Ultratech Cement Limited Jetty Extension Project December 2011

Introduction • Gujarat Cement Works (GCW) of Ultratech Cement Ltd. Intends to extend their existing jetty and augment the material handling system to increase the loading capacity of cement and clinker also like to unload coal, iron ore and gypsum from the jetty to meet their future demand. • At present the length of the existing jetty is 337 m. GCW has decided to extend the jetty by 210 m to develop the new facilities. • Sanjay construction Co. (SCC) has submitted the bid for Construction of Extended Jetty and Associated works 2

Purpose of presentation • Introduction • To present proposed methodology of work for construction of the extension of the jetty. 3

Sanjay Construction Company • Portfolio of work encompasses Port-Harbour & Marine works, Road & Bridges, Water Supply & Irrigation, Industrial Structures, Environment and Modern Mass Transits System. • Incorporated in 1995 registered as ‘AA’ class Government Contractor. • Specialized in Marine and Bridge works • Following gamut of services in Marine Infrastructure offered: • Berths/ Wharves/ Jetties/ • Mooring dolphins • Wharf wall • Breakwaters/Shore Protection work • Water intake structure 4

Sanjay Construction Company Completed Projects - Marine Construction of outfitting Jetty at ABG Shipyard Jageswar, Dahej (Gujarat) 5

Sanjay Construction Company Completed Projects - Marine Jetty for Relocation of port Craft and small boats. (Mormugao Port Trust) GOA 6

Sanjay Construction Company Completed Projects - Marine Construction of Additional Three Nos. Offshore Mooring Dolphins at Mormugao Harbour 7

Sanjay Construction Company Completed Projects - Marine Reconstruction of mooring Dolphin No. 3 & 4 at Gas Jetty -2 Reliance Industries Ltd. Hazira (Gujarat) 8

Sanjay Construction Company Completed Projects Profile - Marine R. C. C. Jetty, Revetment And Reclamation in Minor Fishery Harbour At Dholai Dist. Navsari (Gujarat) 9

Sanjay Construction Company Completed Projects - Marine Construction of Ro - Ro Jetty at Paradip Port (PPT) (Orissa) 10

Sanjay Construction Company Completed Projects - Marine Construction Of R. C. C. Jetty at Port Navlakhi (Gujarat) 11

Sanjay Construction Company valuable client list § Gujarat maritime Board (GMB) § Indian Railways § Government of Gujarat § Ahmadabad Municipal Corporation (AMC) § Marmugao Port Trust, Goa § Ahmadabad Urban Development Authority (AUDA) § Paradip Port Trust, Orissa § Reliance Industries Ltd. § ABG Shipyard, Dahej § Well Spun § J M Baxi & Co. § Ranjit Buildcon 12

Scope of Work • Jetty expansion - 210 m x 32 m with spacing of the pile bents at 8 m in the longitudinal direction. – Bored cast-in-situ reinforced concrete piles – 110 nos of piles of 1200 mm dia and 13 nos of piles of 750 mm dia – Precast pile caps, beams and cast-in-situ deck slab and wearing coat – Provision of fenders, bollards, ladders, constant tension mooring winch, safety hand rails etc. 13

Methodology - Overall Next few slides describe in brief our proposed methodology for execution, and the same is described over the following main points. Mobilization and site establishment Pre. Construction activities Piling Pre-casting yard and installation of pre-cast elements Superstructure Cast-in Situ concrete Marine equipment Demobilization 14

Methodology - Mobilization • Experienced and adequate team of engineers, supervisors, supporting staff and skilled & unskilled labour and tools and plants will be deployed on site. • Following site establishments will be erected upon mobilization • • Site office QC Laboratory Workshops Stores Mobilization and site establishment 15

Methodology – Pre-construction • Pre-construction yards and establishments will be erected like but not limited to: • • • Concrete batching plant Bar bending yard Pre-casting and stacking yard Fabrication of MS Liners etc Pre-Construction activities 16

Outline chart of Construction Methodology Step 1 - Crane is erected on the existing Berth Ex is tin g B er th Roa d C on ran be e rt h Precast Yard Existing Approach Trestle Existing Road Trailer Existing Loading Point 17

