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8840 - Method StatementUpdated
8840 - Method StatementUpdated
Scope: All excavation works in all types of soils/rocks including dewatering as necessary.
Reference Document:
Contract documents / Tender documents.
Relevant “Good For Construction” Drawings.
As per relevant IS specification / JPL Technical Specification.
Equipment Used:
Measuring tape
Leveling instruments
Mechanical Excavator and HYVA
Procedure:
1. After closing of the traverse, survey lines will be plotted 2 m away from the main building
line for reference work.
2. Calibrated Theodolite will be fixed on the survey point available on the particular grid of the
building.
3. Opposite point of the peg shall be bisected.
4. One point shall be fixed at distance given in the drawings for footing. The same process
shall be done for the other side of the footing.
5. Lay out, Alignment & size of the excavation pit will be marked on the ground as per
drawing by considering 300 mm working space.
6. Diagonal of the footing will be verified before starting of excavation.
7. It will be taken care that excavation starts after finalizing disposition place.
8. Excavation will be done mechanically.
9. Depth of excavation will be checked frequently by using calibrated level machine as given
in the drawing.
10. Side slope of the excavation pit will be checked for safety point of view.
11. After getting sufficient depth, the same will be verified & surface shall be dressed by
employing labours. After getting required depth, Joint inspection records will be prepared.
Deployment of manpower
a) Site Engineers as required.
b) Supervisors as required.
c) Operators and drivers - as required for the equipments
d) Time keeper – 1No.
Reference Document:
Contract documents / Tender documents.
Relevant “Good For Construction” Drawings.
As per IS 2720 / JPL Technical Specification.
Equipment Used:
Measuring tape
Leveling instruments
Plate compactor/ Rollers and Compaction hammers.
Dozers, poclains
Procedure:
1. It will be taken care that earth used for filling is free from all roots, grass, vegetation etc.
2. All lumps exceeding 8 cm in any direction will be broken.
3. Execute back-filling or filling in layers of 250 mm.
4. Each layer will be properly spread, watered and compacted. Thickness of each subsequent
layer will be decided by taking into account the type of rammers/compactors to be used.
5. Type of Rammers/Compactors/Rollers
Heavy type - layer thickness 30-40 cm.
Medium type - layer thickness 17-30 cm.
Light type - layer thickness 10-15 cm.
6. It will be ensured that filling is being consolidated up to 95% standard density at optimum
moisture content.
7. It will be take care to ram near walls, columns and plinth beam sides in layers of 15 cm
thickness properly.
8. It will be ensured that the consolidated top layer is dressed to required slope and level.
9. Provision will be made for shrinkage/settlement at the rate of 1/2" per foot depth.
Safety
Prepared By Reviewed By Approved By
GAMMON INDIA LIMITED
4 NOS NDCT FOR 4 X 600 MW OPJSTPP, TAMNAR, RAIGARH
Safety precaution shall be followed by ensuring the following points:-
1) Toolbox meeting shall be conducted on every working day at site prior to commencement of
work. Hazards identification shall be done and discussed in toolbox meeting.
2) Person working at site shall be equipped with Personal Protective equipment.
3) First Aid attendant shall be present at site depending upon the no of personnel working at site.
4) Hazards identification shall be done and discussed in toolbox meeting.
Deployment of manpower
a. Site Engineers as required.
b. Supervisors as required.
c. Operators and drivers - as required for the equipments
Purpose: This procedure gives guidance for Plain concrete work in different kind of civil work.
Scope: All areas below Foundation, Raft and other excavated area wherever we need a hard surface.
Reference Document:
Contract documents / Tender documents.
Relevant “Good For Construction” Drawings.
IS 456 code of practice for plain and reinforced concrete.
IS 10262 Guidelines for mix design.
Abbreviations:
BM : Bench Mark
Drawing : Approved for Construction Drawing
BBS : Bar Bending Schedule
PCC : Plain Cement Concrete
RCC : Reinforced Cement Concrete
Equipment Used:
Batching Plants, 10 / 7 Mixers
Transit Mixers
Chutes
Vibrators ( 40mm / 60 mm) if required
Measuring tape
Leveling instruments
Procedure
1. Proper grade of concrete for PCC will be ensured.
2. It will be verified before starting PCC for sufficient availability of material, manpower &
machines.
