fcr dahej port

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Project Training 07-08 Construction Of Solid Cargo Port Terminal

1.1 BACKGROUND OF THE PROJECT Considering inherent potential of Dahej for developing facilities for handling dry cargo, in the year 1997, Government of Gujarat through Gujarat Maritime Board commissioned International Finance Corporation to advise for the development of two Green field Ports in South Gujarat viz., Dahej & Hazira. IFC assessed the potential of both these ports by conducting a traffic assessment study which revealed huge potential for Dahej port. Thereafter Government of Gujarat decided to develop the Dahej port complex and asked the interested to bid for a cargo handling port. The project was thus envisaged by Adani Petronet (Dahej) Port Pvt Ltd (APPPL), joint Venture of Petronet Ltd. and Adani Port Ltd. in order to develop a “MULTIPURPOSE BERTH” at Dahej. In the Phase I it is proposed to develop a berth with the associated material handling system to handle panamax vessel for imported coal, Fertilizer, FRM and steel, along with the approach trestle. In the Phase II, it is proposed to develop another berth in continuation to the Phase – I berth of about 230m for export cargo and some expansion in back up yard facilities.

1.2 THE PROJECT The “MULTIPURPOSE BERTH” includes construction of Y type structure having 2 jetties (one for coal handling and other for general cargo) in the sea about 2.4 km from shoreline. The following are the major component of works:

Main Structure consisting of 2 no. jetties for berthing for Panamax Vessels of about 80,000 DWT and cargo handling.

Jetty -I is for handling coal and is to be equipped with 2 Nos. of rail mounted mobile Harbour Cranes for a planned throughput of 12.5 MTPA

The Construction of Jetty -II has been planned for handling multi purpose cargo to be equipped with 2 Nos. rail mounted mobile harbour cranes.

Approach of about 1170m length consisting of RCC (reinforced concrete) bridge with 8.0m carriageway spanning on pile caps supported on piles to approach the berth. The pile cap is 13m long to support approach bridge and steel trestles supporting conveyer galleries.

Approach of about 1200m length in the initial portion of land side consisting of rubble bund. Conveyor system capable of handling 4200 tph will be installed on the rear section of the jetties and one side of the approach.

Railway System Consisting of loading line complete and engine escape line, railway line at marshalling yard, loop line, level crossings, locomotive and shunters, signaling and telecommunication as per Railway norms, central control cabin and In motion weigh bridge. The whole project is divided into to 15 packages out of which the marine construction is 15th package.

Sr. No. Package No. Description 1 Package-1 Mobile Harbour Cranes 2 Package-2 Conveyors & Foundations3 Package-3 Stacker Cum Reclaimer 4 Package-4 Rapid Loading System 5 Package-5 Buildings & Utilities 6 Package-6 Electricals , High Mast 7 Package-7 Communication System 8 Package-8 Yard Development

Sr. No. Package No. Description 9 Package-9 Dust Suppression System10 Package-10 Fire Fighting System 11 Package-11 Railway Systems 12 Package-12 Diesel Loco 1200 HP 13 Package-13 Power & Water facilities 14 Package-14 Mechanical Works 15 Package-15 Marine Works 16 Package-16 Mooring Winches

CHAPTER 1. INTRODUCTION



The project cost of the marine works in phase 1 of the project is 250 crores and the major component of works in this are as follows:

Construction of 640m X 15m rubble bund Widening of 600m long existing GMB bund Construction of 1270x15m Approach Bridge supported on bored cast-in situ piles. Bored Cast in – situ piles with pre cast pile muff, precast capping beams, longitudinal beams and in situ & pre-cast deck slab.

Pre-cast deck slab is at the bottom so that no shuttering is required for the top slab. Construction of 619m X 30m Main Jetty, with two numbers of rigid mooring Dolphins. The Approach Bridge is divided into 7 units. Construction of back yard facilities and cargo handling facilities (Stacker, Reclaimer, Conveyor System, Office buildings, etc.)

1.3 OBJECTIVES OF THE PROJECT

As discussed earlier the main objective behind the development of the terminal is to create a multipurpose solid cargo handling facility at Dahej due to its potential for developing into at port complex.

The project has been envisaged in order to develop the material handling system and port back up development for “MULTIPURPOSE BERTH” at Dahej.

The new facility will add to the existing facilities at Dahej and make it a complete port complex. Presently Dahej is having four facilities to handle the cargo. 1. Petronet LNG terminal for LNG receiving and Regasification. It’s a captive terminal of Petronet,

which became operational in the year 2002-03. 2. IPCL’s captive jetty for handling the Naphtha and other petro chemicals for its plant at

Vadodra. 3. Dahej Harbour and Infrastructure Private Limited has a solid cargo terminal upto a capacity of

5 million tones. Birla Copper has commissioned a copper smelter plant at Dahej. This terminal is for captive use of Birla Copper but at present it is allowed to handle outside cargo equivalent to the volume of captive cargo handled.

4. GCPTCL has a terminal in Dahej ports, for handling hazardous liquid and chemicals.

1.4 NEED OF THE PROJECT With the fast growing economy of the country, India’s maritime traffic is growing. Out of this traffic lion’s share is handled by the ports on the western coast mainly due to nearness to Mid-east countries and Europe.

Gujarat state has developed many ports in last 15 years and the maritime traffic handled by these ports has grown by leaps & bounds.

The overall Traffic in the GMB managed port has gone up from 89.36 million tones in 2003-04 to 97.13 million tones in 2004-05 and is expected to go on rising in the coming future.

Based on the studies conducted and envisaging the competition from other ports the dry bulk cargo forecast for the hinterland is as follows:

Based on the studies conducted and envisaging the competition from other ports the dry bulk cargo forecast for the Dahej is as follows:

Table No. 1:- Dry Bulk Cargo Forecast for Hinterland (Million Tones) Year Coal DOC Fertilizers FRM Cement Steel Wheat/Rice Total

2006-07 6.9 1.77 0.31 1.28 0.21 1.30 6.00 17.7 2007-08 7.4 1.76 0.30 1.32 0.25 1.31 6.00 18.3 2008-09 7.9 1.75 0.30 1.36 0.29 1.32 6.00 18.9 2009-10 8.5 1.74 0.29 1.40 0.33 1.33 6.00 19.6 2010-11 9.1 1.73 0.28 1.44 0.38 1.35 6.00 20.3 2011-12 9.8 1.72 0.27 1.49 0.44 1.36 6.00 21.1 2012-13 10.6 1.70 0.27 1.53 0.51 1.38 6.00 21.9 2013-14 11.3 1.69 0.26 1.58 0.59 1.39 6.00 22.8 2014-15 12.2 1.68 0.25 1.63 0.68 1.40 6.00 23.8 CAGR 7.4% -1.0% -2.7% 3.0% 15.6% 1.0% 0.0% 3.6



From the above figures the need of the project both is well satisfied. More over the project is financially sound with an Internal rate of Return (IRR) at 19.04% and Pay back period of 7.08 years.

