FIBRETRON

COMPOSITES
Glass-Fibre Reinforced Polymer (GFRP) Rebar

STRENGTH IN SUSTAINABILITY

FIBRETRON COMPOSITES Pvt. Ltd.

+91 9999997522 | [email protected]
TABLE OF
CONTENTS

COMPANY PROFILE
1
Introduction Letter
GSTIN certificate
Pan card
ISO Certification/or other certification updated
MSME Registration

2 PLANT SETUP & MACHINERY

Manufacturing process
Manufacturing Quality Plan
Information about testing facilities of the product
List of manufactures Plant & Machinery

3 BROUCHURE
Fibretron Brouchure

4 TEST CERTIFICATES
Test Reports, MSDS, MTC

5 APPROVALS & IMPORTANT GOVT. DOCUMENTS

Indian Road Congress 2022 GFRP Bar Guidelines
NHAI Letter Dt. 30.08.22
CONSULTANTS SOURCE APPROVALS, Purchase Orders
To
The Concerned Authority Engineer

Subject: Introduction and Request for Approval of Fibretron Composites Pvt Ltd's Product

Dear sir/mam,

I am writing to introduce Fibretron Composites Pvt Ltd, a leading manufacturer of Glass-Fiber

Reinforced Polymer (GFRP) bars, and to request your esteemed approval for our product.

At Fibretron Composites Pvt Ltd, we pride ourselves on our commitment to quality and
innovation. Our state-of-the-art manufacturing facility, located in Greater Noida, boasts
cutting-edge technology and fully automated machinery to ensure the highest standards of
production. With ISO certification 9001:2015, we guarantee that our products meet and
exceed industry benchmarks.

Our dedicated team of highly qualified engineers and technicians oversees the manufacturing
process, supported by a fully equipped quality control laboratory. We offer value-added
services such as customized cutting and automated bending to meet the unique requirements
of our clients.

We understand the importance of your approval in endorsing the quality and reliability of our
product. Therefore, we earnestly request your consideration and approval of our GFRP bars
for use in your esteemed projects.

Thank you for considering our proposal. We look forward to the opportunity to collaborate and
serve your organization with our superior products and services. Please do not hesitate to
contact us for any further information or clarification.

Sincerely,

Pranav Jain
Director
Fibretron Composites Pvt Ltd
 COMPANY PROFILE

FIBRETRON COMPOSITES Pvt. Ltd.

+91 9999997522 | [email protected]
 Government of India
Form GST REG-06
[See Rule 10(1)]

Registration Certificate

x
Registration Number : 09AAFCF3904J1ZK

Ta
1. Legal Name FIBRETRON COMPOSITES PRIVATE LIMITED

2. Trade Name, if any FIBRETRON COMPOSITES PRIVATE LIMITED

es
3. Additional trade names, if any

ic
4. Constitution of Business Private Limited Company

5. Address of Principal Place of H-30, Noida Greater Noida Link Road, Near Thomson Press
rv
Business Warehouse, Surajpur Site C Industrial, Greater Noida,
Gautam Buddha Nagar, Uttar Pradesh, 201306
Se

6. Date of Liability 16/03/2023

7. Period of Validity From 12/05/2023 To Not Applicable

8. Type of Registration Regular

d
an

9. Particulars of Approving Uttar Pradesh

Signature Signature Not Verified

Digitally signed by DS GOODS AND
SERVICES TAX NETWORK 07
ds

Date: 2023.05.12 13:45:31 IST

Name ANAND KUMAR TRIPATHI

oo

Designation Assistant Commissioner

Jurisdictional Office Sector-2,Gautambudha Nagar

G

Date of issue of Certificate 12/05/2023

Note: The registration certificate is required to be prominently displayed at all places of business in the
State.

This is a system generated digitally signed Registration Certificate issued based on the approval of application granted
on 12/05/2023 by the jurisdictional authority.
15/12/2023, 14:03 Print : Udyam Registration Certificate

UDYAM REGISTRATION CERTIFICATE

UDYAM REGISTRATION NUMBER UDYAM-UP-28-0071987

NAME OF ENTERPRISE M/S FIBRETRON COMPOSITES PRIVATE LIMITED

SNo. Classification Year Enterprise Type Classification Date

TYPE OF ENTERPRISE *
1 2023-24 Micro 15/05/2023

MAJOR ACTIVITY MANUFACTURING

SOCIAL CATEGORY OF
GENERAL
ENTREPRENEUR

S.No. Name of Unit(s)

NAME OF UNIT(S)
1 M/S FIBRETRON COMPOSITES PRIVATE LIMITED

Name of
Flat/Door/Block
H-30 Premises/ .
No.
Building
Surajpur
Village/Town Industrial Block Site-C
Area
OFFICAL ADDRESS OF ENTERPRISE Noida-
Greater
Road/Street/Lane City Gautam Buddha Nagar
Noida Link
Road
UTTAR GAUTAM BUDDHA NAGAR ,
State District
PRADESH Pin 201306
Mobile 9999997522 Email: fi[email protected]

DATE OF INCORPORATION /
16/03/2023
REGISTRATION OF ENTERPRISE

DATE OF COMMENCEMENT OF
16/08/2023
PRODUCTION/BUSINESS

SNo. NIC 2 Digit NIC 4 Digit NIC 5 Digit Activity

NATIONAL INDUSTRY 1 22 - Manufacture 2220 - 22209 - Manufacturing
CLASSIFICATION CODE(S) of rubber and Manufacture Manufacture of
plastics products of plastics other plastics
products products n.e.c

DATE OF UDYAM REGISTRATION 15/05/2023

*In case of graduation (upward/reverse) of status of an enterprise, the benefit of the Government Schemes will be availed as per the
provisions of Notification No. S.O. 2119(E) dated 26.06.2020 issued by the M/o MSME.
Disclaimer: This is computer generated statement, no signature required. Printed from https://udyamregistration.gov.in & Date of printing:-
15/12/2023

For any assistance, you may contact:

1. District Industries Centre: GAUTAM BUDDHA NAGAR ( UTTAR PRADESH )

2. MSME-DFO: DELHI ( DELHI )

https://udyamregistration.gov.in/Udyam_User/Udyam_PrintApplication.aspx 1/2
CERTIFICATE NO:
DIPP129152
Government of India
Ministry of Commerce & Industry
Department for Promotion of Industry and Internal Trade

CERTIFICATE OF RECOGNITION
This is to certify that FIBRETRON COMPOSITES PRIVATE LIMITED incorporated as a Private Limited Company on
16-03-2023, is recognized as a startup by the Department for Promotion of Industry and Internal Trade. The startup is working
in 'Construction' Industry and 'Construction & Engineering' sector as self-certified by them.

This certificate shall only be valid for the Entity up to Ten years from the date of its incorporation
only if its turnover for any of the financial years has not extended 100 Cr.

16-04-2023 15-03-2033
DATE OF ISSUE VALID UPTO
 PLANT SETUP
AND
MACHINERY

FIBRETRON COMPOSITES Pvt. Ltd.

+91 9999997522 | [email protected]
 LIST OF MACHINES AND
MANUFACTURING PROCESS
1. Pultrusion Machine: Used for the continuous production of GFRP bars by pulling resin-
saturated fibers through a heated die, curing them into solid bars of desired cross-
section.
2. Resin Mixing System: Automated system for precisely mixing resin components,
additives, and catalysts to achieve the desired properties and consistency.
3. Fiber Glass Roving Cutter: Machine for cutting glass fiber roving to the required length
for pultrusion process, ensuring uniformity and accuracy.
4. Die Heater: Device for heating the pultrusion die to the optimal temperature to facilitate
resin impregnation and curing of the fibers.
5. Curing Oven: Large oven for curing the pultruded GFRP bars at controlled temperature
and humidity conditions to achieve desired mechanical properties and durability.
6. Cooling System: System for cooling the cured GFRP bars after pultrusion process to
stabilize their dimensions and enhance their strength.
7. Sizing and Surface Treatment Equipment: Equipment for applying sizing agents and
surface treatments to the pultruded GFRP bars to enhance their bonding with concrete
and improve corrosion resistance.
8. Cutting and Finishing Machines: Automated machines for cutting the pultruded GFRP
bars to required lengths, chamfering edges, and finishing surfaces to meet specific
project requirements.
9. Quality Control Equipment: Instruments and devices for testing and inspecting the
physical, mechanical, and chemical properties of the GFRP bars, ensuring compliance
with standards and specifications.
10. Packaging and Labeling Systems: Systems for packaging the finished GFRP bars
securely and labeling them with relevant information such as batch number,
dimensions, and specifications for traceability and identification.

