Method Statement Manual Loading Concrete Mixture Machine For Concrete Works - R1

1 28-12-21 Second Issue
0 04.08.21 FIRST ISSUE
Rev Date Description Checked Approved
DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF

220 KV RUSUMO – NYAKANAZI LINE UNDER REGIONAL RUSUMO FALLS
HYDROPOWER PROJECT - TRANSMISSION LINE COMPONENT.
CONTRACT NO. RUS-TZ/PA/001/2017-18/HQ/W/22
Tanzania Electric Supply Company Limited (TANESCO)

Umeme Park, Morogoro Road, Ubungo
CLIENT
P.O Box: 9024, Dar Es Salaam, Tanzania
Tel: +255 22 245 1130/9
CONSULTING ENGINEER WSP / INTEC GOPA
1600, Rene-Levesque West Blvd,

16th Floor, Montreal, Canada,
H3H 1P9
CONTRACTOR : STERLING AND WILSON PVT. LTD & ELECTROMONTAJ SA. UJV
Sterling & Wilson Pvt. Ltd,

Associates of SHAPOORJI PALLONJI & CO.PVT.LTD
Universal Majestic, 9th Floor, P.L.Lokhande Marg, 1, Candiano Popescu Street, Bucharest, Romania
Chembur, Mumbai, India
Title :
METHOD STATEMENT MANUAL LOADING CONCRETE MIXTURE
MACHINE FOR CONCRETE WORKS
Job no. E/18/0337 Date 28.12.2021

Prepared by Gobinath Sekar Checked Jatin Parikh
Approved Veeranjaneyulu Ravipati
Doc No. RUSTA-1SWE-TL-5100-018-01
STERLING and WILSON METHOD DOC No.: SW-T&D-MS-MNC-01
REV No.: 01
PVT LTD.
STATEMENT DATE: 28. 12. 2021
MANUAL LOADING CONCRETE Page 2 of 18

MIXTURES MACHINE
PROJECT: 220kV RUSUMO-NYAKANAZI TRANSMISSION LINE.

CONTRACT NO: RUS-TZ/PA/001/2017-18/HQ/W/22
Comments Received on: 24th August 2021
Document Title: Method Statement Manual Loading Concrete Mixture Machine for Concrete Works
rev-0 Not Approved
Title: REPLY TO CONSULTANT’S and CLIENT’S COMMENTS
Comments on Method Statement Manual Loading Concrete Mixture Machine for Concrete Works -R0 :-
Sr Comments Reply
No
1 The document contains false information like the date of Date has been changed and revision date is mentioned
creation and revision number;
2 Also does not include the procedure to measure the materials Materials will be measured by only volume ratio and ratio
quantities for every concrete twill; is mentioned in trail mix details
3 The document tries to replace the existent approved method Yes, This is new method statement for using Mixer
statement for preparing the concrete; machine at site
4 There is no certification from the approved laboratory that the there is no change in mix design and instead of weight we
concrete obtained using the proposed method fulfil are going use Volumetric proportion
the contract technical requirements. The supporting documents are attached in annex III
Gobinath Sekar Jatin Parikh Veeranjaneyulu Ravipati

QA/QC Manager (Head Quality - T&D) Project Manager
PREPARED BY: REVIEWED BY: APPROVED BY:

REV No.: 01
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MIXTURES MACHINE
METHOD STATEMENT MANUAL LOADING

CONCRETE MIXTURE MACHINE FOR
CONCRETE WORKS


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Table of Contents Page
1 Purpose of the Method of Statement 5

2 Scope 5
3 Associated Documents 5
4 Responsibility 5
5 Equipment 6
6 Source of material 7
7 Storage of materials used for concreting 7
8 Selecting and mixing of concrete ingredient 8
9 Mixing & pouring of concrete at site 8
10 Precaution while machine mixing concrete 9
11 Care while concrete from Mixture to Foundation 9
12 Testing of concrete 10
13 Defects and repair 12
14 Improper weather conditions 12
15 Health and Safety requirements 13
16 ANNEXURE – I (M30) 14
17 Annexure – II Checklist for concrete pour card 17
18 Annexure – III Cube Test repots 18


