PROCEDURE FOR PIER CAP CASTING

Project:

ISSUED TO

ISSUED BY:
CONTROLLED COPY

SIGNATURE:

METHOD STATEMENT
FOR
CASTING OF PIER CAP

REV DATE DESCRITION PREP’ BY CHK’ BY REV’ BY APP’ BY

OF REVISION

0 Issued for (Planning) (QA/QC) Project

Approval Manager

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TABLE OF CONTENTS

SECTION 1 : PURPOSE

SECTION 2 : SCOPE

SECTION 3 : REFERENCES

SECTION 4 : RESPONSIBILITIES

SECTION 5 : METHODOLOGY

5.1 SURVEY

5.2 STAGING

5.3 TREATMENT FOR OLD CONCRETE OF PIER

5.4 REINFORCEMENTS

5.5 FORMWORK

5.6 CONCRETING

5.7 CURING

5.8 EQUIPMENTS

SECTION 6 : HEALTH, SAFETY & ENVIRONMENT

SECTION 7 : QUALITY ASSURANCE AND QUALITY CONTROL

SECTION 8 : ENCLOSURES

A SAFETY CHECKLIST
B REINFORCEMENT AND FORMWORK INSPECTION FORMAT
C CONCRETE INSPECTION FORMAT
D CONCRETE POUR CARD
E BAR BENDING SCHEDULE
F SHUTTERING INSPECTION CHECKLIST
G CONCRETE INSPECTION CHECKLIST
H ACCIDENTAL OCCURENCE RECORD

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1.0 SECTION - 1: PURPOSE

The purpose of this document is to describe the work procedure adopted for Casting of pier
cap.

2.0 SECTION – 2: SCOPE

Casting of pier cap between top of Pier to top of pier cap.

3.0 SECTION – 3: REFERENCES

1 Contract documents

2 Good for Construction drawing of pier cap.

3 Bar bending schedules as prepared by PJB Engineers pvt ltd and approved by
Engineer.

4 Form-work drawings as prepared by PJB Engineers pvt ltd and approved by

Engineer.

5 Quality assurance manual.

6 Quality system manual.

7 Health, Safety and Environment plan.

4.0 SECTION – 4: RESPONSIBILITIES

Below mentioned person are responsible for following activities.

1. Project Manager: Overall management of activity.

2. Deputy project manager: responsible for control, supervision and direction for
implementation and execution of construction plan also for develop schedule &
preparation of construction record.
3. Site In-charge: Day to day planning at site, Various works at site and preparation of
construction record.
4. QA/QC Engineer: responsible for overall QC activities include subcontractor and
carryout inspections.

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5. Site Supervisor: Report to site engineer and responsible for supervision of all work
guided by site engineer.

5.0 SECTIONS 5: METHODOLOGY

5.1 SURVEY

The location of pier cap and layout will be checked with respect to the reference
points already established during survey work for pier casting.

5.2 STAGING
Staging will be done by means of fixing pipes and clamp to facilitate binding of
reinforcement and placing of shutter.

5.3 TREATMENT FOR OLD CONCRETE OF PIER

All loose materials will be removed from pier top before placing of pier cap
reinforcement and 6 to 8 Shear keys will be provided after pouring of pier by the help
of battens.

5.4 REINFORCEMENTS:

Reinforcement will be fixed as per approved drawings by two methods, (1) by fixing
at the location of pier cap, (2) fixing in rebar zig and lifting and placing by crane at
pier cap location.
Concrete cover blocks of size 65mm, having same grade of that of pier cap concrete,
shall be provided to maintain the required clear cover for outermost reinforcement.
The reinforcements shall be tied with M.S Binding Wires. The location of laps shall
be certified by PMC before execution and coupler will be fixed at suitable location.

5.5 FORM-WORK:

Form-work shall be prefabricated as per the drawings for full height of pier caps to be
cast and they shall be marked suitably for easy assembling at site. The form-work
shall then be transported to concreting location. The form-work shall be done suitably

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as per drawing dimensions and shall be in four segments to cover the entire periphery.
The surface of the form-work, which shall receive the concrete, shall be thoroughly
cleaned. After fixing the form-work in position, they shall be got checked from PMC
representative and once the form-work is found to be in order, concreting shall be
done. The oil applied for easy removal of shuttering shall not leave stains on the
surfaces of the concrete.

