Method Statement - Structures Nfrly 1

VNR Infrastructures Limited,
Hyderabad
Project Name C i v i l E n g i n e e r i n g w o r k s f r o m 0 . 0 0 K m t o 4 2 . 0 0 K m
between Siliguri junction to Galgalia (excluding) in connection
wit h S GU J AU B gu age con v er s ion pr oject u nder D y C h ief En gin eer
Constrution NF Rly New Jalpaiguri
Method Statement for Structures
Version No. 0.00

th
Dated 06 Feb, 2009
This document and its contents are the property of VNR Infrastructures Limited. No part of this
Document can be reproduced in any from (including photocopying or storing in any medium by electronic means)
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TABLE OF CONTENTS
1. METHOD STATEMENT FOR CONSTRUCTION OF PIER & PIER-

CAP..............................5
1.1. PURPOSE
.....................................................................................................................................
.5
1.2. OBJECTIVE
....................................................................................................................................
5
1.3.
SCOPE............................................................................................................................
............... 5
1.4. REFERENCE DOCUMENTS
........................................................................................................... 6
1.5. RESPONSIBILITIES
........................................................................................................................ 7
1.6. CONSTRUCTION MATERIAL DETAILS
........................................................................................... 8
1.7. SEQUENTIAL CONSTRUCTION ACTIVITIES
.................................................................................. 9
1.8. TESTING & RECORD
................................................................................................................... 18
1.9. EQUIPMENTS TO BE USED
.......................................................................................................... 19
1.10. HEALTH, SAFETY AND ENVIRONMENT
.................................................................................. 20
1.11. QUALITY ASSURANCE AND QUALITY CONTROL
................................................................... 20
2. CONSTRUCTION METHODOLOGY FOR PILE-
CAP..........................................................21
2.1. PURPOSE
....................................................................................................................................
21
2.2.
SCOPE............................................................................................................................
............. 21
......................................................................................................... 21
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...................................................................................................................... 22
......................................................................................... 23
................................................................................ 24
................................................................................................................... 31
2.8. EQUIPMENT TO BE USED
............................................................................................................ 32
2.9. HEALTH, SAFETY AND
ENVIRONMENT....................................................................................... 33
.................................................................... 33
3. METHODOLOGY FOR CONSTRUCTION OF PRE-CAST
SEGMENT...............................34
3.1.
SCOPE............................................................................................................................
............. 34
3.2. MATERIALS
.................................................................................................................................
34
3.3. PRE-CASTING CELL COMPONENTS DEFINITION
....................................................................... 34
ST
3.4. CASTING 1 TYPICAL SEGMENT
............................................................................................... 37
3.5. QUALITY CONTROL OF CONCRETE
........................................................................................... 40
3.6. CONCRETE PRODUCTION DETAILS
............................................................................................ 40
3.7. CONCRETE TRANSPORTING AND PLACING SEQUENCE
........................................................... 41
3.8. CURING
......................................................................................................................................
. 41
4. METHOD STATEMENT FOR CONSTRUCTION OF REGULAR PILING WORKS
............42
4.1. PURPOSE
....................................................................................................................................
42
4.2. OBJECTIVE
..................................................................................................................................
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42
4.3.
SCOPE............................................................................................................................
............. 42
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......................................................................................................... 43
...................................................................................................................... 43
......................................................................................... 45
................................................................................ 45
................................................................................................................... 59
.......................................................................................................... 60
ENVIRONMENT ................................................................................... 61
.................................................................... 61
5. METHOD STATEMENT FOR INITIAL PILE LOAD TEST
...................................................62
5.1. PURPOSE
....................................................................................................................................
62
5.2.
SCOPE............................................................................................................................
............. 62
......................................................................................................... 63
...................................................................................................................... 63
......................................................................................... 64
................................................................................ 64
................................................................................................................... 75
ENVIRONMENT....................................................................................... 75
5.9. QUALITY ASSURANCE AND QUALITY
CONTROL ........................................................................ 76
6. METHOD STATEMENT FOR WORKING PILE LOAD TEST
..............................................77
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6.1. PURPOSE
....................................................................................................................................
77
6.2.
SCOPE............................................................................................................................
............. 77
......................................................................................................... 78
...................................................................................................................... 79
......................................................................................... 80
................................................................................ 80
................................................................................................................... 97
ENVIRONMENT....................................................................................... 97
6.9. QUALITY ASSURANCE AND QUALITY
CONTROL ........................................................................ 98
7. METHOD STATEMENT FOR LATERAL PILE LOAD TEST
...............................................99
7.1. PURPOSE
....................................................................................................................................
99
7.2.
SCOPE............................................................................................................................
............. 99
7.3.
REFERENCES ...................................................................................................................
........... 99
7.4. PREPARATION OF LOAD TEST ARRANGEMENTS
...................................................................... 99
7.5. CALIBRATION OF INSTRUMENTS / EQUIPMENTS
..................................................................... 100
7.6. TEST PILE DATA
....................................................................................................................... 100
7.7. TEST PROCEDURE
................................................................................................................... 100
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7.8. TABULATION OF
RESULTS ........................................................................................................ 101
7.9. CONCLUSION
............................................................................................................................ 101
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8. METHOD STATEMENT FOR DYNAMC TESTING

............................................................ 102
8.1.
EQUIPMENT.....................................................................................................................
.......... 102
8.2. TEST PROCEDURES
................................................................................................................. 102
8.3. BENEFITS OF PDA TESTING
.................................................................................................... 103
9. Earth Work and embankment ...............................
104
9.1. PURPOSE
..................................................................................................................................
104
9.2.
SCOPE............................................................................................................................
........... 104
....................................................................................................... 105
.................................................................................................................... 106
....................................................................................... 107
.............................................................................. 108
................................................................................................................. 117
........................................................................................................ 118
ENVIRONMENT..................................................................................... 118
.................................................................. 119
10. METHODOLOGY FOR CONSTRUCTION OF BOX CULVERT.....................................
120
10.1.
SCOPE ............................................................................................................................
....... 120
10.2. MATERIALS
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........................................................................................................................... 120
10.3. CONSTRUCTION EQUIPMENTS
............................................................................................. 120
10.4. SEQUENCE OF
CONSTRUCTION ........................................................................................... 121
10.5. QUALITY CONTROL OF CONCRETE
..................................................................................... 122
10.6. CONCRETE PRODUCTION DETAILS
...................................................................................... 122
10.7. CONCRETE TRANSPORTING AND PLACING
......................................................................... 122
10.8. CURING
.................................................................................................................................
122
ENVIRONMENT ................................................................................. 123
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1. METHODSTATEMENTFORCONSTRUCTION OFPIER & PIER-CAP
1.1. Purpose
The purpose of this procedure is to follow uniform work methodology and to perform
various activities in sequence for construction of Pier and Pier-cap.
1.2. Objective
To summarize proposal for the construction of Pier & Pier cap works associated with the
Elevated Highway Project. Principle methodology is presented and a general sequence of
construction / erection is proposed.
The construction of Pier & Pier-cap shall be completed with a two sets of specially
manufactured Pier formwork along with attachments to cast Anchor & Expansion piers.
The Pier & Pier-cap shall be cast in one go in a single form. The area in which Pier & Pier-
cap is working shall be suitably leveled, compacted and made secure with barricading
boards. Necessary services such as Service crane, Concrete pump with line, Vibrators,
Curing Tank, Trailer, Welding generators, Lighting arrangements, Transit mixtures, etc.,
shall be provided to complete the pier & Pier-cap works. Storage area for steel
reinforcement and attachments shall be provided close to the working location.
1.3. Scope
This procedure is applicable to the execution team. The work shall include the following
construction activities.
I) At Site
a) Layout of Pier/ Pier Plinth

b) Pier Kicker Setting-out
c) Pier Kicker Construction
d) Fabrication of re-bars
e) Fixing of storm water drain pipe & all other embedded parts
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f) Placing, positioning & tying of Rebar

g) Placing of pier & Pier-cap forms
h) Closing of pier formwork
i) Aligning of pier & Pier-cap form.
j) Final checking
k) Concreting
a. Placing & Compaction of concrete
b. Finishing of the concrete
c. Curing arrangements for the finished concrete.
l) Restoration of Excavated Surface
II) Offsite activities
a) Design of pier & Pier-cap formwork

b) Fabrication of pier & Pier-cap formwork
c) Transporting of Pier & Pier-cap formwork
d) Assembling of Pier & Pier-cap formwork.
e) Fabrication & erection / fixing of embedded parts.
f) Producing, transporting of the concrete
1.4. Reference Documents
Sr. No. Document Title Document Details
1 Concrete Mix Specification Mix design submitted to client and approval taken
2 QA/QC Plan As Per client QAP
3 Drawing.
4. Yard Layout
5. Form work Drawing
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1.5. Responsibilities
Following are the responsibilities of personnel involved in the scope of this procedure.
Sr. Category Responsibilities

No.
1 Engineer In-charge He shall be responsible to control the activities for the

laying of concrete.
2 Section In -charge (Sub- Shall report to the EIC. Shall be responsible for overall
structure) implementation, and control of construction activities for
the setting-out, laying of concrete, etc.. Shall be
responsible for overall monitoring and control of man
power, transport facilities etc.
3 Site Engineers Shall report to Section In -charge. Shall be responsible for

execution and implementation of all site activities related
to this procedure.
Shall be responsible for concrete pouring.
4 Site QA/QC In charge Shall report to EIC and shall be responsible for overall
(Civil) implementation, monitoring and control of QC activities.
5 QC Engineer Shall report Site QA/QC In-Charge.
Shall be responsible for overall control and inspection of

QC activities as per checklist and QAP at site during
concrete work.
Shall be responsible for performing all checks and taking

slump / temperature tests and accepting / rejecting
concrete.
6 Safety Officer Shall report to EIC at site.
Shall be responsible for all safety aspects
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1.6. Construction Material Details
a) Concrete
S. No Material Specifications Source
1 Cement IS 12269 Birla, Ultratech, ACC,
Ramco, etc.,
2 Aggregates IS 383 Approved sources
3 Water IS 456 Approved sources
4 Admixtures IS 9103 MBT/ Fosroc/ Sika
b) Reinforcement Steel
1 All dimensions of IS 1786-Fe500 TISCO/ SAIL/ RINL
Reinforcement etc
Steel
c) Structural Steel
1 All dimensions of IS 2062 TISCO/ SAIL/ RINL
Plates, etc
Other construction material shall be procured on later stages as and when need arises.
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1.7. Sequential Construction Activities
I. At Site
a) Layout of Pier/Pier Plinth Construction of pier & pier-cap shall start after completing
the construction of pile-cap / open foundation. Layout of Pier/ Pier plinth shall be
marked on top of pile-cap for alignment and levels in accordance with approved
drawings. The same shall be duly offered for checking for Client and for review to IC.
If the difference between Pile-cap top and Pier-cap top is of non standard length Pier
plinth shall be cast in advance to the Pier kicker. The Plinth dimensions shall be of
100mm more on either side to facilitate the construction of Pier Kicker & Pier.
Barricadi
ng
Main
Carriageway
Pier
Plinth
Granular
Fill
Pile-
cap/Footing
Pile
Cross Section of Pile-cap/Open foundation
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b) Pier Kicker Setting-out After construction of Pier Plinth Setting out for the Pier kicker
shall be clearly marked over the Pile-cap/Pier plinth. This shall be done using neat
cement mortar. With the help of Distomat, the approved Pier setting-out details shall be
translated on top of the Pile-cap/Pier Plinth. The same shall be offered for Client for
their checking and to review by IC.
Barricadi Pier
ng Rebar
Main
Carriageway
Pier
Kicker Pier Plinth
Granular
Fill
Pile-
cap/Footing
Pile
Construction of Pier Kicker

