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Method Statement 20 Bridges PDF Free
Method Statement 20 Bridges PDF Free
E. CONSTRUCTION OF EMBANKMENT.............................................85
DETAILED SURVEY:
A traverse has been closed referring control point C-2 & 36 Km. Stone and
subsequently C/L of proposed bridge has been established.
The survey scheme shall be enclosed for reference. The reference pillars
have also been made @ Balasore & Jaleshwar end for further reference.
Page 3 of 109
FABRICATION MACHINERY:
i) Welding Transformer - 5 Nos.
ii) Drilling Machine (pedestal) - 2 Nos.
iii) Drilling Machine (Magnetic) - 1 No.
iv) Cutting Set - 2 Nos
v) Grinder - 2 Nos
vi) Welding Generator(Electric) - 1 No.
vii) Power Generator (60 KVA) - 1 No.
viii) Welding cables, Holder etc - 4 Set
ix) Hydraulic Jack 50 T - 1 No.
CONCRETING MACHINERY:
i) Batching Plant ( 30 Cu.M./ hr) - 1 No
ii) Crane & Bucket - 1 No
iii) Transit Mixer ( 6 Cu.M./ 4 Cu.M) - 2 Nos
iv) Concrete Tremie & Funnel or chutes - 2 Nos ( In 4 quadrants
of well)
v) Immersion type Vibrator (Electric)
with 60mm needle - 3 Nos
vi) Cube moulds - 30 Nos
vii) Slump Cone - 1 No
viii) Immersion type thermometer (metallic) - 1 No
(for noting ambient temperature and relative humidity)
ix) Generator ( 55, 110 KVA) - 1 No
x) Water Pump 5 HP - 2 Nos
xi) HM Loader -1 No
LIST OF MANPOWER
Supervisory Staff:
Project Engineer – 1 No
Assistant Engineer - 2 Nos
Senior Engineer - 1 No
Foreman - 1 No.
OTHER STAFF:
i) Q.C.Engineer - 1 No
ii) Supervisor (Civil) - 1 No
iii) Foreman (Mech) - 1 No
iv) Electrical Foreman - 1 No
Page 4 of 109
v) Electrician - 2 Nos
vi) Mechanic - 4 Nos
vii) Mechanical Helper- 2 Nos
viii) Store keeper - 2 Nos
ix) Purchase Officer - 1 No
x) Store Helper - 3 Nos
CUTTING EDGE:
It is circular in shape and it is the bottommost component of the foundation
made up of structural steel plates. It is provided for cutting the soil strata
coming below the well during sinking operation. It also accelerates the
process of sinking.
MATERIAL PROCUREMENT:
Materials required for the fabrication of cutting edge shall be procured from an
authorized supplier and the same shall be received at the site fabrication yard.
RECORDS/DOCUMENTS:
Test Certificates of Structural Steel procured shall be submitted for each
consignment received at site.
The received material shall be fabricated as follows:
The smoothened plate shall be bent using 50t hydraulic jack for the required
curvature.
Similarly, ISA 150X150X10 shall be cut and bent with Zig hudraulic jack to the
required curvature.
A lay out shall be made on fabrication sheet floor for welding the plates with
angles. Fillet welding shall be done using Esab Ferroking Electrodes of size
4x450mm (6013 ) conforming to IS 814.
After completion of first run, welding surface shall be chipped off by chipping
hammer and followed by second coat of welding to get the specified thickness
( 8mm/6mm)
8mm thick stiffeners plates shall be welded with a spacing of 700mm c/c in
position to the cutting edge with the specified shape as per drawing.
The whole cutting edge can be split in to 5 segments and all the segments
shall be assembled over a platform to check the diameter of cutting edge.
Holes of 17.5mm dia shall be made on the angle at a spacing of
300mm c/c with magnetic drill
Cross bracing made of ISMC channel shall be put in position on each
segment to prevent bent/ovality.
Joint number shall be assigned and all the segments shall be taken to site for
in situ welding.
RECORDS/DOCUMENTS:
Progress Card for structural fabrication
Checklist for structural fabrication
SAFETY MEASURES:
Welder shall be provided goggles for eye protection and protective clothings.
It shall be ensured arc welding cables are completely insulated, flexible and
capable of handling the maximum current requirements of the work in
progress and free of exposed cuts.
ISLAND:
Making an artificial Island to provide a dry surface for placing the cutting edge
therein and carrying out further operation as per sinking on ground. This
method can be adopted in water where depth varies from 2 to 6m depth which
is stagnant or flowing water.
ERECTION OF CUTTING EDGE:
The fabricated parts shall be taken to the location and segments of cutting
edge shall be erected over leveled and firm ground and wherever situation
arises over Island. The segments of cutting edge shall be laid at the existing
ground level or 300mm above prevailing water level in case of an Island over
wooden sleepers placed below the cutting edge at spacing of 500mm c/c .
Prefabricated segments of cutting edge shall be laid over wooden sleepers
and after keeping it in true level and alignment, the in-situ welding shall be
done as per MOST specification with Esab Ferroking rods size 4x450mm
(6013). The segments shall be spliced by fillet welding of a single cover plate
of size 400 x 280x12 mm at the junctions (in the outside periphery) of 300mm
width MS Plate. The angle sections shall be spliced by fillet welding at the
junctions of segments (in the inside periphery) with a rectangular plate of size
Page 6 of 109
SHUTTERING MATERIAL:
For 9m Curb Inside shuttering shall be of timber and the outside shuttering
shall be of steel shuttering plates.
For 8m Curb both Inside and outside shuttering shall be of steel shuttering
plates.
After completion of fixing of reinforcement and shuttering work, the curb shall
be inspected and checked as per drawing, specification and checklist formats
as mentioned below. For inspecting and movement of supervising staff, a
detachable inspection deck with guardrails shall be provided at the top of the
well curb/ Steining level. After completion of casting, the whole unit
comprising several segments shall be detached for reuse in the next lift of
casting.
DOCUMENTS/RECORDS
Checklist for reinforcement
Steel Register
Checklist of Staging and Formwork
CONCRETING OF CURB:
MIX DESIGN:
The grade of Concrete M-35 using 20mm aggregate shall be produced as per
the method statement submitted earlier.
TESTING OF MATERIALS:
The suitability of ingredient materials of concrete shall be tested at the Quality
control laboratory and shall be approved by Engineer as per specification.
PRODUCTION OF CONCRETE:
The concrete shall be produced by computerized SMM-40 batching plant
having capacity of 30 cum. per hour at Subarnarekha Bridge Site.
The established Batching plant shall be calibrated and got checked by
Engineer well before commencement of production of concrete.
QUALITY CHECKS:
SLUMP TEST:
Slump shall be taken continuously for first 3 loads and thereafter slump shall
be taken periodically as directed by engineer at site. The same shall be
recorded in slump and temperature register.
CUBE TEST:
REMOVAL OF SHUTTERING:
Outside shuttering plates shall be removed after 24 hours and inner shuttering
plates shall be removed after 72 hours.
CURING:
SAFETY MEASURES:
Page 9 of 109
3. WELL STEINING
WELL STEINING:
It is uniformly circular in shape and it completely rests over well curb.
STEINING OF ABUTMENT:
No. of Abutments : 2 Nos.
Outside Diameter of well : 9.0 M
Inside Diameter of well : 6.5 M
Steining Thickness : 1.250 M
STEINING OF PIER:
No. of Piers : 12 Nos.
Outside Diameter of well : 8.0 M
Inside Diameter of well : 5.4 M
Steining Thickness : 1.30 M
MANPOWER:
Supervisory staff:
Project Engineer - 1 No.
Assistant Engineer - 1 No.
Sr.Foreman - 2 Nos.
Other Staff:
SKILLED/UNSKILLED LABORS:
Page 11 of 109
MATERIAL PROCUREMENT:
Reinforcement bars of required diameter as specified in the drawing shall
be procured from authorized agency (SAIL/TISCO/RINL or other authorized
agency) Conforming to IS:1786.
DOCUMENTS/RECORDS:
Checklist for inspection of materials (Cement/Structural Steel/ Reinforcement
Steel)
Treated reinforcement bars shall be cut and bent as per approved Bar
Bending Schedule .Outside threaded vertical bars shall be bolted and fixed
with the cutting edge at the time of laying of cutting edge. Thereafter other
reinforcement bars shall be fixed for the 1st lift of steining as per the drawing
with GI binding wires.
DOCUMENTS/RECORDS:
i) Checklist for reinforcement
DOCUMENTS/RECORDS:
Checklist for staging and Formwork
CONCRETING:
After completion of well curb concreting and thereafter deshuttering Inner and
Outer surfaces, gauge marking is to be done on the outer surface, taking
bottom of the cutting edge as 0.0 M. This marking shall be continued till top
level of concreting and further be done after deshuttering of each steining lift.
DOCUMENTS/RECORDS:
Page 12 of 109
i) concrete Register
MIX DESIGN:
The grade of Concrete M-35 using 40mm aggregate shall be produced as per
the method statement submitted earlier.
TESTING OF MATERIALS:
The suitability of ingredient materials of concrete shall be tested at the Quality
control laboratory and shall be approved by Engineer as per specification.
PRODUCTION OF CONCRETE:
The concrete shall be produced by computerized SMM-40 batching plant
having capacity of 30 Cu.M. per hour at Subarnareka Bridge Site.
The established Batching plant shall be calibrated once in a fortnight and got
checked along with Engineer.
QUALITY CHECKS:
Slump Test:
Slump shall be taken continuously for first 3 loads and thereafter slump shall
be taken for every one hour. The same shall be recorded in slump and
temperature register.
Cube Test:
Cubes of size 150x150x150mm shall be taken. Number of cubes shall be
taken as per Table No.1700 in most specification.
The same shall be tested at the Q.C.lab for 7 day’s strength and 28 day’s
strength and it will be entered in the cube test register.
REMOVAL OF SHUTTERING:
Outside shuttering plates shall be removed after 12 hours and inner shuttering
plates shall be removed after 24 hours.
CURING:
Page 13 of 109
4. WELL SINKING:
METHODOLOGY:
Page 14 of 109
After gauge marking done on the outer surface, the removal of wooden
sleepers underneath the cutting edge shall be started. Initially alternate
sleepers are removed one after one. Then sleepers are removed opposite to
each other in order to prevent tilt/shift.
Likewise all the sleepers shall be removed without disturbing the positioned
cutting edge.
Inner portion of the well curb shall be manually excavated till the possible
depth (approximately 2 M), there after excavation shall be started
mechanically with ¾ Cu.Yd.Grab using Crane or Winch.
Sinking Operation shall be continued till the well is approximately 0.5 M to 1.0
M above bed level. After completion of I stage sinking tilt/shift to be measured
& recorded.
