Company: Kuber Enterprises.

Client : Doosan Projects India Pvt. Ltd.

Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

Revision Status
Rev. No. Date of Description
Rev./1st
Issue

Quality Inspection & Work Procedure (Construction Methodology)

0
for Track Hopper Concrete Pouring Plan

Prepared by Reviewed by Approved by Issued by

Name

Designation

Signature

Date

Dated: 25-June-2018 Page 1 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

TABLE OF CONTENTS

1) Objective

2) Scope of Work

3) Raw Materials

4) Deployment of Equipment/Tools

5) Deployment of Labour

6) Deployment of Technical Staff

7) Reference Drawings

8) Concrete Transportation

9) Placement of Concrete.

10) Temperature Control.

11) Compaction of Concrete

12) Curing

13) Post Concrete Inspection

14) Concrete Test Plan

15) Methodology

16) Safety Measures

17) Miscellaneous Arrangement

18) Staging and Form work for Track Hopper Concrete Pouring Plan

19) Sequence of Pouring of Concrete.

20) Construction Flow Diagram

Dated: 25-June-2018 Page 2 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

1. Objective:

The objective of this procedure is to detail the methodology to be adopted for

construction of Track Hopper Concrete Pouring Plan of 2 X 660 MW Super Thermal
Power Project, Malawan, Etah, UP.

2. Scope of Work:

Construction of Track Hopper Concrete will be carried out as per Construction

Drawings listed in SL no. 7.

Approximate quantity of Concrete: - RCC (M-25) 729.00 Cum

3. Raw Materials:
The following Bulk materials are to be used for Track Hopper Concrete concreting.

Sl. Name of Material Unit Quantity

No.
1 Stone Aggregate 10 mm size cum
2 Stone Aggregate 20 mm size cum
3 Coarse River Sand cum
4 Cement MT
5 Reinforcement steel MT
6 Concrete Admixture kg

4. Deployment of Equipment / Tools:

Machineries Quantity
1. Batching Plant (Capacity- 45 cum/Hour) 1
2. Batching Plant (Capacity:- 30 cum/Hour) 1
3. Transit Mixer (Capacity:- 6 cum) 9

Dated: 25-June-2018 Page 3 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

4. Concrete Pump (Capacity:- 60 cum/ Hour)

2
(Capacity:- 75 cum/Hour)
5. Boom Placer (37 mtr.)
1
(Capacity:- 120 cum/Hour)
6. Needle Vibrator (60 mm) 9
7. Air Compressor (300 cfm) 1
8. Water Tanker (5000 ltr) 1
9. Total Station 1
10.Auto Level 1
11.Communication System As required

5. Deployment of Labour:

For each shift

Sl. No. Category Heads
(A) Civil Labour
1 Mason 4
2 Mason Helper 6
3 Scaffolding Khalasi 8
4 Scaffolding Khalasi Helper 4
5 Carpenter 4
6 Carpenter Helper 6
7 Reinforcement Bender / Fitter 4
8 Reinforcement Bender/ fitter - Helper 8
9 Concrete Pump Piping Fitter 2
10 Concrete Pump Piping Helper 4
11 Unskilled 20
(B) Mechanical / P&M
1 Batching Plant Operator 4
2 Transit Mixer Driver 18
3 Transit Mixer Helper 18
4 Concrete Pump Operator 4

Dated: 25-June-2018 Page 4 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

5 Concrete Boom Placer Operator 2

6 Concrete Boom Placer Helper 2
7 Water Tanker Driver 1
8 Water Tanker Helper 1
(C) Quality
1 Mason 2
2 Mason-Helper 2

6. Deployment of Technical Staff:

For each shift

Sl. No. Category Heads

(A) Civil
1 Shift In-Charge 1
2 Engineer (for Concreting) 2
3 Supervisor (for Concreting) 2
4 Engineer (For Misc. works) 2
5 Supervisor (for Misc. Works) 3
(B) Mechanical / P&M
1 Engineer 1
2 Mechanic 2
(C) Electrical
1 Engineer 1
2 Electrician 2
(D) Safety
1 Safety Engineer / Officer 1
2 Safety Supervisor 2
3 Flagmen 3
(E) Quality
1 Quality Engineer 2
2 Quality Supervisor 2

Dated: 25-June-2018 Page 5 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

7. Reference Drawings:

Sl No. Drawing No. Rev. No.

