UPPER TRISHULI-1 HEP

(216MW)

Method Statement for CSGR Concrete

Contents

1. Introduction ..................................................................................................................................... 04

2. Purpose ............................................................................................................................................ 04

3. Surface Preparation ........................................................................................................................ 04

4. Construction Procedure ................................................................................................................. 05

5. Planning and Preparation .............................................................................................................. 06

6. Mixing .............................................................................................................................................. 06

7. Placing and Compaction................................................................................................................. 06

8. Curing and Protection .................................................................................................................... 07

9. Quality Control ............................................................................................................................... 08

10. Responsibilities and Manpower ................................................................................................... 08

11. References ..................................................................................................................................... 10

Page 3 of 10
 UPPER TRISHULI-1 HEP
(216MW)

Method Statement of CSGR Concrete

1. Introduction

CSGR method is a new technique proposed for Roller Compacted Concrete. The creation of "CSGR"
technology, which has the goals of enhanced safety, rapid construction, reduced construction costs,
and improved environmental protection, is one of many technologies that have been created to
construct dams. The CSGR construction method is, “Spreading CSGR with a bulldozer and
compacting it with a vibrating roller to form a structure.”CSGR Concrete is best described as a zero-
slump concrete that is placed with standard or high-density paving equipment and
consolidated/compacted using steel-drum or rubber-tired rollers to achieve the required strength and
durability.

2. Purpose
The cemented sand-gravel and rock (CSGR) mixtures are widely used for the fast and economical
construction of embankments such as dams/cofferdams. This would ensure an effective consolidation
which is crucial for achieving satisfactory density, strength, smoothness, and surface texture. The
CSGR concrete is constructed without joints, formwork, finishing, steel reinforcement, or dowels.
These characteristics make CSGR concrete simple, fast, and economical. CSGR concrete owes much
of its economy to high-volume, high-speed construction methods. It is applied for the construction
and rehabilitation of dams/cofferdams, roads, airfields, parking lots, power plants, road shoulders,
storage facilities, military facilities, and other industrial complexes and it’s dependingon the desired
thickness. “CSGR” is a concrete, which can be considered as roller compacted concrete, cement, and
cementitious material like fly ash for slow setting and reducing the heat of hydration of mass concrete
with tunnel muck material that can be obtained easily from sites, then the mixing it briefly with the
simple equipment like excavator, loaderand spreading over a designated layer thereafter
rolling/compaction with the rollers.

3. Surface preparation

Well-prepared flat ground surfaces, uniformly compacted to the specified densities will properly
support the loads imposed on the concrete above. In addition, by controlling water content in the
ground over time, soils won't shrink or expand. Proper foundation preparation is very important to the
performance of a project. This includes the removal of weak materials from the surface, sub-grade
evaluation, the selection of suitable materials for use as fill, proper compaction, control of moisture,
and providing flat uniform surfaces for CSGR concrete placement.

Page 4 of 10
 UPPER TRISHULI-1 HEP
(216MW)

Method Statement of CSGR Concrete

Before starting execution of concreting, a detailed concreting program to schedule effective mixing,
placing, loading, spreading and compaction will be performed. Any remaining water shall be removed
by compressed air. Any seepage water entering locally will be dealt with by suitable means such as
drainage borings with grouted pipe nipples connected to collector pipes and local sealing measures.
All nearby water shall be withheld from the fresh concrete until it has sufficiently been set. Any
increase of pore pressures in the surrounding rock mass, which may be harmful to CSGR concrete,
must be avoided.

4. Construction Procedure

Tunnel Mucking

Transportation

Muck Material Storage

Foundation Clearance

Water Weighing Up Cement-Fly Ash

Mixing

Transportation Formwork Erection

Material Spreading

Roller Compaction

Page 5 of 10
 UPPER TRISHULI-1 HEP
(216MW)

Method Statement of CSGR Concrete

5. Planning and Preparation

• Using equipment that is adequate in size and number to meet the construction requirements.
• Provide required equipment at the construction site.
• Sequence construction operation, for instance, access and routing for equipment, air and water
support system, foundation preparation and joint treatment, setting of forms or precast work,
setting of line and grade control, placement of conventional concrete at contacts or in facings,
and placement of bedding mortar. These operations should be carried out with minimum
interference with the placement, spreading, and compaction works of CSGR.

