CONTENTS:

1. PURPOSE
2. SCOPE
3. SPECIFICATIONS / REFRENCE DOCUMENTS
4. RESPONSIBILITY OF THE DESIGNATED IN CHARGE
5. MATERIALS
6. GRADE OF CONCRETE
7. TYPE OF CONCRETE MIX
7.1. DESIGN MIX CONCRETE
8. CONCRETE PRODUCTION
9. PLAIN CEMENT CONCRETE
10.REINFORCED CEMENT CONCRETE
11.TRANSPORTING, PLACING, COMPACTION & CURING
11.1. TRANSPORTING & HANDLING
11.2. PLACING
11.3. COMPACTION
11.4. CURING
12.PROTECTION OF FRESHLY LAID CONCRETE
 13.FIELD TEST

14.CONCRETE REPAIRS

15.FORM WORK

15.1. MAKING OF SHUTTERING PLAN

15.2. FIXING/ERECTION OF FORMS

15.3. DISMENTALLING OF FORM WORK

16.REINFORCEMENT WORKS

16.1. BAR BENDING SCHEDULE

16.2. CUTTING OF REINFORCEMENT

16.3. BAR BENDING

16.4. FIXING OF BARS

17.SAFETY PRECAUTIONS

1. PURPOSE:
  The purpose of procedure is to carry out concreting works at site and to ensure
that proper quality control assurance is achieved at HPCL-VRMP Project –
Visakhapatnam.

2. SCOPE:

 This procedure covers the various steps involved in executing plain &
reinforced concreting works for various structures like pile cap, foundation,
column, slabs, precast elements etc. including curing, testing, finishing and
repairing of concreting.

3. SPECIFICATIONS / REFRENCE DOCUMENTS:

 EIL Specification no.6-68-0002 REV-05 and 6-68-0004 REV-07

 Contract Documents
 IS: 456-2016,IS 10262-2009,IS 383-2016, IS 2052-1963, IS 1786-2008, IS 8112-
2013,IS 269-2015, and IS 516-2009, 1489-1991 Part1, IS 4926:2003, IS 3370-
2009(Part 1) IS 2430-1986
 Approved construction drawings

4. RESPONSIBILITY OF THE DESIGNATED IN CHARGE:

 Resident Construction Manager/Project Manager: Responsible for overall

management for all construction activities at site.

 Lead Civil Engineer /Construction Manager: Responsible for monitor the daily
construction activities at site.

 Safety Engineer: Safety Engineer shall be responsible for safety of all persons
involved in the job.

 Lead Quality Engineer: Quality Manager shall be responsible for overall Quality
activities at site.

 QA/QC Engineer: QA/QC Engineer shall be responsible for site QA/QC

activities, non-conformance management and compilation of records
  Field Engineers: Field Engineers shall be responsible for the site construction
activities and implementation of all the plans following safety & quality
standards.

5. MATERIALS:

5.1. FINE AGGREGATE

 Aggregate for concrete shall be in accordance with IS 383-2016.
 It shall be hard, dense and durable, free from impurities like dust, clay lumps
and any other deleterious matter.
 Sampling and testing shall be as per IS 2386 (Part 3)-1963.
 The total percentage by weight of deleterious substances in sand shall not
exceed. 5% for uncrushed sand and 2%for crushed sand.
 The fineness modulus shall be between 2.2 and 3.2

5.2. COARSE AGGREGATE

 Aggregate for concrete shall be in accordance with IS 383-2016.
 Coarse aggregate shall be granular or crystalline surface shall be free from
elongated, flaky or laminated pieces.
 Total percentage of deleterious substances In the coarse aggregate shall not
exceed 5% for both crushed and uncrushed aggregates.
 Unless otherwise specifically stated on the drawings, the maximum size of
coarse aggregate shall be 20mm, but in no case greater than1/4of the
minimum thickness of the member.
 Aggregates delivered at site in wet condition or becoming wet due to rain or
any other means, shall be used by adjust the water content to achieve the
desired mix.

5.3. CEMENT
  Cement will be as per mix Design for super structure and sub structure
concrete work. Cement will be stored in ready go-downs batching plant to
protect from dampness and will be made easily accessible for proper
inspection and accounting.
 Cement shall be procured from primary manufacture as mentioned in
contract documents.

5.4. STEEL
 Tor steel reinforcement shall be procured from approved manufacture for
cement concrete works confirming to high yield strength deformed steel
bars of GR. Fe 500D of IS 1786-2008 and co related with MTC [Manufactures
test certificate] and challan issued by manufacture.
 Material shall be accepted based on manufactures test certificate and review
of certificates /test reports and other documents like delivery order, delivery
challan, etc.MTC will be produced for all types of reinforcement steel and for
all the consignments coming to site in the case of absence of MTC or
incomplete documentation, the same will be tested in an approved
laboratory as per IS 1786-2008 prior to use.
 All reinforcement bars will be clean and free from dirt, oil, paints, grease,
mill scales and loose rust. Bar bending schedule will be prepared before
cutting.

