WORK METHODOLOGY FOR FUEL OIL TANK FOUNDATION (6*660 MW

SASAN ULTRA MEGA POWER PROJECT)

Setting out: ---

The contractor will be prepared
and submitted to the engineer, detailed drawings of the excavation work as
proposed to be executed by him showing the dimensions of FUEL OIL
TANK FOUNDATION as per drawings and specification adding his
proposals of slopes, approaches, dewatering etc. on receiving the approval
from the engineer with modifications and corrections, if necessary, the
contractor will be set out the work from the control points and markers for
ease of future checking.

These permanent points and markers will be fixed at intervals prescribed

by the engineer and checked by the engineer and certified by him after
which the contractor will be proceed with the work.

Engineer will provide with necessary men, material and instructions for
such checking. This checking by the engineer prior to start of the work will
in no way absolve the contractor of his responsibility of carrying out the
work to true lines and levels and grades as per drawing and subsequent
corrections , if necessary , in case any errors and noticed in the contractors
work at any stage.

The following activities should be considered as per drawing (REL-SUMPP-HES-307-B-0702) given

below.

I. Excavation of dyke wall

II. PCC of dyke wall
III. Reinforcement placing & form work of raft of dyke wall.
IV. Concreting of dyke wall raft
V. Concreting of dyke wall
VI. Backfilling up to FGL
VII. Coarse and sand filling in tank area
VIII. Laying of crush stone
IX. Laying of anti corrosive layer
 X. Pre mix carpet
XI. PCC for drain
XII. Reinforcement placing & formwork of raft of drain
XIII. Concreting of drain
XIV. Grade slab concreting
XV. Brick work (Drain sump)

The discussion & procedure of the above actives are

mentioned below........................................
EARTH WORK------
1) The reference points are located visually
using key plan. The permanent bench mark is located near the workshop
building its value recorded in field survey book.

2) The level of PBM is transferred on temporary bench mark with help of

authentic level instrument. The co-ordinates (S1073, E1362 & S1073,
E1434 & S1211.6, E1362 & S1211.6, E1434.6) of the FUEL OIL TANK
FOUNDATION has been established by the using of TS.

3) The boundary points of the fuel oil tank foundation mentioned on the
above are demarcated on ground.

4) The ground levels in terms of reduced levels are taken at intervals of 10

m to 20 m along/across the centre grid line of structure and square are
plotted on graph papers/drawings sheets. The accuracy of TBM w.r.t PBM
is checked at regular intervals to control any major mistake in future.

5) Initial excavation is carried out with the help of excavator as per

requirement. In case of deep excavation of soft strata, extra width i.e cut
slope 4:1 or 500 mm wide offsets at regular intervals is carried. Excavation
of dyke wall is considered according to the drawing of REL-SUMPP-HES-
307-B-0702, REV 01.

6) Safety precautions are checked as per safety manual.

7) Good excavated earth suitable for back filling is dumped/ stacked at

site. Rubbish, malba, mud or unsuitable excavated earth is disposed away
from site at place allotted by client.
8) During excavation, excavated ground levels and layout are checked
after excavation of planned depth to avoid any over excavation.

9) When specified level is arrived then surface dressing, watering and

compaction by plate compactor or roller is done to lay bed
concrete/leveling course. If de-watering is required then all necessary
arrangement is made.

10) The sides of excavation made for foundation or basement is treated

with chemical from depth of 300-500 mm below the ground level till the
excavation level subjected to confirmation from relevant specification .

PCC (DYKE WALL, DRAIN AND OTHER AREA MENTIONED IN

THE DRAWING):

1) The minimum depth of pcc(M10) as 75 mm will be considered

according to the drawing. Prior to preparation of M10 (lean
concrete) the following information are collected i.e. type of cement
, maximum cement content(for design mix),maximum water cement
ratio, workability, mix proportion .
2) Fine aggregates, cement, water are tested in accordance with
relevant standards and specifications to find out their suitability for
work. Records of test results are maintained. However all above
applicable subjected to relevant contract agreement.

COMPACTION OF SOIL & BACKFILLING (PROCEDURE):-

1.0 Objective

This procedure explains in detail the sequential activities required for

carrying out backfilling with soil, sand, sand and gravel and
aggregate crusher sand mix ( As and when required).

2.0 Scope
 This procedure is applicable for backfilling and area compaction work
at our project.

3.0 Reference

 Technical specification of owner.

 Relevant working drawings issued by the Owner.

4.0 Details

4.1 Tools & tackles

 Spade
 Basket
 Pick
 Shovel

4.2 Machinery

 Hand rammer
 Plate Compactor
 Dumper
 Any mechanical means(if applicable)

5.0 Procedure for back-filling in pits and around structures

a) Prior to commencing back-filling work, exact excavation profile shall

be taken jointly recorded with the representative of the Owner.

b) Backfilling shall be carried out layer by layer using soils from dumps
designated/approved by the Owner. For each specified dump,
laboratory tests shall be carried out by QC engineers for
determination of optimum dry density and optimum moisture
content in terms of both Proctor Density and Modified Proctor
Density and the results shall be intimated to site execution group.
 c) As soon as the work in foundations have been accepted and measured, the
spaces around the foundation structures in pits and trenches shall be cleared of
all debris, brick bats, mortar droppings etc. and shall be filled with earth in layers
not exceeding 150mm, each layer being watered as per the Proctor Density
requirement, rammed and properly consolidated and compacted before the
succeeding layer is laid. Each layer shall be compacted to a dry density not less
than ninety five percent (95%) for Road works and other places minimum of 80%
of the maximum Standard Proctor Dry Density. Standard Proctor Density tests
shall be conducted by the Contractor on soil proposed to be used in the backfill.
Field density tests shall be conducted as directed by the Engineer. Subsequent
filling shall be done only after ensuring satisfactory mechanical compaction of
previous layer. Earth shall be rammed with approved mechanical compaction
machine. No manual compaction shall be done. The final surface shall be trimmed
and leveled to proper profile as indicated in the drawings and as directed by the
Engineer. All backfilling shall be carried out with prior approval of Engineer after
ensuring that no underground services are to be laid in the area.

