Understanding Highway Projects in India

Presentation on Understanding Highway Projects in India

2 Contents Planning Execution Monitoring Billing Costing & Budgeting
Tendering Planning Execution Monitoring Billing Costing & Budgeting
3 Tendering
4 Tendering First of all “Authority / Client” invites tender proposal based on initial survey
or feasibility report done by consultants hired by the authority. Types of Contracts:
There are different types of contracts for highway works, out of which any one chosen
by the client based on feasibility report. Various types of contracts are as under: EPC
Contract: EPC (Engineering, Procurement & Construction) contracts are in which the
contractor execute the work as per specifications with own procured materials and
claims periodically bills to the clients for his work done as per item rate BOQ. After
completing the project there is the provision of maintenance period for which the project
should be maintained by the contractor with or without any cost as described in the
agreement.
5 Tendering BOT (Toll) / DBFOT Contract: DBFOT (Design, Built, Finance, Operate and
Transfer) contracts are in which the contractor called concessionaire which may be the
SPV (Special Purpose Vehicle) who is responsible for Design the work as per
specification & contract normally the concessionaire engaged design consultant for this
purpose. Execute the work as per specifications & design normally the concessionaire
chooses the EPC contractor for the execution. It may be his own subsidiary or any other
company which execute the work as per EPC contract. Arrange the Finance for the
project. Detail financing elaborated further. Contd………
6 Tendering BOT / DBFOT Contract Contd…..Operate & collect the toll for the
stipulated concession period (it may be 10 to 30 years as per contract) and recover his
expenses with interest and after that his profit. Within this period the concessionaire
also responsible for the maintenance of the road. After completion of concession period
the highway stretch will be transferred to authority / client.
7 Tendering BOT (Annuity)/ DBFOT Contract : All the procedures are same as
described for BOT (Toll) the only difference is that instead of toll collection the authority
disbursed fixed Annual Amount up to the concession period as per the agreement (2
installments per year).This type of contract awarded where traffic volume is less & toll
collection is not viable.
8 Tendering OPR C Contract: Output and Performance-based Road Contracts is the
new contract type mainly used for the world bank projects. This is same as EPC
contract but the difference is the EPC contract has an itemized BOQ and its rate and
OPRC has lump-sum deliverable item based rate. Also for this type of project first step
is for financial bid and second is for technical bid which can be qualify by only the
contractor who have given good output and better performance in their previous works.
Execution cycle for a EPC Contract

Tendering Execution cycle for a EPC Contract Site Visit & Cost Estimation Pre-
qualification Project Awarded Proposal of Bid Financial Bid Letter of Acceptance (LOA)
Execution of Project Signing of Agreement Pre-construction Activities Project Planning
Work Execution Project Completion & Handover Periodic Billing Finishing Works Final
Bill
10 Execution cycle for a BOT (Toll)/DBFOT Contract

Tendering Execution cycle for a BOT (Toll)/DBFOT Contract Site Visit & Cost
Estimation Pre- qualification Traffic Survey & Forecast Financial Model Proposal of Bid
Letter of Acceptance (LOA) Project Awarded Signing of Agreement Financial Closer
Financial Bid Toll Collection & Maintenance for entire Concession Period Project
Completion & Commercial Operation Awarding & Execution of EPC Contract Project
Handing over to the client
11 Financing the BOT Projects

Tendering Financing the BOT Projects EPC Cost/ Construction Cost Non -EPC Cost /
Non-Construction Cost (IDC, Financing charges, consultancy etc.)Total Project Cost
(TPC) Equity (To be infuse by the Concessionaire) Debt (To be taken as loan from
banks)Grant(To be infuse by the Client)Grant is the part of amount which the client is to
be infuse in the project but now a day’s some projects have negative grant or it called
premium which amount concessionaire gives to the client / authority from the project.
12 PLANNING
13 Planning Macro planning it is a base programme for further planning.
This is an initial work plan at the time of starting of the project to find out the better way
for working with major sections and items. it is a base program me for further planning.
It can be submitted to the Client / Consultants.