1 1
2 0
3 1
4 1
5 1
6 1
7 0C
8 0C
9 0A
10 0A
11 1
12 1
13 1
14 0
15 1
16 0

8. Concrete Transportation:

Concrete shall be conveyed from Batching Plant to the concrete pumps by transit
mixers. Nine transit mixers shall be engaged for concrete transportation and one
additional shall be kept as stand-by.
All equipment used for transporting and placing of concrete shall be thoroughly
cleaned after each pour.

Adequacy of Transit mixers:

Capacity of transit mixer = 6Cu.m.
Least quantity per transit mixer = 5Cu.m.
Maximum rate of delivery by BP = 75Cu.m.
Cycle time per transit mixer: = 30min.
Loading (5x90sec = 450 sec) = 8min.

Dated: 25-June-2018 Page 6 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

Transit (4 km @ 20 km/h) = 6min. (approx.)

Positioning & unloading = 8min. (approx.)
Return (4 km @ 20 km/h) = 6min.
Positioning = 2min.
Number of trips per hour per transit mixer (60/30) = 2 nos.
Concrete transported per hour per transit mixer = 10Cu.m.

Hence, Number of transit mixers to be deployed (75/10) = 8 nos.

9. Placement of Concrete:

Once reinforcement, formwork is duly inspected, prior intimation shall be given

in writing to the Engineer of DSPI through Concrete Pour Card, seeking his
permission for pouring the concrete.

Concrete shall be poured in successive layers in its final position, as nearly as

practicable, to avoid segregation due to re-handling. Concrete shall be placed
carefully to avoid displacement of bolt, EP and reinforcement.

Two pumps and one boom placer shall be deployed for pumping Concrete. The
pumps, that shall be used here, have a concrete pumping capacity of Pump-1 is
60 m3/ hr., Pump-2 is 75 m3/hr. and boom placer is 120 m3/hr.

The pipelines shall be made of seamless steel pipes. At the end of the placing
boom, a heavy-duty flexible hose may be attached to facilitate Concrete Pouring
at sequenced locations. Strong Couplings shall be used to clamp both the flexible
and rigid pipes in proper alignment.

Cement mortar shall be flowed through the pipeline to lubricate the inner surface
of the pipes. Concrete shall then be pumped in continuation with cement mortar.

10. Temperature Control:

The maximum specified concrete placement temperature shall be 40 o C or less. To

ensure the desired placement temperature of concrete, the following measures
shall be taken:

Dated: 25-June-2018 Page 7 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

1) Calculation for Derived Temperature of green concrete at the time of placement

shall be done to check the requirement of any chilling material to be added in the
mix.
2) Transit mixer drums are insulated & always wet in Condition.
3) Aggregate bins are sprinkled with water.

11.Compaction of Concrete:

Each layer of Fresh Concrete shall be compacted by vibrators to the minimum

practicable consolidated volume. Compacted concrete shall be free from pockets of
coarse aggregates and shall fit tightly against all form surfaces and embedded parts.
Mechanical vibration shall be supplemented by hand spading and tamping,
particularly around EPs.
Immersion type High Frequency Vibrators shall be inserted in a vertical position at
intervals of about 450mm to 650mm. Generally, the influence area of the vibrating
needle is 10 times of its cross sectional area. The vibrators shall be withdrawn slowly
out of the Concrete, approximately at the rate of 75mm/sec. The spacing shall
provide some overlapping of the area vibrated at each insertion. Over vibration shall
be avoided.
Vibrator needle shall be inserted vertically inside the Concrete and shall be allowed
to penetrate through by its own weight. Vibration shall not be stopped when needle
is immersed in Concrete.
The vibrator shall penetrate fully into the layer being placed and also about 50 mm
into the previous layer, while the under layer is still plastic, to ensure good bond and
homogeneity between the two layers and prevent the formation of cold joint. Care
shall be taken so that the vibrator does not touch formwork, rebar and EPs.
Experienced and qualified vibrator operators shall be engaged for compacting green-
concrete. The needle vibrator shall not be used to push or spread the concrete.

Dated: 25-June-2018 Page 8 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

12.Curing:

Curing immediately after placement of concrete shall be carried out as mentioned

above (Protecting fresh concrete). Wet curing shall be carried out by wet Hessian
cloth /ponding water over concrete surface after final setting time. Bund shall be
made all around the pour, of sand-cement mortar, to facilitate the same. Curing of
concrete shall start after final setting time of concrete and shall be continued till 10
days. This shall be maintained moist by spraying water.

