PMC Aimond September MPR Final

Gwalior Shivpuri Toll Road Project
Gwalior-Shivpuri 4-Laning Project for NH-3 of the

National Highways Authority of India under NHDP
Phase-IV
Monthly Progress Report
September2014
Submitted By
Essel Gwalior Shivpuri Toll Roads Pvt Ltd

SEPTEMBER 2014 IPAGE 1 OF 51
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Scope and objective of the Report

This report is being prepared as part of the monthly submissions by the Concessionaire,
Essel Gwalior Shivpuri Toll Roads Pvt Limited, for the execution of the Gwalior-Shivpuri
4-Laning Project for NH-3 of the National Highway Authority of India (NHAI) under NHDP
Phase-IV.
This report is prepared in order to brief the progress about the key developments of the
project during the month of September 2014 and to highlight key issues concerning the
project.
Information being provided in this report supplements the daily, weekly, and other routine
exchanges and correspondence between the Concessionaire and the NHAI.
For the purpose of improved project monitoring, the project has been divided into the
following three sections:
Section-I
from Km. 0+000 to Km. 40+000 (40 km)

(Gwalior to Charairehant)
Section-II
From Km. 40+000 to Km. 80+000 (40 km)

Charairehant to Karaiahamedpur)
Section-III
From Km. 80+000 to Km. 125+300 (45.3 km)

(Karaiahamedpur to Shivpuri)
Period Covered in this Report
September 2014
Monthly Progress Report Number
Nine

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Figure 1: Project Alignment Map

51
Table of Content

51
Table of Content
Table of Content ................................................................................................................ 5

List of Tables...................................................................................................................... 6
List of Figures .................................................................................................................... 6
Executive Summary .......................................................................................................... 7
1. Background and Project Details ............................................................................. 10
1.1. Project Overview ................................................................................................. 10
1.2. Project Contract Details ...................................................................................... 12
1.3. General Contract Details ..................................................................................... 13
1.4. Salient Project Features ...................................................................................... 13
1.5. Contractual Project Milestones .......................................................................... 14
2. Right of WayStatus................................................................................................... 16
2.1. Land Acquisition ................................................................................................. 16
2.2. Shifting of Utilities and Electrical HT/LT Lines ................................................ 17
2.3. R&R Activities ...................................................................................................... 18
2.4. Tree Cutting ......................................................................................................... 18
3. Progress Briefing Contractor Activities .............................................................. 20
3.1. Pre-Construction Activities ................................................................................ 20
3.2. Construction Activities ....................................................................................... 23
3.2.1. SECTION I: Chainage0 to 40 km .................................................................... 23
3.2.2. SECTION II:Chainage40 to 80 km ................................................................. 23
3.2.3. SECTION III:Chainage 80 to 125.3 km .......................................................... 23
4. Physical Progress of Work ...................................................................................... 25
4.1. Physical Progress of Work.................................................................................. 25
4.1.1. Highway (LHS) .................................................................................................. 25
4.1.2. Highway (RHS) ................................................................................................. 26
4.1.3. Maintenance of Existing Carriageway ............................................................ 26
5. FinancialProgress of Work ...................................................................................... 28
6. Construction Programme ........................................................................................ 31
7. Quality Control and Quality Assurance .................................................................. 33
7.1. Material ................................................................................................................ 33
7.2. Source Approval of Materials ............................................................................. 34
7.2.1. Cement............................................................................................................... 34
7.2.2. Admixtures ........................................................................................................ 35
7.2.3. Steel ................................................................................................................... 35
7.2.4. Bitumen ............................................................................................................. 35
8. Environment and Safety .......................................................................................... 37
9. Actions required from NHAI ................................................................................... 39
10
Appendices .......................................................................................................... 40
Appendix A: Organization Chart .................................................................................... 41
Appendix B: List of Plants, Machinery and Equipments .............................................. 42
Appendix C: Chainage-wise progress ............................................................................ 43
Appendix D: Project Cash Flow Statement (Planned) .................................................. 44
Appendix E: Project Progress Photographs ................................................................. 45

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List of Tables
Table 2.1-1: Status of Land Acquisition ..................................................................................... 16
Table 2.2-1: Status of Utility Relocation .................................................................................... 17
Table 2.3-1: Status of R&R Activities ......................................................................................... 18
Table 2.4-1: Status of Tree Cutting ............................................................................................. 18
Table 3.1-1: Status of Design and Drawings-Highway ............................................................. 21
Table 3.1-2: Status of Design and Drawings Structures ......................................................... 21
Table 4.1.1-1: Progress of Highway Construction (LHS) .......................................................... 25
Table 4.1.2-1: Progress of Highway Construction (RHS) ......................................................... 26
Table 4.1.3-1: Status of Maintenance of Existing Carriageway ................................................ 26
Table 6-1: Program for the Total Project Scope (Highways) ................................................... 31
Table 6-2: Program for the Major Project Components (Structures) ..................................... 31
Table 7.1-1: Status of Construction Material ............................................................................. 33
Table 7.2-1: Source of Procuring Material ................................................................................. 34
List of Figures
Figure 1: Project Alignment Map
Figure 2: Typical Highway Cross Section
Figure 3: Financial Progress - Planned vs Achieved
3
11
29