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1. Purpose
The purpose of this Method Statement is to provide the steps and procedures for the preparations of
concrete ingredients, mixing, transporting, placing, compacting, curing, quality controlling and
assurance of the Structural concrete at site for all Tower Foundation bases construction.
2. Scope
The scope of this Method Statement shall apply to all the concrete works at RUSTA Concrete works
only, that include batching, transporting, placing, compaction and curing of all concrete structures.
The Class of concrete is 30MPa cube strength.
3. Associated documents
Together with this Method statement, the following documents will be read in conjunction:
a. Approved drawings for construction.
b. Drawing number: RUSTA-1SWE-Tl-5100-005-00: General notes for RCC Structures.
c. Concrete mix designs for 30MPa.
d. Standard and codes: EN 1992 as per Contracts, ACI 318, ASTM C33, ASTM C39, ASTM C136,
ASTM C143, ASTM C231
e. Site Instructions
4. Responsibility
The following Personnel are responsible to ensure the implementation of this Method Statement:
a. The Site Engineer for the Project shall be responsible for carrying out the Works in accordance
with this Method Statement.
b. Quality Assurance and Quality Control (QA/QC) Engineer is responsible for the preparation
and maintenance of Quality Records as required by Method Statement.


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c. The Land Surveyor shall be responsible for the setting out of the structures and checking the
setting out of all embedded items and cast in items including holding down bolts from permanent
markers provided by the Main Contractor at the job site.
d. The Site Supervisor shall be responsible for planning and carrying out the physical preparations
prior to placing concrete, the cast-in items, the compacting and curing of concrete.
e. The Safety Officer shall be responsible for monitoring and ensuring that all activities are carried
out safely in accordance with the Health, Safety and Environmental requirements as stipulated by
Company SAFETY Policy, the Safety requirements by the Client and the OSHA stipulation.
f. Skilled crew shall be responsible for preparation, fixing and securing formworks in position,
alignment, and elevation as per approved drawings for Construction.
g. Skilled crew (Reinforcement bars) shall be responsible for cutting, bending and fixing re-bars in
position and at designated centers.
h. Skilled crew (Concrete works) shall be responsible for placing, compacting and curing of
concrete.
i. General Helpers (Unskilled) shall assist the skilled crews above.
5. Equipment for Mixing and Batching
The list of Plant for this operation includes:
a. 1 x Cement Container Storages (20feets) or will be transported by properly covered truck having
hood
b. Manual Concrete mixer (Site with no Access)
c. Water Tanks 2000 ltr capacity
d. Buckets for Site Batching or Measuring Box
e. Concrete vibrators (various sizes)
f. Concrete Chute/Steel material
g. Concrete bucket
h. Survey instruments
i. Petrol Generator for Lighting if required
j. Excavator for carrying Concrete at Site (Hill’s Site)


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MANUAL LOAD MIXER MACHINE.

The Manual Operation Mixer Machine which will fits for Hills and Difficult Site Location with Steep terrain.
Manual Batching Will be done by Below Methods of Measurement For 30mpa.
➢ Measuring Bucket
➢ Measuring Box
Alternative Steel Boxes may be fabricated as required on site.
6. Source of materials used for batching of concreting at site:

Specification of Materials used for concreting shall be as per technical contract & procured from approved
sources only.
7. Storage of materials used for concreting:

Cement bags will be stored on site as per below mention points.
Before Concrete arrangement at site, the cement will be taken from our store to site location.
Cement bags will be stored in proper manner by keeping it above the Ground.


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Cement bags will be fully covered by tarpaulin to protect from rain and surface water.
Aggregates shall be placed on ground clear of the vegetation and Aggregate stacks shall be kept physically
separated near the location.
Water for concrete mixing will be taken from store by using 2000 Lt drum or 5000 Lt, Water tank will be
kept near to the location.
Admixture will be taken from store before the concrete kept near the location.
8. Selecting and mixing of Concrete Ingredients

Prior to placing of any concrete into the permanent works, the aggregates (course and fine), Cement,
Admixture Sources shall be taken as per the Approved Mix design with the Technical Specification
9. Mixing and pouring of concrete at site:
The mix quantities shall always be strictly in accordance with the approved design mix quantities.
All the materials such as fine and coarse aggregates, water, and cement required for concrete will be
inspected for use prior to commencement.
Prior to commencement of concreting activities, the following shall be available on site.