c) Pier Kicker Construction After approval of the setting out by Client specially fabricated
Kicker form shall be placed in position and properly supported. Any loose concrete/
material on top of the Pile-cap/Pier plinth shall be removed and the surface shall be
made wet. Concrete shall be laid as per specified approved design mix M-50 grade
3
concrete shall be produced from 30 m / hr. batching plant and shall be transported to
location through transit mixer. Concrete shall be placed in position with the help of
wheel barrow or with gamela. Concrete shall be leveled & compacted with internal
needle vibrator of 40mm needle and hand float of wooden section to get the required
level as per the approved drawing. Curing of concrete shall commence immediately
after 8 to 10 hours of placement. Curing shall be done by covering with wet Hessian
cloth / or sprinkling water on concrete surface. The layout/ centre/Outer line shall again
be transferred over the Pile-cap/footing as a reference for further construction activities
d) Fabrication of rebar The rebar for the pile-cap i.e. both main and stirrups shall be
fabricated at yard as per the approved BBS and shall be transported to site.
e) Placing, Positioning and Tying of Rebar False work for fixing rebar shall be erected
in position along with templates for controlling the rebar position. Then the fabricated re-
bars shall be placed in position and tied with each other to maintain its position. Then
the cover blocks shall be fixed to the rebar to maintain the cover to the reinforcement.
The final alignment of the rebar shall be checked with reference to the templates and
any errors in the same shall be rectified.
Rebar False Rebar Templates
work
Barricadi Pier
ng Rebar
Main
Carriageway
Pier
Kicker Pier Plinth
Granular
Fill
Pilecap/Footin
g
Pile
Placing, Positioning & Tying of Rebar
The same shall be offered for inspection to Client and to IC for review. After inspection
by client / IC the site instructions shall be attended.
f) Fixing of Storm Water drain down take & Other Embedded Parts After completing
rebar works for the pier & Pier-cap, storm water drain down take and other embedded
parts shall be placed in its final position.
Rainwater down
take
Barricadi Pier
ng Rebar
Main
Carriageway
Pier
Kicker Pier Plinth
Granular
Fill
Pile-
cap/Footing
Pile
Fixing of Storm Water Pipe
And then the false work for the same shall be removed from the location
g) Placing of Pier & Pier-cap Formwork After fixing storm water drain down take
and other embedded parts, the Pier & Pier-cap formwork shall be placed in position
along with false work. Prior to the placing of pier formwork in position form surface
shall be applied with form releasing agent. The entire assembly shall be positioned
along with temporary works and inserts.
h) Closing of Pier form work After placing in to final position all the form members shall
be closed with the screw jacks and then bolted.
i) Alignment of complete Assembly After closing the Pier and Pier-cap forms the entire
assembly shall be aligned to its final position. The supports and the false work shall
be locked after final alignment.
j) Final Checking The entire assembly shall be given for the final checking to the CLIENT
and to IC for review. The readiness of the pour shall be first checked by CLIENT for
layout, reinforcement etc. and then the RFI shall be raised to CLIENT for pouring of
concrete.
k) Concreting The Engineers representative at site shall inform to their Q.C.

representative at casting yard to start concrete production, after giving approval for
concrete pour. Before commencement of concreting the pour area shall be made free
from pieces of timber, rebar, and other foreign material. If necessary the earlier concrete
area shall be cleaned with air or water jet.
i) The concrete grades of M50, (with or without Fly ash) are required in the project.
CLIENT & PMC had jointly taken trial mixes and the mixes were reviewed by IC.
3
The concrete produced in 30m /hr. capacity batching plant shall be transported
to the yard by means of transit mixers. The capacity of the transit mixers shall be
3
6m . All transit mixers shall be insulated properly and kept wet till completion of
concrete for better retention.
ii) Concrete Placement Concrete shall be conveyed to placement point through /

Concrete pump with stationary pipe line.
iii) Concrete Compaction Freshly laid concrete shall be duly vibrated in layers by
mechanical vibrator, to ensure the full compaction of concrete and reach of
concrete in all corners and pockets of the pour. Around embedded parts, care
shall be taken while vibrating the concrete.
The concrete shall be vibrated to achieve maximum density. For this purpose
immersion type high frequency needle vibrators shall be used and the vibrator
needle shall always be inserted vertically. The vibrator needle shall be allowed to
penetrate in the concrete by its own weight and external force shall not be
applied. Insertion of the vibrator needle shall be done at an interval of 400 to 600
mm (influence area of needle is generally 10 times the diameter). The best
vibration time is 15 to 20 seconds.
Over vibration shall be avoided. In case plastic shrinkage cracks are noticed
during concrete in spite of all precautions being taken the rectification work shall
be as follows
a) The loose material surrounding the crack shall be removed by scrapping with
the trowel. A local bund shall be made around the crack where ever needed.
b) Cement slurry shall be poured in the crack within the bund.
c) The cement slurry shall be removed with a cloth after half an hour. The bund
shall also be removed.
d) The area shall be finished with a trowel.
e) The area shall be rubbed with Carborondum stone after 72 hours.
iv) Curing of Concrete After 8 to 10 hours of concrete pour, curing shall be started
by covering with wet Hessian cloth or sprinkling of water on it.
l) Backfilling of the Foundation After casting of Pier & Pier-cap, the excavated area
shall be backfilled as per the specifications. And the surfaces shall be restored.
II) At Offsite
a) Design of Pier & Pier-cap Formwork Form work and falsework design shall
be carried out as per ACI standards. The design of Pier& Pier-cap shall be
conceptualized such that the entire pier shall be cast in single pour. The geometry of the
pier form shall be maintained throughout the construction period.
b) Fabrication of Pier & Pier-cap formwork Fabrication agency for manufacturing

pier form shall have a experience in manufacturing similar type of forms for the
elsewhere projects.
c) Transportation of Pier form As the dimensions of pier cap or of 6mx3.6m a
special
transporting vehicle has been engaged to ship the Pier& Pier-cap form from Surat to
Bangalore.
d) Assembling of Pier & Pier-cap Formwork Form received at site shall
be assembled to its final position and trial run of the entire assembly shall be carried out.
After completion of successful trials the same shall be erected in its final position.
e) Fabrication of embedded parts All the inserts required for the job shall be
fabricated in advance.
f) Concrete The concrete grades of M50, (with or without Fly ash) are required in
3
the project. The concrete produced in 30m /hr. capacity batching plant shall be
transported to the yard by means of transit mixers. The capacity of the transit mixers
3
shall be 6m . All transit mixers shall be insulated properly and kept wet till completion of
concrete for better retention.
1.8. Testing & Record
The following routine test shall be carried out on the fresh concrete during concrete work
and to be carried out prior to placing of concrete.
Slump/workability test shall be carried out at the pouring location. Records shall be kept for
all batches of concrete and sampling of concrete shall be done. The Pour card/Slump test
report and recording of following shall be done
-Location/Volume of concrete.
-Grade of concrete.
-Concrete mix used.
-Slump of concrete.
-Sampling of concrete for test cube.
Concrete cubes shall be cast for compressive strength tests. Frequency of testing shall be
as per IS 456 2000.
3
Quantity of concrete in m No. of samples
0-5 1
6 - 15 2
16 - 30 3
31 - 50 4
3
51 & above 4 plus on additional sample for each 50m
or part thereof
Half of the total cubes cast shall be crushed for 7 days compressive strength and the
remaining half shall be crushed for 28 days compressive strength.
Additional cubes shall be taken for testing on 1 day & 3 days for de shuttering and lifting
etc.
1.9. Equipments to be used
Following is the list of various equipments to be used for lean concrete -

S. No. Equipment Description Unit Quantity
3
1 Batching Plant 30 m / hr or more capacity Nos. 1
2 Cement Silos No. 2
3
3 Transit mixer 6 m Capacity Nos. 1 to 3
Nos
4 Vibrators with 60 mm needles Nos 4
5 Chute Nos 1 to 3
6 Concrete Pump Nos 1
7 Crane with bucket Nos 1
8 Hand Float of Wooden /aluminium box section Nos. 1
9 Survey equipment Set 1
10 Cube moulds Nos. As

required
11 Slump cone Nos. 1
1.10. Health, Safety And Environment
Only authorized equipment / personnel will be allowed within the working area.
All utilities shall be identified and protected.
All lifting tools and tackles shall be periodically inspected against any damage.
All workmen, supervisors and engineers shall use proper personal protection gears.
All employees shall follow the Project Health & Safety Rules.
1.11. Quality Assurance And Quality Control
QA/QC shall be followed and maintained by complying with the procedure, relevant
check list, sheet/formats.
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2. CONSTRUCTIONMETHODOLOGY FOR PILE-CAP
2.1. Purpose
various activities in sequence of open foundations/ pile caps / Plinth pier / Pier etc.
2.2. Scope
a) Layout of Structure
b) Earth work in excavation
c) Laying of PCC
d) Cutting, bending and laying of reinforcement as per approved drawings.
e) Providing shuttering for concrete formations.
f) Fabrication & erection / fixing of embedded parts
g) Producing, transporting, placing and compaction of the concrete in various

structural elements such as Footing, pile caps, Piers etc.
h) Finishing the exposed faces of concrete to specified finish.
i) Cutting arrangements for the finished concrete.
Mix design shall be submitted to client and take

1 Concrete Mix Specification
approval before use
2 QA/QC Plan As per client QAP
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Following are the responsibilities of personal involved in the scope of this procedure.
Sr. No. Category Responsibilities
He shall be responsible to control the activities for

1 Engineer in-charge
the laying of concrete.
Shall report to the lC. Shall be responsible for

overall implementation, and control of
2 Section in-charge construction activities for the laying of concrete.
Shall be responsible for overall monitoring and
control of man power, transport facilities etc.
Shall report to Section in-charge. Shall be

3 Site Engineers responsible for execution and implementation of
all shall be responsible for concrete pouring.
Shall report to ElC and shall be responsible for

4 Site QA/QC in charge (Civil) overall implementation, monitoring and control of
QC activities.
Shall report site QA/QC In-charge.

Shall be responsible for overall control and
inspection of QC activities as per checklist and
5 QC Engineer QAP at site during concrete work.
Shall be responsible for performing all checks
and taking slump / temperature tests and
accepting / rejecting concrete.
Shall report to ElC at site.

6 Safety Officer
Shall be responsible for all safety aspects.
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a) Concrete
1 Cement IS 12269 Birla, Ultratech, ACC etc
2 Microsilica ASTM-C-494 Elkem
4 Water IS 456 Approved sources
5 Admixtures IS 9103 MBT/ Fosroc/ Sika / Don etc
All Dimensions of
1 IS 1786 Gr Fe500 TISCO/ SAIL/ RINL etc
Reinforcement Steel
c) Structural Steel
All Dimensions of
1 IS 2062 TISCO/ SAIL/ RINL etc
Reinforcement Steel
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All structures shall start after carrying out survey for alignment and levels in accordance
with approved drawings. Grid pillars shall be constructed at regular intervals and reference
for construction shall be taken from these grid pillars. The same shall be duly checked and
approved by client.
b) Earth Work excavation for open foundations Layout of excavation

area
The area to be excavated shall be clearly marked over the ground. This should be done
using lime powder or similar means. Area to be excavated should be sufficient to allow for
the working space. Initially the Road portion shall be excavated with the help of pavement
braker attached to compressor. Depending upon the site condition, either the mechanized
or the manual excavation shall be done to reach the level as required by the drawings /
specifications.
If any utilities are encountered at the time of excavation the same shall be informed
immediately to the local authorities for removal / diversion to avoid ideal of equipment and
man power. Maytas & client shall follow up with local authorities. After reaching to hard
strata approval from client/IC shall be taken for further activity.
Barricade
Main Carriageway Main Carriageway
Median
Hard Strata
Cross Section of Road after Excavation

