CONST OF MISC.

CIVIL WORK FOR

CRM PROJECTS.

JOB PROCEDURE FOR CONCRETING WORK

DOCUMENT NO.: PISL/QA-QC/AM/NS/HAZ/PJO/JP-05 Rev. No. 00 P a g e 1 of 14

PROJECT : CONST OF MISC. CIVIL WORK FOR CRM PROJECTS.

JOB NO. : WO NO : AM/NS-HAZ/PJO/5200016690

OWNER : ARCELORMITTAL NIPON STEEL INDIA LIMITED

CONTRACTOR : M/s PRAGATI INFRA SOLUTIONS PRIVATE LIMITED

00 26-06-2023 Issued for Review

& Approval

Reviewed
Prepared &
& Approved By
Date
Checked By AM/NS
Rev Description
PISL
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JOB PROCEDURE FOR CONCRETING WORK

DOCUMENT NO.: PISL/QA-QC/AM/NS/HAZ/PJO/JP-05 Rev. No. 00 P a g e 2 of 14

TABLE OF CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 RESPONSIBILITY

5.0 METHODOLOGY

6.0 HEALTH, SAFETY AND ENVIRONMENT

7.0 DOCUMENTATION & RECORDS

8.0 ITP'S AND FORMATS

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JOB PROCEDURE FOR CONCRETING WORK

DOCUMENT NO.: PISL/QA-QC/AM/NS/HAZ/PJO/JP-05 Rev. No. 00 P a g e 3 of 14

1.0 PURPOSE
This procedure is generated in part conformance of purpose to establish a uniform,
predetermined & controlled methodology to enable monitoring of concreting works at site and
to ensure that proper quality control is achieved during construction work under CONST OF
MISC. CIVIL WORK FOR CRM PROJECTS.

2.0 SCOPE
The scope of this Job Procedure includes of all types of Cast-in-Situ & pre-cast concrete
used in foundations, underground & over ground structures, floors, etc. Any requirements
as per drawing shall supersede over the provisions of this procedure.

3.0 REFERENCES
Following documents in totality or in part shall form the reference documents:

 AM/NS Specification /Guidelines (AMDEC/AMNSI/120015/S/CV/22/021)

 Contract (Bid), AFC Drawings,etc.
 Relevant/Applicable IS Codes- IS:456, IS:383,516, 1199, 1786, 2502, 2645, 4656,
2386, 4925, 4926 etc.

4.0 RESPONSIBILITY

Vice President- Project. Shall report to the CDO HO.

Shall be responsible for overall implementation,
monitoring and control of construction &
commissioning activities

QA/QC Shall report to Project QA/QC Manager (Technically)

& Project manager (administratively).
Shall be responsible for the compliance of this
procedure.
Shall ensure proper implementation of this proce-
dure.
Shall checks and verifies the activities.
HSE Officer Shall report to Resident Manager (Administratively)
& Project HSE Manager (Technically).
Manages the implementation of all safety
requirements during operations.
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To verify and ensure that the communication system

is working properly and that emergency equipment
is in place.
5.0 METHODOLOGY
Construction Material:

The materials to be used for concrete shall be as below and as IS-383 AM/NS Technical Speci-
fication.

Coarse and Fine Aggregate

 The specification of coarse and fine aggregates to be used for concrete shall be as below
and as per Technical Specification.

 For approval of source of coarse and fine aggregates, the same shall be tested at site
laboratory or approved laboratory outside for all the properties stipulated in IS: 383.
 The materials shall be free from the injurious amount of alkali, vegetable matter and
other deleterious substances.

 The grading of coarse and fine aggregates shall conform to IS: 383. The grading of ag-
gregates shall be checked on regular basis for their conformity with mix design grading.

 The aggregates shall be tested in field laboratory fortnightly or for every 200 m3 for each
aggregate whichever is earlier and in other respects generally as per IS: 2386 (Part 1 to 8)-1963.

 The total amount of deleterious /foreign materials shall not exceed 5% by weight according to rel-
evant clause of IS: 383-1970.

 The grading of sand aggregate shall conform to IS: 383-1970 and shall be within the limits of
Grading Zone-III. The maximum size of particle shall be 4.75mm and shall be graded down. Sand
containing more than 10% of fine grains passing through 150-micron sieve or having the fineness
modulus less than 2 shall not be used for concrete work.