1.5 PROJECT BREAKDOWN STRUCTURE:

1.6 GENERAL PROJECT INFORMATION:

Table No. 2:- Dry Bulk Cargo Forecast for Dahej (Million Tones) Year Coal DOC Fertilizers FRM Cement Steel Wheat/Rice Total

2006-07 2.5 0.47 0.05 0.20 0.21 0.17 0.67 4.3 2007-08 3.0 0.52 0.05 0.26 0.25 0.20 0.77 5.0 2008-09 3.6 0.59 0.06 0.35 0.29 0.23 0.89 6.0 2009-10 4.2 0.66 0.06 0.47 0.33 0.27 1.02 7.0 2010-11 4.9 0.74 0.06 0.49 0.38 0.32 1.18 8.1 2011-12 5.3 0.83 0.06 0.50 0.44 0.37 1.36 8.9 2012-13 5.7 0.93 0.06 0.52 0.51 0.42 1.57 9.7 2013-14 6.1 1.04 0.06 0.53 0.59 0.49 1.81 10.6 2014-15 6.6 1.17 0.06 0.55 0.68 0.57 2.09 11.7 CAGR 15.2% 12.2% 6.2% 17.5% 15.6% 15.9% 15.4% 15.0%

Name Of The Project Construction of Approach Jetty, Main jetty, & mooring Dolphins For Solid Cargo Port Terminal

Project Code 1005.201.001 Employer (Client)

Adani Petronet Port Pvt. Ltd. (APPPL) Plot No.604, At &Post Lakhigam Taluka: Vagra, Dist.: Bharuch

Project Management Consultants

PMC Projects India Pvt. Ltd. “Infrastructure House”, Nr. Mithakali Six Roads, Navrangpura, Ahmedabad – 380009 Ph : +91(079) 25555801

Structural Consultants L & T Rambol Contractor Simplex Infrastructure Limited (SIL) Type Of The Project Infrastructure Project (Marine project) Contract Type Item Rate Contract Contract Value Rs. 84, 00, 00,000 (Rs. 84.00 Cr.) Estimated Project Value Rs. 250, 00, 00,000 (Rs. 250.00 Cr.) Contract Period 38 months From the date of commencement Commencement of Project 01/04/07 (1st April 2007) Expected Date of Completion 01/06/10 (1st June 2010) End Use Of The Project Loading & Unloading of Dry Bulk Cargo Defect Liability 365 days from the date of Taking Over



1.01 LAYOUT PLAN OF THE PROJECT circle approach & main jetty



1.7 LOCATION OF THE PROJECT: The site of the Project is situated on the East Coast of Gulf of Khambhat in Bharuch District. The total area for the project is around 575 hectares and it also includes a part of land required for storage facilities.

The Jetty under construction is located between the jetties of Petronet LNG & GCPTCL Latitude: 21°47′00′′ North Longitude: 72°32′00′′ East The Site Office is situated at approximately 2 kms from the jetty site. Another site office is also situated in Bharuch city which around 45 kms from the site.

Solid Cargo Port Terminal



1.8 CLIMATIC CONDITIONS & SEISMIC ZONE 1.8.1 Wind The wind regime is dominated by monsoon: SW monsoon (June to August) - Moderate to strong winds, monsoon rains and possibility of cyclones.

Post-monsoon period (Sept. to Nov.) - Light winds from varying directions. Winter season (Dec. to March) – Light winds from North East, Cyclones are rare. Pre-monsoon (March to May) – Moderate winds from South West.

From the earlier studies of the site, the wind climate is summarized as given in table below.

1.8.2 Rainfall The South West monsoon from June to September contributes about 92% of annual rainfall of 1000 mm.

The heaviest rainfall in 24 hours is 480mm recorded on 15th September 1958.

1.8.3 Temperature The variation in temperature is significant, month of April and May are hottest with mean maximum temperature of about 40ºC.January is coldest with a mean minimum temperature of about 13ºC.

1.8.4 Waves HR Wallingford (HRW) has studied the wave climate in the area at the Dahej Coast and the results of the study carried out by HRW are presented below:

Access To Site Mode Of Transportation Description

Road Link

A 42Kms long two lane highway connects Dahej with the district head quarters at Bharuch. Bharuch lies on the National Highway No.8 from

Mumbai to Ahmedabad.

Rail Link

Dahej is a part of Western Railway network of Indian Railways. Dahej railway station which is around 2Kms from the

GMB port site, is connected by narrow gauge rail upto Samni (40kms) and then to Bharuch(25Kms). As a part of the project, the same rail line is going to be

converted into a broad guage line and it will be extended till the port premises.

Air Link The nearest airport is at Baroda which is about 135 Kms away by road.

Table No. 3:- Wind Climate Summary

Duration Pre-dominant wind direction Pre-dominant wind speed (km/hr)

October to March NW 13-19

April to May NW 13-19

June to September SW 30-50

Table No. 4:- Wave Climate SummaryParameter Return Period (100 Yr.)

Hs (mts.) Tp (Seconds) 180o N 1.2m 7 to 11 secs 210o N 3.5m 10.0 secs 240o N 2.7m 9.0 secs 270o N 2.6m 8.9 secs



The significant wave heights are 1.5mts and it has an exceedance probability of approximately 2 to 5 %.

1.8.5 Tides The tides are semi-diurnal and the levels are as below:

1.8.6 Currents The tidal currents are very strong at Dahej site. Reports indicate that the flood current runs at 6 knots, and the ebb current at 4 knots. The current velocity at the north of this location can reach upto 7.5 knots. The current direction reverses approximately 180 degrees. The Tidal currents at Dahej are second highest in the whole world.

1.8.7 Morphology The morphological processes in the Gulf of Khambhat are complicated. From the previous studies carried out at site, it appears that the overall system is in a state of dynamic equilibrium.

