Method Statement of Tunnels Digging

Method statement of waterway tunnels concrete lining.
Owner’s Engineer
Doc. No DLJV-CONS-MS-WT-02 Rev 03
Method Statement for

Waterway tunnels lining concrete
Project Name : Gulpur Hydropower Project
Client : Mira power Limited
Consultant : MWH NESPAK JV
Contractor : Daelim-Lotte JV
Site : Gulpur
03 07/06/2017 Issued for Approval Naveed Naseem Tanzeel Javed Afzal Lee Jae Chul Cho Sang wan
Rev. Date Description Prepared by QA/QC EHS Const. Approved by

Owner’s Engineer
Contents
1. Purpose……………………………………………………………………………….3
2. Scope of work…………………………………………………………………………3
3 Organizatio and responsibilitie ……………………………………………………...9
4. Resources……………………………………………………………………………12
5. Execuation flow diagrame …………………………………………………………..14
6. Execution procedure………………………………………………………………….16
7. Quality assurance and Quality controll Plan………………………………………...26
8. Health, Safety and Environment management plan……………………………….....32
9. Attachments…………………………………………………………………………..44
Owner’s Engineer
1. Purpose
This Method Statement covers the construction works of waterway tunnels concrete lining.
The main purpose of this method Statement is:
 To outline the works involved in this particular Structure.
 To provide a document that managers must read and understand before starting the job.
 To meet legal requirements, that is, hazard identification and control.
 To program work, materials, time, staff, and to anticipate possible problems;
 To use as a tool in quality assurance.

2. Scope of work.
2.1 Introduction of Headrace tunnel
Headrace tunnels are water way pressure tunnels which composed Vertical
pressure shaft, lower bend Horizontal pressure tunnel, penstock and outlet
{Figure 1: waterway tunnels plan}

Owner’s Engineer
Each waterway tunnel contains:
a) A vertical pressure shaft of 44.5 m height and 6.7m inner diameter (after lining concrete)
b) A horizontal pressure tunnel of 122.5 m length with 6.7 inner diameter after lining.
{Figure 2: waterway tunnels 3D profile}
Vertical pressure tunnel

H=44.5, D=6.7(inner)
Horizontal pressure tunnel

2.1 L=122.5, D=6.7(inner)
Owner’s Engineer
2.2 Design and Specification
Each vertical shaft contains:

a) A vertical pressure shaft of 24.5 m height with 6.7m inner diameter(after lining concrete)
b) A vertical transition part of 10.5 m height with 6.7m inner diameter(after lining concrete)
Each horizontal tunnel contains:
a) A lower bend of 19.635 m length with 6.7m inner diameter (after lining concrete).
b) A horizontal pressure tunnel of 50.650 length with 6.7 inner diameter after lining concrete.
c) A Steel penstock tunnel of 55 m length with 6.7 inner diameter after steel lining
{Figure 3: Waterway Tunnels profile}

Owner’s Engineer
Both Headrace tunnels has exactly the same length, diameter and design.
{Figure 4: Vertical pressure Tunnel}
Items Specification Location Typical cross section
Shape circular
7.6m (Inner
Vertical Shaft tunnel 1 & 2
Diameter
Circular)
Height 24.5 m
Type of
Concrete lining
lining
Thickness
400 mm
of lining
{Figure 5: Vertical Tunnel transition part}
Items Specification Typical cross section

Location
shape Square
7.6×7.6m Inner
Size
After lining
Horizontal Tunnel 1 & 2
height 10.5 m
Type of
Concrete lining
lining
Thickness
of lining 1000 mm
concrete
Owner’s Engineer
{Figure 6: Lower bend}

Location
Shape circular
7.6m Inner
Diameter
(after lining)
Lower bend 1 & 2
length 19.635 m
Type of
Concrete lining
lining
Thickness
of lining 1000 mm
concrete
{Figure 7: Horizontal pressure Tunnel}

Location
Shape Horse shoe

Horizontal pressure Tunnel 1 & 2
7.6m (Inner
Diameter
Circular)
length 50.650 m
Type of
Concrete lining
lining
Thickness
of lining 400
concrete
Owner’s Engineer
{Figure 8: steel penstock Tunnel}

Location
Type Horse shoe
7.6m
Steel penstock Tunnel 1 & 2

Diameter
(Inner Circular)
Including out let part

length 55 m
Type of
Steel lining
lining
Thickness
of lining 700~1000 mm
concrete
2.3 Work scope.

The scope of works covers work procedures and technical requirements for cleaning,
leveling concrete, steel fixing, fixing of formwork, pouring of concrete, curing of
concrete, and to maintain quality and ensure structures are built in conformance with the
design alignment.
2.4 Reference Documents.

2.4.1 Drawings(Revision-C)
1. GPDD-C-WT-001---------------------------------------------------------Water way General Plan
2. GPDD-C-WT-001------------------------------------------------Water way Profile (Tunnel No.1)
3. GPDD-C-WT-001------------------------------------------------Water way Profile (Tunnel No.2)
4. GPDD-C-IPTP-CLR-001------Inlet portal Transition part concrete lining reinforcement 1/3)
7. GPDD-C-VPT-CLR-001---------Vertical pressure tunnel concrete lining reinforcement 1/3)

Owner’s Engineer
8. GPDD-C-IPTP-CLR-002-------- Vertical pressure tunnel concrete lining reinforcement 2/3)
9. GPDD-C-IPTP-CLR-003-------- Vertical pressure tunnel concrete lining reinforcement 3/3)
9. GPDD-C-VPT-0001------------------Vertical pressure tunnel Excavation cross sections (1/2)
10. GPDD-C-LB--LBP-0001-----------------------Lower Bend Profile and typical sections (1/2)
11. GPDD-C-LB--LBP-0002------------------------Lower bend profile and typical sections (2/2)
12. GPDD-C-LB-CLR -0001--------------------Lower bend concrete lining reinforcement (1/2)
13. GPDD-C-LB-CLR-0002---------------------Lower bend concrete lining reinforcement (2/2)
14. GPDD-C-HPT-TS-0001--------------------------Horizontal pressure tunnel typical sections
15. GPDD-C-HPT-ESC-0002-------Horizontal pressure tunnel concrete lining reinforcement
16. GPDD-C-SPT-TS-0001---------------------------------Steel penstock tunnel typical sections
17. GPDD-C-OPT-ETS-0001----------------Outlet pressure tunnel typical excavation sections
2.4.2 Specifications(Revision-C)
1. Tunnels.
3. Organization and responsibilities
Site Manager: Cho Sung wan
 Summing up the result of management review of each discipline and reporting the results to project
Manager.
 Planning and controlling project schedule.
 Checking, analyzing and reporting the differences between schedule and actual progress.
 Coordination to each section with respect to relevant technical matters.
 Supervising the operation of document control system.
 Controlling the project's design documents and the change of the design documents at site.
 Controlling for expediting the delivery of purchased material and handling materials at site.
Construction Manager: Mr. Lee Jae Chul
 Ensuring identification and analysis of the technical requirements of the project.
 Assuring that organization is equipped with adequate resources and information to achieve quality.
 Assisting the Site manager in any aspect regarding engineering matter.
 Practical responsibilities for implementation of work execution
 Control of manpower and equipment
 Coordination with QA/QC department regarding inspection and testing
 Check and review of progress as per schedule
Owner’s Engineer
Site engineer: Mr. Naveed Akhtar

 Preparation of work procedures
 Document and drawing control.
 Coordination with QA/QC department regarding inspection and testing
 Check and review of progress schedule.
 Control of manpower and equipment
 Coordination with design and planning department
 Assisting the Construction manager in any aspect regarding engineering matter.
QC Manager Mr. Naseem
 Initializing and establishing the quality management system through project QA/QC plan
 Having responsibility to assure that all project activities affecting quality are in compliance with this
plan.
 Establishing objectives of continual improvement.
 Ensuring surveillance, evaluation and inspection of materials.
 Administering non conformity with respect to material and work execution.
 Determining, collecting and analyzing appropriate data to demonstrate the suitability and effectiveness
of the quality management system.
 Coordination with the Owner’s Engineers on all QA/QC matters.
 Production of concrete and laboratory testing record
QA Manager Mr. Muhammad Aslam

 Planning inspection activity and practicing inspection for work.
 Administering non conformity with respect to material and work execution.
 Checking inspection results and preparing official reports
 Review quality of all materials at site and ensure compliance to all project specifications and quality
and collaborate with department for all material procurement and maintain quality of materials.
 Analyze all products and nonconformance processes and evaluate all documents to ensure
maintenance of optimal quality
 Coordination with the Owner’s Engineers on all QA matters.1
Owner’s Engineer
EHS manager : Mr. Tanzeel

 Avoid all personal injuries during the execution of the Project by targeting to Zero LTI.
 Ensure that all personnel employed on the Project are competent to carry out their designated tasks
safely by supporting continuous HSE training, adequate HSE measures, instruction and supervision.
 Create positive health, safety and environment attitudes and perceptions at all levels of the Site
organization, and to raise health, safety and environmental awareness in general.
 Implement a training program that supports the achievement of personnel competency in relation to
Health, Safety, and the Environment.
 Carry out all operations related to construction and commissioning with the health and safety of
personnel and the impact on the environment as the prime consideration.
 Complete the site work without incurring any significant property damage to permanent or temporary
facilities.
 Continually monitor and improve HSE performance.
Chief Surveyor : Fawad Ahmed
 Create the miniature of the construction plans that would serve as the source of the site plans
 Keep in touch with the engineering and design personnel’s.
 The Survey Engineer is considered part of field management and is responsible for various aspects
of field engineering and surveying for the project. The Survey Engineer is in responsible/ in charge for
all construction layout and survey documentation, and as such (structure alignment, before ,during
and after the concrete placement)
 Works directly with the Field Engineer Manager regarding initial project layout requirements, means
and methods of establishing project survey control, and field reporting.
 Works with Field Engineers in the following tasks: o engage in site layout, construction planning,
scheduling, quality control, and job site safety.
 Provides and maintains horizontal and vertical survey control by use of a level, total station, etc.,
including organized documentation of survey notes.
 Assists in the preparation of final records for the project, including as-built.
 Works with site engineer/foreman to ensure structures are built in conformance with the design
alignment and contractual requirements.
Owner’s Engineer
4. Resources
4.1. Manpower
{Table 1 Manpower detail for Horizontal tunnels excavation and support)
Vertical Tunnels Horizontal Tunnels

S/N Designation
Day Day Night
Night
1 Shift Engineer 1 1 1 1
2 Surveyor 1 1 1 1
3 Surveyor helper 2 1 2 1
4 Foreman 2 2 1 1
Steel fixer
5 10 10 5 5
Carpenter
6 05 05 4 4
Welder
7 05 05 4 4
8 Mason
5 5 4 4
9 Unskilled labor
12 10 5 5
10 Operators 4 4 2 2
47 44
Total 29 28
Note: Manpower can be changed according to site conditions.

Owner’s Engineer
4.2. Major Equipment and Tools

[Table4: Major equipment for waterway tunnels concrete lining]
S/N Site Equipment Capacity Work Qty.
1
Excavator (jack hammer) 0.6 CUM Scaling, trimming 1
2 Cleaning,
Charging car 2 man basket 1
dismantling, rebar fixing
3
Steel plate form 6 M (High) Rebar fixing 1
4
Concrete pump 120 m3/hour Concrete pouring 1
Horizontal tunnels
5
Water pumps 3” Dewatering, curing 1
6
Gas cutter Cutting works 1
7 Welding machine Welding works 2
8 vibrators Concrete pouring 3
9 compressor 750 CFM Cleaning work 1
10 Generator 500 KW Power supply 1
1 shifting of steel liner,

Mobile Crane 50 tons 1
rebar’s etc.
2 Stationary pump 120 m3/hour 1
Concrete supply
3
Vertical tunnels
Welding machine Welding works 1
4 vibrators Concrete pouring 2
5 Gas cutter Steel cutting works 1
6 l shifting of vertical steel

chain blocks 4
liner
Note: Quantity of above major equipment and tool can be changed due to site conditions
Owner’s Engineer
5. Flow diagram
5.1 Vertical tunnels lining concrete flow diagram
[Figure 2: Sequence of work for waterway vertical shafts excavation & support]
Removal of Existing
Temporary facilities
Steel fixing
Assembling of liner
Erection of steel ribs lining

form lifting structure at the
top of shaft tunnel
Fixing of Shifting of squeezed

liner form at the bottom of
vertical shaft
Fixing of steel liner

Survey of alignment and verticality
Pouring of concrete Survey monitoring
Wait for concrete setting
Shifting of liner for next stage Continuous concrete curing

Owner’s Engineer
5.2 Horizontal tunnels Flow diagram

[Figure 2: Sequence of lining concrete works for waterway horizontal tunnels]
Bottom cleaning/ dismantling
Lean/Leveling concrete
Removal of Existing
Temporary facilities
Steel fixing
Assembling of lining form
Side stopper Shifting and Fixing of lining Fixing of plugs for grouting
form
Alignment, leveling survey and

inspection
Pouring of concrete Survey monitoring.
Wait for concrete setting
Detachment of form
Continuous concrete curing
Shifting of liner for next stage