6.0 Procedure for controlled area backfilling

The material shall be spread in uncompacted layers (after removing

and/or breaking clods etc.) of thickness 350mm and any other
mechanical method approved by the Owner. The dry density will not
be less than 95% of the Modified Proctor Dry Density is achieved. At
least one field density test by core cutter or sand replacement method
as per IS:2720 Part XXVIII shall be conducted on every fifth layer (ref.
FQP) to check the effectiveness of compaction.

7.0 Procedure for backfilling with Sand

Where directed by the Owner, backfilling shall be carried out with

selected coarse sand free from impurities. The filled in sand shall be
flooded with water for 24 hours to ensure maximum consolidation.
The surface of the consolidated sand shall be dressed to the required
level or slope. Compaction of sand shall be done as specified in
IS:2720.

8.0 Procedure for backfilling of Coarse Aggregate/ Sand Mix

a) Wherever directed by the Owner, backfilling shall be carried out with

a suitable coarse aggregate (40 mm) and sand mix so as to attain a
minimum Bulk density of 1.75 MT/m 3. Trial mixes shall be carried out
in the concrete laboratory before taking up actual work in order to
ascertain this criterion.
 b) Prior to commencing back-filling work, exact excavation profile shall
be taken jointly recorded with the representative of the Owner.

c) In the field condition the sand/aggregate mix in the designed

proportion shall be spread on the backfill area in layers not
exceeding 300 mm. Small quantity of water shall be added to
facilitate proper compaction. Compaction shall be carried out using a
mechanical compactor. Number of passes of the rammer shall be
governed by the indication that no settlement mark is observed
along the path of travel of the rammer. Successive layers shall be
laid only after compaction of the preceding layer is achieved. Field
density test by sand replacement method as per IS:2720 Part XXVIII
shall be conducted to check the effectiveness of compaction,
wherever directed by the Owner’s Engineer.

d) Where sand/aggregate fill is not done in a confined space, the width

of the fill shall be extended by at least 1.0 metre on the free end(s)
measured at the top of the fill. The edges shall have a slope of 1:1.
After compaction of a layer, the extent beyond the tapered edge as
directed by the Owner’s Engineer shall be filled with selected soil
and compacted so as to ensure stability of the sand/aggregate fill.

Reinforcement :-

Concreting will be done in the following items.................................

 Concreting of dyke wall

 Concreting of grade slab(M20)
Details procedure of concrete work..................

Before starting the concrete, reinforcement and shuttering are the most
important part. Reinforcement is used to hold the tensile stress of the concrete.

The details procedures of reinforcement are discussed below.

1) The diameter of the bars of the fuel oil tank foundation as

mentioned in the drawing are shaped according to its cutting
length mentioned in the drawings. Before laid down the
reinforcement, precautions are maintained described below.
 2) No oily substance will be used for removal of rust prior to
assembly of reinforcement.
3) Overlaps/splices staggered but in no case the overlapping is
to be provided more than 50% cross sectional area at one
section and bound together at intervals not exceeding twice
dia of such bars.
4) Binders ,stirrups, link etc the straight portion behind the
curve will not be less than 8 times the nominal size of bar. Bars
crossing one another will be tied at every intersection.
5) Clear covers & alignment of bars will be maintained.
6) Required binding will be completed before concreting.
7) The spacer bars, binding at every intersections and chairs are
provided to keep in required position before and during the
concreting. When the reinforcements are placed shuttering will
be used to form its shape.
8) Development length of the reinforcement is considered as 49d
(d= diameter of the reinforcement) and all reinforcing shall be
tor steel Fe500 conforming to IS: 1786(latest).
9) BBS to be made with respect to IS 2502 & SP-34.

Form Work :-

1. Objective

Objective of this procedure is to provide a guideline for sequence of

operations pertaining to Formwork for all types of concrete structures,
so as to ensure that the works are carried out in a systematic manner
and to ensure that the works conform to the Owner’s specification and
drawings.

2. Scope

This procedure is applicable for all types of Formwork for the concrete
shapes indicated in the Owner’s drawings and Technical Specification
under scope of the Contractor for the project.

3. Reference
This Procedure is based on the requirements of the Owner’s Technical
Specification for Package-IV Civil/Structural works, applicable Indian
and foreign standards, Owner’s PO Document and the relevant sections
of the Contractor’s Project Quality Manual . Definitions and
nomenclature applied in this document are in conformity with ACIL’s
QMSP.

Resource Deployment

The Contractor shall deploy any or all of the following resources as dictated by the type of
formwork.

4.1 Tools & tackles

 Carpenter’s Kit
 Masking tape/putty

Plant & Machineries

 Tower crane
 Mobile crane
 Tractor/Trailer IF APPLICABLE
 Builder’s hoist

4.3 Material

 Ply-board formwork in shapes and sizes as required

 Fabricated steel formwork in shapes and sizes as required
 Pre-fabricated wall/column formwork complete with support
system
 Scaffolding pipes with clamps
 H-frame, Telescopic prop & collapsible beam
 MS pipe with adjustable props
 MS section soldiers/runners
 Hardwood battens
 Steel trestles
  Stirrups, turnbuckles, screw jacks etc.