Main characteristics are moving channels requiring regular adjustment of navigation buoys. The Dahej site is located just north of the point where the Narmada River enters the Gulf.

The river brings large quantities of sediment to the Gulf, estimated at more than a million tons of material per year.

1.8.8 Seismic Zone Moreover the site falls in seismic Zone V. The site falls near a principal deep seated fault line and is located at a moderate risk zone.

Kim and Surat Fault lines which are minor Faults can also be said to be near, but the impact due to them is considered to minimal.

1.9 DESIGN CONSIDERATIONS

The key factors that forms the basis of the geometry, structural configuration and design of the approach bridge and the berth includes:

The berth is designed for rail mounted cranes on rail on rail gauges. Also provision is kept for Mobile Harbor mounted cranes.

As a part of future expansion a conveyor system capable of handling 4000 tph will be installed on the rear section of the berth and one side of the approach.

The berth and approach will be two separate structures completely independent of each other. The design Draft RL of -15m is adopted. The berth is designed to handle 80000DWT vessels. The berth is designed to handle two cranes working side by side. Load intensity of 5t/m2 is considered for designing the berth. At the time of construction 100 T cranes can be brought on the Approach Bridge and berth and hence should be designed for its loads.

Mean Highest High Water of Spring MHHWS +10.1mCD Mean High Water Spring MHWS +9.1mCD Mean High Water Neap MHWN +7.1mCD Mean Sea Level MSL +5.1mCD Mean Low Water Neap MLWN +2.4mCD Mean Low Water Spring MLWS +0.9mCD Mean Lowest Low Water of Spring MLLWS +0.7mCD



1.9.1 Design Criteria for Approach & Main Jetty Design Life: Main Berth – 50yrs Fender & ladders – 8yrs

1.9.1.1 Vessel Parameters:

Environmental Criteria Considered:

1.9.1.2 Currents

The design Current parameters considered for designing are as follows: Current Velocity at Surface - 3.85 m/sec Current Velocity at Mid depth - 2.25 m/sec Current velocity at Bottom - 1.80 m/sec 1.9.1.3 Wind

Basic Wind speed of 19m/sec is considered for mooring of any vessel. Basic wind speed of 44m/sec is considered for survival condition without any vessel mooring. 1.9.1.4 Earthquake

The seismic loading is considered in accordance with IS 1893 (Part-1): 2002. The maximum live load considered in combination with seismic loading is 50% of the total overall live load.

1.9.2 Design load:

1.9.2.1 Foundation of Piles

Pile capacity of Bored Cast in situ piles are counted as per IS 2911. 1.9.2.2 Scour

A minimum scour of 4m in deep water and 1m in the shallow water is considered in design.

Table No. 5:- 80000DWT Bulk Carrier Vessel’s Parameters Parameter Dimensions

Displacement Tonnage 106667T

Length Overall 259m

Width 36.6m

Depth 19.9m

Draught 13.2m

Table No.6:- Operating Conditions during Berthing/Vessel Approaching

Parameter Consideration Wave Height (Max.) 4.5m

Direction Of Approach 180o-270o N

Significant Wave Height 2.41m

Time Period (Peak) 6-8 sec

Table No. 7:- Survival Conditions during Berthing/Vessel Approaching

Parameter Consideration Wave Height (Max.) 6.5m

Direction Of Approach 210o N

Significant Wave Height 3.5m

Time Period (Peak) 10 sec

Table No. 8:- Self Weight Considered Parameter Consideration

Density Of Concrete 2500 Kg/m3

Density Of Steel 7850 Kg/m3

Table No. 9:- Live Loads Considered

Parameter Value

Deck Live Load (operational Conditions) 2.5 T/m2

Deck Live Load (Maximum Design Load) 5.0 T/m2



1.10 COST BREAKDOWN STRUCTURE 1.10.1 Cost Breakdown Structure for Project

1.10.2 Cost Breakdown Structure for Approach Jetty

Table No. 10:- Cost Breakdown Structure for Project

Sr. No. Elements Cost(Rs.)

1 Approach Jetty 278509364.00

2 Main Jetty 1 263199913.00

3 Main Jetty 2 229061072.00

4 Mooring dolphins for Main Jetty1 19767158.00

5 Mooring dolphins for Main Jetty2 49462520.00

Total - 840000027.00

Table No. 11:- Cost Breakdown Structure for Approach Jetty

Sr No. Items Cost

1 Pile Foundations 198517300.00

2 Precast Works & Cast In Situ Works 76321564.00

3 Miscellaneous 3670500.00 Total 3278509364.00



2.1 WORK BREAKDOWN STRUCTURE

Sub- Structure Super Structure

CHAPTER 2. CONSTRUCTION & METHODOLOGY

Client: Adani Petronet Port Pvt. Ltd. (APPPL) It is a Joint Venture company of Adani Port & Petronet LNG Ltd. (PLL)

Structural Consultants: L & T Ramboll The structural Design for the marine works is carried out by L & T Ramboll

Contractor: Simplex Infrastructures Limited. (SIL) SIL is the main contractor for the Marine works.

Project Management Consultants: PMC Projects India Ltd. Project Management, Procurement, Design, Supervision & Planning

Labor Contractor: JPPL Miscellaneous Works, Formwork Design & preparation, Liner fabrication

Sub Contractor: Joy Construction For Pre cast Works & Cast In Situ Deck Works & Fabrication of Temporary Decks

Geo technical Investigation: Fugro Geotech Ltd.