• Concrete Mixers - in good working order
• Vibrators
• Water - required quantity.
• Fine Aggregate -required quantity.
• Coarse Aggregate -required quantity.
• Cement -required quantity.
• Admixture
• Aggregate measuring boxes, Mixing Sheets, water measuring container.
• Test cube molds / Slump cone
• Concrete chutes / slides / elephant trunks
• De-watering pumps (if necessary for the site).
The concrete mixer shall be placed in such a location so that the transport distance of the concrete to the
foundation is minimized.
• First, wet the inner surfaces of the drum of concrete mixer.
• Coarse aggregates are placed in the mixer first followed by sand and then cement. Farma to be made as
per Weight proportionate from mix design and loaded in the concrete mixer in volumes corresponding to
the weight.
• Mix the materials in the dry state in the mixing machine. Normally it should be 1.5 to 3 minutes.


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• After proper mixing of dry materials, gradually add the correct quantity of water also add admixture
quantity as per approved mix design while the machine is in motion. Do not add more water than required.
It is not advisable as it reduces strength.
• After adding the water, mix concrete for a minimum of two minutes in the drum. If there is
any segregation of concrete after unloading from the mixer, then remix the concrete as long as is
necessary to ensure a homogeneous and workable mix.
10. PRECAUTIONS TO BE TAKEN WHILE MACHINE MIXING OF CONCRETE:

• Concrete mixer machine must be wet before use.
• Take care of mixing time, speed, and numbers of revolution of mixer drum as per the recommendation
of the manufacturers of the mixer machine.
• Concrete should be used within Approved design mix after mixing and discharged by the concrete
mixer.
• If your mixing is batch plant type then, after discharging one batch of concrete, the interior surface of
the mixer drum should be cleaned thoroughly. If not, lumps of hardened concrete from the mix of
previous batch may form a part of the subsequent batch and deteriorate the quality of concrete.
• If your mixing is of a continuous type, it is necessary to clean the concrete mixer after fixed intervals.
• The inner portion of the concrete mixer should be carefully inspected at regular intervals to check for
damages, shatter, or corrosion.
11. Proper care will be taken to transfer the concrete from the mixer to the pit to avoid segregation of the
constituent materials as below:
• The maximum free-fall height shall not be more than 1m. To ensure these chutes shall be employed.
Pad concrete shall initially be placed.
• After and during pouring the concrete shall be continuously vibrated by means of vibrators to
ensure proper compaction.
• Vibration shall not be used as a means of repositioning the placed concrete.


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• Construction joints shall be avoided as far as possible. Under unavoidable circumstances Employer
approval is must.
• To ensure adequate bond between the old and new surface, old concrete surfaces must be made as
a rough surface.
• Immediately before placing the new concrete the surface shall be cleaned and all loose particles
removed.
• The cleaned surface shall be primed with a layer approximately 15 mm thick of a wet mix comprising
cement and fine sand in equal proportions.
• Immediately after placement of the base and chimney concrete the setting dimensions will be
checked and adjusted provided concrete setting has not yet taken place.
• All concrete will be compacted using vibrators. The vibrators will be inserted vertically at regular
intervals into the concrete not more than 30 second to be compacted.
• If the layer currently being placed covers a freshly compacted layer the vibrator will be descended by
about 10 cm into the previous layer. Vibrator will be withdrawn slowly to avoid creation of voids.
12. Testing of Concrete:

There are two types of testing of concrete used for foundations works. One is Slump Test used for testing
fresh concrete, and the other one is Compressive Strength measured from Compression testing of concrete
cubes.
i. Slump Test (as per ASTM 143)
A slump in a truncated cone 300 mm high and of standard dimensions shall be between 50 and 90 mm,
corresponding to a stiff plastic consistency.
The concrete sample should not be taken from the first or last section of the pour.
Tools needed to perform these tests are as follow,
• A bucket or wheelbarrow
• Wooden board / Polythene sheet or similar
• Tamping rod or vibrating poker
• Slump cone
• Pen or marker to identify the samples
• Mound releasing agent and brush
• Scoop
• Trowel/Concrete float
• Tape Measure/Steel Rule
• Damp cloth


