SOP Civil Work WTG Foundation

VIVIID RENEWABLES PRIVATE LIMITED 1.0 / 0 1 .01.
2024
Ver. No. / Date
Package : Civil Work
SOP : WTG Foundation CIP-PROJ-WIND-

Document Id
SOP-01
Title : Document Information & Approval Page 1 of 58
VIVIID RENEWABLES PRIVATE LIMITED
STANDARD OPERATING PROCEDURE
CIVIL WORK
WTG FOUNDATION
DEPARTMENT: CONSTRUCTION MANAGEMENT

VIVIID RENEWABLES PRIVATE LIMITED 1.0 / 0 1 .01.2024
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Contents
1. Introduction ............................................................................................................................. 4
2. Pre-requisites ......................................................................................................................... 7
3. Method Statements and Flowcharts ...................................................................................... 9
4. Record Sheet .......................................................................................................................... 43
5. Checklist ................................................................................................................................ 46
6. Key Requirement of Health, Safety & Environment (HSE) ................................................. 50
7. Resource Required ................................................................................................................. 53
8. Frequently Asked Questions (FAQs) ..................................................................................... 55
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Revision Status Record
Revision Date Page no. Details of Changes Reason for

No. changes
1.0 01.01.2024 All pages Initial version for release -
Document Approval sheet:
Prepared by Signature
Reviewed by Signature
Approved by Signature
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Title : Introduction Page 4 of 58
1. Introduction
1.1. Purpose
The Standard Operating Procedure (SOPs) has been developed to define a framework for the
Construction Management at project sites and to ensure control on schedule and execution of
activities for Domestic, International and Special Renewable Wind power project s. The prime
objective of this SOP is to implement the Planning, Scheduling, Execution and Monitoring aspects
for the Construction activities. This method statement covers the appropriate practices of WTG
Foundation.
1.2. Preparation Work
This activity is to be started ideally after completion of Land Survey.
 Mobilization of manpower with suitable PPEs at the site location.
 Check and ensure the required tools & machineries at the site location.
 Check the requirement of construction material at site location.
 Check the Laydown area for the storage of construction material.

 Required Area grading activity should be completed.
 Construction location where the WTG foundation works to be done should be cleaned & made
ready.
 Approach road to be ready for transportation of Concrete, Reinforcement & Anchor Cage etc.
 Check availability of all construction drawing related to WTG foundation.
1.3. Definition
 Micro Sitting Drawing: - The science of limiting array effects by suitable geometric
arrangements of machine layout is generally known as micro siting of wind turbine
 Geotechnical Investigation of Soil: - The process in which the physical qualities of a site are
evaluated in order to determine if the site is suitable and safe for the proposed purpose.
Geotechnical investigation to get clear information about the soil properties and hydrological
conditions at the site, we get nature and engineering properties of the soil and rock formation
by this activity.
 Approach Road: - An access road to Wind Turbine Generator site.
 Excavation Work: - Work involving the removal of soil or rock from a site to form an open face,
hole or cavity using tools, machinery or explosives.
 Plain Cement Concrete (PCC): - It is a mixture of cement, fine aggregate(sand) and coarse
aggregate without steel. PCC is an important component of a foundation which is laid on the
soil surface to avoid direct contact of reinforcement of concrete with soil and water.
 Anchor Cage: - An anchor cage is a set of bolts, kept together by an inferior and superior steel
rings (or) the anchor cage is a system conceived to transfer the loads to the foundation more
effectively, anchoring the tower to the foundation.
 Torqueing: -Torque is the application of force acting at a radial distance and tending to cause
rotation.
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 Steel Reinforcement works: - Steel reinforcement is steel bars or mesh of steel wires used
in reinforced concrete and masonry structures to strengthen and hold the concrete in tension
 Shuttering work: - Shuttering also known as formwork in concrete construction is used as a

mould for a structure in which fresh concrete is poured only to harden subsequently. It
supports and holds the liquid concrete till the time it solidifies and takes shape.
 Concrete Mix Design: - It is the process of selecting suitable ingredients of concrete and
determining their relative proportions with the object of producing concrete of certain
minimum strength and durability as economically as possible.
 Concrete pouring: - Site-poured concrete is building material that is poured, moulded, and
cured onsite.
 Curing: - Curing is the process of maintaining satisfactory moisture content and temperature in
freshly cast concrete
 Backfilling: - It is the process of replacing or reusing the soil that is removed during building
construction to strengthen and support a structure’s foundation or any other structural
member.
 Grouting: - Grouting is a process in which cement mortar or other same functional material like
epoxy filled in cracks or voids in any construction (or) Cement Grouting is the injection under
pressure of cement or grout to fill voids or fractures in the soil, rock unit
or concrete structure. Cement Grouting is a process by which cement is injected under
pressure to fill fractures and voids in concrete structures.
1.4. Abbreviations
Abbreviations Definitions / Full Forms
VRPL VIVIID RENEWABLES PRIVATE Limited
BOM/BOQ Bill Of Material/Bill of Quantity
CTM Compression Testing Machine
CUM Cubic Meter
DPR Daily Progress Report
CM Cement Mortar
DPR Daily Progress Report
EHS/HSE Environment Health Safety
FDD Field Dry Density
FQP Field Quality Protocol
FAQs Frequently Asked Questions
GPS Global Positioning System
GA General Arrangement
GI Galvanized Iron
IS International Standard
JSA Job Safety Analysis

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Abbreviations Definitions / Full Forms
MTC Manufacturer’s Test Certificate
M Meter
MDD Maximum Dry Density
NCR Non-Conformance Report
NA Not Applicable
NABL National Accreditation Board For Testing LAB
NGL Natural Ground Level
OMC Optimum Moisture Content
OJT On Job Training
OPC Ordinary Portland Cement
PCC Plain Cement Concrete
PPC Portland Pozzolana Cement
PPE Personal Protective Equipment
PVC Poly Vinyl Chloride
PTW Permit To Work
PCD Pitch Circle Diameter
QA & QC Quality assurance and quality control
RCC Reinforced Cement Concrete
SQM Square Meter
SFQP Standard Field Quality Plan
SOP Standard Operating Procedure
SBC Safe Bearing Capacity
TBT Tool Box Talk
TPI Third Party Inspection
WBM Water Bound Macadam
WTG Wind Turbine Generator

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Title : Pre-requisites Page 7 of 58
2. Pre-requisites
2.1. Material
List of Materials
Cement Reinforcement Steel & binding wire
Sand Cement Grout
Aggregate (10mm & 20mm) Anchor Cage including Foundation Bolts

Admixture including accelerator and retarder Hessian Cloth/ Gunny Bags
Water Murrum or WBM
Weather Coating Nito Bond

Silica Fumes Shuttering Material
2.2. Tool
List of Tools
Spirit Level Dumpy Level/
Measurement Tape GPS (Global Positioning System)

Torque Wrenches Concrete Pump
Concrete Batching Plant Concrete Vibrators
Slump Cone Concrete Cube Moulds

Compression Testing Machine (CTM) Transit Mixers
Back Hoe/Excavator Bulldozer

JCB Blasting Machine
Total Station
2.3. Documents & Records
Required Document Ref. Doc. No. Required Record Sheet Ref. Doc. No,
Progress / Record Sheet

Standard Field Quality Plan
(SFQP)
WTG GA Drawing /RCC drawing Concrete Pour Card
Anchor Cage Installation Field Quality Protocol (FQP)

Manual
Bar Bending Schedule Equipment/ Machineries Checklist
Soil Investigation Report Curing Register
WTG Foundation Drawing Compaction Test Record
Concrete Mix Design Level Book for Ground Level

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Title : Pre-requisites Page 8 of 58
Cube Test Ragister Record for Core Cutter Test QA-C/F-21
HSE Manual IMS/AGEL/OHS/MANU Cement Register QA-C/F-14