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Executive Summary
Following summarises the project overview and key highlights of the project up to and
including the month of September 2014.
1. Total project site area is 745 Ha. Out of this the Concessionaire has been handed over
approximately629 Ha till the end of August2014, or approximately 84 % of the site. No
additional areas have been handed over during the current month.
2. A total of 116 Ha or 16 % is not handed over. Out of the area not given possession,
approximately 80 Ha is awaiting clearance and approval from the forest authorities,
and 16 Ha from the wildlife authorities, respectively. In addition, an area of 20 Ha
comprising public and private land is also not yet handed over to the concessionaire
pending its acquisition by the NHAI. As a consequence, a total project length of about 40
kmsdoes not have vacant access to 100% Right of Way.
3. The Contractor, M/sPan India Infrastructure Pvt Ltd (PIIPL) has mobilised on the site
for execution of Highways and structures. Execution of Works is mainly progressing in
the following locations:
a. Chainage 0 to 25 km, 40 to 70 km and 100 to 120 km: Clearing & Grubbing
activities have been completed for a road length of about 95.10km. and this
includes both the Left and Right hand sides of the carriageway
b. Excavations completed for major bridge foundations at Chainage Km 61, Km
57& km 53,for 5 nos box culverts. Excavation has also been done for one Hume
Pipe Culvert (HPC), for which the bedding &pipe-laying has also been
completed .A total of 225 nos electrical poles have been procured and shifting of
75 nos has been completed.
4. Following major equipment and relevant manpower have mobilised on the site:
a. One (1) no. each of RMC, Hot-mix, WMM and Stone Crusher Plants have been set
up and commissioned at both the Mohana and Kheria camps.
b. Major camps have been set up at Mohana and Kheria for the staff, engineers and
labourers working on the project. Concessionaires organisation chart is
attached at Appendix A.
5. Financial progress of the works is Rs 518.07crores in terms of expenditure incurred
towards the project, which amounts to over 32.34% of the total estimated project cost
of Rs 1,601.77 crores.
During the month, bills for approx.Rs 53 lakhs have been raised to NHAI for the
maintenance works carried out on the project, as required by NHAI and directed
through IE.
6. To achieve the scheduled 4-laning date of 11th November 2015 in accordance with the
Concession Agreement, target dates have been worked out for completing the highway
works and all related structures mid-August 2015. Based on these target dates, a barchart has been prepared which indicates the schedule for completion of the various

51
structures and road sections. Monitoring of the project activities will henceforth be
done based on this bar chart program.
7. The targeted completion dates for the various broad elements of the project as per this
bar-chart program are :
Major Bridges
: June30, 2015.
Road Over Bridges
: August 15, 2015
Minor Bridges
: May 30, 2015
Pipe & Box Culverts
: July 22, 2015
Vehicular Under Pass
: End November 2014
Pedestrian Under Pass
: May 23, 2015
Toll Plazas & Misc.
:End May 2015
All Highway construction work has also been targeted for completion by mid-August
2015.
Whereas all effort will be made to achieve these target dates, they are subject to
reasonable modifications considering ground conditions & any unforeseen
contingencies.

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Background and Project

Details

51
1.
1.1.
Background and Project Details
Project Overview
National Highways Authority of India has taken up four laning of NH-3 under NHDP
Phase IV to be constructed between Gwalior to Shivpuri for a design length of
125+300 Kms. The project road stretch is a part of Agra-Gwalior-Shivpuri-IndoreMumbai Road.
The Concession has been awarded to M/s Essel Gwalior-Shivpuri Toll Roads Pvt
Limited for a concession period of 29 years. The Concessionaire has achieved
financial closure on December 13, 2012 and having complied with all the conditions
precedent as stipulated in the Concession Agreement. The Authority has declared
the appointed date as May 16, 2013. Accordingly, the project construction
completion date is scheduled as November11, 2015.
The Gwalior to Shivpuri 4-Laning Project consists of construction of four lane road
between Gwalior and Shivpuri on NH-3 from Km.15+600 (NH-75) to km.236+000
(NH-3). Major towns and developed areas along the route are Ghatigaon, Mohana
and Karaiahamedpur. Land use along the road is of a mixed nature, with presence of
agricultural, forest, vacant & interspersed built up land areas.
The proposed development includes construction of 5.65 km of re-alignment, which
will be new construction in the ghat section, 36.9 km long by-passes& 82.75km
length of road along the existing alignment, which requires widening and
strengthening as well as new carriageway construction. The road alignment
generally encounters plain & rolling terrain & also passes through Forest areas, and
also areas of Son Bird Sanctuary & Madhav National Park.
As of date approximately 84 % of the ROW required for development has been
handed over to the Concessionaire. As a first priority, works have been taken up for
the highways near the Gwalior, Mohana and Shivpuri bypasses, for major bridges at
Km 57 & Km 61 and for 5 box culverts. Clearing and Grubbing activities have
advanced on both the LHS and RHS.
Project offices and laboratories for quality control of the works have been set up
and Plants for the production of aggregates, concrete, hot mix, have been
commissioned. The detailed survey for road and structures has been completed and
the EPC contractor has mobilised at site.
The cross section of the road along the route is designed to generally consist of
bituminous concrete placed on top of layers of bituminous macadam, GSB, WMM,
Sub-base and subgrade layers. A typical cross-section is shown below:

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Figure 2: Typical Highway Cross Section
Major structures along the project alignment include 4 Major Bridges, 49 Minor
Bridges, 71 nos. Box-Culverts, 3 Road Over Bridges (ROBs), 9 nos. Pedestrian
Under Passes (PUPs) and one Vehicular Under Pass (VUP). Seventy five (75) Pipe
Culverts will be placed at appropriate locations for drainage purposes. Also
included in the project are the constructions of service roads near urban areas,
Truck lay byes, Bus bays and Toll Plazas.

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1.2.
Project Contract Details

The following tables summarize the technical and contractual details of the project
and the contact details of key stakeholders and their personnel:
Name of Work
Four Laning of Gwalior-Shivpuri from Km

15+600 (NH-75) to km 236+000
(NH-3) in the state of MP, on DBFOT basis
under NHDP Phase IV
Name of Employer
National Highways Authority of India (NHAI)

Narender Nagar, Chhatri Road
Shivpuri (M.P.)- 473551
Name of Concessionaire
Essel Gwalior Shivpuri Toll Roads Pvt Ltd.

Kohinoor City 513, A-Wing,
Off. LBS Road, Kurla (W),
Mumbai 400070
Tel: +91-22-66012323
Fax: +91-22-66012300
Contact Person: Mr.Kaushik Pal, COO
Independent Engineer
M/s CDM Smith Inc

C/o Aditya Kumar Parasar, Patel Nagar,
Near MoniSagar Gate No 4, TV Tower Road
Shivpuri, M.P. - 473551
Team Leader Mr Ashok Goyal
(Tel 0 91652 76115)
EPC Contractor
Pan India Infrastructure Pvt. Ltd

Kohinoor City 513, A-Wing,
Off. LBS Road, Kurla (W),
Mumbai 400070
Tel: +91-22-66012323
Fax: +91-22-66012300
Design Consultant
Contact Person: Mr.Jayant Torvi, VP (Roads)
: National
I.D.C. Projects. & Asia Infrastructure Advisory

Services
: M/S CDM

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1.3.
General Contract Details

Some salient features of the Construction Contract are noted below:
1.4.
Length of Road (Design

Length)
125.300 Km.
Total Capital Cost
Rs. 1,601.77 Crores
Total Project Cost
Rs. 1,055 Crores (as per concession agreement)
Date of Concession
Agreement
September 9. 2012
Concession Period
29 Years
Appointed Date
May 16, 2013
Construction Period
910 days from Appointed date
Completion Date
November 11, 2015
Amount of liquidated
damages as per CA
0.1% of the amount of Performance Security

For delay of each day until such Milestone is
achieved.
Salient Project Features

Besides the construction of new carriageways and widening and strengthening of
existing carriageways, the following table summarises the major elements of the
project construction:
Major Bridge
4 Nos
Minor Bridge
49 Nos.
ROB
3 Nos.
Cattle/Pedestrian Underpass
9 Nos.
Vehicular Underpass
1 No.
No. of Box Culverts
71 Nos.
No. of Pipe Culverts
75 Nos.
Truck lay byes
2 Nos.
Major Intersections
6 Nos.
Minor Intersections
30 Nos.
Bus Bays
13 Nos.
Toll Plaza
2 Nos.
4 - Lane Divided Carriage Way
2 x 7.60m
1.5 m Width Paved Shoulder
2 x 1.50 m

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2.00 m Width Earthen/Granular Shoulder
2 x (1.00 to 2.00) m Central Median
Urban/ Built up /Rural Section
12.0m & 4.5m & 2.50m
Built up Section
7.0 m
Approaches of VUP/ Flyover
7.0 m
Footpath / Sidewalk / Built
1.5 m
Service Road
up Section
1.5.
Contractual Project Milestones
Following is a listing of the Key Project Milestones:

Mile
Stone
Description
Target Date &

Amount
Mile
Stone -I
Commencement of Highway Construction and

not less than 10 % expenditure of the Total
November 11,
2013 &
th
Mile
Stone -II
Capital Cost on 180 day from the Appointed

Date
160.00 Cr.
Commencement of all Bridges Construction and

not less than 30 % of the Total Capital Cost on
May 15,2014
& 481.00 Cr
th
365 day from the Appointed Date

Mile
Stone -III
Commencement of all Project Facilities and
May 15,2015
not less than 70% expenditure of the Total
& 1121.00 Cr.
th
Capital Cost on 730 day from the Appointed

Date
Scheduled
4 Laning
date
Scheduled four laning date shall occur on 910

day from the Appointed Date
th
November 11,
2015
& 1601.77 Cr.