4.4 Consumable
 Wire nails
 Form Oil except for surfaces to be painted later.

4.5 Manpower
Adequate skilled, semi-skilled and unskilled manpower shall be arranged for
every activity described hereafter.

4. Procedure Details

5.1 General

The form work shall consist of but not limited to shores, bracings, sides of
beams, columns, walls, rafts and bottom of slabs including ties, anchors,
inserts, hangers, false work, wedges etc. complete, which shall be properly
planned for the work. For the floors, supports can be taken from the floors
down below with prior permission of the Owner’s Engineer. Wherever
required provision shall be made to support the floor shuttering by means of
trusses, which shall be spanned from the near by walls/ columns.

5.2 Formwork and Support Structure Design

5.2.1 Formwork

All generic formwork design shall be submitted for approval of the

Owner. Formwork shall be designed to fulfill the following
requirements:
a) Sufficiently rigid and tight to prevent loss of grout or mortar from the
concrete at all stages and appropriate to the methods of placing and
compacting.

b) Made of suitable materials.

c) Capable of providing concrete of the correct shape and surface finish

within the specified tolerance limits.

d) Capable of withstanding without deflection the worst combination of

self-weight, reinforcement and wet concrete weight, all loads and
dynamic effects arising from construction and compacting activities,
wind and weather forces.

e) Capable of easily striking without shock, disturbance or damage to

the concrete.

f) Soffit forms capable of imparting a camber if required.

g) Soffit forms and supports capable of being left in position if required.

h) Capable of being cleaned and/or coated if necessary immediately

prior to casting the concrete; design temporary openings where
necessary for these purposes and to facilitate the preparation of
construction joints.

i) All horizontal forms shall be constructed for pressures from the dead
load of the concrete and embedments and a minimum live load of
200 kg/m2. For any additional loads, the formwork shall be suitably
designed.

5.2.2 Support Structure

The following loading shall be considered for design of the supporting

structure.

a) Dead Load
  Concrete load -- 2500 kg/cum. (set concrete)
 Self weight -- as per design.
 Top formwork -- as per design
 Reinforcement in Un-concreted area -- 200 Kg/sqm on plan
area

b) Live Load

 General area -- 75 Kg/sq.m on plan area

 Local area where concreting is
in progress -- 125 Kg/sq.m on plan area.

 Incidental load -- 170 Kg/sq.m on plan area.

c) Wind load -- As per IS: 875 (part 3) – 1987

d) Green concrete load -- as per ACI provisions

5.3 Centering of Formwork

Centering using steel tubular props, H frames, built-up sections, with

provisions to adjust the heights of the props shall be used and they
shall be to true levels and rigid. They shall be adequately braced
horizontally and vertically. For shuttering supported on floors below,
vertical props shall be so supported on wedges or other measures shall
be taken whereby the props can be gently lowered vertically while
striking the shuttering. Bamboos and wooden poles shall not be used
as props or cross bearers. Centering supported on structural steel
work shall be designed for the conditions mentioned earlier in
paragraph 5.2.

5.4 Tie Rods

As far as possible MS tie rods left in type shall be used for supporting
all forms. Retrievable type can also be used with the prior approval of
the Engineer. Tie rods shall have provision for removal of a section of
each rod at surface of the concrete to a depth of approximately 50mm.
All holes left by the removal of conical nuts or other removable fixtures
embedded in the face of the concrete shall be filled and finished with
cement-sand mortar in a manner specified in the finishing specification.
Use of internal through ties in the structures below ground level shall
not be permitted. Threaded inserts embedded on each face of the wall
shall be cut for attaching the forms to previously placed concrete. No
tie rods shall be directly welded onto the wall liners.

Through Tie rods shall be permitted only upon approval of the Engineer
and when permitted shall be cut off flush with the face of the concrete,
or the countersunk, filled and finished, as required by the Engineer, in
the manner specified under the finishing specification. Measures shall
be taken to prevent rust stains on concrete.

5.5 Form Oil

Only non-staining mineral oil or other approved oil shall be applied

before placing reinforcing steel and embedded parts. Form oil shall not
be used on the surfaces requiring painting. Form oil shall be insoluble
in water and not injurious to concrete and shall not become flaky or be
removed by rain or wash water. Form oils that retard the setting of
concrete shall not be used.
All excess oil on the form surface and any oil on metal or other parts to
be embedded in the concrete shall be carefully removed. Before
treatment with oil, forms shall be thoroughly cleaned of dried splatter
of concrete from placement of previous lift.

5.6 Joints

Joints in forms shall be truly horizontal or vertical unless otherwise

specified and shall be sufficiently tight to prevent any leakage of
cement slurry to avoid formation of fine or blemish. Faulty joints shall
be sealed as directed by the Engineer. Suitable devices shall be used to
hold adjacent edges together in accurate alignment. Sealing tapes shall
be used to avoid leakage of slurry through the formwork joints. On the
removal of forms, marks left by sealing tapes shall be finished so as to
merge with other concrete surface. Care shall be taken to maintain
symmetry in formwork in slabs, walls, columns etc. so as to give a
pleasant appearance to finish concrete surface. All forms shall be so
made that they can be removed without hammering or prying against
the concrete.
5.7 Reuse of Forms

Before reuse, all forms shall be thoroughly scrapped, cleaned,

examined and when necessary, repaired and re-oiled before resetting.
Formwork shall not be used/ reused, if declared unfit or unserviceable
by the Engineer.

5.8 Working Platform

Safe working platform shall be provided for workmen, when working

above ground level. Safe method of approach shall be provided to
reach locations above ground level. Handrails shall be provided for all
working platforms. Hanging platforms shall have safety net provisions.
All ladders shall have handrails and shall not be kept vertical. All
platforms, ladders handrails etc. shall be firmly secured to ground or on
supports. No loosely supported ladders, platforms shall be used in the
works.

