INTRODUCTION

PROJECT SCOPE

UNIQUE FEATURESOF THE PROJECT

CHALLENGES ENCOUNTERED

WATER INITIATIVE

Delhi Faridabad Express Way

HCC is the first engineering company in India to have all three international certifications for Quality, Occupational Health & Safety and Environment

The Making of

Introduction:The project is located on the existing Delhi-Agra section of NH-2 which is a busy road that runs through Delhi, Haryana, Uttar Pradesh, Bihar, Jharkhand, and West Bengal. It starts at 16.10 km (in Delhi) and terminates at 20.50 km (in Haryana) of NH-2 (Delhi-Agra Section). The project road is located in the Yamuna basin adjacent to Aravali trails in the southern part of Delhi and passes through flat terrain. The area adjacent to the project site is dominated by industrial and commercial activities with numerous residential establishments near Badarpur village. This corridor is a vital southward radial from Delhi, the capital of the country. Traffic on this route results from the urban activities of Delhi and Faridabad (Haryana) besides, long –haul traffic from and between north and south of Delhi.

The traffic flow is expected to increase on the project stretch primarily due to its strategic location, short distance connectivity to various prominent regions, induced traffic on account of tourism and development of the Faridabad-Palwal section and the expansion of the Badarpur Thermal Power Station.

National Highway No. 2 forms part of Golden Quadrilateral. It is a vital southward radial from Delhi, the

capital of the country.Owing to a massive increase in population, coupled with economic, industrial and other activities in the town of Faridabad and Badarpur, a tremendous amount of congestion has occurred on NH-2, especially, in the reach from km 16.700 to km 19.700. Successive road intersections at close intervals have further aggravated the traffic problem. Widening of the existing road would have only increased storage capacity of that particular section of road between junctions, resulting in increase in traffic signal cycle time at the junctions to handle the high volume of waiting traffic. High traffic volumes would have lead to delays and congestion. The option of constructing individual flyovers on these closely spaced intersections was not feasible as the approaches would overlap.

Therefore, NHAI envisaged 'Construction of Elevated Six Lane highway from Km 16.100 to km 20.500 (including its approaches) on NH-2' to remove congestion and improve the traffic flow on this section of the National Highway. The Project also includes widening of the entire ground road with provision of service roads on either side. The Project road sections, presently, have a 4/6 – lane carriageway configuration with flexible pavement and service roads on either side of the carriageway at intermittent locations. Generally, the shoulders are either granular / earthen.

The project section has five important junctions apart from 20 access roads meeting either carriageway. The five important junctions are

Ÿ BTPS Junction Ÿ Mehrauli Junction Ÿ Jaitpur Junction Ÿ Sarai By pass Junction Ÿ Sector 37 Road Junction

Of these junctions, the most critical ones are Mehrauli and Jaitpur junctions, where severe traffic congestion is observed. However, other junctions also have significant congestion and the traffic on these is expected to reach the threshold level of 10,000 PCU (as per IRC guidelines) shortly which would warrant provision of grade separated junctions.

Project scope:

The project was awarded to HCC on BOT basis. It included design, construction, development, finance, operation and maintenance of 4.4 kms of a six lane elevated road.

With limited space and a large number of junctions, the challenge was to design an elevated highway in such a way as to eliminate traffic signals at all five junctions and facilitate seamless traffic flows in all directions, thus reducing congestion. The unique “EYE” shaped design which was finalized has the sharpest curves without compromising on safety and ease of movement. This requires a high level of precision, technology and standardization for construction. The greatest challenge was the limited time available for completion keeping in view the difficulties of land acquisition, permission from various government agencies & existing underground utilities etc.

Unique Features of the Project-1. Reduction in traveling time: Travel from Delhi to Haryana necessitates crossing five major junctions

and takes around 45mins to 2 hrs (Depending upon the traffic congestion). This duration will be reduced to about 10 mins with the Badarpur Elevated Highway.