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c) Earth work in excavation for pile-cap Layout of excavation
area
The area to be excavated shall be clearly over the ground. This should be done using lime
powder or similar means. Area to be excavated should be sufficient to allow for the working
space. Initially the road portion shall be excavated with the help of pavement breaker attach
to compressor. Depending upon the site condition, either the mechanized or the manual
excavation shall be done to reach the level as required by the drawings / specifications
immediately to the local authorities for removal / diversion to avoid ideal of equipment and
mam power. Maytas & client shall follow up with local authorities. After reaching required
level approval from client/IC shall be taken for further activity.
Barricade
Median
Required Level
Bored Cast-
in-situ Piles
Cross Section of Road after Excavation for Pile-cap
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Removal of spoil concrete for pile
After excavation of the surface for pile-cap up to the required level the excess and spoil
concrete shall be removed up to the pile cut off level I.e. 150mm above the pile-cap bottom,
with the help of concrete breaker attached to compressor or with electro pneumatic
breakers as per the site conditions. Then the pile surface will be cleaned and any loose
concrete / disturbed concrete will be removed from the surface.
Barricade
Median
Required Level
Bored
Cast-in-
Cross Section of Pile-cap after removal of spoil cone

d) Laying of PCC
The strata on which PCC shall be laid to be cleaned for any loose soil, debris etc. PCC
shall be laid as per specified approved design mix M-15 grade concrete shall be produced
3
from 30 m /hr. batching plant at casting yard and shall be transported to location through
transit mixers. Concrete shall be placed in position with the help of a chute. Concrete shall
be leveled & compacted with hand float of wooden / aluminum box section. Curing of
concrete shall commence after 8 to 10 hours of placement. Curing shall be done by
covering with wet Hessian cloth / or sprinkling water on concrete surface.
The layout/ centre line shall again be transferred over the PCC as a reference for further
construction activities. The rebar positions for the pile-cap / Open foundations will be
marked in the layout and shall be checked by the Site Engineers for the foundations.
Barricade
Median
PCC
Bored Cast-
in-situ Piles
Cross Section of Pile-cap after Laying PCC

e) Reinforcement
All the reinforcement used shall conform to IS 1786 grade Fe500. The bars shall be placed
/ stacked on wooden sleepers / Masonry walls. The bars shall be stacked in lot and
diameter-wise at Yard. Cutting bending of reinforcement will be done at yard and will be
brought to site through trailers/trucks and will be temporarily stacked at location bar mark.
Then the re-bars will be placed on top of the already laid PCC of Pile-cap/Open foundations
with required cover blocks of size 75x75x50mm. And tying of reinforcement shall be as per
approved BBS / drawings with annealed MS binding wire of every junction. After completion
of the fixing of Pile cap/Open foundation reinforcement pier starter bars shall be placed with
template and will be held firmly with pile-cap reinforcement and from ground support. The
alignment of the pier starter bars shall be maintained throughout the operations of pile-cap /
open foundation concrete. Due care will be taken for maintaining the required concrete
cover to reinforcement. The cover blocks shall be PVC or of higher grade of concrete
already cast and cured at laboratory.
f) Embedded Parts All the embedded parts shall be fixed as per drawings.
Barricade
Main Main Carriageway
Pier Started
Shuttering
Pile-cap re-bars
PCC
Bored Cast-
in-situ
Cross Section of Pile-cap after Rebar fixing

g) Formwork
The formwork shall have sufficient strength to withstand the weight and pressure of
concrete and other constructional loads without deflection, distortion, bulging or loosening
the supports. Approved brand of Mould releasing agents / Oils shall be applied on
shuttering plates.
h) Concrete
The concrete grades of M15, M35 & M60 (with Microsilica) are required in the project.
MAYTAS & CLIENT will take trail mixes will be reviewed by CLIENT. The concrete
produced in 30m3 /hr. capacity batching plant at casting yard shall be transported to the
site by means of transit mixers. The capacity of the transit mixers shall be 6m3. All transit
mixers shall be insulated properly and kept wet till completion of concrete for better
retention.
i) Concrete Placement
The readiness of the pour shall be first checked by Maytas for layout, reinforcement etc.
and then the RFI shall be raised to client for pouring of concrete. The Engineer's
representative at site shall inform to their Q.C representative at casting yard to start
concrete production, after giving approval for concrete pour. Before commencement of
concreting the pour area shall be made free from pieces of timber, rebar and other foreign
material. If necessary the earlier concrete area shall be cleaned with air or water jet.
Concrete shall be conveyed to placement point through Chute/ Crane bucket / Concrete
pump depending on the necessity and situation. Concrete shall be placed in layers of
450mm thick panels covering the entire plan area in to two/three panels. Then the
successive layers shall be placed within 6hours from the production time of the previous
layer. Due care shall be taken that the two layers shall be properly keyed when the
concrete in green condition.
Barricade
Main Carriageway
Main Carriageway
Pier Starter bars
Shuttering Pile-cap re-bars
PCC
Bored Cast-in-situ
Piles
Cross Section of Pile-cap after Concrete
j) Concrete Compaction
Freshly laid concrete shall be duly vibrated in layers by mechanical vibrator, to ensure the
full compaction of concrete and reach of concrete in all corners and pockets of the pour.
Around embedded parts, care shall be taken while vibrating the concrete. The concrete
shall be vibrated to achieve maximum density. For this purpose immersion type high
frequency vibrators shall be used and the vibrator needle shall always be inserted vertically.
The vibrator needle shall be allowed to penetrate in the concrete by its own weight and
external force shall not be applied.
Insertion of the vibrator needle shall be done at an interval of 400 to 600mm (influence area
of needle is generally 10 times the diameter). The best vibration time is 15 to 20 seconds.
Over vibration shall be avoided. In case plastic shrinkage cracks are noticed during
concrete in spite of all precautions being taken the rectification work shall be as follows
a) The loose material surrounding the crack shall be removed by scrapping with the
trowel.
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b) A local bund shall be made around the crack where ever needed.
c) Cement slurry shall be poured in the crack within the bund.
d) The cement slurry shall be removed with a cloth after half an hour. The bund shall
also be removed.
e) The area shall be finished with a trowel.
f) The area shall be rubbed with Carborondum stone after 72 hours.
k) Curing of Concrete After 8 to 10 hours of concrete pour, curing shall be started by

covering with wet Hessian cloth or sprinkling of water on it.
Slump/workability test shall be carried out at the pouring location. Records shall be kept for
all batches of concrete and sampling of concrete shall be one.
The pour card/Slump test report and recording of following shall be done
Location/Volume of concrete.
Grade of concrete.
Concrete mix used.
Slump of concrete.
Sampling of concrete for test cube.
as per IS 456-2000.
Quantity of concrete in m3 No. of samples
0-5 1
6-15 2
16-30 3
31-50 4
4 plus on additional sample for each

51 & above 3
50m or part thereof
Half of the total cubes cast shall be crushed for 7 days compressive strength and the remaining
half shall be crushed for 28 days compressive strength. Additional cubes shall be taken for
testing on 1 day & 3 days for de shuttering and lifting etc.
2.8. Equipment to be used
Following is the list of various equipments to be used for lean concrete-
3
1 Batching Plant-30m /hr or more capacity Nos. 1
2 Chilling Plant Nos. 1
3
3 Transit mixer-6m Capacity Nos. 3
4 Vibrators with 60mm needles Nos. 4
5 Chute Nos. 2 to 3
6 Concrete Pump Nos. If req
7 Crane with bucket Nos. If req
8 Hand Float of Wooden /aluminum box section Nos. 1
As
10 Cube moulds Nos.
require
2.9. Health, Safety and Environment
2.10. Quality Assurance and Quality Control
QA/QC shall be followed and maintained by complying with the procedure, relevant check list,
sheet/formats.
3. METHODOLOGY FOR CONSTRUCTIONOF PRE-CAST SEGMENT
3.1. Scope
This work shall consist of furnishing and placing structural concrete in accordance with the
specifications and in conformity with the lines, grades and dimensions as shown on the
drawing.
3.2. Materials
All materials shall conform to the specifications.
3.3. Pre-casting Cell Components Definition
The following item descriptions shall be read in conjugation with their respective
fabrication drawings for clarity.
3.3.1. Fixed Bulk head
This steel form work panel is supported by 3 nos. of support frames, which are anchored
to the ground. This will form the match cast face of the segment
There are types of exchangeable bulkhead panels to suit the different web thickness as
follows
275mm
400mm
Fixed bulk head is always used as the reference for geometry control of the new segment.
It is hence of up-most important to ensure that the bulkhead panel shall always be erected
truly vertical and leveled /aligned to the required position.
st
During casting of the 1 segment, fixed and temporarily bulkhead will need to be
additionally secured by some tie rods.
All shear key formers could be removed for duct penetration point if required. All duct
penetration points that are not utilized shall be covered using from plugs. Timber in-filled
pieces shall be used in the case of long slots.
3.3.2. Temporary Bulkhead
This steel form work panel will be required to cast the first segment of every new span. It
is supported by 2 nos. of props, which are anchored to the ground. This will form the end
st st
face of the 1 segment and can be stripped by rotation. Once the 1 segment has been
st
cast the Temporary Bulkhead shall be removed and stored so that the 1 segment could
be moved into conjugate position.
There are two types of exchangeable bulkhead panels to suit the different web thickness
as follows
275mm Type C
400mm Type B & Type A
3.3.3. Soffit form
This steel structure will form the bottom part of the segment. This form is supported by
four nos. of screw jacks. Soffit form consists of two parts
Main Panel
Hinge Panel
Hinge Panel consists of three parts; one no. of middle part (straight) and two nos. of outer
parts (curved). Hinge panel is to be used for casting new segment only. For segment at
match-casting position, this hinge panel shall be swung down to allow the space for over
lapping to the new soffit form.
Soffit form and Outer Form shall be connected together by blots on top parts to ensure
form work alignment. Two nos. of 28 mm dia threaded bar each side shall also be installed
between soffit and outer forms to prevent any movement during casing.
Tie bars shall also be installed between soffit forms of conjugate/new segment and new
segment soffit form to fixed bulkhead frames during casting to ensure no relative
movement occurs.
3.3.4. Outer Form
This steel structure forms the external part of the segment besides the soffit form. They
are equipped with some screw jacks for vertical adjustment and stripping. They are
longitudinally movable (if required) on steel plates with Bronze plates utilized as sliding
system. The transverse adjustment and fixity at the bottom part shall utilize horizontal
screw jacks provided against concrete plinths cast on foundation. These screw jacks have
to be engaged prior to segment casting to prevent transverse movement. Two nos. of 28
mm diameter thread bars per side shall be fixed to soffit forms.
Longitudinal movements of outer forms Type-C is always require when match casting
segments. They could adjust individually to allow the required overlapping of forms with
conjugate segment and fixed bulkhead, which system shall be used for such longitudinal
movement when required.
External vibrators could be mounted at appropriate locations if required to the main

support frames that are 2.2 m apart.
3.3.5. Transfer Cart
This steel frame move longitudinally on guided flat rollers along the segment casting area
and is equipped with hydraulic jacks (6A) and layers of sliding frames for segment
geometry adjustment. It is also utilized for segment stripping and movement from casting
position to conjugate, parking and storage yard locations respectively with winch system.
The segment geometry adjustment can be defined as follows
Rotation in plan This movement is achieved by activating the 2nos of Transverse /

longitudinal jacks each to different combinations.
Transverse translation This movement is achieved by activating the 2nos of Transverse

jack simultaneously.
Vertical adjustment This movement is achieved by activating the 4nos of Vertical jacks
for cross fall and gradient setting out.
3.3.6. Inner Void Form
This steel structure forms the internal part of the segment. It comprises of several panels
to allow systematically stripping of formwork and is mounted to the Void Form Traveler. It
is equipped with some hydraulic jack (6B) and screw jacks for stripping and adjustment.
There are two Inner Void Forms (which are symmetric)
Void 1 &2 For the inner voids of segment, removable / adjustable panels are
combined to form required geometry for 275mm and 400mm thick webs, 2nos per
cell.
Every inner void form is supported on its own form traveler. Tie bars are used to
connect both void forms during casting.
3.3.7. Inner Void Form
This steel frame carries the Inner Void Form and is longitudinally movable on rails by
winch system during operation.
There is only one type of Form Travelers

Traveler of Void For outer void forms of segment, 2nos per cell.
8 tonne concrete block shall be used on traveler void 2 as a counter-weight. At the front
parts, these form travelers are supported by props on either conjugate segment or
st
temporary bulkhead in the case of casting the 1 segment.
st
3.4. Casting 1 Typical Segment
3.4.1. Initial Setup
1. Erect and commission fixed bulkhead
2. Erect and commission outer form Type A and B
3. Erect and commission soffit form with hinge panel
4 Erect and commission temporary bulkhead
5. Erect and commission inner void form 1 and 2 to travelers

6. Erect and commission transfer cart.
3.4.2. Preparation and Casting of Segment
1. Place rebar cage by tower crane and adjust to position with duct stiffening
tubes (PVC pipes) and duct locators inside ducts (except for blister). Tower
crane still holding the rebar cage.
2. Move in inner void form traveler and adjust them to the correct position.
3. Adjust temporary bulkhead to correct position. Engage void form travelers

front support to the temporary bulkhead.
4. Detach rebar cage from tower crane.
5. Fix P/T anchorages and duct locators to bulkheads.
6. Engage inner void forms against the bulkheads.
7. Adjust and close outer forms against the bulkheads.
8. Fix edge forms for deck slab.
9. Install duct stiffening tubes for blisters.
10. Install geometry control inserts, perform final adjustment and final survey.
11. Engage all fixations, longitudinal and transverse form ties, inner transverse
props, outer/soffit form fixation and transverse props, outer/soffit form fixation
and transverse screw jacks of outer forms.
12. Seal formwork joint.
13. Concreting.
nd
3.4.3. Casting 2 and Subsequent Typical Segments
Stripping and movement of Conjugate Segment,
1. Release all cast-in terms from respective fixities.