14 Planning Micro Planning
This is a detail work plan for execution of work which includes all the activities linked
with each other with appropriate relations. What we can do with this: Finding out the
critical tasks. Plan for utilization of our resources. Anytime execution detail. Anytime
requirement of Equipments & Materials. After updating the programme we can know the
delay and find out the better solution to finish the work in time.
15 EXECUTION OF WORK
16 WORK EXECUTION Pre-Construction Activities

Before starting the construction activities, we have to do some pre-construction

activities as follows: Camp / Office Construction. Survey & Alignment works.
Establishment of Plants and mobilization of Equipments. Appointment of Key personals
& supporting staffs. Finalization of Design & Drawings (For DBFOT projects).Land
acquisition status and pressurize the authority if acquisition balance. Removal of
encroachments. Shifting of utilities apart from ROW.
17 WORK EXECUTION Construction Activities

We have to execute the work as per design & drawings. To quantify & bill the executed
work we have BOQ (Bill of Quantity) for every project. Generally the BOQ item heads
for Highway projects are as follows: Item No. 1 – Site Clearance – C & G, Dismantling,
tree cutting, stump removal etc. Item No. 2 – Earth Work – Excavation (Soil, rock etc.),
Earth Filling (Embankment, Sub-grade, Shoulder, Median etc.)Item No. 3 – Sub-Base –
Granular Sub-Base (GSB), Wet Mix Macadam (WMM), Drainage layers etc. Item No. 4
– Bituminous Course – Primer, Tack Coat, BM, DBM, BC etc. Item No. 5 – Structure
Works – Cross-Drainage (CD) works, Culverts, Bridge, ROB, Under Pass, Grade-
separators etc. Item No. 6 – Drainage & Protection – Road side drains, Pitching,
Turffing & other slope protection works. Item No. 7 – Junctions – Junction improvement
works. Item No. 8 – Traffic Signage, Marking & Other Appurtenances - Kerb, Km
stones, Signage, Road Markings, Guard rails, Crash barriers etc. Item No. 9 –
Miscellaneous Works – Photographs, Lightings, Signals, Cars, etc. Item No. 10 –
Maintenance Work – Pot – hole repair & Existing road maintenance. Item No. 11 – Toll
Plaza – Toll plaza building, Booth & All provisions (BOT Projects)
18 WORK EXECUTION Understanding Major Highway Works BC Earthen
Shoulder
Median Kerb BM/DBM Primer / Tack Coat WMM GSB Sub-Grade Excavation OGL &
C&G Embankment
19 WORK EXECUTION - Understanding Major Highway Works
OGL: For future reference and payment we have to take original ground level (OGL) at
defined offsets and existing road edge etc. Equipments Used: Auto Level & Staff Total
Station
20 WORK EXECUTION - Understanding Major Highway Works
Clearing & Grubbing (C&G)This work shall consist of cutting, removing and disposing of
all materials such as trees, bushes, shrubs, stumps, roots, grass, weeds, top organic
soil not exceeding 150 mm in thickness, rubbish etc. MORTH Specification Clause -
201Equipments Used: Dozer Grader
21 Rock Breaker (For rock only)
WORK EXECUTION - Understanding Major Highway Works Excavation (Soil &
Rock)The work shall consist of excavation, removal and satisfactory disposal of all
materials necessary for the construction of roadway, side drains and waterways in
accordance with requirements of Specifications and the lines, grades and cross-
sections shown in the drawings or as indicated by the Engineer. MORTH Specification
Clause – 301.Equipments Used: Excavator Tipper Grader Water Tanker Rock Breaker
(For rock only)
22 WORK EXECUTION - Understanding Major Highway Works
Earth Filling (Embankment, Sub-Grade, Median, Earthen Shoulder etc.): As per X-
section & level required for formation we have to fill earth in lower area and prepare the
Embankment after that the Sub-grade of required thickness also to be constructs. Filling
in median and preparation of earthen shoulder has to be done as shown in X-section.
MORTH Specification Clause: 305, Material Used: Earth (Soil) / Moorum. Equipments
Used: Excavator Tipper Grader Water Tanker Vibratory Compactor
23 WORK EXECUTION - Understanding Major Highway Works
Granular Sub-Base (GSB): This work shall consist of laying and compacting well-graded
material on prepared sub-grade in accordance with the requirements Specifications.