Owner’s Engineer
6. Execution Procedure
6.1 Concrete lining Lower bend
Concrete lining of waterway tunnels will be started from lower bend,
The lining procedure will include following activities
Cleaning and removing and dirt and left overs due to tunneling works by means of
Bottom cleaning with water jets and manpower.
Placement of lean/leveling concrete, lean concrete will be started from lower bend
towards out let.
Placement of 1st stage concretes according to drawing
Remove any over spray which may prevent correct re-bar placing.
Placing re-bars according to drawing
Fixing of concrete spacers to secure required concrete cover.
Placing of liner segments. (For detail refer to attach#1)
This operation will involve a surveyor which will check
Formwork positioning.
{Figure9: lower bend steel form}
Segments of lower bend lining form will be shifted inside the tunnel by using mobile
crane located at intake Elevation 517, Around 5 meter of bend form plates will be
shifted in the location through horizontal tunnel by using dump truck.
Fixing of segments will be started from horizontal tunnel towards the vertical shaft.
Segments will be joined and fixed on the provided sequence numbers by using
holes and nuts. During fixing of plates charging car will be used from the horizontal
tunnel for worker access and support the plates ,mobile crane will be used through
vertical tunnel to handle the form plates
Welding will be carried out to join the segments when required.
Monolithic concrete will be poured in the lower bend section to avoid the
construction joint.
Concrete pouring will be placed from the bottom of the bend in 50 cm layer. Each
layer will be compacted by means of inner vibrator.
Owner’s Engineer
As the thickness of lining concrete is 1 mete in this section which in enough space
for workers to go in for the positioning of concrete pipes and use of vibrator for
compaction of concrete.
As the poring of lower bend is long job it will take approximately more than 48
hours, so the stripping will be started form initial poured area after 12 hour from the
completion of total pour. During striping of form charging car will be used from the
horizontal tunnel for worker access and support the plates ,mobile crane will be
used through vertical tunnel to handle the form plates. Form will be shifted out
through vertical tunnels by using mobile crane fixed at intake elevation. Plates
which are not accessible by the crane will be loaded on dump truck by using wheel
excavator and will be shifted out through horizontal tunnel.
6.2 Vertical Pressure tunnels

Concrete lining operations for the vertical Shaft will be started after completion of the shaft excavation to its
full cross section
The steel liner is composed of circular shape arranged steel panels of 2 meter
height (as shown in figure below) , reinforced with stiffening ribs and connected to
each other with carriage bolts.
working platform will be also be erected with the liner, it will be connected to the top
of the formwork panels and will consist of steel, supported by steel beams
spanning inside the shaft and fixed to the beams of the main structure and from
these to the yokes.(refer to attached2)
The working platform will host the workers in charge for the placement of the
reinforcement bars and the subsequent pouring of concrete.
Lifting plates are provided at the top of 4 stiffing ribs for the lifting purpose.
Owner’s Engineer
Lifting plate
Working plate form
2000
A temporary steel structure will be erected at the top of shaft for lifting of steel lining
form during lining concrete. Lining form will be lifted with the chain blocks and steel
sling hooked with the provided lifting plates. These plates are provided with form as
well as with steel rib structure.
{Figure 12: Lifting structure for vertical lining form}
A A
Reinforcing bars will be supplied by using crane installed on the top of the vertical
tunnels.
Owner’s Engineer
Steel bars will be lowered by winch on the working platform and will then be placed on a continuous base: in
order to make steel placement operations more comfortable, vertical bars will be provided with
staggered splicing along the shaft perimeter. {Figure 13: Vertical pressure Tunnel view from bottom}
In fact, concrete will have to be workable

enough to be easily placed into the form but, at
the same time, it will have to harden fast
enough to develop a strength capable of letting
the form shift upwards and also of supporting
the fresh concrete poured above it.
Batching and mixing of concrete will be

performed in the concrete batching plant.
Concrete will be transported to the concrete

pump located on the top of the shaft by means
of transit mixers:
Concrete transportation into the shaft and subsequent pouring into the installed
liner will be performed by stationary pump through the steel pipe line.
In order to not create unexpected stresses to the form, concrete lifts will be poured
in layers, so that the difference of level in any part of the casting will not exceed the
limit defined by the equipment designer.
Concrete will be compacted by means of vibrators, inserted in the already placed

concrete for a lower depth than the thickness of two concrete layers.
Detachment of the formwork will be performed when the concrete has hardened
and developed enough strength to self-sustain.
The minimum time that will have to elapse between the end of each pouring and
the start of the removal of the relevant formwork will minimum 12 hours, in
compliance with the technical specifications and based on the selected concrete
admixture. Refer to
At the end of the cycle, the detached formwork will be lifted with chain blocks and
then positioned upward for next cast.
Curing operations of previously cast concrete will be performed by the workers

through the lower working platform provided under the climbing formwork and
accessible from the base level via steel ladders.
Square shape steel form will be fabricated according to the required size for inlet
transition part. Stiffing ribs and yokes will be provide for the stresses caused by the
pouring of concrete.
Same procedure of lifting and pouring will be adopted for the transition part.
Owner’s Engineer
6.3 Inlet transition part.

Lining concrete works of inlet transition part will be started upon completion of vertical shaft lining concrete
Working plate form will be prepared on the top of vertical shaft. As shown in the figure below
Working platform will be made of steel beam and steel mash.
Lining concrete work of inlet transition will include following activities.
Survey inspection and removal of any overspray of shotcrete if found
Fixing of lining rebar according to drawing
Placement of concrete spacers to secure required concrete cover
Fixing of form work, combination of wooden and steel form will be used to meet typical requirement of transition part.
Form plates and supports will be lowered on the location by using mobile crane fixed at intake elevation 517.
Form work will be supported with acrow props.
Surveyor will check the verticality and alignment, after confirmation, form and support will be fixed.
Concrete will be poured in 3.5 meter lifts. As shown in the figure below.
Concrete will be poured by using stationery concrete pump.
Concrete will be poured in 50 cm layers, each layer will be compacted by means of vibrator.
Surveyor will monitor the form work alignment during concrete poring.
. {Figure 14: Inlet transition part formwork}
Working plate form
As the same form will not be used for next pour, it has planned to delay striping few more hours from the
recommended striping time. Striping will be started from the supports, mobile crane will be used to shift form out.
Concrete will be cured continuously by using water pipes and manpower up to 14 days as per project
specifications.
Owner’s Engineer
6.4 Concrete lining Procedure for horizontal tunnels

Horizontal pressure tunnel concrete lining will start from the lower bend towards the outlet.
The concrete lining will be performed by means of self-erecting formwork, major

advantage of using such formwork is that it is equipped with hydraulic jacks which
will allow easy positioning and movement. Refer to attached 3
Form work will be brought at yard located at the top of right side slopes by means
of low bed trailer, form will be assembled in the yard and a visual hydraulic jack test
will be carried out by the manufacture of the form. Form will be shifted to out let by
using 100 ton crane. Form will be shifted in tunnel by using hydraulic jacks.
{Figure 15: Horizontal lining form X-section}
‘
Owner’s Engineer
{Figure 16: Horizontal lining form longitudinal section}
The lining procedure will include following activities

Dismantling any interfering temporary infrastructures such as lightening, water
pipes, drainage pipe and any other obstacles.
{Figure 17: Horizontal lining form and steel}

Owner’s Engineer
Cleaning and removing and dirt and left overs due to tunneling works by means of
Bottom cleaning with water jets and manpower.
Placement of lean/leveling concrete, lean concrete will be started from lower bend
towards out let.
Bottom will be fully cleaned and required top level will be marked at fixed rebar.
Concrete will be placed by using concrete pump.
Survey of the shotcrete face and check for minimum concrete thickness allowance
and remove any over spray which may prevent correct re-bar placing.
Placing re-bars using steel plate form.
Fixing of concrete spacers to secure required concrete cover.
Fixing of grouting plugs according to the drawing and specifications.
Placing formwork according to drawings. This operation will involve a surveyor
which will check formwork positioning.
Pour concrete using long pipes. Special care shall be given during concrete
pouring in order to avoid non symmetrical cast.
Allow initial strength development will be checked by QA department.
{Figure 18: Horizontal lining form and steel}
Detachment of the formwork will be performed when the concrete has hardened
and developed enough strength to self-sustain.
The minimum time that will have to elapse between the end of each pouring and
the start of the removal of the relevant formwork will minimum 12 hours, in
compliance with the technical specifications and based on the selected concrete
admixture.
Owner’s Engineer
At the end of the cycle, the detached formwork will be shifted by using hydraulic
system and then it will be positioned for next cast.
6.5 Steel penstock

Method statement of steel liner installation welding etc. has been submitted and approved by the owner
engineers via references:
DLJV-OE-TR-0257 Dated 7 –Oct-2016
OE-EPCC-4.5-1059 Dated 01 –Nov-2016
Concrete pouring procedure will include the following activities
 Concrete will be placed by using concrete pump.
 Survey of the shotcrete face and check for minimum concrete thickness
allowance and remove any over spray which may prevent correct re-bar
placing.
 Fixing of 6 meter steel according to approved method shells.
 Survey inspection for alignment and positioning of steel liner.
 Pour concrete using long pipes.
 Compaction of concrete by using inner and external vibrators
 Last 50 cm of each shell should not be poured and covered by plastic sheets
for welding with the next shell.
6.6 Concrete lining methodology.
6.6.1 Lining concrete sequence.
Concrete lining of waterway tunnels will be started from lower bend of waterway tunnel#2, after
completion, lower bend form will be shifted to tunnel #1 and horizontal and vertical pressure
section of tunnel 2 will be parallel started.
Upon completion of horizontal pressure tunnel 2 and lower bend tunnel 1, horizontal form will
be shifted to tunnel #1 and execution of steel penstock lining will be started in tunnel #2.
In the mean while vertical pressure shaft #2 will be completed and vertical liner will be shifted in
tunnel #1 and inlet transition part will be started.
For detail lining sequence refer to attachment #4
6.6.2 Concrete supply

 Concrete will be batch in the batch plant
 Concrete will be supplied on site by means of transit mixers
6.6.3 Horizontal tunnels and steel pen stock
 Concrete will be supplied in horizontal tunnel including steel penstock by using stationery
concrete pump installed at outlet.
 Concrete will be supplied by means of 6 inch steel pipe line.
 Pipe will be distributed in two lines to assure symmetrical cast.
 For detail pouring plan in horizontal tunnel see attached 7.
 For steel penstock concreting plan refer to submission (DLJV-OE-TR-0948)
 Concrete in horizontal tunnels will be supply by using concrete supply pipes provided in the
lining form, these pipes will be connected to the main supply (for detail please see attached
lining form drawing). Concrete supply nozzles are provided at the bottom walls/sides and at
Owner’s Engineer
the top. Pouring will be started from bottom then sides and finally top. Wall plugs will be
connected with one main supply for symmetrical cost in both sides.
6.6.4 Vertical tunnels and lower bend

 Concrete will be supplied in Vertical tunnels by using stationery concrete pump which will
be installed at the top of intake right slope beside of already fixed concrete placement
boom at elevation 533.00
 Concrete will be pumped through the m/s pipe line at the desired location.
 At pouring location Pipe will be distributed in two lines to assure symmetrical cast.
 In the lower bend section concrete will be supplied from the vertical shaft through the pipe
line, at the top of lower bend pipes line will be distributed in two lines, these lines will be
inserted on the both sides of bend for symmetrical cast.
 As lining thickness is one meter in this section which is enough space for worker to go in
for positioning concrete supply pipes and using of vibrator. refer to attachment #7
6.7 Concrete compaction

Multiple compaction systems will be used in waterway tunnels for compaction maximum result.
Primarily inner vibrator will be used throughout the waterway tunnels, in horizontal tunnels
7.1 Horizontal pressure tunnels
. {Figure 19: concrete compaction}
Inner vibrator will be used through the windows, however external vibrators will also be used
where internal vibrators is not practicable
4-8 kg wooden hammers will be used for compaction purpose when required. As shown in the
figure above.
7.2 Lower bend
Concrete Lining thickness is one meter in lower bend section, which is enough space for
worker to go to for us of vibrator.
Two inner vibrators will be used on both side for effective concrete compaction.
Each 50 cm layer will be compacted by means of inner vibrator.
5-8 kg wooden hammer will be used when required for better result.
Owner’s Engineer
7.3 Vertical pressure tunnel and inlet transition

In vertical pressure tunnel and inlet transition part concrete compaction will be performed from
the top. Concrete compaction in these section is as simple as in the wall. Simple but enough
inner compaction will be performed by using inner vibrator. Each 50 cm layer will be
compacted.
7.4 Access road to waterway outlet

Current access road will be used to supply steel, concrete and other material to the horizontal
tunnels.
Heavy materials such as horizontal lining form and steel penstock shells will be off loaded in
the yard, located at the top of power house left side slopes near the construction road 1 steel
bridge and then it will be shifted at outlet by using required capacity mobile crane.
Current access road will be maintained until completion of horizontal tunnels
Around 4 meter width of power house covered by the current access road to waterway
horizontal tunnels will be excavated upon completion of waterway horizontal tunnel lining
concrete.
Crack age chemical will be used for rock excavation for damage prevention to the nearby
structures.
7.5 Grouting works.

A separate method statement for waterway tunnels grouting works will be submitted
7.6 Progress schedule.