AL/01
2.4. Personal Protective Equipment (PPEs)
Mandatory
Required
(PPE)
Reflector Jacket Hard Hat Hand Gloves Safety Shoes Safety Eye Wear
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Title : Method Statements & Flowcharts Page 9 of 54
3. Method Statements and Flowcharts
3.1. WTG Micro Setting & Soil Test
Field soil investigation to be carried out by external agency for each WTG location., it is necessary
to carryout core drilling to depth of at least 3m in hard rock or 5m in soft rock / bed rock, and then
bore hole shall be terminated at this point.
 Micro setting drawing with Co-ordinates will be received from AGEL and the same will be
rechecked.
 The Centre of WTG location must be marked by using GPS instrument to external agency to
conduct soil test. Test shall carry out within 30m of the centre point of WTG. If drilling was not
successful, then additional drill may be carried out within the rad ius of 30 m of the centre
point of WTG.
 Standard penetration test to be carried out in accordance with IS: 2131 – 1981 to find out N
value and disturbed & undisturbed samples need to be collected for laboratory investigation
which shall comply with IS 2720.
 Safe bearing capacity at various depths shall be found and the detailed Geo technical
investigation report must be submitted by external agency.
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Flowchart for WTG Micro Setting & Soil Test

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3.2. Approach Road Works
3.2.1. Survey of area
Initial road survey must be carried out by taking following points into consideration
 The Boundary Lines of land coming across the area.
 Elevation of WTG according to the Co-ordinates

 Availability of enough Gradient (Min of 1: 15) along with appropriate turning radius as
per WTG Supplier requirement.
 Availability of enough area for setting up the platform.
 Type of formation Soil.
 Requirements of any Culverts, river crossings at the initial stage.
 Obstacles and other conditional infrastructure to be considered, which includes power

lines, tunnels, bridges etc.
3.2.2. Alignment of Road
After finalizing the survey, alignment has to be done by marking. Before taking up the road
works Natural Ground Level(NGL) / Existing Ground Levels should be noted for every 10m to
15m interval on all the three points’ i.e., Right, Centre & Left of the respective road. Also,
level marking should be done for Cutting / Filling to match the gradient. Suitable turning
radius to provide during road alignment
3.2.3. Thickness of Road
The thickness of the road section mainly depends upon the characteristics of the soil below.
Hence the sections need to be decided based on the soil investigation done and will vary
from site to site. As the general guideline, where the sub base is good enough to carry the
loads as mentioned in this documents, Minimum 150mm thick layer (or thickness as
mentioned in drawing) of approved soil after compaction to the required degree shall be laid
for temporary approach road.
3.2.4. Surface
 The surface of the site roads will usually be unpaved. It should be properly compacted,
 The maintenance of the road during the construction period – both related to bearing
capacity and the smoothness of the surface – must be executed sufficiently to allow
access for all trucks, cranes and ordinary cars without any hindrance.
 The decision of AGEL Engineer-In-Charge is final in accepting the Surface of the road.
3.2.5. Side Drains
 The contractor’s scope of work includes the execution of all permanent and interims
ditches as well as the watercourses needed to ensure sufficient drainage of the access
and site roads.
 A typical earthen drain shall be as per drawing with proper slopes to facilitate the water
flow.
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 Based on the terrain conditions & watercourses the drain has to be made either on one
side or both sides of the road.
 During the entire project, the ditches and watercourses must be maintained by the civil
contractor.
Flowchart for Approach Road
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3.3. Excavation Works
The Contractor appointed shall carry out all excavation works in accordance with the dimensions
and levels indicated on the foundation drawings. Excavation is carried out in accordance with the
guidelines given in IS:3764-1992 “Safety code for excavation work". Blasting, if required, is carried
out in strict accordance with IS: 4081-1986 "Safety code for blasting and related drilling
operations" and the latest state laws, regulations and rules. Blasting, at all-time will be carried out
under the supervision of fully qualified, experienced and licensed supervisors.
Before commencing earthwork, benchmark of location should be fixed for depth reference. In case
of high variation in the level of ground then it should be brought to notice of Construction Head.
3.3.1. Excavation of soil
 Excavation may be carried out by excavator machine. Excavation shall be in all kinds of
soils and shall include careful removal of all materials of whatever nature, whether dry or
wet, to facilitate the construction work, exactly in accordance with lines, levels, grades,
curves etc. shown on the drawings.
 Earthwork shall be done to the exact length, width, depth and profile as shown
irrelevant drawings.
 Bottom of excavation shall be levelled and it shall be free of loose unconsolidated

material. If excavation goes to greater depth from the specified depth then such e xtra
excavation shall be filled in either with PCC or river sand and well rammed as directed by
Engineer in charge. No extra payment will be done for such extra work on account of
excess excavation in any case.
 No excavation for foundations shall be filled in or covered with concrete until Engineer’s
inspection & sanction issued to proceed with the works.
 Stability of the excavation need to be taken care. Any dewatering, shoring, strutting and
timbering or cutting of extra width of trenches required for the work and safety of
workmen and equipment shall be done. Dewatering water shall be drained off in such a
way that it does not cause any damage to any property or any nuisance to neighbours /
others.
 All bottom of excavation shall be lightly watered and thoroughly rammed before laying
PCC.
 Excavated material required for filling (suitability will be checked by Engineer in charge)
shall be stacked or dumped where indicated by the Engineer in charge.
 Boulders more than 100mm in size shall not be permitted for backfilling.
 Surplus material from the stacks or dumps retained for filling and excavated unwanted
earth shall be removed and carted away from the site.
 The method of measurement shall be generally in accordance with the IS: 1200 (Method
of measurement of building and civil engineering works) unless otherwise specified.
3.3.2. Excavation by Blasting in hard rock
 Prior intimation shall be given to Engineer in charge in case of necessity of blasting. It is

necessary to do so to safeguard persons, property, existing work, materials, equipment’s
etc. around the blasting area.
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 The contractor shall obtain all necessary licenses and permission covering the purchase
and use of explosives, and shall meticulously observe the requirements of Government
and local authorities.
 The contractor shall provide a proper secure place for the storage of explosives to the
satisfaction of the Engineer in charge and they shall be handled only by men
experienced and trained in their use.
 In case of blasting with dynamite or any other high explosives, the position of all of the
bore holes to be drilled shall be marked in circles with white paint / lime.
 The bore holes shall be thoroughly cleaned before a cartridge is inserted.
 Only cylindrical wooden tamping rods shall be used for tamping. Maximum of eight bore
holes shall be loaded and fired at one occasion.
 The charges shall be fired successively and not simultaneously. Before firing, warning
shall be given.
 Generally blasting operation shall be in accordance with the (IS 4081-1986 – Safety
code for blasting and related drilling operations).
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Flowchart for Excavation Work

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3.4. Base PCC (Plain Cement Concrete Works)
 Before laying ensure correct level is received, excess excavation to be filled with lean concrete
or river sand.
 The works shall consist of providing and placing concrete for plain concrete works in
conformity with the drawings or in accordance with the written instructions of the Site
Engineer. The details of material specifications shall be as stated under the Reinforced
Concrete works.
 The bottom of excavated surface shall be lightly watered and thoroughly rammed before laying
the PCC
 Proper shuttering shall be provided for required dimension as per drawing for PCC.
 Materials used for PCC (Cement, Sand, Aggregate & Water) shall comply with Field Quality
Plan.
 The offset of PCC shall be the same as the thickness of PCC or as specified in the drawing.
 Curing for minimum 3 days shall be carried out after placing the PCC.
 After PCC is done the levels for the top of PCC shall be recorded in the prescribed formats &
shall be verified by AGEL site engineer.
 The contractor shall be able to produce the record of supplying the concrete for PCC in form of
batch prints of the batching plant. In case of concrete is done with mechanical mixers the
cement bags and other material used for the PCC shall be recorded.
 The measurement of the PCC will be done only as per the drawing for the payment purpose.
Any excess PCC on account of extra excavation or for filling the undulations will not be
payable & deemed to be covered in the rate given in the contract.
 Backfilling work to done in maximum layer of 300 mm and same should be compacted with
rollers.
 95% compaction shall be achieved by standard proctor max dry density.