5.5. WATER
 The water used for concrete work shall be clean and free from harmful
chemicals and organic material to ascertain the same, a sample of water will
be tested in any of the approved laboratories prior to the commencement of
work and later on in case if any visible change is found. The water shall be in
general conforming to the requirement of IS 456:2016.
 It shall be clean and fresh, free from oils, acids, alkalis, or others deleterious
material whether in solution or in suspension.

5.6. ADMIXTURE
 Admixture used shall comply with approved manufacture

6. GRADE OF CONCRETE:
  Grade of concrete shall be as per drawing:
1. M-10 For PCC work
2. RCC with M-40 grade concrete For Pilling work and Pile Cap Work

7. TYPE OF CONCRETE MIX:

 Unless otherwise specified or mentioned in drawings all lean/plain concrete
shall be of ‘’ DESIGN MIX CONCRETE” and reinforced concrete shall be of “DESIGN
MIX CONCRETE” as defined in 456-2016 and as per third party design mix report.

7.1. DESIGN MIX CONCRETE

 Mix design shall be established ahead of start of work &concrete grade shall
be as designated in drawing.
 Mix concrete shall be done at laboratory approved by EIL/Field lab set up.
 Mix design shall be done for each grade of concrete.
 The procedure given in Indian standard recommended guidelines for
concrete mix design IS 10262 shall be followed as far as possible.
 Plasticizing admixtures may be added to concrete as per manufactures
instructions and guidelines given by third party lab to improve the slump
without impairing the specified strength. Maintain constant W/C ratio as per
specification.
 A minimum of six cubes shall be prepared from each sample three for testing
after 7 days and three for testing 28 days.
 The concrete mix design shall be tested and the results shall be submitted
for EIL approval as per the parameters of IS 456-2016.

8. CONCRETE PRODUCTION:
 Availability of all approved ingredients to the required quantity shall be
ensured at Batching plant before start of concrete.
  Concrete shall be supplied from Batching plant after confirmation from site.
 The concrete shall be mixed at the Batching plant as per the approved mix
design.
 Batching of ingredients shall be done in accuracy of +/-2% of cement being
measured &within +/-3% of aggregate, Admixture & water being used as per
IS
 The moisture content of the coarse and fine aggregate shall be checked by
the QC Engineer @ Batching plant and suitable adjustment made as per IS
456-2016 on daily basis.
 The concrete shall be thoroughly mixed to achieve required workability at
the point of pouring.
 Slump requirement at site:
1. For Pilling work – 150mm to 180mm after 3 hours
2. For Pile cap Work – 75mm to 100mm after 3 hours
3. For PCC work – 100mm to 130mm after 3 hours

9. PLAIN CEMENT CONCRETE:

 M-10 Grade of concrete to be used for PCC work at site.
 For all PCC works the concrete design mix will be used and proportion of
cement, CA, FA, & water cement ratio will be used as per report given by
third party laboratory. (Before laying PCC, sub base at founding level shall be
compacted as per specification compaction up to 90% to 95%.
 Formwork for PCC shall be placed true to its line & whenever required
mechanical mixing will be done in mechanical mixer or RMC plant.

10.REINFORCED CEMENT CONCRETE:

 For all the RCC structures, bar bending schedule will be prepared and
approved from client as per drawings. Batching of cement, coarse
aggregates, sand and water will be done in batching plant. The Engineer in
 charge will be informed about the concreting program well in advance and
the arrangement and availability of materials and necessary equipment will
be checked before calling for inspection. All information regarding a
particular concrete pour will be incorporated in concrete program and
inspection plan and the concreting will commence only after due review of
relevant QA document and signing of pour card.
 Whenever a construction joint as per drawing to be provided in a monolithic
structure, bonding grooves will be formed in the concrete already laid and
the surface will be roughened, cleaned and given a wash of neat cement
slurry and bonding agent as per instruction given by client before laying new
concrete as laid down in cause.
 The construction joint shall be vertical in case of beams & slabs & shall be
thoroughly cleaned & hacked before resuming the concrete works.

11.TRANSPORTING, PLACING, COMPACTION AND CURING.

