Method of Statement For Construction of Plunge Column in Station

CEC - UG1B CONTRACT: ICB No.
:-JP/EW/1B/C1 JAIPUR METRO RAIL

CORPORATION LIMITED
METHOD STATEMENT FOR CONSTRUCTION CONTRACT UG1B
OF PLUNGE COLUMN IN STATION
DOC NO: PR/JMRC/MS/UG1B/PHOF/14-R0
Date: 14-03-2015
PROJECT: Design and Construction of Tunnel between Chand Pole and Badi Chouper and
reversal line by Shield TBM, Underground Metro Stations at Choti Chouper &
Badi Chouper by Cut & Cover Method on East-West Corridor of Jaipur Metro
(Phase 1B) at Jaipur, Rajasthan, India.
LOCATION: JAIPUR
METHOD OF STATEMENT FOR CONSTRUCTION OF

PLUNGE COLUMN IN STATION
Project Manager
RV AKASH
GANGA Senior Manager Chief Manager
INFRASTRUCTURE DGM-Planning QA/QC HSE
Construction Pvt. Department, DPM STATION, Department, Department, Project Leader
Ltd. CEC CEC CEC CEC CEC
Page 1
CEC - UG1B CONTRACT: ICB No. :-JP/EW/1B/C1 JAIPUR METRO RAIL
CORPORATION LIMITED
Date: 14-03-2015
Table of Contents
Sr. No. Description Page No.
1.0 Purpose 03
2.0 Scope of Work 03
3.0 Site Establishment & Setting Out 03
4.0 Major Resources to be Deployed 04
4.1 Equipment to be Deployed 04
4.2 Manpower to be deployed 04
5.0 Materials 04
6.0 Responsibility and Authority 05
7.0 Construction Procedure 06
7.1 Traffic Management and Barricading 06
7.2 SHE Measures 06
7.3 Design & Drawings 07
7.4 Site Establishment 07
7.5 Surveying 07
7.6 Pre Trench 08
7.7 Plunge column boring 08
7.8 Muck Disposal 09
7.9 Preparation of Rebar Cage 10
7.10 Concreting 12
8.0 Quality Control / Control Assurance 12
9.0 Environmental Management 12
10.0 Safety and Emergency Procedure 13
11.0 Attachments 13
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CORPORATION LIMITED
Date: 14-03-2015
1.0 PURPOSE
This Method Statement describes the construction process of 1500 mm diameter Plunge columns
in station areas.
2.0 SCOPE OF WORK

The scope of work and the Construction Sequence for installation of permanent Plunge Column
shall be as mentioned below:
a. Traffic Management and Barricading
b. SHE Measures.
c. Design and Drawings
d. Site Establishment
e. Surveying
f. Pre-excavation
g. Boring into soil to the design depth
h. Muck Removal
i. Fabrication of structural steel flange column
j. Cage preparation and cage lowering
k. Tremie Lowering
l. Concreting for Plunge Column
m. Back filling
3.0 SITE ESTABLISHMENT & SETTING OUT

Good firm access shall be provided to allow safe passage of plant and equipment throughout the
Plunge Column construction area.
Adequate, hard, all weather platforms shall be provided and maintained for the execution of the
Plunge Column operations. Platforms shall provide sufficient bearing capacity for the pilling rig and
cranes.
Safety barriers shall be provided at all times to prevent unauthorised access to the operation area.
The position of the Plunge Column shall be determined by the setting out as Per Drawing
No.OKICPL-JM1B-C-SC-0475.
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CORPORATION LIMITED
Date: 14-03-2015
4.0 MAJOR RESOURCES TO BE DEPLOYED