2. Maximum span length (46 meter): The project envisaged a pre - determined number and length of spans over which traffic would have to travel before provision of a U-Turn. In order to optimize the length without increasing the depth of the girders in order to maintain minimum clearance below the spans as well as to allow an easy turning radius for traffic movement, 46 mtr spans were finalized. Launching of a 46 mtr span is difficult

with a Launching Girder. But HCC was able to achieve this by improvising a modification of the launching girder.

3. Minimum Impact on Environment: To minimize the carbon footprint of construction operations, HCC, together with the NHAI, will be planting 10 times more trees than the number that were felled for the operations. The plantation drive has been undertaken along the roads in Delhi, the Haryana side of the project as well as at the Mirzapur casting yard. More significantly, the project undertook to replant ― rather than cut down ― some particularly valuable trees that are remarkable for their age and species. To date, as many as 19 such trees have been successfully replanted and remaining 46 are planned to be transplanted.

4. Landscaping: The project involves major landscaping work as a part of its scope of work. The area near Mehrauli crossing which is presently congested will be given an aesthetic touch with Landscaping.

5. Carpeting: The area alongside the project will be carpeted. This will enhance the beauty of the place in addition to reducing the dust.

6. Use of Fly Ash: Construction of 40000 sqm of RE Wall required 3.1 lac cum of earthwork which was conscientiously saved through the use of flyash which was available at the nearby Badarpur Thermal Power Station.

Challenges encountered during construction

a) Traffic diversion / management during construction

The alignment of the elevated highway was along the existing road which had high traffic density throughout the day. This posed a severe challenge for construction while the traffic movement was continuous on both sides of the elevated structure.

Ideally, the traffic should have been diverted on to an alternate route but here that possibility was ruled out as there was no such route. Construction of temporary roads for traffic diversion was also not possible as the required land for these was not available.

HCC took extra safety precaution and devised a flexible traffic diversion proposal which changed as the construction progressed to overcome this hurdle

• Traffic Movement – The diversion roads were kept at the same width of 10.5 mtrs as the original road alongside the

flyover on both sides.– A stage wise traffic diversion plan was prepared keeping in mind the construction progress– In order to avoid disputes with Traffic Control Authorities during construction HCC prepared a

detailed 3D traffic movement plan and obtained approval from both Delhi & Haryana Traffic Police.

• The construction was done in such a manner that only the stretch on which the actual work was going on was cordoned off from the main road, allowing free movement of traffic on the rest of stretch and avoiding inconvenience to motorists.

• Ample number of signages were provided for smooth traffic movement• Extra Passenger Underpasses Passes (PUP) and Foot Over Bridge

– The project's scope of work included only three such underpasses, yet keeping the safety and convenience of school children in mind two new Pedestrian Underpasses were included in the scope of work in due consultation with NHAI.

– The Detailed Project Report did not envisage the movement of people at Sarai Chowk. HCC in consultation with NHAI decided to provide a Foot over Bridge for hassle free pedestrian movement at Sarai Chowk.

• HCC also deployed adequate numbers of Traffic Marshals and Traffic Coordinators for smoother traffic flow during construction.

b) Times cycle management

The project was scheduled to be completed in 24 months. Completing the project and creating the entire Infrastructure on time in such a congested area given the obstructions faced, was a big challenge. To add to this, the project lost some time in the initial months on account of a delay in handing over of the land by NHAI. However, HCC's engineers planned and managed the operations so efficiently as to complete the project 2 months before the scheduled date of completion. HCC with its superior project management skills utilised optimal time cycle management to carry out various construction sequences in the least possible time.

Pier & Pier cap:

An Innovative shutter design created for both Pier and pier cap made it possible to cast both, pier and pier Cap in one pour. Conventional piers take about 300 hours while this structure takes about 60 hours only. This shutter design, being of one piece, provides additional strength and takes 1/6th of the time otherwise taken to be made ready. This type of self supporting shutter decreased the time cycle from 15 days to 3 days. In addition, the process used resulted in the creation of slim design piers with a high degree of aesthetic value.

Single Pour Pier Cast Finished Pier

Segment Casting:

HCC chose a segmental construction method for the superstructure or deck of the elevated highway. This method is comparatively faster than using girders for the superstructure. Segment casting is generally done using the short line method whereby the segments are cast in one direction only.

