DPR - DP - CH - 7-Construction Methodology For DAM

Chapter - 7
Construction Program, Manpower

and Plant Planning
7.0 General
The construction methodology and equipment planning for

construction of various components of the project are described in this
chapter. The construction methodology for each type of structure, type and
sizes of the equipments to be used for the construction has been described
under the relevant sub sections of this chapter. The construction/
deployment schedule for various components of the project has been
prepared and based on this, the number of machines/equipments and total
requirement for each type and size of the major equipments required for
construction of each component of the project has been worked out.
However, if, the work is executed through award of contract, the
contractors may execute the work based on the equipments actually
available with them thereby suitably adopting the related construction
techniques. The tentative requirement of machines/equipments worked out
herein will help in analysis of rates of works, cost estimation and in
evaluating the viability of construction techniques and equipment, within
overall construction schedule and cost estimate.
7.1 Main Project Components
Damanganga – Pinjal link project has been planned as drinking water

supply project to augment the domestic water supply of Mumbai city. The
surplus water of Damanganga basin available at proposed Bhugad and
Khargihill dam is proposed to be transferred to Pinjal dam (proposed by
Govt. of Maharashtra across river Pinjal, a tributary of Vaitarna river) from
where the combined water of Damanganga and Pinjal rivers will be taken to
Mumbai city to augment its domestic water supply. The project envisages
construction of the following components:
i A 851.50 m long composite embankment (concrete faced rock fill) -

cum - concrete dam across river Damanganga near village Bhugad
with FRL 163.87 m and corresponding gross storage capacity of
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427.070 Mm3. The length of concrete faced rockfill portion of the
dam is 527.50 m and the length of concrete non overflow section and
spillway is 324 m;
ii A Power house at the toe of Bhugad dam with 2 units each of 1.0
MW installed capacity each;
iii A 618.20 m long composite embankment (concrete faced rock fill) -

cum - concrete dam at Khargihill across river Vagh (a tributary of
Damanganga river) near village Behadpada with FRL 154.52 m and
corresponding gross storage capacity of 460.896 Mm3. The length of
concrete faced rockfill portion of the dam is 341.0 m and the length of
concrete non overflow section and spillway is 277.20 m. A saddle
dam of 400 m length and 25.92 m height with FRL 154.52 m is
proposed on the left flank of the reservoir;
iv A Power house at the toe of Khargihill dam with 2 units each of 1.5
MW installed capacity;
v A 17.488 km long D shape tunnel with 3.20 m diameter and bed slope
of 1:1342 connecting Bhugad reservoir with Khargihill reservoir;
vi A 25.224 km long D shape tunnel with 4.00 m diameter and bed slope
of 1:1717 connecting Khargihill reservoir with Pinjal reservoir;
vii A 545 m long Roller Compact Concrete Gravity dam across river
Pinjal (a tributary of Vaitarna river) proposed by Government of
Maharashtra and MCGM near village Khidse with FRL of 145.0 m
and corresponding gross storage capacity of 483.0 Mm3 and a saddle
dam of about 190 m long and 11.4 m high on the right flank.
viii Conveyance system beyond Pinjal dam to carry water upto Mumbai
city to be planned by MCGM.
The Pinjal dam and the conveyance system beyond Pinjal dam to carry
water upto Mumbai city has been planned by Water Resource Department,
Government of Maharashtra and Municipal Corporation of Greater Mumbai
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(MCGM), as such, the construction scheduling & equipment planning for
these components has not been considered in this report.
7.1.1 Salient Features of main Components of the Project
The salient features of the main components of the project are indicated in
Table – 7.1
Table - 7.1
Salient Features of Main Components of the Project
S. No. Project Component Details
1 Bhugad Dam
i Concrete Faced Rockfill Dam
a Height 68.63 m
b Length at Top 527.50 m
ii Concrete Dam (Over Flow and Non
Over flow)
a Length 324.0 m
b Height (from deepest foundation 69.42 m
(level)
iii Spillway
a Type Ogee
b Gates 9 radial gates of
13.5 m X 11.51 m
2 Khargihill Dam
i Concrete Faced Rockfill Dam
a Height 72.92 m
b Length at Top 341.00 m
ii Concrete Dam (Over Flow and Non
Over flow)
a Length 277.20 m
b Height (from deepest foundation 77.92 m
(level)
iii Spillway
a Type Ogee
b Gates 6 radial gates of 14
m X 16 m
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3 Bhugad Dam Power house
i Penstock
a Length 176 m
b diameter 1.5 m/ 1.0 m
c Shape Circular
II Power House
a Type Surface Power House
b Installed Capacity 2 X 1.0 MW
4 Khargihill Dam Power house
i Penstock
a Length 215 m
b diameter 1.5 m/ 1.0 m
c Shape Circular
II Power House
a Type Surface Power House
b Installed Capacity 2 X 1.5 MW
5 Bhugad - Khargihill Tunnel
a Length 17488 m
b Shape D Shape
c Diameter 3.2 m
d Type of lining Cement Concrete
lining
5 Khargihill – Pinjal Tunnel
a Length 25224 m
b Shape D Shape
c Diameter 4.0 m
d Type of lining Cement Concrete
lining
7.2 Basis for Study

7.2.1 General
Methodology for construction of Damanganga – Pinjal Link Project

has been adopted with due consideration of the construction schedule, the
compatibility of the construction equipment to site conditions, the
quantities and utilization factor of the equipment within the scheduled
construction period. Number of machines required for construction of each
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component of the project has been worked out and the total requirement for
each type and size of machine for the project as a whole has been arrived at
after drawing up the construction/deployment schedule for the main
components of the project.
Mechanized construction has been planned for almost all types of

construction jobs so as to achieve consistent quality at a faster rate and also
to minimize the requirement of skilled manpower. Moreover, very high
degree of quality standards are required to be maintained as underground
works are normally not available for regular maintenance after the
completion of construction.
Sequencing of construction activities, wherever possible, has been

attempted in such a way that equipment from one activity, on its
completion can be moved to the other. Thus, the total requirement of
equipment at a time would be reduced and also, sufficient utilization of
equipment on the project would be ensured.
7.2.2 Construction Material Sources
Locations of different borrow areas and quarries for construction

material with respect to the dam location have been described in the chapter
- 2 “Survey & Investigations”.
Suitable fill material for the concrete face rock fill dam has been
found in the borrow area upstream of the proposed Bhugad and Khargihill
dam. Borrow areas with minimum lead have been proposed for utilisation
during dam construction. In case of Bhugad Dam, borrow areas with an
average distance of 2.0 km from dam axis have been considered for the
purpose of equipment planning. Similarly, borrow areas with an average
distance of 4.0 km from dam axis have been considered for the purpose of
equipment planning for Khargihill dam. However, during construction,
appropriate decision may be taken to select the borrow areas which meet
the requisite specifications.
Construction material for concrete, viz. sand/fine aggregate,

rock/coarse aggregate, for both non-wearing and wearing surfaces are also
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located in the vicinity of dam site. The Bila quarry (U/s of Bhugad Dam) at
a distance of 2.0 km and Dadri quarry (U/s of Khargihill Dam) at a distance
of 6.0 km have been identified for meeting the requirement of Rock.
For the construction material for concrete lining of Bhugad-

Khargihill link tunnel, the Baphanvihir quarry and Ojharkhed Quarry have
been identified and for the construction material for concrete lining of
Khargihill-Pinjal link tunnel, Dadri and Mehandhipada quarries have been
identified.
Total concrete requirement of different grades for the main

components of the project has been estimated to be approximately 20 lakh
m3.
The area for disposal of excavated material has been considered at an

average distance of 2.0 km from the dam site for equipment planning
purpose.
7.2.3 Basic Considerations
Based on past experience, about 8 working months in a year are

available in the area where the project is situated. Other projects in the
region have also been planned with this consideration. However, all under
ground works like tunnels can be constructed through out the year.
All the surface works are proposed to be executed in two shifts and
during 8 working months. The Tunnelling works are proposed to be
executed in three-shift operation throughout the year.
7.2.3.1 Scheduled Working Hours
Equipment planning for calculating requirement of equipment is

carried out based on the number of working days available, which further
depends upon climatic conditions of the project area. In the present
scenario, the monsoon sets in during June and continues till October in the
project area. For equipment planning purpose the monsoon season has
been considered from 15th June to 15th October. Thus, for surface/ over
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ground works i.e. dam and appurtenant works a working season of eight
months would be available. The tunnelling works are generally not
affected by the vagaries of weather and thus, the work has been planned to
continue throughout the year. However, since the production capability
would be affected during monsoon months especially for the supplies/
services and muck disposal, etc., suitable reduction in the progress has been
taken into account for the year as a whole. The scheduled working hours
considering 25 working days per month are given in Table - 7.2.
Table - 7.2
Schedule Working Hours
Type of Work/ Surface/Over Tunnelling/Underground
Shift Ground Works Works (Hour)
(hour)
Single shift work/ day 8x25x6 = 1200
Two shifts work/ day 8x25x11= 2200 12x25x20= 6000
Three shifts work/ day 8x25x15 = 3000
Two shifts working of equipment is normally considered most

