Name of the

Project

: INFRASTRUCTURE WORKS FOR VIKRAM UDYOGPURI NEAR

UJJAIN, MADHYA PRADESH.
Reference No. VUL/SPML-OM METALS (JV)/SANGUINE/M/19

METHODOLOGY FOR STRUCTURAL CONCRETE

1.

SCOPE OF WORKS
The work shall consist of producing and placing the concrete of grade M-40, M-35, M-30, M25 and M-15 by weigh batching in accordance with the specifications conforming to
MoRT&H, IRC-21-2000 and the work specifications stipulated in the contract document.

2. REFERENCE
Reference Documents:I) Ministry of Road Transport & Highway Specifications.
II)

Concession Agreement Vol. - I, Schedule D.

III)

Relevant contract drawings.

3. SETTING OUT
After completion of site preparation, alignment of structure of culverts and or minor bridges
is marked on the ground with lime and /or string. With reference to its alignment other points
of structures like wing wall, abutment wall are pegged. For construction purpose temporary
bench marks (TBM) are also established near by the location of structure. The place of TBM
shall be chosen in a such a way that it will not be disturbed by the construction activities and
it shall remain in position until all the works are completed in that location.
4.

MATERIAL

a. Cement
Cement confirming to IS: 12269 shall be used only after ensuring the minimum required
design strength. Manufacturers test certificate shall be submitted to the Engineer for every
consignment of cement. The certificate shall cover all the tests for chemical requirements,
physical requirements and chloride content.
Independent tests of samples drawn from the consignment shall be carried out at the site
laboratory or in an independent laboratory approved by the Engineer, immediately after
delivery.
b. Coarse aggregate

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Coarse aggregate shall be produced from approved quarry in required sizes. It shall consist
of clean, hard, strong, dense, non-porous and durable pieces of crushed stone or a suitable
combination thereof as specified.
Maximum nominal size of aggregate for various structural components shall conform to the
Table 1700-7 of MOSRTH Specifications.
c. Fine aggregate
Fine aggregate for structural concrete shall be clean, hard, strong and durable pieces of
crushed stone or suitable combination of natural sand. They shall not contain dust, lumps,
soft or flaky, materials, mica or other deleterious materials in such a quantity to reduce the
durability and strength of concrete. Gradation of fine aggregate shall conform to Table 10002 of MoRT&H Specifications.
d. Water
Water shall conform to section 1010 of MoRT&H Specifications. Water shall be free from
injurious materials like oils, acids, alkalies, salts, sugar, organic materials or other
substances that may be deleterious to the concrete or steel. Potable water is generally
considered satisfactory for construction purpose. Mixing and curing with seawater shall not
be permitted.
e. Reinforcement steel
Reinforcement / Untensioned steel shall conform to section 1009.3 of MOSRTH
Specifications. Reinforcement shall be thermo-mechanically treated (TMT) deformed bars of
grade Fe500 confirming to IS code 1786. Only uncoated steel shall be used as per shape
and size shown on the contract drawing. It confirms to the specification or as approved by
the Engineer.
Bending of reinforcement
Bar bending schedule will be prepared and submitted to the Engineer for approval before
start of work. Bar bending schedule shall include number, shape and cutting length of bar
and weight in respect of each type. A separate bar bending schedule shall be prepared for
auxiliary bars like spacer, chairs etc.
Placing of reinforcement
-

Reinforcement shall be placed in accordance with the drawing and shall be inspected
and approved by Engineer. After getting approval from Engineer, immediately pouring of
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concrete can be allowed.

-

Reinforcement shall be tied with binding wire (1 mm dia.) in such a way that it shouldnt
be displaced while pouring the concrete on it.

Cover blocks are made of cement mortar with the same durability of surrounding
concrete.

Layers of bar shall be separated by spacer bars kept at approximately 1m interval and
min. size is 12mm, or maximum size of main reinforcement, whichever is greater is
used. Horizontal reinforcement shall not be allowed to sag between supports.

Necessary auxiliary bars like spacer, chairs, and blocks shall be provided to fix the
reinforcement in its correct position.

5.

PROPORTIONING OF CONCRETE
The concreting will be done based on mix design. All measuring equipment shall be in a
clean and serviceable condition. Their accuracy shall be periodically checked. Water cement
ratio is maintained constant to its connecting value taking in to account of moisture content
of aggregates. The amount of water to be added shall be adjusted to compensate the
variation in moisture content due to weather condition.
Proportioning of concrete shall be as per approved design-mix by weigh batching.

TRIAL MIXES:
The trial mixes of all grades of concrete shall be prepared by using samples of approved
materials same as that are proposed to use in the works before commencement of work.
The initial trial mixes shall be prepared at site laboratory. In all cases complete testing of all
the constituent materials proposed in the design mix shall be carried out prior to making trial
mixes.
Additional trial mixes shall be carried out before the production, in case of substantial
changes are made in the material or in the proportion of the materials to be used.
EQUIPMENTS:
Keeping in view of the equipments of the work, equipment proposed to carry out is as under:
1. Batching Plant