5.6 CONCRETING

Concrete of required grade shall be produced as per approved design mix at the
centralized batching plant at casting yard. The concrete shall be transported to the
location of pouring in transit mixer.
The slump shall be kept as per approved mix design. Before pouring of concrete, the
slump shall be checked. In case, due to some reasons, the slump goes below the
specified limit during transit, re-dosing of admixture shall be done in transit mixer.
The concreting shall be done using Concrete Pumps or Morgan Placer or Concrete
bucket with flexible hose or buckets or tremie and the height of fall shall not be more
than 2.00 m. The compaction of concrete shall be done using needle type vibrators
and shutter vibrators. The diameter of the vibrator needle will be 60mm. To check the
quality of concrete, cube shall be taken for testing of compressive strength as per
specification.

5.7 CURING

The pier cap shall be covered with Hessian cloths after removal of form-work and
these shall be kept moist by sprinkling water. On the top surface of pier cap, water
shall be poured directly on the surface to keep it moist.

5.8 EQUIPMENTS

SL. No. Description No. Stand by

1 Batching plant 1 -
2. Transit mixer 3 -
3. Concrete vibrator 1 1
4. Vibrator needles 2 1

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5. Concrete Pump/ Morgan 1 -

Placer/ Concrete Bucket.

As per the actual site condition, the number of equipment’s mentioned above may increase or
decrease. Any other equipment’s, machinery, tools and plants etc. whenever required to
complete the casting successfully shall be deployed.

6.0 SECTION-6: HEALTH, SAFETY AND ENVIRONMENT

Barricade of suitable width and length shall be erected for pier cap casting work. Suitable
reflectors, blinkers, diversions boards, proper illumination, painting of barricade etc. shall be
provided for the road users and their safety. All site personnel shall be provided with helmet,
boots and other personal safety devices.

Proper precaution and safety devices shall be used for activities like fabrication, handling of
electrically operated equipment’s etc.

All site personnel shall follow the health and safety policy of the company and environment
policy.

7.0 SECTION – 7: QUALITY ASSURANCE AND QUALITY CONTROL

Workability test shall be carried out on the concrete on arrival of transit mixer from batching
plant and records shall be maintained. Test cubes shall be cast as specified and the 07 days as
well as 28 days strength results shall be submitted to the Engineer. Cube identifications shall
be embossed on cubes with date of casting, structure identification, concrete grade and
reference number. The reinforcement as per approved Bar Bending Schedule, shall be
inspected with respect to GFC drawing.
All the tests will be done as per ITP & will be recorded as per prescribed formats &
checklists.

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8.0 SECTION – 8: APPENDICES

A Safety check list

B Reinforcement and form-work inspection format
C Concrete inspection format
D Concrete pour card
E Bar bending schedule
F Shuttering inspection checklist
G Concrete inspection checklist
H Accidental occurrence record

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A. SAFETY CHECKLIST

S. No. Items Yes No.

1. All workers wearing Personal Protective Equipments

2. Emergency medical kit and other emergency facilities are provided

at site
3. All lights are properly covered using insulated wires, Halogen lamp
and Hand lamps with wire mesh covering
4. All hot cutting scraps are quenched and removed properly

5. Safety officer/supervisors are on constant duty at site

6. Proper warning sign boards/instructions boards in Hindi and

English provided at site
7. Proper Staging done to provide working platform at top.

CHECKED BY APPROVED BY
SIGN: SIGN:

NAME: NAME:

DATE: DATE:

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B. REINFORCEMENT AND FORM-WORK ON FORMAT

LOCATION : ….............................................

CONTRACTOR’S INSPECTION REQ. NO. : ….............................................

REF. DRAWING NO. : ….............................................

BARRICADING PLACED

WORKING DRAWING CHECKED & APPROVED

BAR BENDING SCHEDULE APROVED

REINFORCEMENT CHECKED

SCHEME FOR EXECUTING THE WORKS APPROVED

FORM-WORK DRAWING APPROVED

FORM-WORK DIMENSIONS CORRECT

FORM-WORK ALIGNMENT CHECKED

REMARKS IFANY

DATE:……………… DATE:………………

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C. CONCRETE INSPECTION FORMAT

LOCATION : ….............................................

CONTRACTOR’S INSPECTION REQ. NO. : ….............................................