Progress schedule of waterway horizontal tunnels lining concrete is attached, refer to attachment #4
7. Quality assurance and Quality Control plan

The QA/QC Department is responsible to ensure that all the activities/executions being performed on the
Project are “Quality Ensured”. Project QA/QC Plan submitted in your office dated 04th October 2016 via
letter no DLJV-OE-QA-120 after review your observation response. The QA/QC Dept. has therefore
established a systematic and fully organized approach to do its job in an efficient and streamlined way.
Inspection and Testing plan is given in attachment #.2
However, a brief description regarding inspection of executed work of Water Way tunnels is given below:
The complete system is described below:
1. Quality Control
2. Quality Assurance
3. Related Documents
Abbreviations Used:
RFI:Request for Inspection
BP: Batching Plant
QC: Quality Control
QA: Quality assurance
RCP: Report of Concrete production
CDN: Concrete Delivery Note
Owner’s Engineer
PQP: Project Quality Plan

OE: Owner’s Engineer
7.1. QUALITY CONTROL SYSTEM
7.1.1 Concrete/Shotcrete Production

The production of Quality Controlled Concrete falls in the scope of QC Department. The concrete batching
plants (BPs) would therefore run under the control of QC department. QC staff would check the moisture
content of coarse and fine aggregate before start of concrete production and provide to BP operator
(signed copy) for adjustment of water, sand and coarse aggregate. These adjustments shall be made by
BP itself when moisture content is input to the system. “Concrete Delivery Note” (CDN) and “QC Report
of Concrete Production” (RCP) shall also be signed by the QC staff and verified by the concerned
authority.
For each Transit mixer, the BP staff would prepare and produce the following record on priority basis. QC
staff would also maintain the same:
 CDN
 BPR
7.1.2 Verification of Quality

QC persons (i.e. Lab Engineer, Lab technician, Lab assistants/helpers) shall be at concrete BP to monitor
the following properties of produced Concrete
 Temperature
 Slump
 Air Content
In addition to above, concrete cylinder shall be cast at site and bring Laboratory to verify its compressive
strength at required ages as per project specifications.
The following information shall be marked on every concrete cylinder.
 RFI #
 Concrete strength
 Casting date
 Concrete cylinder #
 Lab #
QC staff would prepare and maintain a set of following documents against each request of Concrete
production:
 RFI
 RCP
 Compressive strength test results
7.1.3 Quality Control of Works under execution

The Surveyor of construction team is responsible for checking and assurance of survey works and preparing
the mandatory record sheets accordingly.
Rebar cutting bending, transport on site form steel yard, formwork, embedded items installation, dewatering
and concrete placement are the responsibilities of construction department.
Owner’s Engineer
7.2. QUALITY ASSURANCE SYSTEM
QA department would assure the quality of above stated works at each stage. However, construction team is
required to submit RFI along with requisite documents for inspection of each stage on completion to the
QA staff (Refer to 7.2.1 – Inspection procedure and record). This formal inspection procedure is
mandatory as per international standard/ project contract documents. QA staff would be responsible to
maintain all QA related record of inspections for above stated works.
The quality assurance of under execution works; Rebar cutting bending, formwork, embedded items
installation and concrete placement also assured by QA team during the work.
The quality of produced Concrete shall also be assured at site by the QA staff (i.e. Inspector, Lab Technician,
Lab Assistant/helpers etc.). They would prepare and sign the “QA Report of Concrete Placement”.
QA persons (i.e. Inspector, Lab technician, Lab assistants/helpers) would be present at site to check the
following properties of transported Concrete:
 Temperature
 Slump
In addition to above, Concrete cylinder would be casted at site as per frequency of project specification to
verify compressive strength of it’s at required ages. The following information should be marked on every
concrete cylinder which mention below
 RFI #
 Concrete class
 Casting date
 Concrete cylinder #
 Lab #
These concrete cylinders would be carried to laboratory for further necessary testing.
QA staff would prepare and maintain a set of following documents against each request of
shotcrete/Concrete production:
 QA report of Concrete placement
 Compressive strength test result
7.3. Inspection procedure and record

Proper documentation is necessary and would therefore be done as per international standards and
project specifications for the satisfaction and assurance of the client/consultant/lenders. A brief step by
step procedure to manifest the flow of Request for Inspection (RFI) and allied documentation is
explained below:
Step # 1 Construction team would prepare/complete the sub-activity according to design and drawings
and after their satisfaction would generate and submit an RFI to QA/QC department. The
RFI submitted must accompany the Survey sheet and other necessary relevant
documents.
Step # 2 QA/QC Engineer/Inspector would receive and record the RFI in a register and carried out
inspection.
Step # 3 If RFI is related to works of Reinforcement, etc. then QA Engineer/Inspector shall make
inspection accordingly. He shall sign the RFI and relevant checklist and update the record
of “RFI Register”. Representative of Construction team would be present at site throughout
Owner’s Engineer
this process so that important instructions may be delivered to him directly without any
confusion and ambiguity.
Step # 4 If RFI is related to concrete placement then QA Engineer/Inspector would inspect and on
satisfactory inspection he would mark the RFI to Lab Engineer/Snr. Lab Technician for
concrete production accordingly. The representative of Construction team would be
responsible to deal with the manpower to ensure the proper placement of concrete.
Step # 5 Lab Engineer/ Snr. Lab Technician would receive the request and enter the relevant data in
the “Lab Test Request Register”. He would depute QA/QC staff at BP for QC of Concrete
production and it’s QA at site respectively. “RCP” and “QA Report of Shotcrete Placement”
shall be prepared and signed by concerned authorities at BP and site respectively.
During above stated process of Concrete production, the BP operator would issue “CDN” for
each transit mixer duly signed by him and QC staff at BP.
Step # 6 On completion of above process, the QA Engineer would forward the RFI to the QA Manager
for review and signature.
7.4 RELATED DOCUMENTS

The assurance of the quality of diversion tunnel the mention below document is used during execution of work.
The document already submitted in QA/QC plan.
a. Compressive strength (Cylinders & Cubes) Doc no. QAQC-015
b. QC Report of concrete production Doc no. QAQC-022
c. QA report of concrete placement Dec no. QAQC-033
d. Concrete delivery note Doc no. QAQC-036
e. Request for Inspection Doc no. QAQC-040
f. Formwork Checklist Doc no. QAQC-042
g. Reinforcement Checklist Doc no. QAQC-043
h. Concrete Casting Approval Sheet Doc no. QAQC-046
i. ITP for Waterway tunnel Doc no. ITP-13/WT
The QA/QC team always invites and welcomes the criticism and suggestions that would be
helpful to enhance its capacity and efficiency leading to a better and proud finish. After all,
the successful completion of a Project always demands a good “teamwork”.
Owner’s Engineer
8. Health, safety and environment plan

The health, Safety and Environmental plans shall be incorporated during all stages of construction stages of
Power House. It shall be based and shall comply with the policies, standard operation Procedures, and
international safe work practices.
The objective of the Health, safety and Environment plan is to protect health and well-being of workers working
on site, and ensure safety is a prime consideration in project execution by providing hazard free work place.
Before commencement of work the following key Health safety and Environmental issues shall be properly
addressed.
 During construction material transportation proper root shall be designated for heavy equipment
movement to control road traffic incidence,
 Proper area shall be designated for tower crane parts unloading and assembling,
 Competent operator and rigger shall be appointed for crane operation
 Only authorized person shall carry out lifting activity
 To carryout safe lifting operation, compliance of permit to works system shall be ensured,
 The lifting equipment that includes shackles and slings must be of good quality and third party certified.
 Concrete placement boom shall be thoroughly inspected periodically by the heavy equipment department
to ensure good condition of joints and clamps used.
 Whip checks shall be used at each joint of air compressor pipes.
 All the newly hired workers shall be inducted prior to send them to site
 The access way for the workers shall be un-obstructed and proper,
 The construction material shall be unloaded at designated area,
 Signal men to shall be deployed at different point to control traffic in routine and during concrete placement
in particular.
 Ventilation ducts shall be installed for working in confined spaces like DE-watering tanks if required
 As per OHS procedures all the workers shall wear proper full body harness while working at and above
1.5 meters height,
 Workers designated for concrete placing bucket shall be provided water proof gloves, to avoid workers
exposure to concrete.
 In case of workers working inside concrete must be provided gum shoes with steel toe.
 All the workforce including engineers shall use mandatory Personal Protective Equipment during concrete
placement activity.
 Suitable ear muffs must be provided to workers in noisy areas to protect workers from noise induced
hearing Loss injury (NIHL),
Owner’s Engineer
 All the Un-protected/open rotating parts in general and conveyor belt in particular must be appropriately
guarded whereas the un protected edged must be barricaded properly to control fall hazard.
 Lock out/ Tag out procedure to shall be developed when servicing equipment,
 All the chutes in general and Transit Truck Mixers in particular must be secured to reduce injuries from
swinging parts,
 Right person for the right job shall be followed,
 During reinforcement/ steel erection proper rebar caps shall be used to avoid contact with sharp edges,
 To avoid environmental contamination (Soil and water) the grout and waste concrete shall not be thrown
onsite.
 As per spill contingency plane Geo membrane impermeable liners shall be provided to control spill
(chemical and oil).
 The Geo membrane impermeable liners shall be fixed with appropriate bonding underneath power
generators, Compressor etc. onsite.
 All the electrical equipment in general and specifically electrical DB and power generators shall
appropriately grounded to avoid electrocution.
 Loose material above the work site shall be remove to control falling object hazard if prevails.
 Housekeeping of the worksite shall be maintained on daily basis to keep the area clean/tidy
 Capacity of the workers shall be built through daily toolbox meeting regarding worksite hazards and
suitable control measures,
 Platform material in general and scaffolding components that includes (Pipes, joints, etc.) shall be as per
standard and shall be inspected before construction, after platform completion and after alteration to
ensure safety at all stages,
 Personnel working in the area will wear mandatory personal protective Clothing/Equipment,
 Dust and noise will be generated during drilling and grouting; so all the workers on site will wear masks &
ear plugs all the time and maintain a minimum distance of 1 m away from the equipment,
 Powered equipment will not be left running unattended,
 Barricades with warning devices and flashing lights as needs shall be installed alongside of site area
wherever people or vehicles are exposed and warning lights placed at night,
 All the electrical appliances shall be certified (CE Marked) and shall be visually inspected by a competent
person prior to start work on daily basis,
 Welfare facilities in general and an operational toilet must be ensured at site for workers facilitation,
Owner’s Engineer
8.1 Health, Safety and Environmental Arrangements
EPC Contractor EHS department will implement all the agreed EHS plans during the execution of works
explained within the scope of work for Power House. The construction works for the Power House will be
undertaken with.
 Job Safety Analysis

 Risk assessments for critical activities
 Trainings on JSA
 Inductions and Toolboxes
 Inspection schedule
 Audits
 And onsite monitoring by HSE personnel.
8.2 Organization Chart for EPC HSE Department

Health Safety and Environment performance relies on well-functioning line management and their duly
responsibilities. Therefore this places all the managers and site engineers from Project Manager down to site
engineer and foremen in the field at the forefront of Health Safety and environment campaign. Overall
responsibility and accountability for Health Safety and Environment lies with the Project Manager EPCC and
cascade down to all the engineers and foremen and workforce within the EPCC Management structure according
to the framework presented below.
8.2.1Overall Responsibility
The Contractor accepts overall responsibility for all matters including those regarding health, safety and welfare.
The Contractor is responsible for promulgating Contractor’s OSH Policy and ensuring that i t is being
complied with at all levels in the organization.
8.2.2 Management Responsibility

Managers are responsible for ensuring that the Health and Safety Policy is implemented. Managers must monitor
their workplace to ensure that safe conditions are maintained. Where risks are identified the manager must
ensure that these are rectified, so far as is reasonably practicable. The following are the individual responsibilities
for safety and health of key personnel’s within the organization:
8.2.3 Contractor’s Project Manager
 Ensuring that employees, sub-contractors and visitors are aware of safety procedures.
 Establishing that all equipment, plant and substances used are suitable for the task and are kept in
good working condition; this include, the regular maintenance and servicing of equipment.
 Providing adequate training, information, instruction and supervision to ensure that work is conducted
safely.
 Taking immediate and appropriate steps to investigate and rectify any risks to safety and health
arising from the work activities.
Owner’s Engineer
 Bringing to the attention of the Contractor and the Employer any health and safety issues that require
their attention.
 Ensuring that all accidents and “near misses” are properly recorded and reported and that an
investigation is carried out to determine the root causes.
 Maintaining safe access at the workplace at all times.
 Be the Chairman of the Project’s Safety and Health Committee and ensure that all matters relating
to safety and health brought out in the meetings are carried out and enforced appropriately.
8.2.4 Site Manager

 Knowing and understanding the Contractor’s Safety Policy and the responsibility for safety allocated
to each level of staff within the project.
 Coordinating safety activities between the Contractor and sub-contractors.
 Determining at the planning stage:
 The most appropriate order and method of working;
 The provision of adequate lighting;
 The allocation of responsibilities with sub-contractors and others;
 Hazards which might arise from overhead or underground power lines and other situations which
might lead to unnecessary improvisations on site;
 Facilities for welfare and sanitation;
 Basic fire precautions. Pavement
 Providing written instructions to establish working methods to explain the sequence of
operations, outlining potential hazards at each stage and indicating precautions to be adopted.
Provide written safe working statements for plant and equipment as well as operators.
 Checking over working methods and precautions with the Project Manager before starting work.
 Ensuring that work, once started is carried out as planned and in accordance with the Health
and Safety Plan, relevant laws, regulations, and codes of practice.
 Setting good personal example.
 Seeing that proper care is taken of casualties and know where to obtain medical help and
ambulance service in the event of a serious injury.
 Accompanying relevant government authorities on site visits and complies with their
recommendations.
 Releasing supervisors and operators where necessary, for on or off site safety training.
Owner’s Engineer
8.2.5 Construction Engineer

 Organizing work sites so that work is carried out to the required safety standard with minimum
risk to men, equipment and materials.
 Understand the requirement of the Safety Plan in accordance with the applicable legislation
currently in force in Pakistan and other relevant legislation and how it applies to the project.
 Ensuring that all materials and equipment sent to site are safe and fully efficient, are guarded
and equipped with safety devices and are tested in accordance with the safety plan.
 Making certain that all plant operators and maintenance personnel are only employed for that
which they have been thoroughly trained.
 Checking that all repairs and maintenance work carried out on site is done in a proper manner
and that emergency repairs are dealt with properly as soon as possible. Call the attention of site
management if there is a need for dangerous plant to be put out of service.
 Checking that hired plants are safe and that, where appropriate, copies of current test certificates
are available.
 Giving all Foremen and leading hands precise instructions on their responsibilities for proper
working methods; see that they do not require or permit men to take unnecessary risk.
 Arranging delivery and stacking of materials to avoid risks by double handling; positioning plant
effectively, ensuring that the electricity supply is installed and maintained without endangering
men and equipment.
 Planning and maintaining a tidy work site.
 Implementing arrangements with sub-contractors and other contractors on site to avoid any
confusion about areas of responsibility.
 Making sure suitable protective clothing is available and used.
 Liaising with the District Fire Brigade of Municipal Corporation Kotli (MCK) on fire prevention.
Prior approval will be taken from these departments.
8.2.6 Foreman
 Understand the requirement of the Health and Safety Plan and regulations applicable to the work
on which their gangs are engaged and insist that those regulations be observed.
 Incorporating safety instructions in routine orders and seeing that they are being obeyed.
 Restraining workers from taking unnecessary risks.
 Ensuring that new employees to be trained on the workplace safety precautions.
 Transmitting safety knowledge and Contractor’s message to his fellow workers.
Owner’s Engineer
 Discouraging horseplay and reprimanding those who consistently fail to consider their own well-
being and that of others around them.
 Reporting defects in plant or equipment.
8.2.7 Workers
 Using the correct tools and equipment for the job; use safety equipment and protective clothing
supplied, e.g. roof ladders, safety helmets, safety harness, goggles etc., according to job
performed and the hazards identified.
 Keeping tools in good working conditions.
 Reporting to supervisor defects in plant or equipment.
 Developing a personal concern for safety– for themselves and for others, particularly newcomers
and young people.
 Avoiding improvising which entails unnecessary risk.
 Advice and warning new workers of known hazards.
 Refraining from horseplay and the abuse of welfare facilities.
 Suggesting ways to eliminating hazards.
8.2.8 Safety and Health Officers
 Advising site management on the following:
 Prevention of injury to personnel and damage to plant and equipment.
 Further improvement in existing sound working methods.
 Legal requirements affecting safety, health and welfare of the workers.
 Provision and use of protective clothing and equipment.
 Potential hazards on new contract before work start and on the site safety organization.
 Methods of safe working arising from new developments/activity.
 Changes in legislation and safe codes of practices.
 Other related health and safety issues occurred in the project.
 Carrying out hazard identification and assessment, in association with the Construction
Manager, Supervisor to decide on the best safe methods of working are in operation; that
all regulations are being observed.
 Determining the cause of any accident or dangerous occurrence and recommends means
of preventing recurrence.
 Supervising the recording and analysis of information on injuries, damage and loss, analyze
accident trends and review overall safety performances.
Owner’s Engineer
 Provide training input for all levels of employees on safety issues.