 Each type and grade of aggregates shall be stored separately on firm ground and where
two types of aggregates are stored close to each other, they shall be separated by a wall or plate.

Cement

 Cement shall be stacked in go-down to protect from dampness and shall be made easily
accessible for proper inspection and accounting as per IMIR procedure.
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 Cement received at site shall have Manufacturer's Test Certificate (MTC) for each batch
receive
 Ground Granulated Blast furnace Slag IS: 16714 :2018

Reinforcement Steel

Reinforcement bars shall be procured from approved/reputed manufacturer and the material
shall be as per following codes and as per approved IMIR procedure.

High Yield Strength Deformed bars : IS: 1786

Mild Steel bars : Grade I of IS: 432
Welded wire fabric : IS: 1566
Different grades and materials composition of re bars shall not be mixed. Manufacturer's Test
Certificate (MTC) for each type/consignment of reinforcement steel received at site shall be sub-
mitted to owner. The certificate shall show the result of tests necessary to prove that the rein-
forcement complies in respect with the relevant IS codes.

All reinforcement bars received at site, shall be clean and free from dirt, oil, paint, grease, mill
scale, loose rust etc. and shall be stacked on timber sleepers to avoid contact with ground/wa-
ter.

Form work

 The material for form work shall be as below and as per AM/NS Specification & IS: 4900.
 Only modular formwork shall be utilized for all RCC works. Formwork design documents
shall be submitted to AMNS for approval prior to usage at site.
 Plywood form work shall be used for all water retaining, conveying structures and for all
over ground concrete structures. For other areas, steel/plywood form work may be used.
 No metal part of any device for maintaining form work in the correct location shall re-
main permanently within the specified concrete cover to the reinforcement.
 In water tight construction, methods of fixing form work, which result in holes through
the concrete section, when the form work is removed, shall not be used. All wall ties
shall have water baffles and wall kickers shall be cast monolithically with the base slab.
 Form work panels shall be stiff enough to prevent vibration during concreting.
 Damaged and used form work shall not be re used without repairing.
 All joints between the forms shall be sufficiently tight to prevent cement slurry loss dur-
ing concreting. The part of the ties shall be capable of being removed, so that no part
remaining embedded in the concrete shall be nearer the surface of the concrete than the
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DOCUMENT NO.: PISL/QA-QC/AM/NS/HAZ/PJO/JP-05 Rev. No. 00 P a g e 6 of 14

specified thickness of cover to the reinforcement. After the removal of ties, the holes
shall be filled with concrete or mortar of approved composition.
 Form work props shall be positioned between permanent supports, so that all members
are supported at not more than 3 meters center in both directions. Sufficient numbers of
bracings are to be provided to resist buckle.
 Shuttering scheme of each type of structure shall be submitted to AMNS for approval
prior to concrete.

The tolerances of the shapes, lines and dimension shall be within the limit as mentioned in
clause 11.1 in below (IS: 456). The form work stripping time shall be as mentioned below
(IS:456)2000.

Sr.No Type of Form work Minimum period before

Striking form work
1 Vertical form work to columns, walls, beams 16-24 hours
a Soffit form work to slabs (props to be re fixed 3 days
Immediately after removal of form work)

b Soffit form work to beams (props to be re fixed 7 days

Immediately after removal of form work)
2 Props to slabs:
a Spanning up to 4.5 m 7 days
b Spanning over 4.5 m 14 days
3 Props to beams and arches
a Spanning up to 6 m 14 days
b Spanning over 6 m 21 days

Water

Water to be used for concrete mixing and curing shall be clean and free from injurious
amounts of oils, acids, alkalis, salts, sugar, organic materials or other substances that may be
deleterious to concrete or steel.
Water shall be obtained from an approved source. To ascertain the same a sample of water shall
be tested in approved lab prior to start the job and once in two months for each source of
supply The pH value of water shall generally be not less than '6'.

The water will be in general potable water conforming to the requirement of IS:456.
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Add concrete admixture, integral water proofer, binding wire, cover blocks, light structural
work & inserts, steel tube, foundation bolts, threaded fasteners in construction material
section.