The manufacturing process involves precise control of resin impregnation, fiber alignment,
curing conditions, and quality assurance measures to produce high-quality GFRP bars with
consistent properties and performance for various structural applications.
 QUALITY ASSURANCE PLAN
1. Inward Resin Properties:
Physical properties of the inward resin, including viscosity, specific weight, and gel-
time, are regularly verified to ensure consistency and quality.
2. Roving Calculation:
The number of rovings required to achieve a minimum mass fraction of glass fiber
at 80% and resin matrix at 20% is calculated and monitored for each batch.
3. Die Internal Diameter:
The internal diameter of the die is determined and regularly inspected to achieve
the measured nominal diameter of the GFRP bars. Maintaining the cross-sectional
area is crucial for structural integrity.
4. Weight and Diameter Measurement:
The weight per meter and measured diameter of the cured bars are determined for
every batch to ensure adherence to specifications and standards.
5. Glass Transition Temperature:
The glass transition temperature is measured and maintained above 100 degrees
Celsius to ensure the structural longevity of the reinforced concrete.
6. Third-Party Testing:
Mechanical properties of each batch are subjected to third-party testing to verify
compliance with standards and specifications.
7. Documentation and Record-Keeping:
Detailed records of all quality control tests, measurements, and inspections are
maintained for traceability and audit purposes.
8. Continuous Improvement:
Continuous monitoring and feedback mechanisms are in place to identify areas for
improvement and implement corrective actions to enhance product quality and
consistency.
By implementing these quality assurance measures, we ensure that our GFRP bars meet
the highest standards of performance, durability, and safety for use in various structural
applications.
 TESTING PROGRAMME
Testing Program:
Physical Properties Testing:
Viscosity Test: Measure the viscosity of the resin to ensure consistency and proper
flow during impregnation.
Specific Weight Test: Determine the specific weight of the resin to verify the correct
ratio of resin components.
Gel-Time Test: Assess the gel time of the resin to monitor the curing process and
ensure adequate handling time.
Glass Transition Temperature (Tg) Testing:
Conduct Differential Scanning Calorimetry (DSC) analysis to determine the glass
transition temperature of the GFRP bars.
Ensure that the Tg is above 100 degrees Celsius to ensure structural longevity and
durability.
Mechanical Properties Testing:
Third-party testing of mechanical properties, including:
Tensile Strength: Evaluate the maximum tensile load a GFRP bar can withstand
before failure.
Flexural Strength: Measure the maximum stress a GFRP bar can withstand
when subjected to bending forces.
Compressive Strength: Determine the maximum load a GFRP bar can
withstand under compression.
Shear Strength: Assess the resistance of GFRP bars to shear forces.
Modulus of Elasticity: Measure the stiffness of GFRP bars under tensile or
flexural loading conditions.
Ultimate Strain: Determine the maximum strain or deformation a GFRP bar can
undergo before failure.
Dimensional Testing:
Measure the diameter and length of GFRP bars to ensure compliance with
specifications and tolerances.
 Verify the cross-sectional area and uniformity of GFRP bars to meet design
requirements.
Batch Testing:
Conduct batch testing of GFRP bars to ensure consistency in physical and
mechanical properties across production runs.
Random sampling of GFRP bars for testing to ensure representative results and
quality control.
Quality Control Measures:
Implement stringent quality control procedures throughout the manufacturing
process to detect and correct any deviations or defects.
Regular calibration and maintenance of testing equipment to ensure accuracy and
reliability of test results.
Compliance Testing:
Ensure compliance with relevant standards, specifications, and regulatory
requirements for GFRP bars used in construction applications.
Obtain necessary certifications and approvals from regulatory authorities to validate
the quality and performance of GFRP bars.

The testing program aims to validate the physical, mechanical, and dimensional properties
of GFRP bars, ensuring their suitability and reliability for various structural applications.
Regular testing and quality control measures help maintain consistent quality and
performance standards for GFRP products manufactured by Fibretron Composites Pvt Ltd.
 BROUCHURE

FIBRETRON COMPOSITES Pvt. Ltd.

+91 9999997522 | [email protected]
Fibretron Rebar
Glass-Fibre Reinforced Polymer (GFRP) Rebar
ST RE NGT H IN S U STA IN AB I L ITY
FIBRETRON REBARS
FIBRETRON rebars are Glass Fibre Reinforced Polymer (GFRP) Rebars that are a
lightweight, high-strength and corrosion-resistant alternative to traditional steel
reinforcement bars. FIBRETRON rebars are made of composite material, which
comprises of high strength glass fibers embedded in a polymer resin matrix.

SUSTAINABLE INFRASTRUCTURE
SOLUTIONS
(FIBRETRON rebars compared to steel)
Raw Materials
FIBRETRON rebars have a 15% lower carbon footprint than steel*

The Manufacturing Process

Minimal heat, water, and energy used
Lower CO2 emissions Raw
Materials
Process efficiency = minimal waste

Distribution
4 x lighter than steel FIBRETRON Rebars
Recycle Manufacturing
More products per truckload Composite
Less fuel required for transportation Life Style

Use
Increases asset life-cycle by as much as four times
Zero maintenance requirements
Seawater can be used in cement production
Saves fresh water
Use Transportation
Less cement content needed

Recycle
FIBRETRON composites can be crushed and used as
aggregate in concrete
*Comparison based on the manufacture of steel rebar.
STRENGTH IN SUSTAINABILITY
The use of Fibretron rebars in construction can play a significant role in India's mission to
become 'Net zero' by reducing the carbon foo print of buildings and infrastructure.
Fibretron rebars are an innovative and eco-friendly alternative to traditional steel
reinforcement bars, with significantly lower embodied carbon and a longer service life. By
replacing steel with Fibretron rebars, the construction industry can reduce its carbon
emissions and contribute to India's ambitious goal of achieving net-zero greenhouse gas
emissions by 2050.

ADVANTAGES OF USING
FIBRETRON PRODUCTS
Whole of Life Savings
Design life cycle becomes Double with 100+ years with Zero maintenance cost

High Tensile Strength

Twice the strength of steel

Corrosion Free
Exceptional resistance in salt water environments, Does not rust or leach

Highly Chemical Resistant

Exceptionally resistant to a wide range of chemicals

Non-electromagnetic
Non-conductive and electro-magnetically neutral

Non-magnetic
No interference with sensitive enquipment

Lightweight
4 x lighter than steel with Faster installation, reduced injury risks, &
lower transportation costs
 Easy to cut and install
Cut on-site using standard cutting tools

Low Thermal Conductivity

Maintains excellent thermal insulation values

No Thermal Cycling Impact

Thermal expansion coefficient almost identical to concrete

Highly Durable
Over 100 years retention of strength and modulus in high pH environments

Low Environmental Impact

15% lower carbon footprint than steel (comparison based on the manufacture of steel)

2X 4 40%
STRONGER TIMES LIGHTER CHEAPER
APPLICATIONS

SPECIAL APPLICATIONS
These are the applications where traditional steel reinforcement faulters and
FIBRETRON Rebars provide much superior results.

Corrosive and Chemical Environments For non-conductive/non-magnetic

• Bridge decks and approach slabs performance
• Roads • Hospitals
• Underwater, coastal and offshore • Airport compass calibration pads
• Drainage arch and box culverts • Power plants and transformer sites
• Marine pre-cast sea walls • Light Rail
• Sewage treatment plants
• Desalination Plants Easy and safe to cut
• Industrial and agricultural facilities • Tunnels (soft eyes)
• Mining
Thermal Insulation
• Energy efficient buildings

OTHER APPLICATIONS

Parking Bus Retaining Precast Foundations

Garages Stops walls

Walls Industrial floors Swimming Septic tank Columns

pool
STEEL VS FIBRETRON

Material Steel (TMT Bar) FIBRETRON Rebar

Tensile strength
(MPa)/ N/ mm^2 500 1000+

Shear Strength 120 170

Bond strength
Mpa/ N/ mm^2 14* 12.5

Compression
Mpa/ N/ mm^2 500 450

Modulus of
Elasticity (Gpa) 160-200 65

Elongation(%) 25 4

Terms are prescribed in

Durability special building codes 100+ years

Density 1.9
(ton/m3) 7.8

Corrosion Stainless material

resistance to Appearance preserving properties
aggressive of rust products even in alkaline
environment concrete environment

