DELHI METRO

RAIL CASTING OF COLUMN

CORPORATION

WORK METHOD STATEMENT

Casting of Column

Rev Date Prepared By Checked By Approved By

1
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

CONTENTS

Sr.
Content Page no.
No.
1. Objective 3

2. Scope of work 3

3. Field of application 3

4. Reference documents 3

5. Staff responsibilities 3

6. Workmanship 6

7. Equipment’s & Materials 7

8. Preliminary Activities 7

9. Stage wise construction activities 8

10. Work Procedure 9

11. Deshuttering 12

12. Curing 12

13. Test & Records 13

14. Safety 13

2
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

1. OBJECTIVE:

The objective of this method statement is to frame a procedure for the construction of COLUMN
foundation at DMRC, contract Package.

2. SCOPE OF WORK:

Method for casting of columns as per the approved Good for Construction drawings & relevant
technical specifications.
The scope of work includes the following;

 Starter Concrete
 Staging for column
 Reinforcement tying for column.
 Shuttering of column.
 Concreting of column.
 De shuttering of column.
 Curing of column.

3. FIELD OF APPLICATION:

All Columns

4. REFERENCE DOCUMENTS:

Reference Codes & Standards:

 Contract Specifications
 IRS: Concrete Bridge Codes
 IS: 1786:1985 - High Strength Deformed Steel Bars and Wires for Concrete Reinforcement—
Specification
 IS: 2502-1963: Code of practice for bending and fixing of bars for concrete reinforcement.
 IS SP:34 -1987 – Hand book on concrete reinforcement and detailing
 IS:10262- 2009 – Concrete Mix Proportioning – Guidelines
 CWP for Production and Transportation of concrete.
 SHE conditions of contract
 SHE manual of contract
 Project EHS plan

5. STAFF RESPONSIBILITIES:

5.1 STATION INCHARGE:-

 Reporting to the Project Manager.
 Liaison with Engineer/ Engineers representatives.
3
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

 Liaison with specialized agencies.

 Planning and arrangement of resources.
 Liaison between design department and site execution team.
 Liaison with internal departments like planning department, quality control department,
plant & machinery department, safety department, stores etc. for effective progress.
 Safety & quality system implementation.
 Monitoring the program: Planned vs. achievement as per the target.

5.2 PLANNING INCHARGE:-

 Reporting to the Site In charge.
 Interacting with Engineer’s representatives and internal departments.
 Daily review of program and progress with the project manager & Construction
Managers.
 Responsible for resources allocation.
 Projection of material requirement and arrangement for procurement.
 Preparation of monthly programs based on Master Program.
 Monitoring of the progress and updating.
 Documentation of all process related reports as per ISO requirements.

5.3 SURVEYOR INCHARGE:-

 Reporting to the Site In-charge.
 Interacting with the shifting in charges about the daily activities.
 Up keeping the survey instruments including calibration in consultation with QC/QA
section and safe custody.
 Documentation /protection of benchmark and survey points.
 Interacting with Engineer’s survey department representatives.

5.4 CONSTRUCTION MANAGER (D/N):-

 Reporting to the Site In charge.
 Interacting with Engineer’s representatives and internal departments.
 Daily review of program and progress with the project manager.
 Safe working condition and safe acts of all workman, machineries etc.
 Quality at all the stages shall be ensured.
 Responsible for resources allocation.
 Preparation of Daily & Weekly Program.
 Submission of requirement of materials & other resources for the next week/ month to
the Construction Manager.
 Progress to be achieved as per the program.
 Arranging required resource inputs for both shifts according to the activity planned.
 Co-ordination between the shift engineers.
 RFI submission as per the systems according to the activities planned.
 Documentation of all process related reports as per ISO requirements.

5.5 REINFORCEMENT FABRICATION INCHARGE:-

4
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

 Reporting to the Site In charge.

 Responsible for Cutting, Bending & Tying of reinforcement cages for Column.
 Interacting with Engineer’s representatives and internal departments.
 Preparation of BBS based on approved drawings.
 Optimization of Scrap & Offcuts.
 Safe working condition and safe acts of all workman, machineries etc.
 Quality at all the stages shall be ensured.
 Submission of requirement of steel on monthly basis to the Construction Manager.
 Co-ordination between the shift engineers.
 RFI submission as per the systems according to the activities planned.
 Documentation of all process related reports as per ISO requirements.