economical in view of the high cost of three shifts working on account of
low availability of equipment and higher stand-by equipment requirement.
Thus planning for all surface/over ground works has been carried out based
on two shifts per day working. Tunneling/ underground works are planned
for three shifts working as these involve cyclic operations, which do not
follow normal shift operation. Provision of standby equipment has been
considered as follows:
i. Single shift working 10%

ii. Two shifts working 20%
iii. Three shifts working 30%
7.2.3.2 Construction Period
A total period of seven years has been considered for completion of

the project. The infra-structural development, pre-construction surveys and
investigations, preparation of design/ specifications and tender documents
are proposed to be taken up during the first two years. In case the works are
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to be executed through award of contract, it is planned to award contracts
for all major works by the 3rd quarter of year 2. However, some of the
works like stripping, River diversion and portal formation & slope
stabilization for tunnels may have to be undertaken from the 1st quarter of
the 2nd year itself and therefore award of work for these works may be
planned accordingly. The work on infrastructure facilities like project
colonies, approach roads, workshop, haul roads, stores, office buildings etc.
will also start in the second year itself. Some of these activities will
continue for some time during the third year also. The construction of all
civil structures is proposed to be completed within 3rd quarter of year 7.
The erection, commissioning and testing of units would be required to be
planned so that full benefits could be accrued at the end of the proposed
construction period. Though, presently construction period of Damanganga
– Pinjal link project is kept 7 years, but by using advance construction
technology/ equipments and tunnel boring Machines (TBM) in tunnel
excavation, the construction period can be reduce to 6 years.
7.3 Construction Methodology and Equipment
The construction methodology and equipment planning along with

construction programme for different components of the project have been
described in the succeeding sub-sections:
7.3.1 River Diversion Works
No formal diversion arrangement has been provided for the

construction of both the dams (Bhugad and Khargihill Dams). The
diversion arrangement during project construction will be evolved
depending upon the requirement. As sufficient width is available, the flow
only needs to be channelized through diversion channels which can be
decided at construction stage. Also the sluices proposed can be used for
diversion during construction stage. The following construction methods
have been considered for river diversion works:
 Excavation and loading of the material by 2.0 m3 hydraulic

excavator.
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 Transport to the disposal area by means of 18/20t rear
dumpers.
 The rock excavation to be undertaken by drilling & blasting.
Jack hammers and wagon/crawler drill with hole patterns of
1m and 2.75 m c/c respectively to be deployed for drilling of
charge holes.
Separate provision of the equipment for this activity has not been kept
as some of the equipments to be deployed for earth dam can be utilized on
this activity.
7.3.2 Concrete Face Rock-Fill Dam (Bhugad Dam)
The construction of the dam involves surface excavation, placement of fill

materials, spreading & wetting and compaction of the fill materials. Total
quantity of Bhugad dam excavation including OF and NOF section is about
11,90,100 m3. The excavation of 6,93,200 m3 quantity which does not
involve blasting operation is considered as common excavation and
remaining 4,96,900 m3 which requires blasting is considered as rock
excavation. Following assumptions have been made while working out the
quantities of different activities for the construction of dam. The details are
in Table – 7.3.
i. Total river bed excavation quantity has been divided in a ratio of 6:4
for the estimation of excavation quantity for CFRD portion and
Concrete portion of Dam.
ii. While working out the quantity for common excavation and rock
excavation of each portion of dam, same ratio i.e. 6:4 has been used
over the total excavation quantities of each type.
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Table - 7.3
Quantities of Different Activities for Construction of
CFRD Portion of Bhugad Dam
Description of Type / Material Quantity, Unit
Work in-situ
Stripping - 60,000 m3
Excavation
Common 4,15,920 m3
Rock 2,98,140 m3
Fill placement
Impervious material 3,06,000 m3
Filter, Fine (2B Zone+3A 2,77,700 m3
Zone)
Filter, Coarse(Zone 3B) 9,69,000 m3
Filter, Coarse(Zone 3C) 6,52,800 m3
Rock toe 2,800 m3
Total Quantity 22,08,300 m3
7.3.2.1 Surface Excavation
The surface excavation for main dam involves both common and rock
excavations. The volume of required excavation is given in Table – 7.4:
Table – 7.4
Volume of Surface Excavation
Type Common Rock
Description excavation (m3) excavation (m3)
Stripping 60,000 Nil
River Bed Excavation 4,15,920 2,98,140
Total 4,75,920 2,98,140
One working season has been earmarked for undertaking surface

excavation pertaining to main dam. Although work in the river bed can be
undertaken only after completion of river diversion work, the work of
stripping can be taken up earlier. The requirement for which provision of
equipment for the surface excavation is to be made is estimated and given in
Table – 7.5:
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Table – 7.5
Estimation of Hourly Quantity of Excavation
Type Common Rock
Description Excavation Excavation
Total volume (cum) 4,75,920 2,98,140
Time period (months) 8 8
Shift proposed 2 2
Total operational hours (hour) 2200 2200
Volume to be handled in-situ (cum/hr) 216 136
Volume to be handled loose (cum/hr) 270 217
Total quantity 270+217 = 487 m3/hour
Peak quantity 487 m3/hour
Following construction methods are proposed for surface excavations:
 Stripping and excavation for trenching & preparation of base of dam and
loading of the soft material (earth and alluvium) by 2.0 m3 hydraulic
excavators assisted by 180 HP crawler dozer
 Transportation to the disposal area by 18/20t capacity rear dumper
 A 180 HP bulldozer is also considered to stay in the disposal area for
spreading of the unloaded materials
 The rock excavation to be undertaken by drilling & blasting. Jack
hammers and wagon/crawler drill with hole patterns of 1m c/c and 2.75
m c/c respectively to be deployed for drilling of charge holes.
7.3.2.2 Fill Placement
The construction of concrete faced rockfill portion of Bhugad dam

involves placement of 22,08,300 m3 of fill materials. As per construction
schedule the fill placement is to be undertaken in period of three working
season. The break-up of total quantity into different types of fill material to
be placed in different zones and their expected source of supply is given in
Table – 7.6:
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Table – 7.6
Quantities and Source of Fill Material
S. Fill Material Quantity Average distance of
No. (compacted) borrow
(m3) area/quarry (km)
1 Impervious material 3,06,000 2.0
2 Filter, Fine (2B Zone+3A 2,77,700 1.5
Zone)
3 Filter, Coarse(Zone 3B) 9,69,000 1.5
4 Filter, Coarse(Zone 3C) 6,52,800 1.5
5 Rock toe 2,800 1.5
Total 22,08,300
The fill placement will require excavation and loading of material at

the borrow areas/quarries, transportation of the material to the placement
site and unloading. It is necessary that various alternative methods and
equipment are evaluated and appropriate construction methods and suitable
construction equipment are selected.
Hydraulic excavator-rear dumper combination is the most commonly

used method of material transportation in a river valley project. The
selection of hydraulic excavators depends on the quantities to be handled,
limitations of space at the site and the availability of standard equipment.
Matching rear dumpers are estimated taking into account the distance to be
traveled, the load ratings of haul roads and traffic intensity. This method is
considered quite flexible as this allows introduction of additional equipment
to supplement the capacity, if required. These equipments are available as
standard items and most of the sizes which may be required on river valley
projects are manufactured indigenously.
Belt conveyor system is considered a good alternative for

transportation of material over long distances. In this method the capital
cost of equipment is high, but the disadvantage is offset by the low running
and maintenance costs. However, some limitations are posed by the
maximum lump size, which can be transported through these belt
conveyors.
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In the present case, since fill material is available within a distance of
2 kilometer and borrow areas are scattered over different locations, the
conventional method of material transportation, i.e., hydraulic excavator-
dumper combination has been considered for material transportation.
(i) Impervious Material: As mentioned above, the fill quantities are to be

placed in three working seasons. As the quantity of this type material is
comparatively less, single shift work/day is proposed for the placement. The
hourly placement quantities for hearting material have been worked out and
indicated in Table – 7.7:
Table – 7.7
Estimation of Hourly Quantity of Hearting Material Placement
S.No. Description Quantity Unit
1 Total volume 3,06,000 m3
2 Time period 24 month
3 Shift proposed 1 -
4 Operational hours/month 150 hour
5 Total operational hours 3,600 hour
6 Volume to be handled (in-situ) 85 m3/hour
7 Volume to be handled (loose) 106 m3/hour
8 Peak quantity 133 m3/hour
The following construction methods have been considered for hearting fill:
 Excavation and loading by means of 2.0 m3 hydraulic excavator