11.1. TRANSPORTING AND HANDLING

 All concrete shall be conveyed from batching plant to site through transit
mixer and shall be poured at location either through pump or chute or
manually or direct depending on site condition like approach ,lead, height,
quantity, etc.
 A delivery slip or batch slip shall be sent with each load of concrete with
details of grade, mix details, quantity, date and time of dispatch etc. along
with moisture content.
 Slump shall be measured at batching plant &place of pouring
 Method of concrete transportation shall not allow contamination,
segregation or loss of constituents to occur. Proper approaches and areas for
concrete pumps placing; unloading points etc. shall be decided as per site
conditions and in such a manner that there is minimum hindrance to other
activities.

11.2. PLACING
 Pour plan for mass concreting to be submit before 2 days.
 The method of placing of concrete shall depend on quantity of concrete,
type of structure, type of formwork etc.
  The concrete pour shall be checked for the position, level, proper
reinforcements, embedded parts, and adequacy of shuttering, scaffolding
etc & concreting shall be commenced on approval from engineer in charge.
 Concrete shall be laid in layers no greater than 400mm, and each layer shall
be compacted using appropriate vibrators. Concrete shall not be moved
horizontally by vibration and care taken to avoid segregation while pouring.
 Placement of concrete shall continue until the completion of the concrete in
one pour to avoid cold joints in concrete unless construction joints are
specified
 The maximum permissible free fall of concrete may be taken as 1.5mts.
 Mass concrete shall be planned and discussed with clients representative
well in advance, separately with pour sequence, rate of pour, pumping
arrangement and vibrators as required
 Concrete shall be placed without segregation,
 The concrete shall be placed in its final position and compacted before initial
setting time of concrete commences after first mixing of water, cement and
aggregates
 Water for use in mixing concrete and curing shall comply with the
requirements of IS4546
 For provision of construction joint at place other than mentioned in drawing
prior approval shall be taken from engineer in charge.
 No wet concrete shall be placed in flowing water.
 Concreting shall be carried out continuously up to construction joints
 Vertical construction joints shall be formed by the insertion of rigid stopping
off forms.
 Provision of boom pressure and concrete pump to be available at site as per
instruction of client.

11.3. COMPACTION
 Concrete should be thoroughly compacted and fully worked around the
reinforcement, around embedded fixtures and into corners of the formwork.
  Concrete shall be compacted using mechanical vibrators complying
IS456.Over vibration and under vibration concrete are harmful and should be
avoided. Vibration of very wet mixes should also be avoided.
 60 mm Dia of needle for Vibrator to be used at site.

11.4. CURING
 Curing is the process of preventing the loss moisture from the concrete
whilst maintaining a satisfactory temperature regime. The curing regime
shall also prevent the development of high temperature gradients within the
concrete.
 Concrete works shall be cured for minimum of 7 days.
 Adequate Hessian clothes must be used for curing purposes at site.

12. PROTECTION OF FRESHLY LAID CONCRETE:

 Newly placed concrete shall be protected, by approved means, from rain,
sun and wind. Concrete placed below the ground level shall be protected
from falling earth during and after placing.
 The ground water around newly poured concrete shall be kept to an
approved level by pumping or other approved means of drainage and
adequate steps shall be taken to prevent flotation and flooding.

13. FIELD TEST:

 Slump cone shall be used to check the workability of concrete at batching
plant & site as per ITP.
 Sample from fresh concrete shall be taken as per IS:1199-1959 and cubes
shall be made cured and tested at 28 days in accordance with IS: 516-2009.
 1 set of cube will consist of 6 cubes & 3 shall be tested for 7 days & 3 for 28
days.
 Frequency of sampling shall as per IS: 456-2016 each grade of concrete.

14. LAB TEST:

 Lab test to be conducted at RMC plant’s lab as per IS 4926 for all raw
materials like Aggregates, Water, Cement, Etc.
 All reports to be submitted and record with test data sheet at site.
15. CONCRETE REPAIR:
 After the striking of the formwork, all concrete work shall be inspected for
defects such as honey-combed surfaces, rough patches; holes left by from
bolts etc shall be repaired.
 Repair work shall be performed as soon as possible after the striking of
forms so that the concrete has not hardened completely.
 Areas of segregation, stone packets and other damaged areas shall be
chipped and all loose material removed with compressed air by washing,
taking care to remove all water from the concrete. For larger repairs
concrete shall be chipped out to a depth of 100-150mm. loose mortar shall
scrubbed out by using wire brushes.
 Bonding of old concrete with the repair material shall be achieved by wetting
the chipped out surface and either sprinkling dry cement on the wet surface
or by brushing a coat of rich cement grout[1cement:1 sand] followed by the
patch mortar for surface repairs, or patch concrete for larger repairs. If
required epoxy bondage shall be carried out for repairing Patches, which
shall be applied as per manufacturer’s recommendation.