5.9 Removal of Forms

In the determination of time for removal of forms, consideration shall

be given to the location and character of the structure, the weather
and other conditions including the setting and curing of the concrete
and materials used in the mix.

Forms and their supports shall not be removed without the approval of
the Engineer. Improper methods of removal of formwork likely to cause
overstressing or damage to the concrete shall not be used. Supports
shall be removed in such a manner as to permit the concrete to
uniformly and gradually take the stresses due to its own weight.

The supports can be reinstated in anticipation of abnormal conditions.

Re-propping of beams shall not be done except with the approval of the
Engineer.
The minimum period for removal of forms shall be as mentioned in the
table given hereafter. However, seven day test results shall be as per
IS:456 (latest revision). If the strength requirements are not met with,
the formwork shall be removed as per the instruction of the Engineer.

Table Showing Formwork Release Times for Concrete with Ordinary Portland
Cement

Sl. Earliest age of concrete at

No Class of structure stripping for placement
temp. not less than 20° C.

Walls, columns and vertical 24 to 48 hrs or as decided

1.0
sides of beams. by the Engineer.
2.0 Slabs (props left under) 3 days
3.0 Beam soffit (props left under) 7 days
4.0 Removal of props to slab
i) Spanning upto 4.5m 7 days
ii) Spanning over 4.5m 14 days
Removal of props to beams
5.0
and arches
a) Spanning upto 6m 14 days
b) Spanning over 6m 21 days
Not until adequate fixity
6.0 Cantilever construction is developed subject to
minimum of 10 days

Striking shall be done slowly with utmost care to avoid any damage to
concrete surfaces or any projections on it and without shock or
vibrations, by gently easing the wedges/ jacks. If after removing the
formwork, it is found that timber has been embedded in the concrete, it
shall be removed and made good as approved.

Tie rods, clamps form bolts etc., which must be entirely removed from
the walls or similar structure shall be loosened not sooner than 24
hours after the concrete was deposited.

5.10 Special Requirements

5.10.1 Provision of embedded parts projecting from the wall

For the walls constructed by conventional method the embedded
pipings/pipe sleeves or parts which project outside of wall shall be
provided by puncturing the shutters locally, or by making pre-formed
shutters with opening as per profile.

5.10.2 External form work

External formwork shall be provided at all such locations where the

slope of the concrete top is more than 15° to the horizontal. External
formwork shall consist of wooden planks/steel plates spanning between
structural steel member spaced suitably on the concrete. These
structural members shall span over the entire pour and shall be
supported on the edges of the pour. Threaded inserts can be embedded
in the previous concrete pours to support the external formwork. No
through ties shall be permitted in the structure. The scheme of
shuttering shall be submitted to the Owner and approval shall be
obtained before erection of the formwork.

5.10.3 Pockets for foundation bolts

Pockets for foundation bolts shall be made out of plywood or timber.

These shall be made slightly tapered for ease of removal. The bottom of
such formwork shall be closed so as not to allow entry of concrete from
bottom.

5.10.4 Form work for pre cast concrete works

All pre-cast units shall be cast in a suitable yard, bed or platform with
firm foundation and free from wind. The platform shall have a smooth
plaster finish. The yard shall be fenced and shall have a curing tank of
adequate size. The Contractor shall be responsible for the accuracy of
the level and shape of the bed or platform. A suitable serial number
and the date of casting shall be impressed or printed on each unit.
Each unit shall be concreted in one operation. Reinforced concrete
members shall be marked to indicate the upper surface.
The form shall be of steel sheets with rigid steel frames. All
components of formwork shall be so held that during casting there is
no deformation of the form resulting in the concrete units not
conforming to dimensions indicated in the drawings. The shuttering
shall be made with a tolerance of (+/-) 3mm in all directions.

The side shutters shall not be struck in less than 24 hours for Ordinary
Portland Cement and 72 hours for Portland Pozzolana Cement after
concreting and no pre-cast unit shall be lifted during striking the form.

5.11 Formwork Tolerances

The following tolerances are permitted unless otherwise mentioned in

the relevant drawings. The tolerances shall be taken as the departure
from the true position at any point after completion of the structure.

Description of Structure Tolerances

Tolerance for vertical form work

( +/- ) 3 mm.
Variation in walls
3mm per 6m height, but
Plumb
not cumulative

Deviation from specified

dimensions of cross sections of + 12 mm to –6 mm
columns & beams.

Deviation from dimensions of

Footings

+50mm to –12mm
1. Dimensions in Plan
2. Eccentricity 0.02 times the width of
the footing in direction of
 deviation but not more
than 50 mm.

(+/-) 0.05 times the

3. Thickness
specified thickness.

CONCRETING:--
5. Objective

Objective of this procedure is to provide a guideline for sequence of

operations pertaining to Reinforced Concrete work for all types of
structure, so as to ensure that the works are carried out in a
systematic manner and to ensure that the works conform to the
Owner’s specification and drawings.

6. Scope

This procedure is applicable for all types of PCC/RCC work indicated

in the Owner’s drawings and Technical Specification under scope of
the Contractor under GCW-2(SASAN PROJECT) Civil/Structural works
of the project.

7. Resource Deployment

The Contractor shall deploy any or all of the following resources as dictated
by the volume and nature of concrete work.

7.1. Tools & tackles

 Spade.
 Shovel.
  Basket.
 Chute.
 Wheel borrow
4.2. Plant & Machineries

 Concrete Pump.
 Concrete pipeline
7.2. Plant & Machineries (contd)

 Immersion type Vibrator (Electrical, Diesel & Petrol).

 Immersion type vibrating needle, having frequency of 7000 rpm
(40 mm & 60 mm).