Likewise other steining lifts shall be concreted and sunken
In order to facilitate the well cap construction, steining final lift shall be
modified as follows:-
1) for bottom non-recoverable well cap shuttering.
Grooves shall be provided in the final lift steining wall to enable RCC beams to
lock into the steining wall. Size of grooves and number of grooves shall be
fabricated as mentioned in Drawings. After placing pockets, Steining final lift
shall be concreted with Crane Bucket arrangement. In order to have proper
construction joint with well cap, timber key blocks shall be left over the surface
of concreting.
DOCUMENTS/RECORDS:
Tilt/Shift report
Page 15 of 109
FURTHER SINKING:
During Final Stage of sinking of wells, grabbing operation shall be done slowly
to prevent excess sinking. A sump shall be made to a maximum of 1/6th Dia
of well below the cutting edge. Finally, the founding level and sump shall be
checked jointly with clients and permission for bottom plugging shall be
obtained in writing.
Page 16 of 109
ABUTMENT WELLS:
Concrete Quantity in Bottom plugging for a well : 130 M3
Sand filling Quantity for a well : 322 M3
Concrete Quantity in Intermediate
Plugging for a well : 16.6 M3
Concrete Quantity in Well cap for a well : 83 M3
PIER WELLS:
Concrete Quantity in Bottom plugging for a well : 105 M3
Sand filling Quantity for a well : 166 M3
Concrete Quantity in Intermediate
Plugging for a well : 11.5 M3
Concrete Quantity in Well cap for a well : 60 M3
Reference Drawing No : NH-60/B-3/B-38/1-01-17
DOCUMENTS:
Checklist for reinforcement
Steel Register
Q.C.Engineer - 1 No
Other Staff:
Supervisor (Civil) - 1 No
Supervisor (Mech) - 1 No
Foreman (Mech) - 1 No
Electrical Foreman - 1 No
Electrician - 2 Nos
Mechanic - 2 Nos
Mechanical Helpers - 4 Nos
Skilled/Unskilled Labors:
Crane Operator - 2 Nos
Masons - 4 Nos
Khalasis - 10 Nos.
Labors -15 Nos.
CONSTRUCTION METHODOLOGY:
BOTTOM PLUG CONCRETING:
Salient Features:
Concrete Quantity for Abutment: 130 M3
Concrete Quantity for Pier : 105 M3
Concrete Method: Under water Tremie pipe concreting.
Major Equipment: 2 set Tremie pipes, Crane and Bucket.
Concrete Grade : M25
Required Slump : 150mm – 200mm
Minimum Cement Content: 363 Kg/M3
Rate of concreting : 10 M3/hr.
After the sump is jointly measured, Erection of precast RCC beams shall be
started. First the center beam is erected exactly in the pockets of steining.
Then two side beams on either side of the center beams shall be erected.
Beam dimensions and reinforcement details are clearly mentioned in the
drawing (Drawing No.:8007/TS/102/A for pier and Drawing No.: 8007/TS/103
for abutment). Then platform shall be made with channels and planks on the
beams. Tremie pipes shall be used for bottom plugging concreting.
POURING SEQUENCE:
First two tremie pipes shall be placed diagonally in the position A & A1. Then it
shall be shifted again diagonally in the position B & B1. Then one pipe shall
be placed at the center of wall. Two Tremie pipes shall be erected in position
Page 18 of 109
SAND FILLING:
After 3 days of bottom plug, sand filling shall be started manually/ by crane.
Cleaned Fine Sand shall be filled to the required level as shown in the
drawings in the presence of water. This sand layer forms a supporting layer
for immediate plugging.
WATER FILLING
Potable river water shall be filled up to top level of steining.
Page 19 of 109
6. WELL CAP:
Salient Features:
Well cap depth for Abutment well : 1.3 M
Well cap depth for Pier well : 1.2 M
Concrete Quantity in Abutment well cap : 83 M3
Concrete Quantity in Pier cap : 60 M3
Concrete Method : Concrete Pump / Crane
Bucket
Major Equipment : 1. Concrete Pump
Crane 2. Tata 320/ RB 38
Concrete Grade : M25
Rate of concreting : 10 M3/hr.
After water filling, precast RCC slabs shall be placed over the beams as per
the enclosed drawings (Drawing No: 8007/TS/102/A for pier well cap and
Drawing No.:8007/TS/103 for abutment well cap), as non-recoverable bottom
shuttering for well cap. Initially built false wall shall forms the outer shuttering
for well cap casting.
For well steining and well cap permissible tolerances shall be as follows:-
Variation in dimension : +50 mm to –10mm
Misplacement from specified
Position in Plan : 15mm
Variation of levels at the top : +/- 25mm
Placing of concrete shall be done by concrete pump/by crane with concrete
bucket. Mix design for Pumpable mix shall be done at the Q.C.Lab and were
approved from Engineer. Wherever the GL is above (+) 9.0 M, excavation
& backfilling shall be done on surroundings of well surface for maintaining
slopes out side of well cap.
Concrete of M25 with Maximum Size of 40mm aggregate shall be produced
by SMM-40 Shirke, Batching plant of capacity 30 Cu.M. Per hour installed at
Subarnarekha bridge site. The concrete shall be carried by 2 Nos of transit
mixers from batching plant to the pouring point location (BR-38/1). Slump shall
be maintained between 50-70mm throughout the concreting. Before placing
of concrete, Concrete pour card shall be submitted. From Transit Mixer the
concrete shall be poured either with Concrete Pump or with Crane Bucket.
The concrete shall be compacted thoroughly by immersion type vibrator and it
shall be ensured that no honeycombing should be produced. On the top
surface of well cap at the contact area of Pier wall & Abutment wall shall be
roughened and key blocks shall be left over the surface after concreting to
avoid construction joints.
CURING OF CONCRETE:
Bore well water shall be used for curing.
Necessary pipeline arrangement shall be provided for carrying water for curing
the structures. Water Ponding shall be done over the surface of well cap for
continuous curing. In addition, Hessian cloth shall be tied all over the
Page 20 of 109
periphery of the walls for continuous curing. Curing shall be continued for 14
days.
SAFETY MEASURES:
Technical personnel and workers are engaged during concreting operation
both at batching plant and Site shall be equipped with helmets, and safety
shoes shall be provided to masons and khalasis engaged for vibrator
operations. There shall be safety signs painted on boards displayed and
barricading / fencing shall be done. There shall be security guards posted at
suitable locations. For night -concreting, sufficient flood lighting shall be
provided with red light danger signs at vantage locations. First Aid Counter
shall be maintained separately in stores throughout the working hours.
Page 21 of 109
CEMENT:
Source: 43 Grade GRASIM / AMBUJA / CENTURY.
Material shall be tested at the manufacturing source and Test certificate shall
be collected for each lot. In every batch the following test shall be conducted
at Q.C.Lab (Subarnareka site) to ensure Test certificate results are matching
Q.C.Lab result.
Consistency
Initial Setting Time
Final Setting time
Fineness of Cement
Compressive strength
Soundness test.
Acceptance Criteria: Test results shall conform to IS 8112.
REINFORCEMENT STEEL:
Source: TISCO / SAIL / RINL / SRMB.
Chemical and Mechanical properties shall be tested as per IS 1786 at the
manufacturing source & test certificates shall be collected along with the every
consignment of steel. Also steel samples shall be tested randomly in outside
laboratories to check whether the test certificate results match the laboratory
test result.
Acceptance Criteria: Test result shall conform to IS 1786.
COARSE AGGREGATE:
Source: Tarini crusher / Durga crusher
Material 40mm / 20mm / 10mm shall be received beside batching plant at
Subarnareka site. Sample shall be collected for every 200 M3 of aggregate or
any change of source, the following test shall be conducted in Q.C.Lab as per
IS 2386
Gradation of single size aggregate
Page 22 of 109
FINE AGGREGATE:
Source: Gobar ghata
Material shall be received and screened at the stacking yard at Subarnareka
site. Sample shall be collected for every 200 M3 of aggregate or any change
of source, the following test shall be conducted in Q.C.Lab
Gradation
Silt content shall be estimated as per IS 2386 & ensured less than 3%.
ADMIXTURE:
Source: Fosroc
Admixtures expedient for different mix grades shall be procured from
approved agencies. Test certificates shall also be collected along with the
every consignment. The following tests are conducted in Q.C.Lab to verify
with Test certificate result.
Relative density as per IS 6925
Chloride content – Test result shall conform to IS 9163.
SHUTTERING SCHEME:
Shuttering material shall be fabricated with 3.15mm thick plate & angles. For
each lift one set shall be fabricated.
Shuttering plate shall be fabricated as per column dimensions for I lift, II lift &
III lift separately.
Page 23 of 109
METHOD OF CONSTRUCTION:
First Centre point of Column shall be marked with Total Station
Instrument. Then Column layout shall be made with line dory
drenched in red oxide paint.
Staging shall be done on either side 3m away from the center line of
well cap. Vertical & Horizontal bracings of 1.2m spacing shall be done
with staging pipes on either side from the center line of well cap.
Since each lift of minimal concrete quantity, funnel like chute shall be
fed by wheel barrow / Crane bucket with a workability of 60mm slump.
For II lift concreting, shuttering plates shall be placed over the top
channel of I lift concreting & a top channel ISMC 125 placed over the
shuttering plates which will form the bottom channel for III lift
concreting.
Staging pipes shall be clamped with the trestle & rivel pin support shall
be given similar to I lift concreting.
SHUTTERING SCHEME:
Shuttering material shall be fabricated with 3.15mm thick plate, angles & MS
Flat.
For I lift : C set (mentioned in Annexure-2 )1.0 x 2.953 m
= 6 Nos x 2 (sides) = 12 Nos.
A set (mentioned in Annexure-2 ) = 4 Nos
For II lift : C set 1.0 x 2.953m = 8 Nos. x 2 (sides ) = 16 Nos.
B set (mentioned in Annexure-2 ) = 4 Nos.
METHOD OF CONSTRUCTION:
First Center point of Column shall be marked with Total Station
Instrument. Then Pier layout shall be made with line dory drenched in
red oxide paint.
First ISMC 125 shall be placed on the layout area by sleeve nut
arrangement.
Then shuttering plates shall be placed over the channel.
Staging shall be done, from which shuttering plates shall be supported
rivel pin support.
For additional support through bolt shall be connected in 2 layers of 1.0
m c/c.
Over the shuttering plates, a top channel of ISMC 125 shall be placed
which will acts as a bottom channel for II lift concreting.
In round portion on either sides, channel shall be placed and shuttering
plates fabricated for dia of 600mm shall be placed.