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Flowchart for Base PCC

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3.5. Anchor Cage Work

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 Anchor plates/Anchor Bolts/Stubs/Circular Embedment along with necessary templates

will be provided by WEC Supplier. The Contractor shall be responsible for correct placing and
fixation in accordance with dimensions, levels and specifications within the tolerances given
on the drawings.
 Prior to the setting of the lower reinforcement of the foundation, the position of the 6 lower
plates will be marked on the leaning concrete.
 The leveling legs will be set on the marks done. Afterwards, the lower reinforcement will be set.
The plates of the leveling legs will be fixed to the leaning concrete
 The rebar interfering with the leveling legs or the nuts, will need to be slig htly moved, so that
their position can be adapted to the final position of the leveling legs.
 Once the lower reinforcement has been assembled, the lower flange will be introduced on the
leveling legs.
 The unloading of the flanges will be done by a crane provided by slings (textile). In no case will
the lifting be done using chains or any other metallic mean that could damage the flanges.
 Before the leveling, it will be checked that the lower flange is placed at a distance as per
drawing of the leaning concrete (the bolt can be marked before the leveling to make the
process easier).
 A first leveling of the lower flange will be done, using three of the leveling legs (those forming
120º). (Leveling tolerance: +/-0.5mm). Once leveled, the other three legs will be tightened.
 Before introducing the bolts, they will be marked with two lines that will indicate the final
position of the lower face of each nut (lower nut and upper nut).
 Additionally, to marking the bolts, the holes will be numbered on the lower fl ange, to identify
the position of the guide bolts.
 Once numbered, the main bolts will be introduced, in the closest positions to the leveling legs,
but separated two holes from them. These bolts will be tightened to the lower flange.
 Afterwards, the guide bolts will be introduced (they have been previously marked too). There
will be 12 bolts in total or as per WEC supplier (which will be positioned between the main
bolts). These bolts will serve as a template when assembling the first section of the tower.
These bolts are slightly higher (about 1cm) in order to work as the mentioned template.
 Once positioned and tightened the main and guide bolts, the upper flange (or upper template)
will be set. This template will stand on the nuts of the main bolts previously positioned.
 Once the template is on position, it will be leveled. For this we need to set the template in the
correct position, with the help of the previously painted marks.
 Leveling of the upper template. For the leveling of the upper template, the main bolts and the
guide bolts will be used (Leveling tolerance of +/-1 mm or as per drawing requirement).
 Once the main bolts have been leveled, their position will be fixed introducing another nut over
the flange (under the flange the other nut is positioned).
 After the upper flange is leveled, the verticality of the bolts will be verified using a bubble level.
 After the horizontality of the flange and the verticality of the bolts have been checked, the rest
of the bolts will be introduced. Except from the guide bolts, all the bolts need to stand out the
same distance (Tolerance: +/- 2 mm or as per drawing requirement). To help the introduction of
the bolts, the nuts will have to be pushed back the maximum, to the limit where the thread
ends.
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 The wrench torque is necessary now. Minimum 400Nm (or as per drawing) force shall be
applied to the nuts positioned under the lower flange. The wrench torque’s mouth needs to be
special, in order to host the length of bolt standing out of the washer.
 After introducing all the bolts, one more step needs to be done. Because of the length of the
bolts, they may curve on the free upper part. To avoid this and guarantee a perfect coincidence
with the coming tower flange, another template will be positioned on the bolts, holding its free
extreme. In the absence of second flange the top template can be placed 150mm (or as per
drawing) below the top of studs and it should be leveled before casting.
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Flowchart for Anchor Cage Work
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3.6. Steel Binding Work
3.6.1. Reinforcement Steel Works
 The drawings / bar bending schedules shall be thoroughly studied prior to the
commencement of fabrication& installation.
 Fabrication shall be accurately done to the dimensions, spacing and ensuring minimum
cover as called for on structural drawings.
 All reinforcement bars shall be made straight if it is in bent condition before cutting /
bending.
 Bars shall be cut by using cutting machine or blades.
 Bars shall be bent gradually by machine or other approved means without the use of
heat.
 Bars shall be rejected if found having cracks or splits on the bends.
 Bars incorrectly bent once shall not be used without the approval of the Engineer.
 All reinforcing steel shall be in place and firmly wired.

Engineer shall also ensure that embedment, PVC conduits and earth strips are in
position before placing concrete.
 Unless otherwise specified or shown on the drawings, all laps shall be 50 times the
diameter of bar.
 All steel reinforcement shall be accurately placed in position shown on the drawing tied
with 18 gauges GI, (MS wire) steel wire or any tempered wires can be used
 Welding shall be carried out only when specifically shown on the drawings in
accordance with IS: 2751 (or as per drawing) Reinforcement shall have cover as shown
on the structural drawings and where not specified the thickness of cover shall be a
minimum of 50mm.
 Cover blocks shall be either square or rectangular in plan with or without binding wire
embedded in them will be tied to the reinforcement.
 To provide necessary cover for reinforcement at any section, only single cover blocks
shall be used.
 Unless specified otherwise, actual concrete cover should not deviate from the required
nominal cover by ±10mm.
 Lapping of rods shall be done as per AGEL approved drawing requirement.
 Chair bar to be placed at 1m distance or as per technical specification or drawing.

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Flowchart for Steel Binding Work

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3.7. RCC Work
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RCC work shall consist of making and placing concrete for reinforced concrete works in conformity
with the drawings or in accordance with the written instructions of the Site Engineer. All materials,
workmanship and testing shall comply with the latest revisions of the relevant Indian Standards,
Codes of Practices referred to in these specifications and notes given on the dra wings. Unless
otherwise stated in these specifications, the IS: 456-2000 "Code of practice for Plain and
Reinforced Concrete", and the standards referred to in this code of practice are applicable to
reinforced concrete work.
The proportions of ingredients for concrete shall be such that in addition to complying with the
strength requirement, the concrete shall have adequate workability and proper consistency to
permit it to be worked readily into the forms and around reinforcement, under the conditions of
placement to be employed without excessive segregation or bleeding.
3.7.1. Mix Design of Concrete
 Only the Design Mix concrete accordance to RCC drawing shall be used for RCC. The
contractor shall perform trial mixes and preliminary tests of each class of concrete. The
selection criteria will be compressive strength, workability and surface finish and shall
follow the procedures given by WTG manufacturer or as outlined in IS: 456 -2000.
Control tests shall be carried out before undertaking the works accordin g to the
composition selected for the purpose of the concrete works.
 The mix design report shall be submitted for review & approval.
 The trail mix for the submitted design mix along with all the required testing shall be
carried out at site. The foundation concrete will be allowed only after getting
satisfactory result of the trail mix. Quality department will approve the same.
3.7.2. Batching & Mixing of Concrete
The concrete is mixed preferably in an automatic Batch Plant of sufficient capacity. The
mixing is carried out according to IS:4926-1976 (reaffirmed 1990) & IS:4925. The batch
prints of each load produced at batching plant shall be available for verification. The batch
prints shall be submitted to for each cum poured after the concreting is completed.
 All materials for controlled concrete shall be batched as per approved design mix in
suitable weigh-batcher of adequate capacity and approved design.
 The concrete can be sourced from Ready mixed concrete plant, if possible;
 Thorough mixing of the concrete is essential and mixers shall be capable of combining
the materials into a uniform mixture, uniform colour and of discharging this mixture
without segregation.
 The mixers should always be operated at the speed and time recommended by their
manufactures & as recommended in concrete mix design report. Water cement ratio
should be maintained during mixing of concrete,
 Mixers for concrete may be stationary mixers of either tilting or non-tilting type, or truck
mixers of approved design.
 The mixers shall be maintained in satisfactory operating condition, and mixer drums
shall be kept free of hardened concrete.
3.7.3. Transportation of Concrete

