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is one of the fastest growing and leading

private sector organizations in India with interests in


Infrastructure and Agri-Business. , by its
present Group , the Group is well
diversified and professionally managed.

The core businesses of the Group are in the sectors of


Infrastructure comprising of
. In addition, the manufacturing
s e c t o r, s p a n n i n g t h e A g r i - b u s i n e s s i n c l u d e s S u g a r a n d
Ferro alloys.

GMR Holdings Private Limited is holding company of


GMR Group.Its has two subsidary companies, namely:

.
:
a. 2 2 0 M W, T H E R M A L P O W E R P L A N T, M A N G A L O R E , K A R N ATA K A

b. 2 0 0 M W, D I E S E L P O W E R P L A N T, C H E N N A I , TA M I L N A D U

c. 3 8 8 . 5 M W, N AT U R A L G A S P O W E R P L A N T AT V E M A G I R I ,
RAJAHMUNDRY IN ANDHRA PRADESH.

d. 1 4 0 M W, A L A K N A N D A H Y D R O E L E C T R I C P O W E R P R O J E C T,
U T TA R A K H A N D .

e. 1 0 0 0 M W, C O A L B A S E D T H E R M A L P O W E R P R O J E C T, K A M A L A N G A ,
DHENKANAL
D I S T R I C T, O R I S S A .

f. 1 6 0 M W TA L O N G H Y D R O P O W E R P R O J E C T, I N T H E D I S T R I C T O F
S E P PA , O N R I V E R K E M E N G , A R U N A C H A L P R A D E S H .
a. GMR HYDERABAD INTERNATIONAL AIRPORT LIMITED
b. DELHI INTERNATIONAL AIRPORT (P) LIMITED (D.I.A.L.)

a. TUNI-ANAKAPALLI EXPRESSWAYS: 4 lane highway between Tuni - Anakapalli on NH-5 in


Andhra Pradesh for a distance of 60 km.
b. TAMBARAM-TINDIVANAM EXPRESSWAYS: Between Tambaram - Tindivanam on NH-45
in Tamil Nadu for a distance of 93 km.
c. AMBALA CHANDIGARH EXPRESSWAYS: Four Laning Of the 35 Km Ambala-Chandigarh
Road Project.
d. POCHANPALLI EXPRESSWAYS: 107 KM Adloor-Yellareddy-Gundla Pochanpalli stretch,
Andhra Pradesh
e. JADCHERLA EXPRESSWAYS: 58 KM Thondapalli-Jadcherla project on NH-7 in Andhra
Pradesh
f. ULUNDURPET EXPRESSWAYS: 71 KM Tindivanam-Ulunderpet stretch on NH-45 in Tamil
Nadu.
T h i s ex p re s sway w i l l c u t s h o r t t h e t rave l
t im e b et we e n A m b a la a n d C h a n d iga r h f ro m
t h e p re s e nt 7 0 m in u te s to 3 0 m in u te s a n d
b et we e n C h a n d iga r h a n d N ew D e lh i by
a p p rox . 1 h o u r.

T h e f u e l s av in g is e st im ate d to b e
R s . 2 0 , 0 0 0 m illio n p e r a n n u m .

T h e p ro j e c t as a w h o l e st retc h e s f ro m
Z ira k p u r in P u n j a b to B a ld ev n a ga r n e ar
A m b a la in H a r ya n a s p a n n in g
.
I M P O R TA N T DAT E S

Commencement of Construction

C o m p l e t i o n o f t h e P ro j e c t

S TAT I S T I C S
NH22-21, Haryana-Punjab
35 kms
300 Crores
B u i l d , O w n , a n d Tra n s fe r
To l l p ro j e c t
20 years
National Highway Authority Of India (NHAI)

GMR Ambala Chandigarh ExpresswayPvt . Ltd.


(GMRACEPL).

GMR Projects Pvt. Ltd.(GPPL)

S T U P C O N S U LTA N T S P v t . L t d .
:
M/S Sheladia Associates In.