 Transport to the embankment by means of 18/20t capacity rear end
dumpers.
 Spreading in layers up to 30 cm thick by 180 HP bulldoze.
 Moisture adjustment by 8000 L water sprinklers.
 Compaction by 8 passes of 10t pad foot vibrating roller.
An average distance of 2.0 km from dam site has been considered for
the borrow areas for impervious material.
(ii) Filter, fine (2B Zone+3A Zone): The fine filter will have a total
volume of 2,77,700 m3. The fine filter material is used to fill 2B zone and
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3A zone of CFRD Dam. This quantity will be brought from quarries located
at an average distance of 1.5 km from dam site. The material will be
processed in a processing plant located suitably near the quarry itself. The
fine filter material will be processed and brought to the dam site for
placement.
As the quantity of filter material is comparatively less, single shift

work/day is proposed for filter placement. The hourly rate at which
placement of filter is to be carried out has been estimated in Table – 7.8:
Table – 7.8
Estimation of Hourly Quantity of 2B Zone Material Placement
Description Quantity Unit
Total volume 2,77,700 m3
Time period 24 month
Shift proposed 1 -
Operational hours/ month 150 hour
Total Operational hours 3,600 hour
Volume to be handled (in situ) 77 m3/hour
Volume to be handled (loose) 122 m3/hour
The following construction methods have been considered for the

placement of fine filter:
 Loading at the quarry by 2.0 m3 hydraulic excavator and transportation

up to filter processing plant by 18/20t capacity rear dumper
 Processing at the filter processing plant of capacity, 300 tph installed
near the quarry
 Loading by 1.5 cum loader and transport to the dam site by 18/20t
capacity rear dumper
 Spreading on the embankment in layers up to 30 cm thick by bulldozer
with flywheel power of 180 HP
 Compaction with 6 passes of 10t smooth drum vibratory roller.
(iii) Filter, Coarse (Zone 3B): The requirements of coarse filter which is
going to be used in zone 3B filling is approximately 9,69,000 m3. The same
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will be met from rock quarries. The rock will be transported to the
placement site. The Table – 7.9 indicates the estimation of hourly quantities
involved.
Table – 7.9
Estimation of Hourly Quantity of
Coarse Filter and Rock-Toe Material Placement
Time period 24 Month
Shift proposed 2 -
Operational hours/month 275 hour
Total operational hours 6,600 Hour
Volume to be handled/hr (in situ) 146 m3/hour
Volume to be handled/hr (loose) 235 m3/hour
The following construction methods and equipment are considered

suitable for rockfill placement:
 Drilling of charge holes at the quarry by means of jack hammers and

crawler drills with hole patterns of 1-2.75 m c/c
 Blasting by means of electric detonators connected to proper wire
circuits
near the quarry
 Loading at the filter processing plant by 2.5 cum loader and transport to
the dam site by 18/20t capacity rear dumper
 Spreading of the unloaded material on the embankment to about 50 cm
to 70cm layer thickness, by means of 180 HP flywheel power bulldoze.
 Compaction by 6 pass of 10t smooth drum vibrating rollers.
(iv) Filter, Coarse (Zone 3C) and Rock toe: The requirements of coarse
filter which is going to be used in zone 3C filling and rock- toe is
approximately 6,55,800 m3. The same will be met from rock quarries. The
Table – 7.10 indicates the estimation of hourly quantities involved.
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Table – 7.10
Shift proposed 2 -


circuits
 Loading at the quarry by 2.0 cum hydraulic excavator and transportation
near the quarry
 Loading at the filter processing plant by 2.5 cum loader and transport to
to 150cm layer thickness, by means of 180 HP flywheel power bulldozer
7.3.2.3 Major Construction Plant and Equipment for Bhugad

CFRD Dam
Based on above methodology and equipment planning the list of

equipment required for construction of Concrete Face Rock Fill Dam
(Bhugad) is given in Table – 7.11:
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Table – 7.11:
Major Construction Plant and Equipment for
Bhugad CFRD Dam
S. No. Description Size/capacity Quantity
1 Hydraulic excavator 2.0 m3 6
2 Crawler/wagon drill 600 cfm 4
3 Jack hammer 120 cfm 16
3
4 Front end loader 2.5 m 5
3
6 Rear end dumper 18/20t 31
7 Crawler dozer 180 HP 10
8 Vibratory compactor (pad foot) 10t 1
9 Vibratory compactor (smooth 10t 3
drum)
10 Water sprinklers 8000 L 8
11 Air requirement cfm 3500
12 Filter processing plant 500 tph 2
14 Truck 8/10 ton 8
7.3.2.4 Construction Programme
The excavations for the dam will start from the abutments above river
bed level in the 2nd quarter of year 2 and will be completed within three
months working period. Excavations in the river bed will start as soon as the
work area in the river bed becomes dry. The dam foundation treatment,
which includes consolidation grouting and curtain grouting, will start locally
as the excavation is completed in that area.
Embankment construction will start by 3rd quarter of year 3, once the

excavation and foundation preparation works in the river bed are
sufficiently advanced. The period before the beginning of the embankment
construction shall be devoted to the preparation of the haul roads and
development of the borrow area.
A total period of 24 months, excluding the monsoon period has been

allowed for the completion of the dam embankment with the aim to reach
crest elevation by the end of 3rd quarter of year 6.
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7.3.3 Concrete Dam (Bhugad)
Main activities to be undertaken for construction of Bhugad concrete

dam (over flow & non-over flow sections) are surface excavations and
concreting. Surface excavations will comprise of common excavation in
overburden and rock excavation. The total quantity of concrete dam
excavation is about 4,76,040 m3, and total quantity of concreting is about
7,69,900 m3. Details are indicated in Table – 7.12:
Table – 7.12:
Quantities Involved in Construction of Concrete Dam
(Over Flow & Non-Over Flow)
Description of Work Type / Material Quantity, Unit
in-situ
Stripping - - m3
Excavation
Common 2,77,280 m3
Rock 1,98,760 m3
Total excavation 4,76,040 m3
Concreting 7,69,900 m3
The surface excavations have been planned to be completed within 1

working season (8 months). The surface excavation for main dam involves
both common and rock excavations. The excavated material will be
transported to the disposal area using conventional excavator and rear
dumper combination. The provision of equipment for the surface
excavation to be made is estimated in Table – 7.13:
Table – 7.13
Type Common Rock
3
Total volume (m ) 2,77,280 1,98,760
400
Shift proposed 2 2
Total operational hours (hour) 2,200 2,200
Volume to be handled in-situ 126 90
(m3/hour)
Volume to be handled loose 157 144
(m3/hour)
Total quantity 157 + 144 ~ 301 m3/hour
The construction equipment for surface excavations is as under:
 Excavation and loading of the soft material (common excavation) by 2.0

m3 hydraulic excavators assisted by 180 HP bulldozers
 For rock excavations requiring drilling & blasting, drilling the very steep
areas by hand-held rigs (jack hammer) of 38 mm diameter with hole
patterns of about 2.75 m2 and drilling the accessible areas by crawler
drill
 Loading of blasted rock by 2.0 m3 hydraulic excavator, shovel
attachment and assisted by 180 HP dozers
 Transportation to the disposal areas/main dam by 18/20 t rear dumpers
 Crawler dozer, 180 HP to be deployed at the disposal area to spread the
material.
7.3.3.2 Concreting
For concreting of main dam and appurtenant structures, total quantity

of the order of 7,69,900 m3, will have to be placed. A period of 3 working
seasons has been planned for the placement. The rate of placement works
out to 70 m3/hour approximately. The concrete required for main dam is
proposed to be produced in a centralized Batching and Mixing Plant of
capacity 90 m3/hour. The plant shall be located in the vicinity of the dam. In
addition, two numbers mobile batching & mixing plant each of capacity 18
m3/ hour will be provided. The concrete from the plant will be transported
with the help of transit mixers of 4.5 m3 capacity.
Following construction equipments have been considered for

concreting of main dam and appurtenant structures:
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 Placing of concrete with the help of 4 Nos. tower cranes, 6 ton @ 40
metre radius are proposed to be deployed at suitable locations. In
addition, 3 Nos. 38 m3/hr concrete pumps with 25 m boom will be used
for concrete placement
 Concrete transportation by transit mixers of 4.5 m3 capacity
 Batching and mixing plant of capacity 90 m3/hr to be located preferably
within a radius of 2 km from the concrete dam
 The aggregate crushing and screening plant of 250 tph for preparation of
coarse and fine aggregates.

