Four Laning of Bakhtiyarpur-Mokama Section of NH-31 from

Km 153+300 To Km 197+900 (Design Chainage) and (Existing

Chainage Km 153+300 To Km 204+741 of NH-31) in the State of
Bihar on EPC Mode.

METHODOLOGY FOR CONSTRUCTION OF

PRECAST RCC BOX CULVERT

CLIENT

SUPERVISION CONSULTANT

CONTRACTOR:

BSCPL Infrastructure Ltd.

__________________________________________________________________________________

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Construction Methodology for Precast RCC Box Culvert NH-31

 Submitted by: BSCPL Infrastructure Ltd

WORKING METHODOLOGY – CONST. OF PRECAST RCC BOX CULVERT

TABLE OF CONTENTS
S. No. Description of Title Page No.
1.0 Purpose 3
2.0 Scope 3
3.0 Definitions 3
4.0 Code References 3
5.0 Responsibilities 4
6.0 Details of Plant, Equipment and 5
Machinery
7.0 Material 5-6
7.1 Reinforcement steel
7.2 Cement
7.3 Course Aggregate
7.4 Fine aggregate
7.5 Others Material
8.0 Segment Constructions 6-8
Methodology
9.0 Segment Inspections & Testing 8
Process.
10.0 Segment Documentation 8
Requirements:
11.0 Segment Safety & Environmental 8
Requirements:

WORK METHODOLOGY
For (Precast) Box Culvert

1.0 PURPOSE:

The purpose of this Segment Quality Plan for Box Culvert is to provide
details of the Construction Methodology, Quality Control System,
Procedures and Safety & Environment Management Plans to be adopted
by BSCPL INFRASTRUCTURE LIMITED.

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Construction Methodology for Precast RCC Box Culvert NH-31

 2.0 SCOPE:
The Scope of this Segment Quality Plan covers the following activities:
The construction of Box Culvert shall be done in accordance with the
approved drawings and Technical Specifications, and NHAI Guidelines.

3.0 DEFINITIONS:
The words like contract, Contractor, Engineer, Drawing, Employer,
Government, Works, Worksite used in this Work Methodology shall be
considered to have the same meaning as understood from the definitions
of these terms given in the General conditions of the contract.

4.0 CODE REFERENCES:

(i) Volume III of Technical Specifications.

(ii) NHAI Guidelines.

5.0 RESPONSIBILITIES:

Responsible personnel for execution of the Segment of Box Culvert are

as per the following Responsibilities Matrix:

Sl. Responsible Personnel for

Activity Remarks
No. Performing Checking/Verifying Approval
Sampling of QC Engr./Lab
01 Lab-In-charge Engineer
Materials Tech.
Testing of
02 Samples & Lab Technician QC Engineer Engineer
Approval
Cutting,
Bending & Casting Yard
03 Structure In-charge Engineer
Tying of Eng./Supervisor
reinforcement
Fixing &
Casting Yard
04 supporting of Structure In-charge Engineer
Eng./Supervisor
Frame work
Equipment
Production of Dept.
QC Engr./Lab
05 Concrete from Lab In-charge Engineer responsible
Tech.
Batching Plant to provide
infrastructure
06 Placing of Casting Yard Structure In-charge Engineer

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Construction Methodology for Precast RCC Box Culvert NH-31

 Concrete Eng./Supervisor
De-shuttering Casting Yard
07 Structure In-charge Engineer
Work Eng./Supervisor
Transportation Equipment
of Precast Box Site Dept.
08 Culvert From Engineer/Site Site Engineer Engineer responsible
Casting Yard to Supervisor to provide
work place infrastructure
Ground Site Engineer,/QC
09 Site Engineer Engineer
preparation Engineer
Alignment and
10 Surveyor Section In charge Engineer
Level Checking
Clearance to
Section In Section In charge
11 release/final Engineer
charge QA/QC Engineer
approval
Rectification of
Non- Section In Section In charge
12 Engineer
Conforming charge QA/QC Engineer
works

6.0 Plant & Equipments.

The following sets of equipment as necessary for the planned progress

shall be deployed:-
1) Concrete Batching plant
2) Concrete Millar
3) Vibrator
4) Crane
5) Trailer
6) Excavator
7) Dumper

7.0 Materials:
7.1. Reinforcement Steel
The Reinforcement Steel (HYSD-Fe 500 Grade) shall be procured from
manufacturers directly. The Reinforcement bars shall be subject to all
necessary tests. The bars shall be procured and stacked in central stack
yard. The stacking shall be done in such a way that bars do not come in
contact with soil.

7.2 Cement
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Construction Methodology for Precast RCC Box Culvert NH-31

 a. It is proposed to use Ordinary Portland Cement of 43 Grade. The cement
shall be procured from reputed manufactures in bags of 50 kg. Each or
bulk. The cement shall be stocked at raised platform in covered Cement
Godown to protect it from moisture, sun and rain etc. The consumption of
cement shall be done on first-in-first-out basis.

b. Testing of cement shall be done on regular basis to ensure quality as per

requirement.