5.6 SAFETY IN CHARGE

 Reports to Project Manager
 Co-ordinates with corridor in charge for system implementation
 Closely monitors all the pre-requisites for EHS
 Involves in hazard identification, risk assessment and its control measures.

5.7 SAFETY ENGINEER:

 Involves in regular safety pep talks, demonstrations of safe practices in work.
 Helps in providing requisite safety materials as per requirements.
 Implement and supervise EHS requirements before commencement and during work.
 Organize training programs on safety awareness.
 Coordinates with site administration, first-aid center, doctors & hospitals during
emergency.

5.8 QUALITY INCHARGE

 Material source approval
 Vendor development for construction materials
 Finalization of mix designs for concrete
 Review of CWP and get it approved
 Reviews Inspection plan & Test plan
 Implementation of QMS at site

5.9 QUALITY CONTROL ENGINEER:

 Involves in quality pep talks, periodical demonstrations of best practices in work.
 Arranges routine testing for concrete, reinforcement, and other construction material as
per inspection and test plan.
 Checks for the use of right material at right place.

5.10 ENGINEERS:
 Reporting to the respective in-charge.
 Achieving targets as per the planned.
 Targeting for zero accidents.
 Quality check at all the stages of activities.
5
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

 Material wastages control like rebar, concrete, consumables etc.

 Arrangement of necessary materials required for next shift.
 Updating the shift registers/records.
 Handing over & taking over with the counterparts.
 Tools and tackles periodical checks along with P&M and safety section.

6. WORKMANSHIP:

6.1

6.1.1 Column will be constructed in size & shape as shown in the GFC drawing.

6.1.2 Concrete will be of specified grade with using Ordinary Portland Cement.

6.1.3 Concrete will be produced by weight batching of the ingredients.

6.1.4 Clear cover to any reinforcement in column is 40 mm.

6.2 Continuity of Construction

6.2.1 Work will be carried out round the clock.

6.2.2 Concreting of Column shall be completed in single pour.

6.3 Reinforcement

6.3.1 The reinforcement will be of Fe-500D grade.

7. EQUIPMENTS & MATERIALS:

7.1 Equipment’s

7.1.1 Total Station

7.1.2 Pavement breaker

7.1.3 Batching plant of 30 cum/hr. & 60 cum/hr. capacity

6.1.4 Transit mixers 4-6 cum capacity

7.1.5 Air compressor 300 cfm

7.1.6 Chisel, hammer & manual tools

7.1.7 Tippers for soil disposal

7.1.8 Water Tank

6
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

7.1.9 Crane/ Hydra- 2nd Generation

7.1.10 Rebar cutting & bending machine, trailer & truck

7.1.11 Welding machines & Cutting Machine

7.1.12 Power generator of suitable capacity

7.1.13 High frequency Electrical vibrator (2) & needles (4 nos.)

7.1.14 Curing pump & Curing compound spray machine

7.2 Materials

7.2.1 M-40 grade concrete with Ordinary Portland Cement.

7.2.2 Water

7.2.3 Fe-500D grade Reinforcement steel

8. PRELIMINARY ACTIVITIES:

Sequence of work:

 Obtaining statutory work permits.

 Training on Construction Work Procedure (CWP).
 Reinforcement
o Material
o Preparation of BBS & submission to Reinforcement fabrication yard.
o Cutting and bending
o Transportation
o Placing of reinforcement
 Marking of Column co-ordinate on foundation top.
 Starter concrete
o Rebar tying
o Formwork
o Concreting including joint preparation
 Column
o Rebar tying in stages (including staging) including placing drain pipe and inserts.
o Formwork in stages
o Checking co-ordinate for the Column center.
o Access ladder
o Concreting and Joint preparation
 De-shuttering
 Curing arrangement / curing compound application

7
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

9. STAGE WISE CONSTRUCTION ACTIVITIES:

9.0 Survey point will be marked for X, Y & Z (RLs) axes and corners of the Column as per the
drawings for starter casting of column.

