NATIONAL HIGHWAYS AUTHORITY OF INDIA

Construction of two six lane Vups including RE wall, Service Road and
Drain, at new ch. 31+050 near Budiya village junction and new
ch.33+580 near Gabheni village junction on Hazira port -surat -
Gujarat /Maharashtra border section of new NH-53 in State of Gujarat

“METHOD STATEMENT CUM

ERECTION PROCEDURE FOR
LAUNCHING OF PSC GIRDERS BY
CRANES”
Authority
NATIONAL HIGHWAYS AUTHORITY OF INDIA
(PIU - BHARUCH)
Authority's Engineer
M/s GEO Designs & Research (P) Ltd.
VADODARA
EPC Contractor
M/s Shree Manglam Buildcon (l) Pvt. Ltd.
ANKLESHWAR
1. PURPOSE

The purpose of this document is to provide a detailed method statement indicating the

Work procedures for safe launching of Precast Girders work to be carried out at Hazira port -surat
-Gujarat /Maharashtra border section of new NH-53 in State of Gujarat, Budiya Gabheni junction.
NHAI Road project.

2. SCOPE OF WORKS

The scope of work covered under the procedure shall include transportation of pre-cast girder,
shifting of girder, lifting, placing in position, launching by approved method for major/minor
bridges, flyover, ROB etc.in the project:

Casting of PSC girder for main bridges is in two stages. sequence of construction is as follows:

Following scope of works shall be undertaken by girder launching method on the project:

The details of girders to be launched are as under:

 No of spans: 8 no
 No of PSC girder: 8 no
 No of RCC girder: 16 no
 No of girders per span: 4 no
 Type of girders: “I” type
 Length of girders(varying): 19.2 mtrs to 38.7 mtrs
 Weight of girder(varying):app. 40 MT max.to 107 MT.
 Casting of girders are being done near the erection site only

3. REFERENCE DOCUMENTS
Approved schematic drawings for erection / launching of pre-cast girders by cranes and trailers;
approved technical specifications including general & particular project specifications; MORTH
specifications; IS & IRC codes.

4. RESOURCES DEPLOYED:
a. manpower: as per annexure A-IX
b. EQUIPMENTS: as per annexure A-IV, A-V, A-VI, A-VII & A-VIII

5. WORK METHOLOGY:

a. Deployment of cranes, trailers. Tools-n-tackles & man power

i. 2 no hydraulic truck cranes of capacity not less than 200 MT with average working radius
of 8 Mtrs to lift 50 tons. the preferable capacities of two cranes shall be 250 MT and 350
MT (proposed make & models of the proposed cranes groove – TM 2500 (annexure A-IV)
capacity 250 MT, Demag HC 1010 (annexure A-V) or equivalent having capacity of 350
MT). load charts and specification of the cranes are enclosed here with for ready
reference.
ii. Girder will be shifted from the casting bed to the erection location either by using cranes
or by using Hydraulic axle modular trailers (minimum 2X2 I 4X4 axle line) with matching
 prime mover approx. 280 1300 HP. Technical specifications of hydraulic axle modular
trailer -2 & 4 axle line. and prime mover are enclosed at annexure A-IV, A-VII&A-VIII.
iii. sling of minimum 38 mm Dia steel core wire and D-cycles of adequate capacity duly
tested shall have to be used and certified by the third party will be used for the work.
iv. Highly skilled riggers, signal men with sufficient experience to carry out such like works
shall be deployed for the erection works. The details of manpower are attached at
annexure A-IX

b. preliminary works to be done near the casting bed /erection site

i. approaches to the site shall be prepared in a manner so it is fully safe for the cranes and
trailers to reach the desired location /launching location and should be as per HSE manual/
method statement.
ii. ground shall be well compacted around the casting bed and piers before the cranes &trailer
is placed. All due precautions as per the standard practices/ method statement shall be
taken.

c. shifting of PSC girders either by cranes or by using modular trailers (as per annexure-
A-I)

i. In case it is possible to shift the girders from the casting bed to the erection location in
one / two swings then cranes will be deployed for shifting. else, the modular trailer will be
placed near the casting bed and the two cranes shall be so placed that the girder can be
lifted at the two ends and placed at the Centre of the trailer. it will be ensured that girder
rest only at two points on the modular trailer and not all along its length.
ii. Before the cranes leave the girder on to the trailer the same will be secured properly on to
the modular trailer with help of chains and belts to be tightened with turn buckles.
iii. Having completed the loading of PSC girder the same shall be moved to the erection site
taking full safety precautions.

d. fixing of POT-PTFE bearings:

i. Just before erection of the girder, the same shall be held, by the two cranes, at about 30 m
above the ground level for fixing of POT-PTFE bearings under the bottom flange of the
girder erection activity will commence after fixing of these bearings only.

e. erection of PSC girder at site:

i. place the two cranes as shown in the drawing. (As per annexure –A-I)
ii. bring the modular trailer duly loaded with PSC girder in between the cranes as shown in the
drawing, in case the girder is shifted by using trailer.
iii. Lift the girder of trailer or from the ground as the case may be.
iv. Place the girder on to the wooden sleepers its final location.
v. Secure the girder on to the pier with help of temporary A-frame and release the girder off
the lifting shackles .(as per annexure A-III)
vi. Subsequently grout the bearings with GP-2non shrinkable / approved grout material.
vii. Once the grout attains its full strength, the wooden sleepers will be removed by use of
screw jacks.