Ecological Ecologically Does not emit

compatibilty friendly material harmful & toxic substances
during storage & use

Electrical Electrically
conductivity conductive material Dielectric
TABLE OF SUBSTITUTION
BY TENSILE STRENGTH

METAL REBAR FIBRETRON REBAR

Weight Diameter Weight Diameter

(per 12 meter bar) (mm) (per 12 meter bar) (mm)

2.75kg 6 = 0.46kg 4.5

4.74kg 8 = 0.57kg 6

7.40kg 10
= 0.94kg 7

10.65kg 12
= 1.23kg 8

14.52kg 14
= 1.65kg 10

18.93kg 16 = 2.48kg 12

24.00kg 18 = 3.24kg 14

35.76kg 22 = 4.87kg 16

46.22kg 25 = 6.28kg 18

58.02kg 28 = 8.08kg 20

75.79kg 32 = 9.80kg 22
 TECHNICAL DATA
Fibretron (ASTM D7957, ACI 440.6)
#2 #3 #4 #5 #6 #7 #8 #10
Units
(6mm/0.23in) (10mm/0.39in) (13mm/0.51in) (16mm/0.62in) (19mm/0.74in) (22mm/0.86in) (25mm/0.98in) (32mm/1.25in)

kN 27 59 96 130 182 241 297 437

Guaranteed kip 6.1 13.2 21.6 29.1 40.9 54.1 66.8 98.2
tensile force MPa 27 59 96 130 182 241 297 437
ksi 6.1 13.2 21.6 29.1 40.9 54.1 66.8 98.2

Elastic GPa 46
Modulus ksi 6670

kN
Guaranteed kip
transverse
shear capacity MPa 150
ksi 23.2

Primary Materials Epoxy Backboned Vinylester and Corrosion Resistant E-CR Glass

g/m 97 144 315 415 589 780 1030 1680

Weight
lb/ft 0.07 0.096 0.211 0.278 0.395 0.524 0.692 1.128
Nominal mm 2
32 71 129 191 284 387 510 819
cross-sectional
area in 2
0.049 0.11 0.20 0.31 0.44 0.60 0.79 1.27
Outer diameter mm 8.2 10.0 14.0 16.0 19.0 21.8 25.0 31.4
(including
ribs) in 0.250 0.375 0.500 0.625 0.750 0.875 1.000 1.270

Please contact our team for information on the material properties, shape availability and dimensional limitations of bent bars.

DESIGN CODES AND STANDARDS

Design standards make it easy to switch from designing with steel to designing
with FIBRETRON Rebar.

USA: ACI CODE-440.11-22: Building Code Requirements for Structural Concrete

Reinforced with Glass Fiber-Reinforced Polymer (GFRP) Bars; AASHTO LRFD:
Bridge Design Specifications for GFRP -Reinforced Concrete Bridge Decks and
Traffic Railing

Europe: FIB Task Group 9.3 - Bulletin 40 - FRP Reinforcement in RC Structures

Saudi Arabia: ACI 440.1R; ACI CODE-440.11-22: Building Code Requirements for
Structural Concrete Reinforced with (GFRP) Bars

Canada: CAN/CSA S806: Design of Buildings with Fibre Reinforced Polymers,

CAN/CSA S6: Canadian Highway Bridge Design Code

India: IRC 137 - Guidelines on use of Fibre-Reinforced Polymer Bars in Road

Projects
GFRP AROUND THE WORLD
Largest GFRP Rebar Project

Roughly 11,000 km GFRP rebar reinforcen this concrete flood mitigation channel in
jizan, Saudi Arbaia and enable its 100 years service life.

Few of the bridge projects in NORTH AMERICA

CS Huntley Bridge Teed Bridge

Constructed in 2014 has beams that are A 64m single span bridge
simply supported over a single span of 20 constructed using 25 full-scale precast
m. reinforced bridge deck panels.

Pokemouche River Bridge Neils Brook Bridge

Constructed at New Brunswick in A 44.0-m single span bridge of 13.5
2015-2016 with a total length of 130m on mwidth was constructed in 2016.
route 113.
Kwinana Desalination Plant, Perth, Australia Grand Paris Express Metro, Paris, France

Jizan Flood Mitigation Channel, Jizan, Saudi Arabia

World's largest GFRP composite project (23km long channel)

Port of Rotterdam upgrade, The Netherlands Gisborne Port Upgrade, New Zealand
FIBRETRON SAVINGS
Cost Savings & Sustainability
across the Asset Life-cycle Global warming potential of bridge made
with either FIBRETRON or steel, tCO2eq over 100 yrs
1,500
Upfront
global warming
1,090 For replacement potential
1,000 similar
bridge, global
warming between
potential has Fibretron &
500 been amortised steel rebar
bridges
1st Life 1st Life 2nd Life
(100 yr) (75 yr) (100 yr)
0
FIBRETRON Steel 1,480
rebar bridge rebar bridge

Sustainability is achieved by balancing environment, economic, and social needs

– ensuring what is done today will provide a lasting and productive future.
FIBRETRON delivers in all key areas, advancing positive outcomes for asset
owners, communities, and the environment.

Economic Prosperity
Longer life cycles. Non-corrosive durable rebar requires no expensive
maintenance and preventative corrosion measures.
■ Design guides and codes have been improved over time. In recognition of the
high performance of modern Fibretron rebars, the quantities required for rein-
forcement have been reduced.
■ Design and manufacturing of Fibretron rebar have been optimized and are
competitively priced.
■ Eliminating the risk of corrosion in infrastructure results in savings across the
entire asset life.
■ Less maintenance (e.g. roadworks) reduces economic losses through delays,
and business interference.
■ 4x lighter than steel means less tonnage to transport.

Social Responsibility
FIBRETRON is 4x lighter than steel, making it easier to install, and decreases
injury risk to workers.
■ Robust infrastructure, particularly roading and bridges, allows supply chain
companies and communities to travel safely and freely without delays.

Environmental Savings
FIBRETRON does not corrode or cause concrete spalling and breakage.

■ No rust or chemical leaching.

■ Long-lasting structures result in less damage to the environment.
■ Requires less concrete coverage.
■ Fibretron composites have a 15% lower carbon footprint than steel (comparison
based on the manufacturer of steel rebar).
FAQs

How is the FIBRETRON better than metal? What are the advantages
of composite reinforcement in comparison with traditional metal
rebars

STRENGTH - Fibretron has strength characteristics 2-3 times superior characteris-

tics of steel reinforcement British standard for breaking.

DURABILITY - The coefficient of temperature expansion of composite reinforce-

ment is close to the coefficient of thermal expansion of concrete, so that in the
concrete structure there are no associated microdeformations, microcracks and
the overall durability of the structure is substantially increased.

CHEMICAL RESISTANCE - Composite reinforcement has great chemical resist-

ance in various aggressive environments, it is not susceptible to corrosion, which
also positively affects the durability.

LIGHT WEIGHT - Fiberglass reinforcement with comparable strength characteris-

tics is lighter than steel reinforcement in 9 times.

LOW THERMAL CONDUCTIVITY - Due to low thermal conductivity, "temperature

bridges" are not formed in the structures, which reduces the thennal loss to 34%
and, accordingly, the conditioning costs of the building.

EASY INSTALLATION - Reinforcing bars can be cut from the bay of any given
length, fasten with plastic clips, special fasteners-clamps or just a binding wire.
 TEST CERTIFICATES

FIBRETRON COMPOSITES Pvt. Ltd.