16. FORM WORK:

16.1. MAKING OF SHUTTERING PLAN
 Component material [steel, wooden or plywood] shall be selected as per the
drawing, structure, load and the finish required.
 Formwork shall be fabricated as per the drawing of form work schemes.
 Fabricated form work shall be staked in order and transported for erection
as per the sequence of work.
 Formwork shall be cleaned for any concrete leftovers and other elements
detrimental to concrete and its finish.
 Shuttering panels made up of plywood with timber backed shall be used for
6 to 10 repetitions & those with steel moulds can be used for 50 to
100repetitions subject to PMC/Client approval.
 Steel shuttering will only be used for concreting work, No wooden shuttering
allowed for the same at site.

16.2. FIXING/ERECTION OF FORMS

  Erect staging/shuttering as per drawing/sketches in such a way that de
shuttering can be done easily including provision for propping, if being
planned.
 All shutter and plates shall be adequately backed by sufficient number and
size of walers or framework to ensure rigidly during concreting. Shuttering
shall be adequately strutted, braced and propped, to prevent deflection
under deadweight of concrete and superimposed live load of workmen,
materials, plant to withstand vibration. No joints in props shall be allowed.
 Care shall be taken that all formwork is set plumb and true line, level,
camber, or batter where required and as specified.
 When reinforcement passes through the formwork, care should be taken to
ensure close fitting joints against the steel bars, so as to avoid loss of fines
during the compaction of concrete.
 Surfaces of forms in contact shall be oiled with mould oil of approval quality
or clean diesel oil. The use of oil, which darkness the surface of concrete,
shall not be allowed. Oiling shall be done before reinforcement has been
placed and care shall be taken that no oil comes in contact with
reinforcement, while it is being placed in position.
 Before concreting is commenced, the formwork shall be carefully examined
to ensure the following:
1. Removal of all dirt, shavings, sawdust and other refuge by brushing and
washing. The tightness of joints between panels of sheathing and between
these any hardened core so that all wedges are secured and firm in position.
2. The correct location of tie bars, bracing and spacers, and especially
connections of bracings.
3. That provision is made for traffic on form work, not to be bear directly on
Reinforcing steel.
4. Formwork shall be continuously watched during the process of concreting
any weakness develops and formwork shows any distress, necessary
remedial action shall be taken.
5. No gaps are present between shuttering boards. If any, it will be sealed by
proper method and instructions given by client.

16.3. DISMANTLING OF FORMWORK

 Formwork shall be released only after specified periods as per the IS 456-
2016 clause no 11.3.1.
 Tolerances for formed surface shall follow IS 456-2016 clause no 11.1
  Where props are required by the specification to continue to provide
support after the general striking of formwork they shall be removed
without causing damage or deflection to the concrete.
 Removed formwork shall be collected and staked in designated places
without hindrance to other activities.

17. REINFORCEMENT WORKS

17.1. BAR BENDING SCHEDULE
 A Bar Bending Schedule shall be prepared in approved format based on AFC
drawings (Code – 1/R).
 The same shall be reviewed & approved by client before starting and cutting
bending of bars.
 Approved format shall be used to prepare bar bending schedule.
 The lap length shall be as noted in drawings or as per IS code.
 Laps shall be staggered and staggering length shall not be less than 1.3 times
the lap Length.

17.2. CUTTING OF REINFORCEMENT

 Cutting and bending of reinforcement bars shall conform as per approved
drawing. Carried out through skilled workman.
 The cut and bent reinforcement bar shall be shifted and stacked at site in
such a way so as to prevent contamination or damage to the reinforcements.
 The location of cut shall be marked on rod before cutting.
 Cutting of reinforcement shall be cold cut.

17.3. BENDING
 All bending shall be done at rebar yard.
 All vertical bars shall be joggled at top to accommodate the laps, bars shall
be sent cold.
17.4. FIXING OF BARS
 The reinforcement shall be fixed, supported and maintained in position by
adequate use of chairs, cover blocks and binding wire.
  Reinforcement shall be fixed with line, level and spacing to be maintained as
per the approved drawing.
 The lap length shall be as per drawings or otherwise specified by Field
Engineer.
 Laps shall be staggered wherever required or as indicated in the drawing.
 Reinforcements may be cut, adjusted and lapped to accommodate
embedded parts in position and add rebar where shifted.
 Minimum clear cover shall be as per AFC drawings.
 Cover blocks, will be made of same grade of concrete and shall be used to
ensure the required cover for reinforcement.
 Cover blocks are generally square or circular in plain with or without binding
wire embedded in them which will be tied to the reinforcement at the time
of placing.
 No splices shall be made in the reinforcement other than described or
approved.
 Bars crossing each other shall be secured by binding wire, of 16 SWG.

18. SAFETY PRECAUTIONS:

 All safety precautions and safety requirements to be followed as per the EHS
guide lines.