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Case study on Accelerated Construction of Danea –

Ranchi Road doubling project of Dhanbad Division

Sitesh Kumar Singh1&Ashutosh Chourasia2

1Chief Engineer/Construction\South East, East Central Railway, Patna, India

2Dy. Chief Engineer/Construction, East Central Railway, Hazaribagh, India

ABSTRACT: To enhance the line capacity, for improved movability, punctuality etc.

Railway has sanctioned many doubling projects in the year 2015-16 all over Indian

Railway networkwhich are funded by EBR(IF).Since the funding of these doubling

Railway projects is through LIC which need to be returned with interest after 2020.

Therefore, there is a need of fast paced construction. Danea to Ranchi Road (25

km)doubling in important CIC route of Dhanbad division was sanctioned in the year

2015-16. Two out of four block sections in this doubling project has been commissioned

in the year 2018-19 and balance two block sections are in advance stage&targetedfor

commissioning by February, 2020. There were many challenges like obtaining forestry

clearance (obtained in June 2019 for about 10km patch), existing signal & electrical

infringements, law & order problems etc. Therefore, a case study has been presented for

this project in this paper.

Danea to Ranchi Road doubling project consists of56nos of scattered minor bridges, 1

major bridge, 5 nos of LHS, with fivenos of crossing stations & one halt station. The

alignment is mainly going through Naxalite affected hilly & dense forest area of Bokaro

& Ramgarh districts of Jharkhand. In two block sections, namely, Jogeshwar Bihar-

Chainpur-Karmahat, track laying was completed from October’17 to December’18 (12

km) and Non interlocking work of three yards was successfully done in March’19in a

single day with mega block of 8 hours.

Meticulousproject planning needs to be done to complete the work in targeted time. There

will be many hurdles like Forestry clearance, non-availability of approach roads,

foundation in rocky strata, safety & security concerns as heavily naxal infested area, bad

weather, local festivals, objections of nearby residents, regular agitation from land

owners, running signal and electrical infringements like location boxes, signal cables,

masts/portals, signals, sectioning posts etc. All these hurdles have been overcome with

proper project planning, fast paced construction by deploying advanced earthmoving

equipment and regular multi-level co-ordination meetings with fellow signal and

electrical departments and State government.

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1.0 PROJECT PLANNING

Before stating execution work, the following meticulous planning was done. 1.1 Survey, alignment and other clearances:Immediately after sanction of detailed

estimate, it is essential to expedite tree felling permission in Railway land, forestry clearance etc. in consultation with state officials to avoid any delay in processing. State Govt. authorities concerned were consulted regularly telephonically as well as in person to avoid time delay in correspondence between Railway and State Govt. It should be kept in mind that the land acquisition Plots/Khata etc should also be verified in field with alignment and survey team to avoid future litigation by forest or State govt. First of all, the coordinates of railway alignment wereplotted/drawn over forest/village maps with the help of GPS/Total Stationfor the entire alignment from Danea to Ranchi Road and subsequently forest land acquisition was also verified inthe field.

1.2 Identification of running signal & electrical infringements in block sections: After finalization of alignment, it was requiredidentify electrical infringements like overhead crossings (11KV, 33 KV, 132 KVA etc.), location of signal cables (Quad, OFC etc.), so that timely action may be takenby concerned signal & electrical department for their relocation/removal.Fig.1 below shows such infringements.

Fig.1 Home signal & 33KV line

1.3 Preparations of L-section, GADs, designs &drawings: L-section, GADs, design

&drawings of all bridges were prepared before processing of tender and kept ready.For expeditious execution use of standard RDSO design is suggested to avoid time delay in tendering/designing of bridges.