2. Strip deck slabs edge forms. Partial stressing of deck slab transverse P/T.
3. Disengage longitudinal and transverse form ties.
4. Disengage internal transverse props for inner void form, free duct locators
and recess formers from bulkheads.
5. Strip all inner void forms and move back to parking position.
6. Strip outer forms by rotation.
7. Strip temporary bulkhead and move it to storage area using tower crane. (If
applicable)
8. Strip hinge panel of soffit form at fixed bulkhead side.
9. Move transfer cart to position and load segment (including soffit form),
engage the 4 vertical jacks to required force, free the 4 screw jacks of soffit
form.
st
(a)In the case of 1 segment, break bond between segment and fixed
bulkhead by lowering the 2 vertical jacks at temporary bulkhead side.
nd
(b)In the case of 2 and subsequent segments break bond between
conjugate and new segments by lowering the 2 vertical jacks further from
the match-cast face.
st
10. (a) Move segment to conjugate position in the case of 1 segment.
nd
(b) In the case of 2 and subsequent segments break bond between
conjugate and new segments by lowering the 2 vertical jacks further from
the match-cast face.
11. Blinding of recesses at conjugate segment.
3.4.4. Preparation and Casting of New Segment
1. Relocate soffit form for new segment by tower crane.

2. Move/adjust conjugate segment into required match-casting position using
transfer cart.
3. Move/close soffit form for new segment using transfer cart against fixed
bulkhead and the overlapped soffit of conjugate segment.
4. Place rebar cage by tower crane and adjust to position with duct locators
inside ducts at bulkhead face (except for blister). Tower crane still holding
the rebar cage.
5. Move in inner void form traveler and adjust them to the correct position.
6. Engage void form travelers front support to conjugate segment.
7. Detach rebar cage from tower crane.
8. Fix P/T anchorages and duct locators to bulkheads.
9. Engage inner void forms against fixed bulkhead and conjugate segment.
10. Adjust and close outer forms against fixed bulkhead and conjugate segment.
11. Fix edge forms for deck slabs.
12. Install partially inflated duct stiffening tubes from conjugate segment.
13. Fully inflate duct stiffening tubes from conjugate segment.
14. Install duct stiffening tubes to requirement.
15. Install duct stiffening tubes for blisters.
16. Install geometry control inserts, perform final adjustment and final survey.
17. Engage all fixations, longitudinal and transverse form ties, internal transverse
props, outer / soffit form fixation, transverse screw jacks stopper of outer
forms, soffit form fixity between conjugate / new segment and new segment /
bulkhead.
18. Seal formwork joint.
19. Concreting.
3.5. Quality Control of Concrete
Concrete will be produced in accordance with the approved mix design. Concrete will be
dispatched to site along with the dispatch slip containing grade of concrete, workability of
the concrete, time of production, quantity of concrete etc with duly signed by designated
Quality Control / Production Engineer. The concrete specimens will be cast on site as
per MORT&H Table 1700-8 for determine the strength of concrete at 28 days. Additional
cubes may be required for determine the strength of concrete at 7 days or various
purposes.
3.6. Concrete Production details
The fully automatic batching plants shall be used for production of concrete. Concrete
shall be produced as per the approved mix recipe and controlled and monitored by
Quality Engineer. As per the concrete requisition, the concrete making ingredients will be
tested and reported before producing concrete. Only accepted material will be used for
production of concrete.
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3.7. Concrete Transporting and Placing Sequence
Concrete produced in the batching plant will be transported to pouring point using transit
mixer. The concrete will be poured using concrete pumps. Concrete received at site will
be verified for grade and workability.
Make sure that before concrete pouring

All the forms are thoroughly cleaned.
All joints are tight and sealed.
All ducts are aligned and secured.
All inserts are secured at their specified positions.
All liners are fixed and secured.
The form should be lightly oiled for stripping and the face of the conjugate segment shall
be given a coating of suitable bond breaking agent.
During concreting at site, observation data sheet will be maintained mentioning the full
details of concrete poured including its fresh concrete properties.
Do not let concrete to fall from great height, as this will cause segregation and the
impact can damage ducts and displaces re-bars / inserts.
Loading concrete from webs is not good practice. It can distort rebar cage, displace
ducts and cause poor consolidation.
Use internal vibrator to compact concrete but not to move concrete, as this will cause
honeycombing.
3.8. Curing
Exposed surfaces will be covered with wet Hessian cloth after final setting of concrete
and water will be sprinkled frequently to keep the cloth wet. Formwork will be removed
after the concrete attains 20 MPa strength. Then the segment shall be completely
covered with wet Hessian cloth and the cloth shall be kept wet by sprinkling water
frequently for a period of 14 days.
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4. METHODSTATEMENT FORCONSTRUCTIONOF REGULAR PILING WORKS
4.1. Purpose
various activities in sequence for construction of Regular Piling works.
4.2. Objective
To summarize the proposal for the construction of Piling works associated with the
Elevated Highway Project. Principle methodology is presented and a general sequence of
construction / erection is proposed. The area in which piling rig is working shall be suitably
leveled, compacted and made secure with barricading boards. Necessary services such
as Service crane, Trailer, Scoop Tippers/Dumpers, Loader, Welding generators, Lighting
arrangements, Transit mixtures, etc., shall be provided to complete the piling works.
Storage area for steel reinforcement, cage and attachments shall be provided close to the
Rig working location.
4.3. Scope
I. At Site
b) Aligning the Piling Rig
c) Boring of Pile in soft Strata
d) Installation of Temp/Guide casing
e) Boring of Pile in Hard Strata
f) Termination of Bore
g) Cleaning of Bore
h) Placing & Lowering of Rebar Cage
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i) Lowering of Tremie Pipe
j) Concreting of Bore hole
k) Removal of Guide casing
II. At Casting Yard
a) Cutting, bending, and tying of reinforcement cage as per approved drawings.

b) Transporting Rebar Cage to site
c) Producing and transporting the concrete to site as per the approved mix design.
1 Concrete Mix Specification Mix design shall be submitted to client and take
approval before use
2 Technical Specifications RDSO / IRC Specifications
3 Additional Tech Specifications Tender Document
4 IS2911 Code of Practice for Design & Construction of Pile

foundations
5 QA/QC Plan As per QAP
6 Drg.
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No.
1 Engineer In-charge He shall be responsible to control all the activities for the
construction of piling works.
2 Section In -charge (Civil) Shall report to the EIC. Shall be responsible for overall
implementation, and control of construction activities for
the Piling works. Shall be responsible for overall
monitoring and control of man power, transport facilities
etc.

to this procedure.

concrete work.

concrete.
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a) Concrete
Birla, Ultratech, ACC,
1 Cement IS 12269
Ramco etc
3 Water Cl5.4 of IS456 Approved sources
All dimensions of
TISCO/ SAIL/ RINL
1 Reinforcement IS 1786
etc
Steel
c) Structural Steel
Plates, etc
I. At Site
a) Layout of Structure Construction of Piling shall start after carrying out survey for
alignment and levels in accordance with approved drawings. Grid pillars shall be
constructed at regular intervals and reference for construction shall be taken from
these grid pillars. The same shall be duly checked and reviewed by IC. Then each pile
location shall be marked at ground before starting the piling work for the location.
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Bored Piling
Step -1
1. Set out the positions of Bored Piles as Per construction Drawings

2. Mark the pile positions with pegs
3. Survey the existing ground level at the pile positions.
4. Report to the existing ground level to the section incharge
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b) Aligning the Piling Rig Piling shall be mobilized to the pile location and Rig shall be
positioned by keeping Kelly bar true to vertical at the piling location.
1. Mobilize the boring plant to the intended Bored pile position

2. Position the centre of auger/bucket exactly above the pile point
3. Check the verticality of Kelly bar before boring commences.
4. Offset two reference points perpendicular to each other from the pile
position.
c) Boring of Pile in Soft Strata After aligning the piling rig in position boring in the top
soil shall be commenced with soil barrel buckets / soil augers up to the non collapsible
depth. During boring the verticality of the drilled hole shall be constantly checked. And
also the
position of the bore shall be cross checked with the reference points.
1. Commence boring at the pile position

2. Check the verticality of drilled hole during boring works.
3. Cross check the position of the Bore hole during before advancing
boring works.
4. Observe the stability of the bore hole.
5. Collect the soil samples to verify the strata
6. Observe any Ground water table is available
d) Installation of Guide / Temporary Casing While boring through the soft strata the
stability of the bore is most important to arrest any collapse of the soil in to the bore
and making the shaft in to the constant dia min 12mm thick 1.2m internal dia MS
liner/casing shall be installed up to the bottom of the soft strata with the help of service
crane or secondary winch from the Boring rig.
1. Observe the stability of Borehole during Boring works.

2. If the bore hole is unstable insert a temporary casing in to the bore hole
3. Check the verticality of temporary casing during installation. Use two plumbs
positioned in perpendicular directions to each other.
e) Boring of pile in Soft Strata or & Hard strata after installation of Guide casing
After installation of guide casing boring in to the soft strata shall be advanced further
with soil barrel bucket or soil auger till to the design depth or up to the hard strata.
If hard material is encountered during boring use chisel or rock tools to penetrate in to
the hard stratum.
1. Continue boring with an Auger or boring bucket depending on the soil conditions
as shown in figure A & B.
2. Continue to check the verticality of Kelley bar till the completion of Bore hole.
3. Carryout Boring until the designed depth is achieved or Hard stratum
encountered.
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1. If hard material is encountered during boring, use chisel or rock tools
to penetrate into the hard stratum as shown in the figure.
2. Carry-out boring until the designed depth is achieved.
f) Termination of Borehole After reaching the bore hole the designed depth the same
shall be offered to client/IC for inspection and review. The comments and suggestions
of client/IC shall be attended promptly.
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g) Cleaning of Bore Hole After attending the comments and suggestions given by
client/IC after the inspection cleaning of the base of the bore hole shall be carried out
with a cleaning bucket.
1. After reaching to the design depth, clean the base of borehole with a
cleaning bucket.
2. Verify and confirm the pile length with Engineers representative.
h) Placing & Lowering of reinforcement cage Specially fabricated reinforcement cage