Outline chart of Construction Methodology Precast Yard Step 2 – Piling construction using the double gantry platform Temporary Ex is tin g B er th Roa d C on ran be e rt h Gantry Platform Existing Approach Trestle Existing Road Trailer Existing Loading Point 18

Outline chart of Construction Methodology Step 3 – Piling construction using the double gantry platform Precast Yard Ex is tin g B er th Roa d C on ran be e rt h Temporary Gantry Platform Existing Approach Trestle Existing Road Trailer Existing Loading Point 19

Outline chart of Construction Methodology Step 4 - Use of Self Propelling Barge with mounted Crane to transport the precast elements to proposed berth Self Propelling Barge with Mounted crane Ex is tin g B er th Roa d C on ran be e rt h Precast Yard Existing Approach Trestle Existing Road Trailer Existing Loading Point Self Propelling Barge with mounted Crane 20

Outline chart of Construction Methodology Step 5 - Use of Self Propelling Barge with mounted Crane to transport the precast elements to proposed berth Self Propelling Barge with Mounted crane Ex is tin g B er th Roa d C on ran be e rt h Precast Yard Existing Approach Trestle Existing Road Trailer Existing Loading Point Self Propelling Barge with mounted Crane 21

Methodology - Piling • Piling activities will be undertaken in the following order of execution • Gantry Fabrication and Erection • Gantry shifting • Pitching and Driving of the M. S. Liners: • Boring • Reinforcement Cage Placing • Concreting • Gantry Shifting Piling 22

Methodology - Piling RCC Bored Cast-in-Situ Piles Materials and workmanship shall comply with the latest edition and amendment of the applicable Indian Standard or approved International Standard. • IS 2911 Part 1 – Concrete Piles - Section 2: Bored Cast In. Situ Piles • IS 2911 Part 4 – Load Tests on Piles 23

Methodology - Piling Gantry Fabrication, Erection and Shifting • Double gantry platform with two piling equipments on each gantry will be erected, So as to execute four piles at a time. • End on method proposed by erecting two sets of gantry platforms with two sets of piling ‘A’ frames and single drum winch on each gantry. • Designing & Fabrication of gantry to the piling layout will be conducted in the work-shop at the site. • On completion of one bent/row of piles, gantry will be shifted forward and positioned and oriented on the second bent/row, then on third and so on. Piling by End-on Gantry Platform 24

Methodology - Piling Gantry Fabrication, Erection and Shifting Piling by End-on Gantry Platform 25

Methodology - Piling Pitching and Driving of the M. S. Liners: • The fabricated liners will be positioned at marked location on gantry platform as per the pile layout. These will be lifted by the piling frame and placed in correct position truly vertical with the two level guides. • The hammering will be done with the help of the bailer to drive the liners. • After driving the initial length of liner, subsequent pieces of liners (if necessary) of adequate length will be brought and welded on the driven liners and further driving along with the boring activity will be done till the design depth of penetration is achieved. 26

Methodology - Piling Pitching and Driving of the M. S. Liners: Crane Liner pitching 27

Methodology - Piling Existing jetty Gantry Fabrication, Erection and Shifting Proposed Extension On achievement of required strength of concrete of pile, provision of bracings to the previous bents and fixing of wheel blocks; gantry shall be moved forward to next bent of piles. The entire cycle of piling is repeated for the next bents subsequently. 28

Methodology - Piling Gantry Fabrication, Erection and Shifting 29

Methodology - Piling Boring The boring shall be done by one of the following methods: • Direct mud circulation • Reverse mud circulation • Bailer bentonite if approved to be used The actual method of construction to be followed shall be as per approval of the Owner. The method shall be such that any statutory standards are followed especially for piling in Marine environment. 30

Methodology - Piling Reinforcement Cage Placing & Concreting Reinforcement • The reinforcements shall be made into cages sufficiently rigid to withstand handling without damage. I • Stirrups to the main bars shall be tack welded. • Proper cover and central placement of the reinforcement shall be ensured by use of suitable concrete spacers or rollers, cast specifically for the purpose. Concreting • Concrete as per Design Mix will be poured continuously through tremie pipes till the full length of pile gets completed in one operation. The concrete will be transported from the batching plant to the piling location by the transit mixtures and then the concrete will be pumped to the gantry by use of the concrete pump. 31

