METHOD STATEMENT

Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi

Method Statement
1180 MW CCPP, Bhikhi
Central Control Room & Switchgear Building

Rev

R0

Signed
By

Date

Description

26.02.16

Foundation
of
Central
Control
Room & Switchgear
Building

Prepared by:

Engineer
Maj (Retd) Shahid Anwar

Checked by:
Approved by:

Construction of Central Control Room & Switchgear Building

Page 1 of 7

Status
For
Approval

Remarks

METHOD STATEMENT
Central Control Room & Switchgear Building

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi

Table of Contents

1. Scope / Description of Work

2. Attachments
3. Material
4. Equipment / Tools
5. Pre-Start Checks
6. Sequence of Work
7. Concrete Production & Placement:
8. Contingency Plan
9. Post Concreting Corrective Measures
10. Quality Assurance
11. Personnel / Manpower
12. Health and Safety Management and Control Measures
13. Job Risk Analysis

Construction of Central Control Room & Switchgear Building

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Rev. : 00
Date: 26.02.16

METHOD STATEMENT
Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi

1.

Scope / Description Of Work

This method statement covers typical procedure for construction of Central Control Room &
Switchgear Building Foundation.

2.

Attachments:
1. Drawings of Central Control Room & Switchgear Building Foundation

3.

4.

Material:
Sr. Description
Wooden ply
1
Scaffolding Pipes
2
Cement
3
Steel
4
Concrete Admixture.
5

Standard

Equipment / Tools:
Sr #

Description

No. of Items

Remarks

Concrete Batching plant

02

1 Stand by

Mobile Concrete Pump

01

1 Stand by

Transit Mixer

09

2 stand by

Concrete Vibrator

06

02 Stand by

Dump Trucks

08

Flood Lights

08

Construction of Central Control Room & Switchgear Building

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METHOD STATEMENT
Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi

5. Pre-Start Checks
The pre-start checks must cover the following areas:

Availability of plant and equipment to be used

Ground conditions.

Proximity hazards and welfare facilities.

Ensure the construction area has been checked for overhead and underground
services prior to the commencement of work.

6.

Sequence of Work
i. Manual dressing and leveling / trimming will be done at the bottom of the excavation.
ii. Blinding concrete (Thickness = 100 mm) will be placed in one pour prior to commencing
foundation work.
iii. Steel rebar of pile cap and beams connecting the pile caps will be fixed with appropriate
overlapping as per approved drawing. Surveyor will inspect the required elevation of the
steel assembly. Inspection request for steel rebar shall be raised.
iv. Wooden formwork shall be erected for pile caps. Check request for formwork shall be
raised.
v. Site Engineer will ensure that the all the embedded parts (as per drawings) are in place
before commencing the concreting.
vi. Rectification will be carried out as per requirement.
vii. Concrete of desired specifications shall be produced at two Batching plants and
transported to the site in constantly rotating drums of Transit mixers, as per quality &
testing procedures.
viii. Height of fall of concrete shall in no way exceed 1500 mm. Concrete shall be placed in
layers, each having un-compacted thickness of approximately 300mm.
ix. Concreting of whole pile cap will be carried out in one pour.

Construction of Central Control Room & Switchgear Building

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METHOD STATEMENT
Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi
x. Concrete vibrators shall be used and the vibrating process at one point should not
prolong beyond 30~60 seconds in order to avoid bleeding of concrete. To ensure concrete
of homogeneous consistency, proper attention will be paid. Concrete slumps for wall
section shall be 150-200 mm. Collapse slumps shall be avoided.
xi. Steel fixing of piers will commence right after the formwork of pile cap is removed after 24
hours.
xii. Formwork fixing for piers will take place.
xiii. Concrete Pouring for piers will take place. Site engineer will ensure that the steel
assembly is properly placed at required level.
xiv. Top concrete surface of the piers will be rendered rough.
xv. The backfilling will take place.

Construction of Central Control Room & Switchgear Building

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METHOD STATEMENT
Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi
7.