9.1 The column will be checked for variation from the theoretical co-ordinates and submitted to
DMRC for verification. Permissible deviation in plan location for column shall not me more than
10 mm as per the technical specifications.

9.2 Steel shutter/Ply Shutter/ Doka/Cup-Lock will be used as formwork on the sides of the
Column based on the conditions at site. Standard Formwork release oil (Reebol-Fosroc) shall be
applied on the formwork material.

9.3 Cutting & bending of reinforcement as per the approved BBS will be carried out in the
reinforcement yard & the same will be transported by Trailer/Truck to the required location.

9.4 The vertical reinforcement for the Column will be placed in position as shown in the Column
GFC drawings. It shall be ensured that the vertical bars of column reinforcement shall be erected
and tied with proper supporting arrangement to avoid tilting of the reinforcement.

9.5 Concrete will be transported by Transit mixer and it will be poured using mobile placer boom
however for the stand by arrangement bucket/pump will be used. The height of fall of concrete
should be less than 1.5 m Vibration will be carried out using suitable vibrators & top surface will
be wooden trowel finished. The maximum thickness of each layer of concrete will be 300 mm
and concreting will be done in dry conditions.

9.6 The de-shuttering will be carried out after 16 to 24 hrs. Of concreting and curing will be done
for 14 days or application of curing compound at surface of column.

10. WORK PROCEDURE:

10.1 Obtaining statutory work permits:

a. The work shall be commenced after obtaining statutory permits from the Traffic police
department and Greater Haryana Municipality Corporation and other Government bodies.
b. Requisite Permissions shall be kept by site safety department before start the activity and
shall be available at place of work.

10.2 Training on Construction Work Procedure:

8
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

a. Construction team shall be trained / detailed about the approved Construction Work
Procedure (CWP) by Construction manager and Stage In-charge.
b. Awareness through Safety pep talks regarding vehicular movement inside working zone and
road traffic shall be undertaken.

10.3 Reinforcement

A. Material

a. TMT Fe 500D steel bars of approved vendor shall be used.

b. Reinforcement steel shall be supplied to steel bending yard directly from manufacturer.
c. Reinforcement shall be stacked on sleepers / Concrete blocks to avoid direct contact with
local earth. The sleepers/concrete blocks shall be of 200 mm height and placed at a c/c
distance of 3m.
d. Reinforcement shall be marked batch wise and tested as per Inspection and test Plan.
e. Reinforcement which confirms to the requirements shall be used for cutting and bending.
f. BBS shall be used for cutting and bending.
g. Reinforcement shall be protected from rusting, mortars, mills scale, grease oil or paints by
covering with tarpaulin sheets as per the requirement in site.
h. Handling of reinforcement shall be in such a way so as to prevent damage or unwanted
bending.
i. Bars bent during transport or handling shall be straightened. Straightening by heating shall
not be permitted.
j. Reinforcement left projecting from newly placed concrete shall be supported in such a way
that there is no sag or risk of damage to the newly placed concrete.
k. Reinforcing bars will be projected in the crash barriers and coated with cement slurry for
protection. If at all any rusting starts it shall scrubbed with and wire brush.
l. Relevant tests on reinforcement shall be done as per the test plan.

B. Preparation of BBS & Submission to Reinforcement Fabrication Yard

a. Bar Bending Schedule shall be prepared as per the Good for construction drawings.
b. Reinforcement steel shall be fabricated through automatically operated machines and
mandrels confirming to IS1786:2008.
c. Cut and bent reinforcement shall be stacked on sleepers and protected to prevent rusting by
covering with tarpaulin sheets.

C. Cutting & Bending of Reinforcement

a. Reinforcing steel shall conform to the dimensions and shapes given in the Bar Bending
Schedules.
b. Reinforcement steel shall be fabricated through automatically operated steel service centre.
c. Cut and bent reinforcement shall be stacked on sleepers and protected to prevent rusting by
covering with tarpaulin sheets.

D. Transportation of Reinforcement:
9
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

a. Cut and bent reinforcement shall be transported to place of work on trucks /trailers.

b. Unloading of reinforcement at site shall be done either manually or by crane / Hydra.

c. Reinforcement shall be stacked on elevated blocks in clean and dry condition.