1.4 Finalization of ESPs, SIP, removal of yard infringements and construction of station/signal building: Preparation of ESP (Phase planning) is very essential in doubling project. Phase-I plan has to be prepared along with master plan so that movement of ballast train, 20 Rail panel unloading, machine tamping can be started immediately after completion of formation work. In Phase-I plan,Engineering siding can be easily commissioned by dismantling existing sand hump or converting of existing trap into point. Indicative Sketch isshown below in Fig.2.

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Fig.2 Engineering siding by converting trap into 1 in 8.5 point

After finalization of master ESP, a list of yard infringements (like location boxes, signals, mast, portals, sectioning post etc. as shown in Fig.3 below) has to be preparedimmediately so that timely action for removal of infringements may be taken by concerned department. Construction of new S&T building (Relay, IPS, battery room etc.) is time taking activity, therefore, its plan should be quickly finalized in consultation with division and its construction should be started as soon as the contract is awarded.

Fig.3Location boxes, Masts & Portal infringement

1.5 Timely processing of bridge, FOB,CRS sanction for yard modification,

sanction for existinggrade condonation in yard, EIG: There is need for timely processing for obtaining sanctions of bridge &yardmodification & condonations, if any. In doubling,generally existing bridges need to be extended by dismantling wing wall etc. which require sanction of CRS. Further, in old existing yards there

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may be existing grades etc. which need to be condoned afreshdue to proposed yard modification. In case of yard remodelling,if existing FOBinfringe the SOD, then its planning and sanction may be obtained timely so that work is started immediately after award of work.

1.6 Requirement of extra ETA, block and track machines:At the start of work, requirement of caution for extension of bridges, traffic & power block and track machines should be given well in advance so that concerned department may plan for it suitably.

1.7 Timely preparation & identification of Pre-NI, NI activities & preparation of NI program: After finalization of ESP all pre-NI & NI activities to be planned and detailed NI program to be prepared in consultation with division so that division may plan for extra ETA and suitable block for work.

1.8 Requirement of P.way material & its availability:Requirement of all P.way materials, ballast etc. requirement should be given well in advance so that work don’t get delayed on this account and concerned department may plan for it well in advance. If yard modification is planned in phases, then, requirement of materials should be bifurcated accordingly with likely time schedule.

1.9 Timely processing of QAP/WPSS of steel girder: Fabrication of RDSO standard girders for major bridges has to be cleared either from RDSO/Plant depot inspection engineer, therefore, timely processing of QAP and WPSS should be done so that work don’t get delayed on this account.

2.0Tender/Contract proposal with required eligibility criteria:Forestry & other clearancesinvolves various stages and tender of above work has to be floated nearly 3 months before likely time of obtaining clearance. One month has to be kept for mobilization by the contractual agency. All the construction activities have to beclubbedandeligibility criteria for similar nature of work was specified according to the requirement of work so that only capable contractors can participate. Bid was invited through open tendering process for this project.

2.1Selection of location of concrete batching plant & camp office:Earthwork, concrete and P-way work are usuallyscattered so selection of site office & concrete plant is very important. Location of camp office should be selected as per available road facility along with suitable approach roads to various construction sites.

2.2Modern facilities in the camp office& security camp: To maintain quality of work with the desired progress,well equipped laboratory has to beset up in the camp office, all latest communication facilities (Fax, Internet, Walkie Talkie, WhatsApp group), required fabrication set up, water tight cement godown, Concrete plant set up, Transit Mixtures (TMs), required transportation facilities, staying & kitchen facilities etc. should be provided in the camp office.Asper the law & order situation of site pre-fabricated security camp at site may be constructed with 24 hours water and light facility which will boost the moral of staff working in such naxalite area and will provide them security and confidence of working at vulnerable site.

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2.3 Organizational set up: -For day to day monitoring the work,the following Railway organization&Contractor’s organization was set up for coordination on day to day issues:

2.3.1 Railway’sorganization: -As work was in progress, 24x7 hrs manning of site was

essential, therefore adequate nos of SE&JE/Con should be posted with Executive/Assistant Engineer &Dy.Chief Engineer at Hazaribagh under Chief Engineer headquarter at Patna.

