Annexure 21

CONSTRUCTION METHODOLOGY
CIVIL WORKS OF 500 KV CONVERTOR STATION, NOWSHERA

Project Name 500kV Convertor Station, Nowshera, KPK Pakistan

Site Address Nowshera, KPK Pakistan

Client NTDC, Pakistan

Consultant

Contractor COBRA
Table of Contents
1 Theory: .................................................................................................................................... 1

1.1 Site Mobilization / Establishing of Site Infrastructures ................................................... 1

1.2 General Site Requirements: .............................................................................................. 2

1.2.1 Equipment ................................................................................................................. 2

1.2.2 Manpower ................................................................................................................. 2

1.3 Clearing and Grubbing: .................................................................................................... 2

1.4 Demarcation/Layout: ........................................................................................................ 3

1.5 Excavation: ....................................................................................................................... 3

1.6 Backfilling: ....................................................................................................................... 4

1.7 Lean Concrete: ................................................................................................................. 5

1.8 Concrete works:................................................................................................................ 5

1.9 Curing of concrete: ........................................................................................................... 7

1.10 Cutting bending & laying of Steel: ............................................................................... 7

1.11 Form Work ................................................................................................................... 8

1.12 Brick Masonry .............................................................................................................. 8

1.13 Plastering ...................................................................................................................... 8

1.14 Anchor Bolt Setting ...................................................................................................... 8

1.15 Cable Trenches ............................................................................................................. 9

 1.16 Safety, Health and Environment Issue ......................................................................... 9

2 Construction Process:............................................................................................................ 10

2.1 Pre-construction requirements: ...................................................................................... 10

2.2 Design Stage:.................................................................................................................. 10

2.3 Construction works: ....................................................................................................... 11

3 Documentation: ..................................................................................................................... 15
1 THEORY:
1.1 SITE MOBILIZATION / ESTABLISHING OF SITE INFRASTRUCTURES
i. All necessary approvals / permits shall be obtained from relevant departments of the
customer before starting of any works on site.
ii. Approved site mobilization plan, showing at least the location of the equipment to install,
storage areas, emergency devices, location of site offices, vehicle parking areas etc.
iii. Layout plan for temporary site facilities will be submitted and approval be obtained from
customer.
iv. One-way traffic circulatory system where it is practicable, Site Inspection checklists and
list of temporary main equipment including estimated dimensions will be submitted.
v. Prior to construction work commencing, PROTECH Engineering Pvt. Ltd. will provide OHS
Plan to customer for review and comments, if required. This Plan shall cover activities
related to the execution of the Project.
vi. Civil site supervisor shall mark lines and layout with reference to controls in accordance
with the temporary site facility layout plan.
vii. Pillars may be built to line and level as per the temporary site facilities plan.
viii. Prefabricated porter cabins shall be installed in accordance with the approved drawings,
if required.
ix. Temporary underground septic tank to be constructed with piping and chambers to
satisfy the requirements of the site lay down area (if no alternative facilities available at
site).
x. All the debris and loose materials shall be removed or stored at a suitable area at the end
of each day.
xi. All works will be done by skilled and experienced workers under the supervision of the
PROTECH Engineering Pvt. Ltd. Site Manager.
xii. All works to be completed & inspected in accordance with the approved site layout &
temporary site facilities plan.

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1.2 GENERAL SITE REQUIREMENTS:

1.2.1 EQUIPMENT

 Excavator  Hand Shovel

 Shovel  Spade
 Plate Compactor  Pick Axle
 Rammer Compactor  Hand Rammer
 Roller Compactor  Wheel Barrow
 Concrete Chute  Tilting Drum Mixture Machine
 Concrete Vibrators  Measuring Boxes
 Steel Float  Wheel Barrows
 Wooden Float  Hand Shovels
 Lift Machine (Working at Height)  Water Drums
 Slump Apparatus  Water Container

1.2.2 MANPOWER

 Supervising Engineer  Steel Fixer

 Foreman  Formwork Fixer
 Driver  Lab Engineer
 Skilled Workers  Water Carrier
 Surveyor  Mixer Machine Operator
 Safety Officer  Mason
 Unskilled Workers  Lift operator

1.3 CLEARING AND GRUBBING:

i. Land clearing is the removal and disposal of all vegetation, rubbish, and surface boulders
embedded in the ground. Clearing, grubbing, and stripping shall be accomplished by using
heavy engineering equipment.

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 ii. In all areas where excavation is to be performed, removal of roots and other debris to a
depth of 150 mm below the ground surface shall be performed. Roots and other debris
from all excavated material to be used in the construction shall be removed.
iii. The debris and other material shall be piled using a bulldozer outside the tributary area
of the site in such a way that it won’t interfere in the construction plans while remaining
consistent with the methods of drainage for clearing.
iv. As it is not in the PROTECH’s scope of work, so client should be responsible for this work.