Procedure:
Add concrete mix design:
All concrete in the works shall be of design mix as defined in IS 456-2000, unless it is a nominal mix
concrete such as 1:3:6, 1:4:8 or 1:5:10. Whether reinforced or otherwise, all design mix concrete works
to be carried out under this specification.
At the commencement of the contract the Contractor shall make preliminary tests to determine the
proportions by weight of cement, fine aggregates, coarse aggregates and water necessary to produce
required grades of concrete. The mix proportions shall be selected to ensure that workability of the fresh
concrete is suitable for the conditions of handling and placing and when concrete hardens, it shall have
the required strength, durability and surface finish. The Contractor shall get approval of Engineer In-
Charge to such proportions before he starts concreting. However, such approval shall not relieve the
Contractor of his responsibility to produce concrete having compressive strengths as laid down in the
foregoing Table.
For the all major and important R.C. works and for all special works, the design of mixes shall be made
by the Contractor at his own cost, for each grade of concrete as well as for various workability. The
design of mixes shall be made according to I.S. 10262 or any other approved standard methods.
The cement content for various compressive strength of concrete shall be based on design mix.
However, irrespective of requirement of cement found out from design mix, cement content of concrete
shall not be reduced below the quantities specified as under except for the cases specifically approved
by the Engineer In-Charge and minimum compressive strength of 15 cm cubes at 7 and 28 days after
mixing, conducted in accordance with IS:269-1989 & IS: 516-1959 respectively.

The sequential procedures for concrete works shall be as below and as per AM/NS Specification.
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Add Workability & durability criteria of concrete as per IS: 456 specifications.

TRIAL MIXES:
After approval of the Mix Design by the Engineer In-Charge, the Contractor shall make in presence of
Engineer In-Charge the Trial Mixes for each grade of concrete as well as for required workability.
Before commencement of the concreting works of grade of concrete, the Contractor must complete the
work of trial mixes and subsequent testing of the test cubes obtained there from the design of the
Approved Mix for that particular grade of concrete. The entire cost of all the trial mixes including all the
preparatory works for trial mixes, preparation of test cubes and their testing shall be borne by the
Contractor.
In absence of or till contractor own batching plant is not established, concrete should be procured from
AMNS approved RMC vendors only.

Plain Cement Concrete

For all types of PCC works, the concrete shall be mixed by weigh batching or volume
batching as directed by Engineer-in Charge. The concrete shall be mixed with the pro-
portion as mentioned in AFC drawing.
Before laying PCC, the sub grade /base shall be compacted (if required) and de water-
ing shall be done if necessary.
Compaction of lean concrete (PCC) shall be done manually using rammers. PCC for
flooring, filling etc. Shall be compacted with vibrio-rammers. Form works for PCC shall
be done using battens/wooden planks/steel channels etc.
Top level of PCC shall be checked with reference to the AFC drawing.

Reinforced Cement Concrete

Before each concreting, sufficient notice in form of Request for inspection (RFI) forms
shall be given to PMC/Owner at least before 24 hours of concrete pour plan.
The checks are purely in the interest of the work and to draw the contractor's attention
to his contractual obligations to execute the works according to the drawings/specifica-
tion and do not relieve the contractor from his responsibility in getting the end results
for the quality & strength of concrete and for maintaining the shape, level & dimen-
sions of the finished concrete, as well as the inserts, openings, other features within
the tolerance limits.

Bar Bending Schedule

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JOB PROCEDURE FOR CONCRETING WORK

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For all RCC structures, Bar Bending Schedule (BBS) shall be prepared & approval
through AMNS as per drawing. Approved BBS shall be made available during cutting,
bending activities and during pre pour concrete checks at site.

Assembling and Placing of Reinforcement Steel

Reinforcement shall be bent and fixed in accordance with IS:2502, SP:34

After bending, all reinforcement bars shall be placed and maintained in position as
mentioned in AFC drawing by providing cover blocks, laps, chairs etc.
The cutting shall be done using Bar Shearing Machine and bar bending machines with
appropriate diameter mandrels as per IS:2502 provisions of required diameter.