brought to the site shall be checked for the intact & dimensions, cover blocks, etc., and
are appropriate to the intended pile. Sufficient preventive care shall be taken for the
handling disturbances. Then the cage shall be hoist to the service crane and gently
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lowered in to the bore hole. The cage shall be anchored to the guide casing with the
help of 32mm dia re-bars, if any additional length is to be added to form the required
length. Then the second cage shall be hoisted with the help of service crane and
brought to the location and positioned on top the anchored cage. Then the two cages
shall be coupled together firmly and the full cage shall be hoisted to the service crane.
Anchoring arrangements shall be removed and the full cage shall be lowered up to the
pile base.
1. Check & Ensure the reinforcement and dimensions of cage are appropriate for the
intended pile.
2. Ensure that the cage is intact for handling.
3. Ensure the cover blocks are in position
4. Hoist the reinforcement cage to the service crane.
5. Lower the reinforcement cage into the bore hole to the base of bore hole or to the cut-
off-level. Page f53 o
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6. Ensure that the cage is maintained at the cut off level during concreting works.
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i) Lowering of Tremie pipe After placing the reinforcement cage tremie of appropriate
dia i.e. 200/250mm tremie pipe with hopper shall be lowered in to the bore hole. Before
lowering the pipe it will be ensured that the joints are water tight and intact. The gap
between the base of pile and bottom of the tremie shall be kept 150mm if the bore hole
is wet and if it is dry bore the gap between base of pile & tremie shall be maintained
less than 1.5m. A plug is also placed on the hopper for the first charge.
j) Concreting of Bore hole
1. Concreting in Dry hole condition An Indent for the concrete will be sent to the
Centralized batching plant in charge after approval of the borehole for
concreting. Concrete produced as per the approved design mix in centralized
batching plant at casting yard shall be brought to the site through transit mixers
along with the docket specifying the mix details, qty of concrete, bathing time,
initial slum, temperature, etc. After receiving the docket the concrete shall be
sampled for the slum, temperature and cube casting. After the site QC Engineer
certifies the concrete, the concrete shall be discharged directly in to the hopper
of the tremie. When concrete has reached above cut-off- level stop the
concreting works. It shall be ensured the sound concrete has reached above the
cut-off-level.
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1. Discharge concrete directly from the transit mixer in to the hopper.
2. When Concrete has reached above the cut-off-level, stop concreting works.
3. Ensure that sound concrete has reached above the cut-off-levels.
2. Concreting in Wet Hole Conditions An Indent for the concrete will be sent to
the Centralized batching plant in charge after approval of the borehole for
concreting. Concrete produced as per the approved design mix in centralised
batching plant at casting yard shall be brought to the site through transit mixers
along with the docket specifying the mix details, qty of concrete, bathing time,
initial slum, temperature, etc. After receiving the docket the concrete shall be
sampled for the slum, temperature and cube casting. After the site QC Engineer
certifies the concrete, the concrete shall be discharged directly in to the hopper
of the tremie. It shall be ensured that the gap between Base of the Pile and
bottom of the tremie shall be of 150mm. The plug shall be placed in the tremie
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before charging the tremie with concrete. After filling the tremie with concrete
then the plug shall be removed with the help of service crane. Then after
concrete shall be poured in to tremie continuously. It shall be ensured that the
end of tremie shall be in concrete minimum of 3 meters. With draw tremie pipe
as concrete rises upwards. When concrete has reached above cut-off- level stop
the concreting works. It shall be ensured the sound concrete has reached above
the cut-off-level. Extract the Guide/Temporary casing from the bore hole upon
completion of concreting works. It shall be ensured that the guide casing shall be
extracted vertically and no disturbance to the concrete and mixing of soil with the
concrete.
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1. Insert the concrete plug at the top of the tremie pipe hole.
2. Lower the Tremie pipe to the toe of the borehole.
3. Discharge concrete directly from the transit mixer in to the hopper and fill it.
4. Remove tremie plug with the help of service crane.
5. Fill concrete from the bottom of bore hole which displaces the sludge as concrete
rises to the top.
6. Withdraw the tremie pipe as concrete rises upwards.
7. Always maintain minimum 3.0m length of tremie is embedded in to the concrete
during concreting works.
8. When concrete has reached above the cut-off-level withdraw tremie pipe.
9. Ensure that the sound concrete has reached above the cut-off-level.
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1. Extract Guide/Temp casing from the borehole upon completion of concreting
works.
2. Ensure that the temp casing is extracted vertically.
II) At Yard
a) Cutting, bending, and tying of reinforcement cage as per approved drawings All
the reinforcement used shall confirm to IS 1786 grade Fe500. The bars shall be
stacked on wooden sleepers / Masonry walls in a centralised yard at casting yard. The
bars shall be stacked in lot and dia. wise. Cutting bending and tying of reinforcement
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shall be as per approved BBS / drawings for the intended pile. Then cage for the piles
shall be prefabricated in advance as per the schedule and stacked on wooden sleepers
with proper identification. Cover blocks shall be fixed to the rebar cage as per the
requirement. It shall be ensured that the cage shall be intact without distortion during
storage.
b) Transporting Rebar Cage to site After receiving indent from the site piling section
incharge, the intended pile rebar cage shall be once again checked for the correctness
and intactness. Then after the cage shall be loaded on to the trailer with the help of
crane. The rebar cage shall be held properly on the trailer with the help of slings. Then
trailer shall be moved to the site.
c) Producing and transporting the concrete to site as per the approved mix design
The concrete grades of M35, (with Fly ash) are required for the pile shall be produced
after receiving indent from the piling section incharge. The approved mix design for the
3
pile concrete shall be produced in 30m /hr. capacity batching plant at casting yard.
Then concrete shall be sampled for its slum, temperature and cube casting. Then the
concrete shall be transported to the site by means of transit mixers along with the
3
docket.. The capacity of the transit mixers shall be 6m . All transit mixers shall be
insulated properly and kept wet till completion of concrete for better retention.
Slump/workability test shall be carried out at the pouring location.
Records shall be kept for all batches of concrete and sampling of concrete shall be done.
The Pour card/Slump test report and recording of following shall be done
Grade of concrete.
Concrete mix used.
Slump of concrete.
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as per IS 456 2000.
3
Quantity of concrete in m No. of samples
0-5 1
6 - 15 2
16 - 30 3
31 - 50 4
51 & above 4 plus on additional sample for each
3
50m or part thereof
Half of the total cubes cast shall be crushed for 7 days compressive strength and the
remaining half shall be crushed for 28 days compressive strength.
Additional cubes shall be taken for testing on 1 day & 3 days for de shuttering and lifting
etc.

3
2 Trailer No. 1
3
3 Transit mixer 6 m Capacity Nos. 1 to 3 No.s
4 Hydraulic Piling Rig No.s 1
5 Tremie pipe with hopper set No.s 1
6 Service crane Nos 1
7 Guide casing Nos 1
8 Boring tools Set 1
10 Cube moulds Nos. As required
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QA/QC shall be followed and maintained by complying with the procedure, relevant check
list, sheet/formats.
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5. METHODSTATEMENT FOR INITIAL PILE LOAD TEST
5.1. Purpose
various activities in sequence for carrying out for Initial Pile Load Test.
5.2. Scope
activities.
I) At Site
a) Preparation of load Test Arrangements

b) Results & Calibration of Instruments
c) Variation in Temperatures
d) Test Pile Details
a. Drillers Log
b. Pile Log
c. Pile Concrete Pour Card
e) Cyclic Load Test
f) Method of Loading
g) Measurement of Settlement
h) Criteria for Load Test
II) At Off site Location
a) Calibration of Instruments
b) Cube testing
c) Plotting Load Vs. Settlement Curve
d) Plotting the Time vs. Settlement Curve.
e) Test Data Analysis & Reporting.
Page 62 of
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1 Design Booklet Test Pile design report
2 Method Statement Method Statement
3 Contract Document Initial Pile load test requirement
4. IS 2911 (Part IV) As per Client QAP
5. Drg.

No.
1 Engineer In-charge He shall be responsible to control all the activities.
implementation, and control of Load testing activities for
the Initial Pile load test. Shall be responsible for overall
monitoring and control of man power, equipment, transport
facilities etc.

to this procedure.
Shall be responsible for taking levels and making

arrangements.
Page 63 of
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No.

QC activities as per checklist and QAP at site.
The details were reported with the earlier method statements.
I. At Site
a) Preparation of Load Test Arrangements
After the load test assembly is set up using the jacking frame system as described in
the previous method statement for Initial Pile Load Test Arrangements which was shown
in the figure below shall be provided by a safety arrangements and access to the various
elements for inspection during testing and fixing bracings to the main beam girders. After
completion same shall be offered to client/IC for their review and approval for carrying
out the load test. Any comments offered by client/IC shall be attended immediately and
complied before starting the load test.
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Upper Plate Girder
Lower Plate Girder
Pressur
e
Gaug
e
Hydraulic
Jack
Dial gauge
Soil fill
Reference
Beam Magnetic Stressing
Base Pump
Reference
Pillar
Pile
Datum Reference
Scal Frame Scale
e
Rock Anchor
Preparation of Load
Test
Page 65 of
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1. Cube Test for the Concrete and Grout The Cube tests for the pile concrete
and pile head concrete and grout for the rock anchor and bottom plate grout
shall be carried out and shall be recorded prior to the load test.
2. Calibration of Deflection dial gauges The deflection dial gauges shall be

calibrated in a NABL accredited laboratory for their correction factor. The
calibration certificate for the dial gauges shall be submitted to client/IC for the
review.
3. Calibration of Pressure Gauges The pressure gauges shall be calibrated in a

NABL accredited laboratory for their correction factor. The calibration certificate
for the dial gauges shall be submitted to client/IC for the review.
4. Calibration of Hydraulic jacks As such there is no proving ring of 500T

capacity available for testing the efficiency of hydraulic Jacks. For the purpose of
Pile load test the efficiency of Hydraulic Jacks can be considered as 97%. The
Manufacturers drawing shall be used to calculate the area of the ram under
pressure shall be considered.
c) Variation in Temperatures As the test is to be carried out on an open area, the

atmospheric temperatures shall govern. In general the temperature variation will be
0 0
in the range of 20 C to 32 C.
d) Test Pile details

i. Drillers Log A drillers log for the test pile is enclosed herewith for ready
reference.
ii. Pile Log Pile log for the test pile is enclosed herewith for ready reference.
iii. Pile Concrete pour card A pile concrete pour card for the test pile is
enclosed here with for ready reference.
i) Report on Trial Pile No.
Owner Employer
Construction Agency
Name of the Piling Engineer from Contractor
Name of the Supervision Engineer
Location of Trial Pile
ii) Pile Log
Date & Time of Start Climate Location
N E
Date & Time of Compl. Pile Dia. 1200mm Nearest Soil Inv. Bore BH No.
Drg. Ref. N E
G.L Equipment Mait HR- Pier No Nil Chainage

260
G.W.L Pile No. Trial Pile 1
Depth Time Activity Type of Soil
in Mtrs. From To
Boring done by soil Filled up soil

Barrel Bucket
Boring done by soil Soft Disintegrated Rock

Barrel Bucket
Boring done by Rock Hard Rock
Bucket
Reinforcement cage installed time Tremie Install Time
Pile Length Chiselling time Guide Casing Length
Guide Casing Top R.L Guide Casing Bottom R.L.
Pile Toe R.L Top of the Moderately Weathered rock R.L
Top of the Weathered Rock R.L. Top of the Sound rock R.L
Pile Cut off level
Remarks No teeths were broken during pile boring

Owner
Concessionaire
Construction Agency
iii) Pour Card for Pile Concreting
Date & Time of Start Date & Time of Compl. Climate
Temp.
Pile Dia. 1200mm Pier No G.L
Drg. Ref. Pile No. Toe Level
A. Reinforcement
Clean Binding & Welding
Conforms to Drg No. of Laps
BAR Splices Cover blocks provided
Splice joints are tight Spacers
No. of chairs No. of Spacer

B. Concrete
Tremie with Hopper is installed properly in bore hole
Tremie is watertight
Slump cone apparatus is available at site
Thermometer is available at site
Concrete cube casting moulds available at site
Concrete Qty ordered with RMC is more than theoretical
Slump of the concrete is more than 150mm
RMC supplier is issued the dockets stating the mix proportions &
Grade of Concrete
Concrete Mix Time Transit Time
Slump Initial Flowing Theoretical Concrete Qty
Final
No. of Cubes taken Actual Concrete Qty poured
Grade of Concrete M 40
Remarks
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a) Cyclic Load Test Method The Cyclic load test shall be carried on the initial test piles
constructed as per the working methods to be adopted for the regular piling works to
find out separately skin friction and point bearing load on single pile of uniform
diameter.
The following is the procedure for the Cyclic load test where the load applied in
increment of 20% of the design load up to the failure of 2.5 times the design load,
whichever is advance.
Alternate loading and unloading shall be carried out at each stage by applying a series
of vertical downward incremental load and each increment being of about 20 percent of
design load on the pile. Each loading shall be maintained as per the criterion given
below
Dial gauge reading taken at 15 minutes interval & maintaining for 60 minutes
during loading and unloading respectively.
Dial gauge reading taken at 15 minutes interval for the first hour and every thirty
minutes thereafter when maintaining for 24 hours at final load.
Change of load should proceed only if the settlement of the pile is not more than
0.1mm in first thirty minutes or 0.2mm/hour or till 2 hours.
Reading was recorded before and after applying increment/decrement load.
Test Load i.e. 2.5 times the design load or the load at which the total displacement
equal to 10 percent of the pile diameter shall be maintained for 24 hours.
Loading and unloading procedure is as follows
1) Take level reading of the support of the reference beams and test pile datum.
2) Load to 20% of design load and maintain for min 60 minutes
3) Unload to dead load and maintain for min 30 minutes.
5) Unload to dead load and maintain for min 30 minutes
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24) Load to 250% of design load and maintain for min 24 hours
b) Method of loading After removal of initial slack in the soil anchors and connecting
the bracings to the main girder, the hydraulic jacks shall be activated with the help of
power pack. The rate of activation in the hydraulic jacks shall be @20Kg/sq.cm per
minute. The rate of activation shall be controlled from the power pack. After reaching
the required pressure the pressure shall maintained for the required time as specified
in the cycle. If any loss in pressure during the standing time shall be applied.
c) Measurement of Settlement Dial gauges and survey leveling instrument scales