1.4 DEMARCATION/LAYOUT:
As per the foundation plan the location of each foundation, CHB, Trenches, Fence, road, etc. shall
be marked with the help of following equipment.
 Total Station  Theodolite
 Auto Level  Measuring Tape
 Pegs  Nylon String
 Staff Rod  Ranging Rods
 Lime  Hammer

1.5 EXCAVATION:
i. As per the foundation plan the location of excavation shall be marked.
ii. Excavation consists of removal and handling of material encountered when
establishing required grade elevations in accordance with the Contract Documents
iii. Excavate to the required depth as indicated on construction drawings and dispose-off at
designated dump site.
iv. The excavation shall be carried out by using excavators and dozers as per their
functionality.
v. Hand excavation shall be carried out in an area where mechanical equipment could not
be used.
vi. Excavated area shall be kept free of water at all times until completion of construction or
backfill. The water shall be pumped or specific drainage shall be provided.

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1.6 BACKFILLING:
i. Back filling shall be done immediately after completing the foundation and applying the
concrete curing procedure.
ii. Fill materials shall be transported from the excavation area, designated borrow areas or
off-site sources and stacked in heap
iii. Backfilling can be done in several ways, and can be used in tasks such as
protecting foundations, landscaping, or filling in voids that would weaken underground
structures.
iv. Any on site material conforming to the Project specifications and free of muddy
materials, organic matter, rubbish, debris or other unsuitable materials shall be
considered as general fill.
v. The moisture content shall not be more than plus or minus 2 percent from the optimum
moisture content.
vi. Impact loading of the pipeline, shafts, structures and appurtenances must be avoided
during the placement of backfill.
vii. The thickness of the layer will depend upon the nature of the backfill, and the
compaction equipment to be used. Water may be added during the compaction
process, to assist with compaction.
viii. The first layer shall be maximum of 150 mm thickness of loose materials and the
subsequent layers shall be of 200 mm compacted thickness.
ix. The fill material shall be compacted by a vibrating roller/frog compactor / Plate
compactor with adequate number of passes to achieve the 95% maximum dry density as
specified by the Proctor test result (ASTM D1557).
x. The compacted area shall then be tested for required Field Dry Density using sand
replacement technique or core cutter method.

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1.7 LEAN CONCRETE:
i. Compressive strength of concrete used in lean as per approved design & mix design.
ii. Mixing of cement shall be done as per approved concrete mix design.
iii. One to three cylinders shall be casted to verify the required strength.
iv. Slump value shall be checked to verify the W/C ratio.

1.8 CONCRETE WORKS:

Concrete is a composite material composed of aggregate bonded together with fluid cement
which hardens over time. The steps to be carried out prior to the concrete pouring are as follows:
i. Analysis of the coarse and fine aggregates as per ASTM C-33 shall be carried out in the
presence of the engineer for the approval of the material.
ii. The material shall be dumped near the mixture machine over a polythene sheet or clean
surface so that the dust and organic particles do not mix with the coarse and fine
aggregate.
iii. Cement shall be stacked near the mixture machine over a polythene sheet laid on a dry
flat area. The cement bags shall be checked for any setting, upon their arrival and the
hardened bags shall be discarded.
iv. The mixture machine shall be checked for any mechanical fault and for cleanliness to
make sure there aren’t any leftovers in the drum of the mixture machine.
v. Lubricant (Diesel/Grease) shall be applied to the wheel barrow in a very thin layer, so that
the concrete material do not stick with the wheel barrow.
vi. Prior to the pouring of concrete the reinforcement shall be checked and approved by the
Engineer to make sure it is in accordance with the drawings and specifications.
vii. The fixated formwork shall be checked and approved for dimensions, quality, sealing of
joints and application of lubricant etc. to make sure it is according to the drawings and
Project specifications.
viii. The base shall be cleared of any dust or any impurities.