ITD Cementation India Ltd


PROGRESS %
100 85 98
88
86
58 60
50

0
NH 21

NH 22

NH 64
2.82 km
309.31 m
19200 mm
2
4
8750 mm
700 mm
500 mm
2.5 %
Pile, Cast-in-situ, uncased
242
Pre-tensioned, precast
661
1 8 m , 1 1 0 N o s
4 2 m , 3 N o s
Elastomeric
PILING AND PILE CAP

PRE-TENSIONING OF CONCRETE GIRDERS

REINFORCED EARTH WALL

QUALITY CONTROL
C L A S S I F I C AT I O N DEPTH

Sandy Silt with Gravel 0 5 m


(SM-ML)
Silty Clay with Low 5 6 m
Plasticity (CL)
Silty Sand (SM) 6 9 m

Cobbles and Pebbles 9 18 m


I n t e r m i xe d w i t h S a n d a n d
Silt
Silty Clay with Medium 18 23 m
Plasticity (CL)
At the site the level of the rock is low so
foundations are used. All the foundations used are Pile Foundations

No water is present on the site, so pile


foundation is used

Pile foundation is the construction of foundation on piles or it may


also be explained as column support type of foundation. It is adopted
when

Piles transfer the load from structure to surface strata having


adequate load bearing capacity.

. Piles are designed to


transfer a vertical load of about each.
Circular 75 mm

Cylindrical 63 dia

Hydraulic rig 35 dia


:
M35 i. Dia 8mm
ii. P i t c h 2 4 0 m m c /c
1000 mm :
i. No of bars 12
11000mm
ii. Dia 20mm
11100mm
Ro4 u t i n e te s t (T)w a s c a r r i e d f o r 2 %SETTLEMENT
LOAD o f w o r k(mm)
ing piles.
3.5 0.00 0.00
T h e m a x i m u m s e tt l e m e n t o f te s t l o a d i n g i n
3
p o s i t i o n b33.25 0.201
e i n g n o t exc e e d i n g 1 2 m m .
SETTLEMENT (in mm)

2.5 67.11 0.512


I n c r e m e n t s o f 2 0 % o f d e s i g n l o a d a r e g i v e n a f te r
4 52m i n . 100.37 0.842
1.5 135.11 1.121
I n c r e m e n t a l l o a d i n g i s s t o p p e d o n c e t h e ra te o f
s e1tt l e m e n168.01
t i s 0 . 1 m m i n f i rs t 3 0 m i n1.424
s or 0.2 mm
i n f i rs t h o u r.
0.5 202.01 1.875
L o0a d i s m a i n t a i n e d f o r 2 4 h o u rs a n d t h e n
r e b 0o u n d i237.12
s50n o te d .100 150 200
2.602
250 300
272.22 LOAD (in Tons) 3.752
T h e p l o t i s d ra w n f o r s e tt l e m e n t v /s l o a d i n g .
: Rectangular
: Cuboidal
: Cast in situ
: M35
: Fe 415

: 1500 mm
: 4300 mm
: 4300 mm
: 100 mm thick
M15 Grade
: 75 mm.
: 63 dia
: 35 dia
: 28 m
: 1.662 ton
Pile cap is a reinforced concrete structure, which allows the load
from a Pier to be equally shared between groups of piles.

PCC layer of 100 mm is laid

Chipping of the top 1m of pile is done

Marking is done on PCC layer for tying reinforcement leaving a clear


cover of 75 mm on all sides

Shuttering is done after tying reinforcement

Concreting done in M-35 grade and a slump of 180mm.


GIRDERS used at the flyover are
.

Pre-tensioning of concrete means


in a concrete member
before it is actually loaded.

The tension developed in the tension -zone only


tries to counter the compression induced by pre -
stressing. As a result, the becomes

is fully countered by Pre -tensioning


force.
DECREASE IN DEAD LOAD

HIGHER LOAD CARRYING CAPACITY

REDUCTION IN CROSS-SECTIONAL DIMENSION

CRACK FREE STRUCTURE

ECONOMY

ENABLES USE OF SEGMENTAL TECHNOLOGY

TIME SAVING
= 3000mm
= 1000m
= 670 ton
= 100 m
= 45 m
= 4
= 5
= 5500mm
16000 kN
: 7 d ay s
M40

LR ClassII strand
15.2mm dia, 140mm area

16000 kg /cm
260.72 kN

Central Hole Jack Double Acting, Stoke length 385 mm


Monostrand Jack Single Acting, Stoke length 600 mm

50 mm
4
3300 mm

HDPE 18mm dia


10kg/cm2 least count
17950 mm

500 mm
300 mm

720 mm
295 mm

250 mm
200 mm

1700 mm

1
19

9.8 m
1.1 MT
Thread the HTS Strands in the R/F cage of the Girder

Anchor all strands on the Pulling-block with master wedges and barrel

Place Four Central Hole Jacks on live end through already placed
Macalloy Bars

Connect all four jacks to Power Pack through manifold arrangement

Stress the strands upto 100 Kg/cm to remove slackness

Stress the strands by pulling all four Macalloy Bars simultaneously up


to a force of 60% of total force

Keep screwing the Macalloy Nut against the Live-end anchor frame
plate
Go up to full force as stipulated in the structural drawings i.e. 199.42kN
equivalent to a pressure of 526kg/cm