Labor Contractor: M. Panikar For All the works related Gantry Piling

Quality Testing Laboratories AERI (Ahmedabad Engineering Research Institute) KCT For Testing of Materials



2.2 ORGANIZATION CHART OF PMC AT SITE



2.01 BASIC DRAWINGS – PLAN, SEC, ELEV, GAD,



2.02 BASIC DRAWINGS – PLAN, SEC, ELEV, GAD, JOB LAYOUT



2.03 JOB LAYOUT

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2.3 CONSTRUCTION SCHEDULE



2.4 ACTIVITY WISE PROJECT BREAKDOWN

Construction of Solid Cargo Port terminal

Phase-1 Phase-2 Scope of Phase 2 Will be finalized after completion of Phase-1

Sub Structure Activities for Back Up Facilities

Back Up Facilities 1) Storage Yard 2) Office & Other

Buildings 3) Road Works

Super Structure

Sub Structure

Earth Work

Concreting

Reinforcement

Formwork 1. Foundation Work

1) Storage Yard, High Mast

2) Stacker & Reclaimer 3) Conveyor System

1. Structural Works 1) Storage Yard, High

Mast 2) Stacker & Reclaimer 3) Conveyor System 4) Rail Mounted Crane

on Main Berth

Fabrication

Erection

2. Services 1) Mechanical 2) Electrical 3) Fire fighting 4) Plumbing 4) Dust suppression 5) IT Facilities

Sub Structure Activities for Back Up Facilities

3. Finishes 1) Plastering 2) Flooring 3) Painting

Marine Works 1) Approach Trestle 2) Main Berth

Super Structure

Sub Structure

Sub Structure Activities for Marine Works

1. Piling

Gantry Shifting

Reinforcement Fabrication

Liner Fabrication

Concreting

Boring & Liner Driving

2. JUB Piling

3. Gantry Piling

Super Structure Activities for Marine Works

1. Pre casting Works 1) Pile Muff 2) Capping Beam 3) Longitudinal Beam 4) Deck Slab Erection of

Precast Elements

Concreting

Reinforcement

Formwork

5. Services 1) Mechanical 2) Electrical 2) Fire fighting 4) Plumbing

2. Cast In Situ Works 2) Stage – 1 Works 3) Stage – 2 Works 4) Insert Plate Fixing

Concreting

Reinforcement

Formwork

3. Rock Bund Formation 1) Laying Rubbles in

profile as per design

4. Erection of Fender System



2.04 Over all construction sequence of approach and rock bund to be added in it



2.5 WORK METHODOLOGY 2.5.1 Construction Methodology First of all the expansion of the existing rock bund shall be done followed by construction of new rock bund.

Initial 4 piles shall be done with the help of tripod and the Piling gantry shall be made ready in the meanwhile.

Piling shall then be done with the help of Gantry using End on method. Piling for main jetty shall be completely done using Jack up Barge. For Gantry Piling with End on method, Liners shall be fabricated on the shore and brought to the gantry for driving.

After the arrival of Jack up Barge the liners of the approach trestle shall be pitched and driven by jack up barge and the boring and completion of the pile shall be done by the Piling Gantry.

The Liners shall then be filled with Reinforced Cement Concrete. The piling work of main jetty shall completely be done by Jack up barge. Hydraulic Rig, Vibro hammer & 150 Ton capacity crane shall be mounted over the jack up barge to facilitate the piling works through jack up barge.

Precast Elements include Precast Pile Muffs, Precast Pile capping Beams, Precast Longitudinal beams & Precast Deck Planks.

All the Precast Elements are to be manufactured in the precast yard and then transported to the site for the purpose of erection.

All the junctions are cast in situ and shall be casted in one go along the length and two layers in height.

The cast in situ works involve the junction of pile & pile muff, the junction between two pile capping beams, and also between the longitudinal beams of consecutive grids.

After the erection of the slab is completed, the in-situ slab will be casted. This will involve the casting near the expansion joint & placing of the crane rail.

After the casting of the in situ deck, a wearing coat has to be laid with a slope of 1%. All the services like water line, fire hydrant, crane & berth electrical & communication lines will be done after the completion of the berth construction but conduits and provisions for the services shall be kept during the construction.

2.5.2 Justification of Methodology Used The existing rock bund was extended in order to reduce the cost of the project. As all the piles are marine piles, end-on method (piling using Gantry) is preferred. As there is no hard rock available, Majorly Friction Piles are used. The piles are designed in such a way that 80% of the load is transferred through friction & 20% through End Bearing.

Precast Elements are used to reduce the time to a large extent and hence also the cost. Pre-cast slabs (portion of overall slab) are used to reduce the complexity of shuttering & staging of the in-situ slab works. Moreover, it reduces the cost of formwork of the slab & increases the speed of construction.

Slope protection is provided in form of Rock Bund which reduces the washing away of bed.

Table No.12 :- Degree Of Mechanization Sr No. Items Tools ,Equipments & Plants Used Scale

1 Gantry Piling Gantry, Piling Winch

2 Piling With Jack Up Barge & Hydarulic Piling

Jack Up Barge, DGPS, Hydraulic Rig, Vibro- Hammer

3 Liner Fabrication Liner Bending Machine 4 Reinforcement Fabrication Reinforcement Cutting Machine

5 Pre cast Works 20T Gantry, Needle Vibrators, Batching Plant & Transit Mixers

6 Erection Works Erection Gantry 20 T, 75 T Crane & 150 T Crane

7 Cast in Situ Works Batching Plant, Needle Vibrators, Concrete Pump & Transit mixture

Fully Mechanized More Mechanized Partly Mechanized More Manual Manual



2.6 STATUS OF SITE

Sr.No Description unit Total Job

Status at the Time of Joining

Status at the Time Of Leaving

1 Piling works a Approach Piling Nos. 188 104 54 2 Precast works a Slab Nos. 2790 1377 1072 b C Beams Nos. 564 279 181 c Pile Muff Nos. 188 93 66 d Longitudinal Beams Nos. 744 368 277 3 Erection works a Slab Nos. 2790 222 282 b C Beams Nos. 564 62 100 c Pile Muff Nos. 188 94 44 d Longitudinal Beams Nos. 744 67 88 4 Cast In Situ Works a Stage 1 Nos. 376 36 30 b Stage 2 Beams only Nos. 94 9 9 c Stage 2 Slabs only Rmt. 1106 54 58



2.7 PLANTS & MACHINERY

Table No. 13:- Plants & Machinery Sr. No. Plant and Machinery Company Fuel of

Operation Capacity Nos.