3. Formwork & dimension for Plain concrete work will be checked as per drawings.
4. Mix proportion will be displayed on the weigh batcher & the same will be implemented.
Deployment of Manpower :
a) Site Engineers as required.
b) Supervisors as required.
c) Operators and drivers - as required for the equipments
d) Skilled and Unskilled Labours as required
List of Records
i) Concrete Pour Cards
ii) Necessary Quality Control Records i.e. Cement test report, Cube test report, Concrete register, slump
Register, Fine and course aggregate test report, Reinforcement test report etc.
iii) Survey Register.
Purpose: This procedure gives guidance for Reinforced cement concrete work in different kind of civil
work.
Scope: All Reinforced cement concrete work in substructure and superstructure at all elevation,
including Pedestal, Raker column, Shell.
Reference Document:
Contract documents / Tender documents.
Relevant “Good For Construction” Drawings.
IS 456 code of practice for plain and reinforced concrete.
IS 10262 Guidelines for mix design.
Approved Mix Design for Various Grade of concrete.
Abbreviations:
BM : Bench Mark
Drawing : Approved for Construction Drawing
BBS : Bar Bending Schedule
PCC : Plain Cement Concrete
RCC : Reinforced Cement Concrete
Equipment Used:
Batching Plants, 10 / 7 Mixers
Transit Mixers
Chutes
Vibrators ( 40mm / 60 mm) if required
Measuring tape
Leveling instruments
[A] MATERIALS:
I. Cement:
1. Cement will be used of approved quality and that it is not older than 90 days.
2. Loose Cement will be stored in a completely waterproof & air tight cement silos having sufficient
storage capacity.
3. Cement bags will be stored in a completely waterproof godown having standard specified features.
4. In case cement bags will required to be stored in open as a temporary requirement, they will stacked
on a dry platform made of wooden planks or railway sleepers resting on a brick masonry /
concrete / dry sand / aggregate platform about 150 mm above the ground. The number of bags
must be just sufficient for day’s consumption.
5. Entire stack will be covered by tarpaulin or polythene sheet, with an adequate overlap. This
procedure will be adopted during cloudy or rainy seasons.
III. Water:
1. Potable water for construction will be made available at site.
[B] BATCHING:
1. Batching will be done by fully automatic batching plant having concrete production
capacity of 30m3/hour.
2. Batching of materials will be carried out by weight. If require to batch materials on Volumetric
basis will make use of measurement boxes in units of 0.035 m3 equivalents to 50 kg cement bag.
3. batching of cement will be done by weight as per approved Design mix.
4. Exact measured quantity of water will be added to the batch as per w/c ratio.
5. Necessary correction for moisture of aggregate will be done on day to day basis.
Prepared By Reviewed By Approved By
GAMMON INDIA LIMITED
4 NOS NDCT FOR 4 X 600 MW OPJSTPP, TAMNAR, RAIGARH
6. Routine checks of weights as well as sensitivity of balance will be carried out.
7. Addition of admixture will be ensured as specified in the approved mix design.
[C] MIXING:
1. Mixing will be done by batching plant.
2 When mixer machine is used, checking for rpm of mixer, hardened material, number of blades
inside the drum working of discharge chute and hopper, leveling, raising, emptying and release of
hopper will be done.
3. It will ensured that minimum mixing time required for batching plant is 17 to 30 seconds for one
batch i.e. 0.5 cum. and 11/2 to 2 minutes for the drum for mixer machine.
[D] TRANSPORTING:
1. After batching and Mixing, Transportation of fresh concrete will be done by Transit mixer and
Concrete pump.
2 In case of using Weight batcher it will kept as close as possible to the placement site to reduce
transportation.
3. placing of the concrete in position will be done prior to the initial setting time.
4. Segregation and setting of concrete will be avoided.
[E] PLACING:
1. Fixing the position of construction joint will be carried out before starting concrete.
2. Sequence of concreting will be finalized.
3. Placement of concrete in its final position will be carried out before setting starts.
3. Segregation of materials will be avoided by adopting minimum drop.
4. Care will be taken while placing to avoid displacement of inserts, pockets, etc.
5. Laying of concrete in suitable layers will be carried without any break in continuity, maintaining
the thickness of layers.