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Right of Way Status

51
2. Right of WayStatus
2.1.
Land Acquisition
As per the Concession Agreement, the project requires a Right of Way (ROW) of
60.0 metres. Accordingly, the Status of Land availability as on April 30, 2014 is
summarised in the table below. The current status tabulated below shows, that out
of a total of 745 Ha, the land available for work is over 629 Ha (Approx. 84%).
The balance land area not currently available for the project comprises about 80 Ha
of Forest and 16 Ha of wildlife authority land. However out of 80Ha forest land,
NHAI has obtained stage approval for 64.25 Ha. This is an in principle approval
where by the forest authorities have prima facie reviewed & accepted the proposal.
Another 20 Ha of revenue and private land is in the process of acquisition, wherein
the declaration of acquisition by NHAI as per section 3-D of the NHAI Act, is yet to
be made.
Table 2.1-1: Status of Land Acquisition
Description
Sr.
No.
Land
Acquisition
Area in Ha.
Remarks
Land
available for
work in Ha.
Land Not
Cleared/
Encumbra
nce in Ha.
7.765
3D under
process
80.289
Stage-I
approval
acquired(
64.259)
12.371
3D under
process
Private Land Vested

with Central Govt. as per
3a Notifications
263.776
256.011
Clear land of Existing

Road Carriageway
available
238.06
238.060
Reserve /Protected
forest formal approval
from MOEF
80.289
Reserve/ Protected
forest (Not Requiring
Diversion of Land
Govt. land to be
transferred
147.379
Wild life land
15.540
Total
745.044
629.079
115.965
100%
84.43%
15.56%
135.008
15.540

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2.2.
Shifting of Utilities and Electrical HT/LT Lines

To proceed with the project construction, several utilities are required to be shifted
under the supervision of the respective authorities. These include a water supply
line, hand pumps, besides Electrical lines, , as shown in the table below.
Table 2.2-1: Status of Utility Relocation
Sr.No
Authority
Description
Unit
Total
Scope
Work
Done
Balance
MPMKVV
Electric lines
Km
58
Nil
58
MPPHE
Water supply
line
Km
1.5
Nil
1.5
MPPHE
Hand Pumps
No
43
35
Estimates for shifting of the above Electric lines have been prepared. The estimated
cost is approximately Rs. 6.73crores under the Gwalior Section and Rs 7.60 crores
for works under the Shivpuri divisions of MP MKVV. The current estimates are
based on the 2012 SOR and the same is being revised based on the SOR for the year
2014.
Estimates have been done for the shifting of the water supply pipeline & related
items mentioned above. The PHE department of the Shivpuri division has
completed the shifting of all the 17 nos hand pumps. For the Gwalior division, the
shifting of 18 nos. hand-pumps has been completed, out of a total of 26 nos, and the
rest are in progress.

51
2.3.
R&R Activities
The following structures coming within the ROW already handed over to the
Concessionaire are being demolished after resolving the related rehabilitation and
payment issues.
Table 2.3-1: Status of R&R Activities
2.4.
Particulars
Total
Total No. of Temples/Mazaar
22
Total Nos.Shifted
Balance
22
Tree Cutting
Table 2.4-1: Status of Tree Cutting
Particulars
Unit
Total
Permission obtained
Trees to be cut
No
17700
4599
Cutting completed
No
600
Balance
No
17100
The Concessionaire has initiated the process for payment of deposit to the Tree
Authority to cut the trees coming within the ROW. The trees for which cutting has
not commenced are lying within the forest and wildlife land, for which a the Stage
II approval is still awaited.
A detailed list of obstructions and encumbrances has been prepared and these are
being removed progressively in the areas already handed over.

51
Progress Briefing
Contractors Activities

51
3.
3.1.
Progress Briefing Contractor Activities
Pre-Construction Activities
a) Resource Mobilisation
Materials:
Material Procurement has been done to a large extent.
Aggregates to the extent of 67%, GSB- 41% and RCC Hume Pipes-40% have
already been procured / manufactured for the project works.
The total tonnage of aggregates corresponding to the above is about 19 lakh

MT, GSB is approximately 6.5 lakh MT,
The number of Hume pipes of various diameters available at site is over

1400.
Plant & Equipment:
Two nos plants each are mobilised and commissioned for RMC, Hot-Mix,
WMM and Stone crushing, at Mohana & Kheria towns. Site offices and
Quality Control Laboratories have also been set up.
Mobilization of man power, vehicles, equipment and plants by EPC

Contractor has advanced to a great degree.
A detailed list of Plant, Machinery and Equipment is attached in Appendix

B.
The Plan and Profile, as well as the Pavement Designs for the entire 125.30 km
project length has been completed and reviewed by the Independent Engineer (IE).
Construction Methodology submitted to the IE in January 2014 has been reviewed
and accepted.
b) Surveys
The Design Consultants have completed the pre-design survey works and have
obtained an inventory of highways and structures. Geo-technical investigations for
minor and major bridges, as well as for ROBs, etc, have been completed and all the
required data for designs has been obtained.