HCC utilized a unique construction methodology known as the long line method, wherein at first, the bed is prepared for the entre span with the same alignment and coordinates of curves (both vertical and horizontal) as it would actually be on site, after which casting is carried out from both the ends. This methodology not only reduces the time to build the casts by half, but also ensures a greater level of precision.

Similarly launching of the segments and completing the superstructure between two piers usually takes around 7 days. HCC pressed into action a round the clock segment movement with the required logistics to cut down this time cycle to 3 days. The fastest superstructure completion between two piers was achieved in 2.59 days.In general the super structure of an elevated highway is cast keeping the bottom level parallel to the ground and the cross slope is adjusted in the top deck, whereas in the Badarpur project, the soffit (the underside of a span) also has the same cross slope as at top there by giving the overall structure an elegant look. A further effect is reduction in the use of concrete and steel. To achieve this, a special

mould was designed by “Swiz Designer” of Switzerland, which can be positioned in all three dimensions. This method requires complete precision in the detailing of each individual segment before casting.

Segment Erection:

Three Launching Girders and two trestle arrangements were used to complete the entire launching of 144 spans. One of the three launching Girders was brought from NRSTM and manufactured in China, to negotiate launching at steep curves and vertical gradients which conventional girders cannot do.

c) Obtaining approval from IIT, Delhi

In order to avoid delay in approval of design & drawings, special permission was taken from NHAI to have the drawings reviewed by IIT Delhi which resulted in saving of three months.

Integrated storm water management, ground water recharge at HCC's Delhi-Faridabad Elevated

Expressway Project, Delhi and Harayana

Approach:

HCC's UN Water Mandate team, along with the project site team, conducted a study for Proposal Identification and prepared a Feasibility Assessment report. In this, they estimated water neutrality / water positivity potential for the entire project site on the basis of projected water conservation data and forecast of water consumption for the entire project life cycle. A list of achievable targets to become water neutral / water positive were drawn which were discussed with the project management team to ascertain Commitment for UN Water Mandate Implementation at the Delhi Faridabad Elevated Expressway project. Following proposals were undertaken for the implementation:

1) Water conservation through natural percolation a) Artificial pond excavation

2) Water conservation through installation of rain water harvesting systems at site establishment structures 3) Water Reuse/ Recycle methodologies.

a) To reuse treated, effluent Water from the batching plant for dust suppressionb) An innovative concept of recharging the groundwater table using the storm water flowing from the

elevated highway.c) A water recycling system for circulating the Curing water at the casting yard.

Location Set Of Proposals Code Cost Estimates

Accepted

Shelved

Reason UN Water Mandate Tagging

Mirzapur

Natural Pond Recharge BRP-RWH-1

36,000.00

aOwnership issue and clashing with local community's economic interests

Do1, DO2, CE1, CE2

Recharge of Artificially Excavated Pond

BRP-RWH-2

100,000.00 a Feasible and reasonable proposal

Do1, DO2

Roof Top Rainwater HarvestingŸ Main Site office

BuildingŸ Staff camp

BRP-RWH-3

80,000.00 a Feasible and reasonable proposal

Do1, DO2

Recycling of Curing Water BRP-WW-4

30,000.00 a Feasible and reasonable proposal

Do2

Batching Plant Waste Water Management

BRP-WW-5

NIL a Do2

Elevated highway

Elevated highway-Rain water Harvesting

BRP-RWH-6 To be

furnished after designing

a Feasible and reasonable proposal

Do1, DO2

Toll plaza

Toll plaza -Rain Water Harvesting

BRP-RWH-7 a Feasible and

reasonable proposalDo1, DO2

Water freer Urinals at the Toll Plaza Administration unit

BRP-WFU-8

28,000.00 a Feasible and reasonable proposal

Do3, DO4

1) Natural Pond Recharge Proposal (BRP-RWH-1)

The deepening of the natural pond on the site location at Mirzapur was proposed to increase its capacity from 800 KL to 1200 KL. This would have augmented the surface water availability and increase percolation. But owing to certain social issues like ownership and livelihood of the community linked to the pond, this proposal was shelved.