Concrete shall be done using Crane bucket.
After I lift concreting, the shuttering plates shall be placed over the tope
channel of I lift concreting and the supporting shall be rivel pin support
from sides and through bolt connection of 2 layers 1 m c/c.
Pier III lift of 0.3 m height and Pier cap concreting shall be done in a
single pour.
CURING OF CONCRETE:
Bore well water shall be used for curing. Necessary pipeline arrangement
shall be provided for carrying water for curing the structures. In addition,
Hessian cloth shall be tied all over the periphery of the walls for continuous
curing. Curing shall be continued for 14 days.
Page 25 of 109
SAFETY MEASURES:
Technical personnel and workmen are engaged during concreting operation
both at batching plant and Site shall be equipped with helmets, and safety
shoes shall be provided to masons and khalasis engaged for vibrator
operations. There shall be safety signs painted on boards displayed and
barricading / fencing shall be done. There shall be security guards posted at
suitable locations. For night concreting, sufficient flood lighting shall be
provided with red light danger signs at vantage locations. First Aid Counter
shall be maintained separately in stores throughout the working hours.
MAN POWER:
Supervisory staff:
Project Engineer - 1 No
Assistant Engineer - 1 No
Junior Engineer - 2 Nos
Sr.Foreman - 2 Nos
Q.C.Engineer - 1 No
Page 26 of 109
Other Staff:
Supervisor (Civil) - 1 No
Supervisor (Mech) - 1 No
Foreman ( Mech) - 1 No
Electrical Foreman - 1 No
Electrician - 2 Nos
Mechanic - 2 Nos
Mechanical Helpers - 4 Nos
Skilled/Unskilled Labors:
Crane Operator - 2 Nos
Masons - 4 Nos
Khalasis - 10 Nos
Labors -15 Nos
ABUTMENT CAP
Concrete quantity for Abutment cap ( 0.65 m height) : 10.12 M3
Concrete quantity for dirt wall : 7.24 M3
III lift abutment column concreting, abutment cap & dirt wall shall be
cast in a single pour.
Trestles shall be fabricated upto a height of 5.175 m. Then trestle cap
shall be placed with ISMC 125. Also 2 ISMB 400 cross girders shall be
placed over the trestle cap as shown in figure. This cross girder shall
extended 3m beyond trestles T1, T4, T5 & T8.
Then 8 Nos. of ISMB 300 (Longitudinal girders ) shall be placed at
proper spacing from which enable bottom shuttering for dirt wall and
also supports shall be given for cantilever portion of abutment cap &
dirt wall portion.
Supporting arrangement between abutment columns for dirt wall
bottom shuttering is shown in figure.
Concreting shall be done with concrete bucket.
SHUTTERING SCHEME:
Shuttering scheme will be according to drawing.
Shuttering material shall be fabricated with 3.15mm thick plate, angles, MS
Flat & ISMC25
No. of sets to be used : 1 set
Page 27 of 109
ABUTMENT COLUMN
TRESTLE TYPE
T8 T1
A A
T7 T2
T6 T3
T5 T4
FIG: PLAN
TRESTLE SUPPORTING ARRANGEMENT FOR ABUTMENT CAP, ABUTMENT IIIrd LIFT &
DIRT WALL CONCRETING
Page 28 of 109
O
O
O IIIRD LIFT
I I I I
IIND LIFT
IST LIFT
METHOD OF CONSTRUCTION:
After completion of 1st and 2nd lift, column shuttering arrangements for 3rd lift
and Abutment cap is to be made as shown in above fig I.
During casting of 2nd lift of the Pier, sleeve bolts of diameter 125mm are to be
embedded in casting for fixing of bracket, to cast pier cap
3rd lift of Abutment column concreting and abutment cap shall be cast in a
single pour.
Trestles shall be fabricated upto a height of 5.175 m. Then trestle cap shall be
placed with ISMC 125. Also 2 ISMB 400 cross girders shall be placed over
the trestle cap as shown in fig-1. This cross girder shall extend 3m beyond
trestles T1, T4, T5 & T8.
Then 8 Nos. of ISMB 300 (Longitudinal girders ) shall be placed at proper
spacing from which enable bottom shuttering for dirt wall and also supports
shall be given for cantilever portion of abutment cap & dirt wall portion.
Supporting arrangement between abutment columns for dirt wall bottom
shuttering is shown in fig-1.
Separate steel shuttering sets shall be fabricated as per drawing to cast
bearing pedestal monolithically with pier cap in a continuous operation.
Casting of pedestal (M-35) to be done by using concrete bucket.
Proper care should be taken for finishing top surfaces maintaining proper line
and level
Concreting shall be done with crane concrete bucket/ concrete pump taking
due care of slump and compaction.
Drainage slopes 1:100 towards edge to be provided towards Jaleshwar side
of Abutment cap to prevent stagnation of water.
The surface of cap shall be finished smooth and shall have a slope of 1:100
for draining of water.
SHUTTERING SCHEME:
BEARING PEDESTAL
TIE ANGLE
SIDE
SHUTTERING
3600
ISMC125 X 65
BRACKETS ISMC125 X 65
@ 1m C/c
20mm DIA
SLEEVE
BOLT, 1.0m
C/C 2000
METHOD OF CONSTRUCTION:
During casting of IInd lift of the pier, slip bolts of diameter 125mm to be
embedded in casting for fixing of bracket, to cast pier cap.
Pier III lift of 0.3 m height and Pier cap concreting shall be done in a single
pour.
Bearing Pedestals (M35) shall be monolithically cast with pier cap (M25) in a
continuous operation.
drainage slopes 1:100 towards edge to be provided on both sides of pier cap
to prevent stagnation of water
The surface of cap shall be finished smooth and shall have a slope of 1:100
for draining of water.
Casting of pedestal (M-35) to be done by using concrete bucket.
Proper care should be taken for finishing top surfaces maintaining proper line
and level
Concreting shall be done with crane concrete bucket/ concrete pump.
Drainage slopes 1:100 towards edge to be provided towards Jaleshwar side
of pier cap to prevent stagnation of water.
The surface of cap shall be finished smooth and shall have a slope of 1:100
for draining of water.
CURING OF CONCRETE:
Bore well water shall be used for curing.
Necessary pipeline arrangement shall be provided for carrying water for curing
the structures. Also Hessian cloth shall be tied all over the periphery of the
walls for continuous curing. Curing shall be continued for 14 days.
SAFETY MEASURES:
Technical personnel and work men are engaged during concreting operation
both at batching plant and Site shall be equipped with helmets, and safety
shoes shall be provided to masons and khalasis engaged for vibrator
operations. There shall be safety signs painted on boards displayed and also
barricading / fencing shall be done. There shall be security guards posted at
Page 32 of 109
MAN POWER:
SUPERVISORY STAFF:
Project Engineer 1 No.
Assistant Engineer 1 No
Junior Engineer 2 Nos.
Foreman 2 Nos.
Q.C.Engineer 1 No.
OTHER STAFF:
Supervisor (Civil) 1 No.
Supervisor (Mech) 1 No.
Foreman ( Mech) 1 No.
Electrical Foreman 1 No.
Electrician 2 Nos.
Mechanic 2 Nos
Mechanical Helpers 4 Nos.
SKILLED/UNSKILLED LABORS:
Crane Operator 2 Nos.
Masons 4 Nos.
Khalasis 10 Nos.
Labors 15 Nos.
Page 33 of 109
Cement:
Source: 53 Grade L&T / Grasim / Ambuja / Century.
Material shall be tested at the manufacturing source and Test certificate shall
be collected for each lot. In every batch the following test shall be conducted
at Q.C. Lab (Subarnarekha site) to ensure Test certificate results are matching
Q.C.Lab results.
o Consistency
o Initial Setting Time
o Final Setting Time
o Fineness Of Cement
o Compressive Strength
o Soundness Test.
Reinforcement Steel:
Source: TISCO / SAIL / RINL / SRMB/ IISCO
Chemical and Mechanical properties shall be tested as per IS 1786 at the
manufacturing source & test certificates shall be collected along with the every
consignment of steel. Also steel samples shall be tested randomly in outside
laboratories to check whether the test certificate results match the laboratory
test result.
Acceptance Criteria: Test result shall conform to IS 1786.
Coarse Aggregate:
Source: Tarini crusher / Durga crusher/ ECI crusher
Material 40mm / 20mm / 10mm shall be received at Subarnarekha site.
Samples shall be collected for every 200 m3 of aggregate or for any change
of source, the following test shall be conducted in Q.C.Lab as per IS 2386
Page 34 of 109
Fine Aggregate:
Source: Gobar ghata
Material shall be received and screened at the stacking yard at Subarnarekha
site. Sample shall be collected for every 200 M3 of aggregate or any change
of source, the following test shall be conducted in Q.C.Lab
Gradation
Silt content shall be estimated as per IS 2386 & ensured less than 3%.
Admixture:
Source: Fosroc
Admixtures expedient for different mix grades shall be procured from
approved agencies. Test certificates shall also be collected along with the
every consignment. The following tests are conducted in Q.C.Lab to verify
with Test certificate result.
Relative density as per IS 6925
Chloride content – Test result shall conform to IS 9163.
HT Strands:
Source: M/s Indore Wire & Tata SSL
12.7mm dia low relaxation 7 ply strands of class II conforming to IS 14268
1995+ 2.
Random inspection of the materials shall be done by consultant’s engineer at
factory.
Pre-stressing Hardware
Source: M/s Freyssinet Pre-Stressing Concrete Company Ltd., Mumbai 12
T 13-anchorage cone & cir clip.
FPCC will supply 12 T 13 anchorage cones, which will be as per
specifications and drawings.
Page 35 of 109
Construction Methodology:
A: Preparation Of Casting Yard:-
After completion of embankment filling up to required filling further filling will be
continued to reach up to desired casting yard level
Pre-Casting yard shall be constructed behind abutment A1 at Balasore side. Casting
Bed, Stacking Bed and shifting track shall be constructed as per enclosed drawing
8007 / TS / 201A & 203 & sketch.
Carpenter 35
Fitter 35
Khalasis 50
Helper 10
Male Coolie 15
Method of Concreting:
Form Work:
Formwork for the beam is being fabricated at site as per enclosed
drawing 8007/T3/211.
It is fabricated in 12 panels for one beam of 2 sides, for the
alignment of formwork adjustable struts & through bolt shall be
used.
Rigid working platform shall be made at beam top level with
scaffolding Pipes, clamps and 1 ½ “planks shall be used
Shuttering handling gantry shall be erected & shall be put in
operation for shifting, handling and dismantling operations and for
shifting of one side beam from one bed to other whenever
required.