Methodology - Piling Misc. • Defective pile shall be removed or left in place, as judged convenient by the Owner, without affecting the performance of adjacent piles or capping above and additional piles shall be provided to replace them. • A competent supervisor shall be present to maintain piling record the necessary information during the installation of piles. • Immediately after installing, marine piles shall be temporarily braced as necessary to the approval of UCL to resist direct loads and vortex induced oscillations due to current and/or wave action and to resist construction loads. • SCC shall carry the load test as specified by UCL in the detailed specifications. Load test would typically involve static compressive load tests, static tension and dynamic tests. 32

Methodology - Superstructure Manufacturing of precast concrete units: • Pile cap/muff, beams, etc. Pre-cast • Proper lifting hooks will be provided. • Automatic concrete batching plant of required capacity will be established Pre-casting yard and installation of pre-cast elements 33

Methodology - Superstructure Erection of precast units: • Precast concrete units lifted by the crane and placed on trailer and transported to existing loading point. • Precast elements transported to jetty site by using self propelled barge through water ways. • Pre-cast units then placed in position by the use of the crawler crane. Pre-casting yard and installation of pre-cast elements 34

Methodology - Superstructure Cast-in situ Deck: • RC Deck to be in-situ cast • Concreting to be done by concrete pump, supported by transit mixers. • Joints between the precast units and castin-situ members will be completed after providing the reinforcement as per the drawings and pouring the cast-in-situ concrete to achieve the monolithic joints. Superstructure Cast-in Situ concrete 35

Methodology - Superstructure Fenders and Bollards: • As the work progresses, fixtures for bollards and frontal frame for fenders will be installed as per the specification and manufacturer’s recommendations. • Fenders and bollards to be procured form competent manufacturers as approved by UCL. • Only after successful testing, fenders and bollards will be installed. • Moorings/hooks, ladders and safety hand rails will be installed as per the specifications and the drawings. Marine equipment 36

Methodology – De-mobilization • After successful completion of the work, the man-power, machineries, equipments and plants will be demobilized and transferred away from the site of work. • All temporary work like gantry platforms, bracings, workshops , laboratories etc. will be dismantled and the area will cleaned by removing and disposing off the debris. • The site will be cleared and handed over satisfactorily to the owner as per the conditions of the contract. Demobilization 37

Existing jetty Programme Proposed Extension 38

Programme 39

Project Organization Chart Head Office Sanjay Patel Proprietor B. E. Civil G. R. Jadeja Balraj Sharma Rajdipsinh Jethwa Former C. E. , GMB Ex. Navy Former President M/s. Sanghi Industries Ltd. H. R. & Business Promotion 40

Project Organization Chart Construction site Project Manager D. Z. Patel (B. E. Civil) Construction Manager -I Main Civil Works Jayesh Patel (B. E. Civil) Finance & Administration Main Civil Works Kalpesh Patel (B. E. Comp) Safety & Quality Manager Main Civil Works B. S. Yadav (B. E. Civil) Design Associates Main Civil Works Samarthaya Abhiyanta Hitendtra Mojitra Procurement & Store Construction Manager – II Ancillary Works Suresh Patel Yogesh Raval (D. C. E. ) Site Supervisors Anant Prajapati (B. E. Civil) Ramesh Kansara (D. C. E. ) Abhishek Sharma (B. E. M) Amit Patel (D. C. E. ) Sameer Patel (B. E. C. ) Pinkal Patel (D. C. E) 41

HSE & Quality Safety • • • A fulltime safety officer and safety guards will be deputed on site. Continuous training and workshops on safety awareness and practices the labour and all staff. Conducting Mock drills as per the safety plan. Maintenance of the machinery and certification. Providing safety signs, barricades and shelters Our Quality Management Policy • Quality policy of the company is to assure the client of innovative engineering & technology and execution of works up to best level of the quality standards through establishment of the systems for specified inspection and testing requirements to ascertain the specified requirements for the materials, workmanship and finished work are met satisfactorily for constant and consistent assurance of the quality standards. 42

Thank You 43