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 Concrete thus mixed shall be transported to the foundation location by means of transit
mixers of sufficient capacity & numbers.
 The primary products of concrete will be stored and transported without damage of
mixing, contamination or any significant change to its characteristics.
 The time passed since the preparation of concrete in the fac tory and casting in
foundation must not exceed 1.5 hours in any case
 Water must not be added to the concrete to make casting easier in any case. Retarding
admixture shall be added to increase the setting of the concrete without any damage to
the quality of concrete as per design mix recommendation.
 Concrete shall be conveyed from the place of mixing to the place of final deposit as
rapidly as practicable by methods, which will prevent segregation or loss of any of the
ingredients.
 If segregation does occur during transport, the concrete shall be remixed before being
placed
3.7.4. Placing of Concrete
 Concrete is placed in position with concrete pump/ directly by means of proper chutes
in layer in such a way that no segregation, honeycombi ng bleeding of concrete will be
occurred. Sufficient numbers of mechanical vibrators with proper size needles shall be
used while pouring the concrete in place.
 Before the concrete is actually placed in position, the insides of the forms should be
inspected to see that they have been cleaned and oiled, care being taken to see that the
reinforcements do not get contaminated.
 Concrete pump shall be used to deliver concrete of the required consistency and
plasticity without segregation or loss of slump.
 Method of placing shall be such as to prevent segregation and as far as practicable the
placing shall be continuous.
 For general guidance, the maximum permissible free fall of concrete may be 1.50m.
 For pump able concrete the slump of concrete should be 100mm, unless specified in
design mix report
 At least one slump test shall be made at work place for every truck / batch. More
frequent tests shall be made if there is a distinct change in job conditions.
 Adequate precautionary measures shall be in place always t o take care of any

unforeseen weather condition. When such situation arises, the concrete work,
preparation area, cement etc. shall be adequately protected within shortest possible
time to avoid any damage.
 Pouring of concrete will start in a circular way from the edges of the foundation and in
layers with a thickness of 30cm approximately.
 Concrete will have to surround the foundation embed section to a height such that the
bottom flange is covered lightly.
 Pour the concrete inside the foundation section in homogeneous way filling around
50%.
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 Again pour the concrete in a circular way around the foundation section in layers with a
thickness of about 30cm and then pour balance portion inside the foundation section
 The concrete can be poured directly by chutes of transit mixer if the freefall height is
restricted to less than 1.5m.
3.7.5. Compaction of Concrete
 The object of compacting is to achieve maximum density. The concrete should

therefore, be placed a little in excess of its specified depth so that after proper
compaction its final desired depth is obtained.
 For compacting the concrete, mechanical vibrators shall be used.
 Vibrators shall be used with the utmost care and handled only by the most experienced
workmen.
 The contractor must provide a full redundancy of all vibration equipment during the
period of concrete pouring.
 The min diameter of the vibrator needle for raft concrete is 60mm. However smaller
diameter vibrator needle also can be used for the congested reinforcement areas
around embedment’s
 Sufficient distance from the pouring head has to be maintained so that the vibrator is
utilized only to compact the concrete and not to spread it.
 Except for shallow or inaccessible concrete, the vibrator shall be penetrated vertically
and at regular distance intervals, not an angle and not haphazard intervals.
 Vibrator should not be used for the purpose of spreading the concrete.
3.7.6. Cube Casting & Slump Test
 The cube casting procedures is as follows as per IS: 516 – 1959 or as per approved plan.
 The mould shall be with inner dimension of 150mmx150mmx150mm in cubical shape.
 The mould shall be cleaned and free from any hardened concrete.
 Mould oil shall be applied in the joints between the sections of mould, contact surfaces
of the bottom of the mould and the base plate in order to ensure that no water escapes
during filling and to prevent adhesion of concrete.
 No separate concrete has to be prepared for cube casting.
 The concrete has to be collected directly from the weight batcher / pump / transit mixer.
 The concrete shall be filled in to the mould layer by layer of approximately 50mm deep.
 Each layer shall be compacted either by 16mm tamping rod or table vibrator.
 Each layer shall be tamping by 35 blows.
 The strokes shall penetrate in to the underlying layer and the bottom layer shall be
rodded throughout its depth.
 The sides of the mould shall be stored in a place free from vibration.
 The specimens shall be marked with location number, date, and identification number
Ver. No. / Date

Document Id
SOP-01
 The mould shuttering shall be removed after 24hrs and the cubes shall be immediately
submerged in clean fresh water till testing.
 All the cubes have to be tested on site established lab facility or in the AGEL approved
external laboratory.
 The Cube testing machine shall be having valid calibration certificate.
 After fixing the slump cone, 3 layers of concrete shall be poured with each layer of 25
strokes with 16mm tamping rods.
 Acceptable slump limit is +/- 25mm or 1/3 of specified slump value whichever less as per
design mix slump requirement is.
 Temperature of concrete should also be recorded for every batch in case controlled
concrete application
3.7.7. Sampling and Test for concrete strength
A random sampling procedure shall be adopted to ensure that the sampling should be
spread over the entire period of concreting. The minimum test specimen of sampling of
concrete of each grade shall be in accordance with the following as per IS 456 -2000.
Quantity of Concrete in Cum Number of Sample Set
1 to 5
6 to 15
16 to 30
31 to 50
51 & Above
 However, the number of cubes required for shall be as per the WTG manufacturer
requirement which shall be discussed with AGEL Quality representative.
Ver. No. / Date

Document Id
SOP-01
Flowchart for RCC Works

Ver. No. / Date

Document Id
SOP-01
Ver. No. / Date

Document Id
SOP-01
3.8. Curing
 All concrete surfaces shall be maintained in moist condition and be protected against harmful
effects of weather, for at least for 10 days of placing.
 After 12 hours of completion of concreting, the exposed concrete surface shall be kept
constantly wet for at least 10 days for OPC cement & 14 days for PPC cement. It shall be cured
by maintaining the concrete in a damp condition for a period of 10 days after placing the
concrete.
 After de shuttering, honeycombs in the concrete if any have to be rectified by removing the
loose material and the surface shall be prepared wet or apply cement slurry in the
honeycombed area and finish with CM 1:3 and shall proceed for further works.
 Cement slurry in foundation section above the concrete surface shall be cleaned thoroughly
immediate after concreting.
 The pipe conduit openings shall be ensured to be free from debris or blockages & shall be
neatly finished. The both ends shall be closed by means of end caps so as to avoid entry of
foreign material/insects into the same.
 The vertical side of the concrete shuttering shall be removed after 24hrs from the finishing
time of concrete pouring and shall be covered by wet gunny bags tied with ropes all around.
The sides of the foundation shall be backfilled in layers’ thickness and water has to be applied
in that area to keep the foundation side face in moist condition.
 Extreme care should be taken to ensure that all surfaces are kept in a moist condition and no
local area shall be allowed to dry out intermittently.
 As an alternate to water curing, the epoxy resin curing paint of the approved make can be
applied to exposed foundation surfaces. However, the efficiency of the curing paint shall be
established by doing the testing on cubes at site & approval shall be taken for the same.
 All the cubes have to be cured along with the foundation.

Ver. No. / Date

Document Id
SOP-01
Flowchart Curing
Ver. No. / Date

Document Id
SOP-01
3.9. Backfilling
 Backfilling of foundation shall be carried out as shown on the drawings or directed by the Site
Engineer with suitable materials.
 The soil to be used for backfilling shall be tested for the MDD (Max dry density) & OMC
(Optimum moisture content).
 Filling materials shall be spread, levelled and thoroughly compacted in layers not more than 30
cm thick or as per design. Each layer shall be separately compacted to achieve the required
state of compaction.
 The backfilling shall be carried out after completing the minimum curing period.
 The backfilling shall be done normally after 10 days of foundation concrete completion; in case
of necessity it shall be done after 7 days from the casting date of foundation.
 The sides of the foundation have to be cleared of all debris, mortar, boulders if any, concrete
lump etc.,
 De shuttering for vertical faces of concrete shall be done after 12 hours of casting, sides of raft
concrete up to raft top surface of raft shall be backfilled immediately after de shuttering.
 Backfilling above raft surface shall be done in layers, thickness not exceeding 300mm.
 Each layer has to be properly consolidated / watered and 95% compaction to be done with 10-
12MT roller. The dry weight of fill shall be minimum 18T/cum to 20T/cum or as specified in the
drawings.
 Compaction factor to be checked by using Proctor compaction test for each layer. The
compaction testing shall be offered for witness by site engineer & shall be recorded in the
prescribed standard format.
 The final level of the backfilling shall be as per foundation drawing after the final curing
period.
 It shall be ensured that the exposed earth flats are not disturbed during the backfilling. &the
open ends of the pipe conduits shall be closed properly & care is taken so that the ends are not
damaged & the locations of the same shall be marked for the easy identification during the
electrical activities.
Ver. No. / Date