2.3.2 Contractor’sorganization: -To maintain the highest level of quality,

thecontractor’s organization should have Project Director, adequate nos of deputy Project Managers, HR personnel, Accountants, Mechanical Engineers Store Incharge,Sr. Engineers (Earthwork), Material Engineer, Sr. Structure Engineer, Lab Technician,Mechanical Foreman, Mechanical Supervisors, Sr. Mechanics, Mechanical helpers, Welders, Lab helpers, Safety & Security personnel etc.

3.0Methodology adopted for accelerated execution

The following methodology was adopted for fast paced execution.

3.1 Sequencing of Parallel activities: The most important aspect of execution to operate all parallel activities ata time in pre-decided sequence. The following few activities resulted in faster execution of work:

3.1.1 In RCC Box Bridges construction of Return/Wing wall and Box should be constructed parallel.

3.1.2 Earthwork, Dry Stone Backing, Back filling and protection work in RCC Box

bridges should be done parallel.

3.1.3 In Major Bridges (Composite/Plate Girder), construction of Abutment should be done first (as shown in Fig.4) and thereafter, should be continued from one end so that earthwork in filling and girder launching can be done parallel.

Fig.4 Showing Parallel work of Back filling inBridge construction

3.2 Regular Meetings with State Govt. authorities: Regular multi-level meetings were held with the following State Govt. authorities on various unresolved agenda items.

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3.2.1 Chief Secretary: Monthly meetings with Chief Engineer and Deputy Chief Engineers of Railways and Deputy Commissioners & Superintendents of Police of district chaired by Chief Secretary of Govt of Jharkhand were held regarding land, law & order and many other issues with commitment within specific time frames. Fig.5 shows one of such meetings.

Fig.5Meeting with Railway and State Officials in Vikas Bhawan, Ranchi

3.2.2 Secretary Forest/Ranchi:Monthly meetings chaired by Secretary/Forest, Govt. of

Jharkhand, in presence of DFO/Bokaro & Ramgarh with Railway officials on monthly basis was also very fruitful in faster acquisition of forest land and tree felling permission.

3.2.3 Divisional forest officer: Fortnightly meetings were also held by divisional forest

officer of Bokaro & Ramgarhdistricts with Railway officials for reviewing forest land, encroachments, law & order issue etc. for timely solution on all disputed matters.

There above mentioned Three Tier review meetings between StateGovt. and Railway officials helped in better, faster and smooth execution of works. Few meetings were alsoheld with Chief Minister of Jharkhand. 3.3 Use of Concrete Batching plant: -To ensure timely completion ofsuch a huge

concrete work 20 cubic meter/hr capacity 2nosBatching plant were installed each withstorage capacity of 20,000 cement bagsat suitable locations as shown in Fig.6.

Fig.6 View of Batch Mixing plant

3.4 Use of advance earthmoving equipment: For faster progress of earthwork, following advance earthmoving equipment should deployed:Poclains,Graders,Hyvas,Vibro rollers,Dozers,Wagon & Tractor drillsetc. Fig.6 shows some of such equipment used.Use of heavy 400/380/300/220 capacity

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excavator (poclains), heavy vibro roller,graders, dozers, JCB (for small value work) resulted in progress of 10000 to 20000 cubic meter of earthwork per day. Fig.7 below shows such equipment in use.

Fig.7 Various Earthmoving Equipment in use

3.5 Use of Ready-MixConcrete & Boom Placer for concrete work: Manual process of concrete work is time consuming & cumbersome as it involves shifting of mobile batching plant (which has low capacity of 2-3 cubic meter/Hour). It requires concrete pump at each site. Hence Ready-Mix concrete is the best suited for scattered concrete over various bridge locations. Transit Mixers (TM)(Fig.8) should be used for Ready Mix Concrete (RMC) for scattered bridge locations. Concrete boom placer (Fig.8) saves time for pouring arrangements of RMC at deep & high unapproachable locations of bridges wherein it is quite difficult to pour by other methods.