STEP 1:
After completion of casting bed and pedestals, fabricated beam bottom shall
be erected and fixed as per our drawings. Uniform level of beam bottom shall
be made.
STEP 2:
One side-shuttering panel shall be erected and placed over beam bottom as
per drawings and true plumb of side shuttering to be made to start marking of
cable profile.
STEP 4: Reinforcement
Treated bar shall be fabricated in advance as per bar bending schedules.
Fabricated reinforcement shall be shifted by trailer/manually to casting yard
Fabricating of reinforcement cage:
In order to maintain quality, reinforcement cage shall be fabricated in advance
outside the bed and Pre-fabricated cage shall be rolled over bed as soon as
bed is ready to receive reinforcement cage for next beam.
Initially for one/two beams reinforcement will be tied over bed itself.
Page 37 of 109
Cable No.11
500
Cable No.10
300
Cable No.9
300
Cable No.8
300
Cable No.E
300
Cable No.7
300
Cable No.6
300
Cable No.5
300
3550 mm
Cable No.3,4
300
Cable No.1,2
aC
175
C
ba
175
175
Cable No. 6,E,7
la
b
175
b
Cel
115
830 mm
le
FIG: SECTION AT THE CENTRE OF PSC BEAMS
115 150 150 150 150 115
1.
18
9
Method of Stressing
o During curing of PSC beam, arrangements for pre-stressing shall
be started
o Keep all strand ends at particular point approx 450mm from the
anchorage cone.
o Fix the cir clip in each hole of bearing plates by means of a pipe.
o Erect the pre-stressing jacks and place the jacks first in cable-1 of
both end and then fix the barrel and grip in pre-stressing jacks.
Page 42 of 109
Slump Test:
Slump shall be taken continuously for first 3 loads and thereafter slump shall
be taken periodically as per the direction of Engineer. The same shall be
recorded in Concrete Pouring Report.
Cube Test:
Cubes of size 150x150x150mm shall be taken. Number of cubes shall
be taken as per Table No.1700 in most specification.
The same shall be tested at the Q.C.lab for 7 day’s strength and 28
day’s strength and it will be entered in the cube test register.
RECORDS:
Documents/Records
o Format for checklist for reinforcement
o Format for checklist of Staging and Formwork
o concrete pour card
o concrete pouring formats
o Record of Pre-stressing operation along with elongations and jack
pressure data shall be maintained as per format 1800/ii of MOST.
SAFETY MEASURES:
Technical personnel and workers are engaged during concreting operation
both at batching plant and Site shall be equipped with helmets, and safety
shoes shall be provided to masons and khalasis engaged for vibrator
operations. There shall be safety signs painted on boards displayed and
barricading / fencing shall be done. There shall be security guards posted at
suitable locations. For night concreting, sufficient flood-lighting shall be
Page 43 of 109
provided with red light danger signs at vantage locations. First Aid Counter
shall be maintained separately in stores throughout the working hours.
Materials:
Water: clean, potable water free from impurities will be used.
Cement: OPC as mentioned above
Sand: sand conforming to IS:383 will be used
Admixture: admixture if required conforming to IS:9102 will be used.
Equipment:
Grout Mixer & Agitator: the grout shall be maintained in a homogeneous state
with uniform consistency to avoid any separation of cement.
Grout Pump: Positive displacement type grout pumps capable of ejecting
grout in a continuous operation shall be used.
Grout Screen: grout should be passed through this screen, having a mesh
size of 106microns prior to introduction in to the grout pump.
Connections & Air Vents: all the connections shall be of the “Quick Couple”
type and at change of diameters suitable reducers will be provided.
Page 44 of 109
Mixing of Grout:
Proportions of the required materials will be measured by weight before
starting of mixing operation.
Water shall be added to the mixer followed by cement, sand & admixture/
readymade grout mixture.
Mixing shall be done for approximately 2 to 3 minutes until uniform and
thoroughly blended grout is achieved.
Adequate care shall be taken to prevent any addition of water to mixed grout
to increase fluidity.
Cubes of 100mm shall be taken for verification of Compressive Strength
Grouting Operations:
Grouting shall be carried out within 2 weeks of stressing of cables.
Ducts shall be flushed with water for cleaning as well as for wetting the
surfaces of the duct walls. Water used for flushing should be of same quality
as used for grouting.
After cleaning all water shall be drained thoroughly by vent pipe or by blowing
compressed air through duct.
During and after 3 to 4 hours of grouting other non stressed cables shall be
checked manually for free movements.
All outlet points including vent openings should be kept open before to
commencement of grouting.
Injection of Grout
After mixing grout should be kept in continuous movement and injection of
grout must be continuous without any interruptions.
Grouting shall be commenced initially with a low pressure of injection of up to
0.3MPa increasing it until the grout come out through the other end with same
consistency as that of the grout @ injection end.
Full injection pressure (approx 0.5MPa) shall be maintained for a minimum of
1 minute before closing the injection pipe.
RECORDS
Grouting records shall be maintained as per format conforming to MOST,
Appendix 1800/IV
Objective:
GIL has proposed to install steam-curing plant to obtain accelerated strength in high
performance concrete in PSC Girder for Subarnarekha Bridge Casting Yard.
The main purpose of proving steam curing is to reduce cycle time of casting of PSC
beam.
Page 45 of 109
1. After placement and compaction, concrete shall be allowed to attain initial set
prior to steam application. Initial set requires 4 hours normally and 6 hours if
retarders are used.
2. Initially boiler, softener plant, Water Line Chimney shall be installed as per
sketch enclosed and thereafter MS pipes shall be laid to transport steam from
boiler. Proper care to be taken to reduce loss of temperature by providing
asbestos rope over MS pipe and proper flange joint. After casting of girder, it
shall be covered by tarpaulin. The sides to be packed properly by sand bags
to reduce loss of steam. The steam shall be at 100% relative humidity.
3. Ambient temperature around the concrete shall be increased gradually at a
rate not exceeding 50C/hr to reach a maximum temperature of 60-700C
(which corresponds to a pressure of 1 Mpa).
Page 46 of 109
Typical time vs. temperature curve is given for reference for adopting steam
curing
TIME VS. TEMPERATURE
DELAY CURVE
HEATING PERIOD STEADY STATE MAXIMUM
COOLING PERIOD
PERIOD TEMPERATURE PERIOD
70
60
50
TEMPERATURE IN 0C
40
AIR TEMP +
30 10OC
20
10
DATA RECORDS:
SAFETY MEASURES:
Technical personnel and workmen who are engaged during curing operations should
be equipped with helmets. Safety shoes shall be provided to all the workers engaged
in steam curing operations.
There shall be safety signs painted on boards displayed and also barricading /
fencing shall be done. There shall be security guards posted at suitable locations.
First Aid Counter shall be maintained separately in stores throughout the working.
Also no outside visitors shall be permitted inside the steam curing and boiler
premises.
Page 48 of 109
MANPOWER:
Project engineer 01 no.
Assistant engineer 01 no.
Junior engineer 01 no.
Foreman 01 no.
Supervisor 02 nos.
Helper 05 nos.
MATERIALS:
STRUCTURAL STEEL:
Source: TISCO / SAIL / RINL / SRMB/ IISCO
Structural steel shall be used for fabrication of launching truss, A1P1
supporting arrangement and other ancillary structure. Chemical and
Mechanical properties shall be tested as per IS 1786 at the manufacturing
source & test certificates shall be collected along with the every consignment
of steel. Also steel samples shall be tested randomly in outside laboratories to
check whether the test certificate results match the laboratory test result to
carry out fabrication of launching truss A1P1 supporting arrangement and
other ancillary structures.
Acceptance Criteria: Test result shall conform to IS Specifications.
Initially the truss shall be tested for the auto launching condition. Bolts
connecting the front leg with the pier were removed and the front leg was lifted
up by attaching the beam at the rear end of the truss. Deflections were
recorded at various points (such as L/2, L/4, L/3). The truss was kept under
this condition for about 4 hours and deflections were recorded again after
unloading. All the members were carefully observed for any distress.
The launching truss has been designed for a maximum beam load of 225T
and a span of 50m.
Erection of PSC Girders shall be done as per the following sequence:
Page 52 of 109
BALASOR Pier
E SIDE
1 2 3 4 PSC
Girders
U/ D/S No. 1, 2,
S 3&4
KHARAGP Pier
UR SIDE
Rails
PLAN
Tracks shall be laid on PSC Girder Nos. 1 & 3 (as shown in fig. Above)
The launched girder is always unloaded at no.2 location
1st girder unloaded at no.2 location & side shifted to no.4 position on D/S end
2nd girder unloaded at no.2 location & side shifted to no.1 position on U/S end
3rd girder unloaded at no.2 location & side shifted to no.3 position on D/S end
4th girder unloaded at no.2 location and then paced on bearing at no.2
location
Page 53 of 109
DIRECTION OF LAUNCHING
KHARAGPUR SIDE
STAGING
ARRANGEMENT
S FOR
TROLLEY T1 ERECTING
PSC BEAM 47.3m TRESTLES @
3m INTERVAL
A1
Page 54 of 109
TROLLEY T4
TROLLEY T2
Trolley T3 shall be moved over launching truss until it comes over trolley T1.
Connect suspenders to Trolley T3 and PSC beam is offloaded from Trolley T1 and
the beam is resting on T2 & T3.
DIRECTION OF LAUNCHING
KHARAGPUR SIDE
Page 55 of 109
TROLLEY T1
ABUTMENT A1
Page 56 of 109
TROLLEY T3
TROLLEY T4
TROLLEY T2
TROLLEY T5
PIER P2
PSC Beam shall be moved forward and trolley T2 comes near the trolley support
T5.
Trolley T4 shall be brought over Trolley T2.
Connect suspenders to trolley T4, operate jacks over T4 so that the PSC beam is
off loaded from Trolley T2, so now beam is resting on Trolleys T3 & T4.
DIRECTION OF LAUNCHING
KHARAGPUR SIDE
Page 57 of 109
TROLLEY T1
Page 58 of 109
TROLLEY T3
TROLLEY T4
ABUTMENT A1
LAUNCHING TRUSS
TROLLEY T2
PIER P2
FRONT LEG
TROLLEY T5
Fix side shifting arrangements over pier P1 and P2 as per drg. no. TS/761
The PSC beam shall be moved over the longitudinal movement trolley till it
reaches near the trolley support of the launching truss (T5)
The front end of the PSC beam shall be lifted by the first overhead trolley (T4) and
then lower front-end trolley (T2) gets released
The PSC beam then shall be moved further with its front end hanging from
overhead trolley T4 and rear end resting on lower trolley T2 till the rear end of the
beam comes to trolley position 9T5)
Page 59 of 109
Then the rear end of the PSC beam shall be lifted by the second overhead trolley
T3.