are used to measure the pile top settlement. Four settlement gauges are placed
equally at the sides of the test pile to measure the settlement of the pile and
firmly held by magnetic base as shown in figure.
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The average of the four readings is taken as the pile settlement. A vertical scale will
also be installed to the pile head/Hydraulic jack at one side as shown in figure. A
temporary bench mark will be established on the well founded structures. Hence the
TBM, and the vertical scale will serve as a second check for the pile top settlement.
d) Criterion for Load Test After Plotting the load against settlement curve, the load test
shall be considered as passed if the settlement are less than the following
The safe load on single pile for the initial test should be least of the following
Two- thirds of the final load at which the total displacement attains a value of
12mm.
50 percent of the final load at which the total displacement equal to 10 percent
of the pile diameter.
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Upper Plate Girder
Lower Plate Girder
Pressur
e
Gaug
e
Hydraulic
Jack
Dial gauge
Dumpy Level
Soil
Reference fill
Beam Magnetic P a
Stressing
Base
Pump
Reference
ill r
Pile
Datum Reference
Scal Frame Scale
e
Rock Anchor
Measurement of
Settlement
Page 74 of
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II) At Offsite Location
a) Calibration of Instruments All the instruments which are in use for load test shall
be calibrated in NABL accredited laboratory for their accuracy and correction
factors. The correction factor more than 1.5% shall not be brought to site and used
in the load testing works.
b) Cube Testing Concrete cubes cast for the pile concrete, Pile head concrete and
grout cubes for the Soil Anchor grout and Bottom plate grout shall tested and
reported. The Cube compressive strength for the pile shall not be less than 40Mpa
and grout cube compressive strength shall not be less than 30 Mpa.
c) Plotting Load Vs. Settlement Curve The data observed and recorded for load
test shall be plotted for test data analysis.
d) Plotting Time Vs. Settlement Curve The data observed and recorded for
load test shall be plotted for test data analysis.
e) Plotting Load Vs. Elastic Compression The data observed and recorded shall
be analysed for load test and shall be plotted for test data analysis.
f) Test Data Analysis & Reporting After completion of the test data shall be
analysed and reported as a design report for finalizing the design criteria for the design
of working piles.
The routine test shall be carried out on the material as per the QAP.
All workmen, supervisors and engineers shall use proper personal protection
gears.
6. METHODSTATEMENT FORWORKING PILE LOAD TEST
6.1. Purpose
various activities in sequence for carrying out for Working Pile Load Test.
6.2. Scope
activities.
I) At Site
a) Preparation of load Test Arrangements

c) Variation in Temperatures
d) Test Pile Details
a. Drillers Log
b. Pile Log
c. Pile Concrete Pour Card
e) Cyclic Load Test
f) Method of Loading
g) Measurement of Settlement
h) Criteria for Load Test
II) At Off site Location
a) Calibration of Instruments
b) Cube testing
c) Plotting Load Vs. Settlement Curve
d) Plotting the Time vs. Settlement Curve.
e) Test Data Analysis & Reporting.
1 Design Booklet Test Pile design report
2 Method Statement Method Statement
3 Contract Document Routine Pile load test requirement
4. IS 2911 (Part IV)
5. Drg.

No.
1 Engineer In-charge He shall be responsible to control the activities for all the
activities.
implementation, and control of Load testing activities for
the Working Pile load test. Shall be responsible for overall
monitoring and control of man power, equipment, transport
facilities etc.

to this procedure.
Shall be responsible for taking levels and making

arrangements.

QC activities as per checklist and QAP at site.

The details were reported with the earlier method statements.
I. At Site
a) Preparation of Load Test Arrangements The desired pile as decided by client/IC shall
be cast up to ground level along with casing from cu off level. It shall be ensured that
sound concrete is filled in the shaft for this purpose. The testing shall be carried out
after the cube strength reaches 35Mpa or 14 days from the casting date whichever is
later.
b) Construction of Rock Anchors After the pile is installed at the location then the rock
anchors of 14O6 shall be installed as per the previous method statement submitted by
Grips India. The General Arrangements for the Rock anchor is shown in below
c) Site Clearing & Leveling After installation of rock anchors at the location the surface in
and around the pile and the rock anchor location s hall kept clean and away from the
water logging and kept surface all time dry.
d) Fixing & Grouting of Bottom Plate After site clearing the area, Prefabricated
Steel plate of 60mm thick shall be brought to the site and will be placed on top of
the Pile head with 30mm gap. Then the plate shall be leveled true to line & Level. The
area shall be covered with timber shutter for grouting. Then the area between the
bottom plate and pile-head shall be grouted with High strength and non shrink
cementitious grout of either Conbextra GP2 or Master flow 918. The grout shall be
manufactured strictly as per the manufacturers instructions. This should be done using
water and the stirrer in a water tight open container of 25 lt capacity. Care shall be
taken that there will not be any entrapped air pockets below the plate. Then the
grout shall be cured for 7 days my moisture curing or curing compound shall be
applied.
Page 80 of
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60mm thick Bottom Plate Non Shrink Grout
MS Liner
Pile Cutof
level
Fixing of Bottom
Plate
e) Placing of Hydraulic Jacks After grouting of the Bottom Plate 3 nos of 500MT pre-
calibrated Hydraulic jacks on top of the Bottom plate.
f) Placing of Top Plate After placing the hydraulic jacks in position then the top 60mm
plate shall be placed on top of Hydraulic jacks.
Page 81 of
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60mm thick Top Hydraulic jack
Plate
Non Shrink Grout

60mm thick Bottom
Plate
MS Liner
Pile Cuof
Level
Rock
Anchor
Fixing of Top
Plate
g) Placing of Lower Plate Girder This work shall consist of placing and aligning of Lower
Plate Girder on top of Top plate. The Lower Plate Girder shall be of main girder which
was used in initial pile load test and transported from the yard to site through trailor. It
will be unloaded with the help of 50MT Crane. Pre fabricated Cribs shall be placed on
firm ground outside the Pile location to support the Lower Plate Girder. Then the Lower
plate girder shall be placed on top of the Top plate and shall be aligned to the correct
position and supported with props to arrest toppling of the Plate girder. Then Bottom
Page 82 of
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flange of the Plate girder shall be stitch welded with the top of the top plate at different
locations.. After aligning the same it will be connected and locked with the Rock
Anchors.
Page 83 of
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Lower Plate Girder
Hydraulic
Jack
Crib
Rock Anchor
Placing of Lower Plate Girder

h) Placing and positioning of Upper Plate Girder This work shall consists of Placing
and positioning of Upper Plate Girder. After placing of Lower Plate girder then Upper
plate girder shall be brought from casting yard through trailor and unloaded on top of the
ground. Pre fabricated Cribs shall be placed on firm ground out side the Pile location to
support the Upper Plate Girder. Then the Upper plate girder shall be lifted with the help
of 50Mt crane and placed on top of the Lower plate girder. Then the Upper plate girder
shall be aligned and welded to the bottom plate girder to arrest the toppling of the Upper
plate girder. During this time care shall be taken the overturning of the bottom plate
girders since the cantilever loading on the Lower plate girders. The structural stability of
cribs shall be continuously monitored including settlements. Then after the Anchor cable
shall be threaded in to the upper plate girder and four strands shall be stressed to
remove slack and locked in the bearing plate.
Lower Plate Girder
Hydraulic
Jack
Crib
Rock Anchor
Placing of Upper Plate Girder

i) Fixing of Rock Anchors to Lower & Upper Plate Girder After positioning of the upper
plate girders all the four cables shall be threaded in to the Lower & Upper plate girder.
Bearing plates shall be placed on top of the plate girder. All the strands shall be
stressed with the help of mono strand jack to remove initial slack in the cable and
locked. The three hydraulic jacks are connected to the power pack.
j) Construction of Reference System After placing Upper Plate girder Reference

pillar shall be constructed at 3.6 m away from the Centre of Pile in a firm ground.
After construction of reference pillar reference beams shall be fixed to the reference
pillar from the beams frame shall be welded to the reference beam.
k) Placing of Deflection Dial Gauges After construction of reference beam system,

Deflection dial gauges shall be attached with magnetic stand to the reference beam-
frame to measure the deflection of the pile. And the needle of the deflection dial gauge
shall be placed gently on top of the glass plate which is connected to the Pile head.
After the load test assembly is set up using the jacking frame system as described in
the above Load Test arrangements which was shown in the figure below shall be
provided by a safety arrangements and access to the various elements for inspection
during testing and fixing bracings to the main beam girders. After completion same shall
be offered to client/IC for their review and approval for carrying out the load test. Any
comments offered by client/IC shall be attended immediately and complied before
starting the load test.
Upper Plate Girder
Lower Plate Girder
Pressur
e
Gaug
e
Hydraulic
Jack
Dial gauge
Cribs
Reference
Base Pump
Reference
Pillar
Pile
Datum Reference
Scal Frame Scale
e
Rock Anchor
Preparation of Load
Test
l) Results & Calibration of Instruments
1. Cube Test for the Concrete and Grout The Cube tests for the pile concrete
and pile head concrete and grout for the rock anchor and bottom plate grout
shall be carried out and shall be recorded prior to the load test.
2. Calibration of Deflection dial gauges The deflection dial gauges shall be

calibrated in a NABL accredited laboratory for their correction factor. The
calibration certificate for the dial gauges shall be submitted to client/IC for the
review.
3. Calibration of Pressure Gauges The pressure gauges shall be calibrated in a

NABL accredited laboratory for their correction factor. The calibration certificate
for the dial gauges shall be submitted to client/IC for the review.
4. Calibration of Hydraulic jacks As such there is no proving ring of 500T

capacity available for testing the efficiency of hydraulic Jacks. For the purpose of
Pile load test the efficiency of Hydraulic Jacks can be considered as 97%. The
Manufacturers drawing shall be used to calculate the area of the ram under
pressure shall be considered.
m) Variation in Temperatures As the test is to be carried out on an open area, the

atmospheric temperatures shall govern. In general the temperature variation will be in
0 0
the range of 20 C to 32 C.
n) Test Pile details

i. Drillers Log A drillers log for the test pile is enclosed herewith for ready
reference.
ii. Pile Log Pile log for the test pile is enclosed herewith for ready reference.
iii. Pile Concrete pour card A pile concrete pour card for the test pile is
enclosed here with for ready reference.
i) Report on Trial Pile No. 1
Owner .
Concessioaire .
Construction Agency
ii) Pile Log
Date & Time of Start Climate Location
N E
Date & Time of Compl. Pile Dia. 1200mm Nearest Soil Inv. Bore BH No.
Drg. Ref. N E
G.L Equipment Mait HR- Pier No Chainage

260
G.W.L Pile No.
Depth Time Activity Type of Soil
in Mtrs. From To
Boring done by soil Filled up soil

Barrel Bucket
Boring done by soil Soft Disintegrated Rock

Barrel Bucket
Boring done by Rock Hard Rock
Bucket
Reinforcement cage installed time Tremie Install Time
Pile Length Chiselling time Guide Casing Length
Guide Casing Top R.L Guide Casing Bottom R.L.
Pile Toe R.L Top of the Moderately Weathered rock R.L
Top of the Weathered Rock R.L. Top of the Sound rock R.L
Pile Cut off level
Remarks No teeths were broken during pile boring
Page 90 of
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Owner . Employer .
Construction Agency
iii) Pour Card for Pile Concreting
Date & Time of Start Date & Time of Compl. Climate
Temp.
Pile Dia. 1200mm Pier No G.L
Drg. Ref. Pile No. Toe Level
A. Reinforcement
Clean Binding & Welding
Conforms to Drg No. of Laps
BAR Splices Cover blocks provided
Splice joints are tight Spacers
No. of chairs No. of Spacer
Page 91 of
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B. Concrete
Tremie with Hopper is installed properly in bore hole
Tremie is watertight
Slump cone apparatus is available at site
Thermometer is available at site
Concrete cube casting moulds available at site
Concrete Qty ordered with RMC is more than theoretical
Slump of the concrete is more than 150mm
RMC supplier is issued the dockets stating the mix proportions &
Grade of Concrete
Concrete Mix Time Transit Time
Slump Initial Flowing Theoretical Concrete Qty
Final
No. of Cubes taken Actual Concrete Qty poured
Grade of Concrete M35
Remarks
Page 92 of
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a) Cyclic Load Test Method The Cyclic load test shall be carried on the Working Piles
constructed as per the working methods adopted for the regular piling works to find out
separately skin friction and point bearing load on single pile of uniform diameter.
The following is the procedure for the cyclic load test where the load applied in
increment of 20% of the design load up to the failure of 1.5 times the design load,
whichever is advance.
Alternate loading and unloading shall be carried out at each stage by applying a series
of vertical downward incremental load and each increment being of about 20 percent of
design load on the pile. Each loading shall be maintained as per the criterion given
below
Dial gauge reading taken at 15 minutes interval & maintaining for 30/60/120
minutes during loading and unloading respectively.
Dial gauge reading taken at 15 minutes interval for the first hour and every thirty
minutes thereafter when maintaining for 24 hours at final load.
Change of load should proceed only if the settlement of the pile is not more than
0.1mm in first thirty minutes or 0.2mm/hour or till 2 hours.
Reading was recorded before and after applying increment/decrement load.
Test Load i.e. 1.5 times the design load or the load at which the total displacement equal
to 12mm shall be maintained for 24 hours.
Loading and unloading procedure is as follows
a) Take level reading of the support of the reference beams and test pile datum.
b) Load to 20% of design load and maintain for min 30/60/120 minutes
c) Unload to dead load and maintain for min 30 minutes.
d) Load to 40% of design load and maintain for min 30/60/120 minutes
Page 93 of
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e) Unload to dead load and maintain for min 30 minutes
f) Load to 60% of design load and maintain for min 30/60/120 minutes
g) Unload to dead load and maintain for min 30 minutes
h) Load to 80% of design load and maintain for min 30/60/120 minutes
i) Unload to dead load and maintain for min 30 minutes
j) Load to 100% of design load and maintain for min 30/60/120 minutes
k) Unload to dead load and maintain for min 30 minutes
l) Load to 120% of design load and maintain for min 30/60/120 minutes
m) Unload to dead load and maintain for min 30 minutes
n) Load to 140% of design load and maintain for min 30/60/120 minutes
o) Unload to dead load and maintain for min 30 minutes
p) Load to 150% of design load and maintain for 24 hours
q) Unload to dead load and maintain for min 120 minutes
b) Method of loading After removal of initial slack in the soil anchors and connecting the
bracings to the main girder, the hydraulic jacks shall be activated with the help of power
pack. The rate of activation in the hydraulic jacks shall be @20Kg/sq.cm per minute.
The rate of activation shall be controlled from the power pack. After reaching the
required pressure the pressure shall maintained for the required time as specified in the
cycle. If any loss in pressure during the standing time shall be applied.
c) Measurement of Settlement Dial gauges and survey leveling instrument scales