 Promoting awareness of injury prevention and damage control to all levels of employees.
 Keeping contact with official and professional bodies relating to occupational health and
safety in Pakistan.
 Conduct the health and safety programs such as weekly training, weekly toolbox talks,
weekly machinery inspection, weekly walkabout etc.
 Ensure the welfare of the workers to be taken care of such as sleeping facilities, drinking
water facilities, food supply and etc.
 Keeping up to date with recommended codes of practices and new safety literature, circulate
information applicable to each level of employees.
 Acting as secretary for the Project Safety and Health Committee Meeting.
 Liaise with the Health & Safety Manager to ensure that subcontractors are complying with
Environmental and Safety requirements.
8.2.9 Duties of Sub-Contractors
 To submit written disclosures to the Contractor, declaring that they will fully comply with the
Health and Safety policy and adhere to the health and safety management procedure.
 Sub-contractors should familiarize themselves with the Health and Safety Plan. They should
also study the safety requirements fully and prepare their own safety plans which will be
submitted to the Contractor. These plans will be first approved by the Contractor.
 Before start work on site, attend a meeting and discuss with the relevant manager the
method statement, risk management, control of hazardous substances to be used etc.
Upon any change of project activities or site conditions, relevant subcontractors are
responsible for resubmission of the above accordingly.
 Inform, train and remind the workers constantly with regard to the construction activities and
site material risk. Maintain an effective register system to monitor and ensure that all the
workers are made aware of and trained. Tool box talk manual to guide the subcontractor
will be provided by the Contractor.
 Submit detailed information of workers, the plant, equipment, hazardous substances to be
used and the safe working method, relevant and statutorily required test or examination
certificates of plan/equipment, materials safety data sheet etc.
 Ensure that the plants, equipment, hazardous substances supplied and used on site are
strictly incompliance to statutory regulations.
Owner’s Engineer
 Provide appropriate safety equipment and safety measures to employees. In addition,

provide effective safety training and supervise their safe work methods.
 Comply with and support safety audit in the planning stage as well as during operation so
as to continuously improve safety performance.
 Be alert and aware of the stringent safety requirements, which will be communicated orally
and /or by the issuance of safety instructions, rules and regulations.
 Report all incidents and emergencies to the Contractor.
8.3 Environmental Controls
The purpose of this document is incorporate the environmental impacts related to curtain grouting at Weir and
suggest the mitigation measures in order to reduce/minimize the impact on the environment of Poonch River
Mahasheer National Park.
8.3.1 Scope
The monitoring of environmental parameters will be carried out at throughout the grouting activity and different
parameters will be checked on regular basis. Waste disposal, waste water treatment and soil contamination will be
monitored regularly.
8.3.2 Issues
Following are the environmental issues related to curtain grouting.
 Use of water for curtain grouting.
 Waste water generation.
 Solid waste generation.
 Soil contamination
8.3.3 Controls for related issues:

Following controls will be helpful in carrying out the process in an environment friendly manner.
8.3.4 Water Use for grouting:

Water used for grouting and associated activates will be transported from tube well or mobile water storage tank
According to ESIA Section 7.2.4 “water resource depletion”, river water can also be used for construction
purposes to minimize the negative impact on ground water resources available within or near the project area.
8.3.5 Waste water generation:

As per ESIA section 11.1 “Mitigation and management plan”, release of waste water into river without treatment is
prohibited. So there should be sedimentation ponds to collect the waste water and it is treated accordingly prior to
its discharge.
8.3.6 Solid waste generation:

During the drilling of holes for grouting, solid waste will also be produced, or other waste irrespective of it nature
during the process will be categorized and treated as per waste management plan.
Owner’s Engineer
8.3.7 Soil contamination:

Use of power generator for electricity supply, compressor or other oil containing equipment may cause oil spill
onsite, In order to avoid soil contamination from oil or chemical spill, concrete pad with bunds of 120% extra
capacity of fuel storage will be ensured. (ESIA section, 7.2.1 soil quality, 11.1 Mitigation and management plan)
The above mentioned suggestions will protect the environmental degradation and resource depletion during the
curtain grouting activity
Overall Responsibilities of Areas
Mr. Saboor Khan Sr. Health Safety Officer Cofferdam, Intake and Weir /In charge in absence of HSE
Manager
Mr. Muhammad Anees Health Safety Officer In charge for all site areas on EHS matters and Office
Mr. Usman Iftikhar Health Safety Officer In charge for All Sites
Mr. Bilal Iftikhar Health Safety Officer In charge for Outlet/tunnels/Powerhouse
Mr. Rowaid Ullah Health Safety Officer In charge for Cofferdam and Intake Area
Mr. Qadeer Ali Health Safety Officer In charge for Inlet and Cofferdam (Night)
Mr. Salman Ahmed Health Safety Officer In charge for Cofferdam & Powerhouse (Night)
Owner’s Engineer
Mr. Rohail Asghar Health Safety Officer In charge for Stilling Basin and Cofferdam
Mr. Burooj Hateem Environmental Specialist In charge for all site areas on environmental matters and Office
Night Shift
Project Manager
Mr. Dong Ho Lee
EHS Advisor
Sahibzada Tanzeel/Mr. Saboor
Cofferdam/Weir
Health Safety Health Safety

Officer Officer
M. Qadeer Ali Mr. Salman
Overall Responsibilities of Areas
Mr. Qadeer Ali Health Safety Officer Power House, Weir, Stilling Basin
Mr. Syed Salman Health Safety Officer Power house, Weir, Stilling Basin
8.4 Risk Assessment (RA) & Job Safety Analysis

The EPC Health, Safety and Environment will conduct a detail Job Safety Analysis of the activity and share with the
relevant departments for implementation before the start of activity.
8.4.1 Job Hazard Analysis
8.4.1.1 Purpose
The sole purpose of Job Hazard Analysis is to identify, control or eliminate potential or actual dangers in a
job or task.
Factors that will be considered in assigning a priority for analysis of jobs include:
 Accident frequency and severity: jobs where accidents occur frequently or where they occur
infrequently but result in disabling injuries
Owner’s Engineer
 Potential for severe injuries or illnesses: the consequences of an accident, hazardous

condition, or exposure to harmful substances are potentially severe.
 Newly established jobs: due to lack of experience in these jobs, hazards may not be evident or
anticipated.
 Modified jobs: new hazards may be associated with changes in job procedures.
 Infrequently performed jobs: workers may be at greater risk when undertaking non-routine
jobs, and a Job Hazard Analysis provides means of reviewing hazards
EPC management and supervision is responsible for ensuring all work is safely planned while the Contractor
in charge will ensure the implementation of safety protocols at project site; the Job Hazard Analysis will
assist in determining firstly, what are the steps in the job; secondly, what are the potential hazards in the job;
and finally, what are the protective measures for the safety of our worker(s) assigned to do the non-routine
work.
8.4.1.2 Instruction before Starting Work/Job Hazard Analysis (JHA)

Before starting work at any worksite, EPC Project Manager and Environment Health Safety Advisor shall be
contacted for specific instructions concerning known site hazards and any special safe work practices
particular to that site. The EPC Contractor will review the safe work practices with Health and Safety officer
and all other effected parties. The subcontractors also may be required to prepare the Job Hazard Analysis
(JHA) for the proposed work activities. Approval from the Contractor is required prior to work
commencement at the worksite.
8.4.1.3 Method Statement/Penalty System/Safety Award

In case if the Contractor executes the construction task the Contractor HSE Team shall fulfill all the safety
requirements .Prior to the commencement of work on site the EPC Contractor shall present to the JV-
Consultant a detailed method statement incorporating a plan for safe systems of work and explaining how
safety will be managed and controlled throughout the contract works.. This plan must comply in every
respect to Contractor’s Health and Safety Regulations and MPL EHS & CSR Policies. It should specifically
detail how the sub-contractor intends to implement and, if necessary enforce, safety on site including a
system of warnings and penalty to be imposed on individual workers or Sub-contractors for ignoring safety
requirements.
Sub-contractors should also include proposals for a system of safety awards to sub subcontractors and
workers for good safety performance, which they will operate at their own cost. The Contractor will assess
each General Contractor’s safety performance on a regular basis and will rank sub-contractors in order of
good performance. Rankings will be publicized on site.
8.4.1.4 Accident Prevention Introduction and Training

The EPC Contractor shall ensure that all his employees are adequately trained in the proper work
procedures and health and safety regulations pertaining to their duties. This education will be conducted at a
pre-start up safety meeting, or weekly toolbox talks, with all employees and/or groups of employees prior to
their starting the work and, as a minimum, shall be in accordance with the Contractor and/or relevant
authorities’ requirements. Further training and instruction shall be provided by the Contractor as necessary
on an ongoing basis and before the start of any new major segments of the work.
8.4.1.5 Breakdown of Job Steps

Job or task identified for analysis by supervisor.
Owner’s Engineer
Supervisor overseeing the job breaks job into steps (with assistance from crew members, health & safety
rep etc.)
A job step will be defined as a segment of the operation necessary to advance the work
Keeping the steps in the correct sequence
8.4.1.6 Identify Actual/Potential Hazards (refer to checklist)

Once the basic steps have been recorded, potential hazards will be identified at each step. It shall be based
on observation of the job, knowledge of accident and injury causes, and personal experience. To identify
potential hazards, the supervisor will use questions such as follows:
 Can any body part get caught in or between objects?
 Do tools, machines or equipment present any hazards?
 Can the worker make harmful contact with objects?
 Can the worker slip, trip or fall?
 Can the worker suffer strain from lifting, pushing or pulling?
 Is the worker exposed to extreme heat or cold?
 Is excessive noise or vibration a problem?
 Is there a danger from falling objects?
 Is lighting a problem?
 Can weather conditions affect safety?
 Is harmful radiation a possibility?
 Can contact be made with hot, toxic or caustic substances?
 Are there dusts, fumes, mists or vapors in the air?
8.4.1.7 Preventative Measures/Controls

The final stage of Job Hazard Analysis is to determine ways to eliminate or control the hazards identified.
8.4.1.8 Eliminate the Hazard

• This is the most effective measure, some examples are:
• Choose a different process
• Modify an existing process
• Substitute with less hazardous substance
• Improve environment (ventilation)
• Modify or change equipment or tools

Owner’s Engineer
8.4.1.9 Contain the Hazard

If the hazard cannot be eliminated, contact will be prevented by using enclosures, machine guards, worker
booths or similar devices.
8.4.1.10 Revise Work Procedure

Consideration shall be given to modifying steps that are hazardous, changing the sequence of steps or
adding additional steps.
8.4.1.11 Reduce the Exposure

These measures are the least effective and should only be used if no other solutions are possible. One way
to minimizing exposure is to reduce the number of times the hazard is encountered.
8.5 Communication of Job Hazard Analysis to Workers

When the Job Hazard Analysis is completed, the results will be communicated to all workers who are, or who will
be, performing the job. The job hazard analysis shall be discussed by the employees performing the job to
ensure that all the basic steps have been noted, are in the correct order, have suitable controls and be
documented and signed by the worker and supervisor. Supervisors will ensure that workers are following the
appropriate control procedures.
Health, Safety and Environment Plan shall be applied during construction work on the Intake activities. It shall be
based and shall comply with the applicable laws, decrees, administrative rules and regulations, Client’s policies,
standard operation procedures, and international safe work practices. Objective is to protect the health & well-
being of personnel during work site activities and ensure that safety is a prime consideration in the project
execution by establishing and maintaining an injury and incident free culture in the workplace.
8.6 Incident Reporting & Notification Requirements
8.6.1EPCC Incident & Occurrence Notification Requirements

The reporting requirements for the range of scenarios which may occur during Gulpur Hydropower Project
construction works will involve incident reporting to all pertinent stakeholders as per EHS Program and CMP
(Construction Management Plan).
8.6.2 Emergencies
The Emergency response and contingency plan criterion is fully in harmony with emergency plan agreed for
Gulpur Hydropower Project.
All emergencies will be dealt with ERP and CP.
8.6.3Medevac Plan
All medical emergencies will be dealt with medevac plan for GHPP.
If a serious injury or illness occurs, the following actions will be taken:
8.7 Doctor/Medical Officer On-Site

• Advise HSE Coordination Team of Company that MEDEVAC may be required.
• Liaison with Doctor at Rig & confirm requirement for MEDEVAC
• Ensure that Site Manager have all pertinent medical information including; personnel details,
allergies to drugs, condition and symptoms of, causality and medical aid administered. Prepare
patient for MEDEVAC
Owner’s Engineer
• Complete medical forms for transmittal to nearest DHQ Hospital Kotli
8.8 HSE Coordination Team

With Medical Officer On-Site determine mode of transportation in consideration of:
 Number of casualties.
 Nature and extent of injuries.
 Location of nearest Medical Center
 Transport mode and capacity.
 Weather conditions
 Arrange transport, Road or airlift in case of a remote area
 Maintain personnel list and movements up to date
 Re allocate duties
 Request replacement personnel
 Inform Contractors site office
8.9 Site Manager
 Inform Project Manager
 Inform Medical Officer and request associated support
 Arrange MEDEVAC transport requirements
 Arrange to receive casualties
 Monitor situation
Owner’s Engineer
9. Attachments
Attachment #1 lower bend steel form
Attachment #2 Vertical pressure tunnel lining form
Attachment #3 Horizontal pressure tunnel lining form
Attachment #4 Inlet transition part tunnel lining form
Attachment #5 Progress schedule (waterway micro plan)
Attachment #6 Waterway tunnel lining concrete sequence
Attachment #7 Waterway tunnel lining concrete placement plan
Attachment # 8 Inspection and test plan
Attachment # 9 ACI-347
Attachment # 10 Waterway construction joint and water stop detail
Attachment # 11 Waterway vertical tunnel lining concrete cycle time
Attachment # 12 Steel penstock tunnel concreting plan.
Attachment # 12 Summary of concrete strength with early strength admixtures.