The material shall be laid in one or more layers as lower sub-base and upper sub-base
it also called drainage layer. MORTH Specification Clause: 401, Material Used: Natural /
Crushed Aggregate, sand etc. Equipments Used: Excavator for Mixing Wheel Loader
Tipper Grader Water Tanker Vibratory Compactor
24 WORK EXECUTION - Understanding Major Highway Works
Wet Mix Macadam (WMM): This work shall consist of laying and compacting clean,
crushed, graded aggregate and granular material, premixed with water, to a dense
mass on a prepared sub-base/base or existing pavement as the case may be in
accordance with the requirements in Specifications. MORTH Specification Clause: 406,
Material Used: Crushed Aggregate, Stone Dust etc. Plant & Equipments Used: WMM
Plant Wheel Loader Tipper Paver Water Tanker Vibratory Compactor
25 Concrete Batch Mix Plant
WORK EXECUTION - Understanding Major Highway Works Concrete Kerb: Concrete
Kerb / Divider are the item which makes median and separate the lane of the road.
MORTH Specification Clause: 408, Material Used : Concrete (Mostly M-20 grade).Plant
& Equipments Used :Concrete Batch Mix Plant Transit Mixer Kerb Casting Machine
Water Tanker
26 Bitumen Distributer / Browser
WORK EXECUTION - Understanding Major Highway Works Primer Coat: This work
shall consist of the application of a single coat of low viscosity liquid bituminous material
to a porous granular surface preparatory to the superimposition of bituminous treatment
or mix. MORTH Specification Clause: 502, Material Used: Bitumen emulsion (Slow
Setting).Equipments Used: Mechanical Broomer Bitumen Distributer / Browser
27 Bitumen Distributer / Browser
WORK EXECUTION - Understanding Major Highway Works Tack Coat: This work shall
consist of the application of a single coat of low viscosity liquid bituminous material to an
existing bituminous road surface preparatory to the superimposition of a bituminous mix,
when specified in the Contract or instructed by the Engineer. MORTH Specification
Clause: 503, Material Used: Bitumen emulsion (Rapid Setting).Equipments Used
:Mechanical Broomer Bitumen Distributer / Browser
28 WORK EXECUTION - Understanding Major Highway Works
Bituminous Macadam (BM) / Dense Bituminous Macadam (DBM): This is a bituminous
mix item to be laid over WMM or existing road on prepared surface. Bituminous
Macadam (BM) is a more open graded than the Dense Bituminous Macadam
(DBM).The Profile Correcting Course (PCC) also can be done by these items to correct
the existing road’s profile. MORTH Specification Clause: 504 & 507, Material Used:
Crushed Aggregate, Stone Dust, Bitumen & Filler (lime or cement) if required. Plant &
Equipments Used: Hot Mix Plant Wheel Loader Tipper Paver Water Tanker Tandem
Roller Pneumatic Roller
29 WORK EXECUTION - Understanding Major Highway Works
Bituminous Concrete (BC): This is a top surface layer of Highway a bituminous mix item
to be laid over BM/DBM. It also called wearing course. MORTH Specification Clause:
509, Material Used: Crushed Aggregate, Stone Dust, Bitumen & Filler (lime or cement)
if required. Plant & Equipments Used: Hot Mix Plant Wheel Loader Tipper Paver Water
Tanker Tandem Roller Pneumatic Roller
30 WORK EXECUTION Understanding Structure Works
Cross Drainage: These type of structures used to drain out the natural water flow from
one side of road to other side so it calls cross drainage structures. Following are the
type of cross drainage structures mainly used in highway works :1- Box Culverts2- Slab
Culverts3- Pipe Culverts Bridges : These structures are bigger than the culverts and
used to construct on major highway hurdles like Canal, River, Major X-ing, Railway
tracks etc. Following are the type of bridges mainly used in highway works :1- Minor
Bridge – The bridge span less than 60m of length called minor bridge.2- Major Bridge –
The bridge span more that 60m of length called major bridge.3- ROB (Rail Over Bridge)
– As stated in the name it construct over a railway line.4- RUB (Rail Under Bridge) – As
stated in the name it construct under a railway line.5- Flyover/Over Pass – These type
of structures construct over any major junction or crowded area.6- Grade Separator –
These type of structures used to construct where major highways cross each other and
they need to connected without disturbing traffic movements.7- Underpass – When the
main road cross any other road or rail or any hurdle below it called underpass..8-
Pedestrian crossing (PX) / Cattle Crossing (CX) – These types of structures used to
cross the main road by pedestrian or cattle. Mostly it a box type structure.
