National Highways Authority of India (NHAI) had awarded the work of “Four laning of Meerut- Bulandshahr Section of NH-235 from 8.800 km to 73.512 km (Design Chainage in the State of Uttar Pradesh under NHDP Phase IV on Hybrid Annuity Model), for a concession period of 17.5 years including a construction period of 910 days, i.e., two and a half years, and operation and maintenance period of 15 years to Freedom Point Expressways as concessionaire. Apco Infratech, who was the lowest bidder, had incorporated a SPV – Freedom Point Expressways (FEPL) – as the “concessionaire” for development of the project highway. “FEPL had entered into a concession agreement (CA) with NHAI on March 4, 2016, for construction, operation and maintenance of the project,” informs DK Srivastava, Executive Vice President, APCO Infratech. The CA sets out the scope, rights and obligations of all the parties, overall framework for the development, and operation and maintenance of the project. While the project bid was floated by the NHAI at end of 2015, the appointed date was declared as April 28, 2017. “During this course of time and the completion period as well, the project alignment features have been modified to cater to the topographic and demographic variations and inhabitant demands,” Srivastava adds. As built features of the project highway is depicted as follows: Scope of work The site of the four-lane project highway comprises the section of National Highway-235 (New NH-334) commencing 8+800 km to 66+482 km and excluding 3.522 km of existing bypass of NH-24 (i.e., the Meerut- Bulandshahr section), having a total length of 64.712 km including 3.522 km of existing Hapur Bypass of NH-24 in Uttar Pradesh. The total design length of the project road is about 61.19 km. This project road section traverses through three districts of Uttar Pradesh, viz, Meerut, Hapur and Bulandshahr. As Srivastava shares, “NHAI had proposed to bypass nodal towns i.e. Phaphunda Bypass (2.7 km), Kharkhauda Bypass (3.2 km), Hapur Bypass (11.2 km – greenfield and 1.228 km – improvement of existing Hapur Bypass on NH 24), Gulaothi Bypass (7.6 km) and widen two-lane existing alignment into four-lanes with paved shoulder – and divided median on the basis of a detail project (feasibility) report carried out in the year 2010.” The alignment traverses along and across various canals, drains, and railway crossings. In order to cater to these structures, nine minor bridges, one major bridge, and one RoB has been provided. Additionally, a six-lane carriageway underpass (three vehicular underpass (VUP), five pedestrian underpass (PUP)) has also been provided to accommodate various major crossroads without conflict and with respective traffic.Resource planning and execution The concessionaire, FEPL, had to design the project considering the above project particulars as per codal provisions of “IRC: SP: 84 - 2014” and determine the requisite resources, i.e., manpower, material, and machinery to complete the project within the stipulated timeframe. The contractor had identified its need and planned its resources to execute the work within a 910-days timeline. Srivastava shares the key resource deployment in the form of material, manpower and machinery, as tabulated below:Key materials: Description UoM Quantity Aggregates:     Dust MT 519,444 GSB aggregates MT 609,831 Concrete aggregates MT 948,955 Coarse sand MT 332,604 Steel MT 9,010 Fly-ash MT 45,494 Structural steel MT 861 Cement MT 170,478 Curing  compound Kg 1,409,969  Key manpower Description UoM Quantity Manpower required (Average per day) No’s 362 Man-hours working Hours 3,317,400 Key machinery used   Description Quantity Sensor Paver for DLC 2 Sensor Paver for PQC 1 Excavator 11 Grader 8 Roller 9 HYWA Dumper 70 Water Tanker 12 Transit Mixer 3 Batching Plant 100 CPH 4 Batching Plant 30 CPH 1             Execution challenges Various challenges were involved in the execution of this project. Some of them were: Various hindrances and encumbrances in the form of factories, boundary wall, trees, houses, shops, and electrical utilities. Delay in handing over encumbrance-free ROW to the concessionaire; Non-disbursement of compensation or dispute by landowners regarding compensation awarder, leading to frequent and violent disruptions; Hindrances due to irrigation structures and DFCC; Construction ban imposed by the Hon’ble Supreme Court and National Green Tribunal; Delay in finalisation of ‘Change of Scope’ by the authority; Delay in approval for tree felling by the Forest Department; and Lockdown due to outbreak of Covid-19. “The above listed issues had resulted in project delays,” says Srivastava. “The project timeline was stretched for 553 days in addition to 910 days. However, FEPL (the concessionaire), with its prudent approach and accelerated efforts, reduced the time span to 295 days from the additional 553 days required for the project and achieved provisional completion certificate on August 14, 2020.” Challenges during the corona outbreak In March 2020, when the government imposed the nation-wide lockdown to curb the spread of the coronavirus pandemic, the project was about to achieve the provision certificate scheduled on April 25, 2020. Due to the lockdown, the project had lost movement, motivation, resources for executing project facility work (finishing work) and balance major work. The concessionaire, upholding the professional ethics and values of its promoter APCO Infratech, retained manpower at its respective accommodation facilities and provided best services to facilitate them in hard time. “However, manpower exodus begun on the start of special trains and buses for commuting people to their respective home places,” says Srivastava. “The government eased down lockdown restriction for the infrastructure sector on April 20, 2020, but the district administration had not allowed commencing work till May 4, 2020.” Workers were then facilitated with all type of COVID precautions; they were accommodated with social distancing norms and special transport facilities were made to commute them to site from accommodation and vice versa. Safety first! In order to avoid fatalities or accidents at work, FEPL ensured that the labour or manpower wear high visibility clothing, which included a vest, hard hats, safety glasses, face shields, earplugs, fall arrest systems, safety-toed shoes, and respirators and all types of personal protective equipment or PPE. The plan or procedure was well-established – some call it an internal traffic control plan – to separate workers from the path of vehicles and equipment. The idea was to ensure that the vehicles know where workers are located, and workers know where equipment is operating. Social-economic benefit The Minister of Road Transport and Highways has cited that this project will curtail the travel time from Meerut to Bulandshahr to one hour from the two hours earlier. Since it acts as a connector to these major districts with Delhi and its surrounding area, this will give a boost to the sugarcane industry, vegetable industry, textile industry, and meat industry. Also, the highway is in close association with NH-24, near Hapur Bypass, and will serve as a direct access route to Garh-Mukteshwar, where the Government of Uttar Pradesh is planning to develop a waterway and promote tourism. Further, this highway will also serve as an access route to the upcoming Ganga Expressway project in Meerut and Bulandshahr. Achievement The entire project has a rigid pavement and is among the few projects in Uttar Pradesh to have the entire length paved with pavement quality concrete. This plus, the toll plaza has been established within 180 m RoW comprising a 14-lane road; it is one of the most advanced and equipped toll plaza, which includes all lanes as Fastag with all the essential amenities.SHRIYAL SETHUMADHAVANProject details Particular Description Project cost Rs 11.30 billion including COS granted for additions of elevated structures for safety of road users and access to villagers or farmers Month of completion August 14, 2020, (PCOD) and  November 12, 2020 (COD) Total length 61.19 km Developer Freedom Point Expressways Contractor APCO Infratech Consultant SAI Consulting Engineering (SYSTRA) Steel supplier SAIL, REAL Ishpath, JSPL Any other technology or material used Flyash/silica as cement replacement