13.Post Concrete Inspection:

Post concrete inspection shall be carried out after removal of shuttering for
identifying defects like honeycombed surface, unset concrete or any other defects.
Report of the same, if any, shall be submitted to JVUNL/ DESIEN/ DPSI in the
approved format. Rectification measures, as necessary, shall be executed as per
mention in technical specification.

14.Concrete Test Plan:

Concrete testing shall be as per the details in Test & Inspection Plan of Project
Quality Specifications/ IS Codes/ Manuals.

15.Methodology:

i. Area to be cleaned and earth surface to be made compacted to ensure

sufficient load bearing capacity of staging
ii. Staging and scaffolding work to be done as per staging design (refer
design document) and drawing (refer drawing).
iii. Proper access way to be provided to facilitate workmen to carry
materials or doing concrete on Track Hopper at CHS safely.

Dated: 25-June-2018 Page 9 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

iv. Concrete surfaces of Track Hopper at CHS are to be cleaned before

starting of laying of reinforcement.
v. From work for bottom of Track Hopper at CHS will be placed as per
drawing No : DP16003- CC02- 90UEA- 160002, Rev : 1.
vi. Form releasing agent will be applied on form. Care shall be taken that
reinforcement should be free from any grease, oil, etc.
vii. Kuber will request for checking of Staging and bottom form work before
laying reinforcement.
viii. Bar bending schedule will be made by Kuber and approval to be sought
from JVUNL, DESIEN & DPSI.
ix. Concrete cover block (M25 Grade) will be placed on bottom shuttering on
which reinforcement will be placed as per design and drawing. Lapping
and splicing will be done as specified.
x. Simultaneously form for sides to be fixed as required with the progress of
reinforcement tying.
xi. Blow of compressed air will be applied to remove unwanted materials,
Such as: Soils, dust, paper, wood-chips, etc.
xii. Kuber will offer inspection to JVUNL, DESIEN & DPSI after completion of
final staging, form work and reinforcement fixing (Partly or Final).
xiii. Casting of concrete will be started after getting consent from JVUNL,
DESIEN & DPSI
xiv. Concreting will be done with the help of stationed concrete pump and
boom placers.
xv. Temperature of concrete at the time of pouring will be below 40 degree
centigrade.
xvi. Newly placed concrete will be well compacted with the help of 60 mm φ
electrically / engine operated needle vibrator.
xvii. Top surface of the concrete will be made smooth & level as per drawing.
xviii. Top surface will be protected from direct sunlight (if hot weather) to
prevent shrinkage crack in top surface.
xix. After final setting of cement, proper curing by ponding of water will be
carried out by means of walling using cement mortar.
xx. Form work of vertical surfaces will be removed after 24 Hours of
completion of concreting.
a. Vertical surfaces will be wrapped by wet Hessian cloth for curing to
concrete.
b. Sufficient stock will be kept for covering of green concrete to protect
from sudden rain.

a. Proper communication system.

b. Proper lighting arrangement.
c. Proper housekeeping.

Dated: 25-June-2018 Page 10 of 11

Company: Kuber Enterprises.
Client : Doosan Projects India Pvt. Ltd.
Owner : Jawaharpur Vidhyut Utapadan Nigam Limited (JVUNL)

QUALITY INSPECTION & WORK PROCEDURE

(CONSTRUCTION METHODOLOGY) FOR TRACK HOPPER CONCTETE
POURING PLAN AT CHS AREA

d. Proper stacking of construction materials.

e. Close supervision.

16.Construction Flow Diagram:

Start

Making Staging for Track Hopper (2)

Fixing of Form work for Track Hopper (3)

Checking of Alignment and elevation of Track If “NO”

Hopper (4)

Approval Cutting Bending and Fixing of Reinforcement (5)

of BBS

Positioning and Fixing of Embedded Materials etc. (6)

Vertical side shuttering (7)

Cleaning inside of Track Hopper Form (8)

If Not ‘OK'
Offer for inspection before casting (8)

IF OK
Concrete Casting (9)

Curing (10)

Removal of Form work (11)

Dated: 25-June-2018 Page 11 of 11

Finish