krn 3+140. They haveresumed maintenance activity 'from ApJil,2014 onwards by doing pothole filling,laying of BM & SDBC layers in the Project Highway upto krn 30+850 (Branchinqpoint of Bypass).I

! The overall sarety. aspectSlmeasums durinc construction at the site-,,,ere inspected/ reviewed. JILJ ..__s_a_fe_t_Y__ , ,~he concessl~~~~~re has prov~ded diverSion~~vherever requlre~_~~~~work zone sa!ety aspect as

NHAI Page 6of8 SAICon(0/ t,

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Independent Engineer services for 4 lanlng of Barhl -Hazaribagh section of INSPECTION REPORT

NH-33 in the State of Jharkhand under NHDP Phase-In on DBFOT basis May, 2014

DeSCrjPti~~ Remarks of Independent Engineer i

I per provisions of Concession Agreement are lagging and the Concessionaire were reminded I

Iregularly to improve safety measures at work site, iThe Concessionaire was requested to ensure safety measures by keeping a separate safety I

I team headed by a qualified Safety officer with separate vehicle for monitoring day to day safety II arrangement all along the project corridor by providing highway traffic management system, II Concessionaire was also advised to ensure the safety of workers by providing PPE (personal II protective equipments) ,to the workers/labor during execution of work.As there is no site work by II

I the concessionaire, there is no activity on Safety side also,I! , ,II Work zone safety observations Audit report noA & 5 and accident analysis report of HAKS II ; 1

Safety consultants as well as road Safety expert of IE are forvvarded to the Concessionaire from j

time to time for compliance/action taken report. But no significant improvement on safety iaspects/ safety measures has been noticed till date at work site. I

st.No.

1, Embankrnent slope is very steep. and not conforming to the standards at most of the Iplaces and corrections attempted in previous months at Ch39+ 700 to Ch,39+940 B/S. j

Ch35+400 to Ch35+650 Bls, ,

2. Water logging/stagnation is observed over DBM surtace ibetwedn Ch,35+800 to f. I

Ch,35+900, proper drainage arrangements are yet to be made fo'r permanent relief. But I, I

temporary arrangements are made to drain water on bituminous surface, I.3.. GSB,~II/MM toptayer are being uncovered at few locations with growth of grass. in 1

km15+000 to ,16+000. Before laying/dumping next layer corrective actions such as Icleaning the surface free of vegetation, spraying with water/ rolling compaction should be Idone to restore the quality of these layers Intact. I

4, The concessionaire has been advised to submit MPR every 3'd day of the month but .

MPR is pending from July 2013 onwards till date. The concessionaire has been advised', I

to submit an RFI summary along with the copies of RFL The above system IS to resume II

when work is started. II

J 5. The layer chart for high Embankment construction more than 3/6 meter height at bypass

location not yet prepared/submitted to I.E. i_~__' _, __, 6. The foundation work of toll plaza for Admin Block has been car~ied out and the layout I

11 SiteInspection,

Report

NHAI

, ISite visiUinspection report by TL when visited on 2nd

, s'", s'", tt~,15t\ 23rd & zs", zs'" & so" i

, ,April,' 2014 along with IC staff members, The fonowing observations/deficiencies are noted for!

compliance, The rain cuts in earthen shoulders of the project highway throughout its length are Ii

yet to be attended to prevent its extension to BT surface. '

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Independent Engineer services for 4 -Ianing of Barhi -Hazaribagh section of INSPECTION REPORT

NH-33 in the State of Jharkhand under N}-lDP Phase-III on DBFOT basis May, 2014

Sl.No. Description Remerks of Independent Engineer

II

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plan tor the same has been approved. Further the corroded steel bars have been given

a cement slurry wash after removing the scales of corrosion. As there is no activity

vegetation has grown up in foundation pits.

7_ At the Barhi side approach of Shiwaney Bridge at Ch-28+920 to 950 and 28+850 RHScracks and depressions are noted on the bituminous surface and to be rectified.

8. Traffic on newly constructed Major Bridge across river Shivani (RHS) was opened totraffic in the last week of August 2012. Still Mastic asphalt laying as part of wearingsurface is not yet done over Shivani Bridge deck slab. The methodology and Mixdesign/Job mix formula of Mastic Asphalt as per CI No 515.3.3 section 515 of MoRTHspecifications for laying mastic asphalt is not yet done submitted to I.E for our review/comments. Embankment protection works not yet started to prevent rain cuts & soilerosion further and yet to be completed by the concessionaire.

9. Concrete KERB casting has not been done during the month of May,2014. I

10. The Daily Progress Report is not yet submitted to I.E by the concessionaire. I11. The scrap/scarified materials from ECW or any debris should be disposed of in a Isuitable iocation by the .Concessionaire as per provisions of EMP (Environmental Imanagement plan) requirements at Km 6+740 t07+000, Km.11+000to 12+000. The removal

is yet to be done.

12_ As per the comments from IE and as per CI 2.7.2 of IRC SP: 84-2009, extra widening

should be provided for a curve with radius lip to 300 meters. It was observed that no extra

widening has been provided throughout the project road and it is to be implemented Iimmediately..' I13_ HAKS-/1as submitted Work zone Safety Audit report No.4&5 t1tJtthe Concessionaire has inot yet complied and the observations on safety aspects.' I14.There is no construction activity since 1s1 of June 2013. .. I15. Some patch work done in the first week of October 2013 for 3 days no further maintenancel ~activity is,witnessed since yth of October 2013 till end of October 2013.Hence, NHAI has taken'

up maintenance through M/s Narayan Constraction, other agency from 2nd week of NovemberJ -

2013 and SDBC laid from km 0+000 to km 3+140. They have resumed maintenance activity

from April,2014 onwards by doing pothole filling, laying of BM & SDBC layers in the Project

Highway upto km 30+850 (Branching point of Bypass).

