Signature Bridge Okha Beyt Dwarka

Construction procedure for Construction of PILE

CAP OP11 TO OP1 & BP1 TO BP11

METHOD STATEMENT FOR CASTING OF PILE CAP

OP11 TO OP1 & BP1 TO BP12

S.No Rev. Date Description Prepared by Checked by Approved by

Casting
arrangement of Lalit Tomar Devinder Singh
1. 0 18.03.2019 Pile cap OP11 (Planning Engineer) (Project Manager)
TO OP1 & BP1 SPSCPL SPSCPL
TO BP11

P a g e 1 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

TABLE OF CONTENT

1. Scope of Work………………………………………………………………………………………03

2. Technical Specification references………………………………………………………..03

3. Operational Strategy……………………………………………………………………………..04

4. Construction Methodology……………………………….…………………………….…….08
.
5. Quality Control & Quality Assurance…………………………………………….……….13

6. SAFETY AND ENVIRONMENT………………………………………………………………….14

1 .Scope of work:

P a g e 2 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

This construction Work procedure is applicable for execution of Pile cap as per approved GFC
drawings at OP11 to OP01 & BP01 to BP11 for Construction of New 4-lane Signature Bridge (900m long
Central Cable Stayed module) connecting missing link between Okha and Beyt Dwarka on EPC mode
including construction of approaches on new national highway on NH-51 in state of Gujarat.

This work procedure includes the following main activity:

a. Making arrangement for casting of shuttering slab for construction of pile cap.
b. Shuttering of sacrificial slab.
c. Reinforcement & concreting of sacrificial slab.
d. Deshuttering of sacrificial slab.
e. Shuttering of pile cap
f. Lowering of sacrificial slab.
g. Dismantling of excess pile.
h. Fixing of Reinforcement.
i. Concreting of Pile cap.
j. Curing.

2. Technical specifications:
2.1 CODES & SPECIFICATIONS
1) MORTH Specifications.
2) IS: 456-2000- Indian Standard specification for Plain & reinforced Concrete.
3) IS: 383:1970- Indian Standard specification for coarse and fine aggregate.
4) IS2502 – Code of Practice for Bending and fixing of Bars for concrete Reinforcement.
5) IS: 1786: 2008 Indian Standard specification for High strength deformed steel bars and wires for
concrete Reinforcement.
2.2 Drawings:
Main work drawings.
1) General Arrangement Drawing B-0001 Rev F.
2) B 117 Rev 0 Dimension and Reinforcement Detail of Pile cap and pier shaft for piers casting
arrangement of Pile cap OP11 to OP1 & BP1 to BP11 of beyt Dwarka sea link project.

P a g e 3 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

3. Operating Strategy

3.1 Organization chart

The roles & responsibilities for CWP for Construction of Pile cap has been elaborated in the organization chart
below:

I. Project Manager
II. Planning Engineer
III. Manager Construction
IV. Resident Engineer Construction
V. Site Engineer
VI. Formwork foreman
VII. P & M In charge
VIII. Manager Quality
IX. Quality Engineer
X. HSE Officer
XI. Surveyor

3.1.1 Roles & Responsibilities:-

Project Manager:

 Organize & manage all resources field activities to achieve an effective completion of the contract,
within the agreed time & cost, whilst paying due regard to safety & meeting quality requirements.

Planning Engineer:

 Receive the drawings from client and issuing to site team.

 Plan the resources, with inputs from site team.
 Contract review and preparation of MSP schedules.
 Coordinate with vendors for arranging resources.
 Monitor the progress, financial performance and resource usage.
 Update the resources schedule and look ahead progress.
 Responsible for collecting and maintaining the documents like RFI/All checklists formats etc. after
client signature.

Manager Construction:

 Responsible for all construction works such as reinforcement, shuttering, and concrete etc. as per GFC
drawings issued to him from planning.
 Preparation and indent of materials and consumables to execute the job.
 Maintenance of site CWP formats and checklists.
 Responsible for proper usage of concrete and other major consumables materials such as TMT bars,
without any wastage.

P a g e 4 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

 Responsible for implementation of safe work environment at work place.

 Responsible for execution and maintain the good quality of work.

Resident Engineer Construction

 Coordination with Site engineers and planning team.