Community sentiments may supersede a potentially good proposal.

2) Recharge of Artificially Excavated Pond (BRP-RWH-2)

A 400 sq.m low lying part of the land was used to create an artificial pond with the capacity of 1614 KL. The accumulated storm water collected at the site was used to fill the pond. With an average 600 mm of rainfall, the projected water conservation was 30000 KL/year. Owing to the scanty rain fall the estimated quantity of ground water recharge for 2009-2010 was 8400 KL and for 2010-2011 was 6288 KL.

Basic Engg Details

Pond capacity = 1614 M3 = 1614 KLExpected peak runoff = 1200 KLExpected water availability for recharging = 30,000 KLPercolation = observed low due to low permeability of soil available (cohesive –clayey soil)Likely to act as a surface storage pond & recharging the upper shallow aquifer

The surface runoff at the site, due to periodic rain showers, helped the artificial pond to get filled resulting in water percolation into the soil. Based on the rainfall data provided by the site, the computed quantity of ground water recharge for 2009 – 2010 was 8400KL and for 2010 – 2011 was 6288KL. The total computed percolation was 14688 KL against the estimated 14048 quantity of percolation in the proposal.

When the bore well vendor was queried about the impact of the pond on the ground water table, he informed that the water table in the vicinity of the pond was always high due to the rainwater percolation in the region. He also said that the accumulated water in the pond would add to the groundwater but would show negligible impact in an area of ample water.

Currently, the vacated land is filled with soil to make it as levelled land as per the terms laid in the contract. This has ended the significance of the artificially excavated pond.

3) Roof Rainwater Harvesting (BRP-RWH-3)

The area receives scanty rainfall of average 600-800 mm. The significant water extraction from the bore well was used for concrete making in the batching plant and curing. Water collected on the roof surface area of

the labour camp buildings adjacent to the bore well was used for recharging the well. Water from the roof area of the store building was used to recharge the pond. The intervention projected total 522 KL/year of water conservation. To some extent, the recharging of bore well with rainwater compensated for the water extracted from it. Similarly, the rainwater collected at the store helped to increase the groundwater table.

Basic Engg Details ·Ÿ Roof surface area of Buildings = 560 sqmŸ 9” galvanized rain water channels (or PVC) to be fitted to the galvanized sheet roofing.Ÿ Water collected is to be used for recharging the bore.Ÿ Area of roof surface = 560 sqmŸ Water available to recharge bore = 358 KL

Though the quantity of water conservation was not available; the rainfall data was used to compute the water conservation through RTRWH systems. With 80% efficiency of system, the values computed were 316KL/season and 237KL/season for the years 2009-10 and 2010-11. The total computed percolation was 553 KL against the estimated 716 KL quantity of percolation in the proposal.

4) Recycling of Curing Water (BRP-WW-4)

The major work at the Mirzapur site was to construct the concrete segments for the elevated highway. The site showed a designated area for casting the segment and followed by the curing yard. During the assessment, it was observed that the water for curing was extracted from bore wells with proper arrangement of collecting curing water through the peripheral water channels. It was decided to Recycle curing water by establishing a proper drainage system along with an impervious ground surface made with paver blocks. It helped in streamlining the flow of water into an equalization tank, facilitating the water reuse for curing. The mathematical calculation projected the water reuse of 6132KL in 12 months. The 6828 KL of water was recycled in 14 months for this activity as mentioned in the water forms provided by the site.

5) Batching plant wastewater management (BRP-WW-5)

The treatment of wastewater from the batching plant was carried out through the sedimentation tank. The treated water was reused for dust suppression activity, considerably reducing water extraction from the bore well thereby conserving the groundwater. 1080 KL of treated water was reused for the activities viz. dust suppression and ground percolation in 14 months.