Concrete Dam
Based on above construction methodology, major construction plant

and equipment required for construction of concrete dam are listed in Table
– 7.14:
Table – 7.14:
Major Construction Plant and Equipment for Bhugad Concrete Dam
S. N0. Equipments Size/capacity Quantity
3
3 Front End Loader 2.5 m 2
6 Rear dumper 18/20 t 15
3
7 Tippers 4.5 m 3
8 Tower Crane, traveling type 6t@40 m 4
9 Aggregate processing plant 250 tph 1
3
10 Batching & mixing plant 90 m /hour 1
3
11 Mobile Batching & mixing plant 18 m /hour 2
3
12 Transit mixers 4.5 m 12
3
13 Concrete pump with 25 m boom 38 m /hour 3
14 Concrete Vibrator (electrical/ 8
pneumatic)
15 Compressed air cfm 1600
2
16 Grout pump 20 kg/m 4
17 Trucks 8/10 ton 4
18 Mobile Crane 16t 2
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The sequence of construction of concrete dam takes into account the

following aspects:
 Surface excavation of concrete dam to start during the 3rd quarter of Year
2
 The total quantity of excavation to be completed in a period of 1 working
season. The activity to be completed by the end of 1st quarter of year 3
 Concreting to start in the 3rd quarter of Year 3 and will continue for 3
working seasons and to be completed by the end of the 2nd quarter of
year 6
 Since a part of over-flow section (two blocks) is to be used for diversion
of river during construction of earth dam, the phasing of concreting is to
be planned in such a way that the work of these two blocks is completed
during lean season
 Gate installation work to start in the beginning of 4th quarter of year 5
and will be completed by the end of 3rd quarter of Year 7.
7.3.4 Bhugad Dam Power House

7.3.4.1 Excavation and Concreting
Main activities to be undertaken for construction of power house are

surface excavations and concreting along with erection of electro-
mechanical equipment. The quantities involved in the dam power house
complex are indicated in Table – 7.15:
Table – 7.15
Quantities Involved in Bhugad Dam Power House Complex
S. No. Description Quantity (m3)
1 Surface excavations
Common Excavation 8,300
Rock excavation 20,700
2 Concreting 4,240
The sequence of operations for power house complex is based on the

following construction methods and equipment:
403
 Excavation and loading of the soft material by 2.0 m3 hydraulic
excavators assisted by 180 HP dozer
 For rock excavations requiring drilling and blasting, drilling the very
steep areas by hand-held rigs with 38 mm diameter with hole patterns of
about 1-2.5 m2 and drilling the accessible areas by crawler rigs with 76
mm bits and hole patterns ranging from 7.5 to 9.0 m2
 Loading of the blasted rock by 2.0 cum hydraulic excavator bucket
shovel attachment and assisted by 180 HP dozers
 Transportation to the disposal areas by 18/20t rear end dumpers
 Placing of concrete with 20 m3/hr concrete pumps with 25 m boom
 Concrete transportation by 4.5 m3 transit mixers
 Concrete production in a Batching and mixing plant of capacity 90 m3/hr
coarse and fine aggregates
 Mobile crane of 16t is to be utilized for handling of construction
material, shutter forms etc.

Power House
No separate equipment for construction of Bhugad powerhouse

complex has been provided as equipment deployed for concrete dam shall
be utilized for construction of power house.
As the excavation quantities are not much, a period of 3 months has

been planned beginning in the 3rd quarter of year 6. The construction of the
concrete structures will begin by the 4th quarter of Year 6 starting from the
structures of the erection area. Almost 15 months have been considered
necessary to complete the powerhouse.
All works including electro-mechanical works will be essentially

completed by 3rd quarter of year 7.
404
7.3.5 Concrete Face Rock-Fill Dam (Khargihill Dam)
Total quantity of Khargihill dam excavation including OF and NOF section

is about 21,35,500 m3 in which 8,93,200 m3 quantity is considered as
common excavation and remaining 4,96,900 m3 is considered as rock
excavation. Following assumptions have been made while working out the
quantities of different activities for the construction of dam. Details are in
Table – 7.16.
i. Total river bed excavation quantity has been divided in a ratio of 1:1
for the estimation of excavation quantity for CFRD portion and
Concrete portion of dam.
ii. While working out the quantity for common excavation and rock
excavation of each portion of dam, same ratio i.e. 1:1 has been used
over the total excavation quantities of each type.
Table – 7.16
Quantities of Different Activities for
Construction of CFRD Portion of Khargihill Dam
Work In-situ
Stripping - 57,500 m3
Excavation
Common 4,29,050 m3
Rock 6,55,200 m3
Fill placement
Impervious material 2,81,100
Filter, Fine (2B Zone+3A Zone) 2,29,200
Filter, Coarse(Zone 3B) 12,05,600
Filter, Coarse(Zone 3C)Rock toe 7,16,900
Total Quantity 24,32,800 m3
The surface excavation for main dam involves both common and rock
excavations. The volume of required excavation is given in Table – 7.17:
405
Table – 7.17
Volume of Surface Excavation
Type Common Rock excavation
3
Description excavation (m ) (m3)
River Bed Excavation 4,29,050 6,55,200
Total 4,86,550 6,55,200
Two working seasons have been earmarked for undertaking surface

excavation pertaining to main dam. Although work in the river bed can be
equipment for the surface excavation to be made is estimated in Table –
7.18:
Table – 7.18
Type Common Rock Excavation
Description Excavation
3
Total volume (m ) 4,85,550 6,55,200
Shift proposed 2 2
Total operational hours (hour) 4400 4400
(m3/hr)
Volume to be handled loose (m3/hr) 138 238
3
Peak Volume to be handled(m /hr) 173 297
Total quantity 173+297 = 470 m3/hour
Peak quantity 470 cum/hour
loading of the soft material (earth and alluvium) by 2.0 m3 hydraulic
excavators assisted by 180 HP crawler dozer
 Transportation to the disposal area by 18/20t capacity rear dumper.
406
spreading of the unloaded materials
hammers and wagon/crawler drill with hole patterns of 1m c/c and 2.75
m c/c respectively to be deployed for drilling of charge holes.
The construction of concrete faced rockfill dam involves placement

of 24,32,800 m3 of fill materials. As per construction schedule the fill
placement is to be undertaken in period of three working seasons. The
break-up of total quantity into different types of fill material to be placed in
different zones and their expected source of supply is given in Table – 7.19:
Table – 7.19
Quantities and Source of Fill Material
S. Fill Material Quantity Average distance
N (compacted) of borrow area/
o. (m3) quarry (km)
1 Impervious material 2,81,100 4.0
2 Filter, Fine (2B Zone+3A Zone) 2,29,200 6.0
3 Filter, Coarse(Zone 3B) 12,05,600 6.0
4 Filter, Coarse(Zone 3C) 7,16,900 6.0
Total = 24,32,800 m3
In the present case, since fill material is available within a distance of

6.0 kilometer and borrow areas are scattered over different locations, the
conventional method of material transportation, i.e., hydraulic excavator-
dumper combination has been considered for material transportation.
(i) Impervious Material: As mentioned above, the fill quantities are to be

placed in three working seasons. As the quantity of this type material is
comparatively less, single shift work/day is proposed for the placement. The
hourly placement quantities for hearting material have been worked out and
indicated in Table – 7.20:
407
Table – 7.20
Estimation of Hourly Quantity of Impervious Material Placement
S. No. Description Quantity Unit
1 Total volume 2,81,100 m3
2 Time period 24 month
3 Shift proposed 1 -
4 Operational hours/month 150 hour
5 Total operational hours 3,600 hour
6 Volume to be handled (in-situ) 78 m3/hour
7 Volume to be handled (loose) 98 m3/hour
8 Peak quantity 122 m3/hour
The following construction methods have been considered for hearting fill:
 Excavation and loading by means of 2.0 m3 hydraulic excavator

 Transport to the embankment by means of 18/20t capacity rear end
dumpers
 Spreading in layers up to 30 cm thick by 180 HP bulldoze
 Moisture adjustment by 8000 L water sprinklers
 Compaction by 8 passes of 10t pad foot vibrating roller
An average distance of 4.0 km from dam site has been considered for the
borrow areas for impervious material.
(ii) Filter, fine (2B Zone+3A Zone): The fine filter will have a total
volume of 2,29,200 m3. The fine filter material is used to fill 2B zone and
3A zone of CFRD Dam. This quantity will be brought from quarries located
at an average distance of 6.0 km from dam site. The material will be
processed in a processing plant located suitably near the quarry itself. The
fine filter material will be processed and brought to the dam site for
placement.
As the quantity of filter material is comparatively less, single shift

work/day is proposed for filter placement. The hourly rate at which
placement of filter is to be carried out has been estimated in Table – 7.21:
408
Table – 7.21
Estimation of Hourly Quantity of 2B Zone Material Placement
Time period 24 month
Shift proposed 1 -
Operational hours/ month 150 hour
Total Operational hours 3,600 hour
Volume to be handled (in situ) 64 m3/hour
Volume to be handled (loose) 102 m3/hour
The following construction methods have been considered for the placement
of fine filter:

up to filter processing plant by 18/20t capacity rear dumper.
near the quarry.
 Loading by 1.5 cum loader and transport to the dam site by 18/20t
capacity rear dumper.
 Spreading on the embankment in layers up to 30 cm thick by bulldozer
with flywheel power of 180 HP.
 Compaction with 6 passes of 10t smooth drum vibratory roller.
(iii) Filter, Coarse (Zone 3B): The requirements of coarse filter which is
going to be used in zone 3B filling is approximately 12,05,600 m3. The
same will be met from rock quarries. The rock will be transported to the
placement site. The Table – 7.22 indicates the estimation of hourly
quantities involved.
409
Table – 7.22
Shift proposed 2 -
The following construction methods and equipment are considered suitable

for rockfill placement:

circuits
near the quarry
 Loading at the filter processing plant by 2.5 m3 loader and transport to
to 70 cm layer thickness, by means of 180 HP flywheel power bulldozer
(iv) Filter, Coarse (Zone 3C) and Rock toe: The requirements of coarse
filter which is going to be used in zone 3C filling and rock- toe is
approximately 7,16,900 cum. The same will be met from rock quarries. The
Table – 7.23 indicates the estimation of hourly quantities involved.
410
Table – 7.23
Shift proposed 2 -


circuits
near the quarry
 Loading at the filter processing plant by 2.5 m3 loader and transport to
to 150 cm layer thickness, by means of 180 HP flywheel power
bulldozer
7.3.5.3 Major Construction Plant and Equipment for Khargihill