Attachment #1
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Attachment #2
Vertical pressure tunnel lining form
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Attachment #3
Horizontal pressure tunnel lining form
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Inlet transition part lining form
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Attachment #5
Progress schedule
(Waterway micro plan)
Water Way
IPS Rev 19( 4 week look ahead)
Activity ID Activity Name Original aining ysical Start Finish Total Qty. Unit Resource IDs 2017 2018
Duration % c Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb
ti
464d 271d l t 11-Oct-16 A 17-Jan-18 4966.00
Water Way
Tunnel 2 398d 205d 11-Oct-16 A 12-Nov-17 2394.00
Horizontal 357d 87d 11-Oct-16 A 02-Oct-17 1900.00
A1000 Excavation Horizontal + Lower Bend 141d 0d 100% 11-Oct-16 A 28-Feb-17 A 122.00 Mtr
A1100 Bottom Cleaning 5d 0d 100% 28-Feb-17 A 04-Mar-17 A Mtr
A1110 Invert Leveling Conc. 20d 0d 100% 02-Mar-17 A 21-Mar-17 A Mtr
A1120 Drilling for Grouting & Drain Holes 30d 0d 100% 24-Mar-17 A 03-Apr-17 A 1778.00 Mtr
A1125 Dewatering And cleaning 28d 0d 100% 08-Apr-17 A 05-May-17 A
A1130 Removal of Temperory Facilities 4d 4d 0% 08-Jul-17* 11-Jul-17 EA
A1220 Rebar Fixing 30d 30d 0% 12-Jul-17 10-Aug-17
A1230 Assembly Of Lining Form & Hydraulic Jack Test 10d 10d 0% 12-Jul-17 21-Jul-17
A1250 Setting Of Lining Form 8d 8d 0% 22-Jul-17 29-Jul-17
A1260 Lining 1st Segment - 10 Mtr 4d 4d 0% 30-Jul-17 02-Aug-17
A1270 Lining 2nd Segment 4d 4d 0% 03-Aug-17 06-Aug-17
A1280 Lining 3rd Segment 4d 4d 0% 07-Aug-17 10-Aug-17
A1290 Lining 4th Segment 4d 4d 0% 11-Aug-17 14-Aug-17
A1300 Lining 5th Segment 4d 4d 0% 15-Aug-17 18-Aug-17
Steel Penstock 45d 45d 19-Aug-17 02-Oct-17 0.00
A1310 Erection of 1st Shell 6 Mtr and Conc Pouring 5d 5d 0% 19-Aug-17 23-Aug-17
A1320 Erection of 2nd Shell 6 Mtr and Conc Pouring 5d 5d 0% 24-Aug-17 28-Aug-17
A1330 Erection of 3rd Shell 6 Mtr and Conc Pouring 5d 5d 0% 29-Aug-17 02-Sep-17
A1340 Erection of 4th Shell 6 Mtr and Conc Pouring 5d 5d 0% 03-Sep-17 07-Sep-17
A1390 Erection of 9th Shell 6 Mtr and Conc Pouring 5d 5d 0% 28-Sep-17 02-Oct-17
Lower Bend 46d 46d 23-May-17 07-Jul-17 0.00
A1070 First Stage Conc. 10d 10d 0% 23-May-17 01-Jun-17
A1080 Rebar Fixing 5d 5d 0% 02-Jun-17 06-Jun-17
A1090 Setting Of Lining Form 15d 15d 0% 07-Jun-17 21-Jun-17
A1140 Lining Conc. 6d 6d 0% 22-Jun-17 27-Jun-17
A1210 Removal of Form Work 10d 10d 0% 28-Jun-17 07-Jul-17
Vertical 368d 205d 10-Nov-16 A 12-Nov-17 494.00
A1010 Excavation Vertical Shaft + Transition Part 170d 31d 90% 10-Nov-16 A 22-May-17 50.00
A1040 Preperation Of Lifting Structure 6d 6d 0% 23-May-17 28-May-17 444.00
A1050 Drilling for Grouting & Drain Hole 8d 8d 0% 08-Jul-17 15-Jul-17
A1060 Rebar Fixing 6d 6d 0% 16-Jul-17 21-Jul-17
A1400 Setting of Lining Form 10d 10d 0% 22-Jul-17 31-Jul-17
A1410 Lining Conc. 1st lift -1.8 Mtr 4d 4d 0% 01-Aug-17 04-Aug-17
A1420 Lining Conc. 2nd lift 4d 4d 0% 05-Aug-17 08-Aug-17
A1430 Lining Conc. 3rd lift 4d 4d 0% 09-Aug-17 12-Aug-17
A1440 Lining Conc. 4th lift 4d 4d 0% 13-Aug-17 16-Aug-17
A1480 Lining Conc. 8th lift 4d 4d 0% 29-Aug-17 01-Sep-17
A1490 Lining Conc. 9th lift 4d 4d 0% 02-Sep-17 05-Sep-17
A1510 Lining Conc. 11tht lift 4d 4d 0% 10-Sep-17 13-Sep-17
Transition Part 48d 48d 26-Sep-17 12-Nov-17 0.00
A1550 Preparation of Working Plate Form 8d 8d 0% 26-Sep-17 03-Oct-17
A1560 Rebar Fixing 10d 10d 0% 04-Oct-17 13-Oct-17
A1570 Installation of Lining Form- 1st 6d 6d 0% 14-Oct-17 19-Oct-17
A1580 Lining Conc. 1st lift - 3.5 Mtr 4d 4d 0% 20-Oct-17 23-Oct-17
A1590 Installation of Lining Form-2nd 6d 6d 0% 24-Oct-17 29-Oct-17
A1600 Lining Conc. 2st lift - 3.5 Mtr 4d 4d 0% 30-Oct-17 02-Nov-17
A1610 Installation of Lining Form-3rd 6d 6d 0% 03-Nov-17 08-Nov-17
A1620 Lining Conc. 3rd lift - 3.5 Mtr 4d 4d 0% 09-Nov-17 12-Nov-17
Tunnel 1 464d 271d 11-Oct-16 A 17-Jan-18 2572.00
Horizontal 395d 171d 11-Oct-16 A 09-Nov-17 2128.00
A1630 Excavation Horizontal + Lower Bend 141d 0d 100% 11-Oct-16 A 28-Feb-17 A 122.00 Mtr
A1690 Bottom Cleaning 4d 0d 100% 04-Mar-17 A 21-Mar-17 A Mtr
A1700 Invert Leveling Conc. 20d 0d 100% 04-Mar-17 A 23-Mar-17 A Mtr
A1710 Drilling for Grouting & Drain Holes 31d 0d 100% 25-Mar-17 A 02-Apr-17 A 2006.00 Mtr
A1715 Dewatring And Cleaning 43d 1d 100% 08-Apr-17 A 23-May-17*
Actual Level of Effort Remaining Work M. Blue Shaded Portion Showing Monsoon Period Prepared : Zill-e-Huma / T.M.Khan Data Date: 22-Apr-17
Actual Work Critical Remaining Work %. Red Shaded Portion Showing Ramadan Period Checked : J.W.Song / S.H.Han Print Date: 22-Apr-17
Normal Day Working - 7 Day/Week Approved : Bruce Lee / E.M.Moon Page 1 of 2
Water Way
IPS Rev 19( 4 week look ahead)
Activity ID Activity Name Original aining ysical Start Finish Total Qty. Unit Resource IDs 2017 2018
Duration % c Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb
A1720 Removal of Temperory Facilities 5d ti5d l0% t 24-May-17 28-May-17 EA
A1820 Rebar Fixing 20d 20d 0% 24-May-17 12-Jun-17
A1830 Shifting Of Lining Form 10d 10d 0% 19-Aug-17 28-Aug-17
A1840 Setting Of Lining Form 8d 8d 0% 29-Aug-17 05-Sep-17
A1850 Lining 1st Segment - 10 Mtr 4d 4d 0% 06-Sep-17 09-Sep-17
A1860 Lining 2nd Segment 4d 4d 0% 10-Sep-17 13-Sep-17
A1870 Lining 3rd Segment 4d 4d 0% 14-Sep-17 17-Sep-17
A1880 Lining 4th Segment 4d 4d 0% 18-Sep-17 21-Sep-17
A1890 Lining 5th Segment 4d 4d 0% 22-Sep-17 25-Sep-17
Steel Penstock 45d 45d 26-Sep-17 09-Nov-17 0.00
A1900 Erection of 1st Shell 6 Mtr and Conc Pouring 5d 5d 0% 26-Sep-17 30-Sep-17
A1910 Erection of 2nd Shell 6 Mtr and Conc Pouring 5d 5d 0% 01-Oct-17 05-Oct-17
A1920 Erection of 3rd Shell 6 Mtr and Conc Pouring 5d 5d 0% 06-Oct-17 10-Oct-17
A1930 Erection of 4th Shell 6 Mtr and Conc Pouring 5d 5d 0% 11-Oct-17 15-Oct-17
A1970 Erection of 8th Shell 6 Mtr and Conc Pouring 5d 5d 0% 31-Oct-17 04-Nov-17
A1980 Erection of 9th Shell 6 Mtr and Conc Pouring 5d 5d 0% 05-Nov-17 09-Nov-17
Lower Bend 77d 77d 23-May-17 07-Aug-17 0.00
A1660 First Stage Conc. 10d 10d 0% 23-May-17 01-Jun-17
A1680 Setting Of Lining Form 15d 15d 0% 08-Jul-17 22-Jul-17
A1740 Lining Conc. 6d 6d 0% 23-Jul-17 28-Jul-17
A1810 Removal of Form Work 10d 10d 0% 29-Jul-17 07-Aug-17
Vertical 434d 271d 10-Nov-16 A 17-Jan-18 444.00
A1640 Excavation Vertical Shaft + Transition Part 141d 31d 80% 10-Nov-16 A 22-May-17 444.00
A1650 Preperation Of Lifting Structure 6d 6d 0% 23-May-17 28-May-17
A1730 Drilling for Grouting & Drain Hole 8d 8d 0% 29-May-17 05-Jun-17
A2000 Setting of Lining Form 10d 10d 0% 26-Sep-17 05-Oct-17
A2010 Lining Conc. 1st lift -1.8 Mtr 4d 4d 0% 06-Oct-17 09-Oct-17
A2020 Lining Conc. 2nd lift 4d 4d 0% 10-Oct-17 13-Oct-17
A2030 Lining Conc. 3rd lift 4d 4d 0% 14-Oct-17 17-Oct-17
A2040 Lining Conc. 4th lift 4d 4d 0% 18-Oct-17 21-Oct-17
A2070 Lining Conc. 7th lift 4d 4d 0% 30-Oct-17 02-Nov-17
A2080 Lining Conc. 8th lift 4d 4d 0% 03-Nov-17 06-Nov-17
A2110 Lining Conc. 11tht lift 4d 4d 0% 15-Nov-17 18-Nov-17
Transition Part 48d 48d 01-Dec-17 17-Jan-18 0.00
A2150 Preparation of Working Plate Form 10d 10d 0% 01-Dec-17 10-Dec-17
A2160 Rebar Fixing 8d 8d 0% 11-Dec-17 18-Dec-17
A2170 Installation of Lining Form- 1st 6d 6d 0% 19-Dec-17 24-Dec-17
A2180 Lining Conc. 1st lift - 3.5 Mtr 4d 4d 0% 25-Dec-17 28-Dec-17
A2190 Installation of Lining Form-2nd 6d 6d 0% 29-Dec-17 03-Jan-18
A2200 Lining Conc. 2st lift - 3.5 Mtr 4d 4d 0% 04-Jan-18 07-Jan-18
A2210 Installation of Lining Form-3rd 6d 6d 0% 08-Jan-18 13-Jan-18
A2220 Lining Conc. 3rd lift - 3.5 Mtr 4d 4d 0% 14-Jan-18 17-Jan-18
Actual Level of Effort Remaining Work M. Blue Shaded Portion Showing Monsoon Period Prepared : Zill-e-Huma / T.M.Khan Data Date: 22-Apr-17
Actual Work Critical Remaining Work %. Red Shaded Portion Showing Ramadan Period Checked : J.W.Song / S.H.Han Print Date: 22-Apr-17
Normal Day Working - 7 Day/Week Approved : Bruce Lee / E.M.Moon Page 2 of 2
Attachment #6
Waterway tunnels lining concrete sequence
Waterway Tunnel Concrete Pou
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EL:465.800
16.85 50.65 45.00

LOWER BEND HORIZONTAL PRESSURE TUNNEL STEEL PENSTOCK TUNNEL
122.50
Waterway Tunnel Concrete ~o
Tunnel # 2
t
WLD
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~--- 10.00 10.00 10.00 10.00 10.65 6.00 , 6.00" 6.00 , 6.00 , 6.00 , 6.00 , 6.00 ,6.00 7.00_
1ST POUR 2ND POUR 3RD POUR 4TH POUR 5TH POUR I 1ST 2ND 3RD 4TH 5TH 6TH 7TH 8TH 19TH 1
SHELL SHELL SHELL SHELL SHELL SHELL SHELL SHELL SHELL
EL:465.800
16.85 50.65 45.00

LOWER BEND HORIZONTAL PRESSURE TUNNEL STEEL PENSTOCK TUNNEL
_ ------__________________________________________________~1~2~2~.5~O___________________________________________________
----------
Attachment #7
Waterway tunnels lining concrete
Placement plan
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Lower Bend Concrete Supply/Casting la
--::: -=:""'1,,< ',,", D:':

.i' ,,:., "", ." ','
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MAIN SUPPLY PIPE
CONCRETE SUPPLY PIPE
'., 4"" . '. 4,' .