For Piling Works

1 B.P. Winch c/w 6 YDA Engine Siemens Diesel 7.5 Ton 6

2 B.P. Winch c/w 6 YDA Engine Greaves Diesel 5 Ton 2

3 Hydraulic Rotary Rig IMT Diesel -- 1

4 Crawler Crane Sany Diesel 150 Ton 1

5 DGPS System -- -- 1

6 Vibro-Hammer with Powerpack -- Diesel 400KN 1

7 Lighting DG Set Sudhir Diesel 125 kVA 1



10 Submersible Pump -- Electricity 5 HP 3

11 Vacseal Pump -- Diesel 4

12 Welding Transformer Greaves Electricity 125 kVA 10

13 Diesel Welding Generator Greaves Diesel 75 kVA 2

For Concrete

14 Batching Plant Mecon Electricity 30m3/Hr. 2

15 Transit Mixer Greaves Diesel 6 Cum. 6

16 Concrete Pump Sany Diesel 43 Cum. 3


For Civil Works

18 Vibrator -- Electricity 12

19 Tailor made Yard Gantry -- Electricity 15 Ton 2

20 Tailor made Erection Gantry -- Electricity 25 Ton 2

21 Lighting DG Set Kirloskar Diesel 75 kVA 4


23 Welding Transformer Greaves Diesel 125 kVA 9


25 JCB/Loader JCB Diesel 0.9 Cum. 1

For Common Works

26 Crawler Crane Sany Diesel 75 Ton 1

27 Hydra Crane Escorts C-8000 Diesel 8/10 Ton 2

28 Twin Screw Tug -- Diesel 1500BHP 1

29 Air Compressor Sany Diesel 365 cfm 2



30 Tractor Trailer -- Diesel -- 3

31 Lighting DG Set Kirloskar Diesel 75 kVA 3



34 Welding Transformer Greaves Diesel 125 kVA 10


36 Water Pumps Local Electricity 10/5/3/2 HP 12

37 Total Station Trimble Battery

Operated --

1

38 Tug Boat -- Diesel 800 BHP 1

39 Dumper TATA Diesel 8 Ton 2

2.8 Material Details

2.9 SPECIFICATIONS

2.9.1 Cement Cement conforming to IS: 12269 may be used provided the minimum cement content mentioned elsewhere from durability considerations is not reduced.Strength tests shall be carried out for 56 and 90 days to fine tune the mix design from strength considerations.

Total chloride content in cement shall in no case exceed 0.05 percent by mass of cement. Also, total sulphur content calculated as sulphuric anhydride (SO3) shall in no case exceed 2.5 percent and 3.0 percent when tricalcium aluminium percent by mass is upto 5 or greater than 5 respectively.

Each consignment shall accompany with manufacturers certificate stating that the cement offered, is tested and it complies with the Indian Standard Specifications in all respect.

Cement in bags shall be unloaded under cover and stored in a perfectly watertight & well ventilated building accommodating sufficient cement to ensure continuity of the work & having a floor raised not less than 30cms from the ground.

Each consignment shall be stacked separately. The age of cement at the site of delivery to the site shall not be more than 2 months old and shall be used in the works within 3 months thereafter.

Table No.14 :- Material DetailsSr No. Material Unit Cost/Unit Transport Code

1 Cement (OPC 53 Grade)

50 Kg. Bag

Rs. 210 Trailer 500 Bags IS 12269

2 Fly Ash MT. Rs. 1500 Bulker IS 1489 3 Aggregate (20mm) Cum. Rs. 700 Dumper - 5 brass IS 369 4 Aggregate (10mm) Cum. Rs. 700 Dumper - 5 brass IS 383 5 Sand MT. Rs. 450 Dumper - 5 brass IS 383 6 Reinforcement Steel MT. Rs. 31850 Truck – 20T IS 1786 7 ISMB MT. Rs. 35700 Truck – 20T IS 432 8 ISMC MT. Rs. 26800 Truck – 20T IS 432 9 ISA MT. Rs. 31263 Truck – 20T IS 432 10 MS Plates MT. Rs. 27750 Truck – 20T IS 432 11 Admixture Kg. Rs. 105 Truck IS 9103

12 Water Liters Rs. 100/1000 Ltrs.

Tanker – 8000 Ltrs.

IS 456

13 Bentonite Bags

(1MT.) Rs. 512 Truck – 24 bags IS 6186



2.9.2 Aggregates Aggregates shall comply with the requirements of IS: 383 “ Coarse & Fine Aggregates from Natural Source for Concrete”

Aggregates shall be from approved quarries. The aggregates shall be hard, strong, durable, clean &free from any adherent coating or deleterious matter.

Aggregates which are not clean shall be washed in clean fresh water to the satisfaction of the employer.

Coarse aggregates having coloured layer shall not be used in the permanent works. All aggregates shall be subjected to inspection and testing. Sampling shall be in accordance with IS: 2386 (Part I to Part Viii) “Methods of Test for Aggregates for Concrete”.

Aggregates shall be stored on site on clean well drained area which is not flooding. Aggregates of different size shall be stored separately. The maximum value for flakiness index for coarse aggregate shall not exceed 35 %. The fineness modulus of the aggregate shall neither be less than 2.00 nor greater than 3.50.

2.9.3 Water Clean fresh water only shall be used for mixing all concrete, grout and mortar. The water shall be free from any deleterious matter in solution or in suspension and be obtained from an approved source.

The quality of water shall confirm to IS: 456 and chloride content of water should not be more than 300 ppm irrespective of IS: 456 specifications.

Contractor shall make adequate arrangements to deliver and store sufficient water at the works for use.

Contractor shall make arrangements for daily checking PH value of water at site. 2.9.4 Reinforcement steel Reinforcing bars for concrete shall be round bars of Grade 1 quality complying to IS: 432 “Mild Steel& Medium Tensile Steel Bars & Hard Drawn Steel Wires for Concrete Reinforcement” or High Yield Strength Deformed Round Bars confirming to IS: 1786 “Specifications for Cold Twisted Steel Bars for Concrete Reinforcement”.

Reinforcing steel to be used for various different structures shall be as given below:

Binding wire shall comply to IS: 280 “Mild Steel Wire for General Engineering Purpose” with size 1mm or over.

Reinforcing bars shall be stored at site on timber or concrete supports suitably spaced and of sufficient height to keep steel clear of the ground.

2.9.5 Structural steel Structural steel used for works shall comply to IS 2062 “Weldable structural steel”.

Table No. 15:- Type Of Reinforcement Used in Different Structures Structure Type Of Steel Grade Of Steel

Jetty HYSD as per IS: 1786 Fe 500

Other Structures Main Bars HYSD as per IS: 1786 Fe 500 Placement Bars, Ties, Saddles MS as per IS: 432 Fe 250

Table No. 16 :- Cover To ReinforcementSr. No. Elements Tolerances

1 Piles 75 mm

2 Pile Muff 60 mm 3 Pile Beam 50 mm 4 Longitudinal Beam 50 mm 5 Deck Plank 50 mm



Irrespective of the manufacturers’ certificate, samples must be collected and sent to external laboratory test for one set/100MT.