All intersections shall be tied with 20 BWG approved quality galvanized iron (GI) bind-
ing wire.
Clear cover to main reinforcement shall be as mentioned in respective drawings.
However, tolerance for cover to main reinforcement bars in higher side would be allowed
up to (+10) mm as per IS: 456 – 2000.
Lap lengths as per drawing shall be provided. Where bars are cranked at laps the slope
at the crank shall not exceed 1 in 6. Laps shall be staggered in such a way that not
more than 50% of the bars are lapped at the same location.
Welding of reinforcement, if required shall be carried out as per the set standards IS
2751:1979 & IS: 9417 for mild steel reinforcement bars and IS 1786-2008 for cold
worked high strength deformed bars. As per the site requirements Sample testing of
the welded reinforcement shall be done and the report to be submitted to the client.
Welding if to be done shall be done by qualified welder only. Separate WMS and WPS
to be submitted and approved for bar welding. Test piece shall be made and tested by
NABL third party lab before welding of routine bars to prove that the joints are of the
full strength of bars connected.
In no case hot cutting and bending of reinforcement is permitted on site. In case of
reinforcement fouling with any inserts, same shall be brought in notice of AMNS Engineer
In-charge and approval to be taken accordingly.

Mixing of Concrete

The concrete shall be mixed in the mixer of adequate capacity having a power elevated
loading hopper. The mixer shall be equipped with an automatic water measuring tank
filled with a device for locking the discharge setting.
The mixing shall continue until there is a uniform distribution of the materials and the
mass is uniform in color and consistency.
Any concrete surplus to immediate requirements shall be thrown away. In no case or
circumstances may the surplus be used later.
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Volume of mixed materials in each batch shall comply with the mixer manufacturer's
written recommendations.
The mixing time from the time of adding water shall be in accordance with IS: 1791 -
1985 but in no case less than 2 minutes or at least 40 revolutions.
Contractor has to set up a Concrete Mixing Plant (weighing batches type), of minimum
capacity of 10cubic meter per hour. The Batching Plant should have a recording and
printing slip facility of each batch of concrete with details of each ingredient, date,
time, and serial number of batches of the day. The Batching plant should have sepa-
rate mounded water storage tank, also have a tank to supply additives at least two.
Contractor has to maintain periodic calibration of the batching plant as and when re-
quired. Contractor has to submit the calibration certificate to the Owner before produc-
ing the concrete for the project work.
Transporting of Concrete

After mixing, concrete shall be transported to the pouring point as early as possible
without loss or segregation of any of the ingredients. No water shall be mixed with the
concrete after it has left the mixer.

All equipment’s/transit mixers are to be used for transporting the concrete from batch-
ing plant, shall be kept clean and wrapped with wet gunny bag to reduce the loss of
water by evaporation in hot weather.

Placing of Concrete
The concrete shall be deposited as nearly as practicable in its final position to avoid re
handling or may be pumped by mechanical means.
Before placing of concrete, the contractor shall give his detailed concreting program for
that structure to the Engineer In-Charge. Such programs, shall specify all information
such as the locations where concrete is to be poured, type/grade of concrete, volume
of concrete to be poured, number and Type of vibrators proposed to be used as well as
proposed to keep as standby, number of skilled technicians and supervisors proposed
to be engaged, the proposed time and period of pouring etc.
Concrete shall be placed continuously up to the construction joints (if any) while it is
still sufficiently plastic for adequate compaction.
Method of placing concrete should be such as to avoid segregation. Care should be
taken to avoid displacement of reinforcement bars or movement of form work.

At all time when reinforced concrete is being placed, a competent re bar fitter and car-
penter shall be in continuous attendance.
Maximum permissible free fall of concrete is 1.5m.
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Compaction of Concrete

Concrete shall be thoroughly compacted by mechanical vibrators and fully worked

around and fully worked around the reinforcement, around embedded fixtures and into
the corner of the form work.
Over vibration and under vibration of concrete are harmful and should be avoided.

Major Equipment Foundations

Special requirements for concreting of major equipment foundations shall be as stated below
and as per Project Specification.