4.1 Equipment to be Deployed
1. 70 Ton capacity crawler crane - 1 no
2. Supporting crane(70Ton) - 1 no
3. Hydraulic self-propelled Kelly Rig -1 no
4. Polymer setup -1 unit
5. Tremie pipe (200 mm Dia; with hopper) -1 unit
6. Welding set -4 no
7. Cutting and bending machine -2 no
8. Transit Mixer - 8 no
9. Batching Plant (60 cum/hr) - 1 no
4.2 Manpower to be deployed
Sr. No. Category Number
1 Construction Manager 1
2 Site Engineer 2
3 QC Engineer (Field and Lab) 1
4 Mechanical Engineer 1
5 Surveyor 1
6 Foreman 1
7 Supervisor 4
8 Electrician 2
9 Safety Officer 2
10 Mechanic 2
5.0 MATERIALS
 Concrete as per Approved mix design M35 Grade.
 Reinforcement – Steel conforming to specification
 Polymer (from approved supplier)
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Date: 14-03-2015
6.0 RESPONSIBILITY AND AUTHORITY

6.1 DPM-Stations
• He shall be overall responsible for following
o Safety Rules
o Statutory Compliances
o Quality Manuals
o Construction Methodology
• Overall responsible for the whole operation.
6.2 Station Manager

• He shall be overall responsible for the whole procurement of Men, Material and Machinery at
site, including operation planning and adhered with works program. He shall be liaison with Utility
Owning Agency for approval of Utilities Diversion Plans (if any).
6.3 Site Engineer

• Responsible for site operation.
• Material and equipment planning.
• Ensure works are carried out in accordance with the method statement.
• Ensure works follow approved drawings and specification.
• Ensure works are carried out in a safe manner.
• Field control and supervise all site activities.
• Apply and issue relevant work permits.
6.4 Design Engineer

 He shall be responsible to issue controlled copies of all drawings to the site personnel and return
back all obsolete copies. He shall provide detailed design specifications to carry out the work.
6.5 Planning Engineer

 He Shall be Responsible for arrangement of all external resources
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CORPORATION LIMITED
Date: 14-03-2015
6.6 Safety Personnel

 Ensure works are carried out in a safe manner and in accordance with the safety requirements
stipulated in the SHE plan.
 Conduct tool box talks on the safety requirements, construction risks and its control measures
etc.
6.7 Surveyor
 Carry out setting up works and locate as per submission drawings.
 Carry out inspection for location and level of structure.
 Keep monitoring the movement of ground and structure.
6.8 QC Engineer
 Ensure works are carried out in accordance with specification.
 Carry out inspection for all activities in accordance with the Inspection and Test plan.
 He shall be responsible to prepare the method statement in co-ordination with Design, Safety &
Quality and enclose Inspection and Test Plan and risk assessment. He shall review the method
statement as per site requirement.
7. CONSTRUCTION PROCEDURE
7.1 Traffic Management and Barricading

Traffic management shall be carried out as per the approved Traffic Diversion Plan. For heavy
equipment mobilization, necessary precautions shall be taken to bring the required items within
the work area boundary by carefully managing the traffic. The work location shall be barricaded as
per the site requirement and all the equipment shall be installed inside barricaded area.
7.2 SHE Measures

1) All the workers shall be provided with required PPE (safety jacket, shoes, helmet, hand gloves etc.)
before they are engaged in the work.
2) Safety induction shall be provided to the supervisors, engineers and workers.
3) Tool box meetings shall be organized every day by site supervisor before start of work in order to
keep workers aware of associated risks and safe working in order to avoid accidents/injuries.
4) Unauthorized/outsiders shall not be allowed to enter inside/stay near the area barricaded during
work in progress.
5) First aid facilities shall be made available at site and male nurse shall be available at principal work
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Date: 14-03-2015
spot to render the first aid services, if so required.