6. Proper walkways will be provided in advance.
[F] COMPACTION:
[G] FINISHING:
1. Finishing will be carried out after a little stiffening of concrete has occurred with suitable tools.
2. Green cut will be provided immediately after finishing a particular layer of concrete by using wire
brush and small brooms and cleaning it thoroughly. In case of preceding concrete surface being
old, chipping must be done with 10-15mm depth and should be thoroughly cleaned using air or
water jets before placing the subsequent layer of concrete.
[H] CURING:
1. One or a combination of the following curing methods will be adopted depending on site
conditions, availability of curing materials, type of job, economics etc. :
a) Methods to prevent loss of water in concrete during the early stage of hydration by ponding,
water spraying or saturated wet coverings.
b) Methods to prevent loss of water in concrete by sealing the exposed surface i.e. covering the
exposed surface with sheets of plastic or other impervious materials, applying membrane
forming compounds etc.
2. The curing period in ambient temperatures above 17o C will be for 14 days, or the time necessary to
attain 70 percent of the specified compressive strength.
2. The uses of curing compounds are useful on vertical surfaces, or in the event of water shortage.
[I] COVER:
Calibrated instruments: Measuring tape, leveling instruments, weigh batcher, Batching Plant.
Deployment of manpower
a) Site Engineers as required.
b) Supervisors as required.
c) Operators and drivers - as required for the equipments
d) Skilled and Unskilled Labours as required
List of Records
i) Concrete Pour Cards
ii) Necessary Quality Control Records i.e. Cement test report, Cube test report, Concrete
register, slump Register, Fine and course aggregate test report, Reinforcement test report etc.
iii) Survey Register.
Scope: All around the PCC & RCC work in substructure including Pedestal, Racker column and Ring
Beam.
Reference Document:
Contract documents / Tender documents.
Relevant “Good For Construction” Drawings.
Equipment Used:
Measuring Tape
Leveling Instruments
Wooden Batten/ Suitable MS section(for Side Support)
Procedure:
1. Rigid & closely fitted Formwork with sufficient strength to support wet concrete will be
used.
2. Proper cleaning of centering plates, planks or plywood will be ensured.
3. Suitable form release agent will be applied after proper cleaning of formwork, before
placing reinforcement.
4. Proper check for line, level and plumb will be ensured before starting concreting activity.
5. Shuttering will be checked in stage wise. i.e. as per the approved shuttering scheme
1) Ist - beam bottom - alignment and level and rigidity of staging to take the load.
2) IInd - Beam sides.
3) IIIrd - Slab shuttering and levels.
4) IVth - Fixing of side supports, bhada, etc. for rigidity.
6. Special care will be taken to check column caps supports at junction of beams.
7. Pockets, insert will be carefully placed and check before placing concrete.
8. Fixing of Pockets and inserts should be rigid to avoid displacement during concreting.
9. Mastic tape for gap filling will be used.
10. Extra supports at joints of wall plates, beam bottom will be provided. Proper care will be
taken to prevent buldging of centering.
Purpose: This procedure gives guidance for Reinforcement work in different kind of RCC work.
Scope: All RCC work in substructure and superstructure of all elevation for construction of Cooling
Tower.
Abbreviations:
BM : Bench Mark
Drawing : Approved for Construction Drawing
BBS : Bar Bending Schedule
TC : Manufacturing Test Certificates
Reference Document:
Contract documents / Tender documents.
Relevant “Good For Construction” Drawings.
IS 1786 (Fe 500) Specification for High Strength Deformed Steel Bars and Wires for
concrete Reinforcement.
Equipment Used:
Measuring tape
Leveling instruments, Total Station
Bar cutting and Bending Machine.
Procedure:
1. It will be ensured that reinforcement bars are clean free from grease, oil, paint, rust, dust or
any other objectionable foreign material.
2. It will be ensured that all the reinforcement rods are thoroughly cleaned before fabrication,
pitted and defective rods are rejected.