Document Id
SOP-01
Flowchart for Back Filling
Ver. No. / Date

Document Id
SOP-01
3.10. Grouting
3.10.1. Pre-grouting procedure
 After Curing period backfilling should be done as per procedure for easy access of
grouting.
 Both Top flanges should be removed without damages.
 Remove all nuts & washers in the Anchor bolts.
 Remove all uneven/ loose concrete, excessive length of PVC sleeve above the concrete
level.
3.10.2. Fixing of Levelling Plates
 Before fixing the level plates clean the concrete surface without dust by using
compressor.
 Find out the highest level point of concrete surface in the Anchor bolt circumference.
 From the highest level point, Mark other 5 points of levelling plates forming 60 degrees
from each other.
 Fix the levelling plate at first point by using Rich cement mortar Minimum height should
be maintained as per the drawing. Check the horizontal level by using spirit level.
 After marking of six levelling plates points, Apply Duct tape or geo textile tape over geo
textile cloths / gunny bags on Anchor bolt above the Grouting height to avoid any
touches between anchor bolt and grouting. The same material will be used to cover the
PVC pipe sleeve to stop the grouting material entry inside the pipe.
 After covering the Anchor bolts with the above material, all other Levelling plates also
fixed with the same level of Point one. All six points rechecked for level.
3.10.3. Form work for Grouting
 GI sheet form work/ MS plate made for Grouting with Minimum gap equal to height of
grouting from flange both inside and outside.
 Height of form work is maintained minimum 3 cm above the grouting level.

 The gap is maintained same all-round to pour the grout both inside and outside.
 Sufficient supporting will be provided to form work.
3.10.4. Grouting Works
 Grouting surface shall be roughened thoroughly by chipping or grinding or any other

methods.
 Before grouting Moist the area is important, by using water jet/ compressor the surface
is cleaned for dust and surface is moisturized before one hour.
 Nito bond STD shall be used as an adhesive bonding agent between concrete surface
and Grouting surface just an hour before grouting.
 Mixing will be batch by batch, each batch may be containing of 2-3 bags.
Ver. No. / Date

Document Id
SOP-01
 Mixing will be done up to reach the recommended consistency. Water dosage will be
strictly followed as per product recommendations
 Mix the grout until it reaches the desired consistency for pouring. Do not add additional
water to improve the consistency of the mortar. Both the necessary mixing time and the
amount of water are specified by the manufacturer.
 The pouring of the grout will have to be carried out in such a way that there are no
voids.
 Once pouring is completed, Curing will be started immediately after one hour by using
gunny bags with water.
 Maximum Time duration for grouting of one location is 2 Hours.

Ver. No. / Date
CIP-PROJ-WIND-
SOP : WTG Foundation Document Id
SOP-01
Flowchart for Grouting
Ver. No. / Date

Document Id
SOP-01
3.11. Top PCC
 The works shall consist of providing and placing concrete for plain concrete works in
conformity with the drawings or in accordance with the written instructions of the Site
Engineer. The details of material specifications shall be as stated under the Reinforced
Concrete works.
 The bottom of excavated surface shall be lightly watered and thoroughly rammed before laying
the PCC.
 Either brickwork or shutters shall be provided for required dimension as per drawing for PCC.
 PCC has to be laid as per the given specification in the drawing and procedures for concrete
work has to be strictly followed
 Materials used for PCC (Cement, Sand, Aggregate & Water) shall comply with Field Quality
Plan.
 The offset of PCC shall be the same as the thickness of PCC or as specified in the drawing.
 Curing for minimum 3 days shall be carried out after placing the PCC.
 After PCC is done the levels for the top of PCC shall be recorded in the prescribed formats &
shall be verified by site engineer.
 The contractor shall produce the record of supplying the concrete for PCC in form of batch
prints of the batching plant. In case of concrete is done with mechanical mixers the cement
bags used for the PCC shall be recorded.
 The measurement of the PCC will be done only as per the drawing for the payment purpose.
Any excess PCC on account of extra excavation or for filling the undulations will not be
payable & deemed to be covered in the rate given in the contract.
 Installation of Anchor Bolts if applicable (refer construction drawing).

Ver. No. / Date

Document Id
SOP-01
Flowchart for Top PCC
Ver. No. / Date

Document Id
SOP-01
3.12. Weather Coating
 All surfaces must be clean and free from debris, lose or flaking material, standing water, oil,
grease and organic growth.
 Concrete surfaces must be free from laitance and any traces of shuttering, release oils and
curing compounds.
 For application onto bituminous torched-on membranes, no surface primer is required.

 Need to use mixed weather component as per suggested by manufacturers
 The entire contents of the hardener and base containers must be mixed together thoroughly,
until a uniform consistency, a fully homogeneous trowel able mortar, is achieved.
 Due to the easy workability of the product, the mixed product can be taken directly from the
mixing vessel or subdivided onto spot boards for individual applicators.
 Apply the weather coat material with help of knife, scrapper or trowel
 Need to ensure that application area is free from the dust and scrubs
 All cracks shall be chased to a 5mm x 5mm grove and filled using the weather coating mixed
component or cement mortar or grouting material
 Apply first coat with approved mixing component suggested by the manufacturers or as per
approved VIVIID technical specification.
 Drying time for each coat is if the temperature is 35ºC to 40ºC and it varies depends on the
temperature. Ensure that the surface is thoroughly dried before applying each coat.
 The painting materials are applied at rate not exceeding that recommended by paint
manufacturer for each coat.
Ver. No. / Date

Document Id
SOP-01
Flowchart for Weather Coating
Ver. No. / Date

Document Id
SOP-01
Title : Record Sheet Page 44 of 58
4.0 Record Sheet
Sr. Frequency/ Ref. Doc.
Activity Records Acceptance Norms
No Quantum of Check No.
Document Availability Ensure availability of
1 Manufacturer’s test reports, As per SFQP
Approved drawings and layout
Availability of QA/QC manpower
2 - As per SFQP
& laboratory
Concrete design mix approval
Sampling for testing of building
shall be done at NABL approved
3 materials, concrete mix design As per SFQP
laboratory & IS 10262, IS 456, IS
etc.
383 etc.
Submission of tests to be done Technical specification and
4 As per SFQP
monthly/quarterly construction drawing
Technical specification and
Stacking & storage of
5 construction drawing and As per SFQP
construction materials at site
IS:4082
Availability of all survey, layout Technical specification and
6 As per SFQP
details construction drawing
7 Cement
1. Fineness
2. Initial & Final Setting time
IS 8112, IS 12269 for OPC
7.1 3. Soundness As per SFQP
IS 1489 for PPC
4. Compressive Strength
5. Chemical Test
7.2 MTC Review IS 8112, IS 12269, IS 1489 As per SFQP
7.3 Storage of cement IS 4082 As per SFQP
8 Coarse Aggregate
IS 456, IS 383, IS 2386/ technical
8.1 Moisture Content As per SFQP
specification
Specific gravity, Water IS 2386, IS 456, IS 383/ technical
8.2 As per SFQP
absorption, Bulk density, Void specification
IS 2386, IS 383/ technical
8.3 Sieve analysis As per SFQP
specification
Flakiness index & Elongation IS 2386, IS 383/ technical
8.4 As per SFQP
index specification
8.5 Deleterious Materials As per SFQP
specification
8.6 Soundness As per SFQP
specification
Crushing value, Abrasion value & IS 2386, IS 383/ technical
8.7 As per SFQP
impact value specification
8.8 Alkali Aggregate reactivity test IS 2386, ASTM-C1260, IS 383 As per SFQP
9 Fine Aggregate
9.1 Moisture Content, Bulk age As per SFQP
specification
9.2 Sieve analysis, Silt content As per SFQP
specification
All other tests similar to Coarse IS 2386, IS 383/ technical
9.3 As per SFQP
Aggregate mentioned above specification
Ver. No. / Date