are used to measure the pile top settlement. Four settlement gauges are placed
equally at the sides of the test pile to measure the settlement of the pile and
firmly held by magnetic base as shown in figure.
The average of the four readings is taken as the pile settlement. A vertical scale will also
be installed to the pile head/Hydraulic jack at one side as shown in figure. A temporary
bench mark will be established on the well founded structures. Hence the TBM and the
vertical scale will serve as a second check for the pile top settlement.
Page 94 of
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d) Criterion for Load Test After Plotting the load against settlement curve, the load test
shall be considered as passed if the settlement are less than the following
The safe load on single pile for the working pile test should be least of the following
Total displacement at working load shall be less than 10mm.

Net settlement at working load shall be less than 6mm.
Stressing
Pump
Page 95 of
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Upper Plate Girder
Lower Plate Girder
Pressur
e
Gaug
e
Hydraulic
Jack
Dial gauge
Cribs
Dumpy Level
Reference
Base Pump
Reference
Pillar
Pile
Datum Reference
Scal Frame Scale
e
Rock Anchor
Measurement of
Page 96 of
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Settlement
Page 97 of
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II) At Offsite Location
a) Calibration of Instruments All the instruments which are in use for load test shall
be calibrated in NABL accredited laboratory for their accuracy and correction factors.
The correction factor more than 1.5% shall not be brought to site and used in the
load testing works.
b) Cube Testing Concrete cubes cast for the pile concrete, Pile head concrete and
grout cubes for the Soil Anchor grout and Bottom plate grout shall tested and
reported. The Cube compressive strength for the pile shall not be less than 35 Mpa
and grout cube compressive strength shall not be less than 30 Mpa.
c) Plotting Load Vs. Settlement Curve The data observed and recorded for load test
shall be plotted for test data analysis.
d) Plotting Time Vs. Settlement Curve The data observed and recorded for load test
shall be plotted for test data analysis.
e) Plotting Load Vs. Elastic Compression The data observed and recorded shall be
analysed for load test and shall be plotted for test data analysis.
f) Test Data Analysis & Reporting After completion of the test data shall be analysed
and reported as a design report for finalizing the design criteria for the design of
working piles.
The routine test shall be carried out on the material as per the QAP.
7. METHODSTATEMENT FORLATERAL PILE LOAD TEST
7.1. Purpose
The purpose of this method statement is to follow uniform work methodology and to
perform various activities in sequence for carrying out Lateral Routine Pile Load Test.
7.2. Scope
The work shall include the following activities.

a. Preparation of the Load Test arrangements.
b. Calibration of Instruments / equipments to be used.
c. Test Pile details
d. Tabulation of results.
e. Conclusion.
7.3. References
i. IS 2911 (Part 4) 1985 (Reaffirmed 1995), Code of Practice for Design and
Construction of Pile Foundations. Part 4 Load Test on Piles.
7.4. Preparation of Load Test Arrangements
The lateral load test assembly shall be set up using the structural steel box section and
hydraulic jack between two piles. Two dial gauges shall be placed directly opposite the
loading points diagonally on the other side of the pile. The loading & measuring shall be
done at cut off level of the pile. Necessary safety arrangements and access to various
elements shall be provided for inspection during testing. After erection of the system,
necessary packing / initial pressure shall be applied for keeping the arrangement in
position. After completion of the arrangements the same shall be offered to Engineer/IC
for their review and approval for carrying out the Pile Load Test. Any comments offered by
Engineer/IC shall be attended to immediately and complied before starting the Load Test.
7.5. Calibration of Instruments / Equipments
All the Instruments like Dial Gauges for settlement measurements, pressure gauges
/proving rings for Hydraulic Jacks shall be calibrated and the Certificates shall be made
available for inspection of the Engineer / IC.
7.6. Test Pile Data
The details of piles being tested are as below
7.7. Test Procedure
The test procedure shall be as per IS 2911 (Part 4) 1985.

The following is the procedure for the load test where the load is applied in increments of
20% of the estimated safe load. The following is the procedure to be followed for each
stage of incremental loading.
First 20% of the test load (estimated safe load) shall be applied.
Dial gauge readings are taken at 15 minutes interval for the incremental loadings.
Next stage of the load should be applied after the rate of displacement is nearer to
0.1 mm per 30 minutes. (Ref Cl. 7.2 of IS2911 (Part 4)-1985)
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7.8. Tabulation of Results
The displacements observed as above shall be tabulated. A Load - Displacement curve

shall be drawn for the obtained results.
7.9. Conclusion
As per Clause 6.1.5 of IS 2911 (Part 4) 1985 the safe load on single pile for the lateral
test should be least of the following
Fifty percent of the final load at which the total displacement increases to 12mm
Final load at which the total displacement corresponds to 5mm and;
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8. METHODSTATEMENT FORDYNAMC TESTING
8.1. Equipment
The Contractor shall supply all personnel and equipment needed to strike the test pile with
the pile hammer. The Contractor shall also supply a source of 115 V, 1500 VA, 60 Hz
electrical power with extension power cords. When fluted piles are being used, the
Contractor shall supply a cutting torch.
The Department will provide the transducers, the Pile Driving Analyzer, and the personnel
to operate the equipment.
8.2. Test Procedures
Approximately three piles will be tested in one day. Department personnel will drill holes
into the piles to be tested so that electronic transducers (2 accelerometers and 2 strain
gages) can be attached. When the transducers have been placed in position and the Pile
Driving Analyzer has been made ready to receive the acceleration and strain
measurements, the Contractor shall strike the pile with the pile hammer as many times as
is required to obtain adequate measurements as determined by Department personnel.
After the dynamic testing measurements have been obtained and analyzed, the
Department will provide instructions for driving the piles.
Strains induced under the impact of a heavy falling hammer from a pre-determined height
are measured with the help of strain transducers attached to the pile, whereas
accelerometers record the accelerations generated in the pile. The Pile Driving Analyzer
converts strain to force, and acceleration records are converted to velocities. The
resistance developed by the pile is then a function of force and velocity and includes few
assumed factors such as the quake and damping parameters as inputs based on the soil
type. The maximum pile top compression is obtained by integrating the pile top velocity. A
more accurate value of these parameters is then obtained from CAPWAP analysis
conducted on field data.
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8.3. Benefits of PDA Testing
Significantly faster and economical than static tests; with proper setup arrangements
can test at least 2 bored piles and even more driven piles per day.
Very effective for large diameter bored piles with huge capacity & applicable for both
offshore & onshore piling
Applicable to almost all kinds of piles includes bored, driven, micro, steel piles etc.
Reduces or eliminates static load testing especially in case of jetties, flyovers,
bridges, multistory buildings where space is a constraint.
Provides information on friction, end-bearing, pile integrity, hammer performance
etc. and plot simulated load test curve for comparison with static testing.
Reduces controversies and eliminates risk enabling a safe foundation.
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9. Earth work in Embankment
9.1. Purpose
various activities in sequence for construction of Earth Work in Embankment.
9.2. Scope
I) At Site
a) Setting out
b) Earth work in excavation
II) At Casting Yard
a) Preparation of bed for casting precast drain elements

b) Preparation of bed for reinforcement cage preparation
c) Preparation of yard for curing and storage of precast drain elements
d) Cutting, bending, and laying of reinforcement as per approved drawings.
e) Providing shuttering for concrete formations.
f) Fabrication & erection / fixing of embedded parts.
g) Producing, transporting, placing and compaction of the concrete in various drain
elements such as lid & Box.
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h) Finishing the exposed faces of concrete to specified finish.
i) Curing arrangements for the finished concrete.
j) Lifting of precast elements from casting bed
k) Storage of precast drain elements.
l) Transporting precast elements to site.
1 Concrete Mix Specification Mix design shall be submitted to client
2 QA/QC Plan As per client QAP
3 Drg.
4. Yard Layout
5. Form work Drawing
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Sr. No. Category Responsibilities
1 Engineer In-charge He shall be responsible to control the activities for the

laying of concrete.
implementation, and control of construction activities for
the laying of concrete. Shall be responsible for overall
monitoring and control of man power, transport facilities
etc.

to this procedure.

concrete work.

concrete.
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a) Concrete
1 Cement IS 12269 Birla, Ultratech, ACC
3 Water IS 456-2000 Approved sources
Reinforcement
Steel
c) Structural Steel
Plates,
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I. At Site
a) Layout of Structure Construction of drain shall start after carrying out survey for
alignment and levels in accordance with approved drawings. Grid pillars shall be
constructed at regular intervals and reference for construction shall be taken from these
grid pillars. The same shall be duly checked and reviewed by IC.
Service Main
Road Carriageway
Existing
Drain
UCR
Masonry
Cross Section of Existing Road
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b) Earth work in excavation Layout of excavation area The area to be excavated shall
be clearly marked over the ground. This should be done using lime powder or similar
means. Area to be excavated should be sufficient to allow for the working space.
Initially the Road portion shall be excavated with the help of Pavement breaker attached
to compressor. Depending upon the site condition, either the mechanized or the manual
excavation shall be done to reach the level as required by the drawings / specifications
immediately to the local authorities for removal / diversion to avoid ideal of equipment
and man power. Client & IC shall follow up with local authorities. After reaching to the
required level, approval from IC shall be taken for further activity.
Barricade /
Cone
Service
Road Main
Carriageway
UCR
Masonry
Cross Section of Road after Excavation

c) Laying of PCC The strata on which PCC shall be laid to be cleaned for any loose soil,
debris etc. PCC shall be laid as per specified approved design mix M-15 grade
concrete shall be produced from batching plant and shall be transported to location
through transit mixers. Concrete shall be placed in position with the help of a chute.
Concrete shall be leveled & compacted with hand float of wooden / aluminum box
section to get the required gradient as per the approved longitudinal profile drawing.
Curing of concrete shall commence after 8 to 10 hours of placement. Curing shall be
done by covering with wet Hessian cloth / or sprinkling water on concrete surface. The
layout/ centre/Outer line shall again be transferred over the PCC as a reference for
further construction activities
Main
Barricade / Carriageway
Cone
PCC
UCR
Masonry
Cross Section of Road