 Responsible for implementation of work as per approved drawing.
 Guiding site team for proper execution of work.
 Responsible for reinspection of reinforcement and shuttering before casting.
 Liaising with clients, subcontractors and other professional staff.
 providing technical advice and solving problems on site

Site Engineer

 Responsible for setting out site and organizing facilities

 Checking technical designs and drawings to ensure that they are followed.
 Responsible for supervising contracted staff.
 Preparing site reports and filling in other paperwork
 Ensuring that health and safety and sustainability policies and legislation are adhered to

Formwork Foremen:

 Responsible for formwork assembly and erection as per scheme drawing with consulting site engineer.
 Responsible for checking line, level and dimension trueness of formwork.
 Responsible for reinspection of Formwork alignment after completion of concrete pour.
 Responsible to take care of Deshuttering of formwork without injuring the concrete.

P & M In charge:

 Responsible for equipment fitness inspection, monitoring and maintain records.

 Responsible for all mechanical and electrical equipment ensuring continues availability and proper
functioning of P&M at site.
 Ensure periodic preventive maintenance & timely breakdown repairs of all machinery & electrical
equipment as per their inspection manual.
 Ensure operation of P&M as per company norms.

P & M ENGINEER:-

 Responsible for operational inspection and maintenance of P&M equipment’s on regular basis.
 Reporting of required data related to operation and maintenance of records.
 Responsible for arranging power supply at workplace on day to day basis by co-ordination with site
engineer.
 Ensure continues availability and proper functioning of P&M at site.
 Ensure periodic preventive maintenance and timely breakdown repairs of all machinery & electrical
equipment as per their inspection manual.
P a g e 5 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

Manager Quality:-

 Check the quality of cement, fine aggregates and coarse aggregates etc.
 Responsible for the compressive strength of the concrete batched for site at RMC.
 Identify material sources, and conduct material tests and ensure conformity with specification &
standards.
 Conduct routine tests on materials as per ITP for conformance and maintenance records.
 Identify, calibrate and maintain master list of testing and measuring equipment.
 Responsible for submission of all reports related to quality matters.

Quality Engineers:-

 Responsible for casting of concrete cubes for every batch produced from the plant.
 Responsible for check and maintenance of required workability of concrete at pour location.

HSE Officer:-

 Responsible for implementation of company norms at site.

 Responsible for all safety related works and proper functioning of safety at site.
 Identify potentially unsafe acts, areas and implement practice measures and educate staff &
workmen.
 Investigate unsafe occurrence and initiate corrective steps.
 Organize training programs for safety awareness.
 Helps to provide necessary safety materials as per work requirement.

Surveyor:-

 Setting out of control points and those approved from Consultant.

 Alignment and leveling of formwork as per approved drawing.

3.2 Resource Resourcing:

3.2.1 WORKMEN:

S Manpower No’ per No’s per Remarks

No day shift night shift
1 Pump/Boom Placer operators 1 1
2 Crane Operator 1 1
3 Barge Operator 1 1
4 Tug Operator 1 1
5 Unskilled 4 4 Pile Chipping

6 Shuttering Foremen 1 1
7 Shuttering Labour 10 10
P a g e 6 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

8 Reinforcement Foreman 1 1
9 Reinforcement Labour 10 10
10 Rigger/khallasi 6 4
11 Helpers for concrete, Reinforcement, formwork and mechanical 10 10
work.
12 Housekeeping supervisor’s 01 01
Total Manpower 47 45

3.2.2 Materials:

1. Ready mix Concrete (RMC) M50.

2. Reinforcement FE 550D.
3. GI Binding wire 18 gauge.
4. Formwork.
5. Curing.

3.2.3 Equipment:

Si No Machinery No’s per day Remarks

1 Batching Plant As per site requirement For Concrete production (calibrated once
2 Chilling plant As per site requirement in a month)
3 RO plant As per site requirement
4 Crane 1 No For handling of reinforcement &
shuttering
5 Dumb Barge 1 No To mount crane on that
6 Concrete Pump / Boom 1 No For Concrete Pouring
Placer
7 Pontoon Barge 1 No To mount Boom placer on that
8 Transit Mixer (Tyre 4 No To shift concrete from plant to jetty
mounted)
9 Transit mixer Barge 2 No 3 TM mounted on each for shifting
concrete from jetty to pile cap location
10 Needle vibrators 3 No For proper Compaction of fresh concrete
11 DG 62.5 KVA 2No On both Dumb barges.
12 Compressor 1 No For curing of concrete (Curing compound)
13 Bar bending Machine 2 No Bending the reinforcement as per
schedule
14 Bar Cutting Machine 2 No Cutting the reinforcement as per schedule
15 Welding Machine 2 No For cable profile work, insert, fixing etc.
16 Electrical chipping machine 2 No For chipping and cleaning of spill over
concrete
17 Hydra 14 MT 1 No For shifting of reinforcement
18 Total station 1 No For survey work

P a g e 7 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

4.0 Construction Methodology:-

The casting of pile cap will be done in two parts, first is casting of sacrificial slab and second is casting
of main pile cap, construction sequence for the same is as follow

4.1 Casting of sacrificial slab

We will cast a sacrificial slab to be used for pile cap shutter at MHTL, the work sequence for
the same is as follow-

Arrangement of the same will start during liner driving of pile. Before the liner driving of pile,
we will weld brackets on periphery of all the four liners, During liner driving it should be confirmed
that top level of bracket will remain at + .180, these brackets will be for the resting of sacrificial slab.