7.3. Manpower
Adequate skilled, semi-skilled and unskilled manpower shall be arranged for
every activity described hereafter.

8. Procedure Details

5.1 Pre-pour Activities

a) Level, layout, formwork and formwork support system of the
pouring area shall be checked with respect to relevant
construction drawings before starting RCC.
b) Reinforcement bar size and placement shall be checked with
respect to relevant construction drawings and bar bending
schedules. Where applicable, provision of chairs shall be checked
for adequacy.
c) Location, size details, level etc. of all embedment parts shall be
checked.
d) Any accumulated water shall be drained out / pumped out.
 e) Any accumulated dust, wooden pieces, other foreign materials etc
within the formwork shall be removed by compressor/ manually
as per requirement.
f) All cover blocks having proper thickness shall be placed in proper
location as per drawing & specification.
g) Cover block shall be made of same grade of concrete in which it is
to be embedded.
h) Tarpaulins shall be kept in readiness if there is possibility of rain.
i) Proper lighting arrangement shall be made from unloading area
to the placing area if the pouring continues through night.
j) Pour plan for each pour elaborating the scheme of concreting,
tools and tackles to be used, manpower deployment etc. shall be
submitted to the Owner for approval.
k) The aforesaid checks shall be jointly made with the Owner’s
Engineer and pour clearance shall be obtained on Pre-pour
Inspection format.
l) Based on pour clearance protocol, Concrete Requisition (CR) shall
be made on appropriate format. The CR No. shall be the linking
document no. for all pour related documents. Grade of concrete,
slump requirement and placement temperature as per relevant
drawing and mode of placement shall be clearly mentioned in the
CR.

5.2 Laying of Concrete

a) Concrete shall be placed in its final position within 90 minutes of

its production or well before initial setting time, so as to leave
sufficient time for proper compaction.
b) Concrete shall be placed in layers having a thickness of maximum
of 300 mm. Generally the pour height of columns and wall shall be
restricted to 2.4 m. With special formwork and support
 arrangement to prevent segregation and keeping access for
vibration, casting of columns and walls for greater heights (even
full height) can also be planned. Such special arrangements shall
be demonstrated to the Owner first by submission of suitable
proposal and after acceptance of the same, by carrying out mock-
up trials to the satisfaction of the Owner.
c) Before laying any subsequent layer of concrete, the previous
layer shall be fully compacted and there shall not be any initial
setting in the previous layer. This requirement shall be clearly set
out in the approved pour plan.
d) Bedding planes shall be kept horizontal & care shall be taken so
that cold joints are not formed.
e) When manual pour of PCC is contemplated, any visible
segregation of concrete unloaded from transit mixer on to the
receiving platform, shall be remixed manually by spade & shovel
before placement by head load.
f) Concrete shall be well-compacted using immersion vibrator.
g) Concrete shall be leveled & finished in proper level as per the
requirement of the drawing.
h) Slumps shall be checked & cubes shall be taken as per Quality
Assurance Plan.
i) Concrete shall be cured for at least 10 days by water
spraying/ponding. Jute cloth shall be provided over the vertical
surface to facilitate for keeping the surface wet.
j) In case of pre-cast concrete, the pre-cast block shall be removed
as per the instructions given in the drawing.

5.3 Vibration and Compaction of Concrete as and when applicable:-

a) Each layer of concrete shall be worked with suitable types of

equipment till the concrete has been consolidated to the
maximum practicable density, and is free of pockets of coarse
aggregate or of entrapped air and the concrete fits tightly against
all form surfaces and embedded materials.
b) The operator/mason handling the Vibrator shall have been
qualified for the job by the Owner’s Engineer.

c) The concrete shall be compacted by mechanical vibrating

equipment where thickness of pour allows the process. For lower
thickness, compaction shall be achieved by manual tamping with
heavy timber planks.

d) The vibrators shall be internal-immersion type high frequency

vibrators with speed of not less than 7000 rpm when immersed in
the concrete. Vibrators shall be used in sufficient number of units
and power of each unit to properly consolidate all concrete in
each layer immediately after it has been placed in the forms.

e) Vibrators shall be manipulated so as to thoroughly work the

concrete around the reinforcement and embedded fixtures, and
into corners and angles of the forms. Care shall be taken to
ensure that the vibrator does not come in contact with the
reinforcement steel. Sufficient numbers of vibrators with standby
arrangement should be kept ready at site of work depending
upon size and duration of pour before start of work.

f) Internal vibrators shall be inserted in a vertical position only, at

intervals of about 450 to 700 mm depending upon the mix, the
equipment used, the type of structure and continued experience
on job. The vibrators shall be withdrawn slowly, approximately at
the rate of 75 mm/sec. The spacing shall provide some
overlapping of the area vibrated at each insertion. In no case
shall vibrators be used to move concrete laterally inside the
forms. Vibration needle shall be kept clear of forms at least by
100 mm. Over-vibration shall not be permitted. Hand tamping in
some cases may be allowed subject to the approval of the
Owner’s Engineer.

g) Vibrators shall not be applied directly or through the

reinforcement to sections or layers of concrete, which have
hardened to the extent, the concrete ceases to be plastic state.

h) In placing concrete in layers, which are advancing horizontally as

the work progresses, great care shall be exercised to ensure
adequate vibration and thereby blending of the concrete between
the succeeding batches.

i) The vibrator shall penetrate full in the layer being placed and also
penetrate the layer below by about 50 mm while it is still plastic,
to ensure good bond and homogeneity between the two layers
and prevent the formation of cold joints.
 j) Care shall be taken to prevent contact of vibrators against
reinforcement steel. Vibrators shall not be brought in contact
with reinforcement steel after start of initial set. Vibrators shall
not be allowed to come in contact with forms or finished surfaces
and embedment.

k) Form-attached vibrators shall be used wherever feasible.

l) The use of surface vibrators shall not be permitted for

compaction of concrete under ordinary conditions. However, for
thin slabs, surface vibration by specially designed vibrators may
be permitted upon approval of the Owner’s Engineer.

m) The formation of stone pockets or mortar bondage in corners and

against face of forms shall not be permitted. Should these occur,
they should be dug out, reformed and refilled to sufficient depth
and shape for thorough bonding.

n) Concrete of excessive slump, which is segregated or otherwise

unworkable, shall not be placed in the forms.