3. Straightening of bars will be done without damaging the configuration. Cutting, bending
should be as per Bar Bending Schedule (B.B.S.).
4. It will be ensured that the vertical distance between the successive layers of bars in beams
or other members are maintained by providing mild steel spacers at required interval.
5. Reinforcement size, spacing, location, numbers, overlaps, welding joints, hooks, bent ups,
rusting, greasing and ties will be according to drawings and bar bending schedule.
Prepared By Reviewed By Approved By
GAMMON INDIA LIMITED
4 NOS NDCT FOR 4 X 600 MW OPJSTPP, TAMNAR, RAIGARH
6. Staggered overlaps, cold bending and anchorage will be ensured, wherever necessary.
7. Sufficient nos. of ghodies, chairs etc. will be provided to ensure the position of
reinforcement as per drawing; during placing and compaction of concrete.
8. Proper placement of cover blocks embedded inserts and cut outs if any will be ensured.
9. It will be ensured that cat ladders are provided on the reinforcement to avoid displacement
of reinforcement.
10. Before placing the concrete; the reinforcement is checked for bent up bars, lap length,
hooks, rings and distribution bars, etc.
11. Proper binding of reinforcement will be ensured.
12. It will be ensure that the lap joints of bars are staggered in about 40% to 50% in column,
walls, etc. or as specified.
Safety: Safety precaution shall be followed by ensuring the following points:-
1) Toolbox meeting shall be conducted on every working day at site prior to commencement of
work. Hazards identification shall be done and discussed in toolbox meeting.
2) Person working at site shall be equipped with Personal Protective equipment.
3) First Aid attendant shall be present at site depending upon the no of personnel working at site.
4) Hazards identification shall be done and discussed in toolbox meeting.
Deployment of manpower
a) Site Engineers as required.
b) Supervisors as required.
c) Operators and drivers - as required for the equipments
d) Skilled and Unskilled Labours as required
List of Records
a) Bar Bending Schedule (BBS)
b) Measurement books
LIFTING
1. Initially two jacks are in expanded condition & one end is fixed to I section & other end to the
guide channel.
2. Lift rig partially to remove the bottom bracket A.
3. Pass the bracket to the middle plat form & fix to anchor screws on last concrete Lift.
4. Remove bottom anchor screws & plug the holes.
5. Continue to lift rig on hydraulic ram until the bottom anchor point passes the bottom bracket B
spring loaded wedge. Now lower the rig so that it is fully engaged on bracket B wedge &
weight of the rig is transferred to bracket B.
6. Now jack extends again, which lift the guide channel.
7. The wedge of the guide channel is fixed with the top bracket A.
8. Now the middle wedges also reach to the bracket C.
9. Maximum load of jump form is taken by the bottom anchoring point B, then top point A & no
load taken by the middle point C.
10. Now rig is in normal working condition & ready for concreting next lift no.6.
1. ANCHOR SCREW: These are embedded in the shell, carry the bracket & take load of the rig.
2. BRACKET: Transfer load to anchor screw.
3. GUIDE CHANNEL & I –SECTION: These are the main components for lifting of rig. They
transfer load to the brackets.
4. BEAM LADDER: It keeps the outer rig hanging outside. It also helps in lifting the shuttering by
chain pulley. Chain pulleys are fixed to the ladder during lifting of shutter.
5. GUIDE ROLLER
Rollers guide the movement of both inner & outer rigs along with the shell.
6. INNER PLATFORM
TOP: It is mainly used for fixing of inner vertical reinforcement
MIDDLE: It is used for tightening of radius bolt & through bolts
BOTTOM: It is generally used for shell finishing & lifting the jump form.
7. OUTER PLATFORM
8. HAND RAILING
COMPONENTS OF SHUTTERING
1. MAIN SHUTTER: It is the larger shutters are placed according to node points of shell. It carries
2 pair of holes for anchor screw except from 4 holes for through bolt.
Dimensions: 4030mm*1500mm (inner)
4060mm*1500mm (outer)
2. MAKEUP SHUTTER: It is the smaller one placed between two main shutter.
Dimensions: 1890mm*1500mm (inner)
1930mm*1500mm (outer)
3. PAN SHUTTER: It is a small steel plate placed in the gap between main & makeup shutter. It is
for adjustment with the reducing radius of shell.