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The slump cone is filled in three layers, each approximately one-third of the height of the slump cone when
compacted. Each layer is compacted with 25 strokes of the compacting rod so that the strokes just
penetrate the immediate underlying layer.
After the top layer has been compacted, Remove spilled concrete from the base plate/surface. Remove the
cone from concrete by raising it carefully in vertical direction.
Perform the operation of raising the slump cone in 5s to 10s, by a steady upward lift, with no lateral or
torsional motion being imparted to the concrete. Carry out the entire operation from the start of the filling
to the removal of the slump cone without interruption and complete it within 150s. Immediately after
removal of the slump cone, measure and record the slump (h) by determining the difference between the
height of the slump cone and that of the highest point of the slumped test specimen in mm.
Once the slump test procedure is carried out, if the slump of the concrete is not within consistency class,
then concrete can be adjusted by applying additive to the concrete in consultation with client/consultant.
ii. Compressive Strength Testing (as per ASTM C231)
During mixing of concrete for each section of the work and at such other times as directed by the Employer,
1 sets of test cubes, size 15x15x15 cm shall be taken, each set consisting of 6 cubes. From each set 3 cubes
shall be tested after 7 days and the remaining 3 cubes after 28 days. The compressive strength of the cubes
after 28 days shall not be less than as specified in the Technical Schedules.
Before the concrete is scooped into the molds, the molds must be lightly coated in a mold release agent.
When using a 150mm mold, the concrete sample is scooped into the mold in 3 equal layers (50mm) and
compacted between each layer manually by compacting rod.
The test cubes (specimens) shall be marked clearly and indelibly, without damaging the specimen.


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The test specimens will be left in the mold for at least 16 hours, but no longer than 3days, protected against
shock, vibration, and dehydration.
After removal from the mold, the test specimens will be cured till immediately before testing, in water.
The cubes are tested on the face perpendicular to the casting face. The compression machine exerts a
constant progressing force on the cubes till they fail. The reading at failure is the maximum compressive
strength of the concrete.
13. Defects and repair

a. Defective Concrete: Concrete not conforming to required lines, details, dimensions, tolerances or
specified requirements shall be brought to the attention of the Consultant.
b. Repair or replacement of defective concrete shall be determined by the Owner or the Consultant.
c. The Contractor shall not patch, fill, touch up, repair, or replace exposed concrete except upon express
direction of the Owner or the Consultant for each individual area.
14. Improper weather conditions.

i. Hot weather
The following steps will be taken if it becomes unavoidable to pour concrete during hot afternoons:
a. Dampen the substrate and formwork with cool water prior to pouring concrete.
b. Placing ice cubes in the mixing water to reduce the initial mixing temperatures.
c. Laying hessian clothes with water on the surface after finishing of concrete surface is completed.


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ii. Rain
As self-loading mixers are operating nearby to pouring location, plastic tarpaulin arrangements required
during rain. Cement can be stored in small porta cabin type container or covered store.
15. Safety Requirements
Standard Safety Instructions:
• Housekeeping and Disposal of special waste- SWPL Environmental Management Plan.
• General Safety Measures- SWPL Health & Safety Plan. (Submitted separately)
• Drugs & Alcohol- Caspian Drug & Alcohol Management Plan. (Submitted separately)
All works will strictly follow the above Safety, health, and environmental guidelines to ensure everybody, at
the end of the shift, goes back to his/her family safe and healthy as they did at the beginning of the shift.


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ANNEXURE – I : M30 – As per Approved MIX design
Ingredients UOM (Kg/m³)

Cement 372
CA – 20mm 1096.8
Quarry Dust 354.55
Sand 354.55
Water 183.3
Admixture 6
Mix Ratio of Concrete
As Per Mix Design

Bag Volume/B Total
Kg/m3 Weight Number of bags ag Volume/m3
Cement ( As Per Mix Design) 372 50 7.44 0.0347 0.258
Total Sand Kg Bulk Density

/m3 50% Kg/m3 Volume / m3
Sand - 50% 709.1 354.55 1649 0.215
Total Sand Kg Bulk Density

/m3 50% Kg/m3 Volume / m3
Quarry Dust- 50% 709.1 354.55 1737.2 0.204
Bulk Density
Kg / m3 Kg/m3 Volume / m3
C/Aggregate 14-22mm 1096.7 1511.5 0.726
PROPOSED RATIO AS PER MIX DESIGN DOCUMENTS; -
Volumes Per Cement: Sand: PROPOSED