 First step as mentioned above will be casting of sacrificial slab.

 A crane mounted dumb barge will be placed near pile group to fix the shutter.
 Temporary platform for working will be made.
 Marking of level for welding of temporary bracket is done.
 Temporary bracket are welded on inner face of all four pile liners for resting of main and cross
girder for shuttering of sacrificial slab.
 After that, shuttering for sacrificial slab will be placed as per temporary structure drawing.
 After that, main beams (B1 As shown in drawing below) will be placed on the top of liner at
the level nearly +6 m with jacks and macalloy bars for holding and lowering of sacrificial slab.
 After that we will start binding reinforcement for the sacrificial slab.
 After reinforcement we will place anchor bolts on sides of sacrificial slab at 1500mm c/c in
periphery and side shuttering is done following concrete.
 Suitable waiting period for attaining minimum strength of concrete.
 Side shutter for pile cap casting is placed all around with the help of crane, suitable rubber
packing for making shutter water proof will be used.
 After complete shutter fixing we will start lowering the sacrificial slab which will be rested on
the already welded bracket on the liners (As mentioned in the picture below). As the dia of
hollow area is 1850mm (drawing attached), so will grout that space to make it waterproof
from bottom also.

P a g e 8 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

P a g e 9 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

4.2 Pile Cap Casting

4.2.1 Chipping of Extra Pile above Cut off Level.

 Now, start the Chipping of extra pile above cut off level, that we have provided for Good and
sound concrete.
 The main purpose of chipping is to remove the surplus slushy concrete over cutoff level.
 The chipping should be done with electrical breakers, Chisel or hammers.

4.2.2 Reinforcement cutting, bending & Fixing

 Reinforcement steel shall be of FE 550 D grade Epoxy Coated & it shall be approved from
Authority Engineer & tested prior to usage.
 The BBS shall be prepared for Pile cap as per GFC drawing and the same should be obtained
approval from Authority engineer before cutting and bending of steel.
 Reinforcement bars shall be kept free from rust and other foreign materials.
 Cutting and bending machine with required manpower to be provided to meet the schedule
requirements. Cutting and bending reinforcements shall be shifted to Site work by truck or
trailer from reinforcement yards and stacked on wooden/RCC sleepers/structural frames.
 Prefabricated Reinforcement from steel Yard will be transported through barge.
 On the completion of Cutting of Pile Heads, the bottom slab will be cleaned completely prior to
installation of Pile cap reinforcement.
 Layout of Pile cap to be marked on PCC with the help of Total Station.
 The reinforcement for Pile cap will be fixed as per the approved drawings and the Bar bending
Schedule.
 Cover to reinforcement will be maintained by placing concrete cover blocks of 75mm
thickness as specified in the drawing.
 Reinforcements once made ready shall be offered to Authority Engineer for checking through
RFI and get approved.

4.2.3 Survey Check for conformity of Geometry of Pile cap & pier
 Check the Geometry of pile cap and Pier with the help of Total station.
 Formwork once made ready shall be offered to Authority Engineer for checking through RFI
and get approved.

4.2.4 Concrete placing, compaction and finishing.

 The reinforcement and formwork shall be offered for inspection and shall be approved prior to
order of concrete.
 The concrete should be transported through Transit mixers. The transit mixers should be
covered with wet hessian cloth. The control of concrete activities and tests to be conducted
should be as per concrete procedure explained in inspection plan & test plan of the procedure.
 Remove any loose foreign materials those are inside before starting concrete.
 Get Inspected and approval for concrete pouring by Authority Engineer by obtaining pour card.
 Please check and ensure the manpower, tools and tackles are in good working condition.

P a g e 10 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

 The grade of concrete should be as per approved drawings, and same supplied from batching
plant should also be as per approved mix design.
 The concrete workability, temperature and retention should be checked at batching plant as
well as site before placing concrete.
 The concrete pouring should be done by static pump or boom placer. Care should be taken
that no concrete is placed against reinforcement or shuttering to avoid dislocation. For this
purposes a baffle board made of plywood or steel shall be kept in front of stream of concrete
from pipes of pump.
 Proper working platform shall be made available for concrete.
 During concrete, compaction should be ensured at all times, but over vibration is also not
desirable as it may lead to segregation and bleeding of concrete.
 All the supports shall be ensured rigid, not disturbed while concrete placing.
 Concrete shall be finished true to its line and level.