5.4 Construction Joints and Keys

a) When concrete placement is to be interrupted, horizontal and

vertical construction joints and bonding keys shall be located and
shall conform in detail to the requirements of the plans. In case of
water retaining structures, containment structures and other
structures water stops of approved material shall be provided.
Construction joints shall be provided in positions as shown or
described in the drawings.

b) In a column, the joint shall be formed below the lowest soffit of

the beams framing in to it, joint location being determined by the
relevant drawings and ‘Technical Requirement’ document.
Concrete in a beam shall be placed throughout, without a joint
but if the provision of a joint is unavoidable, joint location shall
be determined by the relevant drawings and ‘Technical
Requirement’ document. Before fresh concrete is placed, the
cement skin or any loose or porous material of partially hardened
concrete shall be thoroughly removed and cut back until the solid
face is exposed and surface made rough by hacking using a
pneumatic tool. The rough surface shall be thoroughly wetted for
about two hours and shall be dried and coated with 1:1 freshly
mixed cement sand slurry, immediately before placing the new
concrete. Special care shall be taken to see that the first layer of
concrete is placed after a construction joint is thoroughly rammed
against the existing layer.

5.7 Treatment on Suspension of Work

 Whenever work is suspended on any section for more than one hour,
the horizontal edges of the concrete next to the forms on surfaces,
which will be exposed, shall be brought to a horizontal plane
perpendicular to the plans of the forms and treated so that the
finished work will show smooth straight lines.

5.8 Expansion Joints

Expansion joints in concrete structures shall be provided at specified

places as indicated on the drawings. The materials shall be as
specified by the Owner’s Engineer or as detailed in the
specifications.

5.9 Separation Joints

Separation joint shall be obtained by using a high-density

polystyrene sheet/ neoprene sheet or as specified. High-density
polystyrene sheet, if used shall be wrapped in heavy-duty polythene
sheet as specified, stuck on the surface against which concrete will
be placed or as mentioned in the working documents. Adequate
care should be taken to cause no damage to the sheet.

5.10 Wash Water

Wash water shall be removed in a manner to prevent running down

and staining of concrete surfaces, which would be exposed at the
completion of the job. Should unsightly wash-water streaks develop
on the exposed surface, they shall be removed to obtain a uniform
colour and texture.

5.11 Placement Interval

Each placement of concrete shall be allowed to set for 72 hours and

longer, when required, before the start of a subsequent placement,
or as mentioned in the working documents.

5.12 Special Provisions for Concrete Placement

a) When placing concrete in walls with openings, in floors of

integral slab and beam construction and other similar condition,
the placing shall stop when the concrete reaches the top of the
opening, or bottom horizontal surface of the slab, as the case
 may be. Placing shall be resumed before the concrete in place
takes initial set, but not until it has had time to settle to the
desired level as determined by the Owner’s Engineer. The fresh
concrete shall be vibrated in place to avoid cold joints.

b) To avoid visible joints as far as possible upon exposed faces, the

top surface of the concrete adjacent to the forms shall be
smoothened with a trowel. Where a feather edge might be
produced at a construction joint, as in the sloped top surface of
a wing wall, an inset form-work shall be used to produce a
blocked out portion in the preceding layer which shall produce
an edge thickness normal to the slope of not less than 75 mm in
the succeeding layer.

c) Immediately following the discontinuation in placing of concrete,

and after the final set of concrete has taken place, all
accumulations of mortar splashed upon the reinforcing steel and
the surface of the forms shall be removed. Dried mortar chips
and dust shall not be puddled into the unset concrete. If the
accumulations are not removed prior to the concrete getting set,
care shall be exercised not to damage or break the concrete
steel bond at or near the surface of the concrete while cleaning
the reinforcing steel. The sequence of placing concrete shall be
as instructed by the Owner’s Engineer or as shown on the
drawings.

5.13 Placement of Concrete Through Rebar

In placing concrete through reinforcing steel, care shall be taken to

prevent segregation of the coarse aggregate. Where the congestion of
steel makes placing difficult, it may be necessary to move top steel aside
to get proper placement.

5.14 Placement of Concrete around large Openings

While placing concrete around large openings in the walls, adequate

care shall be taken to ensure proper flow and compaction of
concrete at the underside of such openings. A list of such openings
is as below, but shall not be limited to the following.

Adequate size and numbers of openings (window) shall be provided

in the form work, around and in particular the underside of such
large openings to allow escape of entrapped air and for insertion of
vibrator needle if necessary. Once the concrete reaches the level of
the window provided in the formwork, the same shall be closed and
sealed by suitable means temporarily. Permanent sealing shall be
done after hardening of the concrete.
5.15 Placement of Concrete by Pumping
b) Placing of concrete by pumping shall be as specified or authorized
by the Engineer to achieve the required speed of construction and
maintain targeted schedules.

c) Pumping of concrete shall be done only after conducting pump

ability trials to ascertain the performance of fresh concrete on
pumping. During pumping, concrete shall be conveyed either
through rigid pipe or through flexible hose and discharged
directly into the desired area. No conveying pipe shall be
supported on reinforcement steel. A steady supply of pumpable
concrete is necessary for satisfactory pumping. The mix design
of the concrete to be pumped shall be developed and approval for
same obtained from the Owner’s Engineer. Trials shall be carried
out to demonstrate pumpability. They shall be used for concreting
densely reinforced structures, internal structural elements of
buildings and for large pours of concrete.