Concrete Faced Rockfill Dam

equipment required for construction of Khargihill Concrete Face Rock Fill
Dam (CFRD) is in Table – 7.24.
411
Table – 7.24
Major Construction Plant and Equipment for
Khargihill Concrete Faced Rockfill Dam
S. Description Size/ Quantity
No. capacity
4 Front end loader 2.5 m3 5
3
9 Vibratory compactor (smooth drum) 10t 3
14 Filter processing plant 250tph 1
15 Truck 8/10 ton 8
The excavations for the Khargihill dam will start from the abutments
above river bed level in the 2nd quarter of year 2 and will be completed
within three months. Excavations in the river bed will start as soon as the
work area in the river bed becomes dry. The dam foundation treatment,
which includes consolidation grouting and curtain grouting, will start locally
as the excavation is completed in that area.
Embankment construction will start by 3rd quarter of year 4, once the

412
A total period of 24 months, excluding the monsoon period has been
crest elevation by the end of 1st quarter of year 7.
7.3.6 Khargihill Concrete Dam
Main activities to be undertaken for construction of Khargihill

concrete dam (over flow & non-over flow sections) are surface excavations
and concreting. Surface excavations will comprise of common excavation in
overburden and rock excavation. The total quantity of concrete dam
excavation is about 10,84,250 m3, and total quantity of concreting is about
9,58,970 m3. Details are in Table – 7.25:
Table – 7.25
Quantities Involved in Construction of Concrete Dam
(Over Flow & Non-Over Flow)
Work in-situ
Stripping - - m3
Excavation
Common 4,29,050 m3
Rock 6,55,200 m3
Total excavation 10,84,250 m3
Concreting 9,58,970 m3
The surface excavations have been planned to be completed within 2

working seasons (16 months). The surface excavation for main dam
involves both common and rock excavations. The excavated material will be
transported to the disposal area using conventional excavator and rear
dumper combination. The provision of equipment for the surface
excavation to be made is estimated in Table – 7.26:
413
Table – 7.26
Type Common Rock
3
Total volume (m ) 4,29,050 6,55,200
Shift proposed 2 2
3
(m /hour)
3
(m /hour)
Peak Volume To be 153 297
3
Handled(m /hour)
Total quantity 153 + 297 = 450 m3/hour
The construction equipment for surface excavations is as under:
 Excavation and loading of the soft material (common excavation) by 2.0

m3 hydraulic excavators assisted by 180 HP bulldozers
 For rock excavations requiring drilling & blasting, drilling the very steep
areas by hand-held rigs (jack hammer) of 38 mm diameter with hole
patterns of about 2.75 m2 and drilling the accessible areas by crawler
drill
 Loading of blasted rock by 2.0 m3 hydraulic excavator, shovel
attachment and assisted by 180 hp dozers
 Transportation to the disposal areas/main dam by 18/20t rear dumpers
 Crawler dozer, 180 HP to be deployed at the disposal area to spread the
material.
7.3.6.2 Concreting
For concreting of main dam and appurtenant structures, total quantity

of the order of 9,58,970 m3, will have to be placed. A period of 3 working
seasons has been planned for the placement. The rate of placement works
out to 90 m3/ hour approximately. The concrete required for main dam is
proposed to be produced in a centralized Batching and Mixing Plant of
414
capacity 120 m3/hour. The plant shall be located in the vicinity of the dam.
In addition, two numbers mobile batching & mixing plant each of capacity,
18 m3/hour will be provided. The concrete from the plant will be transported
with the help of transit mixers of 4.5 m3 capacity.
Following construction equipments have been considered for

concreting of main dam and appurtenant structures:
 Placing of concrete with the help of 3 Nos. tower cranes, 10 ton @ 50

metre radius are proposed to be deployed at suitable locations. In
addition, 3 Nos. 38 m3/hr concrete pumps with 25 m boom will be used
for concrete placement
 Concrete transportation by transit mixers of 4.5 m3 capacity
 Batching and mixing plant of capacity 120 m3/hr to be located preferably
within a radius of 2 km from the concrete dam
coarse and fine aggregates.

Concrete Dam
Based on above construction methodology, major construction plant

and equipment required for construction of concrete dam are listed in Table
– 7.27:
Table – 7.27
Major Construction Plant and Equipment for Khargihill Concrete Dam
S. No. Equipments Size/capacity Quantity
3
1 Hydraulic excavator 2.0 m 3
3
3 Front End Loader 2.5 m 2
6 Rear dumper 18/20t 15
3
7 Tippers 4.5 m 3
8 Tower Crane, traveling type 10t@50m 3
9 Aggregate processing plant 300 tph 1
415
10 Batching & mixing plant 120 m3/hour 1
11 Mobile Batching & mixing plant 18 m3/hour 2
12 Transit mixers 4.5 m3 16
13 Concrete pump with 25m boom 38 m3/hour 3
14 Concrete Vibrator (electrical/ 9
pneumatic)
15 Compressed air cfm 1600
16 Grout pump 20 kg/m2 4
17 Trucks 8/10 ton 4
18 Mobile Crane 16t 2
The sequence of construction of Khargihill concrete dam takes into

account the following aspects:
 Surface excavation of concrete dam to start during the 3rd quarter of Year
2.
 The total quantity of excavation to be completed in a period of 2 working
seasons. The activity to be completed by the end of 1st quarter of year 4.
 Concreting to start in the 3rd quarter of Year 3 and will continue for 3
working seasons and to be completed by the end of the 2nd quarter of
year 6.
 Since a part of over-flow section (two blocks) is to be used for diversion
of river during construction of earth dam, the phasing of concreting is to
be planned in such a way that the work of these two blocks is completed
during lean season.
 Gate installation work to start in the beginning of 4th quarter of year 5
and will be completed by the end of 3rd quarter of Year 7.
7.3.7 Khargihill Dam Power House

7.3.7.1 Excavation and Concreting
Main activities to be undertaken for construction of Khargihill power

house are surface excavations and concreting along with erection of electro-
mechanical equipment. The quantities involved in the Khargihill dam power
house complex are indicated in Table – 7.28:
416
Table – 7.28
Quantities Involved in Khargihill Dam Power House Complex
S. No. Description Quantity (m3)
1 Surface excavations
Common Excavation 5,382
Rock excavation 11,810
2 Concreting 4,364
The sequence of operations for Khargihill power house complex is based on

the following construction methods and equipment:

 Loading of the blasted rock by 2.0 m3 hydraulic excavator bucket shovel
 Placing of concrete with 20 cum/hr concrete pumps with 25 m boom
 Concrete transportation by 4.5 cum transit mixers
 Concrete production in a Batching and mixing plant of capacity 120
m3/hr
coarse and fine aggregates
 Mobile crane of 16t is to be utilized for handling of construction
material, shutter forms etc.