Concrete Production & Placement:

1. Concrete of desired specification shall be produced at batching plant under strict quality
control. Consistency shall be maintained by performing slump tests at regular intervals at
the pouring site, and recorded in dockets. For ring beam slump shall vary between 140
to 200mm. Specimens shall be taken for compressive strength determination as per ACI
Code @ 1 set (6 cubes) for 100 m or less. Additional samples shall be taken if so
desired by the consultants.
2. Concrete shall be transported to the pouring site by means of transit mixers and shall be
poured with mobile pumps. Height of fall of concrete into the object should be less than
1.5 meters to avoid segregation.
3. Compaction is to be carried out with vibrators. Time of compaction with vibrators should
not exceed 30~60 seconds to avoid bleeding. Special attention shall be given to
congested areas and corners.
4. While pouring, care shall be taken with respect to setting of concrete. All activities from
production to pouring, compaction and surface finishing shall be so timed that the risk of
cold joint is eliminated.
5. Surface shall be wooden trowelled up to initial setting time, then by using steel trowel.
6. After final setting the finished surface will be cured with water and later putting socked
jute cloth. The curing process shall last for a minimum period of 7 days.
Note:
During the concrete placement process, dimensions, verticality, diagonal etc. & the level of
pouring shall be closely monitored. Any defects in the dimensions shall immediately be
rectified. In case of major failure like slippage of formwork at any point (which occurs in rare
cases), pouring operation shall be paused, formwork shall be rectified, extra concrete shall
be cleaned away. The whole process shall immediately be performed to avoid any delay.

8.

Contingency Plan

i.

Climate:
MET official web site shall be checked for the weather forecast. No concreting shall be
carried out during inclement weather (i.e. high temperatures, heavy rains etc).

ii.

Production:
a. Materials:
Sufficient stock of all materials shall be ensured.
b. Batching Plant:
Two Batching plants are ready, out of which one shall be operational whereas
the other shall remain stand by to meet any emergency requirement.
c. Transit Mixers:
08 Transit mixers are required to meet the pouring requirement. At least 02
transit mixers shall remain standby.

Construction of Central Control Room & Switchgear Building

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METHOD STATEMENT
Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi
iii. In Case Of Any Equipment Failure
Two mobile pumps shall be operational simultaneously. One mobile crane shall also be present at
the pouring point as contigency arrangement.
04 vibrators shall be required to compact the concrete at one time, 01additional vibrator shall be
stand by.

9.

Post concreting corrective measures:

When the concreted member is stripped off after 24 hours of pouring, surface shall minutely
be inspected. The sizes, verticality and diagonals shall be noted. Any defect shall be treated
as under:
Chipping of the defective, depressed or bulged surface with light chisels and removal
of loose particles.
Soaking the surface with water
Application of Bonding Bridge, consisting of 1 part op cement, 1 part sand and 1 part
liquid (by volume). Liquid is 1 part SBR Bonding Agent + 1 part water. Bonding bridge
shall be applied at saturated surface dry condition in 1 to 2 mm thin layer.
When the bonding bridge is still wet, repair mortar as per following composition.
Portland cement
:
50 Kg
Sand
:
125Kg
Bonding agent
:
7 Liters
Water
:
12Liters
Approximate yield
:
90 Lit
5mm size coarse aggregate (25 kg per 50 kg cement) will be added to above if the
repair depth exceeds 12mm.

10. Quality Assurance:

Quality assurance team will be appointed at the designated site. The team will be headed by
QC in Charge. The QC in charge will be assisted by the assistant QCs. The team will look look
after the following points to ensure the up to standard and quality work.

Lighting of the area by flood lights so work continuous without interruption.

Water pump is provided for continuous supply of water. Water Boozer will also be used
as contingency measure.
Analysis of the project documents and on time submission of the RFI.
Developing the concrete structures quality performance plan.
Checking the Reinforcement assembly and cross check it according to approved bar
bending Schedule.
Delivery, reception and site transport of concrete from the Batching Plant.
Casting, compaction, Cultivation and protection of concrete.
Analysis and preparation of the reports on the procedures of conformity assessment of
concrete with the project.
Subsequent testing of compressive strength of concrete.

Construction of Central Control Room & Switchgear Building

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METHOD STATEMENT

Rev. : 00

Central Control Room & Switchgear Building

Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi

The adjustment of the geometry of the concrete elements of the designed size.
Checking the consistency of fresh concrete on site.

11. Personnel / Manpower:

12.