5.16 Pumping Equipment

a) Requisite numbers of modern dependable concrete pumps

capable of pumping concrete of specified quality at a rate
required to meet the construction schedules, together with a
balanced complement of pipelines, accessories, spare parts,
power controlled placing booms, and experienced pump operators
and maintenance staff shall be provided at locations.

b) The pumping plant shall be completely installed on each occasion,

with preliminary mock operation for a sufficient length of time
prior to scheduled placement of a particular concrete pour, to
enable conduct pump ability tests and necessary adjustments for
the concrete mix, prior to use of the pumping for placement of
concrete.

5.18 Pipelines and Accessories

a) Rigid Pipelines

Concrete transported to the placement area by pumping methods

shall be pumped thorough rigid pipes or a combination of rigid and
heavy-duty flexible hoses. Rigid pipe shall be made available in
minimum 125 mm diameter size. Aluminum alloy lines shall not be
used for delivery of concrete. Rigid pipes shall be furnished in such
lengths as can be manually handled by a single person.

b) Couplings
 The couplings provided to connect both flexible and rigid pipe
sections shall be adequate in strength to withstand handling during
erection of the pipe system, misalignments, and poor support along
the lines. They should be nominally rated for at least 3.45 MPa and
greater for rising over 30 meters. The strength and tightness of
joints shall be guaranteed. Couplings shall be designed to allow
replacement of any pipe section without moving other pipe sections,
and shall provide a full internal cross-section with no obstructions or
crevices to disrupt the smooth flow of concrete.

c) Pipe Lubrication and Cleaning

Prior to commencement of pumping concrete, the pipeline shall be

lubricated by passing an 1:1 sand-cement slurry of suitable
consistency through the pipeline. Except for a small portion of this
mortar, which may be used for bedding at the construction joint, it
shall be wasted and not used in the concrete placement. In order to
ensure that only minimum quantity of grout mortar is used to
lubricate the pipeline, a rubber sponge ball shall be allowed to pass
through the pipeline immediately before the first batch of grout
mortar is pumped. This rubber ball shall be pushed by the following
mortar along the pipeline slowly and allowed to emerge at the open
end.

 .

5.19 Pump Placement Planning

 Proper planning of concrete supply, pump location, line layout,

placing sequence and the entire pumping operation shall be done
and got approved by the Owner’s Engineer on every occasion
before commencement of concreting job. The pump shall be as
near the placing area as practicable, and the entire surrounding
area must have adequate bearing strength to support the
concrete delivery trucks, thus assuring a continuous supply of
concrete. For important concrete placements and large jobs,
adequate standby power and pumping equipment shall be
provided as replacement, should break down occur.
 Direct communications shall be maintained between the pump
operator, concrete placing crew and batching plant. The placing
rate shall be estimated so that concrete can be operated at an
appropriate delivery rate. As a final check, the pump shall be
started and operated without concrete to ascertain that, all
moving parts are operating properly. As stated previously, the
grout mortar shall be pumped into the line to provide initial
lubrication for the concrete. As soon as concrete is received, the
pump shall be run slowly until the lines are completely full and
the concrete is slowly moving. Once the pumping is started, the
operator shall ensure that the hopper of the pump is not emptied
beyond a certain level, as air may enter the pipeline and cause
 choking. Continuous pumping should be ensured. If a delay
occurs because of concrete delivery, form repairs, or other
factors, the pump shall be slowed down to maintain some
movement of the concrete till normal supply is resumed. For
longer delays, the concrete in the receiving hopper shall be made
to last as long as possible by moving the concrete in the lines
occasionally with one stroke of the pump. In confined areas,
attempt shall be made by the Contractor to run a return line back
to the pump, so that concrete can be re-circulated during delays.

 The Contractor shall ensure that obstructions are not found in the
pipe due to interruption in the feed of the concrete by more than
30 to 45 minutes. Minor blockages shall be cleared by operating a
few strokes of the pump in reverse momentarily and then by
returning to normal forward pumping. If this fails, a succession
of reverse and forward strokes shall be carried out to remove the
blockage. Should this fail also, the blockage may be due to air
lock and the entrapped air has to be removed.

5.22 Curing of Concrete

a) All concrete shall be maintained in moist condition for at least

the first 10 days after placing. Mode of curing shall be by wet
burlap method with provision of sprinkling water or by ponding,
depending upon the type of structure. Membrane curing by use
of curing compound may also be adopted if approved by the
Owner’s Engineer.

b) Curing shall be assured by use of an ample water supply under

pressure in pipes, with all necessary appliances of hose,
sprinkles and spraying devices with a terminal pressure of 2
kg/cm2. Continuous fine-mist spraying or sprinkling shall be
used, unless otherwise specified or approved by the Engineer.

c) Curing of concrete shall start after 8 hours of placement and in

hot weather, within 4 hours of placement. During the first 24
hours, the concrete shall be cured by use of wet bur lap or such
other means to cover the concrete surfaces. The formwork
shall also be kept wet by sprinkling of water.