Now the PSC beam shall move in fully hanging condition over the two overhead
trolleys (T3 & T4) till it reaches its exact location over pier and locked. The beam
is then lowered cautiously by hydraulic jack over the side-shifting track fixed over
the pier cap and shifted laterally to the desired location.
Lowering of the beam from the suspended position shall be done cautiously by
2sets of lifting devices placed at trolley T3 & T4 as described in drg.TMS/710.
After lowering of the beam over side shifting arrangement, side shifting of the
beam shall be done.
Details of Lowering
Length of Travel In Launching Truss: 47.60m
Time taken for Travel: 10 min
Time for lowering of Girder: 5 hrs
Similar procedure shall be under taken for launching of the other beams by
repeating the above operations in sequence as at stage I(e)
The diaphragms shall be cast in situ.
Fixing of Bearing:
During casting of end blocks and pedestals on pier-caps, 90mm diameter
pockets shall be provided as per drawings and specifications.
Bearings shall be placed at location as per drawings and shall be aligned
properly before placing of beams.
(w/c ratio » 0.4) by natural pouring to get a uniform thickness (i.e. 10mm) mortar
in between bearing and pedestal.
Erection and launching of girder
Side shifting of girder & placing over bearings
Fixing of bolt sleeves in top plates of bearing, ensuring bearing sleeves are in
vertical position
Lower the girder over grouted bearing after 48 hours when required strength is
attaining.
Grout the top pockets as in item no. 1 &2 for fixing bearing by plasticized
expanding grout admixture i.e. Conbex100 @ 225 g per 50 Kg of Cement with the
help of Hand Grouting Pump through PVC hose.
IN CASTING/STACKING YARD
SAFETY MEASURES:
Jacks shall be operated in such a manner and from such a position that the
safety of all concerned is ensured.
Technical personnel and workers engaged during side shifting and launching
operation shall be equipped with adequate safety gears like helmet and safety
shoe.
Helmets, safety belts and safety shoes shall be provided to masons and
khalasis engaged for the operations.
There shall be safety signs painted on boards displayed and barricading /
fencing shall be done.
There shall be security guards posted at suitable locations. For night-
shifting/launching, sufficient flood lighting shall be provided with red light danger
signs at vantage locations.
Page 62 of 109
Cement:
Source: 43/53 Grade Grasim /L&T/ Ambuja / Century.
Material shall be tested at the manufacturing source and Test certificate shall
be collected for each lot. In every batch the following test shall be conducted
at Q.C. Lab (Subarnarekha site) to ensure Test certificate results are matching
Q.C. Lab results.
Consistency
Initial Setting Time
Final Setting time
Fineness of Cement
Compressive strength
Soundness test.
Reinforcement Steel:
Source: TISCO / SAIL / RINL / SRMB.
Chemical and Mechanical properties shall be tested as per IS 1786 at the
manufacturing source & test certificates shall be collected along with the every
consignment of steel. Also steel samples shall be tested randomly in outside
laboratories to check whether the test certificate results match the laboratory
test result.
Acceptance Criteria: Test result shall conform to IS 1786.
Coarse Aggregate:
Source: Tarini crusher / Durga crusher
Material 40mm / 20mm / 10mm shall be received beside batching plant at
Haldipada/Subarnarekha site. Sample shall be collected for every 200 M3 of
aggregate or any change of source, the following test shall be conducted in
Q.C.Lab as per IS 2386
Gradation of single size aggregate
Gradation for graded aggregate
Elongation Index, Flakiness index & combined index.
Page 63 of 109
Acceptance Criteria: All course aggregates shall conform to IS 383 and tests
for conformity shall be carried out as per IS 2386, Parts I to VIII.
Fine Aggregate:
Source: Gobar ghata
Material shall be received and screened at the stacking yard at Subarnarekha
site. Sample shall be collected for every 200 M3 of aggregate or any change
of source; the following test shall be conducted in Q.C.Lab
Gradation
Silt content shall be estimated as per IS 2386 & ensured less than 3%.
Acceptance Criteria: all course aggregates shall conform to IS 383 and tests
for conformity shall be carried out as per IS:2386, Parts I to VIII.
Admixture:
Source: Fosroc/ Chembond/Sika
Admixtures expedient for different mix grades shall be procured from
approved agencies. Test certificates shall also be collected along with the
every consignment. The following tests are conducted in Q.C.Lab to verify
with Test certificate result.
Relative density as per IS 6925
Chloride content – Test result shall conform to IS 9163.
Manpower:
Project engineer 01
Assistant engineer 01
Junior engineer 01
Foreman 01
Supervisor 01
Surveyor 01
TM Driver 03
Male Coolie 25
Details of Diaphragms:
DIAPHRAGM SPAN C A2
15 16 17 18 19 20
21 A3
DIAPHRAGM SPAN B 8 9 10 11 12 13
14
DIAPHRAGM SPAN A
1 2A4 3 4 5 6
7
Rigid common platform shall be made on beam top to receive concrete for
diaphragm casting. Walkway with hand railing shall be provided for
conventional pouring inside diaphragm shuttering.
The concrete shall be laid in layer not exceeding 400 mm depth.
Normal curing shall be continued up to 14 days.
Diaphragm shuttering shall be released as follows:
Side shuttering: 16 to 24 hrs.
Soffit of diaphragm: 7 days.
Concrete shall be pumped over rigid platform and then shall be poured
conventionally (mostly) at locations by providing walkways and hand railings
since quantity and thickness of diaphragm is less.
The concrete shall be laid in layer not exceeding 400 mm depth.
Normal curing shall be continued up to 14 days.
Diaphragm shuttering shall be released as follows:
Side shuttering: 16 to 24 hrs.
Page 66 of 109
ERECTION OF GIRDERS
DIAPHRAGM CASTING FOR
OVER 4TH SPAN >> 10 DAYS
4TH SPAN >> 10 DAYS
1 2 3 4 5
TO REACH UPTO SPAN P12
Page 67 of 109
MIX DESIGN: -
M40 grade of concrete using 20mm aggregates shall be produced as per
approved Mix Design.
TESTING OF MATERIALS: -
The suitability of ingredient materials of concrete shall be tested in QC
Laboratory and shall be approved by the Engineer as per specifications.
PRODUCTION OF CONCRETE:-
The concrete shall be produced by Shirke-40 Batching Plant having a capacity
of 30cum/hr @ Subarnarekha Batching Plant. The established batching plant
shall be calibrated and got checked by Engineer well before commencement
of production of concrete.
Page 68 of 109
CURING OF CONCRETE:
Bore well water shall be used for curing.
Necessary pipeline arrangement shall be provided for carrying water for curing
the structures. Curing of concrete shall be done by water ponding method.
TESTING & SAMPLING PROCEDURES:
Slump Test:
Slump shall be taken for each batch of Transit Mixer. The same shall be
recorded in Concrete Pouring Format.
Cube Test:
SAFETY MEASURES:
Technical personnel and work men who are engaged during concreting
operation both at batching plant and Site shall be equipped with helmets.
Safety shoes shall be provided to masons and khalasis engaged for vibrator
operations. The Planks of the walkway shall be carefully checked for safety
regularly. There shall be safety signs painted on boards displayed and also
barricading / fencing shall be done. There shall be security guards posted at
suitable locations. For night concreting, sufficient flood lighting shall be
provided with red light danger signs at vantage locations. First Aid Counter
shall be maintained separately in stores throughout the working.
Page 70 of 109
VOID FORMER:
Source: JK Steel & Polymer India, associate of Steel Auto (India) Ltd.
Void formers shall be fabricated at Balasore/ Bhadrak from approved agencies
and same shall be transported by Trailers to respective locations. Details of
void former are enclosed along with this method statement.
Light steel metal strips shall be used to make the void formers by using the
void former machine.
MANPOWER:
Project engineer 01
Assistant engineer 01
Junior engineer 01
Foreman 01
Supervisor 01
Page 71 of 109
Surveyor 01
CONSTRUCTION METHODOLOGY:
D2 W
D1 D
D0
W2 W1
Pockets shall be kept for providing drainage spouts between void slab casting
as per drawing by using PVC pipes/ Thermocol. During construction of
wearing coat drainage spout shall be fixed to match with top surface of deck.
MIX DESIGN:-
M30 grade of concrete using 20mm aggregates shall be produced as per
approved Mix Design.
TESTING OF MATERIALS:-
The suitability of ingredient materials of concrete shall be tested in QC
Laboratory and shall be approved by the Engineer as per specifications.
PRODUCTION OF CONCRETE:-
The concrete shall be produced by computerized Shirke-40 Batching Plant
having a capacity of 30cum/hr @ Subarnarekha and Haldipada Batching
Plant. The established batching plant shall be calibrated and got checked by
Engineer well before commencement of production of concrete.
CURING OF CONCRETE:
Bore well water shall be used for curing.
Necessary pipeline arrangement shall be provided for carrying water for curing
the structures. Also Hessian cloth shall be tied all over the periphery of the
walls for continuous curing.
Page 74 of 109
Slump shall be taken continuously for first 3 loads and thereafter slump shall
be taken periodically as per the direction of Engineer. The same shall be
recorded in Concrete Pouring Format.
Cube Test:
SAFETY MEASURES:
Technical personnel and work men are engaged during concreting operation
both at batching plant and Site shall be equipped with helmets, and safety
shoes shall be provided to masons and khalasis engaged for vibrator
operations. There shall be safety signs painted on boards displayed and also
barricading / fencing shall be done. There shall be security guards posted at
suitable locations. For night concreting, sufficient flood lighting shall be
provided with red light danger signs at vantage locations. First Aid Counter
shall be maintained separately in stores throughout the working hours.
Page 75 of 109
SCOPE:
Supplying and fixing of strip seal type of expansion joint under the supervision
of approved manufacturer Sanfield (India) Limited
MATERIAL:
WABO strip seal expansion joint comprises of
Edge beam
Anchorage
Strip seal
Anchor Loops
70m
m EDGE BEAM:
It is claw leg profiled member having
good weldability and made of hot rolled
82m steel section conforming to RST 37-2 OR
37-3 (DIN), ASTM A 36. It mechanically
m locks the sealing element in place
throughout the normal movement cycle.
The height of the edge beam is 82mm
and is placed parallel to the width of the
deck slab.
ANCHORAGE:
The edge beams shall be
anchored to deck by
reinforcement bars & anchor
studs cast in concrete. The
16 dia Anchor wheel loads acting on steel edge
Studs members are transferred to
staggered at bridge deck by means of
200 mm c/c anchorage. It bonds the
expansion joint to the bridge deck. 16mm dia anchor studs, made of
steel conforming to IS2062 shall be used at 200mm c/c.