+91 9999997522 | [email protected]
MANUFACTURER’S TEST
CERTIFICATE
 Elmech Labs Pvt. Ltd.
ffi
An ISO 9001:2015
"EI-2007030"

Test Report No. ELPL|2S-241 LL9LU 1,A lr

Report lssued to Fibretron Composites Pvt. Ltd. Booking Receipt No. 11813
H-30, Site-C, Surajpur lndustrial Area,
UPSIDC, Greater Noida-201310 Date of Receiving 09l09l2023
Contact !nformation [email protected] Test Start Date LLl09l2023
Customer Ref. No. Test Completion Date L2lOsl2023
Sample Condition Good Date of Report Lzl09l2023
location of Testing Permanent Facility Environmental Cond. (23t5)oC, RH<70%
Sample Description GFRP Rebar, as per ASTM D7205

RT,SULTS

TENS!LE TEST:
Parameters Results-1 Results-2
Mass per meter, g 111.25 ttt.24
Density, g/cm3 2.L 2,L
Area, mm2 52.98 52.97
[oad. kN 59.04 51.96
Tensile Strength, MPa 1114.38 tL69.72
Modulus of elasticitv, GPa 55.03 58.66

tl. {. tr {. r} {. :x tlr {t rlr

End of

c#u
1. This test refers only to tested samples and applicable parameters only.
2. The sample description is not verified in all case and is given as described by the customer.
3. Test samples will be disposed after 15 days from the date of issue of test reports.
4. Complaints if any should be in writing within seven days from the date of issue of test reports,
5. This Report cannot be reproduced wholly or in part and cannot be used as in a court of law
and shall not be used in the Advertising media without written approval of (Doc. No.:

E-mail ID : [email protected] Website : www.elmechlabs.com

Phone:0120-4563398 M : 981087 4287, 8896767002
 Elmech Labs Pvt. Ltd. ,/
Certified
A'37, sector-63, Trimala ventures (suite No. B-05) Noida - 201301, u.p.
CIN : U74900DL2015PTC288823 o GSTIN : 09AAECEI460BtZ4 ,\n ISO 9l)l) I :2{) I 5
" r. I-20070-t0"

Test Report No.

Report lssued to Fibretron Composites pvt. Ltd. Booking Receipt No. 11813
H-30, Site-C, Surajpur lndustrial Area,
UPSI DC, Greater Noida-201310 Date of Receiving 0910912023
Contact lnformation [email protected] Test Start Date Lt|0912023
Customer Ref. No. Test Completion Date tI-l09l2023
Sample Condition Good Date of Report 1210e12023
tocation of Testing Permanent Facility Environmental Cond. (23ts)oc, RH<7IYo
Sample Description GFRP Rebar, Size: 5 mm, as per ASTM 7617
Client

SHEAR TEST:
Parameters Results-1 Results-2 Results-3 Results-4 Results-5
Mass per meter, g 49.354 49.355 49.348 49.350 49.352
Density, g/cm3 2.1 2.t 2.L 2.L 2.1
Area, mm2 23.50 23.50 23.50 23.50 23.50
Load, kN 11.133 9.9s2 tL.492 9.662 9.671
Shear Strength, MPa 236.87 21,-.74 2M.5t 205.57 20s.77

Average Shear Strength = 220.892 Mpa

't!*'t* *{.{.'* **End of Report ** *:f, **** *

DISCLAIMER:
1. This test refers only to tested samples and applicable parameters only.
2. The sample description is not verified in all case and is given as described by the customer.
3. Test samples will be disposed after 15 days from the date of issue of test reports.
4. Complaints if any should be in writing within seven days from the date of issue of test reports.
5. This Report cannot be reproduced wholly or in part and cannot be used as evidence in a court of law
and shall not be used in the Advertising media without written approval of the lab. (Doc. No.: ELPL/LFI18)

E-mail ID : [email protected] Website : www.elmechlabs.com

Phone : 0120-4563398 Mobile : 981087 4287, 88967 67 002
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Plot No.107/43, Chauhan Colony, Tirthrup Nagar,
Fq.fi.rd. t
eidc crs, rig1r - 442 401, Near W.C.L. Quarters, Chandrapur-442401

gvl : 7888097397 Tel. No. : 7888097397

Na , 9325687905, 9096674739 l\.4obile : 9325687905, 9096674739

{-ii, : [email protected], [email protected] E"mail : [email protected], [email protected]
iflTrfc : $ /vwcipet.gov.in websile : www.cipet.gov.in

M/ SERIES :A E'l No 0656

qrfuffq$erqiFq
I
PLASTICS TESTING CENTRE

qfferq qqlq q, / TEST CERTIFICATE

rc-10192
ULR No,: TC.1 01922300000020sF
lssued to. Test Report No.: 2300165
M/s. Fibrehon Composites Pvt. Ltd., Date : 11.09.2023
A:H-30, Site-c, Suralpur lndustrial Area,. Ref.
Your : Nil,
UPSIDC, Greater Noida - 201 310.
P eno. 1of2
Test Report as per requisition
PART -A
PARTICULARS OF SAMPLE SUBMITTED
(a) Name of Sample : "GFRP Reber Samptes" as stated by party
(b) Grade/Variety/Type/Size/Class : Nil,
(c) Declared value, if any : Nil,
(d) Code No : Nil,
(e) Batch No. and Date of Manufacturing : Nil,.
(0 Quantity : 4nos.x 250 length
(g) lVode of Packing : Packed in envelopes.
(h) Sealed or not : Not Sealed.
(i) Date of Receipt . 17.08.2023
(j) Date (s) of Performance oftest : 19.08.2023 to 06,09.2023.
(k) Any other information : Nil.

PART.B
SUPPLEMENTARY INFORMATION
i) Reference to sampling procedure Samples supplied by the Party
ii) Supporting documents for the measurement taken and result derived As given in Part C
iiD Deviation from the test method as prescribed in relevant work
Nit
instruction, if a

--- \
B Karthik (Assistant Technical Officer) A. K. Joshi (Quality Manager)
sft a 0+am*+-attAuth ori zed S ig n atory sft -f -d d€drarrfi -dttluth o rize d S ig n ato ry
 fttz , (S qq E w) trcrN CONTINUATION SHEET

CIPET : (CSTS) CHANDRAPUR

fui-e crper ULR No.: TC-1019223000000205F

Test Report No. :2300165
Date :11.09.2023
Pa eno.2of2
PART.C
Test Results
Sr. Clause Test
Name of The Test Test Method Units
No. No. Results

lgnition loss of GFRP Rebar ASTTV D2584-08 o/o

809

Water absorption I
ASTIV D57O-98 0.17
@ 5C'C for 24 hrs

Water absorption
3 ASTIV D57O-98 026
@ 23"C for 2 week in water
PART.D

Remarks, if any: Nil.

**'*End of Report****
No te:
1 lhe test report is issued for the samples submitted to this lab only.
2 The above results are subjected to the item tested.
3 The quality ofthe subsequent production/Lot has to be ensured by the purchaser.
4 The repo(s shall not be reproduced in full / part without written approval of the laboratory
5 Selection of samples for individual test has beendone in accordance with respective clauses of Test method
6. Remnant samples will be disposed after three months from the date of issue of test report.
7. Statement of conformity of a specification or standard is provided by laboratory considering
the level of risk associated/borderline case with the decision rule employed.
8. Details of tests subcontracted: Nil

B Karthik (Assistant Technical fficer) A. K. Joshi (Quality Manager)

re-5 C+anm-attAuthorized Si g n atory sft-"ra O+ararc+-attAut h o ri zed S ig n ato ry
Website –www.finefinish.net Doc No.- FFOPL/AL/QF/7.8-02-04
Date of Issue-21.03.2020

fine fINISH aNALYTICALlABORATORY

fine finish organics pvt. ltd.
PLOT No. 76 & 29, M.I.D.C.,
TALOJA - 410 208.India.
PH: +91 9029829777
CIN NO. U24110MH1994PTC078790
TEST REPORT
ULR No: TC633223100000512F
Test Report Number: FFO/23-24/E-223
Date of Report:19.07.2023

Date of Sample Receipt:05.07.2023

Date of testing:12.07.2023
To:
Fibretron Composites Pvt Ltd.
H-30, Site C, Surajpur Industrial Area,
Greater Noida Uttar Pradesh - 201306, India

Product: GFRP Re bar

Condition of Sample: GFRP Re bar & resin provided by customer

Customer Batch No: NA

Discipline: CHEMICAL Group: Plastic & Resin products
Instrument:
Make: TA instruments
Model: DSC Q20

Page 01 of 04

NOTE:
These results relate only to the sample tested
This test report should not be reproduced except in full, without written approval of the laboratory
Website –www.finefinish.net Doc No.- FFOPL/AL/QF/7.8-02-04
Date of Issue-21.03.2020
ULR No: TC633223100000512F
Test Report Number: FFO/23-24/E-223
Date of Report:19.07.2023

Sr. No. Characteristics Specification Measured Value Test Method

Glass Transition
1. ≥100°C 100.75°C ASTM D 3418:21
Temperature (Tg)
*Specification is provided by customer

Graph:

Page 02 of 04

NOTE:
These results relate only to the sample tested
This test report should not be reproduced except in full, without written approval of the laboratory
Website –www.finefinish.net Doc No.- FFOPL/AL/QF/7.8-02-04
Date of Issue-21.03.2020
ULR No: TC633223100000512F
Test Report Number: FFO/23-24/E-223
Date of Report:19.07.2023

Sr. No. Characteristics Specification Measured Value Test Method

Enthalpy of
1. - 399.9J/g ASTM E 2160:2004
Polymerization

Graph:

Page 03 of 04

NOTE:
These results relate only to the sample tested
This test report should not be reproduced except in full, without written approval of the laboratory
Website –www.finefinish.net Doc No.- FFOPL/AL/QF/7.8-02-04
Date of Issue-21.03.2020

ULR No: TC633223100000512F

Test Report Number: FFO/23-24/E-223
Date of Report:19.07.2023

Sr. No. Characteristics Specification Measured Value Test Method

1. Degree of cure ≥95% 95.01% ASTM E 2160:2004

*Specification is provided by customer

Remarks: Material passes acceptance criteria for above testing.