Store shade

Rainwater pipeline

Rainwater collector

Bore well -

existing

6) Elevated highway – Rainwater Harvesting (BRP-RWH-6)

The 4.4 km long elevated highway design incorporates storm water drains alongside the highway. This proposal suggested an innovative way to conserve the rainwater in the same area through recharge bore wells at predetermined locations along the highway.

The project site appointed a hydo-geologist who studied the characteristics of ground strata using bore logs and a physical survey of the area to decide on the locations appropriate for maximum percolation of rainwater. The consultant provided the technical knowhow about the bore well's diameter, depth and locations. During designing, a sophisticated filter system was considered for recharge of the bore wells to avoid clogging which might reduce the efficiency of the recharged system. Accordingly, the sophisticated “Furaat” filter mechanism was used. The rainwater available through the rainwater storm drain was passed into the recharge bore well after getting filtered through this filter system. HCC implemented two Rain Water Harvesting (RWH) systems, as pilot systems, at this project.

The Elevated Highway Project is a BOT project and under maintenance of HCC for 18 years; the system would be taken care of by the Company for the whole period. This intervention will help to reduce the water stress of the area in the future and will be available to the society at large by increasing the ground water supply. The quantitative impact of the innovation will be measured, over a period of time, through the flow meters at the RWH systems.

Basic Engineering detailsRecharge quantity Ÿ Length of highway under consideration = 4400 mŸ Width of highway = 10.5 mŸ Rainfall = 0.8 mŸ Total water collected /season /stretch = 36960 m3/seasonŸ Total surface run off due to elevated highway = 16580 m3/season/stretchŸ Available water for percolation = 53540 m3/stretch/yr

Bore wellŸ Circumference of bore = 0.94Ÿ Surface area of borehole of avg depth 25 m = 23.5 sqm

Percolation: @ 0.5 inch/hr, gives 0.3m/dayŸ Total percolation through bore per day = 7.05 m3/dayŸ Total percolation through bore for 90days = 634.5 m3/seasonŸ Total percolation of water through 10 bores = 6345 m3/yr/stretch

Total surface runoff Ÿ Available water for percolation = 53540 m3/stretch/yrŸ Total percolation of water through 10 bores = 6345 m3/yr/stretch

-------------------------= 47195 m3/yr/stretch= 94390 m3/yr

Typical Longitudinal section of ground strata between piers 26 to 28

Maintaining the record of water usage on construction activities at site

As a part of the implementation of the UN Water Mandate, the IMS water balance form was introduced. The site initiated the water data filling in the water balance form expressing the water extraction /procurement and consumption at site for its construction activities. To achieve realistic water data on water extraction from bore wells, the site installed the flow meters. The log records of tankers used for water procurement or dust suppression were maintained. Though the project started in November 2008, it was not in practice to keep record on water. Since September 2009, the site started maintaining the water data and reporting it monthly to UN water mandate team

Summary of Water conservation over a period of 14 months:

# The main intervention of water conservation through the RWH along the highway stretch is not considered as the intervention was recently completed and the water conservation figures are not yet available.

Epilogue

With unprecedented increases in urban populations, constrained water supplies, energy shifts to mitigate climate change, and vulnerability to disasters, cities worldwide are seeking more sustainable infrastructures that are resilient, high-performing, resource-efficient, cost-effective and environment-friendly. In order to create an enabling environment, there is need of coordinated efforts from all the stakeholders, in general, and industries engaged in developing infrastructure in particular. HCC recognizes the correlation of business sustainability with water resource and committed to reduce the amount of water used across our construction project sites; especially in regions where water availability is already under pressure. Water Conservation measures taken at Badarpur Elevated Highway project. as outlined above, are in line with HCC commitments towards water resources management.Rain water harvesting has been in practice in India and elsewhere from time immemorial. However, the concept of harnessing this technique to harvest rainwater collected through specifically designed storm water drains alongside an infrastructure project like elevated highway is unique and exemplary. This innovative application of rainwater harvesting technique has the potential to recognize the significance of ground water recharge of rainwater from paved surfaces and gives an idea to offset the impact of ever increasing paved surfaces being built in the process of infrastructure development, in general, and Roads, highways, and Elevated Highways, in particular.