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Table 3.1-1: Status of Design and Drawings-Highway

Sl
No
Description
Unit
Total
Scope
Design
completed
Review By IE
Good For Construction

(GFC) Drawing Issued
Sch. B
1
Pavement Design
Km
125.300
125.300
125.30
Nil
Plan & Profile
Km
125.300
125.300
125.3
75.0
Typical Cross
Sections
Type
11
11
11
Nil
Major Intersections
No
Nil
Nil
Minor
Intersections
No
30
Nil
Nil
Toll Plazas (Typical

Details)
No
Nil
Nil
Toll Plaza (Aid

Posts)
No
Nil
Nil
Truck Lay Bye
No
Nil
Nil
Bus Bay with Bus

Shelter
No
13
Nil
Nil
10
Road Signs
Km
Nil
Nil
11
Street Lighting
Km
Nil
Nil
12
Land Scaping
Km
& Plantation
Median,
GSI
location,
At grade
island &
Toll
plaza
location
Nil
Table 3.1-2: Status of Design and Drawings Structures

Sr.
No
Description
Unit
Total
Scope
Design
completed
Reviewed by
IE
Good for Construction

Drawing
Issued
Sch. B
1
Rail Over Bridge
No
Nil
Nil
MJB
No
Nil
MNB
No
49
49
49
Nil
VUP
No
Nil
PUP
No
03
Pipe Culverts
No
75
75
75
Nil
Box Culverts
No
71
71
71
Nil

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c) Authority Approvals
Railways
Included in the project alignment are three nos. ROBs at Chainage km 2+050,
km 109+900 and at km 121+040 respectively. The General Arrangement
drawings (GADs) of these were submitted to the relevant Railway Authorities
and all the three GADs were approved by them vide their letters dated August
20, 2012 and May 24, 2012
Ministry of Environment & Forests
Environmental clearance for the project has been granted by the Ministry of
Environment & forest onMay10, 2013. The National Wild Life Board (NWLB)
clearance for both the Madhav National Park, as well as SON bird sanctuary is
awaited. Stage I forest clearance for 64.259 Ha has been obtained on
November 21, 2013
In addition to the above, following permissions / clearances / licenses /
approvals have been acquired for the project:
Quarrying permission from the State Govt
Permission of Village Panchayat & Pollution Control Board for installation of

stone crusher, asphalt plant and use of borrow area
License for the use of explosives for quarrying
State Govt permission to draw water from river / reservoir
License from Inspector of Factories or other competent authority for setting

up batching plant
State Govt permission for cutting of trees.

51
3.2.
Construction Activities
Out of the clear fronts available to the Concessionaire within the ROW and along the
alignment, work has commenced at various locations in each of the three sections along the
alignment. Up to and including this month, the construction works have progressed as
mentioned below:
3.2.1. SECTION I: Chainage 0 to 40 km
a)
Highway
Clearing and Grubbing work has been completed for a length of 36.8 km on
the Left Hand Side in this section, up to and including this month.
3.2.2. SECTION II:Chainage 40 to 80 km

a)
b)
Highway
Clearing and Grubbing work has been completed for a length of 3 km

between chainages Km 74+000 to Km 77+000, on the Left hand side. The
total length of road for which this item has been executed in this section is
now 38.3 km, up to and including this month.
Embankment construction has commenced in this section during this month

and the placement of the first layer for a total length of 1.11 km has
commenced between the chainages of Km 46 to Km 61.
Structures
Foundation Excavations have been completed for all abutments and piers,
during this month, at the Major Bridge site at km 61.
For the Major Bridge at Km 57, excavation for all foundations have been
completed except for Pier P3 and P4 in the river-bed portion, on both the
LHS and the RHS.
Work has also commenced at five nos box culvert locations at Km 50+745 ,
59+645, 60+055, 60+881 and 63+765
3.2.3. SECTION III: Chainage 80 to 125.3 km

a)
Highway
No Clearing and Grubbing work was done in this section during the month
of September 2014. The total length of road for which this activity has been
achieved so far in this section is 20 km.
The detailed Chainage-wise progress in Appendix C

51
Physical Progress of
Work

51
4.
4.1.
Physical Progress of Work
Physical Progress of Work

The following tables summarize the quantum of work achieved towards the
construction of the various elements of the highway, both LHS & RHS
4.1.1. Highway (LHS)