Page 76 of 109
STRIP SEAL:
This shall be of chloroprene with high tear
strength. This component is provided to
ensure water tightness. The bulbous shape of
the part of the strip seal is inserted into the
groove provided in the edge beam. The seal shall be vulcanized in
single operation for minimum full length of the joint.
ANCHOR LOOPS:
This shall be welded steel connecting the rigid anchorage with deck
reinforcement.
During deck slab, concreting a recess of size equal to dimensions of the edge
beam shall be made conforming to the approved design data of manufacturer.
The surface of the recess shall be cleaned before installation of joint.
The exposed reinforcement from the deck slab shall be adjusted to permit
unobstructed lowering of the joint into the recess.
The gap between the steel edge members shall be adjusted depending on the
temperature at the time of installation of the expansion joint using clamp plate
arrangement.
Expansion joint is lowered in the predetermined position and the levelling of
Edge beam assembly using U-frame with threaded rod and lock nut
arrangement.
The level and gradient is adjusted matching with the final finish level of the
deck slab at the carriageway.
Anchor studs of 16mm dia shall be welded with the deck slab reinforcement to
support the Edge beam firmly without any side movement. Link bars of
16mm dia @ 200 mm c/c shall also be welded with the deck reinforcement.
Detailed sketch of this and the Methodology of Welding is also provided at the
end.
Shuttering shall be done suitably taking into account of the prevalent site
conditions.
The gap between the edge beam and the central beam shall be covered by
masking tape.
Concreting of Grade M35 shall be done at the recess portion. Good
compaction and careful curing of concrete shall be done.
After concrete has cured, the movable installation brackets shall be removed.
Rolled up neoprene strip seal shall be cut into the required length and inserted
between the Edge beams by using crowbar pushing the bulb of the seal into
the steel grooves of the Edge beams.
Bonlastic shall be applied by brush to the full perimeter on the walls of the
extrusion cavity for proper bonding.
Page 77 of 109
WELDING METHODOLOGY
Prepare double V groove for Butt Joint or as required.
Rigidly clamp the two pieces in straight line.
Preheat electrode at 150 – 170 C for 2 Hrs.
Current value [for AC or DC] should be in between 85 to 120 amps for 3.15
mm electrode [As per relevant specification of IS 814]
After each welding lap, remove slag deposit with the help of sharp Ttype
Chisel and wire brush.
Once the weld deposit filled property, grind off extra weld deposit.
Check quality level by Dye Penetrate Test.
Weld joint must be free from blowhole, pin hole and crack etc.
Clean the Weld Surface by Wire Brush and apply suitable anti – corrosive
coating.
throughout the length of the Joint touching the Anchor studs and then welded /
tied to these Studs.
This Transverse Bar, if not a part of the Deck Reinforcement is also weld
attached or tied with the Deck Reinforcing Bars thus to become an integral
part of the Deck Reinforcement.
In addition to the above, the Anchor Studs [both the straight and staggered one] are
also welded to the main deck reinforcement using link bars of different sizes and
shapes to achieve integrity with the main Deck Reinforcement.
Page 79 of 109
B. OPEN FOUNDATION
SURVEY:
A traverse shall be closed considering intermediate stations and closing
station and the co-ordinates of intermediate station shall be calculated and the
miss-closed shall be adjusted to find the adjusted co-ordinates. From the
traverse, a station on the Centerline of project shall be located for prolongation
of Centerline of proposed project. A Temporary Bench Mark shall be
established on the top of mother pillars. This Temporary Bench Mark shall be
tied with reference benchmarks.
DEWATERING:
If water is met with in the excavation due to springs, seepage, rain or other
causes, it shall be removed, by pumping out through with two numbers of 5
H.P dewatering pump and the excavation kept dry whenever so required. The
pumped out water shall be drained in to the original stream.
Page 80 of 109
REINFORCEMENT:
The HYSD bars conforming to IS 1786 shall be used in the work. The
reinforcement shall be fabricated as per approved Bar Bending Schedule in
accordance with relevant drawings. The bars shall be bent to specified shape
and dimensions using a proper bar bender operated by hand or power. The
anti-corrosive treatment shall be done by CPCC (Cement Polymer Composite
Coating) method.
PLACING OF REINFORCEMENT:
PVC/Concrete cover blocks of 40mm shall be placed between the bars and
formwork. Laying of reinforcement shall be separated by spacer bars at
approximately one meter intervals. The minimum diameter of spacer bars
shall be 12mm. Necessary blocks, metal chairs, spacers, supporting wires etc
or other subsidiary reinforcement shall be provided to fix the reinforcement
firmly in its convenient position.
Documents/Records:
Checklist for reinforcement
Format for material inspection
ERECTION OF SHUTTERS:
The contact surface of the forms shall be cleaned and dried. The form
surfaces shall be evenly and thinly coated with release agent. The vertical
surface shall be treated before horizontal surface and the excess shall be
wiped out.
The concreting area shall be cleaned and all the loose materials shall be
removed. The erection of shuttering (Standard plate size 1250mmx600mm)
shall be done manually. All the joints of shuttering shall be provided
Page 81 of 109
waterproof by providing Flaxo Foam between joints. The form works shall be
done in the true line and level in accordance with the drawing. The forms shall
be supported by the pipes from the ground.
Documents/Records:
Checklist for Shuttering
QUALITY CHECKS:
Slump Test:
Page 82 of 109
Slump shall be taken continuously for first 3 loads and thereafter slump shall
be taken for every one hour. The same shall be recorded in slump and
temperature register.
Cube Test:
REMOVAL OF SHUTTERING:
The form plates shall be removed after 12 to 24 hours after concreting and
form shall be cleaned again and staked properly for reuses.
CURING OF CONCRETE:
Curing shall be done with the Bore well water established near the bridge site.
A two H.P. pump shall be installed to lift the water from Bore well and delivery
pipe of 1½” diameter shall be installed from pump to bridge location. It shall be
laid parallel to the axis of bridge up to entire length of bridge with nipples at
every foundation location from where ¾” pipe shall be installed for curing of
the structure for 14 days.
Introduction:
The piling for the entire package is proposed to be done by direct mud
circulation method in compliance with the IS 2911. The following is the
construction m procedure for the piling works.
Manpower Deployment
1. Winch operator
2. Skilled khalashi
3. Wireman
4. Welder
5. Mechanic
6. Unskilled labour
7. Khalasis
Procedure
Boring operation shall be done by percussion type drilling rigs using direct
mud circulation of chisel bailor method to extract soil out. A suitable capacity-
piling rig operated by power winch diesel engine shall carry out the entire pile
installation
Temporary guide casting of required diameter about 2 to 3 m in length shall be
driven by means of MS bailor accurately on desired pile location which will act
as guide to cutting tools. This shall be removed after concreting of pile.
Page 84 of 109
After driving of guide casing, cutting tools shall be fitted with boring tube
100mm dia with water swivel at top and shall be lowered in the borehole. The
size of the cutting tool shall not be less than the diameter of pile by more than
75mm. The boring of pile shall be done by the free fall of entire cutting tools
from the desired height frequently and the soil shall be removed from the
borehole through circulation of mud by direct mud circulation system or/and by
the use of bailor.
In direct mud circulation system Bentonite slurry shall be pumped through the
boring tube to the bottom of cutting tools with high capacity mud pump from
the Bentonite tank. The soil with the Bentonite slurry comes out from the
borehole shall be taken back to the Bentonite tank through channels to re-
circulate again in the borehole. As the borehole progresses, boring tubes shall
be added till the required depth is achieved.
Bentonite slurry
Sodium based Bentonite powder shall be used for making slurry. The
Bentonite shall be mixed thoroughly with water to make a suspension, which
will maintain the stability of the borehole for the period necessary to complete
the piling operation. The density of the Bentonite suspension shall be between
1.03 to 1.10g/ml depending on the soil and site conditions and shall be
checked periodically with the help of hydrometer.
Reinforcement work
The CPCC treated reinforcement shall be prefabricated in to cages sufficiently
rigid to withstand handling without damages. The methodology for CPCC
treatment shall be submitted separately reinforcement cages shall be made in
segments and the same shall be lowered in to the borehole and assembled by
providing necessary laps, which shall be staggered. Proper cover of the
reinforcement shall be ensured by use of suitable concrete roller blocks, cast
specifically for the purpose. The full length of reinforcement cage shall be kept
in position. Cover blocks made of concrete of same strength as specified in
the member. This shall be checked by testing of corresponding control cubes
of 7.06 cm size cast simultaneously. Alternatively plastic over blocks approved
by the Engineer shall be used.
Concreting of pile
Concrete for piles is of grade M35, submission and approval of mix design
shall be done separately. Concrete for piling shall be carried using 2nos. of
transit mixers from batching plant located at Subarnarekha. Alternately
concrete shall be produced at site using mini batching plant. Placing of
concreting shall be done manually using concrete trolleys.
Page 85 of 109
The tremie pipes shall be gradually withdrawn as the level of the concrete in
the borehole rises. The top level of concrete in the bore hole shall be brought
up above the cut-off level by 0.6m (as per MOST page 354, cl 1115.1.5) so as
to permit removal of all laitance and weak concrete, to ensure good and
sound concrete at the cut-off level for proper embedment in to the pile cap.
The entire pile installation work shall be carried out in accordance with IS 2911
and sound engineering practice.
Quality Control:
Slump shall be measured at site periodically as directed by the engineer.
Work cubes shall be taken as specified in Table 1700-8 of MOST or as
directed by the Engineer.
Page 86 of 109
INTRODUCTION:
National Highway Authority of India has proposed to widen the existing road
between Balasore to Kharagpur. The job of preparing detailed project report
was entrusted to M/s SHELADIA/PBI/MRC and the same was prepared after
carrying out proper topographic and hydrographic survey, pavement condition
investigation, geotechnical investigation etc as required in NHAI’S TOR. The
National Highway Authority of India based on the Detailed Project Report has
entrusted to M/s gammon India Limited with the construction of major bridges
in this stretch. Out of these 20 Bridges, one is located at CH: KM 116+888.20
[ROB4].
SURVEY:
Referring control points Z-16 & Z-17 established by LBII, a traverse shall be
closed considering intermediate station A,B and Z-16 & Z-17 as closing station
and the co-ordinates of intermediate station shall be calculate and the miss-
closed shall be adjusted to find the adjusted coordinates. From the traverse, a
station on the Centerline of project shall be located for projection of Centerline
of proposed project i.e., from CH KM 116+86.604. A sketch for the survey
layout for ROB-4 is enclosed in Annexure-1 and the co-ordinate’s sheet is
enclosed in Annexure-2 for your reference. A temporary benchmark shall be
established on the top of mother pillar. This temporary Bench Mark shall be
tied with reference benchmarks i.e., 24.237 M1 & P2/R & A1/L having value &
24.319 & 20.049 respectively.