Tested by Checked by Authorized by:

Ms. Snehal Yerunkar Ms. Snehal Yerunkar Mr. Prathamesh Phansekar
(Analytical Chemist) (Analytical Chemist) (Technical Manager)
Email Id- [email protected]

END OF REPORT

Page 04 of 04

NOTE:
These results relate only to the sample tested
This test report should not be reproduced except in full, without written approval of the laboratory
 APPROVALS
AND
IMPORTANT GOVT.
DOCUMENTS

FIBRETRON COMPOSITES Pvt. Ltd.

+91 9999997522 | [email protected]
 Fi te No. RW/NH- 3 4049 I 01 I 2020-StuR (P&B)pt.
Government of lndia
Ministry of Road Transport & Highways
(S&R (P&B/New Technology) Zone)
Transport Bhawan, 1 , Partiament Street, New Dethi 'l 10001
Dated: 30th August, 2022

CIRCULAR

To

1. The Chief Secretaries of atl the State Governments/ UTs.

2. The Principat Secretaries/ Secretaries of atl States/ UTs Pubtic Works Department/
Road Construction Department/ Highways Department (dealing with Nationat
Highways and other centratty sponsored schemes).
3. The Chairperson, National Highways Authority of lndia, G-5 & 6, Sector-10, Dwarka,
New Dethi-110 075.
4. The Managing Director, NHIDCL, PTI Buitding, New Dethi-110001.
5. The Director General (Border Roads), Seema Sadak Bhawan, Ring Road, New Dethi-
110 010.
6. Att Engineers-in-Chief and Chief Engineers of Public Works Department of States/
UTs/ Road Construction Department/ Highways Departments (deating with Nationat
Highways and other centratty sponsored schemes).
7. Att CE-ROs, ROs and ELos of the Ministry.

Subject: - Value Engineering Practices for the Design, construction & Maintenance of
National Highways Projects- Reg,

Madam/Sir,

The Government of lndia has set an ambitious ptan for devetopment of National
Highways in the country. Many initiatives have been taken to materiatise this ambitious ptan
such as adopting wortdwide best practices in engineering techniques in design, construction
and maintenance of highways, bridges and tunnets. Further, the need is fett to adopt value
engineering practices in design, construction and maintenance with regards to use of
materiats and technotogy as an important and vital step to meet the sustainabte
devetopment of the NH network throughout the country in a cost-effective manner with
improved durabitity & safety, de-carbonise & grow, reduction in project execution timetine,
increase in quatity and reduction in maintenance.

2. The vatue engineering is very crucia[ for sustainabte highway devetopment. lt is a

systematic method to achieve the targeted function of the highway at the lowest whote-of-
[ife cost without compromising on functionatity, quatity, performance, safety and
aesthetics. Vatue Engineering practices aim at optimizing the vatue of the project at various
stages viz. project inception, project preparation, project bidding stage, project
imptementation and maintenance management to achieve at least one or atI of the foltowing
objectives:
a. lncreasing the speed of construction without compromising the quatity
b. Reducing the cost of construction and maintenance
c. lmproving asset durabi tity
kJur yodsh
""ulDq
Hr,!fr,
 d. lmproving aesthetics
e. Enhanced safety
f. Promoting environmental sustainabitity

g. lncreasing resitience to ctimate change and

h. Lowest tife cycte cost
3. Vatue engineering can be apptied at any point in a project, even in construction.
However, the eartier it is apptied the higher is the return on the time and effort invested
and also the acceptance. As per the World Bank report on the lndian Road Construction
lndustry, it has been estabtished that the savings reatized by undertaking vatue engineering
exercises can be in the order of 10-15% of the cost of the originatty designed project.

4. EPC/ HAM / BOT mode of project implementation has the potentiat that the
contractors/concessionaire woutd be abte to adopt designs and construction methodotogies
to suit the requirements of the project to bring down the initiat construction cost white not
impacting other aspects such as functionatity, quatity or durabitity. Atthough enabting
provisions for vatue engineering is taid out in the governing IRC Manuats for highway projects
(lRC SP: 73184/87199), however Contractors / Concessionaire, out of an aPPrehension that
the Authority woutd take adverse views about any alternative technotogies, avoid any
deviations from the specifications/technotogies specified in the Concession/ Contract
Agreement. The Concessionaire/ Contractors are also apprehensive about the long-term
risks of adopting innovative vatue engineering proposats, which would be entirety borne by
them.
5. To dispet such apprehensions and mind-set among Feasibitity & DPR
Consultant/Concessionaire/Contractors/ lElAE and add vatue engineering practices for the
design, construction & maintenance of the Nationat Highway, fo[towing has been decided:

5.1 Va[ue Engineering shatt be assigned as one of the tasks in the Terms of Reference
(ToR) for Feasibitity Study and Detaited Engineering Projects. ln the lnception Report itsetf,
there shatl be a Chapter regarding Value Engineering, in which the Consuttant shatt inctude
the potential & project-specific vatue engineering aspects identified by the respective
domain experts based on site reconnaissance surveys, ln the Feasibitity Report, the
Consultant shatt examine the appticabitity, durabitity, constructabitity & appropriateness of
the identified vatue engineering aspects and recommend the cost-effective strategies.
During the design stage, the design sha[[ be done for the approved value engineering criteria
and considering the same the Schedutes and Project Costs shatl be prepared. Some examptes
of value engineering concepts are given in Appendix-1. However, in addition to the same
other value engineering aspects shalI atso be exptored.
5.2 During the Project appraisat, in PATSC/SFC memo, there shatl be a para regarding
Value engineering Practices examined and finatty adopted.

5.3 Further during imptementation, the concessionaire/ contractors shatt be atlowed to

propose vatue-engineered atternative design/ materiat/ technotogy. lE/AE shatt review the
proposed vatue-engineered design and if it is not reviewed within the stipulated time period
specified in the contract/concession Agreement or rejected for any frivotous reason,
Authority may take approPriate action against the lE/AE.
5.3.1 After acceptance of design, a detailed construction methodotogy along with requisite
detaits such as proposed machinery/ ptants/equi pment, quatity assurance & quatity contro[,

[6]oL*r Y-a'^]
jo'lo ( )A
$S,
L2- - ,,
traffic diversion, pottution control measures, environmentaI comptiance/construction
sequence/materiat design shatI be submitted to lElAE for review,
5.3.2 Subsequentty, during trial laying, validation of considered material characteristic in
design sha[[ be done and if necessary, modification in design shall be done. Construction
shaU be started incorporating the modifications, if any.

5.3.3 The Concessionaire/Contractors shatt be entitted to retain all the savings accrued to
them on account of vatue engineering practices adopted by them.
6. The content of this circutar sha[[ be appticabte for alt the ongoing/ upcoming projects
henceforth and untiI any further orders,
7. lt that the contents of the circutar may be brought into the notice of atl
is requested
concerned for immediate needfuI comptiance.