Sr Activity Intervention Estimated conservation

(KL)

Total(KL)

Computed conservation

(KL)

Total(KL)

1 Groundwater recharge

Artificial pond 14048 14764 14688 15241

2 553

3 Water reuse/recycle

Recycling of curing water 6132 6132 6828 7908

4 Reuse of treated water 0 1080

TOTAL 20896 23149

Legend for UN Water Mandate matrixUN Water Mandate document available at: http://www.unglobalcompact.org/docs/news_events/8.1/Ceo_water_mandate.pdf

Areas of Action Corresponding to Specific Actions at Project Site

Direct Operations

DO 1 Conduct a comprehensive water-use assessment to understand the extent to which the company uses water in the direct production of goods and services.

DO 2 Set targets for our operations related to water conservation and waste-water treatment, framed in a corporate cleaner production and consumption strategy.

DO 3 Seek to invest in and use new technologies to achieve these DO2 goals.

DO 4 Raise awareness of water sustainability within corporate culture.

DO 5 Include water sustainability considerations in business decision-making – e.g., facility-siting, due diligence, and production processes.

Supply Chain And Watershed Management

SCWM1 Encourage suppliers to improve their water conservation, quality monitoring, waste-water treatment, and recycling practices.

SCWM2 Build capacities to analyze and respond to watershed risk.

SCWM3 Encourage and facilitate suppliers in conducting assessments of water usage and impacts.

SCWM4 Share water sustainability practices – established and emerging – with suppliers.

SCWM5 Encourage major suppliers to report regularly on progress achieved related to goals.

Collective Action

CA 1 Build closer ties with civil society organizations, especially at the regional and local levels.

CA 2 Work with national, regional and local governments and public authorities to address water sustainability issues and policies, as well as with relevant international institutions – e.g., the UNEPGlobal Programme of Action.

CA 3 Encourage development and use of new technologies, including efficient irrigation methods, new plant varieties, drought resistance, water efficiency and salt tolerance.

CA 4 Be actively involved in the UN Global Compact's Country Networks.

CA 5 Support the work of existing water initiatives involving the private sector – e.g., the Global Water Challenge; UNICEF's Water, Environment and Sanitation Program; IFRC Water and SanitationProgram; the World Economic Forum Water Initiative – and collaborate with other relevant UN bodies and intergovernmental organizations – e.g., the World Health Organization, the Organisation for Economic Co-operation and Development, and the World Bank Group.

Public Policy

PP 1 Contribute inputs and recommendations in the formulation of government regulation and in the creation of market mechanisms in ways that drive the water sustainability agenda.

PP 2 Exercise “business statesmanship” by being advocates for water sustainability in global and local policy discussions, clearly presenting the role and responsibility of the private sector in supporting integrated water resource management.

PP 3 Partner with governments, businesses, civil society and other stakeholders – for example specialized institutes such as the Stockholm International Water Institute, UNEP Collaborating Centre on Water and Environment, and UNESCO's Institute for Water Education – to advance the body of knowledge, intelligence and tools.

PP 4 Join and/or support special policy-oriented bodies and associated frameworks – e.g., UNEP's Water Policy and Strategy; UNDP's Water Governance Programme.

Community Engagement

CE 1 Endeavour to understand the water and sanitation challenges in the communities where we operate and how our businesses impact those challenges.

CE 2 Be active members of the local community, and encourage or provide support to local government, groups and initiatives seeking to advance the water and sanitation agendas.

CE 3 Undertake water-resource education and awareness campaigns in partnership with local stakeholders.

CE 4 Work with public authorities and their agents to support – when appropriate – the development of adequate water infrastructure, including water and sanitation delivery systems.

Transparency

TY 1 Include a description of actions and investments undertaken in relation to The CEO Water Mandate in our annual Communications on Progress for the UN Global Compact, making reference to relevant performance indicators

TY 2 Publish and share our water strategies (including targets and results as well as areas for improvement) in relevant corporate reports

TY 3 Be transparent in dealings and conversations with governments and other public authorities on water issues.