6. Mixing

The CSGR method changes the production-controlling elements of mass-concrete placements from
the rate of placement for conventional mass concrete to the output of the concrete plant and delivery
system for CSGR. Rapid and continuous delivery of CSGR is important to mass applications. The
tunnel muck material shall be sieved by a 150mm sieve and 150mm passing muck material, Cement,
and other ingredients according to the mix design ratio shall be properly mixed with appropriate
volume by the Excavator. Mixture uniformity should be maintained at all production rates that will be
used. Continuous mixers typically work efficiently above a minimum production rate, and up to
production levels that are two to three times that of the minimum rate.

CSGR ROLLER COMPACTED CONCRETE FINAL MIX PROPORTION

(ACI 207.5R-99)
Nominal Ingredients (Kg/m3)
Maximum
Concrete 150mm
S.N. Size of Remarks
Grade Fly NMSA Super-
Aggregate, Cement Water
mm Ash Muck Plasticizer
Material
1. C 6/8 150 140.0 50.0 1959 0.57 144

7. Placing and Compaction

CSGR Concrete is a type of concrete that can support a roller during its unhardened state while it is
being compacted. The placement and compaction of CSGR is a rapid construction process and
therefore its success relies on the pre-construction planning and coordination of all interrelated
activities. The CSGR concrete should be as fresh as possible at the time of placement to compact it

Page 6 of 10
 UPPER TRISHULI-1 HEP
(216MW)

Method Statement of CSGR Concrete

adequately and achieve maximum density. Generally, static rollers are initially used to compact
CSGR lifts, and then a vibratory roller is used to complete the compaction process. First spread the
uncompacted material on the required area up to 500 mm thick and proper roller compaction four to
six passes then it will be 300 mm thick. Four to six passes on 150 mm to 300 mm thick lifts usually
result in suitable compaction for tight areas, with density achieved with large rollers. Spreading and
compacting should be accomplished within 120 min of mixing, and preferably within 90 min of
mixing. This limit is applicable at mixture and weather conditions of approximately 70 F (21°C) and
mixtures that are non-retarded. The time can be extended for cooler weather and should be reduced in
warmer weather.

At the time of compaction, CSGR concrete mixture should still be fresh to get the best compaction
results. The bond between different lifts of CSG concrete should be ensured by performing lift surface
cleaning, maintaining surface moisture, and utilizing a bonding mixture like fluid bedding mortar or
concrete. The concrete mixture should be compacted when placed and spread in a uniform lift
thickness. Normally, rolling procedures start with a static pass to even out the loosely placed concrete,
and then the vibratory roller is applied.

The minimum number of passes for a given vibrating roller to achieve specified compaction depends
primarily on the CSGR mixture workability and lift thickness. The compacted thickness of any CSGR
lift should be at least 3 times the diameter of the NMSA. The concrete placement should correlate the
number of passes to obtain the designated density for the mixture within a given moisture content
range.

8. Curing and Protection

After CSGR has been placed and compacted, the lift surface must be cured and protected just as for
concrete placed by conventional methods. During curing, concrete shall be protected from harmful
effects, e.g., severe cooling or heating, drying (including drying due to wind), heavy rain, running
water, chemical or mechanical attack, The surface must be maintained in a moist condition, or at least
so that moisture does not escape. It should also be protected from temperature extremes until it gains
sufficient strength. The final lift of CSGR should be cured for an appropriate time, generally in excess
of 14 days. Membrane curing compounds are not suitable because of the difficulty in achieving 100%
coverage on the relatively rough surface, the probable damage to the membrane from construction
activity, and the low initial moisture in the mixture. Curing compounds also do not provide the
beneficial surface temperature control that is associated with moist curing.