REF. DRAWING NO. : ….............................................

METHOD STATEMENT APPROVED

FORM-WORK APPROVED

REINFORCEMENT APPROVED

CONCRETING EQUIPMENT IN WORKING ORDER

ACCESS PROVIDED

SAFETY ARRANGEMENTS ADEQUATE

ADEQUATE LIGHTING PROVIDED/STAND BY PROVIDED

COMMUNICATION BETWEEN VARIOUS POINTS PROVIDED

PIER CAP TOP LEVEL CHECKED

REMARKS IFANY

DATE................... DATE..........................

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D. CONCRETE POUR CARD

TYPE
LOCATION OF PIER CAP
HEIGHT OF PIER CAP

CONCRETE MIX :

SOURCE OF CONCRETING :

THEROTICAL QNTY. OF CONCRETE : CUM

ACTUAL QNTY OF CONCRETE : CUM

QNTY. OF OCNC. POURING CUBES CYLINDERS

S.NO. RECORD
MIXER SUMP TEMP
EACH CUMULATIVE NO. STAT FINISH NOS. ID NOS. ID MARKS.
POUR MARKS.

TOTAL NOS.OF CUBES CAST

TOTAL NOS. OF CYLINDERS CAST

REMARKS (IF ANY)

DATE…………......... DATE..........................

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E. BAR BENDING SCHEDULE

Location : Schedule no Ref Drawing no Pier No

BAR BENDING SCHEDULE

Total Length in Meter/feet for bar of diameter of
Bar Dia
S. Total Cutting Bending
Item Ma in
No Nos. Length Details 8mm 12mm 16mm 20mm 25mm 32mm
rk mm
10mm

Total
Length
Unit
Weight
Weight
(Kg.)

DATE........................ DATE..........................

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F. SHUTTERING INSPECTION CHECKLIST

LOCATION
CONTRACTOR’S INSPECTION REQ NO :

REF DRAWING NO

1. BARRICATING PLACING YES / NO

2. WORKING DRAWING CHECKED & APPROVED
3. BBS APPROVED
4. REINFORCEMENT CHECKED
5. SCHEME FOR EXECUTING THE WORKS APPROVED
6. FORM WORK DRG APPROVED
7. FORM-WORK DIMENSIONS & ALIGNMENT CORRECT
8. REMARKS IF ANY

DATE......................... DATE..........................

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G. CONCRETE INSPECTION CHECKLIST

LOCATION
CONTRACTOR’S INSPECTION REQ NO:

1. METHOD STATEMENT APPROVED YES/NO

2. FORM-WORK
3. REINFORCEMENT APPROVED
4. CONCRETING EQUIPMENT IN WORKING ORDER
5. ACCESS PROVIDED
6. SAFETY ARRANGEMENTS / DEQUATE
7. ADEQUATE LIGHTING PROVIDED / STAND BY PROVIDED
8. COMMUNICATION BETWEEN VARIOUS POINTS PROVIDED
9. REMARKS IF ANY

DATE......................... DATE..........................

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H. ACCIDENTAL OCCURENCE RECORD

ACCIDENT OCCURRENCE REPORT FORM ACCIDENT NO :
NAME OF CONTRACTOR : PJB ENGINEERS PVT LTD CONTRACT NO :
INSTRUCTION :
9. A copy of this form shall be completed for every Accident and Dangerous
occurrence.
10. It must be signed by a senior site management representative.
11. A copy shall be sent to the employer’s representative within 24 hours of the
accident.

Part A: Details of Injured person

Name ___________________ Date of Birth___ Male/Female

Address _______________________________________________________________

_______________________________________________________________

Job Title :________________________ Name of Employer_______________________

Part B: Details of Accident

Date :_______________Time : ______________Location :___________________________

1. Describe the task the injured person was doing at the time of the accident.

2. Description in details how the accident happened (Attach, sketch, plan, photograph etc.)

3. Was any or machinery involved yes / no : if yes give details :

4. Name of witness :

Part C : Details of Injury

What part of body injured?

Fatal Injury [ ] Major Injury [ ] Minor Injury [ ]

Was the injured person sent to first aid [ ] Doctor [ ] Hospital [ ]

Part D : Certification

I have checked the above information and confirmation that is a true record of the accident.
Signed_______________ Officer________________Date__________________

Signed___________ Project Manager_____________Date__________________

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