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..,f • 4· . ., "" \\ '<II • </1' 7 ..
:::: /' ~ -'4' . ., . .d ".' 1ST STAGE CONCRETE

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7
::::>"1 , 4.' .: ,.; ·3 ....
,"
(pLANU)
( SECTION A-A-)
Attachm nt #8
Inspection and test plan
IftA 102MW Pakistan Gulpur Hydro Power Project
Inspection and Test Plan
EPCC: Daelim-Lotte )V Owner's Engineer (OE): MWH-Nespak )V-l Structure: Waterway Tunnels Concrete Doc. !ITP-13/WT
No.
Inspection codes:
Ref. Doc./Dwg. No. Method statement
R =Review of documents W =Witness Point H =Hold Point
Inspections
Frequency
Sr.No. Activity Description Acceptance Criteria Verifying Documents
(if applicable) EPCC EPCC
OE
Con"t: OAfOC
1 Drawings
---~-- 1-- - -- ------------- ----- -- --- - --- ----- 1--- ~----------- - - - ----- -------
1.1 Check approved drawings for latest revision, if any. Document control log book Document transmittal Each R R R
-- ------- --"--- ~--.,,------- -------------------- ---"---- .-..-. --._- i- 1------
2 Control of Inspection, Measuring & Test equipment
-- ---------- ~- ---- -
2.1 All the laboratory equipment, related to job Manufacturer's Specifications Calibration report Applicable Standard R H R
------ --------- - - - - - -- -- --- --------~ ---"-------
2.2 Survey equipment Manufacturer's Specifications Calibration report Applicable Standard H II R
-~-- ------ -----------~--"---.-
------ ---- - - - - - _..---- --- ----- - -- - --- -_.. -- - -------
3 Construction Materials
-~- - -------- --- -- - ------ - ---
Material Source Approval Form
i. Source Approval Profile, Test reports, Certificates Each Source H H R
- - - . - - - - - I--~- ------~-- ----- ------
___ ____(QJ1QC -001 L_______ ____ - - --------- -- -------- -- --
Project Specifications / Material Inspection Report (MIR)
3.1 Cement Each Delivery II H R
- - - - - - - - i~- -------------------------- ---- ___ ASTM-.:C15~_ ---- --- -------
Lab: test reports ~----~.~~- "----~~-- ----~---
-- -----------
Material Inspection Report (MIR)
3.2 Aggregates Project Specifications / Standard Each Delivery H H R
-_._.__...
Lab: test reports
---- ---~-'"--- - -_._----. -~---- ----.-"--~--- -------- -------
Project Specifications/ Material Inspection Report (MIR)

3.3 Rebar Each Delivery H H R
ASTM-A615 Lab: test reports
------ --"-",. - ------------- --_.._- - - -------- --- ----- ---- "-.---.~--
Project Specifications/
3.3.1 Sampling of reba I' Lab register Each Delivery R II R
- _ . _ - - _.._- _.---------" ---- -------_._- ---- ----_._---
ASTM-A615 . ".~.--.--
._-_._-- -- ------ --- -----------
3.3.2 Testing of rebar ASTM-A615 Third party test report Each Delivery R H R
---"".-~---------
---- - - - - - - --"---- ----
Embedded items (Drain pipe, PVC Waterstop, Material Inspection Report (MIR)
3.4 Project Specifications / Standard Each Delivery H H R
instrumentation and sensor if applicable) ..- ---
Lab: teEJ~~p_o_r!s~ ______ ---
---- ---~
---~ ----~- ---~
3.4.1 Sampling of embedded items Project Specifications Lab register Each Delivery R H R
3.4.2 Testing of embedded items Project Specifications Third party test report Each Delivery R H R
Manufacturer's Specifications Material Inspection Report (MIR) H
3.5 Chemical additives Each Delivery H R
ASTM-C494 Manufacturer's test certificates
3.6 Water to be used for concrete production ASTM-C1602, ASTM-C1603 Test reports Every 3 months H H R
-- --------- '-~-- -- - - ---_.--- _L_ _._- -------- ... _-_.- ---, -- -------- - ---~ ,---
Page 1 of 3
...... ,.:;. 102MW Pakistan Gulpur Hydro Power Project
EPCC: Oaelim-Lotte jV Owner's Engineer (OE): MWH-NespakjV-l Structure: Waterway Tunnels Concrete Doc.
No.
I ITP-13 /WT
Inspection codes:
Ref. Doc./Dwg. No. Method statement
=
R Review of documents W =Witness Point H =Hold Point
Inspections
Frequency
Sr. No. Activity Description Acceptance Cl"iteria Verifying Documents
OE
(onst: OAfOC
4 Batch equipment's
-~~-~-
1-- ,.----.~
-- -~--- - ---- .----- ----~ - -- - - -----~-- - --- -- --- --~.--~--- .. ~.-~ ------ --- ---- -----
Calibration as per approved

4.1 All the equipment's to be used during batching of Concrete Concrete Mix Design Whenever required R H R
Concrete mix design
-~~-.-.-.
1------ ------------~--~----~- - -------~- ------------ -- -- ----- - - - - -----
5 Execution
---- - -- - -- - - - -- - -------------------- -- - - - - - - - - - - - - -- - - - - ---- - - - --- ---- - ----- - - - - ------ --
5.1 Survey & E.L record with coordinates Construction Drawing Survey data sheet Each round H R R
---------------~
---~---~"--.--.---- ---~-~--.----~- .. ------ - -----------
Completion of
5.2 Final Survey & Level (X-section) Construction Drawing Construction Drawing 1-1 R R
- ----- -------~----------------------- --- - - -- - ------ --------~----------- ---- --- structure ---
-- - ------- ---- ---------------- --- -----
6 Rebar and Formwork
1----- - ----- .._----------------------- - - - - - - - - - - -- ---------------------------- ------ -- ---- -- -- - - -- ._--- ~ -~--
-- -----~--- ---- --- -- - - - - ""-
6.1 Inspection of Rebar Construction Drawing Construction Drawing Each round H H R

I-- i- -
Each Structure, or a
6.2 Inspection of Rebar at site Construction Drawing Checklist: QA/QC-043 H H R
1--- --_. __.._-
."~"---- ." ---_.- ---,,_.- ----------- - - - - -- ---- ___ Jl<ll't o[iL ___ - 1--
Each Structure, or a I-I
6.3 Inspection of Rebar at site Construction Drawing Checklist: QA/QC-042 H R
i---~------ -------~------'"--- ----------------- . _-------- -~--.----------~~---~~~
___llilrt oLit__ .. ----_ ... ---- .. _-
7 Structural Concrete
,-~- ------ --------~---
I~-' ---,,---_.--- -~
._._._---- -------
As per required concrete class /

7.1 Preparation of concrete Mix Design ACI211.1R Each Design R H R
strength -----
------ -- .-----------~---.---- ~--- -------- ---
Mix Design Sheet with 07& 28 days

7.2 Approval of concrete Mix Design As per required Shotcrete strength compressive strength results, or as required Each Design R H R
(Forms attached)
-_.-- - - _..- -------- -------- ---------- ---~~ ---------
Production report: QA/QC-022 Each Structure, or a

7.3 Concrete production & placement at site Approved concrete Mix Design R H R
Placement report: QA/QC-033 part of it
- - - - ------- ----- - - - - - - - - - - - - - - - - - - - - - - - - - - - - --- ------- "" - ----""------
7.4 Sampling
---~---- 1--- ---_.- - -------- ------------ ----"_._._. ._-- ------~ -------- -------
Both site
Approved Shotcrete Mix Design Concrete placement report
7.4.1 Slump test Batching plant and W H R
ASTM-C143 Form: QA/QC-033
placement site
7.4.2 Casting of concrete cylinder ACI 506R / ASTM-C31 Each pour R H R

-~-----~---~--- ._--- ---- ------~~--~-- ..----.--.----- .- --- ---""--""'-----
Page 2 of 3
102MW Paldstan Gulpur Hydro Power Project
Doc.
EPce: Daelim-Lotte jV Owner's Engineer (OE): MWH-Nespak jV-l Structure: Waterway Tunnels Concrete ITP-13jWT
No.
Inspection codes:
Ref. Doc.jDwg. No. Method statement
R = Review of documents W =Witness Point H = Hold Point
Inspections
F"equency
Sr.No. Activity Description Acceptance Criteria Verifying Documents
OE
Compressive strength test sheet
7.4.3 Testing of concrete cylinder ASTM-C39 / AASHTO-T22 At required ages R H R
Form: QAQC-015 ~-~~- ... -~~-.---.~. ~~-~------ ------
--~--.--
8 After Concreting
~. - - - - - - _... - -------- ~---.----.~~ --- ---- -------------~~ ..- --- ----------
8.1 Final cross section Construction Drawing Construction Drawing I-I H R
--------~~
--- ---------~--.~-.--.-
8.2 Curing Visual Visual H H R

-------~-.---- - ~~~~--~----- .. ----.~.-
After completion of each part of Each part of

8.3 As build drawing H R R
- - - - _.._--- _______~~!IJcll:l:llre -----~~~ --~---.-- ..--.. -- ..- -
structure
-------_. __.... --- --_.-
9 Non-conformities & corrective actions
--- - -----------_._-- --------~---------.-- --_.._--------
Official Letters
In case of any shortcoming, and/or non~conformity, Site
9.1 NCR Form
Note, NCR and CAR will be generated at any stage
.-~~~-.- ..
CAR Form
-".-~."~~--~----~- --~----~~
----.----.-.~-------
NOTES:
R = Review of documents (Properly compiled accompanied with all the data sheets and test results, whichever applicable)
W = Witness point (Should be informed but presence is not mandatory)
H = Hold oint Activit will not commence an further unless ins ected b the en ineer or as he advises otherwise
Page 3 of 3
Attachment #9
(ACI 347-01)
I'
AC1347-01
Guide to Formwork for Concrete
Reported by ACI Committee 347

David \V. Johnston Kevin L. Wheeler
Chairman Secretary
Randolph H. Bordner Kevin D. Heiner! Robert G. McCracken