Page 7 of 10
 UPPER TRISHULI-1 HEP
(216MW)

Method Statement of CSGR Concrete

9. Quality Control

While quality control is customarily considered to be an activity performed during CSGR concrete
placement, it is also essential that quality control be considered during design, planning, and the initial
phases of construction of a CSGR concrete. After, the compaction of concrete the DT (Density Test)
shall be performed by the sand replacement method in accordance with standard code ASTM D 4914.
Routine quality control tests shall be performed to determine whether the concrete made for use on
the job attains the requisite properties. The Temperature shall be tested and cubes will be made for
compressive strength test, cured, stored, and tested in accordance with ASTM Standards under
ambient climatic conditions. From each shift, three specimens (cubes) will be made for testing
(compressive strength) at 7 days, three specimens for testing at 28 days, and three specimens for
testing at 90 days for control purposes. For the compressive strength test of the core sample, the
preferred minimum core diameter is three times the nominal maximum size of coarse aggregate, but it
should be at least two times the nominal maximum size of coarse aggregate. The NMSA of CSGR
concrete is 150mm thus the core sample shall not be taken.
A structure should be designed with consideration of what measures will be required during
construction to ensure that the required quality is attained. It is obvious that the design of projects
where little quality control is anticipated should be more conservative than the design of a project
where a very effective quality-control program will be implemented. In addition to testing, a quality-
control program should consider the various construction operations basic to CSGR and how they are
performed. Preparation and advance planning are key to the success of quality construction.
Preconstruction meetings, preconstruction testing, and preconstruction evaluations such as test
sections, are critical parts of the quality program. Once CSGR placement is underway, the quality-
control program should include continuous evaluations that quickly resolve quality variations.

10. Responsibility and Manpower

The responsibilities of the contractor are specified below:

1. Providing construction schedule weekly and monthly and distributing to the

construction team and tracking the progress.
Technical
2. Measurement of work quantity.
Department
3. Providing construction method statements and induction for the construction
team.

Page 8 of 10
 UPPER TRISHULI-1 HEP
(216MW)

Method Statement of CSGR Concrete

4. Documentation of technical and QA/QC for the overall period of construction.
5. Audit design drawing and method of statement.
1. Proving inspection test plan and quality control documentation.
2. Management of lab test equipment.
Laboratory 3. Assistance for defection corrective action and acceptance check.
4. Optimization mix design.
5. Providing concrete test reports and documentation.
1. Quality assurance audit
2. Quality assurance record
3. Corrective action

QA/QC Testing 4. Nonconformance control

Engineer 5. Materials quality control
6. Site inspection and test
7. Training and indoctrination
8. Informing checking the time to engineer
1. Providing a daily report
2. Site inspection with engineer
3. Quality control and check the procedure of construction works
Site Engineer
4. Construction document management
5. Technical support to contractor
6. Measurement of construction works.

Manpower

Description Nos. Remarks

Technical Manager 1
Chief Engineer 1

Site QC Engineer 6
Foreman 2
Welder 2

Electrician 2
Yardman 2

Page 9 of 10
 UPPER TRISHULI-1 HEP
(216MW)

Method Statement of CSGR Concrete

11.References
a) Roller Compacted Mass Concrete,ACI 207.5R-99
b) Research review of the cement sand and gravel (CSG) dam,Xin CAI, Yingli WU, Xingwen
GUO, Yu MING, College of Water Conservancy and Hydropower Engineering, Hokai
University, Nanjing 210098, China, Nanjing Hydraulic Research Institute, Nanjing 210098,
China, College of Mechanics and materials, Hohai University, Nanjing 210098, China
c) 30 Years’ History of Roller-compacted Concrete Dams in Japan. Isao Nagayama Public
Works Research Institute, Japan ShigeharuJikan, Water Resource Development Public
Corporation, Japan
d) Roller Compacted Concrete Dams, L. Berga, J.M. Buil, C.Jofre& S. Chonggang
e) Study on Application of CSG Cofferdam in Hydropower Station Construction,Yunfeng
PENG, School of Water Resource and Hydropower, Wuhan University, Wuhan China,
Yunlong HE, School of Water Resource and Hydropower, Wuhan University, Wuhan, China
f) Trapezoidal CSG Dams, Atsuyoshi Higuchi, Takashi Ikeda, Japan Dam Engineering Center

Page 10 of 10