6) Proper Lighting arrangement shall be maintained during night work (or in day time in case of low
visibility).
7) Housekeeping shall be maintained at work spot to avoid any undesirable incident.
8) Emergency contact number shall be available and displayed at the designated locations near the
work spot to tackle any emergency situation occurring at site.
9) All the machines shall be inspected before deploying to the work and proper guarding for moving
parts
Shall be in place prior to commencement of work. Operators with valid licence (where applicable)
shall be allowed.
10) Silent type DG sets shall be deployed at work location.
11) Drip tray shall be provided underneath the machineries to avoid land contaminations.
12) Dust bins shall be available at prominent locations of work site to collect generated waste out of site
activities.
13) Risk assessment shall be discussed among all concerned prior to start of the activity.
14) After completion of work at a particular stretch required back filling shall be taken up depending
upon site requirement.
15) After completion of work post inspection shall be carried out to ensure that the tidiness has been
maintained and the work location has been restored to original condition.
7.3 Design & Drawings

A. The work shall be carried out as per the approved design and drawing.
B. Controlled copies of relevant drawings shall be made available at site and shall remain available
with site engineer throughout the work.
7.4 Site Establishment

Before starting any activities, a site utilization plan is drawn showing the various establishments at
site such as location of Panel formation, Putting DG’s, Polymer tanks, Muck bin, office etc. through
a detailed survey. The site area shall be then cleaned properly and made free from any on and over
ground obstruction and necessary barricading shall be installed. All plant and equipment shall be
placed as per this plan.
7.5 Surveying
Upon clearing the site area, the setting outpoints shall be marked for the subjected Plunge Column
panel and with reference to that guide wall, points shall be marked through requisite survey.
Reference pillars shall be always preserved for checking of constructed guide wall at later stage. All
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Date: 14-03-2015
the survey points/coordinates shall be maintained in survey sheet and checked/approved by

Engineer prior to construction work.
7.6 Pre Trench

During this pre excavation process, investigation and verification of underground utilities shall be
done at the subjected location. Manual excavation shall be done for finding the underground
utilities. In case of any utilities found, the mapping shall be done through requisite survey and a
drawing shall be drawn. In order to construct the Plunge Column such utilities if required to be
shifted marginally, the same shall be done either through local shifting or providing the local
diversion as agreed upon by the utility owner. The diversion process if necessary shall be done in
consultation with utility owner. Utility diversion shall be done as per Approved Method Statement.
The utility diversion method statement shall provide detailed information about the underlying
utilities and the process to be followed for the diversion process.
7.7 Plunge Column Boring

(a)Boring of Soil
1.5 meter dia; Boring of soil shall be carried out using a rotary Hydraulic pilling rig in normal
soil strata to the required depth as Per Drawing No.OKICPL-JM1B-C-SC-C-0411.Soil
stabilization will be ensure by polymer final depth of concrete shall be confirmed by sounding
method. The verticality of the Bore shall be monitor during installation and letter check
before lowering of cage. The eccentricity shall be jointly done with verticality.
(b)Setting out of guide frame
Minimum 200mm trench shall be excavated, a levelling PCC (M15/M20) will laid for placing
the guide frame as per the Drawing attached.
(c)Placing of Guide frame
After placing of PCC guide frame shall be placed carefully in line and level layout as per the
surveyor.
(d)Instillation of temporary casing
To stabilize the upper bore, temporary steel casing of length 2.5 m shall be installed at the
bored pile locations as follows:
A 1500mm Dia bore shall be drilled using a Hydraulic Boring machine to a required depth.
A 2.5m long steel casing shall be installed in the 3-4m deep bore holed by lowering the Casing
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Date: 14-03-2015
with crane. Vertically shall be checked and ensured during installation.