Ramon J. Cook G. P. h un Horst John R. Paine, Jr.
James N. Cornell, II Mary K. Hurd Russell B. Peck
William A. Dortch, Jr. Roger S. Johnston Wil liam R. Phillips
Jeffrey C. Erson Dov Kaminetzky Sa lvatore V. Pizzuto
Noel J. Gardner Harry B. Lancelot , III W. Thomas Scott
Samuel A. Greenberg H. S. Lew Aviad Shapira
R. Kirk Gregory Donald M. Marks Pericles S. Stivaros
Awad S. Hanna
Objectil1es ofsafety. quality, and economy are given priority in these guide- CONTENTS
Iinesforform1\·ork. A section on contract documents e.'plains the kind and Preface, p. 347-2
amoulll of specification guidance the engineer/architect should providefor
the contractOl: The remainder of the report advises the fonl1lmrk engineer/
Chapter 1-lntroduction, p. 347·2
colllraclOr on the best lrays to meet the specification requiremellls safe/l"
1.I-Scope
and economicall),. Separate chapters deal I";th design. constructiol1. and
materialsforfonl1lmrk. COl1Sideratiol1S peculiar to architectural concrete 1.2-Definitions
are also ollliined in a separate chapte/O Other sections are devoted to form- I .3-Achieving economy in formwork
II'0rk for bridges, shells, mass concrete, and underground 1\·ork. The con- lA-Contract documents
cluding chapter onfoJ'/l/lmrkfor special methods of construction includes
slip/arming. prep/aced aggregate concrete, Iremie concrete, precast, and
prestressed concrete.
Chapter 2-Design, p. 347·5
2 , I-General
2,2-Loads
Keywords: anchors; architectural concrete; coatings; concrete; construc-
tion: fa lsework : forms; formwork; fornl ties; foundations; quality control: 2.3-Unit stresses
reshoring: shoring: slipform construction; specifications; tolerances. 2.4-Safety factors for accessories
2.S-Shores
2,6- Bracing and lacing
ACI Committee Reports, Guides, Standard Practices, 2.7-Foundations for formwork
and Commentaries are intended for guidance in planning, 2.8-Settlement
designing, executing, and inspecting construction. This
document is intended for the use of individuals who are
Chapter 3-Construction, p. 347·9
competent to evaluate the significance and limitations of 3 . I-Safety precautions
its content and recommendations and who will accept re- 3 .2-Constl1lction practices and workmanship
sponsibility for the application of the material it contains. 3.3-Tolerances
The American Concrete Institute disclaims any and all re- 3 A-Irregularities in formed surfaces
sponsibility for the stated principles. The Institute shall 3.S-Shoring and centering
not be liable for any loss or damage arising therefrom. 3.6-Inspection and adjustment of formwork
Reference to this document shall not be made in con-
tract documents. If items found in this document are de- AC I 3-l7·0 1 supersedes AC I 3-l-7R·9.t lRcappro\cd 1999) and beC3ll1e cfTc:cII\l'
D\.'ccmber 11.200 I
sired by the Arch itect Engineer to be a part of the contract COP) n ght ' ~ ~OO I. :\mcncan Co ncn:tc In"tllutc
All nght" rc ~en t:d II1cludlllg right-. of rL'productll1ll and U"C 1I1 an) form or b) elll)
documents, they shall be restated in mandatory language IllC,Ub, lllc\ udlllg the lllah1Jlg of copn: .. b) .111) photo proct:'''''''' or b) l'k·ctrOllH.: or
IllCrllilJllCal dc\ ICC. pnntecl. \\ nttcil. or omL 01 IL'cordln g 1\..11 s,o und or \ l"ual repn1duc-
for incorporation by the Archi tec t Engineer. 11 0 1\ lW fO I 11 ,,(..' III a ll ) kIl0\\ ledge 01 n:tnl:\ al ~: " It.:!ll (Ir dc\ Ice . 11Il1e ... :- PCJ"l111, ... ltlll III
\\ riling h l)bl.WlL'd fn~111 the CLIP) right pll1pnetor...
347-1
"
GUIDE TO FORMWORK FOR CONCRETE 347-25
structures entirely different than for their aboveground coun- Concrete placement method and, for tunnel arch forms,
terparts. First, concrete to fill otherwise inaccessible areas whether the design is based on the unit or bulkhead sys-
can be placed pneumatically or by positive displacement tem of concrete placement or the continuously advanc-
pump and pipeline . Second, rock sometimes is used as a ing slope method; and
form backing, permitting the use of rock anchors and tie rods The capacity and working pressure of the pump and the
in lieu of ex tema I bracing and shores . Third, the limits of the size, length, and maximum embedment of the discharge
excavation demand special handling equipment that adds line when placement by pumping is anticipated.
particular emphasis to the removal and reuse of forms.
6.6.4 Constl'uctiol1- The two basic methods of placing a
Fourth, rock surfaces can sometimes be used for attaching tunnel arch entail problems in the construction of the fom1-
hoisting devices.
work that require special provisions to permit proper reuse.
When placement is done by pneumatic or positive dis- These two basic methods are commonly known as the bulk-
placement pump and pipeline methods, the plastic concrete head method and the continuously advancing slope method.
is forced under pressure into a void, such as the crown of a
The former is used exclusively where poor ground condi-
tunnel lining. For more infom1ation on the pumping process,
tions exist, requiring the lining to be placed concurrently
see ACI 304.2R.
with tunnel driving operations. It is also used when some fac-
6.6.2 Design loads
tor, such as the size of the tunnel , the introduction of rein-
6.6.2.1 Vertical loads-Vertical and constlUction
forcing steel, or the location of constlUction joints, precludes
loads assumed in design of formwork for underground
the advancing slope method. The advancing slope method, a
stlUctures are similar to those for surface stlUctures, with
continuous method of placement, usually is preferred for
the exception of unusual vertical loads occurring near the
tunnels driven through competent rock, ranging between 10
crown of arch or tunnel forms and flotation or buoyancy
and 25 ft (3 and 8 m) in diameter and at least I mi (1.6 km)
effect beneath tunnel forms.
in length.
In placing concrete in the crowns of tunnel forms, pres-
sures up to 3000 Ib/ft 2 (144 kN /m2) have been induced in ar- The arch fom1 for the bulk11ead method is usually fabricated
eas of overbreak and near vertical bulkheads from concrete into a single unit between 50 and ISO ft (15 and 45 m) long,
placed pneumatically or by positive displacement pump. Un- which is stripped, moved ahead, and reerected using screw
til more defin ite recommendations can be made, the magni- jacks or hydraulic rams. These are pem1anently attached to
tude and distribution of pressure should be determined by the the form and supporting traveling gantry. The arch form for
formwork engineer. In no case should the assumed pressure the continuously advancing slope method usually consists of
be less than 1500 Ib/ft2 (72 kN /m2) acting normally to the eight or more sections that range between IS and 30 ft (5 and
form plus the dead weight of the concrete placed pneumati- 9 m) in length. These are successively stripped or collapsed,
cally or by pump. telescoped through the other sections, and reerected using a
fom1 traveler.
6.6.2.2 Lateral loads-For shafts and exterior walls
against rock, the values listed in Sect IOn 2.2 .2 should apply. Although the minimum stripping time for tunnel arch
When the shaft f0I111 relie,sQl1 the single shear value of em- forms usually is established on the basis of experience, it can
bedded anchors in the previous placement as a means of sup- be safely predetem1ined by tests. At the start of a tunnel arch
port, the minimum time lapse between successive concreting operation, the recommended minimum stripping
placements (or minimum concrete strength) and maximum time is 12 h for exposed surfaces and 8 h for construction
allowable loading additional to the dead weight of the fom1 joints. If the specifications provide for a reduced minimum
should be specified. stripping time based on site experience, such reductions
For arch forms and portions of tunnel f0I111s above the should be in time increments of 30 min or less and should
maximum horizontal dimension or spring line of the form, be established by laboratory tests and visual inspection
the pressure should be compatible with the pressures dis- and surface scratching of sample areas exposed by opening
cussed under vertical loads in Section 6.6.2 .1. the fom1 access covers. Arch forms should not be stripped
6.6.3 Drall'ings~In addition to the provisions of Chapters prematurely when unve nted groundwater seepage could
1,2, and 3, the following data should be included on the draw- become trapped between the rock surface and the concrete
ings for specialized f0I111work and formwork for tunnels: lining .
All pressure diagrams used in the design of the form, 6.6.5 A1atel'ials- The choice of materials for underground
including diagrams for uplift, for unbalanced lateral or formwork usually is predicated on the shape, degree of reuse
vertical loads, for pressurized concrete, or for any other and mobility of the f0I111 , and the magnitude of pump or
load app licable to the particular insta llation; pneumatic pressures to which it is subj ected. Usually, tunnel
Recommended method of supplementa l stlUlling or and shaft forms are made of steel or a composite of wood and
bracing to be employed in areas where form pressures stee l. Experience is important in the design and fabr ication
can exceed those just listed due to abnormal conditions; ofa satisfactory tunnel f0I111, due to the nature of the pressures
Handling diagrams and procedures showing the pro- developed by the concrete. placing techniques, and the high
posed method of handling the form during erection or degree of mobility usually required.
installation for concrete placement plus the method of When reuse is not a factor. pl)'\\'ood and tongue-and-groove
bracing and anch orage during norm al operation; lumber are sometim es used for ex po sed surface fini shes .
347-14 ACt STANDARD
• 0 ,
..
'----=
"
INCORRECT: FORMS AND SHORING

STRIPPED IN THIS MANNER WILL CAUSE
STRESS REVERSAL IN THE MIDDLE STRIP .
..,
BY STRIPPING THE MIDDLE STRIP

FIRST. THE SLAB WILL DEFLECT
AND BE LOADED AS DESIGNED.
Fig. 3.5 -Stripping seq1lence for two-way slabs.
periods can be reduced as approved by the engineer/ One-way floor slabs

architect. Conversely, if ambient temperatures remain Under lOft (3 m) clear span
below 50 F (lOC) , or if retarding agents are used, then between structural supports ..... .4 days~ 3 days
these periods should be increase d at the discretion of the 10 to 20 ft (3 to 6 m) clear span
eng ineer/architect. between structural supports ...... 7 dayst 4 days
Over 20 ft (6 m) clear span
Walls' .. ...... .. ................ .. .. ........ ... ..... 12 h between structural supports .. .. 10 days t 7 days
Columns' .............. ............ .. .. .... ....... 12 h
Si..d~s of beams and girders· .. .. ......... 12 h Ty.'o.::y.'ay slab systems t ........ Removal times are contingent
Pan joist forms t on reshores where required, being placed as soon as prac-
30 in. (760 mm) wide or less ......................... 3 days ticable after stripping operations are complete but not later
Over 30 in. (760 mm) wide ....................... .. .. .4 days than the end of the working day in which stripping occurs .
Where reshores are required to implement early stripping
Structural live Structural live while minimizing sag or creep (rather than for distri-
load less load more bution of superimposed construction loads as covered in
than structural than structural Section 3 .8), capacity and spacing of such reshores
dead load dead load should be designed by the formwork engineer/contractor
and reviewed by the engineer/architect.
Arch centers ........................ .. ....... 14 days Post-tensioned slab system1'. ....... As soon as full post-ten-
7 days
Joist beam or girder soffits sioning has been applied.
tSee Section 3.8 for special conditions affecting number
Under 10ft (3 111) clear span
of floors to remain shored or reshored .
between structural supports ...... 7 dayst 4 days
10 to 20 ft (3 to 6 m) clear span
3.B-Shoring and reshoring of multistory structures
between structural supports ..... 14 dayst 7 days
3.8.1 DisClIssiol1-The fo llowing definitions app ly for
Over 20 ft (6 m) clear span purposes of this discussion:
between structural supports ..... 21 dayst 14 days Shores-Vertical or inclined suppOIt members designed to
CatTY the weight of fonnwork, concrete, and construction loads.
Reshores-Shores placed snugly under a stripped concrete
• \\'hLTt: ""udt rorlll~ :11(,,0 ~llJ1rort fml1l\\ mh for ~lJb or bl:JI11 :'Clftib. tht: rt:I1111\ JI
IlIll!.:!. orl h~' laller shou ld gO\t'nl. slab or structural member after the original forms and shores
1 or tht: I~ pt' \\ Inch t:JI1 b. . . 1't:1ll11\ L't! \\ Hllllllt <11 . . turblllg forming or . . 1wr1ng
\\'hert' form ... Ill.l) be rCIlll1\ cd \\ Ilhnul (\1 .. 1111 hlng .. hurl· .... Il"'C h.111" of \ .llue ...... hO\\ 11 \\lwlt: fo rm " CJ.1l be r~nH1\L'd \\l1 l11'Ut dl~turbIIH.! ... hon: ... U"~ h:11fof\,tllll'" .. h(l\\11
hut 1\(1\ k ...... Ih.1Il .3 d<l) ~ but Iwt 11.;" .. th,UI 3 d,I)" -
Attachment #10
(Construction joint and water stop detail)
SCALE 1:200
'l: HEADRACE TUNflEL
'l: HEADRACE TUNNEL
'l: HEADRACE TUNNEL
u<
;Um
"
m;u
(J)..,
~O
o ..,~~
'"'"eO ,0 3,350 C
Z
z
,
m
~ LINING CON'C
------- WATERSTOP
W=300mm
OJ,
WATERSTOP mO
fck=28MPa z~
W=300mm om
;JJ
C SECTION B-B )
o ( VERTICAL PRESSURE TUNNEL) o
'"'"<D \
LINING CON'C 'l: HEADRACE TUNNEL
I
\ LOWER
BEND
LINING CON'C
'l: HEAD RACE TUNNEL
I I
. JI ~ .
I
3n
I
z, ,
..,m "
..-.. ~
u< o
WATERSTOP ;um 0 0
o
m;u
(J).., 0 0 o 0
W=300mm r-- r-- c5
~o ro ro '"'"
;uf::
..,c
m "
o
a
o.
eO
0
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'"
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z ©
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v.
z
c ,m
V
WA ERSTOP
W=300mm
a
'"'" ~
t
eO
~
POFILE
-g
_kdl_--=3~,3:::5::..0_ _ _ _::.:3,3:=;5:::0_ _k d _ 1ST STAGE CONCRETE
fck=21Mpa
t
C SECTION A-A ) __
C~ LO_W
__ER__
B_EN_D_P_R_O_F_IL_E__) C,-_S_EC_T_IO_N_C_-_C---,)
'l: HEADRACE TUNNEL
PLASTIC FIBER
REINFORCED SHOTCRETE
T=160, fck=21 Mpa SCALE = NONE
l
~
<J D
D 0 0 D 0
D o 0
01
NOTES
L-
/' 1st
CONCRETE ~
LINING /'
L 2nd
CONCRETE
LINING
7
11-~I ~~ 1. WATERSTOP SHOULD BE INSTALLED FOR PREVENTING LEAKAGE
FROM CONSTRUCTION JOINT OF WATERWAY TUNNEL EXCEPT
D
2017
18, Feb
DATE
For Approval
DESCRIPTION REMARK
1 N I C:...IENT
~
1 CROSS·SECTION CHANGE AREA AND STEEL PENSTOCK.
A A
2. THE POSITION OF CONSTRUCTION JOINT SHOULD BE DETERMINED
~C-O~NTAA~C~TO~R------------------~~~~~=-----~
WATERSTOP IN CONSIDERING OF STEEL FORM LENGTH AND CONSTRUCTION
W=300mm CONDITION OF LINING, ETC.
3. WATERSTOP SHOULD BE INSTALLED AT THE CENTER OF LINING, PROJ NAME
PAKISTAN GULPUR HYDROPOWER PROJECT
C~ ___C_O_N_S_TR_U_C_T_IO_N__JO_I_NT__D_ET_A_I_L___) AND IT CAN BE CHANGED BY DISCUSSION WITH OWNER'S
ENGINEER IN CONSIDERING OF CONSTRUCTION CONDITION.
TITLE
CONSTRUCTION JOINT & WATERSTOP DETAIL