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2. Mixer Trucks
3. Vibrator
4. Wheel Loader
5. Excavator
6. Shutter Material
7. Bar Bending & Cutting machine
8. Concrete Pump
6. TRANSPORTING, PLACING & COMPACTION OF CONCRETE
Transportation of concrete is carried by transit mixer or pumps. Hose pipe from the pump to
the placing area should be laid out with minimum bends. Concrete at the time of pouring
should have temperature minimum 5 degree Celsius & maximum 40 degree Celsius. . It
shall be compacted to its final position within 30 minutes of its discharge from the mixer.
Concrete shall be poured in horizontal layer of compacted thickness of 300 mm. Fresh
concrete shall not be placed against concrete which has been in position for 30 minutes or
as fixed by mix design unless appropriate construction joints are provided. Free fall of
concrete should not be more than 1.5 meter. Placement of concrete shall not be carried out
when the day temperature exceeds 40 deg. Celsius.
Design (if required specially), Erection & Removal of Form work.
The design and erection of formwork shall be as per IRC- 87 & conforming to MoRT&H
section 1500. Convenient removal of the shutter without disturbing the concrete shall be
ensured. Design shall be to facilitate proper and safe access to all parts of formwork.
Staging shall have cross bracing and diagonal bracing in both directions. Staging shall be
provided on firm strata.
The inside surface of the forms shall be coated with approved release agent supplied by the
reputed manufacturer to prevent adhesion of concrete to formwork. Application shall be
strictly as per manufacturers instruction and shall not be allowed to come into contact with
any reinforcement & other embedment.
The formwork shall be removed in such a way that it does not cause damage to the concrete
surface. Centering shall be lowered gradually and uniformly to prevent the concrete to take
stress due to its own weight uniformly and gradually to avoid any shock or vibration. Period
of removal shall be as per section 1500 of MoRT&H.
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FORMWORK:
Formwork shall conform to section 1500 of MoRT&H Specifications. Material

and

components used for formwork shall be examined for damage or excessive deterioration before
use/reuse and shall be used only if found suitable after necessary repairs.
Mostly steel formwork shall be used. The steel used for forms shall be of such thickness that
the forms remain true to shape. All bolts should be countersunk. The use of approved internal
steel ties or plastic spacers shall be permitted. Structural steel tubes used as support for forms
shall have a minimum wall thickness of 4 mm.
CONSTRUCTION JOINTS:
Construction joints shall be provided as minimum as possible and shall be as per drawings.
Laitance shall be removed before fresh concrete is cast. The surface shall be roughened
enough not to dislodge the coarse aggregate. Concrete may be brushed with stiff brush in its
green stage at the location of construction joint. Fully hardened concrete shall be treated
with mechanical tools to remove the laitance.
CURING:
Water curing shall be done with water specified in section 1000 of MoRT&H. Exposed
surface of concrete shall be kept continuously in a damp or wet condition by ponding or by
covering with a layer of sacks, canvas, Hessian or similar materials and shall be kept
constantly wet for a period of not less than 14 days from the date of placing the concrete.
FINISHING:
Finishing shall be done as specified in clause 1714 of Section 1700 MoRT&H.
7. PLANTS AND EQUIPMENTS

Batching Plant

Transit Mixer

Vibrator rod type

Water tanker

Diesel Generator set

8. QUALITY CONTROL
Sl.
No.
1.

Item

Ref. Code

Tests on quality concrete

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Frequency

Cement (Physical & Chemical IS:268/81/

1.

Tests)

1.1.1
1.1.2
1.1.3
1.1.4
2.

112/12269

Consistency
Initial and Final setting time
Soundness
Fineness
Fine Aggregate & Coarse

1 Test/lot
1 Test/lot
1 Test/lot
1 Test/lot

Aggregate

1.2.1 Gradation

IS:2386(Pt 1)

1 Test/days work

1.2.2 Deleterious content Test

IS:2386(Pt 2)

1 Test/days work

1.2.3 Water Absorption

IS:2386(Pt 3)

1.2.4 AIV/LAV

IS:2386(Pt 4)

1.2.5 Soundness

IS:2386(Pt 5)

1.2.6 Alkali Aggregate Sensitivity

IS:2386(Pt 7)

3.
Water
1.3.1 Chemical Tests
4.
Reinforcement Steel

IS 456

Min. 1 Test/day for coarse

Aggregate & 2 tests for Fine
aggregate
1 Test/source of supply & every
month
1 Test/source of supply & every
month
1 Test/source of supply & every
month
Once per approved source

Relevant IS
5.

Concrete

Specification
(IS 432 (Pt 1)/

One/lot

IS 1786
Workability of fresh concrete
5.5.1
(Slump Test)
5.5.2 Consistency
Cube Test (Strength) 7 days & 28
5.5.3
days
9.

IS 1199

1 Test/10 m3

IS 1199

1 Test/10 m3

IS 516

4 plus one additional sample for

each additional 50 m3

SAFETY
Traffic shall be maintained over a reasonably smooth traveled way which shall be so marked
by signs, delineators, guiding devices and other methods that a person who has no
knowledge of conditions may safely and with a minimum of discomfort and inconvenience
ride, drive or walk, day or night, over all or any portion of the highway and/ or structure under
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construction where traffic is to be maintained. The contractor is placed on notice that

maintenance and protection of traffic over a highway during construction is considered as
important as the construction itself. The contractor shall, therefore, at all times conduct his
operations in a manner to insure the convenience of all travelers and the abutting property
owners and their safety as well as the safety of his own employees.
10.

MEASUREMENT FOR PAYMENT

Quantity of work done will be taken in cubic meters as per the dimension in the working
drawings.

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