The casing shall then be driven into the ground with rotary machine until about 300 mm is left
protruding above the ground.
Drilling rig is then used to progress the excavation to the bottom of the casing pipe and then
polymer shall be added before any further excavation is made.
During excavation polymer shall be added continually from the storage tank such that level is
maintained with in 1000mm below top of casing pipe. Excavation depth shall be found by
sounding tape.
(e)Polymer Slurry Preparation, Storage and circulation
Dry polymer powder shall be tested and approved prior to the use. The batching plant shall be
erected on adequate impermeable slab. Dry polymer powder shall be mixed in the mixing
tank with the water. The mixing shall be achieved by dedicating a pump and compressed air
system. The mixing tank capacity may be 1.5 times the excavation's volume. The mixing tank
shall be connected to the slurry storage tank with appropriate routing valves. Thus polymer
slurry is made ready for use with required properties.
In the second phase the polymer slurry shall be pumped to the trench and circulated
continuously till excavation is over. While the panel excavation is going on the polymer slurry
continuously flows to the trench and thus stabilizes the trench throughout its depth. While
excavation, the polymer slurry get mixed with soil and loses its properties. Continuous
circulation of fresh polymer shall help to keep the properties of the polymer slurry even then
it is mixed with the soil. The return slurry shall be pumped into the sedimentation tank. The
sedimentation tank shall be kept open to the top to allow an easy cleaning and removal of
sediments. As sedimentation tank is included with three deflector vertical plates, continuous
flow of slurry shall occur in "cascade" like mode and increase the speed of the sedimentation
occurring between different compartments. The final de sanded slurry shall be connected to
the storage tank with after being treated properly to achieved required property and sent to
storage tank with proper pumping arrangement.
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Date: 14-03-2015
(Details of Polymer Batching Plant mix is shown in Annexure - B)The polymer characteristics shall
be checked with respect to the following prescribed values:
Permissible Value
Sr.
Test Prior to concrete
No. Fresh mix Reused Slurry
pour
1 Density (kg/m3) 1.00 to 1.04 ≤ 1.06 ≤1.05
2 pH Value 11 to 12 11 to 12 9-12
Marsh Cone
3 55-140 55-140 50-140
Viscosity API (s)
4 Sand Content (%) - <2% ≤2%
Properties as per annexure – G

7.8 Muck Disposal
The Bore Muck generated from excavation process shall be shifted to space available near by the
work area using JCB. The shifting shall be continued till the completion of grabbing operation. After
Completion of grabbing the working area shall be cleaned for stacking of Stop End and
Reinforcement Cage. The Bore muck initially dumped at available space near working area then
shifted to designated dumping yard by covered and leak proof tipper/truck having the fitness
certificate checked by Engineer. The tyres of the truck shall be cleaned thoroughly and be made
free from muck before the truck exits the site. After removing all the muck the area shall be
cleaned using water through the water pipe line arrangement at site.
7.9 Preparation of Rebar Cage
7.9.1 Reinforcement Steel Cage Cutting, Bending
The reinforcement cage shall be in single piece or two pieces depending upon the site condition
and equipment availability, the cage may be fabricated and lowered into Bore Pile. The
reinforcement should be cut and bend at the steel yard or at site as per bar bending schedule and
the cages shall be prepared at site over a level ground. Necessary spacer bars, fixtures, inserts and
cover blocks shall be provided along with the reinforcement cage. Care shall be taken to fabricate
the cage in true line and level with cover blocks fixed with proper supports and brought to the
panel by crane. Cover blocks shall be provided at close spacing of 1.5m to 2.0m. While cage
fabrication, roller cover block shall be introduced to the outer rebar’s before fixing.
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Date: 14-03-2015
7.9.2 Fabrication of Rebar Cage