5.23 Concrete Repair/Replacement

a) Unsatisfactory concrete shall be repaired by cutting out the

unsatisfactory material and by replacing it with new concrete.
Voids to be so filled shall be provided with anchors, keys or
dovetail slots whenever necessary to attach the new material
securely in place. Surface of prepared voids shall be wetted for
24 hours immediately before the patching material is placed.
Skilled workmen shall make repair of concrete. Repairs shall
be made as soon as practicable after removal of forms and in a
 manner to meet the requirements for the finish specified for
the particular location. The portion of the concrete to be
repaired may be reinforced with steel mesh.

b) All materials, procedures and operations used in the repair of

concrete and also the finished work shall be subject to the
approval of the Owner’s Engineer. All fillings shall be tightly
bonded to the concrete and shall be sound, free from shrinkage
cracks or dummy areas after the fillings have been cured and
dried. Any concrete not found to be in accordance with the
acceptance criteria shall be made good with suitable injection
grouting.

c) The use or otherwise of epoxy for the repair work will be at the
discretion of the Owner’s Engineer. Epoxy shall be applied in
strict accordance with the instructions of the manufacturer.
Epoxy shall be used as a bonding agent prior to placing fresh
concrete. The Contractor for this job shall arrange approved
material.

d) Where the dry pack method of repair is used, pockets shall be

sharp and square at the surface edges, but corners within
pocket shall be rounded. The perimeter of the pocket shall be
under cut in several places. Pockets for dry pack shall have a
minimum depth of 25 mm. The pockets to be repaired shall be
scrupulously clean and slightly wet with no free water on the
surface. The surface shall then be dusted lightly with cement
by means of dry brush. Under no conditions shall the pockets
be painted with neat cement grout.
e) The dry pack mix shall be proportioned by weight; 1 part
cement to 2.5 parts of sand that will pass a No. 16 screen. Only
enough water shall be used to produce a mortar, which will
stick together when moulded into a ball by a slight pressure of
the hands and will not extrude water but will leave the hands
just damp. Dry pack material shall be placed and packed in
layers having a compacted thickness of about 10 mm. Each
layer shall be solidly compacted over its entire surface by use
of hardwood stick and hammer. The stick is normally about
300 mm to 460 mm long and not over 30 mm in diameter. Most
of the tamping should be directed at a slight angle and towards
the side of the pocket to ensure maximum compaction and
bond. Water shall not be used to facilitate finishing.

f) Filling material used in repair of surfaces which will be exposed

after completion of the project shall be made with cement from
the same sources as that used in concrete and blended with a
sufficient amount of white Portland cement to produce the
same colour as in the adjoining concrete. Patched surfaces
shall be given a final treatment as required to make the texture
of the patch to match that of the surrounding material.
 g) Immediately after patching is completed, the patched area
shall be covered with an approved non-staining, water-
saturated material, which shall be kept wet and protected
against sun and wind for a period of 12 hours. Thereafter, the
patched area shall be kept continuously wet by a fine spray or
sprinkling as required for the duration of minimum curing time
or as decided by the Engineer.

Brickwork:
BRICK WORK IS DONE IN ONLY DRAIN SUMP.

Purpose

 This procedure explains in details about the procedure of executing Brick

Masonry work.
Details

Tools & tackles

1. Spade.
2. Shovel.
3. Basket.
4. Mason tools.

Reference IS Codes

IS-1077, IS- 3495, IS- 2116

Material

 All Bricks used must be approved prior to the actual use at site.
  Bricks are to be checked for its dimension, straightness, strength and
efflorescence
 Bricks shall be sound, hard and homogenous in texture, well burnt and deep red,
cherry copper coloured of regular shape and size.
 The minimum crushing strength should not be less than 50 kg/cm 2.
Workmanship as & when applicable:-

 Mortar for brick masonry shall consist of cement and sand and will in the
proportion of 1:5 for brickwork of thickness one brick and above 1:4 for brickwork
of thickness half or below, unless otherwise specified in the respective items of
work.
 For preparing cement mortar, the ingredients shall first be mixed thoroughly in
dry condition.
 Water shall then be added and mixing continued to give a uniform mix of required
consistency. Mixing shall be done in the mechanical mixer unless hand mixing is
specifically permitted by the engineer.
 The mortar thus mixed shall be used as soon as possible, preferably within 30
minutes from the time water is added to the cement.
 Any mortar which is partially set shall be rejected and shall be removed forthwith
from the site.
 Bricks shall be thoroughly splashed with clean water at least one hour
immediately before being laid.
 Brickwork 250mm thick shall be laid in English bond unless otherwise specified.
 Each brick shall be slightly pressed into the mortar and shoved into the final
position so as to embed the brick fully in the mortar. Only full size bricks shall be
used for the works and cut bricks utilized only to make up required wall length or
for bonding.
 Bricks shall be laid with frogs uppermost.
 All brickwork shall be plumb, square and true to dimension shown.
 Vertical joints in alternate courses shall come directly one over another and be in
line. Horizontal courses shall be leveled.
 The thickness of the brick courses shall be kept uniform.
 In case of one brick thick and half brick thick wall, at least one face should be kept
smooth and plane, even if the other is slightly rough due to variation in size of the
bricks.
 The thickness of the joints shall not be less than 6 mm and not more than 10 to
12mm. Raking of joints should be properly done.
 Brickwork shall be kept constantly moist on all the faces after 24 hrs laying for 7
days.
 Double scaffolding having two sets of vertical supports shall be provided to
facilitate execution of masonry works. Scaffolding shall be properly maintained
during the entire period of construction.
 PVC mesh fabric shall be provided at the junction of brick masonry and concrete
before taking up the plastering work.
 Transoms and Mullions are to be fixed as per the drawing
 Brickworks shall be kept clean and free from damages, discoloration, etc, at all
times.
Miscellaneous:

The given items will be followed up according to the drawing no REL-

SUMPP-HES-307-B-0702, REV 01

 Bottom plate of drain sump

 Anti corrosive layer of 50 mm thick.