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. -Independent Engineer services for 'llaning of Barhi -Hazarlbagh section ofNH-33 in the State of Jharkhand under NHDP Phase-ilion DBFOT basis

Inspection ReportMay, 2014

Annexure-I

PLANT, MACHINERY & LABORATORY EQUIPMENT LlS'[

J .' A. Plant & Machinery

Sn. Descriptions Unit Quantity Rcmnrks

I 200 TPH Crusher Plant No. 1

2 30 CUM Baiching Plant No. J J

3 200 TPH WMM Plant No, 1

4 lOOML Cap. Weigh Bridge No. 1

5 160 TPH Hot-Mix Plant No. I

6 Concrete Transit Mixer No. i ,, J

7 Apollo WMM Paver No. 1

8 Vogele DBM Paver No. 1

9 1010KVADG No. 1

10 5001<VA DG No. ];

11 160KVA DeJ No. 1.,._ ..-

12 125.KVA DO No. 1.--.- ..-~.13 50 KVA DeJ No. 1 I14 Vibrating Roller No. 2

15 Water tankers No: 2 ;

16 Bitumen Sprayer No. I

B. Deployment of Resources for Bridges & CDworks,

Shuttering Plates & shuttering materials for bridges - 3 Sets each for major bridge, 2 sets each forminor bridges .

. Shuttering Plates & shuttering materials for Box Culverts -18 Sets.

• list of QC Laboratory Eguipnients

Sr.Description Of Items I Nos. Remarks

No.

1 Compressive Testing Machine-2000KN Capacity 1

2 CBRTesting Machine 1--3 Modified Marshal! Testing Machine e 1

4 Marshall Mould Casting Apparatus 2

5 Impact Testing Machine 1

6 Abrasion Testing Machine 1 J

7 Cement mortar Cube Casting Machine 1I---

Bitumen Extractor-manualiy hand operated 289 Ductility Testing Machine 1

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Independent Engineer services for 4 lanlng of Barhi -Hazaribagh section ofNfI·33 in the State of Jharkhand under NHDP Phase-H] on DBFOT basis

Inspection ReportMay, 2014

. --Sr.

Description Of Items Nos. RemarksNo.

10 Hot Water Bath -20 liters 1

11 Flash & Fire point Equipments 1

12 Viscosity Testing Machine 1

13 Penetration Testing Machine 1.__ .-.'

14 Softening Point Testing Machine with all Accessories 2, ..--

15 Digital Thermometer 2~.-.16 Mercury Thermometer 517 Electronic Balance -200 Kg (Platform Type) 1---..18 Electron ie Balance ·35 Kg " 1- --- .19 Electronic Balance -10 Kg 1

20, Electronic Balance -2.30gm 1 J

-21 C.B.R MOU LDs with al! Accessories including Tripod Stand 2722 Dial Gauges 10 ,.-.23 Proving Rings 50 Ton Capacity 224 Cube Molds (150x150) 54·25 Cement mortar Cube Moulds (70.6x70.6j 12.

I26 Slump Cones 3 !---~27 HAMMEll (Wooden & iron) 5 i.- !28 Aluminum Trey (Big & Small) 19 -J29 Iron Trey 1 I'--- ---~-. I30 Stop Watch 2 I31 Vernier Scale 1 i32 Pycnometer Bottle 2 !33 Net Basket 3 i34- Sand Pouring Cylinder (100 mm & 150 mrn) I 100·2,150·3=535 Hapid Moisture Meter 5 ~---36 Modified Proctor mould Apparatus with all Accessories (1000

1000-2,2250-2=4 • !cc & 2250 ec) I

37, Atterberg Limit apparatus 1 I38 Cone Penetrometer 1 i

39 Flakiness& Elongation testing 2

40 Bulk Density Basket 3

41 I Vicat Apparatus 1 ..-.._--42 Concrete Lab.Mixture Machine '> 1

43 Specif'ic Gravity testing Bottle r2

44 Cement Soundness Testing 5

45 Mechanical Pan Balance 546 Hot Air Oven (Thermostatically Controlled) 1

,47 Core Cutting Machine 1

48 Hot Plate 1

49 Aluminum Containers 50

50 Rain Gauge 2i

I

51 PVCCylinder (lOOOml & 500 ml) 8 i52 Glass Cylinder (lOGOml , SCOrn!& 100ml) 4+8+10=22

53 Pipet rvc 2

I54 Borosil-SOOml 6

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·Independent Engineer services for 4laning of Barhl -Hazuribagh section ofNH-33 in the State of Jharkhand underNHDP Phase-Ill on DBFOTpas is

Inspection Report

May, 2014

-- -Sr.

Description Of Items Nos. RemarksNo.

55 Marshall Moulds 13..H._.

56 Sieves -450 mrn Dia 2457 Sieves- 300 mm Die 2058 Sieves Brass -200 rnrn Dia 21.._ ..59 Hygrometer 1

60 Wail elate Thermometer 1

61 Sodium Hexametaphosphate as Pack.----....-...~....•~-.----.. ._._-_.

62 Needle Vibrator 1 ,-_ ..__._---_.

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NHAISAI Consulting Engineers Pvi. LId.