Fig.8 Transit Mixer & Concrete Boom Placer

3.6 Maintenance system for concrete plant and other equipment: Fully experienced & well-equipped maintenance team was deployed for day to day maintenance of heavy equipment, concrete plants etc.

3.7 Use of Heavy Road Cranes: With easy availability of 150/250T Road cranes, launching of 18.30/24.40/30.5m composite girders of Major Railway bridges and 24/30/36m composite girders for Road bridgesbecomes very easy, fast, smooth and saves lot of time. Fig.9 shows use of road crane for launching of bridge girders& FOBs.

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Fig.9Use of Road Cranes for launching of girders

3.8 Use of advance earthmoving equipment for P.way work: Advanced earthmoving

equipment were effectively utilized as track machines for P.way linking. Effective utilization of few such machines have been listed below:

3.8.1 Use of Hydra/JCB for shifting of P.way materials including rail: Hydra & JCBs were effectively utilized for shifting/carrying of P.way materials including rails as shown in Fig.10. Special slings are attached to Hydra for lifting of rails/sleepers like UTV machine.

Fig.10 Use of Hydra for shifting of panel rail

3.8.2Use of JCB as Ballast Regulating Machine (BRM:JCB was used for ballast

regulation as shown in Fig.11 below. During ballast regulation, front wheel of JCB is in lifted condition.

Fig.11 JCB being used as BRM

3.8.3Modification of Tractor with Trolley as BOBYN rake:Tractor wheels are

modified for its mobility over rails as shown in Fig.12 below for unloading of ballast directly in track, similar to BOBYN rake.

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Fig.12Modification of Tractor with Trolley as BOBYN

3.8.4Modification of Truck for ballast unloading in track: Tyre of truck is modified as

shown if Fig.13 below so that ballast can be directly unloaded in track.

Fig.13 Modification of Truck for ballast unloading in track

3.8.5 Use of Hydra for dismantling/laying of Points & Crossings: 2 nos of Hydra

working in tandem were efficiently utilized for dismantling/laying of Points & Crossings as shown in Fig.14 below.

Fig.14 Use of Hydra for dismantling/laying of Points

4.0Problems faced during execution & solution Some of the problems faced during execution of this project have been mentioned below: 4.1 No approach road: The entire project is in densely and heavily naxal infested area

of Jharkhand state wherein no approach road or access to work site was available. At each bridge location except RUB/ROB no approach road was available. Work was immediately started after handing over the forest land. Local roads were made and connected with existing roads wherever available.

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4.2 Rough weather:The weather in hilly regions of Jharkhand changes frequently and even after rainy season, rains affected work in the months of October, November and May. By studying the daily weather pattern, the work was continued during the period of least disturbance.

4.3 Local festivals: In Jharkhand area, there are various local festivals almost in every

month which affected work progress.Some outside labourers were hired & kept in camps on permanent basis to continue progress of works even during these festivals.

4.4 Frequent law & order problems:The alignment falls in Bokaro and Ramgarh

districts of Jharkhand. It passes through forest, infested with Maoist activitiesand other militant groups.There were frequent disturbance/stoppages of work by extremist groups. Number of times extremists have damaged machineries and other plants (Fig.15) and carried out firing at work sites and labourers camp office.

Fig.15Labour camp and Poclain burnt by extremists

This caused great setback and disruption in works at various work sites.Police camps were constructed at suitable & strategic locations manned by Jharkhand police commandoes with latest arms and ammunitions to tackle this problem to some extent.

4.5 Delay in approval of running infringements: Delay in running infringements like

location boxes, mast, portals etc. affect engineering work badly, therefore timely identification and regular chasing with concerned department may help in timely removal.