31 WORK EXECUTION Understanding Structure Works
BOX CULVERT: As per its name it is monolithic box type structure. It may be single or
multiple box type as shown in the picture. It may be precast also.
32 WORK EXECUTION Understanding Structure Works
SLAB CULVERT: These type of culverts has different parts as foundation (Raft), Wall,
Bracket & Slab. It may have separate foundation for each wall or combined also as per
design requirements.
33 WORK EXECUTION Understanding Structure Works
PIPE CULVERT: These type of culverts made of RCC Hume pipe having dia 300mm to
2000mm. The different parts of these culverts are PCC below pipe, RCC Hume pipe &
Head wall etc. As per IS-458 classification concrete pipes are NP(Non-Pressure)-1, NP-
2, NP-3 & NP-4 and P(Pressure)-1, P-2, P-3. Normally NP-4 pipe used for pipe culverts
in highways.
34 WORK EXECUTION Understanding Structure Works
MINOR BRIDGE : The bridge span less than 60m of length called minor bridge. It can
be BOX type Structure or having different structure segments ie. Foundation (Raft or
Pile), Substructure (Pier, Pier cap or Wall), Super structure (Diaphragm wall, RCC
Girder or Steel Girder, Slab etc.)
35 WORK EXECUTION Understanding Structure Works MINOR BRIDGE
36 WORK EXECUTION Understanding Structure Works
MAJOR BRIDGE: The bridge span more than 60m of length called minor bridge. It have
different structure segments ie. Foundation (Raft or Pile or Well), Substructure (Pier,
Pier cap), Super structure (Diaphragm wall, RCC Girder or Steel Girder, Slab etc.)
37 WORK EXECUTION Understanding Structure Works MAJOR BRIDGE
38 WORK EXECUTION Understanding Structure Works ROB
39 WORK EXECUTION Understanding Structure Works RUB
40 WORK EXECUTION Understanding Structure Works FLYOVER
41 WORK EXECUTION Understanding Structure Works GRADE SEPARATOR
42 WORK EXECUTION Understanding Structure Works UNDER PASS
43 WORK EXECUTION Understanding Structure Works Pedestrian Crossing
Cattle Crossing
44 Process Flow of General Major Item Execution in Highway
WORK EXECUTION Process Flow of General Major Item Execution in Highway
Materials Obtains after crushing of boulder :40mm Agg.20mm Agg.10mm Agg. Stone
Dust Boulder Crushing in Crusher Plant with the help of other equipments & Labour.
Boulder Extraction By Tipper Crusher Plant Through Weigh Bridge Processing in
production plants like WMP/HMP/RMC plants with Materials & Other Equipments
Materials Production Plant :Aggregates, Cement/Bitumen & Other Materials By Tipper &
Loader Materials Issue Central Store Crusher Plant By Tipper Through Weigh Bridge
Through Weigh Bridge Processed Material reached at Site and with the help of some
other Equipments & Labours it become a final BOQ Item Other purchased Item like
Cement, Bitumen, Emulsion etc. By Tipper / TM
45 MONITORING
46 Monitoring Daily Progress Report
Monitoring is an essential part of any project. To know the progress of work and to plan
further action daily progress has to be monitored without fail. Daily Progress Report This
is a daily basis report of work done at site with all the details showing physical progress,
financial progress, equipment and manpower utilization etc. (It will be generated at the
site and sent to Corp. for further information & utilization)What we can do with this: All
the functions of PMC are depends on this report. All other reports like weekly progress,
monthly progress, status of highway and structures can be made with this. It will help to
update the work programme. Its summarized report can be send to upper Management
for daily progress review.