Ingrediencies Material.
Mix C/Aggregate RATIO PER MIX
Cement 0.258 1 1
Sand (CHATO) 50% + Quarry Dust
50% 0.269 1.6 1.6
C/Aggregate (KASSCO) 14-22mm 0.406 2.8 2.8
PER RATIO/VOLUMES IN CALLCULATION SHEETS


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Trail mix No: 01 ( 50% Sand and 50 % Dust)
Using by Baby Mixer machine
Date of Trail Mix: 21-12-2021
Ratio of Mix for Half bag cement: 1:0.4:0.4:1
• 1 - Half bag Cement

• 0.4 - Sand in box (size 30cm x 30cm x 30cm)
• 0.4 - Dust in box (size 30cm x 30cm x 30cm)
• 1 - 20mm aggregate in Box (Size 30cm x 30cm x 40cm)
• 10lt - water
Slump – 35mm
No of Cube sample taken: 6 Nos
Test Results
Date of testing
Percentage of
cube passing
Factor Load
Age of cube
location No
Correction
Structures
load in kN
in N/mm2
Strength
concrete
Casting
Type of
Date of
casting
in kN
in N/mm2
Sl.no
Strength
Average
0.9862
572 564.14 25.07
5
7 28-12- 0.9862 97.9
715 705.17 31.34 29.37
days 2021 5 %
Baby Mixer 0.9862 Baby
Trail 723 713.06 31.69
Machine 5 mixer
1 21-12-2021 Mix
Ratio machi
01
1: 0.4:0.4:1 ne
28 18-01- Waiting
days 2022 for test


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Trail mix No: 02 ( 100% Sand)

Using by Baby Mixer machine
Date of Trail Mix: 28-12-2021
Ratio of Mix for 1 bag cement: 1:2:3
• 1 - Full bag Cement

• 2 - Sand in box (size 30cm x 30cm x 30cm)
• 3 - 20mm aggregate in Box (Size 30cm x 30cm x 40cm)
• 26.5lt - water
1st Slump – 30mm at 25ltrs water

2nd Slump – 60mm at 26.5ltrs water
No of Cube sample taken: 12 Nos
Test Results – waiting for Test
Type of concrete
Factor Load in
Date of casting
Date of testing
Percentage of
cube passing
Age of cube
location No
Correction
Structures
load in kN
in N/mm2
in N/mm2
Strength
Strength
Average
Casting
Sl.no
kN
3days 31-12-2021
Baby 7days 04-01-2022

Mixer Baby
2 28-12-2021 Trail Mix 01 Machine Waiting for test mixer
Ratio machine
1:2:3 14days 14-01-1900
28 days 28-01-1900


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ANNEXURE – II : CHECKLIST FOR CONCRETE POUR CARD
Drawing
no. : Date:
Structure :
Location :
Segment :
Grade of concrete :
Quantity of concrete :
Date & time of start :
Time of completion :
Method of transportation :
Method of mixing :
Method of pouring :
Rate of pour achieved : cum/hour.
Slump observed:
1 2 3 4 5 6 7 8 9 10 11
mm mm mm mm mm mm mm mm mm mm mm
No. Of cubes taken :

ID Marks on cubes :
APPROVED TO POUR : YES/ NO


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ANNEXURE – III : Cube Test Reports
Trail Mix -01 : 7days Cube Crushing Reports


Method Statement Manual Loading Concrete Mixture Machine For Concrete Works - R1

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1 28-12-21 Second Issue

0 04.08.21 FIRST ISSUE

Rev Date Description Checked Approved

DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF

CONTRACT NO. RUS-TZ/PA/001/2017-18/HQ/W/22

Tanzania Electric Supply Company Limited (TANESCO)

CONSULTING ENGINEER WSP / INTEC GOPA

1600, Rene-Levesque West Blvd,

Sterling & Wilson Pvt. Ltd,

Job no. E/18/0337 Date 28.12.2021

MANUAL LOADING CONCRETE Page 2 of 18

PROJECT: 220kV RUSUMO-NYAKANAZI TRANSMISSION LINE.

Gobinath Sekar Jatin Parikh Veeranjaneyulu Ravipati

PREPARED BY: REVIEWED BY: APPROVED BY:

MANUAL LOADING CONCRETE Page 3 of 18