E. Placing / fixing of reinforcement

Placing / fixing of reinforcement are described in the applicable sections.

10.4 Marking of Column and Coordinated area:

Marking of column as per coordinates shall be done as per the GFC drawing at site and co-
ordinates furnished by designer.

10.5 Starter Concrete

a) The height of the starter shall be decided based on the height of the Column above Starter.
b) Reinforcement ring and links shall be tied with main vertical reinforcement as per GFC
drawing.
c) Formwork :
 Starter formwork shall be fixed with supporting arrangement either of frame or System
formwork.
 Every corner of shutter shall be tightened and made leak proof with the help of rubber
sheets / foam.
 The starter shutter shall be checked for its axis coordinates.
 Concrete of M-40 grade shall be placed to the required height and thoroughly vibrated
to have a homogenous layer.

 The starter shutter shall be removed after the concrete has gained sufficient initial
strength, say about 12 hours.

d) Construction joint shall be prepared by cleaning with an air-water jet and by wire booming on
the concrete which is still soft enough that laitance can be removed, but hard enough to
prevent aggregate from loosening. If the concrete for some reason is set before the
construction joint preparation, then in such situation the joint shall be prepared using a wet
sand blast or ultra-high pressure water jet.
e) All types of construction joint shall be tooled and made free from any loose mortars /
concrete.

10.6 Column

a. Rebar tying.
i. Temporary Staging shall be done using formwork or with the help of 40 mm dia. Ledger
pipes around the Column to facilitate tying of re-bar according to site.
10
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

ii. Working platforms at proper intervals shall be formed to facilitate the workers for tying the
reinforcement.
iii. Vertical ladders shall be used to climb up to the staging.
iv. Reinforcement shall be tied together for full height and at every intersection (with
rings/links/ stirrups) with GI Binding wire according to our code.
v. Rings/ links/stirrups shall be tied in place as specified in drawing.
vi. The drain pipe shall be held in place with a link or ring tied to the reinforcement at 1 m
interval.
vii. The drain pipes shall be joined using couplers.
viii. Earthing rod shall be placed as shown in the GFC drawing.
ix. Cover blocks shall be provided at suitable intervals to have a clear cover 50 mm according
to GFC Drawing.
x. Lap length shall be as given in the GFC drawing and shall be staggered.

b. Formwork for Column

i. Shutter shall be free from any foreign materials and dried before applying release agent.
ii. Surface shall be coated with mould releasing agent using brush to prevent adhesion of
concrete to the formwork before fixing of shutters. It shall be applied as per the
manufacturer’s specifications. Care shall be taken that the material so applied does not
leave any blisters, voids, blow holes and detoriation of application.
iii. Working platform shall be made along with the frame for placing further shutters.
iv. Top working platform which is part of the Column shutter shall be erected.

c. Checking of coordinates
i. Coordinates for Column center shall be checked as per Survey CWP.

d. Inserting Tremie pipe for concreting

i. PVC tremie pipe of 150 mm diameter shall be placed alongside the drainage pipe for placing
concrete. 1.5 mts pipes shall be joined together by threading to make the total length of the
tremie pipe. The length of the pipe shall be adjusted as the concrete progresses by removing
each length of pipe.

e. Access ladder

i. Staging with ladder shall be placed on one side of the column shutter and connected to the
working platforms of the column shutter.

f. Concreting and joint preparation

i. M-40 grade of concrete from the batching plant shall be placed in the column.
ii. Concrete shall be placed with the help of Boom placers/concrete pumps/concrete buckets in
layers.
11
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

iii. The elephant hose of the boom placer shall be lowered into the concrete delivery pipe to have
control on the free fall of concrete.
iv. The height of free fall of concrete shall be restricted to 1.5M and the layer thickness shall not
exceed 300mm.
v. The concrete layers shall be vibrated with the help of suitable vibrators.
vi. Shutter vibrator may also be used depending on the shape and size of the structure.
vii. Care shall be taken not to vibrate for a long time, since this may lead to the segregation of
concrete. No concrete shall be allowed inside the drain pipe at the time of concreting.
viii. Placing of concrete shall be as per the concrete pour plan.
ix. Top level shall be leveled and finished smoothly.
x. Construction joint shall be prepared by cleaning by an air-water jet on the concrete which is still
soft enough that laitance can be removed, but hard enough to prevent aggregate from
loosening. If the concrete for some reason is set before the construction joint preparation, then
in such situation the joint shall be prepared using a wet sand blast or ultra-high pressure water
jet.