Based on the approved reinforcement drawing, the Bar Bending schedule shall be prepared and
shall be submitted for approval. The reinforcement shall be cut and bent as per approved Bar
Bending Schedule in reinforcement yard situated at the casting yard. The cut and bent steel shall be
shifted to the site with the help of Trailer for making the cage.
The reinforcement cage shall be fabricated at the site. If there is insufficient space on site, the same
shall be fabricated at the casting yard or other offsite location and the prefab cage shall be shifted
to site through trailer. The reinforcement cage shall be fabricated using the Binding wire and
wherever required welding shall be done. (Details of Plunge Column Reinforcement are shown in
Drawing No. OKICPL-JM1B-C-SC-D-072A).
The cage shall be fabricated over the fabrication bed consisting either of steel chairs, channels or
wooden sleepers. The clear cover shall be maintained as per design which is 75 mm. Concrete
spacers (same grade as Plunge Column concrete , circular or trapezoidal skid shape) shall be fixed
to the cage typically at intervals of 1500mm horizontally and 4000mm vertically.
1. Cutting / Shearing of Rebar’s : The bars with improper ends like bent, too much heated, improper
manufactured ends etc., are cut with Bandsaw machine or sheared with shearing machine. This is
done in order to achieve a flat surface for further forging of the rebar. Also the face of the rebar
becomes perpendicular to the axis of the bar. This flat face also helps in abutment of two rebar when
in contact with each other.
7.9.3 Cage Lowering and fabricated plunge Column

After cage preparation, lifting and placing of the cage shall be done with the help of service crane
and the cage lifter. The cage lifter shall be fixed directly to the lifting hooks of the cage with
shackles and slings of the crane. The cage shall be lowered up to the desired level and shall be
rested with the help of resting hooks and supports from guide frames. Front and rear sides of cages
shall be marked on site to identify the soil face and excavated face during placement. Lifting points
and lifting lugs are designed (to be approved by our designer) in such a manner which shall not
cause distortion of the cage.
the plunge column shall be lifted with service crane and inserted in eccentric part of cage to the
required depth as per the drawing, holding and jointing of both reinforcement cage with fabricated
plunge column shall be done.
After removal of all the hanging supports, both reinforcement and plunge column shall be lowered
with service crane, maintain the eccentricity and verticality of plunge column by fixing the survey
coordinates on guide frame.
The lowering of cage and plunge column shall be done to the required depth of pile as per the
drawing N0. OKICPL-JM1B-C-SC-0411.
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Date: 14-03-2015
7.9.4 Tremie and Lowering

After lowering of reinforcement cage, tremie of minimum 200mm dia and length of 1.2 to 2m shall
be lowered in pieces and connected while lowering for full depth of trench with the help of service
crane and hopper of approximately 1.5 cum capacity shall be attached to the top of tremie pipes.
7.10 Concreting
Concrete of required grade M35 shall be batched in the batching plant and same shall be
transported through the transit mixer and poured to the hopper/tremie pipe. Initial setting and
final setting time of concrete shall be 5-6 hrs and 13-14hr respectively. The concrete shall be
directly discharged into the hopper/tremie. Before initial discharge there shall be at least 2 nos.
delivery trucks on site. Uniform rising shall be ensured by periodically measuring the rise of
concrete adjacent to the tremie location not less than once per concrete truck per tremie. There
must be a minimum 1.0m immersion of the tremie pipes in the concrete. This is necessary to avoid
polymer inclusions in the concrete. Tremie pipes shall be shortening depending on the rise of level
of concrete. The tremie lengths and concrete rise shall also be monitored / recorded.
Concrete shall continue to a minimum cut-off level at Bottom of base slab as per the Drawing No.
OKICPL-JM1B-C-SC-72A (typical elevation of pile with plunge column) as required to ensure sound
homogenous concrete at cut-off level. Any significant remaining portion of Plunge Column from
bottom of base slab to top of concourse slab shall be filled with M5 /M10 Grade slurry Mortar
Design Mentioned Below:-
Cement Fly ash Sand Water Admixture
90 KG 100 KG 1625 KG 310 KG 1 KG
The next remain level of plunge column from concourse slab to the top slab shall be filled with
backfill soil and sand as required.
8 Quality Control / Control Assurance
Quality Control and Quality Assurance of Plunge Column operations at different stages shall be
done using the following ITP & Formats.
Particular care must be shown with respect to control of polymer slurry. Drip trays to be used
underneath compressors and generators. Site is to be kept free of dust. Noise levels shall be kept
well within the allowable limits.
9. Environmental Management
Safety, Health and Environment (SHE) plan shall be followed throughout the construction program.
The Construction of Plunge Column involves the use of heavy machineries such as crane, excavators
and trucks etc. and these machines inevitably create noise. However, in order to minimize the noise
and discomfort to the people living in the neighborhood or the shopkeepers and people coming to
the nearby markets, all the machines shall be provided with suitable silencers and with acoustic
enclosures, Noise barriers shall be erected to minimize the noise pollution.
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Date: 14-03-2015
The construction shall also involve the removal of earth from site to dumping areas by dumpers
that shall use the public roads. During transportation the dumpers shall be covered by tarpaulins.
The muck shall be disposed during the night hours only and one supervisory level staff shall be
engaged permanently at dumping yard with JCB for leveling the upcoming soil leveling, while
dumping the soil.
Simultaneously the area leveling and shall create a proper way for soil dumping. The used polymer
slurry shall be transported in dumpers.
The washing bay shall be installed near each exit gate. These washing bays are of improved design
using a heavy-duty pump having high head and large discharge. The tires and the undercarriage of
the vehicles shall be washed before the vehicle leaves the working area for dumping site. In case
water is not available due to water scarcity, tire shall be cleaned manually with wire brush.
Required persons shall be engaged to clean the sides of the vehicles manually. The working area
shall be kept clean and tidy.
10. Safety and Emergency Procedures