Table 4.1.1-1: Progress of Highway Construction (LHS)
Sr.
No.
Achieved
Description
Unit
Total
Scope
August14
In
September
-14
Total
Up to
Date
Qty.
Achieved
%
Up to
Tree Cutting
km
125.30
20.0
10.0
30.0
23.90
Clearing and
Grubbing
Km
125.300
61.30
3.00
64.30
51.3
Embankment
Km
125.300
Sub grade
Km
125.300
GSB
Km
125.300
WMM
Km
125.300
DBM
Km
125.300
BC
Km
125.300
Road Furniture
km
125.300

51
4.1.2. Highway (RHS)

Table 4.1.2-1: Progress of Highway Construction (RHS)
Description
Sr.
No.
Unit
Total
Scope
Achieved
Up to
In
August -14
September
-14
Total Up
to Date
Achieved
%
Tree Cutting
km
125.300
20.0
10.0
30.0
23.90
Clearing and
Grubbing
Km
125.300
30.80
30.80
24.58
Embankment
Km
125.300
Sub grade
Km
125.300
GSB
Km
125.300
WMM
Km
125.300
DBM
Km
125.300
BC
Km
125.300
Road Furniture
km
125.300
4.1.3. Maintenance of Existing Carriageway

The existing carriageway maintenance like pot holes, patch work etc. is in progress
along the project Highway, as required
Table 4.1.3-1: Status of Maintenance of Existing Carriageway
Sr. No.
Description
Unit
Total
Up to
August 14
0
In
September
-14
Total Up
to Date
Qty.
2.00
2.00
133
6.30
14.0
20.30
Km
133
133
133
SDBC
Km
133
80
86
Structures
repair/culvert
No
146
10
10
Earthwork in
shoulder
Km
133
GSB
Km
133
WMM
Km
BM
5
6

51
Financial Progress of
Work

51
5.
Financial Progress of Work
Up to and including the month of September 2014, there has not been any
progress related payments to contractors engaged on the project.
During the month, bills were submitted to NHAI for the following works done
by the Concessionaire :
Maintenance works.Rs53 lakhs (approx.)
The approximate costs incurred on the project till date areRs518.07Crores as

against the planned expenditure of Rs 657 Crores. Hence, the achieved financial
cumulative progress is. 32.34 % against the cumulative targeted progress of
41.02 % as per the financial programme.
The above expenditure has been incurred on setting up the various plants and
equipment for the project, procurement and production of aggregates and
materials, and also to set up the camps at various places along the alignment.
The concessionaire has worked out the planned cash flow details for the entire
project duration and these are attached at Appendix D
A snapshot of the S-Curve up to and including this period shown below,

indicates that the actual financial progress is presently lagging behind the
planned figure by Rs 139 crores. As most of the initial physical mobilisation has
been completed, this shortfall will now have to be largely covered through
progress payments to the contractors, executing the project works

51
Figure 3: Financial Progress - Planned vs Achieved

51
Construction program

51
6.
Construction Programme
Based on the requirements of the Concession Agreement (C.A.), the total scope of highway
works for the project falls into the following broad categories for which the start and
completion dates have been targeted as shown below :
Table 6-1: Program for the Total Project Scope (Highways)
Description
Start Date
End Date
New Carriageway Construction (82.75 km)
September 9, 2014
August 15,
2015
Widening &Construction. of existing C/way

(82.75 km)
October 02, 2014
July 11, 2015
Construction of Bypasses (36.9 km)
January 01, 2015
June 02, 2015
May 17, 2015
August 15,
2015
Construction of Re-Alignment portion

(5.65 km)
The above scope has been broken down into various heads and the completion of these
items including the carriageway construction, has been targeted for completion by
August15, 2015. :
The various structures to be constructed as part of the project and their planned start and
end dates are shown in the table below :
Table 6-2: Program for the Major ProjectComponents (Structures)
Description
Start Date
End Date
Major Bridges at Ch. 53+782, 57+915 &

61+827
September 01, 2014
April 09, 2015
Major Bridge at Ch. 83+678
September 01, 2014
June 30, 2015
ROBs at
121+040
Ch.
2+050,
109+900
and September 01, 2014
August 15, 2015
Minor Bridges (49 nos)
September 01, 2014
May 30, 2015
Pipe Culverts (75 nos.)
September 01, 2014
April 22, 2015
Box Culverts (71 nos.)
September 01, 2014
July 22, 2015
PUPs (9nos.)
September 01, 2014
May 23, 2015
VUP ( 1no.)
September 01, 2014
November 27, 2014
Toll Plaza Construction
March 01, 2015
May 30, 2015
Miscellaneous works
September 01, 2014
April 29, 2015