Document Id
SOP-01

10 Water
Test for acidity & alkalinity by
10.1 neutralization of water using IS 3025, IS 456 As per SFQP
indicator
10.2 Sulphate content IS 3025 As per SFQP
10.3 Chloride Content IS 3025 As per SFQP
Test for ascertaining limit of
10.4 solid like Organic, Inorganic & IS 3025 As per SFQP
Suspended matter
10.5 Test for pH value IS 3025 As per SFQP
11 Cement Concrete
Crushing strength Compressive
11.1 As per IS 516, IS 456 As per SFQP
Strength
11.2 Workability- Slump test As per IS 456 As per SFQP
11.3 Admixture (If applicable) As per IS 9103 As per SFQP
As per construction methodology
11.4 Placement of Concrete As per SFQP
,As per IS 456
11.5 Compacting As per IS 456 As per SFQP
11.6 Curing Period of Curing as per IS 456 As per SFQP
IS 1786, IS 456, IS 1566,
Reinforcement (Physical &
12 Technical Specification & As per SFQP
Chemical Properties)
Construction drawing
13 Batching plant As per IS 4925 As per SFQP
CTM (Compression Testing
14 As per IS 14858 As per SFQP
Machine)
Mechanical Vibrators, Transit
15 As per requirement As per SFQP
Mixers, Hydraulic Crane
Survey- Establishment of master
16 grid pillars & permanent bench Each Foundation As per SFQP
marks of every WTG foundation
Excavation-
Nature of Soil/rock/water table
Check the center line in both X
and Y co-ordinate and initial
ground level
17 Each Foundation As per SFQP
Check the depth of bottom level
of excavation with respect to
reference level Side slope
protection during excavation
Source Approval of Filling
18 Technical Specification As per SFQP
material
19 Concrete
19.1 Trail mix for Mix Design IS 456, IS 516, IS 10262, SP-23 As per SFQP
19.2 Workability (Slump Test) IS 456, IS 1199 As per SFQP
Concrete cube sampling &
19.3 IS 456, IS 516, IS 1199, IS 4926 As per SFQP
testing
20 Anchor Cage assembly As per drawing As per SFQP
21 Reinforcement placement As per drawing As per SFQP
Ver. No. / Date

Document Id
SOP-01

22 Pre-Pour Check of Concrete element
Cleanliness
Reinforcement laying, fixing,
binding, spacing, diameter
IS 456, Approved drawing &
22.1 Form work, Form work release As per SFQP
specification
oil, alignment, vertically, rigidity,
sealing
Embedded parts
23 Concrete Conveying, Placing, Compaction & Curing
Pouring (Placing layers, Slump,
23.1 - As per SFQP
Compaction, Construction Joint)
23.2 Curing methodology IS 456 As per SFQP
24 Post Pour Check
Bodily defects: Deformation in
24.1 - As per SFQP
concrete formation
Surface defects: Surface finish
24.2 - As per SFQP
& Honey combs, cracks
Dimensional and level check of
24.6 - As per SFQP
finished structure
25 Backfilling
Standard proctor test to
determine optimum moisture
25.1 IS-2720 As per SFQP
content and maximum dry
density
As per technical specification &
26 Cement grout As per SFQP
Grouting data sheet
Ver. No. / Date

Document Id
SOP-01
4. Checklist
Status of
Sr.
Activity checks description completion Ref. Doc. No.
No.
Yes No NA
1. Pre- Inspection
1 JSA & RA is carried out and records are available at site for daily review.
2 Tool Box Talk (TBT) is conducted daily.
3 Ensure team have valid work permit.
4 Drinking water is available.
5 Contractor’s supervisor present at site.
6 First Aid Box is available at site.
End to end barricading with pictograms and displays (No Smoking,
7
Emergency No., Work in Progress) are provided at site.
8 Fire Extinguishers of required capacities are available at site.
9 All personnel involved in the site activity are trained.
Proper PPEs (Hand Gloves, Ear Plug, Hard Hat, Safety Shoes, Goggle,
10
Reflective jacket, etc.) are used.
11 Cleanliness of the workplace during and after the job
12 All the materials stacked properly & walkways free from obstacles.
Emergency and rescue plan is explained before starting the work.
13
(check for awareness in the people on the site)
All equipment's are inspected before work commences and statutory
14 certificates & operator licence is available at site. (Full body harness
inspection report, Hydra, Lifting equipment's, JCB, DG Set etc.)
15 Is electrical power is taken from an approved source.
Standard Distribution Boards with Residual-current circuit breaker
16
(RCCB 30 mA) and MCB is provided.
17 Cables are laid properly to avoid slip, trip & fall.
18 Distribution board is provided with proper stand and canopy sheet.
19 Undamaged/tested electrical equipment at site are being used.
Industrial quality fittings /distribution boxes with continuous wire and
20
three pin plug covered in socket are available at site.
21 Only double insulated electric cable is used at site.
22 Check the availability of Micro Siting drawing & verify the co-ordinates
Check the availability of machineries & manpower to perform soil
23
investigation at WTG locations
24 Check whether the approach road layout is approved by client
Check the material to be used for construction of approach road is
25
approved by client (Murrum or WBM)
26 Is the laboratory setup completed prior to construction?
27 Check the location marking is done prior to soil excavation
Check whether the top soil is stripped & debris is removed prior to soil
28
excavation
Check the availability of machineries, manpower & survey tools to
29
perform excavation at WTG locations
Check whether the soil treatment/soil stabilization is required prior to
30
excavation works
Check whether the approval for construction material is done by client
31
(Cement, Sand, Aggregate, Water, Admixture, Reinforcement Steel,
Department : Construction Management - Wind Section No. : 07
Ver. No. / Date

Document Id
SOP-01
Status of
Sr.
No.
Yes No NA
Cement Grout etc.,)
32 Has the mix design been approved by Client?
33 Has the sample batch/trail mix being approved by Client?
34 Has the batching plant being calibrated & approved by client?
35 Has the test cube being procured as per requirement?
36 Has the cube storage or cube curing tank available at site?
37 Check whether the pour area is free from trash and construction debris.
38 Size of bars and grade mark acceptable as per drawing
Check whether the required reinforcement quantity is available at site
39
as per construction drawing
40 Are splice connector such as tie wire in good condition & acceptable?
41 Is Rebar clean from oil, grease, mud and any other contamination?
Has the anchor cage being shifted from store yard to location along
42
with required accessories?
Check the availability of Slump Cone at site location prior to concrete
43
works
Check the availability of Concrete Vibrators at site location prior to
44
concrete works
45 Check whether the shuttering material is shifted to WTG location
Check for the availability of shuttering/form removal oil & other
46
required items
Has the adequate quantity of has sin clothes/gunny bags available for
47
curing works
48 Check the availability of Water tankers for curing of WTG foundation
Check the backfilling material used in WTG foundation is approved from
49
Client
Check whether the backfill material is free of organic material, rock or
50
gravel.
Check the approved grout material is procured for cement grout
51
process.
Check the test certificates of all construction material such as Cement,
52 Sand, Aggregate, Water, Admixture, Reinforcement Steel, Cement Grout
etc.,
2. In-Process Inspection & Check points
Check the micro siting drawing and mark the WTG location as per the
1
co-ordinates mentioned in drawing
2 Check the soil investigation is being performed as per IS 1892
3 Are sample types and depth recorded?
4 Is the bore depth measured and is as per standard?
Check whether the laying of road material (Murrum or WBM) is done as
5
per approved drawing
Are the layouts, gradient and camber of the road as per the approved
6
drawing?
Is the sub grade prepared as per the layout & gradient and compacted
7
to required degree of compaction?
Is the coarse aggregate & Murrum as per specification and free from
8
flat elongated and soft stones?
9 Has the spreading of the aggregate and the binding material been
Ver. No. / Date