Site Engineer
QC Engineer
Assistant QCs
20 Steel Fixer
25 Carpenter
20 Scaffolder
20 Mason
20 Labor
02 Surveyor

Health and Safety Management and Control Measure

Personal protective equipment: All operatives will wear the following: safety wellington
boots whilst working , safety helmet, high visibility vest and gloves.
Site rules: All operatives will be informed (via a site induction / toolbox talk) of and
expected to comply with the contractors site rules.
Specific site hazards: Any specific site hazards will be identified and dealt with prior to any
excavation work.
Access to the work area: The provision of a safe means of access to the work area is the
responsibility of the contractor / client.
Falls into excavation: The groundworks sub-contractor must provide and maintain fencing
to prevent operatives from falling into the excavation where required.
Welfare facilities: The contractor / client must provide access to the welfare facilities.

Risk assessment

Measures

Sharp Edges of Metal and

Scaffolding Pipes
Lighting Arrangements for
Night work
During Construction PPEs
must be worn

Sharp edges shall be located and

covered with barricaded tape.
Proper lighting arrangements shall be
provided for night work
During Construction PPEs shall be
worn properly.
During Transportation of equipment,
distance/ safety sign boards shall be
fixed. Transportation area shall be
marked.

Transportation of
Equipment

Construction of Central Control Room & Switchgear Building

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Area In charge
Mr. Malik Zafar(DPM)
Mr. Rashid (Electrical
Forman)
Mr. Shahid
HSE Officer
Mr. Malik Zafar(DPM)

METHOD STATEMENT

Rev. : 00

Central Control Room & Switchgear Building

Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi

Removal of Formwork

Cleaning of Construction
Area

During Removal of Formwork under

the slab, special care shall be ensured
for safety of workers and also for
structure.
After completion of the concrete shall
be much cleaned after completion of
structure.

Mr. Malik Zafar(DPM)

Mr. Malik Zafar(DPM)

10. Job Risk Analysis

Sr.
No.

Activity

Hazard

Working With Ladder

Slip, Trip, Fall,

Electrocution

Working With Hand

Tools

Cut, Bruises,
Electrocution, Slip,
Trip, Fall

Excavating

Employees working
in the ditch; Potential
for Cave-in, Potential
for atmospheric
hazard
Striking personnel
with in radius of
boom Hitting buried
utilities
Crushing, flying,
debris & noise

Recommended Safe Procedure

1. Always face the ladder when climbing. 2.
Ladder must be secured from movement. 3.
Do not use Metal Ladder where there is an
exposure to electrical hazard. 4. Ladder shall
be of the proper size & design for which it is
used. 5. Fall protection must be warned if
working of ladder in excess of 06 feet above
the ground. 6. All ladders shall be erected so
at least three feet of the rail extend over the
landing
1. Inspect each hand tools prior to each use.
2. Appropriate PPE's, Including Hand gloves
should be used when using hand tools. 3.
Never Remove safety guard from power
tools. 4. Portable electrical tools shall not be
lifted or lowered by means of the power cord.
Ropes shall be used. 5. Only appropriate
tools shall be used for the job. 6. Damaged
tools/equipment shall be removed from
service & tagged "DEFECTIVE"
Excavation over 05 feet deep shall be sloped
or shored. Excavation over 04 feet deep
requires confined space permit. Always
monitor at all time while employees are in the
ditch. Completed mark-outs of utilities and
excavation permit prior to start of excavation
work. Wear proper PPE.
The competent person will ensure & examine
area before work. Keep spoils pile at least
three feet from edge of excavation. Keep
non-essential personnel away from work
activities

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METHOD STATEMENT
Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi
Bad weather

Grading

Struck by,
Caught in between,
Noise

Deep Excavation

Wall collapse,
engulfment

Compacting

Wall collapse, noise,

engulfment

Elevated Crane
Operation

Over Head Hazards

Pinch point and
obstruction
Personnel caught
under out rigger
Faulty equipment
Fall hazards
Pinch point
Electrical hazard
Dropping tools on
personnel
Equipment
Damage;
Potential to roll over
crane
Left running &
unattended