DATE SCALE DRAWING NO REV
Feb. 2017 1 :200 GPDD~C·CJ~WSD·0001 D

Attachment #11
Waterway vertical tunnel lining concrete cycle time
Waterway verticalTunnel lining Concrete Cycle Time
Duration
day 1 day 2 day 1 day 4
Activity
(Hours) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 # # # # # # # # # # # # # # # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 # # # # # # # # # # # # # # #
Steel fixing 10
con. Spacer
2
and support
Liner shifting 5 hr
Liner fixing
7 hr
/Support
Liner
4 hr
Alignment
Pouring and
6
compaction
Wait for due

12
stripping time
Fixing of steel 10
Con. Spacer
2
and support
stripping 5
Form removal 4
Liner shifting 5
Liner fixing
7
/Support
Liner
4
Alignment
Pouring and
6
compaction
Note: Time calculated in this sechuedle is based on smooth working conditions, Time cycle can be changed according to site conditions.
Attachment #12
Steel penstock tunnel concreting plan.
Attachment #13
Summary of concrete strength tests with early strength admixtures
Master Rheobuild® 1100
(Formerly known as Rheobuild 1100)
High range water-reducing superplasticizing admixture

DESCRIPTION APPLICATION
Master Rheobuild® 1100 is a ready-to-use, high Use Master Rheobuild® 1100 as supplied after
range water-reducing agent designed to produce thorough stirring, without any dilution.
high slump concrete. This is a ready to use Material condition
chloride free liquid admixture and meets ASTM Cement : For optimum performance, always use
C494 requirements for type F, and AS1478 fresh cement, since the reactivity of cement is
requirements for High Range Water-Reducing reduced with ageing.
Admixtures. Aggregates : Use of properly graded, good
quality, coarse aggregates and sand helps to
FEATURES AND BENEFITS
achieve higher impermeability and strength.
Very high Short placement time. Dispensing
workability Saves time and labour. The addition of Master Rheobuild® 1100 to a dry
mix is not recommended.
High water High impermeability and Master Rheobuild® 1100 can be dosed either at
reduction strength. Improved
the batching plant or at the placing site.
durability.
At the batching plant, introduce
Superior No segregation even at Master Rheobuild® 1100 at the specified dosage
cohesion high workability. Excellent directly into the mixer through a dispenser along
concrete quality. with mixing water, when the concrete is thoroughly
High early Early demoulding. Shorter wetted (i.e. after adding at least 75% of the mixing
strength steam curing cycles. water) and mix for at least 3 minutes.
Low shrinkage Better dimensional stability If added at the placing site, mix for at least 3
and creep minutes after the addition.
RECOMMENDED FOR DOSAGE
• precast concrete Master Rheobuild® 1100 is normally used at a

• all types of concrete mixes in which high early rate of 0.5 – 2.0 litres per 100 kg of cementitious.
strength or high strength and very high flow Other dosages may also be used depending on the
ability are essential mix design of the concrete and ambient conditions.
• ready-mixed concrete The actual dosage depends on the degree of water
• pumped concrete reduction or flow required.
• hot weather concreting
RATE OF HARDENING
used with all cements and air-entraining
admixtures approved under ASTM, AASHTO and Setting time is influenced by the chemical and
CRD specifications. physical composition of the basic ingredients of the
concrete, temperature of the concrete and climatic
COMPATIBILITY condition. Trial mixes should be made with job
materials to determine the optimum dosage
Master Rheobuild® 1100 is compatible with both required for a specified setting time and a given
water reducers and air entraining agents approved strength requirement.
under SAA, SANZ and ASTM specifications but it
should be dispensed separately into the concrete PACKAGING
mix. It should only be used with water reducers
after specific testing at the proposed dose rates. Master Rheobuild® 1100 is supplied in 205 liter
sealed drums and bulk delivery.
DISPENSING
The addition of Master Rheobuild® 1100 to a dry
mix is not recommended.
STORAGE It is safe for use with standard precautions followed

in the construction industry, such as use of hand
Master Rheobuild® 1100 must be stored at gloves, safety goggles, etc.
temperatures above 0°C in tightly sealed original For additional information on
drums. If found to be frozen, thaw it and Master Rheobuild® 1100 and its use in
reconstitute by stirring. developing a concrete mix with special
performance characteristics, contact your local
SHELF LIFE BASF Construction Chemicals sales
Master Rheobuild® 1100 can be stored for 12 representatives.
months if stored as recommended in unopened
original packing.
PRECAUTIONS
Health : Master Rheobuild® 1100 does not
contain any hazardous substances requiring
labelling.
STATEMENT OF The technical information and application advice given in this BASF publication are based on the present state of
RESPONSIBILITY our best scientific and practical knowledge. As the information herein is of a general nature, no assumption can be
made as to a product’s suitability for a particular use or application and no warranty as to its accuracy, reliability or
completeness either expressed or implied is given other than those required by law. The user is responsible for
checking the suitability of products for their intended use.
Field service where provided does not constitute supervisory responsibility. Suggestions made by BASF either
NOTE orally or in writing may be followed, modified or rejected by the owner, engineer or contractor since they, and not
BASF, are responsible for carrying out procedures appropriate to a specific application.
®= Registered Trademark of BASF Group in many countries of the world
BASF Chemicals & Polymers Pakistan (Pvt) Ltd.

Construction Chemicals Division
46-A, Block-6, P.E.C.H.S.,
Shahrah-e-Faisal,
Karachi-75400
email: mohsin.zia@basf.com
Lahore Islamabad
Karachi Tel: 042 111 550 550 Tel: 051 4446106-08
Tel:021 111 550 550
Website: www.master-builders-solutions.basf.pk
CARBOPLAST E 3003
Ultra high range water reducing & accelerating hyper
plasticizer for Concrete
DESCRIPTION: FIELD OF APPLICATION:

E-3003
CARBOPLAST E 3003 is based on unique poly Pre-cast concrete manufacture
carboxylic ether polymers that greatly improves
cement dispersion by the action of conventional In congested reinforcement
electrostatic dispersion forces along with lateral
chains linked up with backbone which generate In hot weather is extended workability
steric-hindrance effects to stabilize the concrete mix
and make it highly flow able without any extra water Bridges and cantilever structures
demand.
Pre-stressed concrete
Reduction of 25-30% water contents whilst maintain
workability, durability & impermeability Floor slabs
The increase in strength, especially evident at early Foundations

ages remains at later ages, both in air cured and
steam cured processes Walls and columns
Act catalytically to increase the rate of hardening of Beams and slabs

cement particles thereby leading to higher early
strength For fair face results
Produces highly impermeable, dense concrete with For self compacted concrete
enhanced durability.
Increases ultimate compressive strength and other

strength developing properties
Compatible with all type of cement including

sulphate resisting
Reduce the placing problems in hot weather

concrete
Improve trowel ability & surface finish
Reduces the incidence of honeycombing and cold

joints during vibration.
Reduce water contents would be of benefit to

reduce permeability
SPECIAL SURFACE WATER

ADMIXTURE SHOTCRETE GROUTS
ADMIXTURE IMPROVEMENT PROOFING
CRACK
FLOORING COATING JOINT SEALANT REPAIR TILING
INJECTION
CARBOPLAST E 3003 Ultra high range water reducing &
accelerating hyper plasticizer for Concrete
DIRECTION OF USE:
E-3003 TECHNICAL DATA
MIXING:
TYPE E-3003
Color Light brown liquid CARBOPLAST E 3003 should be added to concrete
Chloride content to Nill
during mixing cycle at same time as the water and
aggregates. Never add CARBOPLAST E 3003 to the
BS5075 :1982 dry cement.
Nitrate content Nill
Consumption with 100kg 0.2 - 2% Setting Time:
Cement
CARBOPLAST E 3003 ensures that rheoplastic
High Dosages permissible subject to trial concrete remains workable in excess 3 hours at +20°C.
Specific gravity 1.01@ 25 °C Workability loss is dependent on temperature, and on
the type of cement, the nature of aggregates, the
Air contents Less than1 %
method of transport and initial workability. It is strongly
Freezing point: 0°C. can be reconstituted, recommended that concrete should be properly cured
if stirred after thawing particularly in hot and dry climates.
Flash Point: None
Effect of over dosage:
Retardation of initial set
STANDARDS: Increase in air contents

ASTM C494: Type A, C, E & F
BS 5075: Part 1 Increase in workability
European Standard EN 934-2.
COMPATIBILITY:
PACKAGING:
CARBOPLAST E 3003 is compatible with all types of
Supplied in: 210 Liter cement complying with international standards. It can
be used in combination with the following admixtures
Storage: Dry; Frost free, out of direct sunlight and additives
Shelf life: 24 months, when stores as above Air entraining admixtures.
Hazard class: No dangerous goods, Observe Material Anti freezing admixture

Safety datasheet.
Pozzolanz ( Micro silica, flyash,GGBFS)
Synthetic fibers
Alkali silica reaction control admixture
Waterproofing admixture
.
CAUTION:
CARBOPLAST E 3003 is not a fire or health hazard.

Spillages should be washed down immediately with
cold water. For further information refer to the material
safety data sheet.
The information provided in this leaflet, is supplied by our consulting service and is the end result of exhaustive research work and extensive experience. They are, however, without
liability on our part, in particular with regard to third parties proprietary rights, and do not relieve the user of the responsibility for verifying that theproducts and processes are suitable
for the intended application. The data presented was derived from tests under normal climate conditions according to DIN 50014 and mean average values and analysis. Deviations
are possible when delivery takes place. Given that recommendations may differ from those shown in this leaflet written confirmation should be sought. It is the responsibility of the
purchaser to ensure they have the latest leaflet issue and that its contents are current. Our customer service staff will be glad to provide assistance at any time. We appreciate the
interest you have shown in our products. This technical data sheet supercedes pre viously issued information.
PAGEL PAKISTAN (PVT.) LTD.
1-A, MISC. ZONE, VALUE ADDITION CITY Phone: +92-41-850-7212-13

SAHIANWALA ROAD, KHURRIANWALA. Fax: +92-41-850-7214
FAISALABAD Email: info@pagelpakistan.com Technical Ref. Sheet 1.15 PK
Website: www.pagelpakistan.com QS-Formblatt 01/14 Rev. 02
SPECIAL SURFACE WATER

ADMIXTURE SHOTCRETE GROUTS
ADMIXTURE IMPROVEMENT PROOFING
CRACK
FLOORING COATING JOINT SEALANT REPAIR TILING
INJECTION

Method Statement of Tunnels Digging

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Method Statement of Tunnels Digging

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Method statement of waterway tunnels concrete lining.

Method Statement for

Project Name : Gulpur Hydropower Project

Client : Mira power Limited

Consultant : MWH NESPAK JV

Rev. Date Description Prepared by QA/QC EHS Const. Approved by

3 Organizatio and responsibilitie ……………………………………………………...9

5. Execuation flow diagrame …………………………………………………………..14

7. Quality assurance and Quality controll Plan………………………………………...26

8. Health, Safety and Environment management plan……………………………….....32

The main purpose of this method Statement is:

 To outline the works involved in this particular Structure.

 To meet legal requirements, that is, hazard identification and control.

 To program work, materials, time, staff, and to anticipate possible problems;

 To use as a tool in quality assurance.

{Figure 1: waterway tunnels plan}

Each waterway tunnel contains:

{Figure 2: waterway tunnels 3D profile}

Vertical pressure tunnel

Horizontal pressure tunnel

2.2 Design and Specification

Each vertical shaft contains:

Each horizontal tunnel contains:

{Figure 3: Waterway Tunnels profile}

Items Specification Location Typical cross section

{Figure 5: Vertical Tunnel transition part}

Items Specification Typical cross section

{Figure 6: Lower bend}

Items Specification Typical cross section

{Figure 7: Horizontal pressure Tunnel}

Items Specification Typical cross section

Shape Horse shoe

{Figure 8: steel penstock Tunnel}

Items Specification Typical cross section

Type Horse shoe

Steel penstock Tunnel 1 & 2

Including out let part

2.3 Work scope.

2.4 Reference Documents.

1. GPDD-C-WT-001---------------------------------------------------------Water way General Plan

2. GPDD-C-WT-001------------------------------------------------Water way Profile (Tunnel No.1)

3. GPDD-C-WT-001------------------------------------------------Water way Profile (Tunnel No.2)

4. GPDD-C-IPTP-CLR-001------Inlet portal Transition part concrete lining reinforcement 1/3)

5. GPDD-C-IPTP-CLR-002------Inlet portal Transition part concrete lining reinforcement 2/3)

6. GPDD-C-IPTP-CLR-003------Inlet portal Transition part concrete lining reinforcement 3/3)

7. GPDD-C-VPT-CLR-001---------Vertical pressure tunnel concrete lining reinforcement 1/3)

8. GPDD-C-IPTP-CLR-002-------- Vertical pressure tunnel concrete lining reinforcement 2/3)

9. GPDD-C-IPTP-CLR-003-------- Vertical pressure tunnel concrete lining reinforcement 3/3)

9. GPDD-C-VPT-0001------------------Vertical pressure tunnel Excavation cross sections (1/2)

10. GPDD-C-LB--LBP-0001-----------------------Lower Bend Profile and typical sections (1/2)

11. GPDD-C-LB--LBP-0002------------------------Lower bend profile and typical sections (2/2)

12. GPDD-C-LB-CLR -0001--------------------Lower bend concrete lining reinforcement (1/2)

13. GPDD-C-LB-CLR-0002---------------------Lower bend concrete lining reinforcement (2/2)

14. GPDD-C-HPT-TS-0001--------------------------Horizontal pressure tunnel typical sections

15. GPDD-C-HPT-ESC-0002-------Horizontal pressure tunnel concrete lining reinforcement

16. GPDD-C-SPT-TS-0001---------------------------------Steel penstock tunnel typical sections

17. GPDD-C-OPT-ETS-0001----------------Outlet pressure tunnel typical excavation sections

Site engineer: Mr. Naveed Akhtar

QA Manager Mr. Muhammad Aslam

EHS manager : Mr. Tanzeel

Vertical Tunnels Horizontal Tunnels

Note: Manpower can be changed according to site conditions.

4.2. Major Equipment and Tools