Document Id
SOP-01
Ver. No. / Date

Document Id
SOP-01
Status of
Sr.
No.
Yes No NA
checked before laying?
Has compaction been done with 8-10 T power/vibratory roller up to the
10
required number of run?
Has the surface been applied with sufficient amount of water and rolled
11
to fill the voids?
12 Has the compacted thickness been checked & verified as per drawing?
13 Is core samples collected and tested for FDD (Field Dry Density) test?
14 Is drainage provided as per the drawing to the approach road?
Check the excavation width, diameter & depth of WTG foundation as
15
per drawing?
Check whether soil stabilization/re-engineering is required to soil as per
16
soil investigation report.
17 Check the dressing and leveling faces of excavated wall
Is core samples collected and tested for FDD (Field Dry Density) test
18
prior to PCC works?
19 Check the marking for the PCC to be laid
20 Check the PCC diameter-thickness as per drawing
21 Check the dimension of Sunken Portion (if applicable)
22 Check the assembly & positioning of Anchor ring and bolts
Check the Torque value of joint bolts at connection plate Torque value
23 of anchor stud for anchor ring Torqueing of anchor stud for anchor ring
as template
Check the Stud length projected below anchor nut at the bottom side,
24
Stud length projection above concrete top of pedestal
Check the Spot welding (Bulb formation) at 1 thread below nut at lower
25
surface of anchor ring (if applicable)
26 Check the inner & outer PCD (Pitch Circle Diameter) as per drawing
Check the distance between top of anchor ring & top of pedestal
27
concrete
28 Check the levelling of load spreading plate / Template
Check the distance between top of anchor ring & PCC top in sunken
29
portion
30 Check the cut length & lap length of steel reinforcement bars
31 Check the placement of steel reinforcement as per drawing
Check the binding of reinforcement bar to be done using binding wire
32
for longitudinal & transverse reinforcements
Check the placement of earthing strip inside the foundation as per
33
drawing
34 Check the fixing of form work as per drawing
Check the tightening of bolts and applying the PVC tape for
35
interlocking the shuttering plate
36 Check the adequate support is supplied to shuttering
Check the application of form removal oil is adequately applied before
37
concrete works
Is adequate cover provided between reinforcement steel & shuttering
38
as per drawing
39 Check the batching of concrete as per approved concrete design mix
40 Has slump value being verified as per mix design using slump cone?
Ver. No. / Date

Document Id
SOP-01
Ver. No. / Date

Document Id
SOP-01
Status of
Sr.
No.
Yes No NA
41 Has concrete cube being filled during concrete pouring?
42 Check the compaction of concrete done using concrete vibrators
Check whether the concrete pouring is done in layers as per approved
43
plan
44 Check the level of concrete finish during concrete pouring
45 Check whether the curing is done for 7 days & 28 days as per IS 456
46 Check whether 2 coats of water proofing paint is applied on pedestal
Are there any debris, brick bats and vegetation mixed with the
47
backfilling material and have been removed?
Check the thickness of compacted Murrum/backfilling material in
48
horizontal layer
49 Check the field density of backfilled material
50 Check the mix of PCC used for Top PCC works
51 Check the length of PCC beyond the edge of pedestal
52 Check the thickness & slope of PCC
53 Check the mixing of cement grout as per standard
54 Check the laying of grouting cement done in layers
55 Check the level of grouting
3. Post Inspection
1 Check the finishing and top level of approach road
2 Check the finishing level & dimension of PCC
3 Check the top level of anchor bolts as per drawing
4 Check the PCD of outer & inner anchor bolts
Check for availability of any honey comb, cracks on concrete after
5
removal of shuttering
6 Check whether the concrete repair is done as per approved plan
7 Check the top level finishing of pedestal as per drawing
8 Check the positioning of shim plates/LSP (Load Spreading Plate)
Check for cracks after curing period and repaired as per approved
9
procedure
10 Check the finishing of Top PCC done as per drawing
11 Record all the inspection check results in FQP
Ver. No. / Date

Document Id
SOP-01

Ver. No. / Date

Document Id
SOP-01
5. Key Requirement of Health, Safety & Environment (HSE)

Sr.
Description for Key Requirements of HSE
No.
1. Potential Hazard
1 Non-compliance of EHS Regulations and procedures
2 Unskilled People
3 Defective equipment/ Sub-standard equipment
4 Inadequate Lighting at work location (Early morning hour work and night work)
5 Over Time
6 Cell Phone
7 Traffic accident
8 Toppling of Vehicle
9 Fall of person from Trailer/vehicle
10 Hit by Material
11 Run over due to vehicular movement
12 Environment Hazard
13 Pinch Points
14 Ergonomic Hazards
15 Head-on collision of vehicles
16 Slip, Trip and Fall
17 Animal/ Reptile bites
18 Heat Stress/ Extreme Cold
19 Falling into trenches or excavations
20 Excavated material or other objects falling on workers
21 Damage of underground utilities
22 Excavation Hazard
23 Chemical burns to body.
24 Biological Hazard
25 Exposure to cement dust
26 Electrical Shock
27 Sparks generated when using angle grinder, drop saw or oxy to cut steel reinforcement
28 Fire Hazard
29 Flying Object Debris
30 Fall of materials/tools
31 Personnel contact with equipment moving part
32 Poor Housekeeping
33 Scattered Material
2. Suggestive Control Measure
1 Ensure all personnel have undergone Health check-up, safety Induction and OJT training.
2 Ensure all personnel have completed EHS awareness trainings as applicable as per EHS Manual.
3 Ensure EHS Requirements as per EHS Manual for Lifting – Shifting and Material Handling are followed.
4 Ensure only competent/authorized personnel are carrying out the task.
5 Daily TBT should be given to workers.
6 Organized motivational program for worker.
7 Obtain required Permit to Work and refer respective JSA.
8 Identify the personnel/ equipment to be mobilized.
9 Ensure all equipment are having valid restricted area passes
10 Physically check all equipment, tools & tackles by supervisor with help of inspection checklist.
Ver. No. / Date

Document Id
SOP-01
Sr.
No.
11 Ensure all firefighting equipment available.
12 Ensure that the Emergency Numbers are posted at site, and personnel are informed in the TBT.
For early morning works/ night works, ensure sufficient lighting arrangements/ lighting towers are in
13
place at the work areas as applicable.
14 More than 12 hours work should not be carried out.
15 Using of mobile phone strictly prohibited during work
16 Convex mirror to be fixed at Blind spot and Ensure that the Reverse horn and Beacon lights are working.
17 Ensure that the vehicle driver has valid driving license.
18 Ensure that cleaner is present with driver.
19 Before allowing for entry inside the site premises do alcohol test of driver & cleaner.
20 Instruct to driver to driver carefully within the speed limit as per site guideline.
21 Ensure that the pathways for the vehicle is defined and barricaded.
22 Do not feed or befriend with stray animals / wild life and make sure the team always stay together.
Ensure a cooperative arrangement whereby individuals are paired or teamed up and assume
23
responsibility for one another's welfare or safety.
24 Take a short break.
25 Ensure availability of ample quantity of fresh water.
26 Do not touch any plant/Tree or utilities without proper knowledge.
27 Do not touch any unidentified objects. immediately stop the activity, inform site in charge.
28 Ensure that all the vehicles are inspected for damaged hose or Oil leakage daily.
29 Ensure periodic maintenance is done for the vehicle and equipment's.
30 Ensure trained spill response team and Spill kit is available on the site.
31 Positive Isolation to be done If any Underground services is present.
32 Check the ground with metal/ Cable Detector for any underground services.
33 Check previous drawings for underground services.
Ensure no charged electrical cables or other service line is present underneath the excavate area, if not
34
sure make a trial pit.
35 Inspection of excavation tools.
36 Ensure all area must be barricade to restrict un-authorized entry with display the safety signages.
37 Wash the effected body part with water immediately after concrete burns.
38 Use of anti-itching cream or lotion over itching body part.
Remove all combustible materials from the location of the cutting, grinding, and abrasion activities
39
taking place.
40 Should check electrical equipment, extension lead, Lead severed by angle grinder disk or saw blade.
41 RCCB should installed on mains supply or portable generator.
42 Ensure guard on moving part and compatible size of wheel for the equipment rating.
43 Ensure Dust Control is done by spraying water to avoid flying Dust.
44 Ensure to handle the material carefully.
45 Ensure that the moving part of M/c must be guarded.
Ensure the workers are having tight clothes and no dangling or lose clothing to avoid entanglement with
46
the vibrator.
Lifting gear/equipment inspected with help of inspection checklist and ensure TPI to be done by a
47
competent person.
Check wire rope, shackles, hooks and rings for cracks, corrosion, wears, mechanism faults etc. and
48
remove from service if faults are found.
Pre lifting plan should be prepared before start of lifting any materials by crane. It is to be ensured that
49
it should not cross the SWL of the crane.
Ver. No. / Date