11 De shuttering:

i. De-shuttering shall be done as per IRS: CBC.

ii. De shuttering shall start after 16 to 24 hours of concreting.
iii. De shuttering shall be done in the reverse sequence. Supporting staging shall be removed
simultaneous with the column shutter and shall be brought down to ground level using tyre
mounted cranes/ hydra.
iv. De shuttering shall be done carefully so as to avoid any damages to the edges of the column.
v. All the shuttering materials shall be then thoroughly cleaned and stacked properly.

12 Curing:

i. Curing of concrete shall start immediately after removing of formwork.

ii. Curing shall be done by using water/ approved curing compound for 14 days.
iii. Curing compound shall be applied as per Manufacturer’s guidelines

13 TEST & RECORDS:

All tests will be done as per inspection & test plan & will be recorded as per prescribed format.
Checklist for different activities will be followed and recorded.

14 SAFETY:
All safety precautions will be taken care as per approved site safety plan. All works shall be carried
out within the barricaded area. Adequate traffic marshals and safety personnel’s will be deployed
during the course of work.

12
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

13
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

Client : Delhi Metro Rail Corporation

Contractor :

REINFORCEMENT INSPECTION CHCKLIST-COLUMN

Location/ Pier No : Date of Inspection :
Pier No : Pier Type :
Drawing No : BBS Approved Ref. :
Sr.
Description Yes No. Remarks
No.

1. Working drawing checked and approved

2. Bar Bending Schedule Approved

3. Reinforcement Steel Approved

4. Bar Bending and Cutting Satisfactory

5. Bar Lap length correct

6. Bar Laps at correct locations

7. Bar tied as specified

8. Covers are adequate and correct

9. Cover blocks approved including fixing

10. Stray Current arrangement made as per drawings

Representative DMRC Representative

Date: Date:

14
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

Client : Delhi Metro Rail Corporation

Contractor :

FORMWORK INSPECTION CHCKLIST-COLUMN

Location/ Pier No : Date of Inspection :
Pier No : Pier Type :
Drawing No :
Sr.
Description Yes No Remarks
No.
Formwork alignment and dimensions correct,
1.
including screeds
Face Boarding/ plywood / metal thickness
2.
correct
3. Joints between panels flush (no gaps)- no gaps
4. Formwork clean

5. Formwork release oil material approved

6. Formwork release oil applied correctly

7. Safe access constructed

Adequate work space provided for Labour
8.
equipment

Representative DMRC Representative

Date: Date:

15
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

Client : Delhi Metro Rail Corporation

Contractor :

CONCRETE INSPECTION CHCKLIST-COLUMN

Location/ Pier No : Date of Inspection :
Pier No : Pier Type :
Drawing No :
Sr.
Description Yes No
No.
1. Proportions of ingredients as per design mix are OK

2. Nos. of cube moulds available

3. Slump cone available at site

4. Slump observed at site satisfactory

5. Sufficient nos. of transit mixers available

6. Sufficient nos. of masons gang available

7. Sufficient nos. of labour gang available

8. Sufficient nos. of vibrators and needles available

9. Lighting arrangement satisfactory

Representative DMRC Representative

Date: Date:

16
DELHI METRO
RAIL CASTING OF COLUMN
CORPORATION

Client : Delhi Metro Rail Corporation

Contractor :

CONCRETE POST POUR INSPECTION CHCKLIST-COLUMN

Location/ Column No : Date of Inspection :
Column No : Column Type :
Drawing No :
Sr.
Description Yes No
No.
1. Surface finish OK

2. Repair done as per approved methodology

3. Curing is proper as per approved methodology

Representative DMRC Representative

Date: Date:

17