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 ix. The level and Layout of the object to concrete shall be checked and approved by the
Engineer, to make sure that the layout and level of an object is according to the Project
Drawings and specifications.
x. The chute shall be placed for pouring below ground level and lift shall be used for pouring
above Ground level.
xi. The base shall be watered before the application of concrete.
xii. The measuring boxes/measuring wheel barrows shall be cleaned of any impurities.
xiii. Proper lighting must be available in case of night Concreting.
xiv. Vibrators shall be checked to make sure they are in working condition.
xv. The measurement (measuring box/wheel barrow calculation) for the material input for
concrete mixing as per the approved mix ratio shall be submitted for the approval of the
Engineer at site.
Following steps would be followed for the concrete pouring:
i. Dry material shall be loaded on to the Mixture Container as per approved quantity
(based on approved mix ratio).
ii. 70% Water shall be poured onto the empty drum as per the approved quantity (based
on the approved mix ratio).
iii. The dry material shall then be loaded onto the mixing drum. The material shall be mixed
for 1.5 to 2 minutes and remaining water shall be added in the drum during the mixing
process.
iv. The mixed material shall then be loaded onto the wheel barrows and transported to the
location of concrete.
v. The placement of concrete is with the help of a portable chute if depth is more than 2.0
meters from the bottom of the mixer truck chute, or concrete pouring pumps are used
as required.
vi. Admixtures and retarding gents shall be used according to the requirements and
specifications as approved
vii. The slump of the concrete does not exceed 10 cm gap in case of Pad and Block
foundations. 12 cm slump is maintained in case of auger I Caisson and Pile foundations.

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viii. The temperature of concrete shall be checked and shall not exceed 32 degrees as per
Project Specifications.
ix. The mixed material shall then be poured on to the structure (to be concreted) via
concrete chutes or lifting machines.
x. The concrete shall be spread by means of the spade.
xi. Material shall be compacted by the concrete vibrators.
xii. The process is repeated until the required level is reached.
xiii. The finishing and leveling of concrete is carried out using wooden and steel floats

1.9 CURING OF CONCRETE:

i. Concrete shall be cure to protect it from the loss of moisture and to keep it within a
reasonable temperature range.
ii. Curing shall increase strength and decreased permeability.
iii. Approved Curing Compound shall be applied on the vertical structures or moistened jute
bags shall be used for curing purpose.
iv. Whereas water shall be suspended on the horizontal structures using sand boundaries.
v. The curing shall be carried out until the concrete is matured (follow ACI- 308).

1.10 CUTTING BENDING & LAYING OF STEEL:

i. Bar bending schedule shall be prepared as per the approved steel.
ii. Sample shall be tested to verify the required strength.
iii. Test shall be carried out as per standard ASTM A615.
iv. Steel fixer will cut/bend/fix the rebar to their respective locations as per drawings and bar
bending schedule in the presence of engineer at the site.
v. Proper precautionary measures shall be employed at the site to keep the steel free from
rusting.

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1.11 FORM WORK
i. Where required, forms are used to cast the required size and shape of the foundation.
ii. Form Work to be used may be of the steel or wood, for each type of foundation except
Caisson and Pile types, where form is not required.
iii. The forms are made as per the size of structure member dimensions in parts and bolted
together for the completed foundation.
iv. The fixing of the form work in position is obtained by jacks and wooden props as per the
space availability

1.12 BRICK MASONRY

i. Prior to commencing the brick masonry work, the surface of brick shall thoroughly be
cleaned and sufficiently moistened in order to ensure smooth adherence of mortar to
the brick surface.
ii. Ist class bricks shall be used which shall be approved by the Engineer.
iii. The masonry joints shall in principle be 10 mm in thickness and mortar shall be filled
sufficiently in each masonry joint.

1.13 PLASTERING
Cement plasters (1:3) or (1:4) up to 6.00-meter height 13mm thick shall be applied on brick
masonry.

1.14 ANCHOR BOLT SETTING

Setting of anchor bolt for 132 kV equipment foundations are done by means of setting templates
for four (4) legs. The setting dimensions are prepared separately as per the tower designs. The
Bolts are bolted on to the template to hold it in the final position. All dimensions and setting
checks and cross checks are performed as per the drawing and declared ready for concrete.

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1.15 CABLE TRENCHES
Outdoor Cable Trenches will be of steel reinforced concrete or reinforced concrete cast-in situ
with precast cover. Cable Duct Banks or cable trenches of road crossing type under transformer
skid ways or where vehicles can pass. Buried PVC-pipes will be of heavy gauge type and soil
resistant.

1.16 SAFETY, HEALTH AND ENVIRONMENT ISSUE

i. Conditions and precautions listed in the project specifications shall be followed as
minimum.
ii. All staff involved with the project shall be inducted on the safety, health and
environmental issues associated with the work.
iii. Only trained personnel with relevant experience shall be allowed to handle machinery.
iv. Appropriate Safety Signboards, barriers and lighting shall be and other safeguards shall
be provided as required by the nature of and location of the works. All operations shall
be carried out in accordance with the safety requirements.
v. All field personnel will use PPE safety requirements like safety shoes, helmets, cover all,
goggles, Full Body Harness and dust mask, etc. as required.
vi. All the vehicles and machinery which would be used is to check before their use.
Equipment shall have the fitness certificate.
vii. Risk assessment shall be carried out before the start of work and permit shall be issued
before the start of everyday work.
viii. Safety Rules shall be followed.