51
Quality Control and

Quality Assurance

51
7.
7.1.
Quality Control and Quality Assurance
Material
Construction materials like aggregates, sand, GSB are being produced by stone
crusher located at the Mohana & Kheria towns. Materials are being tested in the
Contractors Laboratory as per MoRTH Specifications and Indian Standard Codes.
A site laboratory has been set up with all equipment required for testing soil, GSB,
WMM, Bitumen, aggregate and concrete. GSB material, soil samples from borrow
areas, aggregates, cement and bitumen are being tested regularly. Trial mix design
for concrete with different admixtures is also in progress.
Production and stocking of aggregates, procurement of all other construction
materials is in progress. The following table shows the up to date position:
Table 7.1-1: Status of Construction Material
SR.
ITEMS
UNIT
SCOPE
No.
Cumulative
QTY
Procured
up to
August-14
QTY
procured
during
month of
September
-14
Cumulative
QTY
procured
up to
September
- 14
AGGREGATES
MT
2855500
1898067
1898067
66.47%
STEEL
MT
17187
BITUMEN
MT
55000
CEMENT
MT
136000
GSB
MT
1560000
635860
635860
40.76%
RCC Hume pipe
(a)
1200mm Dia
No.
570
248
248
43.50%
(b)
1000mm Dia
No.
820
500
500
60.97%
(c )
600mm Dia
No.
2250
695
695
30.88%
Furthermore, Concrete Mix Designs for different grades have been finalised during
this month. These designs are now available for grades M15, M20, M25&, M30.

51
7.2.
Source Approval of Materials

The following sources of materials have been approved by Concessionaire.
Table 7.2-1: Source of Procuring Material
Material
Sr.
No
Source
Remarks
Coarse Aggregate
Mohana & Kheria
Fine Aggregate
Mohana & Kheria
GSB
Mohana & Kheria
Stone Dust
Mohana & Kheria
Test results
conform to
Specification
Steel
TATA Tiscon Fe500 D
Test results
submitted to
NHAI/IE
Materials conform
to Specification
SAIL Fe500D
RINL TMT
JSPL TMT
6
Admixture
Fosroc
Test results
submitted to
NHAI/IE
Cement
Jaypee & Vikram Premium, ACC
Test results
submitted to
NHAI/IE
(OPC 43), Shree Ultra(OPC 43),

Ultra Tech(OPC 43) & Ambuja
OPC 43 Grade
8
Bitumen (VG-30)
To be submitted
Emulsion (RS-1 &

SS1)
To be submitted
10
Curing Compound
Fosroc
Test results
submitted to
NHAI/IE
11
Water
Bore Well Mohana Camp
Test results
submitted to
NHAI/IE
Bore Well Kheria Camp
7.2.1. C
51
ement
Sample material tested at EPC contractors lab & results are found confirming to
specifications. & have to be submitted for third party testing.
7.2.2. Admixtures
7.2.3. Steel
7.2.4. Bitumen
specifications. & have to be submitted for third party testing

51
Environment and Safety

51
8.
Environment and Safety
Various issues related to environment and safety, such as traffic management,

safety signages, disposal of waste materials and oil spillage, housekeeping, area
barricading and traffic management, etc, are being taken care of during the
execution of the project. .
At the quarry and crushing plants, regular sprinkling of water by tankers is being
done for dust abatement.
As mentioned earlier in this report, cutting of trees coming within the road
alignment will be necessary. The required compensatory tree plantation
programme will be taken up in hand as per the guidelines of MoEF approval, which
is under review.
A detailed Environment Management Application Plan (EMAP)has been prepared

and submitted to the Independent Engineer (IE) on 14th August 2014 and
conditionally approved.

51
Action required from

NHAI

51
9.
Actions required from NHAI
Concessionaire requests NHAI to take early action on the following issues :

1. Procurement of the Site : NHAI is requested to procure the balance 15.57% of the
land so as to provide the concessionaire vacant access to 100% Right of Way. This
procurement, which was to be completed by 12th August 2013, is still pending.
2. Applicable permits : NHAI is requested to secure the stage-II forest clearance for
about 80 Ha of land, which has been pending since the Appointed date.
3. Shifting of Electrical utility : NHAI is requested to approve estimates of electrical
utility shifting and deposit the required supervision charges with the respective
departments.
4. Shifting of EHT Line : A total of five EHT lines would be required to be shifted in
order to proceed with the project construction. NHAI is requested to deposit the
supervision charges with the concerned department.
5. Site to be free of encumbrances : NHAI is requested to provide the site free from all
encumbrances, This is pending since 12th August 2013.

51
10 Appendices
Appendix A
Organization Chart
Appendix B
List of Plant, Machinery and Equipment
Appendix C
Chainage-wise progress
Appendix D
Project Cash Flow Statement
Appendix E
Project Progress Photographs

51
Appendix A: Organization Chart

51
Appendix B: List of Plants, Machinery and Equipments

Sr.
No
350 TPH
Crusher Plant (
with sand
classifier unit)
Crusher Plant
Condition of
Equipment
working/
breakdown
Working
250 TPH
Working
Kheria
HMP
200 TPH
Working
Mohana &
Kheria
WMM Plant
200 TPH
Working
RMC Plant-
60cum/hr
Working
Excavator
Working
Loader
Working
Grader
Working
JCB backhoe
Working
10
Hydra
Working
11
Hywa (Tippers)
14
Working
12
Weigh Bridge
Working
13
Tandem Roller
Working
14
Vibratory Roller
Working
15
PTR Roller
Working
16
Apollo Sensor
Paver
Working
17
Tractor
Working
18
Bitumen Sprayer
Working
19
Needle Vibrators
Working
20
Welding Machine
Working
21
Dewatering pump
Working
22
Air Compressor
Working
Plant &
Equipment
Capacity
/ Make
Min.
Requirement
Mobilized
Location
Mohana