4.6 Delay in supply of detonators:The progress of work hampered due to short supply

of detonators due to fulfilment of stringent mandatory provisions. The detonators had to be used within 72 hours of supply. There is only one licensed supplier in Ranchi district (Jharkhand). However, some detonators were procured from adjoining districts i.e. with alternate sources.

4.7 Non-availability of skilled workers in Bokaro/Ramgarh area: There is shortage

of skilled workers in this area. Due to Maoist activities and poor law and order situation in the area, the participation in tenders was very poor. In addition, the villagers did not allow outside labourers to work. Even good engineers and supervisors are not willing to work in the area. However, there was many ongoing

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road projects of State Govt., therefore many skilled labourers were imported from other states also.In addition, the local labourers were trained over a period of time and this helped in smooth progress of work.

4.8 Encroachment removal:Removal of encroachment is a very difficult task during

construction stage but with the help of local administration, all encroachments were removed in time bound manner and this resulted into smooth progress of works.

5.0Few completed photographs:Photographs of a few completed structures have been shown in Fig.16& Fig.17.

Fig.16 New Station building, new yard lines& FOB at Karmahat station

Fig.17 New Station building, new yard lines& FOB at Jogeshwar Bihar station

6.0 Conclusion

From the above deliberations, it is concluded that:

In every project, more focus should be given to the meticulous planning aspects so that parallel activities are sequenced and monitored.

Construction projects get delayed/fail due to delay in forestry clearance and preparation and approval of design/drawing of bridges/station buildings/ESPs etc.

Prior finalization of L-section, GADs, Bridge design, ESPs,Station building plans & design etc. before award of tender is a critical item for timely completion of the project.

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Finalizations of ESPs, SIP, removal of yard infringements and construction of signal building is very important.

Timely processing of bridge, FOB, yard CRS sanctions, various existing condonations from CRS, EIGs are very essential.

Requirement of extra ETA, block and track machines should be given well in advance.

Timely preparation & identification of Pre-NI, NI activities & preparation of NI program is very essential.

Timely procurement of P.way material & ballast is very essential. Timely processing of QAP/WPSS of steel girder for clearance from RDSO is a

important item. Timely processing of tender (including all works) with suitable eligibility criteria

is very important. Use of advance and latest technology-based construction equipment like heavy

earthmoving machines, Vehicles, Tippers, Hyvas, Compactors, Dozers, Concrete batching plant with Ready Mix concrete, Concrete Boom placer for placement/pouring of concrete are very useful for expeditious planning and execution of work.

Suitable selection of camp office and concrete batching plant with ready mix concrete is key factor to monitor the concrete quality as per the requirement.

Adequate organizational set up of client as per as contractor is key to monitor day to day work as well quality.

Regular liasioning with district administration is very helpful to resolve day to day issues.

At militant infested work sites, it is better to arrange police camps in advance for smooth progress of work.

Launching by road crane is most suitable for composite girder bridges. For long lead works, locally available manpower may be trained to carry out

skilled jobs. Based on the above observations, similar case studies can be shared for better

appreciation of field engineers. With experiences gained, an objective framework for decision making can be presented with constraints as inputs.

7.0 References

Ahuja, Vanita. and Khanna, Hitesh. (2013). “An International Railway Project – A Project Management case study”. Construction, Building and Real Estate Research Conference (COBRA), DOI: 10.13140/2.1.1098.0487.

Sirong, Yi. (2018). “Principles of Railway Location and Design”. Academic Press,ISBN 9780128134870

Anette Ostbo Sorensen, Nils O.E. Olsson and Anandasivakumar, Ekambaram. (2015).

“Evaluation and Learning – Experiences from a Construction Project in Norway”. Procedia Economics and Finance, Volume 21.

Anbang, Qi. and Hailong, Chen. (2014). “Research on China Construction Project Management Paradigms Change and Development in the Last 30 Years”. Procedia - Social and Behavioral Sciences, Volume 119.