P a g e 11 | 14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of PILE
CAP OP11 TO OP1 & BP1 TO BP11

5 Quality Control & Quality Assurance.

5.1 Inspection Plan:

Inspection Plan for reinforcement, Formwork, Surveying and concreting works of Pile Cap works:

Si Description of Sub Activity Check by Check By Documentation Remarks

No SPSCPL Authority
Engineer
1 Fixing of temporary bench marks W R RFI

2 Alignment and leveling of long line bed W W RFI

3 Receipt of reinforcement steel W R Invoices and MTC
4 Sampling and testing of reinforcement steel W R Third party report
5 Bar bending schedule as per GFC W W BBS
6 Tying of reinforcement steel W R -
7 Trueness of formwork or dimensional check W W RFI and Checklist
and level checking as per level sheet
8 Mix design of Concrete and its approval. W W RFI and Mix design approval
9 Placing of concrete W W RFI
10 Sampling for workability, casting of cubes W W Pour card and slump test record

*Note
MTC- Manufacture Test Certificate
W- Witness
R- Review
RFI- Request for Inspection
BBS- Bar Bending Schedule

13
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of Pile
Cap

5.1 Test plan -This chapter deals with the materials, methods and equipment used in the manufacturing,
transporting, placing and compaction and curing of concrete.
1) Cement
2) Coarse and fine aggregate
3) Water
4) Admixture
5) Fly Ash

5.2 Cement
 The cement shall be Ordinary Portland cement of 53 Grade conforming to IS 12269 Codes
respectively and shall meet all physical and chemical requirements as specified.
 The cement for the works will be procured in bulk forms, MTC shall be obtained for all batches /
consignment received at site. Routine test like setting time and compressive strength test shall
also be conducted at site laboratory for each batch as per ITP.

5.3 Coarse aggregate / fine aggregate

 Aggregate for concrete works shall be used from approved source. Routine test like gradation,
flakiness and elongation index, specific gravity, Impact value and silt content for fine aggregate
and moisture content test shall be carried out at site laboratory as per ITP.

5.4 Water
 The water for the concrete will be potable water and it will be pumped into the RO Plant and
chilling plant and stored in storage tank near batching plant. Water to be used for concrete will be
tested and got approved.

5.4.1 Admixture
 Approved and compatible admixture conforming to IS 9103 shall be used to improve concrete
handling and placing capabilities.
 Admixture shall be stored away from sunlight and shall be stirred well before usage for uniformity.
 Mixing of two different admixture batches or manufactures shall not allowed unless it is
controlled.

5.4.2 Fly ash

 The fly ash should possess the properties as mentioned in IS 3812:2008.

14
 Signature Bridge Okha Beyt Dwarka
Construction procedure for Construction of Pile
Cap

7. Environment Health and Safety

7.1 Environment
 Vehicle / Machinery and equipment operation, maintenance and refueling shall be carried out in
such a fashion that spillage of fuels and lubricants does not contaminate the ground.
 General refuse shall be stored in enclosed bins or units and it should to be separated from
construction and chemical waste.

7.2 Health
 HSE officer shall ensure all workers are screened before engaging them for duties. In charge shall
ensure availability of First aider with first aid kit.
 Shed shelter shall be provided for workers for weather protection along with drinking water.

5.5 Safety
 All transit mixers shall be provided with reverse horns.
 Warning sign boards like “Men at work” shall be displayed at work area.
 If night work is to be carried out the area shall be sufficiently provided with lightening.
 It should be ensure that safety belts were worn tied and anchored properly while working at
heights.
 All working platforms shall be tied at both ends firmly.
 All goliath crane/gantries should be fitted with limit switches and siren (to blow before starting
movement).
 The working condition of reinforcement cutting and bar bending machines limit switches shall be
ensured before starting the day’s work.
 Hand gloves shall be used for cutting, bending and shifting of reinforcement rods.
 The electrical connections for vibrators, lightening shall be given by qualified/experienced P&M
personnel through ELCB only.
 Ensure that all moving parts of vibrator compressor if any shall be provided with Guards.
 Sign Boards & warning signs shall be displayed at prominent location nears to work place.
 Ensure lifting tackles such as D Shackle, wire rope slings are of requisite capacity and are in good
condition.
 All lifting personnel will be supplied with standard PPE which consists of, Hard Hat, Safety Boots,
Overalls, Gloves, Hi-Vis (and Safety Goggles if required).

14