The steel shall be stored on timber or concrete supports suitably spaced. The steel should be stored section wise.

2.9.6 Specifications For Concrete All underwater concrete works shall have minimum cement content of 400kg/cum. All concrete works above pile cut off level in jetty shall have minimum cement content of 360 kg/cum.

Minimum 25% of cement shall be replaced by Fly Ash. Fly-ash shall be as per IS: 3812. Test cubes shall be made in accordance with IS: 516 “Method of Tests for Strength of Concrete”, except that all test cubes unless otherwise ordered by the Employer, shall be compacted by vibration.

All Sampling and testing of concrete shall be carried out in accordance with IS: 1199 “Method of Sampling and Analysis of Concrete”.

Three out of each batch of nine cubes will be tested by the employer for crushing strength and weight at seven days and remainder at 28 days or at such other time as the Employer may determine.

A fully qualified & experienced quality control engineer shall be always present at the time of concreting.

No deviation from the declared proportions will be allowed unless and until the employer shall give his written authorization for the adoption of revised proportions for any class of concrete.

All loose materials, grease, oil, dirt, etc. shall be removed from the concrete surface, which is to receive grout.

The surface shall be left rough but not so rough as to interfere with proper placing of the grout. The contractor shall agitate the placed concrete thoroughly by means of sufficient number of mechanical vibrators of adequate power and having a frequency of 6000 impulses per minute.

In no case shall concrete be dropped or thrown from a height more than 1.5mts. Concrete Beams, slabs & similar structures shall be carried out in continuous. Slump for Cast in Situ Elements should be in range of – 150mm to 190mm. All exposed faces of concrete shall be kept continuously moist for a period of 10 days. In places where water curing is not possible compound shall be applied by the procedure approved by the employer.

2.9.7 Precast Concrete No precast element shall be lifted from the bed till it attains 50% of design strength. The casting tolerances, unless otherwise specified, shall be within 3mm of true dimension. The method and time after casting of units of striking side shutters shall be subject to approval of the Employer.

Slump For Precast Elements- 75mm

2.9.8 Specifications For Formwork Form shall be true to shape, lines and dimensions of the concrete works. The contractor shall fix all the form work in perfect alignment and it shall be securely braced so as to be able to withstand, without appreciable displacement, deflection or movement of any kind, the weight of construction or movement of persons, material and plant.

Form shutters shall not be disturbed until the concrete has sufficiently hardened. Any damage resulting from premature removal of shutters or from any other cause shall be made good by contractor at his own expense.

All formwork has to be made by the contractor and the drawings of the formworks are to be submitted to the client and approved.

Table No. 17 :- Tolerances in Concrete ElementsSr. No. Elements Tolerances

1 Variation in Piles from their Location ±75mm

2 Shape & Dimension of Precast Elements ±3mm

3 Variation In Erection Of Elements ±25mm



3.1 PILE FOUNDATION USING PILING GANTRY

3.1.1 Scope There are in all 188 nos. of piled foundations in Approach Trestle. Depending upon the change in reinforcement, 188 nos. of pile foundations can be divided into two types i.e. P-11 & P-12.

3.1.2 Specification Construction and testing of bored piles shall be in accordance with IS: 2911(Part 1) “Code of practice for Design and Construction of Pile Foundations”.

To avoid deflection of piles during construction stage, contractor shall provide temporary structural steel bracings immediately after casting of bored cat in situ piles till the piles are interconnected with RCC deck beams.

Liners have to go 5 to 10 mts. below the sea bed level or as per the requirement of the client. In soils liable to flow the bottom of the liners should be kept ahead of boring in all cases. The size of the cutting tool shall not be less than 75mm of the diameter of the pile. Where stabilization of the sides of the bore hole is effected by the use of drilling fluids, the fluid level shall be maintained at a level not less than 1.5 mts above the level of the sub soil water or high water level as the case may be and the hole shall always then kept full with it till the concreting is completed.

For determining the founding strata, standard penetration test shall be carried out in the bore hole by “Nordmeyer Standard Penetrometer” for 2 piles in every 50m length of the berth and the approach.

A sample of bentonite suspension shall be taken from the base of the boring using an approved sampling device. If specific gravity of the suspension exceeds 1.5, the placing of the concrete shall not proceed.

The concrete shall be placed through a tremie pipe of 20-25 cm in dia. with a suitable hopper. The tremie pipe joints shall be air tight and the hopper must such that it produces a build up of atleast 2m concrete in pile.

Placing of concrete shall be continuous. At all times a shaft of 1.5 mts as per IS specifications shall be maintained between the tremie pipe opening and the concrete or as may be directed by the employer.

Any short fall in actual consumption of concrete in pile shall not be more than 5 % of the theoretical volume.

The clear concrete cover to main reinforcement shall be 75 mm and suitable spacer blocks shall be provided at intervals not exceeding 2mts and wired to the reinforcement.

3.1.3 Standard of acceptance for piles The head of the pile shall be within 75mm of the specified position. The pile shall not be out of plumb by more than 2%. The toe of the pile shall always be at the approved bearing level in each case. The total volume of concrete shall not be less than 95% and not more than 120% of the calculated volume.

The concrete shall be of design strength.

CHAPTER 3. CONSTRUCTION ACTIVITIES



3.1.4 General Information

Location : Approach Trestle (Approach Jetty)

Type of Pile : Bored Cast In – situ Pile.

Method of piling : End on Method.

Total Approach piles : 188 nos.

Pile Diameter : 1000mm, 1100mm & 1200 mm

Founding Level : (-) 30.00m, (-) 34.00m, (-) 38.00m

Pile Cut-off Level : (+) 12.395m.

Reinforcement Cut-off Level : (+) 14.495m.

Load Transfer Mechanism : 80% - Friction, 20% - End Bearing

Designed Capacity Of Piles : 300 Tonnes

Liner Tip Level : Till Refusal level

(Between (-) 5m to (-) 10m as per Tender Specifications)

Liner Material : 6mm & 8mm M.S. Plate.

Grade of Concrete : M 40.