Power House
No separate equipment for construction of powerhouse has been

provided as equipment deployed for concrete dam shall be utilized for
construction of power house.
417
As the excavation quantities are not much, a period of 3 months has

been planned beginning in the 4th quarter of year 6. The construction of the
concrete structures will begin by the 1st quarter of Year 7 starting from the
structures of the erection area. Almost 12 months have been considered
necessary to complete the powerhouse.
All works including electro-mechanical works will be essentially

completed before one month of completion of the project.
7.3.8 Khargihill Saddle Dam
The construction of the dam involves surface excavation, placement

of fill material, spreading & wetting and compaction of the fill material.
The quantities involved in construction of the Khargihill Saddle dam are
given in Table – 7.29:
Table – 7.29
Quantities Involved in Construction of Khargihill Saddle Dam
Description of Type / Quantity, Unit
Work Material in-situ
Stripping 18,900 m3
Excavation
Common 34,600 m3
Rock 3,100 m3
Fill placement
Hearting 42,200 m3
material
Casing material 2,24,900 m3
Filter, Fine 31,590 m3
Filter, Coarse 33,440 m3
Rock toe 16,200 m3
Total 3,48,330 cum
418
The surface excavation for main dam as well as for cofferdams

involves both common and rock excavations. The volume of required
excavation is given in Table – 7.30:
Table – 7.30:
Volume of Surface Excavation for Khargihill Saddle Dam
Type Common Rock Excavation
3
Description Excavation (m ) (m3)
Excavation for trenching 34,600 3,100
and preparation of base
Total 53,500 3,100
Four month has been earmarked for undertaking surface excavation

pertaining to Khargihill saddle dam. Although work in the river bed can be
equipment for the surface excavation is to be made is inTable – 7.31:
Table – 7.31: Estimation of hourly quantity of excavation

Type Common Rock
Total volume (cum) 53,500 3,100
Shift proposed 2 2
(cum/hr)
(cum/hr)
Total quantity = 60+4 = 64 m3/hour
Peak quantity = 64 m3/hour
419
loading of the soft material (earth and alluvium) by 2.0 cum hydraulic
excavators assisted by 180 HP crawler dozer.
 Transportation to the disposal area by 18/20 t capacity rear dumper.
spreading of the unloaded materials.
hammers and wagon/crawler drill with hole patterns of 1m and 2.75 m
c/c respectively to be deployed for drilling of charge holes.
The construction of earth fill dam involves placement of 3,48,330 m3 of fill

materials. As per construction schedule the fill placement is to be
undertaken in a period of 5 working months (Table – 7.32):
Table – 7.32:
Estimation of Hourly Quantity of Excavation for
Khargihill Saddle Dam
Type Hearting Casing Fine Coarse
Description Material Material Filter Filter
3
Total volume (m ) 42,200 2,24,900 31,590 49,640
Time period (months) 5 5 5 5
Shift proposed 2 2 2 2
Total operational 1375 1375 1375 1375
hours (hour)
Volume to be handled 31 163 23 36
3
in-situ ( m /hr)
Volume to be handled 39 205 37 58
3
loose ( m /hr)
Total quantity = 39+205+37+58 = 339 m3/hour
Peak quantity = 339 m3/hour
The Following construction methods have been considered for fill:
 Excavation and loading by means of 2.0 m3 hydraulic excavator.

 Transport to the embankment by means of 18/20 t capacity rear end
dumpers.
420
crawler drills with hole patterns of 1-2.75 m c/c.
circuits.
 Loading at the quarry by 1.5 cum hydraulic excavator and transportation
up to filter processing plant by 18/20t capacity rear dumper.
 Processing at the filter processing plant of installed near the quarry.
 Spreading by 180 HP bulldoze.
 Moisture adjustment by 8000 L water sprinklers.
 In case of Hearting and casing material, compaction by 8 passes of 10t
pad foot vibrating roller and in case of fine and coarse filter 6 passes of
10t smooth drum vibrating roller.

Saddle Dam

equipment required for construction of Khargihill saddle dam is given in
Table – 7.33:
Table – 7.33
List of Equipment Required for Construction of Khargihill Saddle Dam
S. No. Description Size/capacity Quantity
3
3
9 Vibratory compactor (smooth drum) 10t 1
13 Truck 8/10 ton 4
421
The excavations for the saddle dam will start from the abutments
above river bed level in the 3rd quarter of year 6 and will be completed
within 4 months. Excavations in the river bed including cut-off trench will
start as soon as the work area in the river bed becomes dry. The dam
foundation treatment, which includes consolidation grouting and curtain
grouting, will start locally as the excavation is completed in that area. The
timely completion of the surface treatments for the core foundation in the
river bed is essential in order to allow the beginning of the clay placement.
Thereafter, this work will proceed slightly in advance of the raising of the
core where it is required.
Embankment construction will start by 4th quarter of year 6, once the

A total period of 15 months, including the monsoon period has been

crest elevation by the end of 3rd quarter of year 7.
7.3.9 Bhugad-Khargihill Tunnel
The Bhugad-Khargihill Tunnel having 3.2 m diameter (finish) is of

17488 m length. Two construction adits have been proposed for
construction of Bhugad-Khargihill tunnel. The provision of two adits
provides opportunity to excavate tunnel from 6 faces simultaneously;
provided deployment of equipment sets is feasible at all the faces at a time.
The RD of each adits and distance between them is in Table – 7.34:
422
Table – 7.34
Bhugad – Khargihill Tunnel Adits – RD and Distance between Adits
Adit Adit Length RD from Tunnel Length (m) Distance
(m) Inlet Portal Face Length Served b/w Adits
(m) Number Through Face (m)
Inlet - 0.00 F1 3350
Portal 6500
Adit-1 205 6498 F2 3150
F3 3125
6250
Adit-2 154 12750 F4 3125
F5 2422
4738
Outlet - 17488 F6 2316
Portal
Total 17488 17488
7.3.9.1 Excavation of Tunnel
Before taking up actual tunnel excavation, portal construction and

slope stabilization would be required for which following construction
sequence is suggested:

 Slope Stablization using shotcrete machine and anchoring by jack
hammer/hydraulic drilling rig
 Portal concreting by using portable concrete mixer with weigh batches.
The portal excavation and slope stabilization will be completed

within three month from start of work. Once the same is completed, the
excavation of adits and tunnel (from inlet and outlet faces) will start. In
view of its size, both adits and tunnel are proposed to be excavated by full
face drill and blast method. For a finish diameter of 3.2 m, the minimum
423
excavated diameter of the tunnel shall be 4.2m to account for 500 mm thick
concrete lining and shotcrete. Following construction method for the
excavation of tunnel and adits may be adopted.
 Drilling of charge holes by means of single boom hydraulic drill jumbo

 Driving of each round variable according to the Class of rock
(approximate 3.5 m for the Class I & II, 3.0 m for the Class III and 2.5
m for the rock Class IV and V)
 Number of holes per round (including those necessary for carrying out
the smooth blasting along the peripheral surface) approximately 30-40
 Charging operations of explosive to be executed by means of man basket
and firing of the rounds using nonel detonators
 Loading of the muck resulting from blasting, by Railway Hydraulic
mucker/rock loader (40 m3/hr output capacity)
 Transport of the muck to the spoil area by Granby-type Side dump cars
(6 to 9 m3 capacity) mounted on rail system
 Shotcrete with the help of 4-6 m3/hr capacity wet shotcrete machine
 Rock bolting using mechanized rock bolting rig.
With the above construction methods and equipment, it is possible to

complete a cycle of operation within a period of 10.7 hours. Although the
time of each activity within a cycle may vary according to class of rock
encountered, the total cycle time for the pull [planned as indicated above for
different classes of rock will be the same order. A typical cycle for Class III
(pull of 3.00m) is in Table – 7.35:
Table – 7.35
Typical Cycle for Class III (Pull of 3.00 m)
1 Preparation of job 0.5hr
2 Drilling of Charge Holes 2.2hr
3 Charging 1.0hr
4 Removal of Jumbo to safe position 0.5hr
5 Blasting and defuming 1.0hr
6 Mucking 2.0hr
7 Scaling 0.5hr
8 Shotcreting and rock bolting 3.0hr
Total 10.7hr
424
In whole tunnel, 99% tunneling is in rock class of I, II & III (no –rock
support system required) and 1% tunneling is in rock class IV & V(require
rock support system). As per the rock condition of tunnel and with above
cycle time, an average sustainable progress of 140 m/month/face can be
achieved.
Considering 6 face excavation, all the construction activities of

Bhugad – Khargihill tunnel would be planned and staged for optimum
utilization of equipments for planned time period.
7.3.9.2 Concrete Lining
Concrete lining is to be undertaken after the completion of

excavation. Following sequence of operation will be followed for concrete
lining of the head race tunnel:
 Concrete to be placed in three stages viz., kerb, overt, invert

 Kerb concreting to be placed with the help of 20 m form work
 Installation of Rails on kerb for movement of 10 m travelling collapsible
formwork for overt concreting
 Pouring of concrete for Overt by 25 m3/hr capacity concrete pump.
 Transportation of concrete by 4.5 m3 capacity transit mixers.
 Invert concreting with the help of screed board.
 Pouring of concrete for invert with similar equipment as deployed for
overt.
 Preparation of Concrete in a Batching & Mixing Plant of 30 m3/hr
capacity installed near Portal of each adit and outlet.
 An Aggregate Crushing & Screen Plant of 70 tph to be installed near
each adit location for preparation of coarse aggregate. A tertiary crusher
for preparation of crushed fine aggregate is also to be provided as river
sand is to be blended with crushed
 Excavated material from tunnel excavation to be utilized as aggregate
after crushing & screening. In case material from quarries is to be
obtained, tipper, 10 T payload capacity to be utilized for transportation
and wheel loader, 1.0 m3 for loading .
A typical cycle time for overt concreting is in Table – 7.36:
425
Table – 7.36
Estimated Cycle Time in Overt Concreting (10 m)
1 Erection time 16.00 hr
2 Pouring time 8.00 hr
3 Setting time 20.00 hr
4 Dismantling of formwork 4.00 hr
Total 48.00 hrs
With 48 hr cycle time and two set of shutter form, a progress of 10 m

per day or an average progress of about 200 m/month/face at each face can
be achieved. Invert concrete to be undertaken simultaneously with overt
concreting with a time lag.
Based on the above methodology, major Construction Plant &