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2 CONSTRUCTION PROCESS:
Following steps are involved in construction process and will be followed in their respective
order.
I. Pre-construction requirements
II. Design Stage
III. Construction Works

2.1 PRE-CONSTRUCTION REQUIREMENTS:

i. Legal requirements and documentation
ii. Site Preparation (Site Clearance, disposal of un-wanted material and removal of Tress &
Bushes)
iii. Cutting & filling up to required level
iv. Site Level

2.2 DESIGN STAGE:

i. Control house Building
 Architectural Design
 Structural design
 Electrification design
ii. Civil structural design of Equipment, Gantry & transformer Foundations
iii. Transformer way & Roads
iv. Cable trenches of all type with drainage
v. Switch yard Fence & Fence gate etc.

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2.3 CONSTRUCTION WORKS:
A. Control House Building
 Construction of Foundation
i. Excavation
ii. Lean
iii. Laying of steel
iv. Placing of Scaffolding & Shuttering
v. Pouring of concrete
vi. Curing
 Column up-to Plinth Level
i. Placing of Scaffolding & Shuttering
ii. Cutting & fixing of rebar
iii. Pouring of concrete
iv. Curing
 Plinth Beam
i. Placing of Scaffolding & Shuttering
ii. Cutting & fixing of rebar
iii. Pouring of concrete
iv. Curing
 Backfilling
 Column up-to Roof Slab
i. Placing of Scaffolding & Shuttering
ii. Cutting & fixing of rebar
iii. Pouring of concrete
iv. Curing
 Roof Slab with Beam
i. Placing of Scaffolding & Shuttering
ii. Cutting & fixing of rebar
iii. Pouring of Concrete

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 iv. Curing
 Wall Construction
i. Brick Masonry (Placing of Scaffolding & shuttering)
ii. Placing of Doors Frames
iii. Plastering (Placing of Scaffolding & shuttering)
iv. Curing etc.
 Selecting and Fixing the Finishes
i. Flooring
ii. Roofing Materials
iii. Window Frames and Windows, ventilator etc.
iv. Doors
v. Screens
vi. Exterior Wall Finishes
vii. Interior Wall
viii. Paint etc.
 Installation of Services
i. Electrical
ii. Plumbing
B. Cable trench Construction
i. Excavation to required dimensions
ii. Lean concrete
iii. Fixing of reinforcement and formwork
iv. Pouring of concrete
v. Fixing of tie- channels in walls for Cable Trays.
vi. Formwork for Walls
vii. Concrete of Walls
viii. De-shuttering
ix. Preparation, Filling and sealing of expansion joints
x. Backfilling with compaction

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C. Equipment / Gantry Foundations
i. Excavation
ii. Placing of Lean Concrete
iii. Cutting & fixing of Rebar
iv. Placing of Shuttering
v. R.C.C for pad
vi. Steel fixing and installation of Stubs/ Anchor Bolts
vii. Placing of Shuttering for pedestals
viii. R.C.C pedestals
ix. Curing
x. Backfilling & removing of shuttering
xi. P.C.C grout under base plate of Equipment foundations
D. Fence Wall
i. Excavation up to required Depth
ii. Placing of Levelling concrete
iii. Brick work upto Yard level
iv. Construction of brick column
v. Backfilling
vi. Fencing Frame
vii. Fixing of barbed wire
viii. Finishing
E. Switchyard Drainage
i. Excavation
ii. Laying of RCC Pipes
iii. Construction of manhole
iv. Grouting
F. Transformer foundation
i. Excavation
ii. Placing of Lean Concrete

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 iii. Cutting & fixing of Rebar for pad
iv. Placing of Shuttering
v. R.C.C pad
vi. Cutting & fixing of Rebar for walls.
vii. Placing of Shuttering for RC Walls
viii. Placing & fixing of Rail
ix. R.C.C Walls
x. Curing
xi. Backfilling & removing of shuttering
G. Transformer pathway
i. Excavation
ii. Placing of levelling concrete
iii. Cutting & fixing of Rebar
iv. Placing of Shuttering
v. Concrete poring
vi. Curing
vii. Backfilling & removing of shuttering
H. Miscellaneous Work
i. Roads works
ii. Placing of Gravel

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3 DOCUMENTATION:
Following documents are attached for reference:
i. Compaction Test (By Drive Cylinder Method) Performa (Appendix-01)
ii. Compaction Test (By Sand Cone Method) Performa (Appendix-02)
iii. Concrete Pouring Form (Attached in Appendix-03)
iv. Sieve Analysis Form (Attached in Appendix-04)
v. Cylinder Testing Form (Attached in Appendix-05)
vi. Project Specifications (Appendix-06)

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