Dimensions: 750mm*1500mm or 550mm*1500mm or 300mm*1500mm
4 .SOLDIER: It is a supporting member made of 2 back to back ISMC 100 length 2.4m It is fixed
to the both inner &outer shutter to take lateral load of concrete.
5. THROUGH BOLT:
TOP- It is fixed between inner & outer shuttering to maintain thickness. It also takes load of
concrete. Through bolt is protected by PVC pipe for removing them after concreting.
BOTTOM- Shutter rests on the bottom through bolt. Both of the through bolts are passed through
the soldier & tightened by nut from out side.
7. RADIUS BOLT:
It is very useful component to align the shutter. It is fixed perpendicularly to the shell surface both
inner & outer side through the bottom of the soldier. If inner radius bolt is tightened the total shutter
system tilts outside & vice versa. The inner radius bolt takes huge load during concreting without
settlement.
Prepared By Reviewed By Approved By
GAMMON INDIA LIMITED
4 NOS NDCT FOR 4 X 600 MW OPJSTPP, TAMNAR, RAIGARH
LIFTING OF SHUTTERING
1. STRIPPING SHUTTERS
Undo bolts through inside shutter holding anchor screws . loosen nuts on shutter bolts.
Lift out inside steel pan shutters up to top platform, clean, oil, & store against handrail.
Remove wedges from top shutter bolts; withdraw bolts to inside of shell, store bolts in box
on back of inside shutters to rest against scaffold rig posts .
Lift out outside steel pan shutters up to top platform, clean, oil, & store against handrail.
Attach hooks of chain pulley blocks to lifting ‘u’ bolts on top of inside shutters.
Take weight of shutters on chain pulley blocks & hoist up so those bottoms of shutters are level
with top of previously. concreted lift
From the inside of the shell, insert shutter bolts partially into holes at top of previously
concreted lift.
Lower shutter on chain pulley blocks to allow the shutter to rest on the bolts.
Remove chain pulley blocks leveling shutters resting back against the access scaffold posts.
clean & oil shutters, tilt shutters up towards shell & hook top of shutters to reinforcement.
Attach hooks of chain pulley blocks to lifting ‘u’ bolts on the top of outside shutters.
Remove wedges from lower shutter bolts; withdraw bolts to inside of shell pass the bolts from
platform b to platform.
Hoist shutters
Knock lower shutter through from inside of shell so that wedges can be located through bolt on
outside.
Remove chain pulley blocks, the shutters will be self supporting with lower shutter adjuster
bolts resisting overturning.
4. FIXING SHUTTERS
Insert top shutter bolts from inside of shell so that bolts project past outsiye so soldiers
enough to locate wedges.
Tighten all shutter bolt so that shutters are held firmly, but not tightly, to shell.
Slide inside & out side steel pan shutters down into position.
Place temporary distance pieces between top of inside & outsite shutters, and tighten
shutters bolts,
Adjust inclination of shutters to correct batter using inside & outside adjuster bolts.
Using expanding cement mortar grout or similar, fill shutter bolt holes in previous lift.
Concrete form upper platform removing temporary shutter distance pieces as shutters are fitted.
Procedure:
Embedment of Hook
During process of casting of the parapet wall at top of the shell a 28mm Dia. steel hook with U bend
of 550mm depth is being embedded into the parapet up to a depth of 450mm exposing 100mm of
hook over the parapet wall.
The hooks are being placed at a regular distance of 3m throughout the periphery of the parapet wall.
ANCHORING OF WIRE ROPE
Following to the embedment of hooks in the concrete, wire rope of 20mm Dia. steel core is passed
on through the hooks throughout the periphery of shell along parapet wall.
The 20mm Dia. wire rope is passed on twice from each hook to obtain a greater lifting capacity.
The rope is properly clamped at joints and fixed to a proper anchorage point.
Note: The lifting hook has to be shifted between the hooks at parapet top to carryout the erection works
at desired quadrant and location within the tower.