7.3 Coarse Aggregates

a. Coarse Aggregates shall be of clean, hard strong, dense, non-porous

crushed stone of specified gradation. Initially the aggregates shall be
purchased from market and later these shall be produced from Crusher
setup for the project.

b. The aggregate shall be tested for all physical properties before

incorporation in work.

7.4 Sand/Fine Aggregates

a. The Fine Aggregate shall consist of clean, hard, strong and durable pieces
o crushed stone or natural sand from river bed. It shall be tested for
Fineness Modulus, Silt Content, etc.before using in the works.

7.5 Other materials

a. Associated materials and consumables like water for concrete works,

binding wire and cover blocks for reinforcement works, supports, nails
and shuttering oil for formwork, tools and tackles shall be arranged and
checked for conformance to good engineering and accepted standards.

b. Concrete admixture-used as super –plasticizers:

Concrete Admixtures shall be obtained only from the established
manufactures with proven track record, quality assurance and testing of
concrete.

8.0 Segment Construction Methodology

8.1 Concrete Design Mix (ISI0262-1982, IS SP-23-1982) and IS 456-

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Construction Methodology for Precast RCC Box Culvert NH-31

 1978/2000):

8.2 Well before proposed start for RCC works, Mix Design for M-30 grades
of concrete to be used in works shall be conducted in Field Laboratory
as per approved Technical Specifications. The Mix Design shall be
conducted in the presence of Consultant/Client’s representatives. The
Design Mix results shall be submitted to Consultant for approval.

8.3 Bar Bending schedule shall be prepared for each Segment structure and
reinforcement, steel shall be cut bent at centralized reinforcement yard
and shall conform to the dimensions and shapes as given in the approved
Bar Bending schedules.

8.4 The bars shall be placed in accordance with the drawings and cross bars
shall be tied together with binding wires at every intersection.

8.5 Appropriate cover between the formwork and bars shall be provided as
per the requirement by placing cover blocks. Necessary spacer bars,
chairs, etc shall be provided to fix the reinforcement firmly to its correct
position.

8.6 Overlaps in main reinforcement shall be provided as per technical

requirements and care shall be taken that overlaps are staggered to avoid
weak construction zone.

8.7 The Form work shall be made of Structural Steel with standardized plates
& other formworks. The scaffolding material shall be of standard in
nature and shall be of MS pipes, jacks etc.

8.8 Placement of shuttering shall be done manually or with help of crane and
care shall be taken that there are no weak joints from where the concrete
slurry can leak.

8.9 In order to prevent sticking of concrete to shuttering plates, coating on

shuttering plates shall be done with shuttering oil of approved quality.

8.10 After placement of reinforcement, formwork of side walls haunches shall

be done so that concrete structure of required shape, line, level and
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Construction Methodology for Precast RCC Box Culvert NH-31

 dimensions is achieved and remains within the specified tolerances.
Necessary staging, scaffolding and temporary supports shall be provided
to the main shuttering so that the formwork is capable of withstanding all
ramming and vibrating pressures while placement of concrete is carried
out. The false work for shuttering shall be done in accordance to the
technical requirements/specifications.

8.11 The Concrete shall be produced as per approved Mix Designs.

8.12 Admixtures such for concrete may be used with exceeding specified limit
prescribed by the manufacturers, as the selection of appropriate concrete
admixtures is an integral part of the mix design.

8.13 The production of concrete shall be done with Concrete Batching and
Mixing plant of 30 cum/hour and shall be transported though transit
mixers and placed at the casting yard work site.

8.14 Transportation of concrete shall be done in transit Mixers.

8.15 Appropriate number of labors shall be engaged to lay concrete and

vibrators shall be used to have a uniform, homogeneous and compacted
surface. Concrete shall not be freely dropped into place from a height
exceeding 1.5m to avoid segregation of material.

9.0 Segment Inspections and Testing Process:

All the Inspection and Testing requirements for various activities in the
present segment will be carried out as per relevant NHAI Specification &
Article-11 of Contract Agreement.

10.0 Segment Documentation Requirements:

The following general documents/records shall be kept maintained as per

relevant applicable BSCPL Infrastructure Limited Quality Management
Procedures:
1) Construction Schedules for the Segment
2) NHAI and other Technical Specifications including relevant
IS/BS/ASTM Codes
3) Field memos/notes/complaints etc including action taken status
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Construction Methodology for Precast RCC Box Culvert NH-31

 4) Product Non-conformance Reports etc.

All the above document/records shall be maintained at appropriate

locations with proper and defined filing system, which can be identified
& traceable.

11.0 Segment Safety & Environmental Requirements:

Hazard Identification, Risk assessment and Risk control measures for

each and every activities and sub-activities involved in the present
Segment shall be identified and necessary action plan shall be initiated.
Environmental Aspects and Impacts associated with various activities and
sub-activities involved in the present segment and their mitigation/control
measures shall be identified and necessary measures shall be initiated.

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Construction Methodology for Precast RCC Box Culvert NH-31