51
Appendix C: Chainage-wise progress
Clearing and Grubbing

LHS
Upto Previous Month
This Month
August -14
September-14
From
To
0+500
15+400
14.9
14.900
15+400
22+400
7.00
7.000
47+000
67+000
50+000
54+100
54+100
57+000
77+000
79+400
108+000
Length (KM)
From
To
Total up to
date
Length (KM)
Length(KM)
20.00
20.000
4.1
4.100
2.9
2.900
74+000
77+000
3.00
5.400
2.40
10.0
118+000
Total
10.000
61.30
3.00
64.300
Clearing and Grubbing

RHS
Upto Previous Month
This Month
July-14
August -14
From
To
0+500
15+400
14.90
14.90
54+100
57+000
2.90
2.90
60+000
63+000
108+000
118+000
Total
Length (KM)
From
To
Total up to
date
Length (KM)
Length (KM)
3.00
10.00
30.80
10.00
0.00
30.80

51
Appendix D: Project Cash Flow Statement (Planned)

51
Appendix E: Project Progress Photographs
Clearing and Grubbing Operation
Grading of Embankment at Ch 63+000

51
Rolling of Embankment at Ch 63+000
Laying of Hume Pipe for Culvert at Ch 51+250

51
Transit Mixers at Ch 59+150
Hot Mix Plant (200TPH) at Mohana camp

51
Batching Plant (60cum) with cement store at Mohana camp
Rolling of Embankment at Ch 61+000

51
Shifting of Electrical Poles
Testing Laboratory at Mohana camp

51
Maintenance work of Existence Road
Maintenance work of Existence Road

51
Ready Mix Concrete Plant at Ch 58+950

51

PMC Aimond September MPR Final

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Gwalior Shivpuri Toll Road Project

Gwalior-Shivpuri 4-Laning Project for NH-3 of the

Monthly Progress Report

Essel Gwalior Shivpuri Toll Roads Pvt Ltd

Gwalior Shivpuri Toll Road Project

Scope and objective of the Report

from Km. 0+000 to Km. 40+000 (40 km)

From Km. 40+000 to Km. 80+000 (40 km)

From Km. 80+000 to Km. 125+300 (45.3 km)

Period Covered in this Report

Monthly Progress Report Number

SEPTEMBER 2014 IPAGE 2 OF 51

Gwalior Shivpuri Toll Road Project

Figure 1: Project Alignment Map

SEPTEMBER 2014 IPAGE 3 OF 51

Gwalior Shivpuri Toll Road Project

SEPTEMBER 2014 IPAGE 4 OF 51

Gwalior Shivpuri Toll Road Project

Table of Content ................................................................................................................ 5

SEPTEMBER 2014 IPAGE 5 OF 51

Gwalior Shivpuri Toll Road Project

SEPTEMBER 2014 IPAGE 6 OF 51

Gwalior Shivpuri Toll Road Project

SEPTEMBER 2014 IPAGE 7 OF 51

Gwalior Shivpuri Toll Road Project

Road Over Bridges

: August 15, 2015

: May 30, 2015

Pipe & Box Culverts

: July 22, 2015

Vehicular Under Pass

: End November 2014

Pedestrian Under Pass

: May 23, 2015

Toll Plazas & Misc.

:End May 2015

SEPTEMBER 2014 IPAGE 8 OF 51

Gwalior Shivpuri Toll Road Project

Background and Project

SEPTEMBER 2014 IPAGE 9 OF 51

Gwalior Shivpuri Toll Road Project

Background and Project Details

SEPTEMBER 2014 IPAGE 10 OF 51

Gwalior Shivpuri Toll Road Project

Figure 2: Typical Highway Cross Section

SEPTEMBER 2014 IPAGE 11 OF 51

Gwalior Shivpuri Toll Road Project

Project Contract Details

Four Laning of Gwalior-Shivpuri from Km

National Highways Authority of India (NHAI)

Essel Gwalior Shivpuri Toll Roads Pvt Ltd.

M/s CDM Smith Inc

Pan India Infrastructure Pvt. Ltd

Contact Person: Mr.Jayant Torvi, VP (Roads)

I.D.C. Projects. & Asia Infrastructure Advisory

SEPTEMBER 2014 IPAGE 12 OF 51

Gwalior Shivpuri Toll Road Project

General Contract Details

Length of Road (Design

Total Capital Cost

Rs. 1,601.77 Crores

Total Project Cost

Rs. 1,055 Crores (as per concession agreement)