Planned no. of piles/month : 16

C/C distance between piles : 12.00 m (1-2) 9.00m (A-B) ( Refer Drawing 2.01 & 2.02)

Reinforcement used : Thermo Mechanically Treated (TMT) Bars

Type Of Gantry : 6 Pile Gantry ( 4 Permanent Piles & 2 Temporary Piles )

Self Weight Of Gantry : 850 Tones



3.01 Layout Of Piles



3.1.5 Flowchart for Gantry Piling

PARRALEL ACTIVITIES

Till Founding Lvl. is achieved

Survey Works

Liner Lifting, Guide Welding, Liner Joining, Liner Pitching

Boring, Chiseling

Checking the Reinforcement Cage

Liner Driving

Bailing

Lowering Of R/FCage

Lowering Of Tremie Pipe

Gantry Shifting

Concrete Placing

Flushing of the Borehole with

Bentonite Slurry & Air

If Sp. Gravity > 1.25, Reflushing To

Be Done

Liner Fabrication

Shifting To Site

R/F Cage Fabrication

Shifting To Site

Checking By Apppl Engineer

Cutting & Shifting Of Rolling Bracing

Fixing Of Steel Capping Beam

Cutting Of Liner to the Required Level

Placing Of Wheels on the Capping

Beam



3.02EnaBling Structure Gantry Plan Section Elevation



3.03 General Job Layout Of Gantry



3.1.6 Liner fabrication Liner is a circular hollow tube made up of steel plate which is driven in the sea bed up to desired depth to act as a guide in piling operation & left permanently at the place. 3.1.6.1 Advantages of Liner

It is casing/extra anti corrosive layer to the piles. It prevents any collapse inside the bore hole at the time of piling. It acts as a formwork and doesn’t allow sea water to mix with the fresh concrete at the time of the concreting.

It prevents deterioration of concrete due to direct contact with the sea water. First liner gets corroded, than concrete gets deteriorated due to contact with sea water and at last reinforcing steel inside the pile come in contact with the sea water. Thus it increases the life span of pile.

Its rate of corrosion is very slow – 1mm / 10 years in sea water.

3.1.6.2 Equipment Details For Liner Fabrication

1. Plate Bending Machine: Purpose : Bending of plate Quantity : 1 no. Motor capacity : 7.5 HP Power consumption : 6.00 KW/Hr. Electricity Source : Diesel Generators 2. Diesel Generator: Purpose : Alternate source of electricity Quantity : 1 no. Capacity : 180 KVA 3. Welding Machine: Purpose : Welding of joints Quantity : 2 no. Current Capacity : 210 Amp. 4. Hand Gas Cutter: Purpose : Cutting 6mm thick plates Quantity : 1 no.

Machine cost: Welding machine: Rs. 30,000 / machine (approx) Plate bending machine: Rs. 50,000 / machine (approx) Gas cutting machine: Rs 5000 / machine (approx) Maintenance detail of machines: Gear oil : once every fortnight Consumption : 1-1.3 Liter approx.

Table No. 18 :- Details Of Liner StudiedSr. No. Parameter Description

1 Location Unit-1 & Unit-2

2 Internal diameter 1000 mm

3 External diameter 1012 mm

4 Length of single unit 1510 mm

5 Liner Cut Off Level +12.395m

6 Material for liner 6 mm Ms plates

7 Type of weld Metal arc weld

8 MS Shoe Of 8 mm Thickness 1000 mm long

9 No. of Lifting Plates 2 Nos.



Cost : Rs. 150 / Lt.

Grease : once a week Consumption : 1.5-2 Kg. approx. Cost : Rs. 105 / Kg

3.1.6.3 Material Details For Liner Fabrication

1. Steel Plates:

Purpose : Raw material for liner Type : Mild Steel Size : 6300 x 1500 x 6mm Cost : Rs.26000/MT

2. Oxygen cylinder: Purpose : Gas-cutting Capacity : 50 Kg. Consumption : 50 rmt. Cutting (approx.) / cylinder for 6mm plate Cost : Rs.175/cylinder 3. LPG Cylinder: Purpose : Gas-cutting Company : HP Gas Capacity : 14 Kg. Consumption : 250-300 rmt. Cutting (approx.) / cylinder for 6mm plate Cost : Rs. 450 4. Welding rods:

Company : ESAB Electrodes Pvt. Ltd. Type : Metal – Arc Welding Code reference : IS 4111 Size : 3.15 x 350 mm & 4.00 x 350mm Cost : Rs. 275/ packet (55 rods). Consumption : 170mm weld length /rod (4mm x 350mm) 120mm weld length /rod (3.15mm x 350mm)



3.1.6.4 Construction Sequence For Liner Fabrication

Bending it again in bending machine to get perfect circular

shape

Removal of Liner unit from the bending machine

Welding Throughout the length of the liner

Joining With another Member

Stacking in Fabrication Yard

Placing if plates in bending machine to get the circular shape

Tack Welding along the length of the plate from both the sides

Unloading of Mild Steel Plates

Stacking in Fabrication Yard

Cutting of Plates in required



3.04 Bending machine Drg.



3.1.6.5 Unloading MS plates are brought to site in the trailer of 20 ton capacity. It is unloaded from the trailer by sliding it over the roller, at the place of the storage. Transportation to the fabrication yard from the Material storage area is done through cranes (Hydra).

3.1.6.6 Cutting MS plates are available in size: 6320 X 1510 mm. Length of each liner unit is same as the width of the plate and it is 1510 mm. The length of the plate required for fabrication of liner is.

L = π x (T +NB) Where, L = length of plate required T = thickness of plate NB = nominal bore So to fabricate 1000 mm liner length of plate required is: L = π x (6 + 1000)

= π x 1006 = 3160.44 mm ≈ 3161 mm

Length provided on site at the time of cutting is 3164 mm.

To fabricate 1200 mm liner length of plate required is: L = π x (6 + 1200)

= 3.14 x 1206 = 3788.76 mm

Length provided on site at the time of cutting is 3790 mm. Extra length is provided as cutting allowance. Size of full plate is: 6330 X 1510 mm. Plate length required for 1000 mm liner is 3164 mm. So 2 nos. of plates of 3164 X 1510 mm can be cut from 1 full size plate without any wastage.

Before cutting plate diagonal check is carried out to check the proper geometry of plate. Then required distance is measured from both the ends of one side and that point is marked on the plate. Than again diagonal check is provided for that marked points to check proper geometry.

Then line is marked with the help of chalk and string between those two points. Then the plate is cut with manual gas cutting machine. Oxygen and L.P.G. are the gases used for the cutting of the plates.