REINFORCEMENT:
The HYSD bars conforming to IS:1786 shall be used in the work. The
reinforcement shall be fabricated as per approved Bar Bending Schedule in
accordance with relevant drawings. The bars shall be bent to specified shape
and dimensions using a proper bar bender operated by hand or power. The
anti corrosive treatment shall be done by CPCC [Cement Polymer Composite
Coating] method. The CPCC treatment shall be done at treatment yard
established at ROB-4 Site. The detailed methodology has already been
submitted to you.
PLACING OF REINFORCEMNT:
PVC/Concrete cover blocks of 50mm shall be placed between the bars and
formwork. Laying of reinforcement shall be separated by spacer bars at
approximately one meter intervals. The minimum diameter of spacer bars
shall be 12mm. Necessary blocks, metal chairs, spacers, supporting wires etc
or other subsidiary reinforcement shall be provided to fix the reinforcement
firmly in its convenient position.
Documents / Records:
1] Checklist for reinforcement
2] materials inspection
ERECTION OF SHUTTERS:
The contact surface of the forms shall be cleaned and dried. The form
surfaces shall be evenly coated with release agent. The vertical surface shall
be treated before horizontal surface and the excess shall be wiped out.
The concreting area shall be cleaned and all the loose materials shall be
removed. The erection of shuttering [Standard plate size 1250 mm x 500mm]
shall be done manually. All the joints of shuttering shall be provided water
proof by providing Flaxo Foam between joints. The form works shall be done
in the true line and level in accordance with the drawing. The forms shall be
supported by the pipes from the ground.
The shuttering shall be fixed in the following limit of tolerances:
Variation in dimension - +50mm, – 10mm
Misplacement from specified position in Plan – 15mm
Surface irregularities measured with 3m straight edge-5mm
Variation of levels at the top - +/-25mm.
Document / Records:
i] Checklist for staging and formwork
per hour installed at Debra Site. To take care of concrete mix quality in Transit,
mix design shall be adjusted accordingly.
a] Each Gamcie will by supported by adequate number of manpower and
weighing boxes.
Per batch of production will be with respect to two bags of Cement.
b] Concrete by Batching Plant: -
The concrete shall be transported to ROB-4 location at a distance of 25 KM by
Transit Mixer of capacity 4 to 6 Cu. M. capacity. From Transit Mixer the
concrete having a slump of 80-100 mm shall be placed in Pile foundation
through a mobile chute to avoid segregation in concrete being poured from a
height. The concrete shall be compacted by means of immersion type vibrator
having needle diameter of 60mm and the temperature of poured concrete
after vibration shall be recorded in the pour card format. The concrete shall be
compacted thoroughly and it shall be ensured that concrete is properly
compacted. The concrete shall be laid in layers not exceeding 300/500mm
depending on the dimension of structure and next layer shall be laid before
initial setting time of previous layer. The whole concreting operation shall be
done in one single operation to avoid any Construction joint. The concrete
shall be laid to the shape, true line and level as shown in the relevant drawing.
The top surface shall be finished smooth except the construction joint portion
with Abutment’s/Pier’s Shaft where the surface shall be roughened and key
blocks shall be left for proper bonding with foundation.
Documents / Records:-
i] Concrete Pour card
ii] Concrete Register
QUALITY CHECKS:
i] Slump Test: - Slump shall be taken continuously for first 3 loads and
thereafter slump shall be taken periodically as directed bythe Engineer. The
same shall be recorded in slump and temperature register. The format for the
slump register is enclosed in Annexure
ii] Cube Test: -Cubes of size 150 x 150 x 150 mm shall be taken.
Number of cubes shall be taken as per Table No. 1700 in most specification.
The same shall be tested at the Q.C. Lab for 7 day’s strength and 28 day’s
strength and it will be entered in the cube test register.
Format for Cube Testing is enclosed in Annexure
REMOVAL OF SHUTTERING:
The form slates shall be removed after 12 to 24 hours after concreting and
form shall be re-cleaned and stacked properly for reuses.
CURING OF CONCRETE: -
Curing shall be done with the Bore well water established near the bridge site
[ROB-4]. A 5 HP pump shall be installed to lift the water from Bore well and
delivery pipe of 1 ½” diameter shall be installed from pump to foundation
location.
Page 89 of 109
PLANTS: -
Batching Plant [30 Cu.M / Hr] : 1 No & Gamcie – 4 Nos
Transit Mixer [6 Cu. M / 4 Cu. M] : 5+1 Nos
Immersion type Vibrator [Electric]
with 60mm needle : 3 Nos & Diesel Vibrator
– 1 No
Generator [25 /30 KVA] : 2 No
Water Pump 5 HP : 2 Nos
JCB : 1 No
Dumper / Tipper 6 Cu.M : 1 No
Welding Transformer : 1 No
MANPOWER
Supervisory Staff: -
Sr. Engineer :01 No
Junior Engineer :01 No
Foreman :01 No
Other Staff:
Q.C. Engineer : 1 Nos
Supervisor [Civil] : 4 Nos
Foreman [Mech] : 1 No
Electrical Foreman : 1 No
Electrician : 2 Nos
Mechanic : 2 Nos
Mechanical Helper : 2 Nos
Store Keeper : 2 Nos
INTRODUCTION:
The work of back filling/embankment forming shall be started only after
ensuring that the work in the abutment/bridge structure is sufficiently
advanced to permit the completion of the filling without any risk of damage to
the structure.
The fill materials shall be deposited in horizontal layers in loose thickness and
compacted thoroughly to the requirement of IS Specifications. For laying filter
media behind abutment, the media shall be laid in layers simultaneously with
the laying of fill materials.
MANPOWER:
Assistant engineer 01 no.
Junior engineer 01 no.
Foreman 01 no.
Supervisor 01 no.
Surveyor 01 no.
Field Test Assistant 01 no.
FILLING MATERIALS:
Page 91 of 109
RIVER SAND:
Source: Subarnarekha River
Acceptance Criteria: Test result shall conform to IS 383 and tests for
conformity shall be carried out as per IS 2386 Part I to VIII
MOORUM/ EARTH:
Source: Material shall be received from approved quarry at Amarda Road and
any change in quarry shall be intimated and approved from the Engineer
before using the same.
CONSTRUCTION METHODOLOGY:
PREPARATORY WORKS:
Initially Trees, roots shall be uprooted behind abutments A1 & A2 manually /
mechanically.
Layout for embankment construction shall be done with Total Station
Instrument / Theodolite. Toe level marking shall be done with lime powder.
Layout shall be marked true to lines, curves, slopes and grades.
Within the marked limit cleaning, grubbing operation shall be done and debris,
deleterious materials and boulders shall be cleared.
Page 92 of 109
FILLING WORKS:
Sand filling shall be done wherever furrows are seen to form a supporting
leveled ground.
Earth/Sand from approved borrow areas shall be excavated and placed on
the supporting leveled ground.
The embankment material such as Moorum/earth shall be spread in layers of
uniform thickness not exceeding 250mm-compacted thickness over the width
of embankment. Number of layers of 250mm compacted thickness to reach
the proposed formation level shall be stipulated from beginning of work so as
to maintain density records, levels and date on which tests are done.
Successive layers shall not be placed until the layer under construction has
been properly compacted and which is to be ascertained after field density
tests. Wherever water is required, it shall be added by tankers fitted with
sprinklers. Compaction shall be done by Vibro roller of 10T capacity to achieve
relative compaction as follows:
Embankment up to 6m-height ≥ 95% relative compaction
Embankment exceeding 6 m height ≥ 98% relative compaction for backfill
Then earth/Moorum shall be sprayed by Tractor/dozer in between two
Moorum layers of two extreme ends to achieve compaction thickness of
250mm.
For additional compaction Vibro roller (10 T) shall be engaged to achieve 97%
of maximum dry density.
Every layer shall be tested for density test by Sand replacement method.
(Field test)
Samples shall be collected from each layer and Modified Proctor density test
shall be conducted at Q.C.Laboratory.
FILTER MEDIA:
The material for filter shall comply with grading zones in Table 400-3 of MOST
and shall consist of sand, gravel, stone or coarse sand to prevent escape of
the embankment material through the voids weep holes in abutments as well
as to allow free movement of water without creating any uplift head.
The filter material shall be laid in two layers:
40mm coarse aggregate of 150mm thickness
10 mm coarse aggregate of 150mm thickness
Followed by crusher dust/sand of 150mm thickness
Page 93 of 109
Moisture content of the material shall be checked at the site f placement prior
to commencement of compaction in accordance with IS 2720(Part 2)
SURFACE FINISH
Surface finish of the filling shall be checked in accordance to requirement of
Clause 902 of MOST specifications.
Documents & Records
Request for inspection (RFI)
SAFETY MEASURES:
Technical personnel and workers engaged at site shall be equipped with
helmets and safety shoes. There shall be safety signs painted on boards and
Page 94 of 109
INTRODUCTION:
Laying of stone pitching and boulder apron are the two major methods used in
bridge construction. This method is adopted in OR/WB-I package in BR-4/1,
BR-17/1, BR-20/2, BR-20/3, BR-24/1, BR-24/2, BR-25/2, BR-32/3 and BR-
89/1 A. In addition to bed protection, stone pitching helps in guiding the
stream without damaging the abutment walls, whereas boulder apron
provides protection against scouring of river sand.
MACHINERIES:
Excavator - 1 No
Dumper - 2 Nos
MANPOWER:
Project Engineer - 1 No
Site Engineer - 1 No
Page 96 of 109
Safety Engineer - 1 No
SAFETY ARRANGEMENTS:
All stone carrying labors shall be provided hard hand gloves, boots and
helmets.
Acute surveillance shall be done by the safety engineer for smooth execution.
Page 97 of 109
During heavy rain, laying of stones shall be stopped to avoid any casualties
caused due to slippery.
Page 98 of 109
LENGTH OF APPROACHES:
Balasore end - 67.91 m
Panel D : 32 Nos
Panel E : 6 Nos
Panel F : 6Nos
Panel F’ : 02 Nos
Panel D’ : 08 Nos
Panel E’ : 02 Nos
Panel G’ : 08 Nos
Panel C’ : 04 Nos
QUANTITY INVOLVED:
R.E.W at Starting End Total Area of Quantity
Chainage Chainage Length Facia involved in
(Rm) Panels(Sqm) earth work
(Cum)
Balasore Side 0+234.625M 0+302.28M 67.655 750.21 17,225
Approach (L.H.S)
Balasore Side 0+226.883 0+295.094M 68.166 662.45
Approach (R.H.S) M
REFERENCE DRAWINGS:
Page 100 of 109
Reinforcing Strips
Sand from the bed of River Budo Balango near Balasore is tested in
Laboratory and satisfied as fill material for REW zone, fulfilling all design
criteria such as Φ angle, grain size distribution and PI.