8. This issues with the approval of Competent Authority.

Yours sincerety,
e.il."r yeJStq
zrr ?olaP]-:o>L_
(Bidur Kant Jha)
Director
(New Technology for Highway Devetopment)
For Director General (Road Devetopment) & Speciat Secretary
Copy to:
1. Att CEs in the Ministry of Road Transport & Highways
2. Att ROs of the Ministry of Road Transport & Highways
3. The Secretary Generat, lndian Roads Congress
4. Technical circutar file of S&R (P&B) Section
5. NIC-for uptoading on Ministry's website under "What's new"

Copy for kind information to:

l. PS to Hon'ble Minister (RT&H, MS&,\ E)
2. PS to Hon'bte MOS (RT&H)
3. 5r. PPS to Secretary (RT&H)
4. PPs to DG (RD) e SS
5. 5r. PPs/ PPS to Addt. Secretary (Road Safety)/ Addt. Secretary (RT&H & LA)
6. Sr. PPS/ PPS to AS&FA
7. Sr. PPS/ PPS to ADG (sKN) / ADG (RP)/ ADG(DS)
8. Sr. PPS/ PPS to JS (RT&A4VL)/ JS (ElC) i JS (Logistics)/ JS (NH|DCL)

Page3/3
Appendix-l: Formulation of Value Engineering Strategy for National Highway Projects

The cost component of a highway project generatty comprises of 70% of Material costs, 20%
of Machineries costs and 10.0% of Manpower costs. Hence, to have a vatue-engineered
optimum highway emphasis shatl be on material selection and design.
1. Policy for Design & Construction of Futuristic Flexible Pavement (FFP)

Ftexibte Pavement (New Construction) shatl be designed for maximum altowed effective
subgrade design CBR 15.0% as per IRC: 37 -2018. lt can be achieved by:

. using setect soil (either borrow or excavated) of required CBR for subgrade and
embankment construction as per IRC:37 and MORT&H Specification,
. improved subgrade upper layer(top 250mm) using setect soit treated with hydrated
lime/cement/fty ash/pond ash etc. as per IRC:37, MORT&H Specification, and
IRC:SP:89(Part l& Part ll),

o using mechanicat modification of setect soil btended with Pond Ash/non-ptastic

soit/sand /gravet/ mining waste/crushed aggregate/rectaimed granutar materia[ etc.
in subgrade tayer construction as per IRC:SP:89(Part l)
For stabitization purpose built soiI stabitizer shatl be used. Use of indigenous
equipments/ ptants/ machineries shalI be encouraged.

Enhanced quatity control more particutarty the comptiance of minimum specified

compaction, 4-days soaked CBR at specified density and design stabitizer content shatl be
met in construction.
Benefits of Futuristic flexible Pavement (FFP)
i. Exptoitation of maximum soil strength using technotogy (as we cannot minimize
earthwork quantity for a particular design road tevel)
ii. No need of any re-work in subgrade at the time of rehabilitation i.e. it is compatible
with future maintenance/augmentation etc. i.e. futuristic pavement
iii. Enhancedperformance
iv, Reduction in
designed pavement composition i.e. tesser thicknesses of
subbase/base/bituminous layer (reduction of DBM thickness in the range of 20-
50mm) resulting into a cost reduction in the range of 5-15.0 %

v. Less consumption of aggregates

vi. Less burning of bitumen i.e. [ower emission of Green House Gases(GHG)
vii. Cost-effective, durabte and environmentatty sustainabte.
2. Rational lnputs for Rate Analysis
Presently, inputs used for rate anatysis is not ctosety simutated with the inputs taken by the
devetoper in actuat construction. That is why, there is a bidding cost difference in the tune
of 70-30% lower side than that of Ministry. To have more ctosety simulation or rate anatysis
at same platform, fottowing strategy can be adopted.
i. The minimum rate of bitumen from the Government refinery and private
producers shatl be taken as per stipulated guidetines.

pg"r ,r-a{ffi',,,a-a-
Pagel/6
Appendix-1: Formulation of Value Engineering Strategy for National Highway Projects

ii. The minimum rate of Steel from the SAIL/TISCO and private manufacturers
sha[[ be taken.

iii, The rate anatysis of concrete shatl be taken considering 20 per cent fly ash
by weight of total cementitious materiat subjected to avaitabitity of fty ash
within economic hautage.
3. Suggested Flexible Pavement layer Combination - Att the layer combinations
atternatives avaitable in IRC: 37-2018 shat[ be techno-economicatty evatuated and
recommend the appropriate one. At[ designs and estimations shalt necessarity be based on
actual optimat requirements for tayer thicknesses as per IRC: 37-7018. Suggestive
thicknesses as per catatogues (Ref. Section 12 of IRC: 37-2018) shatl not be used even for
estimation purposes.
4.Use of Glass/Carbon/Aramid Fiber Reinforced Polymer Rebar for non-load bearing/
minor CD Structures
Fiber Reinforced Potymers (FRP's) are a proven and successfuI atternative reinforcing that
wit[ give structures a longer service life. To reduce the demand of conventional
reinforcement for highway projects, it is prudent to attow Glass/Carbon/Aramid Fiber
Reinforced Polymer Rebar for non-toad bearing structures [ike Crash barrier, Drain and
minor CD structures i.e. Hume pipe Cutvert and box Cutvert. There is a reduction ol 5-10%
of the cost.
As the IRC Guidetine and State-of-Art Report for Gtass Fiber Reinforced Polymer Bars has
recently been finalised. However fotlowing design standards & Specifications may atso be
referred:

MSHTO LRFD Bridge Design Guide Specifications for GFRP-

Reinforced Concrete Bridge Decks and Traffic Railings, First
Edition.
. Pubtished in November ZO09, this document offers
authoritative design guidance to the bridge design community
in safely adopting FRP bars in bridge decks and railings.
CSA 5-806 - Canadian Code

. "Design and Construction of Buitding Components with Fibre-

Reinforced Potymers".
CSA 5-6 Canadian Highway Bridge Design Code

. Widespread adoption of GFRP bars in Canadian bridge

structures is being made possibte by this important document.
ACI 440.1R "Guide for the Design and Construction of Structural
Concrete Reinforced with FRP Bars"
. The American Concrete lnstitute 440 guide is a mature and
living document that as undergone a number of revisions since
its first pubtication in 2001. Companion documents to the
440.1R design guide include the ACI 440.3R "Guide Test
Methods for FRP's for Reinforcing or Strengthening Concrete
Structures" which is intended as an interim document

ffisffi"i;?
Appendix-1: Formulation of Value Engineering Strategy for National Highway Projects

superseded by new ASTM test methods as they become

availab[e.
lnternational Studies
o FIB Task Group 9.3 - bulletin 40 "FRP Reinforcement in RC Structures"
. ln Europe, the Federation lnternationale du Beton FIB Task Group
9.3 has pubtished a technical report "Bulletin 40", which is a "state
of the art" of FRP reinforcement in RC structures. Work is under
way on provisions for FRP bars in Euro Code 2 format. Norway and
Italy have pubtished internal design codes for the use of FRP bars,
o 4th Structural Specialty Conference of the Canadian Society for Civil
engineering Montr6al. 2002
. Field application of FRP composite bars as reinforcement for
bridges and decks.
5. Use of Locally available marginal/ road building material/lndustrial Waste/Municipal
Solid Waste landfill for Road construction

To reduce the GHG gases emission and cost of transportation, it is suggested during DpR
stage itself the localty available marginat road buitding materiat as welt as industrial
waste/Stag/mines waste has to be evaluated. DPR must have the recommendations
regarding improvement measures to uptift locatty availabte materiat/industriat/ mines waste
to the premium road building material in the vicinity of the project Road.
6. Type of Concrete Pavement
6.1 Bonded Concrete Pavement
Bonded concrete pavement shatl be designed as per IRC: 58-2015 for new construction. lt is
similar to conventional concrete pavement except no potythene sheet in between DLc and
PQC. However, joint groove cuts are required in the DLC [ayer for 1/3rd depth exactty at
the location of the joints in PQc to avoid random reftection cracking of the pec due to
cracks in the DLc. Generatty the thickness of conventional concrete pavement is zgo-
300mm, whereas with bonded concrete pavement it is 220-240mm. That is reduction of 20-
25% PQC concrete votume and initiatly construction cost itself is comparabte to the
conventional f lexi bte pavement.
6,2 Short-Panelled Concrete Pavement/Geo-cell filled Concrete pavement

For new construction, even short-panelted concrete pavement may be considered. lt js

simitar to conventional concrete pavement with shorter panel sizes i.e. 1.0mX1.0m,
1.5mX'1.5m and '1.75mX1.75m. The design thickness may generatty vary from 150-ZZ0mm.
Tria[ sections have been laid in some of the projects, such as panagarh - Barwa Adda (NH-
2) , Baharagora - Kharagpur section of NH-33, NH 848 (Nashik peth Section) and are being
monitored; so far generalty the performance has been observed as satisfactory. IRC
Guidelines for the same are under devetopment presentty.