Retract the jack fully and remove the jacks from the Macalloy Bars

Stress top strand/s one by one by Single Strand Jack requiring a


pressure of 482 kg/cm

Concrete with RMC M40 grade with a Boom Placer, cast 15 cubes

Cure the Girder on the stressing Bed for 3-4 days till it attains 90%
strength (36 MPa)

De-tension the girders with help of arrangement same as that for


Stressing

Cut the extra strand and shift the girder to curing bed
MACALLOY BARS CENTRAL HOLE JACKS

MACALLOY NUT

POWER PACK
SINGLE PULL STRESSING
COMPACTIONARRANGEMENT

NEEDLE VIBRATOR

MONOSTRAND
JACK

CONCRETING BY BOOM PLACER


DOWELS
DIAPHRAGM

TOP STRAND

BOTTOM STRAND
DIAPHRAGM

OUTER GIDER INNER GIRDER


WEDGE-BARREL
Length of Strand Between Pulling Block = 95850 mm
Nos of Strand = 19 Nos
Area of each strand = 140 mm.
Jacking Force Of Each Strand = 199.42 kN
Modulus Of Elasticity = 1.95x10^6 kg /cm2
Elongation Of Strands L = P L /A E
= (199.42E3x19x95850)/(140x19x1.95E5)
L1 = 700.2 mm

Length of Macalloy Bar = 3300 mm


Nos of bars = 1 SET (4 BARS)
Area of each bar = 1256.6 mm.
Jacking force on each bar = 199.42x19 kN
Modulus of Elasticity = 1.95 E5
E l o n g a t i o n o f M a c a l l o y B a r, L = P L /A E
= (199.42E3x19x3300)/(1256.6x19x1.95E5)
L2 = 12.8 mm
GRINDING, BUFFING, OILING OF
SHUTTERING AND BASE PLATE
EFFICIENCY OF POWER PACK
REINFORCEMENT COVER 95%

PROFILE OF STRANDS SLUMP TEST AND CASTING OF


CUBES
JOINTS IN STRANDS
CUBE TEST FOR DE-TENSIONING
TAPING OF DE-BONDING BARS

HORIZONTAL ALIGNMENT OF
SHUTTERS
TRANSPORTATION
ERECTION OF GIRDER
OF GIRDER
BY CRANE
AT SITE

TEREX DEMAG GIRDER


Carried out at night when the traffic volume is low

Proper arrangements are made for traffic control

Speed of trailer is limited to 10km/h


CRANE
Equipments used

1. Trailer 50 T capcity
2. Terex Demag 120 T capacity
3. Crane 100 Tcapacity TRAILER
4. Lifting hooks
A M BA L A E N D CHANDIGARH
Reinforced Earth is a composite material formed by
E Nthe
D
interaction between a frictional soil and reinforcing strips.

LEN
The G T H O Fstrips resist
reinforcing 1 3 9stresses
. 1 1 4 mproduced2within
1 4 . 1 1the
4 msoil
massWA L L

Stresses are transferred to the strips via friction


MAX HEIGHT 5.605 m 8.045 m

Precast
M I N HConcrete
E I G H T panels :1 . 4 8 9 m 1.295 m
prevent erosion of the backfill
provide
G R A D Ian
E Nattractive,
T finished appearance
3.00 %
150mm x 350mm
M30 grade

Stone Dust
C = 0.03, = 44.3, = 22kN/m

M35 grade
A , B , I , J , K , L , M , N , P, Q
suffix 2,4,6 etc.

300-460mm wide
EPDM Pads

High Adherence (HA) strips


40mm x 5mm varying length

10mm and Sand (70:30)

12mm dia bolts


Excavation and installation of drainage system (if any)

Form and pour levelling pad, M30 grade, 150 mm x


350mm

Set and brace the course of facing panels

Set batter (12-15 mm) , Check horizontal alignment and


level

Wood wedges and clamps to hold panels in position

Attach filter cloth with adhesive

Spread, water and compact backfill in lifts up to 50-75


mm above panel tie strips
Connect reinforcing strips to panel tie strips with bolts