Temperature Control of Concrete

The placing temperature of fresh concrete shall not exceed 23º C. for maintaining the temper-
ature of 23º C during concreting of machine foundations; crushed ice shall be used in mixing
water

Admixture (Shift to construction material section)

Plasticizer cum retarder type admixture shall generally be added to the concrete for promoting
workability in addition to retarding the setting time for mass concreting works. However, the
approved Design Mix for various grades of concrete shall be used. The slump shall generally
be in the range given below: as per is 456

Ultrasonic Testing (Prepare separate method statement for UPV and Rebound
hammer test and submit)

Ultrasonic Pulse Velocity Test shall be carried out for the top decks of all machine foundations
and TG substructure to ascertain the homogeneity and integrity of concrete.
In addition, additional cubes (at the rate of one cube per 150 cum of concrete subject to a
minimum of six cubes) shall be taken to carry out Ultrasonic Pulse Velocity (UPV) testing on
the cubes to serve as reference UPV values.
Testing shall be done as per IS: 13311 (part-1). In case of any defects, the rectification shall
be done suitably by using cement/epoxy grout etc.

Curing
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JOB PROCEDURE FOR CONCRETING WORK

DOCUMENT NO.: PISL/QA-QC/AM/NS/HAZ/PJO/JP-05 Rev. No. 00 P a g e 12 of 14

Exposed surfaces, immediately after final set, shall be protected from the sun.
All concrete shall be well watered after it has been set and shall be kept continuously damp
until thoroughly cured for 10 days. Provision shall be made for adequate water distribution to
all parts of the work so that if required, this treatment can be continued sufficiently through-
out the whole period of construction.
In order to keep the concrete continuously damp, all exposed surface shall be covered with
damped gunny bags or shall have water compound on them, for full period of curing.

Sampling Procedure, Frequency and Acceptance Criteria for Concrete

The sampling procedure, Frequency and Acceptance Criteria for Concrete shall be as below
and as per IS:456.
A random sampling procedure shall be adopted to ensure that each concrete batch shall have
a reasonable chance of being tested that is, that sampling should be spread over the entire
period of concreting and cover all mixing units.

Frequency

The minimum frequency of sampling of concrete of each grade shall be in accordance with the
following:

Sr.No Quantity of Concrete in the work, m3 Number of Samples

1 1–5 1
2 6-15 2
3 16-30 3
4 31-50 4
4 plus one additional sample for each
5 51 and above
additional 50 m3 or part thereof

Acceptance Criteria

The concrete shall be deemed to comply with the strength requirements as tabulated in mix
design section in procedure above. Concrete surface shall be free from voids and
honeycombing.
After removal of form work if the surface is get honey combing, contractor should inform to
the Engineer In-Charge immediately .after visual inspection Engineer In-Charge will take the
decision to get it repair /grout with the suggested material or the NDT test shall be done for
the acceptance of such member or the structure or the part of structure shall be totally
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dissented, so that the adjoined structure should not get damaged or disturbed. Contractor has
to bear all such cost on his own. No payment shall be made for such type of work.

Prepare separate MS for concrete repairs.

6.0 HEALTH, SAFETY AND ENVIRONMENT

 Contractor shall ensure that the machine operators involved must be an experienced/
competent person.
 All PPE is a must in this activity.
 It is to be noted that the special care to be adopted against snake / insects bite.
 During the movement of equipment the operator must blow horn to caution the people
around.
 All Measuring & Test Equipment’s used must be well maintained.
 All lifting devices & Tolls used shall be well maintained.
 It is to be taken care that no spillage of fuel or lubricants is allowed at site.
 Contractor shall arrange Regular Tool Box Meeting.
 Contractor shall arrange First Aid Box at site.

7.0 DOCUMENTATION & RECORDS

Documentation shall be in the line with approved inspection / test plans. Quality document will
be maintained by systematic implementation of this procedure and generating necessary
quality records. Inspection reports in approved formats shall be raised upon carrying out the
work.

8.0 ITP’S / FORMATS

ITP no. : PISL/QA-QC/AM/NS/5200016690/ITP-06,REV-00

: PISL/QA-QC/AM/NS/5200016690/ITP-07,REV-00

Format : PISL/QA-QC/AM/NS/5200016690/TRF-07,REV-00
: PISL/QA-QC/AM/NS/5200016690/TRF-08,REV-00
: PISL/QA-QC/AM/NS/5200016690/TRF-09,REV-00
: PISL/QA-QC/AM/NS/5200016690/TRF-10,REV-00
: PISL/QA-QC/AM/NS/5200016690/TRF-11,REV-00
: PISL/QA-QC/AM/NS/5200016690/TRF-11A,REV-
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Note: In case on any conflict between the above procedure and project specification the later
shall govern, without any prejudice to the terms and conditions of the contract.