6.3 Pre-tensioned Pre-cast Concrete Pavement (ppCp)

For construction of new concrete pavement in urban/congested locations and panel
reptacement of existing concrete pavement, pre-tensioned pre-cast concrete pavement
(PPCP) shatt be adopted. The design thickness varies from 180-200mm.lt shatt be designed
(g"rgt|fi:.oz-
PSge'3 / 6
Appendix-1: Formulation of Value Engineering Strategy for National Highway Projects

using IRC: 58-2002 and computation of stresses should be done based on Finite Etement
Modetting (FEM). Sections have been taid in some of the projects, such as Nagpur lnner Ring
Road, Nagpur Hingta lndustria[ Area, Amravati Pathan Chowk; so far generatty the
performance has been observed as satisfactory. IRC Guidetines for the same are under
development presentty.
6.4 White-Topping for Existing Flexible Pavement Rehabilitation
White-topping shatl be also evaluated for rehabititation of existing ftexible pavement. lts
thickness varies from 150-180mm as per IRC: SP:. 76-2015.

7. Uti lisation/re-use of Reclaimed Road Material

7.1 Expansive Black Cotton Soil
Expansive black cotton soiI is avaitabte in Maharashtra, Madhya Pradesh, Andra Pradesh,
Chhattisgarh, Gujarat and Karnataka. Generatty this unsuitabte soi[ is being removed and
replaced with suitable material to a minimum depth of 500mm. For the same, there is
always a probtem of dumping site.

It is better to improve this unsuitabte soil with fty ash/pond ash/hydrated time/cement and
reuse it for earthwork. With the same, there is no requirement of suitab[e borrow earth as
wetl as savings in transportation cost and reduction in GHG emission.
Therefore, suitabte decision may be taken to adopt appropriate methodotogy based on
retative scale of economy of atternate options.
7.2 Reuse of Excavated Soil
There must be accountabitity regarding reuse of excavated suitabte soil.

7.3 Reuse of Reclaimed Existing Pavement Granular layer material

It is observed that there is a substantial generation of granular layer material white doing
up-gradation /capacity augmentation/rehabititation/submerging due to proposed VUp/pUp.

It is prudent to rectaim the

same and use in subbase/base of proposed pavement. There
must be accountabitity regarding reuse of rectaimed existing pavement granutar layer
materia[.
7.4 Reuse of Reclaimed Bituminous layer material (RAP) of existing flexible Pavement
It is observed that there is a substantia[ generation of existing bituminous tayer material
white doing up-gradation/capacity augmentation/rehabititation/submerging due to
proposed VUP/ PUP/conversion of ftexibte to concrete pavement.

Generally it is observed that the existing bituminous layer materiat is dismantted and
dumped atong national Highway in case of reconstruction/submerging due to proposed
VUP/Pup/change of pavement type to concrete pavement. lt is merely a huge loss to the
nation due to wastage of costty RAP. There must be a MP bank atong the National Highway.

However, in rehabititation of existing flexibte pavement it is being rectaimed through mitIing

and being reused in DBM layer mix. The proportion of RAP is 20-30% with conventional Hot
Mix Ptant (batch type) with RAP attachment. lt can be further increased to with purpose-
built Double barrel continuous hot mix ptant.

a$l#lePage4l6
Appendix-1: Formulation of Value Engineering Strategy for National Highway Projects

The mitted RAP is atso being used as RAP tayer by adding 25% virgin aggregate, 1.0% cement
and 7-3% foamed bitumen /emutsion. RAP is used as bituminous base course.

Even RAP can be used for DLC of Concrete Pavement.

It is prudent to rectaim the same and re-use RAP generated. There must be accountability
regarding reuse of rectaimed RAP.

The guidetines to be referred are IRC: 37-2018 and IRC: 120-2015 except for % of RAP, which
may be increased with the approval of authority.

8. Use of Fiber Reinforced i icro-surfacing for Renewal Course

Micro-surfacing is an eco-friendty treatment which is used to restore the surface
characteristics of the road. lf the pavement is structuratly adequate, Micro-surfacing is very
suitable to preserve the
pavement from ageing, oxidation, aggregate loss and potishing irrespective of the t
raffic (i.e. suitabte for [ow, medium, and high traffic). Fibre-reinforced Micro-surfacing is
much superior to conventional Micro-surfacing. Presence of gtass fibre in Fibre-reinforced
Micro-surfacing hetps in enhancing the ftexuraI strength of the Micro-surfacing and thereby
drasticatly reduces the chances of reftective cracking. There are no specifications in lndia
for Fiber-reinforced Micro-surfacing, hence Downers Report to be referred. Generatty the
doses of fiber is 0.2% by dry weight of aggregate. The guidetine for conventional micro-
surfacing to be referred is IRC: SP: 81.

For wearing course renewat, fiber reinforced micro-surfacing of 8-1omnm thickness shatt be
adopted.

9. Use of lntegral Super-Structures in r ajor Structures

lntegral structure deck super-structure, which gives continuity shatt be used. Due to deck
continuity, there witt be reduction in deck depth, lesser number of bearings & expansion
joints and hence lesser maintenance and improved rideabitity.
10. Use of High Damping Rubber bearing for Structures
High Damping Rubber (HDR) bearing may be used. lt witt also act as seismic isotators during
earthquake and cost-effective. Design codes and testing procedures for such bearings are
already avaitabte in some countries, as also, in CEN (2005) ,,Eurocode 8: Design of Structures
for Earthquake Resistance Part 2: Bridges", pr EN 1998-2 (Finat Draft), Comite Europ6en
de Normatisation, Brussets, Betgium.

1 1. Use of Pre-cast Structures

Use of pre-cast for VUP/LVUP/PUP/8ox Cutvert shatI be promoted. lt witt resutt into time
savings. Use of precast element [ike Girders/ planks/segments for att types of structures
may be adopted as per project suitabitity. Use of Precast Arch type Cutvert or Minor-Bridges
or animal underpass or cut & cover tunnel with nominal or zero Reinforcement may be
adopted instead of Conventional Structures. Use of Precast Pre-stressing Elements for Box-
Type and Other Structures (i.e. Precast Pre-stressed Raft, Watt, Stab, Toe-Watt, Retaining
Watl, Road Side Drain etc.) may atso be adopted. The Ministry's poticy on the use of pre-
cast technology issued from time to time may be referred in this context.

12. Waste to Wealth

U^a"".f$1[*
Page5/6
Appendix-1: Formulation of Value Engineering Strategy for Nationa[ Highway Projects

Pond Ash is the proven materia[ for embankment/subgrade layer construction. lts
avaitabitity shatt be ensured for the construction of highways.
13. Use of Soil Stabilised Earthen Shoulder
Presentty in upper 150mm of earthen shoutder crushed aggregate is being used. As a cost-
effective atternative soil treated wilh 3-4% cement shatl be used. lt wit[ atso not require
virgin aggregate. The guideline to be referred is Kenyan Pavement design Manuat.
14. Use of Construction & Demotition(C&D) Waste
A C&D bank shatl be atong the National Highway and the material sha[[ be used as an
alternative to sand/fine aggregate for concrete. For this crushing of C&D material wit[ be
required. The guideline to be referred is IRC: 121- 2017 "Guidetines for Use of Construction
and Demotition Waste in Road Sector".

15. 1O0% Recycling of Reclaimed Bituminous Layer l aterial

lndia has presently about 1.41 takh km tength of National Highways Network. Progress of
about 37 km per day was achieved for development works on NHs during 2021-72. However,
the quantum of the aged asset is increasing, which warrant rehabititation to extend its life
further. Therefore, emphasis is also required to begiven fortaking up
rehabititation/strengthening works on NHs. Therefore to have cost-effective and sustainabte
rehabilitation/strengthening, lt is prudent to rectaim the bituminous layer material and
reuse as much as permitted with the approvaI of authority by adding innovative rejuvenating
agents to get rectaimed bitumen properties at par with fresh bitumen.

16. Promote use of new sustainable materials for bridges (Such as Stainless Steel,
Weathering Steel ...etc.) based on life cycle costing
17. Promote use of modular, prefabricated, adaptable and re-usable structures for
temporary, emergency and permanent bridges in remote areas
18. Use of Fiber Reinforced/High Strength Shotcrete for Tunnel works
19. Geometric Design
FRL / Cutvert sizes shatl be fixed based on hydrotogical modetling. FRL of VUP shatl be fixed
in duty consideration of the cross-road [eve[.
Avoid the Curvature Sections & super elevation on the major structure locations, since it
may increase the cost of structure and pose safety issues.

During road profile design, section having lined drains, the profite shoutd be such that
natura[ streams / proposed/existing CD structures shatl be the natural disposal of storm
water. This wit[ result in economic sections of the drain.
With afore-mentioned vatue engineering practices, there may be a reduction of
initial project cost in the tune of 20-30 %. Besides this, there is a time savings, less
consumption of road buitding materiats and tess emission of GHG without compromising
performance durabitity of the NationaI Highways Asset.