Document Id
SOP-01
Sr.
No.
50 Ensure Outrigger Pad or Mat shall be used for the crane.
51 Ensure that two-point Tag Line or Guide-rope shall be used at the time of lifting of the equipment.
52 Ensure that no one is keeping hand directly on the Load.
53 Ensure no obstacles on pathway while unloading the equipment.
54 Not to stand under/near to the suspended load.
Ensure that the vehicular movement is to be restricted where the shifting or handling of material is
55
carried out.
56 Ensure the ground is levelled and graded to avoid toppling of vehicle.
During shifting of material if there is any HT electrical utilities proper & necessary precaution should be
57
taken such as Goal post/Bunting Pole should be ensured.
58 Material Should not be stacked below the Overhead HT electrical lines.
59 Use of stopper/ wheel chock is to be ensured.
60 Ensure that person should not take rest below the vehicle or shadow of vehicle.
Ensure all Drivers/ Operators have gone through Defensive Driving Training, Safety Induction and have
61
valid driving license.
62 Do not position any equipment close to the trench.
63 Ensure Supervisor to be available at site.
64 Ensure a competent signalman with proper Hi Viz fluorescent Jacket and Whittle is assigned.
65 Don’t allow the person to lift more than 30kg material to shifting from one place to other.
66 Two or more workers shall be deployed for handling of Material.
67 Proper coordination shall be maintained by workmen among them while manual handling of material.
Before deploying workmen for manual handling, their physical capabilities shall be taken in to
68
consideration by activity supervisor.
69 Prior to access the material the route needs to be clear.
70 Sharp edges of material can be removed by abrasive method before lifting.
71 Ensure for housekeeping shall be done at all times.
72 Ensure no one walks over the material to avoid Slip Trip and Fall.
73 A tools bag shall be carried while working at height
The equipment (tools, tackles, cables & sockets / terminals etc.) not being used must be disconnected
74
and stored separately.
75 Ensure proper wind up.
76 Ensure that working area shall be left clean and tidy before leaving the site.
77 PTW to be closed on completion of Job.
78 Cross verify the all isolation before leaving the site.
Ensure all shall wear mandatory PPEs with job specific PPEs like (Cut resistant/leather/Rubber hand
79
gloves, Face shield, Safety goggle, Nose Mask)
Ver. No. / Date

Document Id
SOP-01
6. Resource Required
Assuming the manpower calculation for 25 Nos. of WTG Foundation.
 Assuming the 2 MW WTG wind foundation and capacity may vary from 1.5 MW to 2.5 MW.
 Concrete quantity and cement quantity are totally depending on WTG type, OEM selection, Soil strata
and location of site.
 Assuming, Cement quantity/WTG vary from 2800 Bags to 47 Bags and depend on WTG type/design
mix.
 Assuming, reinforcement quantity/WTG vary from 34Tons to 55Tons and depend on WTG type/design
mix.
 Foundation cost will be varying from 16 Lacs to 23 Lacs depend OEM selection and WTG type
 As per industry standard practice, a total of 1 teams will be required for a 50 MW Wind Project.
 WTG tower erection will be start after 7 days cube test/achieving compressive strength 70% or as per
OEM /WTG technical specifications.
 The table below shows the table for Manpower and No. of Man-days calculations for the activity:
Manpower & Man-days Details Machine Required
Dressing Steel Hydra Pock lane Concrete Transit

RCC
Target & PCC binding Required Tracker Pump mixture
Task team/man
WTG team/man team/man days Trolley
power
power power
WTG
Foundation
Ver. No. / Date

Document Id
SOP-01
7. Frequently Asked Questions (FAQs)

During WTG Foundation activity do not act as mentioned below points;
 Don’t enter the site without PPEs.
 Don’t operate the Ajax/JCB etc. if you are not competent for it similarly not allow to other to do so.
 Don’t deployed untrained worker for work.
 Don’t allow any loose electrical connection.
 Don’t allow unsafe joints of electric cables.
 Don't use without guard grinding & cutting M/c.
 Don’t handle the cement bag without nose mask.

 Don’t left the excavated area without barricade or marked.
 Don’t work in absence of supervisor.
 What is micro sitting?
 How the safety of the work force is being taken care/ensured?
 The roads are in private land or revenue?

 Is there any agreement for the roads with local administration body/village body? If yes, then where is
that contract?
 What is the size of the crane?
 How levelling has been done?
 What is the process to acquire the land?

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VIVIID RENEWABLES PRIVATE LIMITED 1.0 / 0 1 .01.

SOP : WTG Foundation CIP-PROJ-WIND-

VIVIID RENEWABLES PRIVATE LIMITED

STANDARD OPERATING PROCEDURE

DEPARTMENT: CONSTRUCTION MANAGEMENT

SOP : WTG Foundation CIP-PROJ-WIND-

SOP : WTG Foundation CIP-PROJ-WIND-

Revision Status Record

Revision Date Page no. Details of Changes Reason for

1.0 01.01.2024 All pages Initial version for release -

Document Approval sheet:

SOP : WTG Foundation CIP-PROJ-WIND-

1.2. Preparation Work

This activity is to be started ideally after completion of Land Survey.

 Mobilization of manpower with suitable PPEs at the site location.

 Check the requirement of construction material at site location.

 Check the Laydown area for the storage of construction material.

 Check availability of all construction drawing related to WTG foundation.

 Approach Road: - An access road to Wind Turbine Generator site.

SOP : WTG Foundation CIP-PROJ-WIND-

 Shuttering work: - Shuttering also known as formwork in concrete construction is used as a

Abbreviations Definitions / Full Forms

VRPL VIVIID RENEWABLES PRIVATE Limited

BOM/BOQ Bill Of Material/Bill of Quantity

CTM Compression Testing Machine

CUM Cubic Meter

DPR Daily Progress Report

DPR Daily Progress Report

EHS/HSE Environment Health Safety

FDD Field Dry Density

FQP Field Quality Protocol

FAQs Frequently Asked Questions

GPS Global Positioning System

JSA Job Safety Analysis

SOP : WTG Foundation CIP-PROJ-WIND-

Abbreviations Definitions / Full Forms

MTC Manufacturer’s Test Certificate

MDD Maximum Dry Density

NCR Non-Conformance Report

NABL National Accreditation Board For Testing LAB

NGL Natural Ground Level

OMC Optimum Moisture Content

OJT On Job Training

OPC Ordinary Portland Cement

PCC Plain Cement Concrete

PPC Portland Pozzolana Cement

PPE Personal Protective Equipment

PVC Poly Vinyl Chloride

PTW Permit To Work

PCD Pitch Circle Diameter

QA & QC Quality assurance and quality control

RCC Reinforced Cement Concrete

SQM Square Meter

SFQP Standard Field Quality Plan

SOP Standard Operating Procedure

SBC Safe Bearing Capacity

TBT Tool Box Talk

TPI Third Party Inspection

WBM Water Bound Macadam

WTG Wind Turbine Generator

SOP : WTG Foundation CIP-PROJ-WIND-

Cement Reinforcement Steel & binding wire

Sand Cement Grout