47 Monitoring Monthly Progress Report
This is a detail report about monthly status of the project comprising with upto date
Physical & Financial progress and overall project status as on date with some graphical
charts. What we can do with this: Based on this report we can prepare the MPR for
Client / Consultants. This report will show the overall status so that we can plan our
further step. It will show us the actual status of hindrances and other problems for the
project. It will helps to update the work programme.
48 Monitoring Updating Highway Strip Chart
Highway is a linear part of the project so the progress can be monitor with the strip chart
with all the major layers. What we can do with this: It will show the physical progress of
Highway works at a glance. It will show the Hindrances / Land availability status. With
the help of this chart we can calculate the work done and balance quantities of highway.
It will help to know the linear progress of all the layers.
49 Monitoring Updating Structure Strip / Pictorial Charts
To know about the structure wise progress at a glance this is the best way to maintain
the pictorial chart for individual structures. What we can do with this: It will show the
physical progress of Structure works at a glance. With the help of this chart we can
calculate the work done and balance quantities of Structures. It will help to know the
actual status of structures and to finalize the further step for structure progress.
50 Monitoring Other Reports
Some other report which can help for monitoring the projects are as follows: Daily
Manpower Status : It will show the status of manpower present at site and further
requirement if any. Daily Equipment Status: It will show the status of equipments
deployed at site, working, idling and breakdown status and further requirement if any.
51 BILLING
52 Billing Monthly Running Account Bill (R.A. Bill)
A periodic RA Bills to has be claimed to the client for payment of work done items. This
is very important part of the project because the cash – flow depends on the correct
claims made and timely payment released by the Client / Authority. Following checks
should be done for billing: Quantities claimed in the bill is correct. The method for
calculating the quantities is correct. How much quantities are with held. Previous with
held quantities paid or still with held if yes then reason for held.
53 Billing Monthly Comparison Charts (To be made by site staff)
Following comparison charts should be made on monthly basis: Actual Work done and
Billed quantities. Quantities billed by us and paid by clients including reason for
deductions (If any).Quantities billed by Sub-Contractors and paid by us.
54 Billing Tracking of Non BOQ Items
The items which don't exist in BOQ called Non-BOQ or Extra Items. For the payment of
this item we must have approval of quantities and rates. The checks for these type of
items are as follows: How much quantity is going to be execute? Is the item similar to
any other BOQ item? If yes then derive the rate from that particular item. If no then
make a proper rate analysis. The rate & quantity is to be approved by client. After
approval all executed quantity should be paid.
55 Billing Tracking of Variation Items
The items which exist in BOQ but the quantity of that particular item overshoot from
BOQ quantity called Variation Item. For the payment of these item we must have
approval of quantities only. The checks for these type of items are as follows: How
much quantity is going to be execute further? The quantity is to be approved by client.
After approval all executed quantity should be paid.
56 Billing Re-Conciliation of Major Materials
Upto date and monthly material re-conciliation should be done for the following major
materials: Aggregate & GSB material. Fine sand & coarse sand. Bitumen Cement Steel
Reinforcement Re-Conciliation of Major Materials will be done by comparing the
consumption by Job Mix Formula and actual consumption done at site as per store
records.
57 Costing & Budgeting Costing of Balance Work
To find out the balance cost to go for any particular project , periodical costing will be
done on following basis: Actual balance work quantity. Actual rate of Materials as on
date. Actual PRW rate as on date. Actual Sub-contractor’s rate. Actual Equipment
output.
58 Costing & Budgeting Budgeting for Balance Work
On the basis of actual cost to go and work programme for any particular project,
monthly head wise budget for the balance work can be prepared.
59 photographs
60 Photographs Stone Crusher Plant
61 Dozer at spreading work
Photographs Dozer at spreading work
62 Shuttering & Bar Binding Work in Progress
Photographs Shuttering & Bar Binding Work in Progress
63 Concrete Pump Pouring Concrete
Photographs Concrete Pump Pouring Concrete
64 Gantry Crane for Girder Erection
Photographs Gantry Crane for Girder Erection
65 PSC Girder Erected Over Pier Cap
Photographs PSC Girder Erected Over Pier Cap
66 Road with Concrete Guard Stone
Photographs Road with Concrete Guard Stone
67 Stone Pitching for Slope Protection
Photographs Stone Pitching for Slope Protection
68 Thanks for your Kind attention