If rain/ lightening starts stop all activities &

reassess the situation
Insure that all back up alarms and other
safety equipment are working properly. Wear
seat belt.
Wear safety glasses.
Wear hearing protection during operations
when required by noise level above 85 dB(c).
Safety vests to be worn at all times.
Excavations deeper than 3 ft. in depth require
an excavation plan. The required excavation
plan must be complied with at all times. All
excavation egresss shall be inspected daily
and maintained.
Excavate slopes to 1.5 to 1 ratios, (34
Degrees), install trench box when inadequate
space is available for sloping.
Watch for signs of collapse (tension cracks,
ground settlement, water seepage etc.).
Safe-off excavation area as required.
Insure the vibration does not collapse
excavation. Wear appropriate hearing
protection if the noise levels require it, above
85 dB(c). Have competent person inspect
excavation before work starts every day and
as often as necessary during the shift or after
a rain storm. Safety vest are to be worn at all
times.
Ensure crane is operated by qualified
operator
Never work or walk under load
Tape off or barricade the work area
Keep hand clear of wire rope and rigging
Ensure all personnel are clear of out rigger
before setting
Dont place any part of your body in a pinch
point with load
Utilize appropriate PPEs, hard Hat, safety
Glasses, safety shoes, ear plugs for crane
operation and gloves for rigging
Ensure pre-use inspection has been
completed on crane prior to lift
Review load chart and ensure lift is within
capacity of crane. Never leave crane running
& attending Do not use mobile phone/songs
while operating equipment

Construction of Central Control Room & Switchgear Building

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METHOD STATEMENT
Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi

10

11

12

Area Preparation

General Site Security

General Material
Lifting/Handling

Employee Protection
Slips, trips, falls,
uneven surfaces

Unauthorized access
by HRL populous
Ergonomic Injury
Impact Injury
Back injury-muscle
pulls
Sprains & strains
Lacerations

Hitting People Or
Obstacles On Site
With Truck
Unwanted loss of or
shifting load
Backing vehicle
striking worker
Slips, Nails In The
Foot, Tripping

13

Delivery Of Material
On Site

14

Unloading Trucks

Strains & Struck by

15

Concrete Saw
Cutting and Drilling

Silica dust inhalation

Physically inspect work areas prior to start of

work. Follow good housekeeping practices:
create walkways. Assure materials & debris
does not block traffic. Keep work areas clean
& neat, free from rubbish & debris. Watch
where you walk. Be cognizant of your own
safe work practices as well as those of your
co-workers. Be careful on slopes or
wet/muddy areas. Appropriate warning signs
will be posted
Guard against unauthorized access to
excavation by erecting fencing around the
work area. Protect HRL Populous
Use proper lifting methods, including team
lifting when necessary. Use mechanical
equipment whenever possible. Lift with legs,
keep loads close to body, and dont twist
while picking up loads. Wear cut-resistant
work gloves whenever materials are being
handled.
Drive The Proper Speed Limit (15 km/h) And
Constantly Scan For Potential Accidents
Driver reads and signs off on document.
Have proper PPE available for drivers so they
can exit the cab to remove/tie down loads. Be
sure all items are securely tied and out of
harms way.
Keep loads secure until ready to be removed
from the truck. Effective back up alarm and/or
flagger to direct truck while backing. All wood
scraps, nails, banding must be cleaned up
immediately and placed in containers.
Utilize Proper Rigging And Equipment. Slings
and chains must be inspected prior to use,
and be designed for the proper lifting capacity
of the load. Follow manufacturers
recommendation on all equipment. Driver will
stay clear of unloading and loading
operations
Use engineering controls and wetting of
concrete as a containment method to prevent
any dust When sawing concrete, use saws
that provide water to the blade. Use adequate
respiratory protection when source controls
cannot prevent dust. Utilize proper personal
protective equipment

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METHOD STATEMENT
Central Control Room & Switchgear Building

Rev. : 00
Date: 26.02.16

(Foundation)
1180 MW COMBINED CYCLE POWER PLANT, Bhikhi

16

Site Maintenance

Personal Injury
Tripping & falling
Property Damage

Be sure all debris & material are stored to

avoid tripping hazard. All work areas are kept
clean
All work areas are secure from unauthorized
access

Construction of Central Control Room & Switchgear Building

Page 12 of 7