Compact backfill to within 60 mm of the top of the panels


(min. 95% of MDD) upto 1500mm from inner face of panel

Lay filter media upto 600 mm from inner face of panel

Compact inner, 1500mm wide backfill upto min 90% MDD

Plumb Check of completed panels

Bearing blocks/EPDM pads and set the second course of full


panels

QUALITY CHECK OF COMPACTION: SAND REPLACEMENT TEST

Repeat the steps to attain desired height


90% MDD 95% MDD
HOOK FOR
BRACING
LIFTING

WEDGE

EPDM PAD

CLAMP
LIGHTWEIGHT PLATE
VIBRATOR

FILTER
LUG MEDIA

SMOOTH-DRUM VIBRATORY
ROLLER
HIGH ADHERENCE
STRIPS

1500MM

INWARD SLOPE OF 2.5%


DESCRIPTION UNIT TEST 1 TEST 2
FIELD DENSITY
Mass of wet soil from hole (Ww) gm 3645 4410
DATofESand
Mass O F+ Cylinder
T E S T before pouring 06-12-07
gm 14000 14490
(W1)
Mass of Sand + Cylinder after pouring
LO C AT I O N (W2) L H S , R Egm A M B A L AREPLACED
- WA L L 10882 S IDE
10881
EARTH
Mass of Sand in hole + Cone (W3 = W1-
gm 3118 3609
M A X . D RY W2) DENSITY C 2.02
Mass of Sand in Hole (Wb = W3-Wsc) Y gm 2238 2729
L
Volume of Sand in the hole (V) cc 1659.01 CONE
2022.98
OMC I 9.5 %
Bulk Density of Soil (Gb = Ww/V) N gm 2.197 2.180
MOISTURE D
CONTENT SAND
B U L KMoisture
D E N Meter
S I T Yreading
OF SAND E 1 . 3 4 97
R % 5
Corrected moisture as per calibration (w) % 9 7
WEIGHT OF S AMOISTURE
RAPID N D I N CRESULTS
O N E ( Ws c ) = 8 8 0 g m
METER HOLE
WEIGHgm/cc
Density of Soil, Gd = (Gb100)/(100+w) 2.016 2.037
BALANCE
Percentage Compaction obtained % 99.78 100
PCC TOP LEVEL CORROSION OF STRIPS

SURFACE DEFECTS IN IN-SITU DENSITY BY SAND


PANELS REPLACEMENT

PANEL BATTER PLUMB CHECK OF PANELS

HORIZONTAL ALIGNMENT
OF PANELS

POSITION AND WIDTH OF


FILTER CLOTH
Done at plant and
on recieval at site SLUMP CONE

6 cubes are cast


for each Transit
Mixer at plant as
well as on site

TAMPING
ROD
CUBE NAME
WEIGHT DENSITY
OF STRUCTURE AGE LOAD AT COMPRESSIVE AVERAGE
NO. : PSC GIRDER
(gm) (gm/cc) (days) FAILURE STRENGTH (N/mm )
(kN) (N/mm )
GRADE OF CONCRETE
: M 40
2 8305
STRUCTURAL 2.461
MEMBER 450 20.00
: RP 39
4 8299 2.459 450 20.00
3 19.85
7 LOCATION
8300 2.459 440 19.56
: Site Lab
5 8342 2.472 860 38.25
SIZE OF CUBE (mm)
6 8295 2.458
: 150*150*150 870 38.70
7 37.81
9 8311 2.463 820 36.47
LOADING
1 8296 2.458
: 315 kN/min 1200 53.38
3 8300 2.459 1190 52.94
28 53.38
10 8329 2.468 1210 53.83
Characteristic Compressive Strength 40 N/mm

Maximum size of Aggregate 20 mm

Degree of Workability 0.9 compacting factor

Degree of Quality Control Good (Table 40, SP23:1982)

Type of Exposure Normal (Table1700-3, MORTH)

Initial current margin 12kN/mm


(Table 1700-5 MORTH)
Target Mean Strength = 40 + 12 = 52 N/mm
Table 5, IS: 10262-1999

Sand Content 38% Water 180kg

High Range Water Reducing Admixture 1.1%

Water : Cement 0.36


(figure 2 ,IS: 10262-1999, Curve E)

Free Water Content 158 kg

Cement 440kg

Total Water (after adjustments) 182.10kg


Fa (Sand) 672 kg

Ca (10mm+20mm) 1130 kg

20 mm aggt. (50%) 565 kg

10 mm aggt.(50%) 565 kg

Batch for 20 kg Cement:

Water Cement Sand 10 mm 20 mm


8.28 20 30.55 25.68 25.68