Bi{q'r rze"ldtq
aoloq ><'>)..--
Page6l6
 File No.RW/NH-34049/01 /2020-S&:R(P&:B)pt.
Government of India
Ministry of Road Transport a Highways
(SaR (paB/New Technology) Zone)
Transport Bhawan, 1, Parliament Street, New Delhi-110001
Dated: 22nd February, 2023
CIRCULAR

To

1. The Chief Secretaries of all the State Governments/ UTs.

2. The Principal Secretaries/ Secretaries of all States/ UTs Public Works Department!
Road Construction Department! Highways Department (dealing with National
Highways and other centrally sponsored schemes).
3. The Chairman, National Highways Authority of India, G-5 &: 6, Sector-10, Dwarka,
New Delhi-110 075.
4. The Managing Director, NHIDCL, PTI Building, New Delhi-110001.
5. The Director General (Border Roads), Seema Sadak Bhawan, Ring Road, New Delhi-
110010.
6. All Engineers-in-Chief and Chief Engineers of Public Works Department of States/
UTs/ Road Construction Department! Highways Departments (dealing with National
Highways and other centrally sponsored schemes).
7. All CE-ROs,ROsand ELOsof the Ministry.

Subject: - Value Engineering Practices for the Design, Construction a Maintenance of

National Highways Projects - Reg.

Reference: Ministry's Letter No. RW/NH-34049/01 /2020-S&:R(P&:B)pt.dated 30.08.2022

Madam/Sir,

In continuation to the above referred circular of Ministry, following

have been decided:

i. The Executing Agencies of MoRT&:H shall do the Value Engineering during

Feasibility/DPR of the project itself as detailed in para 5.1 &: 5.2 of the
Ministry's circular even no. dated 30.08.2022.
ii. For the upcoming Projects, Value
Engineering may be kept open after award of the work in respect of the items
which are not pre-decided as certain components are fixed based on multiple
considerations of reliability, durability, amenability for consistency checks,
etc.
iii. In the ongoing Projects, it is preferred that EPC Contractor/Concessionaire
shall follow the provisions as mandated in Schedule-B and schedule-C of the
EPC Agreement!Concession Agreement. However, EPC Contractor/Concessionaire
are free to adopt
any alternative proposal as per applicable design standards as specified in
Schedule-D which is costlier (jnjtjal construction cost) than that of the
base proposal as per Schedule-B &: Schedule-C for better
performance/durability without any claim for extra cost from the Authority.

Page 1 / 2
 iv. Any material/technology/design shall be called "New" until there is no available
MoRT8:H Specification/IRC guidelines. Once it is available, it will be called as
conventional/ proven.

v. For any proprietary products (patented/monopolistic etc.) such as RE Wall,

Retaining Wall, Expansion Joints, Bridge Bearing, Pre-stressing Systems,
Commercial Stabilizer, Geosynthetics Products etc.; EPC
Contractor /Concessionaire shall ensure signing of tripartite agreement
between the Authority, EPC Contractor/Concessionaire and Technology
Provider before use of such material/technology/design in NH Projects. The
tripartite agreement shall have the provision of involvement of the
Technology Provider right from design to execution. Technology Provider
shall deploy the requisite design experts/material technologist/skilled 8:
trained construction supervision personnel to certify material testing 8:
material characterization for design, proof check of the design, approve
construction methodology including field trial sections before actual
construction, quality control and supervision 8: certification of the day-to-day
construction / execution.

2. It is requested that the contents of the circular may be brought into the notice of all
concerned for immediate needful compliance.

3. This issues with the approval of Competent Authority.

Yours sincerely,
'~A'4Y ¥-e~ Jt.a.
''2-- 2_t)'2-~~2--3,
(Bidur Kant Jha)
Director
(New Technology for Highway Development)
For Director General (Road Development) 8: Special Secretary
Copy to:
1. All CEsin the Ministry of Road Transport 8: Highways
2. All ROsof the Ministry of Road Transport 8: Highways
3. The Secretary General, Indian RoadsCongress
4. Technical circular file of S8:R(P8:B)Section
5. NIC-for uploading on Ministry's website under "What's new"

Copy for kind information to:

1. PSto Hon'ble Minister (RT8:H,MS8:ME)
2. PSto Hon'ble MOS(RT8:H)
3. Sr. PPSto Secretary (RT8:H)
4. PPSto DG (RD) 8: SS
5. Sr. PPS/ PPSto Addl. Secretary (Road Safety)/ Addl. Secretary (RT8:H8: LA)
6. Sr. PPS/ PPSto AS8:FA
7. Sr. PPS/ PPSto ADG (SKN) / ADG (RP)/ ADG(DS)
8. Sr. PPS/ PPSto JS (RTttMVL)/ JS (EIC) / JS (Logistics)/ JS (NHIDCL)

Page 2/2
 CEIGALL BATHINDA DABWALI HIGHWAYS PRIVATE
LIMITED
Site Office: - Village Sangat Kalan Teh -Sangat, Distt.-Bhatinda pin no.:- 151401
E-mail: - [email protected]
CIL/IE/JRMD/2023-24/194 Date: 11-12-2023

To,
The Team Leader,
M/S Highway Engineering Consultant
#08, basheshar nagar, opposite
zail singh college, dabwali road,
near AIIMS hospital Bathinda-151001
Email: [email protected]

Project: 6- Laning of Jodhpur Romana (Bathinda) - Mandi Dabwali (Punjab, Haryana

Border) Section of NH-54 from Design CH: 0.000 to Design CH: 27.400
(Design length 27.40 Km) in the state of Punjab on Hybrid Annuity Mode –
Compliance of Drawing & Design Details of GFRB Drain (Glass Fiber
Reinforcement Bar) – Reg.

Ref:
1. IE Letter HEC/NHAI/IE/Bathinda-Dabwali/2023-24/2690 Dated:17-11-2023
2. This office letter: -CIL/IE/JRMD/2023-24/84 Dated 13-10-2023

Dear Sir,

This is with reference to your letter dated 17.11.2023 (under ref-1), vide which certain
observations were given on submitted Drawing and Design of GFRB Drain (Glass Fiber
Reinforcement Bar) by Concessionaire vide its letter under ref-2. In this regard, we
hereby submitting the Compliance/Reply of the observations as under for your review
and concurrence:

Sl Concessionaire
IE observation vide letter 2690
No. Compliance/Reply
As in submitted drawing from
the Concessionaire end, there is
no variation in any dimension as
Drawing and Design Details of GFRB Drain
compared to the Concession
(Glass Fiber Reinforcement Bar) submitted by
Agreement. Further, it is also to
Concessionaire have been reviewed and found
1 mention that the submitted
that submission is not as per provisions of
drawing is meeting the Codal
Schedule-B (Page no.-172) and Drawing Volume
Requirement. As the Design is
(Page no.-26) of the Concession Agreement.
part of the Concessionaire,
accordingly the Design of the
section has been submitted.
Submitted Design and Drawing is not
2 Do the same as S. No. 1
acceptable, you are requested to submit revised

Regd Office: - A-898, Tagore Nagar, Civil Lines, Ludhiana Punjab-141001

E-mail: - [email protected]
 Design and Drawing Considering minimum
dimensions mentioned in Concession
Agreement Drawing.
In this context, it is to apprise
It is requested that during preparation of Design
you that the submitted design is
and Drawing of Road side Drainage criteria
supported by IRC 137 & relevant
mentioned in Clause4. 18 (Road Side Drainage)
NHAI circulars. The drain
of Schedule-B of the Concession Agreement,
3 discharge, adequacy and others
Criteria mentioned in IRC SP 42:2014 and NHAI
parameters have been evaluated
Policy Circular no. 18.48, dated 08.07.2020 shall
as per IRC SP-42. Overall there is
be followed.
no variation in submitted
section.

In view of the above it is requested you that the submitted the design and drawing of the
drain is nowhere compromised by the Concessionaire end and the submitted design is
supported by IRC 137. Therefore, we once again request you to please review the
submitted drawing.

This is for your kind information & necessary action.

Thanking you and assuring you of our best services at all times.

Yours sincerely,

For and on behalf of

Ceigall Bhatinda Dabwali Highway Pvt. Ltd.

(Authorized Signatory)
Enclosure: As Above.

Cc: (I) The Project Director, PIU-Bathinda.

 CONTACT US
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