after PCC
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d) Placing of Precast Box drains Precast elements brought from the precast yard by
truck shall be lowered with the help of Hydra / Crane in to the trench as per the layout
which has already marked.
Main
Cone
Precast
Box
UCR
Masonry
Cross Section of Road after Laying Precast Box
e) Stitching of Precast Elements Joining of the precast boxes will be stitched at site. The
re-bars will be joined with 40 times dia of the bar as a lap length and the main
reinforcement will be placed as per the design. Then cover blocks of required size will
be fixed to the rebar to maintain the cover to the reinforcement.
Prefabricated shutter will be placed in position overlapping the precast elements and
secured the same with props to arrest the sliding/bulging during compacting the
concrete.
Then concrete shall be laid as per specified approved design mix M-30 grade concrete
shall be produced from batching plant and shall be transported to location through transit
mixers. Concrete shall be placed in position with the help of a chute. Concrete shall be
compacted with the help of immersion needle vibrators and then leveled with hand float
of wooden / aluminum box section. Curing of concrete shall commence after 8 to 10
hours of placement. Curing shall be done by covering with wet Hessian cloth / or
sprinkling water on concrete surface.
Main
Cone
Precast
Box
UCR
Masonry
Cross Section of Road after Stitching Precast Box
Precast
Box
I
Service Road n
S
i
t
Masonry Bench u
Shoulder &
Slope
Main Carriageway
Plan showing the arrangement of Stitching drain segments

f) Placing of lid Precast lids brought from the precast yard by truck shall be lowered and
placed with the help of Hydra / Crane on top of the precast and cast-in-situ box.
Main
Cone
Precast Box
Precast
Lid
UCR
Masonry
Cross Section of Road after Placing Lid
g) Grouting of lid with box After placing the lid on top of the box drain shear key will be
grouted with cement mortar.
h) Fixing of manhole grating with frame Especially cast lid will be placed at the
designed interval to provide a manhole to the drain network. The lid shall have a
prefabricated frame with MS Grating.
i) Backfilling of the Excavation After placing the lid the excess excavated surface on
service road side will be filled with granular material i.e. mixture of crushed stone of
12mm down up to 50mm below the weep hole and will be compacted thoroughly. A
50mm M15 grade concrete will be placed on top of the backfill upto the bottom of Weep
hole. Above the Concrete permeable backing will be placed up to the bottom of DBM.
On the Carriageway side the gap between the Drain box and the UCR Masonry will be
filled with metal packing in layers and the interstices will be filled with Crushed stone
aggregates in layer wise.
Permeable Backing Main

Cone
Precast
Box
Precast Lid
Granular Metal Packing

Fill
UCR
Masonry
Cross Section of Road after backfilling
II) At Yard
a) Preparation of bed for casting precast drain elements A suitable location for the
same will be identified and will be developed as per the drawing referred. Preferably
the same casting yard for which segment casting shall be developed to the
requirement.
b) Reinforcement All the reinforcement used shall confirm to IS 1786. The bars shall be
placed on wooden sleepers / Masonry walls. The bars shall be stacked in lot and dia.
wise. Cutting bending and tying of reinforcement shall be as per approved BBS /
drawings
c) Embedded Parts All the embedded parts shall be fixed as per drawings.
d) Formwork The formwork shall have sufficient strength to withstand the weight and
pressure of concrete and other constructional loads without deflection, distortion,
bulging or loosening the supports. Approved brand of Mould releasing agents / Oils
shall be applied on shuttering plates.
e) Concrete The concrete grade of M30 is required in the project. CLIENT & PMC had
jointly taken trial mixes and the mixes were reviewed by IC. The concrete produced
from batching plant shall be transported to the yard by means of transit mixers. The
3
capacity of the transit mixers shall be 6m . All transit mixers shall be insulated properly
and kept wet till completion of concrete for better retention.
f) Concrete Placement The readiness of the pour shall be first checked by CLIENT for
layout, reinforcement etc. and then the RFI shall be raised to IC for pouring of concrete.
The Engineers representative at site shall inform to their Q.C. representative at casting
yard to start concrete production, after giving approval for concrete pour. Before
commencement of concreting the pour area shall be made free from pieces of timber,
rebar, and other foreign material. If necessary the earlier concrete area shall be
cleaned with air or water jet.
Concrete shall be conveyed to placement point through Chute/ Crane bucket /

Concrete pump depending on the necessity and situation.
g) Concrete Compaction Freshly laid concrete shall be duly vibrated in layers by
mechanical vibrator, to ensure the full compaction of concrete and reach of concrete in
all corners and pockets of the pour. Around embedded parts, care shall be taken while
vibrating the concrete. The concrete shall be vibrated to achieve maximum density. For
this purpose immersion type high frequency vibrators shall be used and the vibrator
needle shall always insert vertically. The vibrator needle shall be allowed to penetrate
in the concrete by its own weight and external force shall not applied. Insertion of the
vibrator needle shall be done at an interval of 400 to 600 mm (influence area of needle
is generally 10 times the diameter). The best vibration time is 15 to 20 seconds. Over
vibration shall be avoided.
In case plastic shrinkage cracks are noticed during concrete in spite of all precautions
being taken the rectification work shall be as follows.
a) The loose material surrounding the crack shall be removed by scrapping with
the trowel.
b) A local bund shall be made around the crack where ever needed.
c) Cement slurry shall be poured in the crack within the bund.
d) The cement slurry shall be removed with a cloth after half an hour. The bund
shall also be removed.
e) The area shall be finished with a trowel
f) The area shall be rubbed with Carborondum stone after 72 hours.
h) Curing of Concrete After 8 to 10 hours of concrete pour, curing shall be started by

covering with wet hessian cloth or sprinkling of water on it.
Slump/workability test, shall be carried out at the pouring location
Records shall be kept for all batches of concrete and sampling of concrete shall be done.
The Pour card/Slump test report and recording of following shall be done
Grade of concrete.
Concrete mix used.
Slump of concrete
The concrete specimens will be cast on site as per MORT&H Table 1700-8 for determine
the strength of concrete at 28 days.
3
Quantity of concrete in m No. of individual Cubes
0-5 6
6 - 15 12
16 - 30 18
31 - 50 24
51 & above 4 plus on additional sample for each
3
50m or part thereof
Additional cubes shall be cast for determine the strength of concrete at 7 days or various
purposes.

3
2 Chilling Plant No. 1
3
3 Transit mixer 6 m Capacity Nos. 1 to 3
Nos
4 Vibrators with 60 mm needles Nos 4
5 Chute Nos 1 to 3
6 Concrete Pump Nos 1
7 Crane with bucket Nos 1
8 Hand Float of Wooden /aluminium box section Nos. 1
10 Cube moulds Nos. As

required
10. METHODOLOGY FOR CONSTRUCTIONOF BOX CULVERT
10.1. Scope
This work shall consist of furnishing and placing structural concrete in accordance with the
specifications and in conformity with the lines, grades and dimensions as shown on the
drawing.
10.2. Materials
All materials shall conform to the specifications.
10.3. Construction Equipments
Sl. No. Description Type Size / Capacity No.
1 Shuttering L & T Doka or MS Plates 3 m x 1.2 m 20
2 Batching Plant 30 cum/hr. 1
3 Transit Mixers 6 cum 3
4 Welding Generator As required 1
5 JCB / Loader 1
6 Dumper 1
7 Level instrument 1
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10.4. Sequence of Construction
(a) Excavation for the Structure
Foundation for the bed shall be excavated as per the lines and grades as per the
approved drawings to match the existing culvert.
(b)PCC Laying
PCC of M15 grade will be laid of thickness as mentioned in the approved drawing.
(c)Raft and Walls
Reinforcement Fixing & Fabrication Reinforcement will be cut using cutting machines
or manually and will be bent at steel yard (casting yard) and will be transported to site by
trailer.
The TMT bars will be provided using following procedure
The reinforcement will be fixed as per the approved BBS, cover blocks will be provided
at a spacing of 2m c/c on all four sides of the cage to provide a clear cover of 40 mm.
The rebar cage will be offered for checking and approval at site to the Client.
Cut and bent reinforcement will be fixed in position and before placing the shuttering in
position it shall be cleaned to remove all stains of rust and then shall be oiled with thin
coat of shuttering oil. Between existing culvert and new culvert mastic pad will be placed.
Concreting The concrete required (M 30 grade) will be produced as per the approved
design mix. The concrete will be placed in the layer of 200mm to 300 mm thickness and
needle vibrators will be used for compaction of concrete.
(d)Pre-cast Slab
Pre-cast slab of 1.2 m to 2.0 m in length and depth as mentioned in the drawing will be
pre-cast at the casting yard and same will be transported and placed in position at site
and the same shall be concreted as per the methodology described above.
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10.5. Quality Control of Concrete
Concrete will be produced in accordance with the approved mix design. Concrete will be
dispatched to site along with the dispatch slip containing grade of concrete, workability of
the concrete, time of production, quantity of concrete etc with duly signed by designated
Quality Control / Production Engineer. The concrete specimens will be cast on site as per
MORT&H Table 1700-8 for determine the strength of concrete at 28 days. Additional
cubes may be required for determine the strength of concrete at 7 days or various
purposes.
10.6. Concrete Production details
The fully automatic batching plants shall be used for production of concrete. Concrete
shall be produced as per the approved mix recipe and controlled and monitored by Quality
Engineer. As per the concrete requisition, the concrete making ingredients will be tested
and reported before producing concrete. Only accepted material will be used for
production of concrete.
10.7. Concrete Transporting and Placing
Concrete produced in the batching plant will be transported to pouring point using transit
mixer. The concrete will be poured using concrete pumps. Concrete received at site will
be verified for grade and workability.
10.8. Curing
Exposed surfaces will be covered with wet Hessian cloth after final setting of concrete and
water will be sprinkled frequently to keep the cloth wet. Formwork will be removed after
24hrs of concreting and the surface shall be kept continuously wet by covering a Hessian
cloth for a period of 14 days.
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All workmen, supervisors and engineers shall use proper personal protection
gears.
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Method Statement - Structures Nfrly 1

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VNR Infrastructures Limited,

Method Statement for Structures

Version No. 0.00

1. METHOD STATEMENT FOR CONSTRUCTION OF PIER & PIER-

4.4. REFERENCE DOCUMENTS

8. METHOD STATEMENT FOR DYNAMC TESTING

1. METHODSTATEMENTFORCONSTRUCTION OFPIER & PIER-CAP

a) Layout of Pier/ Pier Plinth

f) Placing, positioning & tying of Rebar

II) Offsite activities

a) Design of pier & Pier-cap formwork

1.4. Reference Documents

Sr. No. Document Title Document Details

2 QA/QC Plan As Per client QAP

5. Form work Drawing

Sr. Category Responsibilities

1 Engineer In-charge He shall be responsible to control the activities for the

3 Site Engineers Shall report to Section In -charge. Shall be responsible for

Shall be responsible for concrete pouring.

5 QC Engineer Shall report Site QA/QC In-Charge.

Shall be responsible for overall control and inspection of

Shall be responsible for performing all checks and taking

6 Safety Officer Shall report to EIC at site.

Shall be responsible for all safety aspects

1.6. Construction Material Details

1.7. Sequential Construction Activities

Cross Section of Pile-cap/Open foundation

Construction of Pier Kicker

Placing, Positioning & Tying of Rebar

Fixing of Storm Water Pipe

k) Concreting The Engineers representative at site shall inform to their Q.C.

ii) Concrete Placement Concrete shall be conveyed to placement point through /

b) Cement slurry shall be poured in the crack within the bund.

d) The area shall be finished with a trowel.

e) The area shall be rubbed with Carborondum stone after 72 hours.

b) Fabrication of Pier & Pier-cap formwork Fabrication agency for manufacturing

1.8. Testing & Record

-Concrete mix used.

-Sampling of concrete for test cube.

1.9. Equipments to be used

Following is the list of various equipments to be used for lean concrete -

6 Concrete Pump Nos 1

7 Crane with bucket Nos 1

8 Hand Float of Wooden /aluminium box section Nos. 1

9 Survey equipment Set 1

10 Cube moulds Nos. As

1.10. Health, Safety And Environment

1.11. Quality Assurance And Quality Control

b) Earth work in excavation

d) Cutting, bending and laying of reinforcement as per approved drawings.

e) Providing shuttering for concrete formations.

f) Fabrication & erection / fixing of embedded parts

g) Producing, transporting, placing and compaction of the concrete in various

h) Finishing the exposed faces of concrete to specified finish.

i) Cutting arrangements for the finished concrete.

2.3. Reference Documents

Sr. No. Document Title Document Details

Mix design shall be submitted to client and take

2 QA/QC Plan As per client QAP

Sr. No. Category Responsibilities

He shall be responsible to control the activities for

Shall report to the lC. Shall be responsible for

Shall report to Section in-charge. Shall be

Shall report to ElC and shall be responsible for