Equipment required for construction of tunnel have been listed out in Table
– 7.37:
Table – 7.37:
Major Construction Plant & Equipment for Construction of
Bhugad – Khargihill Tunnel
S. No. Item Qty./ No.
1 Single Boom hydraulic Drill Jumbo with 4

working platform
2 Rock Bolting Jumbo 4
3 Railway Hydraulic mucker/rock loader 4
4 Wagon Drill 4
5 Heavy Duty Rock Drill, 120 cfm 4
6 Muck cars 6 m3 capacity 24
7 Crawler Dozer, 165 hp 4
8 Loader-cum-Excavator, 1.0 m3/ 0.24 m3 4
9 Shotcrete m/c, 4-6 m3 4
10 Shotcrete m/c with Robot Arm, 10 cum 4
11 Air Compressor, 500 cfm, Diesel 4
12 Aggregate Crushing & Screening Plant, 4
70 tph
13 Concrete Batching & Mixing Plant, 30 4
m3/hr
426
14 Collapsible Shutter Form with Traveller, 6
6.8x10 m
15 Transit Mixer, 4.5 m3 12
3
16 Concrete Pump, 25 m /hr 4
17 Concrete Mixer, 14/10 cft 4
18 Tipper, 10 t 28
19 Wheel loader 1.0 m3 4
20 Grout pump 6
An average distance of 7.0 km from quarry site has been considered

for calculating the number of tippers required.
7.3.9.3 Construction Program
The sequence of Construction of Bhugad – Khargihill tunnel takes

into account the following aspects:
 Open excavation for face and portal construction is to be started in the

1st quarter of year 2 and will completed within three months
 Adits/Tunnel excavation to start in 2nd quarter of year 2 and are to be
completed by the end of 1st quarter of year 4
 Concrete lining of whole of tunnel to be taken up from all the face
simultaneously. Lining to start in the 4th quarter of year 3 and to be
completed by the end of 1st quarter of year 6
 Contact/consolidation grouting of the tunnel to start simultaneously
with the concreting and will finish in three months after concreting
 Final cleaning of tunnel and other miscellaneous work will be
completed in two months after consolidation grouting.
7.3.10 Khargihill - Pinjal Tunnel
Khargihill - Pinjal Tunnel having 4.0 m diameter (finish) is of 25224

m length. Four construction adits have been proposed for construction of
Khargihill - Pinjal tunnel. The provision of 4 adits provides opportunity to
excavate tunnel from 10 faces simultaneously; provided deployment of
equipment sets is feasible at all the faces at a time. The RD of each adits and
distance between them is given in Table – 7.38.
427
Table – 7.38
Khargihill - Pinjal Tunnel Adits – RD and Distance between Adits
Adit Adit RD from Tunnel Length (m) Distance
Length Inlet Face Length b/w Adits
(m) Portal Number Served (m)
(m) Through
Face
Inlet - 0.00 F1 3690
Portal
5729
Adit-1 1700 5729 F2 2039
F3 3216
5983
Adit-2 2283 11712 F4 2767
F5 2135
4370
Adit - 2050 16082 F6 2235
3 F7 2231
5862
Adit - 623 21944 F8 3631
4 F9 1722
3280
Outlet - 25224 F 10 1558
Portal
Total 25224 25224
7.3.10.1 Excavation of Tunnel
Before taking up actual tunnel excavation, portal construction and

slope stabilization would be required for which following construction
sequence is suggested:

 Transportation to the disposal areas by 18/20 t rear end dumpers
 Slope stabilization using shotcrete machine and anchoring by jack
hammer/hydraulic drilling rig
 Portal concreting by using potable concrete mixer with weigh batches.
428
The portal excavation and slope stabilization will be completed
within three month from start of work. Once the same is completed, the
excavation of adits and tunnel (from inlet and outlet faces) will start. In
view of its size, both adits and tunnel are proposed to be excavated by full
face drill and blast method. For a finish diameter of 4.0 m, the minimum
excavated diameter of the tunnel shall be 5.0 m to account for 500 mm
thick concrete lining and shotcrete.
Following construction method for the excavation of tunnel and adits

may be adopted:
 Drilling of charge holes by means of single boom hydraulic drill jumbo

 Driving of each round variable according to the Class of rock (approx.
3.5 m for the Class I & II, 3.0 m for the Class III and 2.5 m for the
rock Class IV and V)
 Number of holes per round (including those necessary for carrying out
the smooth blasting along the peripheral surface) approximately 45-55
 Charging operations of explosive to be executed by means of man basket
and firing of the rounds using nonel detonators
 Loading of the muck resulting from blasting, by Railway Hydraulic
mucker/rock loader (60 m3/hr output capacity)
 Transport of the muck to the spoil area by Granby-type Side dump cars
(6 to 9 cum capacity) mounted on rail system
 Shotcrete with the help of 4-6 m3/hr capacity wet shotcrete machine
 Rock bolting using mechanized rock bolting rig
With the above construction methods and equipment, it is possible to

complete a cycle of operation with in a period of 11.9 hours. Although the
time of each activity within a cycle may vary according to class of rock
encountered, the total cycle time for the pull [planned as indicated above for
different classes of rock will be the same order. A typical cycle for Class III
(pull of 3.00m) is given in Table – 7.39:
429
Table – 7.39
Typical Cycle for Class III (Pull of 3.00m)
1 Preparation of job 0.5 hr
2 Drilling of Charge Holes 3.3 hr
3 Charging 1.0 hr
4 Removal of Jumbo to safe position 0.5 hr
5 Blasting and defuming 1.0 hr
6 Mucking 2.1hr
7 Scaling 0.5 hr
8 Shotcreting and rock bolting 3.0 hr
Total 11.9 hr
In entire tunnel, 99% tunnelling is in rock class of I, II & III (no –

rock support system required) and 1% tunnelling is in rock class IV & V
(require rock support system). As per the rock condition of tunnel and with
above cycle time, an average sustainable progress of 125 m/month/face can
be achieved. Considering 10 face excavation, all the construction activities
of Khargihill - Pinjal tunnel would be planned and staged for optimum
utilization of equipments for planned time period.
7.3.10.2 Concrete Lining
Concrete lining is to be undertaken after the completion of

excavation. Following sequence of operation will be followed for concrete
lining of the head race tunnel:
 Concrete to be placed in three stages viz., kerb, overt, invert

 Kerb concreting to be placed with the help of 20 m form work
 Installation of Rails on kerb for movement of 10 m travelling collapsible
formwork for overt concreting
 Pouring of concrete for Overt by 25 m3/hr capacity concrete pump
 Transportation of concrete by 4.5 m3 capacity transit mixers
 Invert concreting with the help of screed board
 Pouring of concrete for invert with similar equipment as deployed for
overt.
 Preparation of Concrete in a Batching & Mixing Plant of 30 m3/hr
capacity installed near Portal of each adit and outlet
430
 An Aggregate Crushing & Screen Plant of 70tph to be installed near each
adit location for preparation of coarse aggregate. A tertiary crusher for
preparation of crushed fine aggregate is also to be provided as river sand
is to be blended with crushed
 Excavated material from tunnel excavation to be utilized as aggregate
after crushing & screening. In case material from quarries is to be
obtained, tipper, 10 T payload capacity to be utilized for transportation
and wheel loader, 1.0 cum for loading
A typical cycle time for overt concreting is in Table – 7.40:
Table – 7.40
Estimated Cycle Time in Overt Concreting (10 m)
1 Erection time 16.00 hr
2 Pouring time 8.00 hr
3 Setting time 20.00 hr
4 Dismantling of formwork 4.00 hr
Total 48.00 hrs
With 48 hr cycle time and two set of shutter form, a progress of 10 m

per day or an average progress of about 200 m/month/face at each face can
be achieved. Invert concrete to be undertaken simultaneously with overt
concreting with a time lag.
Based on the above methodology, major Construction Plant &