During excavation all necessary precautions to ensure stability to the excavations and guide walls
shall be taken. If excavation be suspended for any reason, polymer in the trench shall be agitated,
periodically with the grab or by circulation for a maximum period of 24 hrs. This shall be followed
by backfilling of trench with excavated materials.
In the event of a sudden loss of polymer slurry or trench collapse, the excavation shall be
immediately stopped and the trench backfilled with excavated materials.
11. Attachments
I) INSPECTION AND TEST PLAN
Inspection and Test Plans attached as annexure D
II) FORMAT/ CHECKLIST
1. Inspection Checklist for Plunge Column - Annexure El
2. Reinforcement Inspection Checklist - Annexure E2
3. Plunge Column concrete pour card - Annexure E3
4. Concrete Pre Pour Card - Annexure E4
5. Plunge Column Boring Excavation Record - Annexure E6
6. Plunge Column Boring Construction Record - Annexure E7
7. Inspection Checklist for Poly Mud Slurry - Annexure E8
8. Concrete Pouring Records – Annexure E10
9. Properties of Polymer slurry - Annexure E11
10. Welding Inspection check list-Annexure E12
11. Risk Assessment – Annexure K
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Method of Statement For Construction of Plunge Column in Station

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CEC - UG1B CONTRACT: ICB No.

:-JP/EW/1B/C1 JAIPUR METRO RAIL

METHOD OF STATEMENT FOR CONSTRUCTION OF

2.0 SCOPE OF WORK

3.0 SITE ESTABLISHMENT & SETTING OUT

4.0 MAJOR RESOURCES TO BE DEPLOYED

Sr. No. Category Number

6.0 RESPONSIBILITY AND AUTHORITY

6.2 Station Manager

6.3 Site Engineer

6.4 Design Engineer

6.5 Planning Engineer

6.6 Safety Personnel

7.1 Traffic Management and Barricading

7.2 SHE Measures

spot to render the first aid services, if so required.

7.3 Design & Drawings

7.4 Site Establishment

the survey points/coordinates shall be maintained in survey sheet and checked/approved by

7.6 Pre Trench

7.7 Plunge Column Boring

with crane. Vertically shall be checked and ensured during installation.

1 Density (kg/m3) 1.00 to 1.04 ≤ 1.06 ≤1.05

4 Sand Content (%) - <2% ≤2%

Properties as per annexure – G

7.9.2 Fabrication of Rebar Cage

7.9.3 Cage Lowering and fabricated plunge Column

7.9.4 Tremie and Lowering

10. Safety and Emergency Procedures

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