Repeat the above procedure for erection of all the girders in the same span and for all the

spans in a bridge before moving to the next location.

6. HEALTH SAFETY AND ENVIROMENT
a. GENERAL SAFETY PROVISIONS:

as launching of girders is one of the riskiest Job which must tale utmost precaution at all
stages like; planning, establishing casing yard, casting segments, transporting segments,
fabrication and erection of launching girders, launching of segments, pre-stressing, auto
launching of girder etc.

A Comprehensive Safety Guidelines to be adopted throughout the launching operations.

a) Necessary working platforms and fall protection anchorage arrangement to be provided in

the launching girder itself.
b) Provisions for mounting light fitting also available in the launching girder.
c) If in case of material unloading area is not maintainable as PPE zone, the same shall be
segregated properly and made as a non-PPE zone with appropriate barricades.
d) Electrical system shall also be suitably planned so that location of diesel generator, if any
location of DBs, routing of cable and positioning of area lighting poles/masts does not
infringe on any other utility and pose danger.
e) The casting yard shall be established ensuring the access roads and internal circulation road
shall be well laid and maintained properly at all time.
f) The workmen engaged in fabrication of reinforcement, concreting the segment shall be
provided with necessary PPEs including compulsory hand protection gloves.
g) Casting and curing of segment shall be undertaken under the direct supervision of the
responsible engineer of the contractor.
h) Tailer/truck with valid registration, license, safe worthiness certificate, employer approval
certificate and pollution under check certificate shall only be used for transport of
segments.
i) Drivers engaged for driving these trailer / truck shall be trained on periodically defensive
driving.
j) Drivers shall also have undergone proper medical examination as per relevant HSE manual
mentioned under medical facilities.
k) The segment shall rigidly secure to the trailer /truck with necessary red indicator/ safety
tapes provided so that vehicle is clearly seen by other road users both in day/night time.
l) Every launching girder shall have a responsible engineer on duty all the time.
m) All the time from erection to dismantling the area between the two Pier where in launching
is in progress shall always be barricaded.
n) Unloading of segment from trailer / truck, lifting of segments, shifting of segments, gluing
shall be done under the direct supervision of the approved engineer of the contractor.
o) Auto launching shall be done only after approval from the employer. after every auto
launching the stability of launching girder shall be ensured.
p) The vertical deflection of launching girder shall be monitored at all critical stages like
with/without loads and after every auto launching.
q) A register containing all important operational details from erection to loading, unloading
and launching girders shall be maintained and made available to employer whenever called
for.
r) Test certificate for all lifting gears including Macalloy bars shall be maintained at a location
closer to the launching girder itself so that it can be referred during all inspections.
 s) Adequate lighting at all time shall be ensured in the entire area of operation.
t) Access to drinking water & toilet shall be ensured to all workmen engaged for launching
process.

u) the site conditions, including the ground where the machine will be set up, access roads and
ramps it must travel, space for loading and unloading and any obstacles that might impede
access or operation.

v) the contractor shall ensure that a valid certificate of fitness issues as per HSE manual is
available for all lifting appliances including synchronized mobile jack, pre-stressing hydraulic
jacks, jacks fitted with launching girders etc.

w) emergency response plan shall be followed as per approved HSE manual.

b. MANDATORY SAFETY PROVISIONS/REQUIRMENTS:

 Safety helmet, safety shoes, jacket to be compulsorily used.
 Packing to be suitably provided at rope bends around sharp edges.
 Adequate supervision to be ensured.
 Proper illumination to be ensured.
 Third party test certificate of tool/tackles & equipment’s to be available
 Removal of slings from blocks is prohibited until the blocks are completely installed and
fastened.
 At the place where rope bends around sharp edges, fasten semi-tubes or wooden pads with
wire in plate.
 All approach, ingress / egress to and from work area, walkways kept clear, tools etc.
 Storing area for lifting tools& tackles, ropes, wire ropes &PPE is dry, clean &free of corrosive
material.
 Store equipment and material in their assigned place.
 Permit for working at height is used in prescribed format shall be used for job.
 Working at height should be avoided in adverse weather conditions, such a during rain, high
wind, combination of high temperature & humidity.
 The person working at height should be medically examines for their fitness for working at
height.
 Area of work shall be barricaded with boards with proper anchoring, bolting and weight to
be kept for stability of barricades.

7. QUALITY ASSURANCE &QUALITY CONTROL:

Quality assurance and quality control requirements shall be as per the QAQC manual and
project Specifications. EPC contractor shall ensure that the approved project policies, procedures,
instructions and documented evide0nce thereof, are effectively and efficiently implemented all
actions necessary to maintain the desired level of quality for the activities shall be exercised and
recorded in accordance with the contact requirements and QA/QC procedures.

8. DOCUMENTATION/RECORDS

All records and checklist, as specified in the method statement and as per directions of
engineer (PMC) shall have to be recorded and reported for launching of each girder, duly
approved by the authorized signatory of JSTPL