Equipment required for construction of HRT have been listed out in
following Table – 7.41:
Table – 7.41
Major Construction Plant & Equipment for
Construction of Khargihill – Pinjal Tunnel
S. No. Item Quantity
/ No.
1 Single Boom hydraulic Drill Jumbo with working 6
platform
2 Rock Bolting Jumbo 6
3 Railway Hydraulic mucker/rock loader 6
4 Wagon Drill 6
431
5 Heavy Duty Rock Drill, 120 cfm 6
6 Muck car 9 m3capacity 42
7 Crawler Dozer, 165 hp 6
8 Loader-cum-Excavator, 1.0 cum./ 0.24 m3 6
9 Shotcrete m/c, 4-6 m3 6
10 Shotcrete m/c with Robot Arm, 10 m3 6
11 Air Compressor, 500 cfm, Diesel 6
12 Aggregate Crushing & Screening Plant, 70 tph 6
13 Concrete Batching & Mixing Plant, 30 m3/hr 6
14 Collapsible Shutter Form with Traveller, 6.8x10 m 10
15 Transit Mixer, 4.5 m3 24
16 Concrete Pump, 25 m3/hr 6
17 Concrete Mixer, 14/10 cft 6
18 Tipper, 10 t 48
19 Wheel loader 1.0 m3 6
20 Grout pump 10
An average distance of 10.0 km from quarry site has been considered for
calculating the number of tippers required.
7.3.10.3 Construction Program
The sequence of Construction of HRT takes into account the following

aspects:
 Open excavation for face and portal construction is to be started in the 1st
quarter of year 2 and will be completed within three months
 Tunnel excavation to start in 2nd quarter of year 2 and are to be
completed by the end of 2nd quarter of year 5
 Concrete lining of whole of tunnel to be taken up from all the face
simultaneously. Lining to start in the 4th quarter of year 3 and to be
completed by the end of 2nd quarter of year 7
 Contact/consolidation grouting of the tunnel to start simultaneously with
the concreting and will finish in three months after concreting
 Final cleaning of tunnel and other miscellaneous work will be completed
in two months after consolidation grouting.
432
7.4 Deployment Schedule
Based on equipment planning and construction programme described

in preceding Sections, a construction schedule for whole of the project has
been prepared in the form of a Bar Chart and is placed at Annexure - 7.1 in
Volume - II. Keeping this construction schedule as one of the major
criteria, a deployment schedule of major construction equipment that would
be required for the project is shown in Annexure - 7.2 in Volume - II. The
number of equipment shown in the list has been arrived at after scheduling
the equipment in such a way that minimum number of equipment, in
general, would be needed. The basis for planning, indicating the type of
equipment to be used, has already been dealt with in the respective sections
and sub-sections corresponding to different items of the structures. As the
deployment schedule may differ depending upon the number of executing
agencies, the total number of equipment required will have to be reviewed at
the time of project execution.
7.5 Total Requirement of Major Construction Equipment
A list of major construction equipment and plants, which would be

required for construction of various components of the project is shown in
Annexure - 7.3 in Volume - II. The latest budgetary prices of the equipment
have been indicated in the list which could be utilized for working out the
analysis of rates as required. The total cost of construction equipment has
been worked out as Rs. 27663 lakh.
The provision on this account will not be included in the sub-head Q -

Special T&P of Cost Estimate when works are to be executed by the
contracting agencies.
7.6 Manpower Planning

7.6.1 Organisation Set Up
The project will be implemented under an organisation set-up headed

by an officer of the rank of General Manager. The works will be executed
under the overall supervision of four Officers of the rank of Chief Engineers
who will report to General Manager. In addition, there will be four officers
433
of the rank of Superintending Engineer to assist General Manager: Director
(Administration), Director (Finance), Director (Technical Coordination) and
Director (Planning) and Public Relation Officer and Labour Welfare
Officer. Each will be assisted by appropriate subordinate officers and staff.
The organisation chart for the project is appended as Annexure - 7.4 in
Volume - II.
There will be four Chief Engineers for the Project to look after the
works, viz., Chief Engineer (Head works), Chief Engineer (Tunnels), Chief
Engineer (Designs) and Chief Engineer (Electrical & Mechanical). Each
Chief Engineer except Chief Engineer (Designs) will be supported by two
officers of the rank of Superintending Engineer who will be heading the
field formations of circles. Each circle will have three to four division
offices which will be headed by the officers of the rank of Executive
Engineers. Executive Engineers in turn will have Assistant Engineers as
their subordinate officers who will man Sub-Divisional offices. The Chief
Engineer (Designs) will be supported by four officers of the rank of
Superintending Engineer: two for design units, one for Quality control and
one SE for EMP and R&R. These SEs will be further supported Executive
Engineers/ Assistant Engineers and other supporting staff.
Chief Engineer (Head Works) will be responsible for execution of

works related to construction of Bhugad and Khargihill dams and Power
Houses. One of the Superintending Engineers under him will be responsible
for construction of Bhugad dam and Power House and another
Superintending Engineer will be responsible for construction of Khargihill
dam and Power House. They will be supported by appropriate subordinate
officers as elaborated under the organisation chart. The designs of various
components of the project will be carried out by the Chief Engineer
(Designs).
Chief Engineer (Tunnels) will be responsible for execution of works

related to construction of both the tunnels: Bhugad - Khargihill tunnel and
Khargihill – Pinjal tunnel. One of the Superintending Engineer under him
will be responsible for construction of Bhugad – Khargihill tunnel and
another Superintending Engineer will look after the construction of
Khargihill – Pinjal tunnel.
434
The civil designs of all the components of the project will be carried
out by the Chief Engineer (Designs). The Chief Engineer (Electrical &
Mechanical) will look after the electro-mechanical works of the two power
houses. His formation will also provide assistance in respect of electrical
and mechanical works for whole of the project.
Detailed manpower requirement has been indicated in Annexures -

7.5 to 7.7 in Volume - II.
7.7 General Purpose Equipment and Inspection Vehicles
In case the works are to be executed through award of contract, the

general purpose equipment for infra-structure works and inspection and
transport vehicles which are required to be procured and used by the project
owners for the project have been estimated and indicated in the Annexure -
7.3 in Volume - II. The total cost of general purpose equipment and
inspection vehicles has been worked out as Rs. 1593 lakh.
7.8 Year Wise Allocation of Cost
The year wise allocation of cost for the project is in Table – 7.42 and
the details are at Annexure - 7.8 in Volume – II.
Yearly phasing of Expenditure

Year Allocation of cost (lakh Rs.)
st
1 Year 3925
nd
2 Year 31835
rd
3 Year 68628
th
4 Year 62240
th
5 Year 51869
th
6 Year 38984
th
7 Year 17180
Total 274661
435

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Chapter - 7

Construction Program, Manpower

The construction methodology and equipment planning for

7.1 Main Project Components

Damanganga – Pinjal link project has been planned as drinking water

i A 851.50 m long composite embankment (concrete faced rock fill) -

iii A 618.20 m long composite embankment (concrete faced rock fill) -

7.1.1 Salient Features of main Components of the Project

7.2 Basis for Study

Methodology for construction of Damanganga – Pinjal Link Project

Mechanized construction has been planned for almost all types of

Sequencing of construction activities, wherever possible, has been

7.2.2 Construction Material Sources

Locations of different borrow areas and quarries for construction

Construction material for concrete, viz. sand/fine aggregate,

For the construction material for concrete lining of Bhugad-

Total concrete requirement of different grades for the main

The area for disposal of excavated material has been considered at an

7.2.3 Basic Considerations

Based on past experience, about 8 working months in a year are

7.2.3.1 Scheduled Working Hours

Equipment planning for calculating requirement of equipment is

Two shifts working of equipment is normally considered most

i. Single shift working 10%

7.2.3.2 Construction Period

A total period of seven years has been considered for completion of

7.3 Construction Methodology and Equipment

The construction methodology and equipment planning along with

7.3.1 River Diversion Works

No formal diversion arrangement has been provided for the

 Excavation and loading of the material by 2.0 m3 hydraulic

7.3.2 Concrete Face Rock-Fill Dam (Bhugad Dam)

The construction of the dam involves surface excavation, placement of fill

7.3.2.1 Surface Excavation

One working season has been earmarked for undertaking surface

Following construction methods are proposed for surface excavations:

7.3.2.2 Fill Placement

The construction of concrete faced rockfill portion of Bhugad dam

The fill placement will require excavation and loading of material at

Hydraulic excavator-rear dumper combination is the most commonly

Belt conveyor system is considered a good alternative for

(i) Impervious Material: As mentioned above, the fill quantities are to be

 Excavation and loading by means of 2.0 m3 hydraulic excavator

As the quantity of filter material is comparatively less, single shift

The following construction methods have been considered for the

 Loading at the quarry by 2.0 m3 hydraulic excavator and transportation

The following construction methods and equipment are considered

 Drilling of charge holes at the quarry by means of jack hammers and

The following construction methods and equipment are considered

 Drilling of charge holes at the quarry by means of jack hammers and

7.3.2.3 Major Construction Plant and Equipment for Bhugad

Based on above methodology and equipment planning the list of

7.3.2.4 Construction Programme

Embankment construction will start by 3rd quarter of year 3, once the

A total period of 24 months, excluding the monsoon period has been

Main activities to be undertaken for construction of Bhugad concrete

7.3.3.1 Surface Excavation

The surface excavations have been planned to be completed within 1

The construction equipment for surface excavations is as under:

 Excavation and loading of the soft material (common excavation) by 2.0

For concreting of main dam and appurtenant structures, total quantity

Following construction equipments have been considered for