Sample shall be collected from the borrow area [sand from Budhabalang
River] and the same shall be tested at any other approved laboratory for
getting approval as a fill material, before starting the work. Borrow area plan
shall be enclosed. The following test shall be conducted.
ACCEPTANCE CRITERIA
i) Pick Friction Angle shall not be less than 30 degree.
ii) All Backfill Materials used within the RE wall shall be reasonably free from
organic or other deleterious material
Iii) Gradation shall conform the limits as shown below:
Sieve Size Percent Passing
25mm 100%
10mm 75% - 100%
75 Micron 0 – 15 %
REINFORCING STRIPS
Reinforcing strips [Kolo ties] shall be manufactured & supplied by M/s Kolon
International Corporation, Seoul, South Korea in the form of KT-70, KT-50, KT-
30, KT-20 .
ACCEPTANCE CRITERIA
The test results shall conform to ASTM D–5262 & 5261, ASTM D– 4595, GRI
- GG4 [b], ASTM D-794, ASTM D-746, ASTM D-543 & ASTM D-4355
Testing facility is not available any where in India however; Test results from
out side India will be submitted.
Kony horizontal drain & pack drain shall be manufactured and supplied by M/s
Kolon International Corporation, Seoul, South Korea.
ACCEPTANCE CRITERIA
The material shall conform to MOST Specifications.
The RCC Facia Panel of M35 Grade in cruciform shape 18 Cm thick and
nominal dimension of 1.5 M / 1.5 M shall be cast in our casting yard at ROB-1
[Haldipada] as per specifications, Drawings & approved methodology.
After 14 days of curing shall be transported to Fly-01 side by means of low
bedded open Trailer / Truck & stack properly.
ACCEPTANCE CRITERIA
The Facia Panel shall be cast for its structural connection and back filling
loading as per IS 456 & IRC 21.
This work method statement is specific for FL-1 fly over but for detailed
installation procedure in general, drawing no. DB-4/R1 is to be referred
simultaneously.
ACTIVITIES INVOLVED :
1. Layout
2. Excavation of trenches
3. Casting of P.C.C
4. Casting of U-Beam
5. Casting of corner Junction Column
6. Erection of pre-cast Facia panel
7. Alignment of pre-cast Panels at 2 degree inclination with vertical.
8. Filling of approved materials up to KONY-Drain level.
9. Compaction of approved materials up to KONY-Drain level
10. Layout of KONY-Drain & Vertical Pack-Drain.
11. Fixing of KONY-Drain & Vertical Pack-Drain with Proper
connection between them with 100 micron P.V.C Tape.
12. Filling of Pack-Drain with graded material as specified in
drawing.
13. Filling of approved Backfill materials in layers of 300mm thick
upto 1st layer of friction Tie.
14. Fixing of 20mm dia rod as required considering different
combination factor of Configuration
15. Laying of friction-tie.
16. Dumping of approved fill materials within RE walls.
17. Spreading of dumped material with EX-60 excavator above
friction ties.
18. Leveling of spread material by Grader/ Dozer & manually.
19. Compaction of filled material by 10 Ton Vibro-Roller , except
1.5 m patch behind R.E.W Panels.
20. Compacting the left out 1.5 m width patch behind R.E.W
panels by 1ton compactor or 75 Kg. Plate compactor. In case of
plate compactor will use, layer thickness will be 100 mm.
Otherwise layer thickness will be 250mm.
21. Laying of Horizontal Pack-Drain as per approved drawing at
an interval of 50m c/c.
22. Erection of 2nd layer of facia panel after backfilling 3/4 th height
of first layer of pre-cast panel.
23. other layers of friction-ties will be laid as specified in drawing
at 0.75m interval from 1st tie.
24. The dimensions of top layer of Facia Panel will be adjusted
considering the vertical curve.
Page 104 of 109
1. ,LAYOUT
The R.E.W in approaches will be in circular curve as well as in transition
curve. Since this Fly over is a part of a 360m radius minute survey deficiency,
physical center of the existing Concrete structure of Fly over is to be matched
with the Road center line of Road contractor on far end. This will give a true
center line and alignment of Fly over. For preliminary alignment to carry out
excavation of trenches for casting of pcc, at every 10 Mtrs interval along the
center line of left side and right side of REW panel lines will be marked. to set
out the center line of R.E.W wall. Before casting of U-Beam a fresh layout will
be given at an offset of 2 metre interval to get a smooth profile of circular
curve. This survey will be done using Total-Station and measuring tape.
2. EXCAVATION OF TRENCHES
After setting preliminary alignment , excavation of trenches will be carried out
upto an approximate depth of P.C.C level by EX-60 Excavator. Dressing of
trenches will be done upto required founding level by manually.
2(a) Trenches in between pile caps and between Pile cap and corner column
shall be dug upto RL 6.125 and shall be filled up with boulders in layers and
voids filled up with sand so as to avoid relative settlement or tilt of the portion
of the standing RE wall. This shall be checked by Engineer before laying
PCC.
3. CASTING OF P.C.C
A thin layer of sand will be placed over the bottom surface and plate compactor will
be used to get a properly leveled surface before casting of PCC with M15 grade of
concrete. As the trenches had made with due care, no shuttering will be placed and
the edges of PCC will touch the trench wall. The PCC will be laid only after test for
SBC has been satisfactory. If required SBC is not achieved, soil stabilization work
shall be carried out.
4. CASTING OF U-BEAM
After getting a fresh layout on P.C.C top, CPCC treated steel will be fixed as per
approved bar bending schedule. Outside shuttering of U-beam will be fixed and
aligned . M35 grade Concrete upto bottom of U-beam wall will be done first . Next
the inner side shuttering of U-beam wall will be fixed and concreting upto required
level will be done.
Detail layout of corner junction column will be done at pcc level RL 5.875. .Shuttering
For a height of 1.5 m will be fabricated at our Fabrication Yard. After placing
reinforcement steel and proper fixing of shuttering, first 1.5m casting will be done by
M35 grade of concrete. Next 1.5m casting will be done in layers only after erection of
first layer of Precast Panels and completion of reinforced earth filling upto 3/4th of
first layer. The base of corner junction column to be done as per Drg.No.DB-1/R4
(Rev 5).
25mm thick thermocol will be placed in U-beam bottom & 2sides and corner
junction column groove conforming the approved drawing. After that First
layer of Precast panels will be erected starting from the Corner junction side
i.e the Abutment end side. The first Panel will be E-type as specified in
Drawing. After that alternately B and A Type Panel will be erected with the help
of 5 ton Capacity Crane. The panels shall be placed at 92 degree for RE
walls on LHS & RHS ends and vertically on Abutment face between the
corner columns of LHS and RHS ends.
A temporary spacer bar shall be used for panel to panel centering. , the panel
shall be aligned at an inclination of 92 degree and horizontally intermittently.
The spacer bars will be removed after the erection of one layer of RE panel.
The vertical alignment consists of aligning the panel along the centre line of U-
beam. This shall be done by adjusting the panels by means of crow bar
[Rubber pad shall be used to avoid direct contact crow bar to facia panel] to
match that panel with respect to the control line and sighting both the lines
until all offsets are eliminated. For vertical alignment panel so placed are tilted
to the required batter by means of hard wood wedges inserted at the bottom
of the panel. The 92 degree inclination shall be ascertained by a shopmade
template with a level-tube. When desired inclination is achieved, the bottom
wedges are tightened and consecutive panel is adjusted to the same
inclination.
The panels are secured in the position by a pair of seasoned wooden clamps
and supported by wooden props used only for base course.
The procedure shall be carried up to the last panel of the row. The aligned
panel shall be sighted by the both end and any offset if observed, corrected by
adjusting wooden clamps.
The recess formed at the bottom due to inclination of panels shall be plugged
by cement slurry grouting / thermocol.
The joints between the panels are sealed by non-woven geotextile filter
fabric or closed cell Polyethylene Foam.
Second layer of Panel will only be placed after first layer is covered in
compacted earth up to ¾ th height. All subsequent layers of panels will
also be put when its bottom layer is earth filled and compacted upto ¾ th
height.
Page 106 of 109
The precast panels for the top layer will be cast at site considering the
vertical Curve profile.
The same template to be used to check the alignment of panels at 92
degree. [Ref Drg. No. DB-7)].
BACKFILLING
Approved back fill material conforming the requirement of reinforced soil fill
[Budhabalang River sand] shall be laid by means of Tippers / Trucks at a
distance of 1 m to 2 m from the Facia panel and towed by excavators [up to
drainage bay].
It shall be leveled to thickness such that the compacted thickness shall not be
more than 250 mm.
All visible organic impurities and clayey clods shall be removed and disposed
before its spreading. Water shall be sprinkled on the sand near about OMC
[+2% & -1%] and rolled over by Vibro Roller of 10 MT capacity from center to
edges on either side for leaving portion 1.5m from face of facia panel on either
side.
Normally 5 passes shall be given. The compacted soil shall be tested for in –
situ density. The patches not confirming to the specification shall be lightly
drenched, rolled and recheck for density i.e., 97% of MDD.
The portion approximately 1.5 m from the facia panel shall be compacted with
the help of 1 Ton Roller normally 10 passes are required to compact the same.
The compaction shall be from inner side to outer side. When the compacted
fill reaches the level of GI hook in the panels the friction ties shall be
connected to panels with the help of anchor bar of 16 dia and vertical pin of 20
dia [600 mm deep].
Page 107 of 109
Any over lapping of friction ties [Kolo Ties] if required, shall be done with the
help of 50 Micron tape [KR wonder 555 make or equivalent, as propriety
product of M/s Kolon is not being manufactured].
The over lap length shall be 1 M. Further back filling operation shall be carried
till the height of 75 cm.
Thereafter the second course of panel shall be erected, with the help of wooden
clamps. The panels shall be placed on a special type of EPDM bearing pads [90mm
x 90mm x 10 mm], which shall be placed on the top of the bottom panel as per
drawing.
CURING:
SAFETY MEASURES:
Technical persons & workers engaged for the work shall be
equipped with helmets.
Safety shoes shall be provided to the Masons & Khalasis engaged
for erection
operation.
During night shift, sufficient lighting shall be provided with Red light
danger sign at vantage location and illumination tape.
Page 109 of 109