3.1.6.7 Bending After cutting the plate in required size it is taken to the plate bending machine with the help of labourers as it is not far from the cutting site.

Total three nos. of rollers are there. Two bottom roller and one top roller. First the top roller of the plate bending machine is loosened. The plate is then kept over the two bottom circular rollers. After this, the top roller is tightened to the required amount.

Table No. 19 :- Liner Dimensions

Sr. No. Type

Liner Length (m)

(Theoretical)

Liner Length (m)

(Studied) Unit Weight

(Kg. / M) Total Weight

(Kgs.)

1 Shoe 1.00 1.00 201.32 201.32

2 Bottom Liner 12.08 12.06 148.917 1818.37

3 Middle Liner 9.6 9.6 148.917 1429.603

4 Top Liner N x 3.02 5x3.02=15.1 148.917 2248.646

Total 5557.96Kgs.



Then plate is allowed to pass 2 to 3 times for proper straightening. Then initial curvature is given to the plate with the help of wedge. It is inserted between top roller and plate at three locations center and at the ends of the plate.

Then top roller is tightened as per the marking they have marked on the tightening screw to get proper profile. Curvature of the liner is continuously checked with the help of piece of steel plate cut in an exact fashion of internal diameter of the liner.

Whole circular shape is obtained in one rotation after inserting wedge block. Once the circular shape is formed tack welding of 100mm @ 200 C/C is done on both the sides of plate.

After tack welding it is rotated in the machine for additional 3 to 4 minutes to get exact curvature. Then liner is removed from the machine by withdrawing the movable side from the machine.

3.1.6.8 Welding Each liner unit is then welded along the length with 6mm shielded metal arc welding on both the sides.

Two liner units are welded along their circumference such that welded joints along the length are not in the same alignment (staggered).

For bottom most liner of the pile 7 such units are welded together. And at the bottom most portion shoe is created by providing additional plates of 8 mm of the varying length 1000 mm.

For other member 3 to 4 units are welded. Then this assembly is stacked properly with the help of hydra crane.

3.1.6.9 Quantities (Theoretical) 1. Steel Plate (6mm Thk.)

Length of one unit : 1500mm. No. of Units required : 2 Nos. Length of plate required for one unit : L = π x (6 + 1000) = π x 1006 = 3.161 m But provided at site = 3.164 m Now assuming 15 mts as Liner Refusal Level Pile Cut off level is +12.395m Including 5% wastage due to cutting of Liner while driving = 1.37mts Therefore Total Length of Liner = 15 +12.395 + 1.37 = 28.76 mts To Fabricate 28.77 mts of Liner Length the amount of units required are

= 28.76/1.51 = 19 units approx.

Therefore Total Quantity of MS Plate Required = No. of liner units x Length of each liner unit x

Width of each unit x Thickness of plate = 19 x 1.51 x 3.164 x 0.006 =0.5446 m3

Now, Density of steel is 7850 Kg / m3 Therefore, Quantity of 6mm plate = 0.5466 x 7850 = 4275.51Kg. Adding 2% wastage in cutting = 85.51 Kg Therefore, TOTAL QUANTITY OF 6 mm PLATE = 4275.51 + 85.51 = 4361.02 Kg (4.361 MT) 2. Shoe of the liner (8mm Thk.)

Quantity of 8 mm thick liner shoe = (1 X3.164 X0.008) = 0.02531 m3 = 199 kg. Adding 2% wastage = 202.97 Kg



3. Quantity of oxygen and L.P.G. required: Available length of 6mm steel plate : 6.33m Length required for single liner unit : 3.164m No. of liner units / 6.33m plate : 2 Total no. of 6mm liner units required : 19 Total no. of 6mm steel plates required : 9.5

Therefore, Length of cutting required = No. of 6mm steel plates required x Width of plate = 9.5 x 1.51m = 14.345 m Quantity of Oxygen cylinders required = Length of cutting required Approx. cutting / cylinder = 14.345m / 45 m = 0.319 no. of Oxygen cylinders Quantity of LPG cylinders required = Length of cutting required Approx. cutting / cylinder = 14.345 m/ 280 m = 0.051 no. of LPG cylinders 4. Quantity of welding: (thickness – 6MM) For 6 mm thick Liner units on external face:

Along the length = No. of units x Length of single unit = 19 x 1.51m = 28.69 m

Along the circumference = (No. of units – 1) x 3.164m = (19 – 1) x 3.164 = 18 x 3.164 = 56.952 m For 6 mm thick Liner unit on internal face:

Along the length 100 mm weld is provided @ 200 C/C. Along the length = 1+ (total length/ (100+200))

= 1 + 100 = 101 = 101 X 0.1 = 10.1 m

For shoe plate 8 mm thick Along the length = 1 m Along the circumference = 2 X 3.2 = 6.4 m

Total welding length = 28.69 + 56.952 + 10.1 + 6.4 = 102.142 m Quantity of rods = Total length of welding

Length of welding / rod = 102.142 m / 0.170 m = 601 rods (approx) 3.1.6.10 Labour Requirement For Liner Fabrication

Table No. 20:- Labour Requirement For Liner Fabrication Sr. No. Type Skilled Unskilled

1 Unloading (once) - 6 2 Marking 1 1 3 Cutting 1 - 4 Bending 2 4 5 Welding 2 -

Total 6 11



3.1.6.11 Time Cycle For Liner Fabrication

3.1.7 Reinforcement Cage Fabrication 3.1.7.1 Scope of Work Supplying, cutting, bending, welding the reinforcement bars and placing in position reinforcement cage including cleaning, wire brushing, straightening, tack/lap/but welding with approved electrodes including material and labour. etc, complete.

3.1.7.2 General Information

Diameter of pile : 1000 mm Pile Type : P 11 Depth of pile : (-) 30 m Pile cut off level : 12.395 m R/F cut off level : 14.395 m Tip level of R/F : 29.925 m Total length of R/F cage : 44.955 m Main reinforcement : 25/32mm TMT bars No of R/F cage : 4 nos Lap length : 2200 (mm) Dia of inner stiffener ring : 20 mm TMT bars Lap for inner stiffener ring: : 300 mm Helical stirrups : 12 mm TMT bars 150 c/c Clear cover to main R/F : 75 mm

Type of weld : lap weld 3.1.7.3 Material Details For Reinforcement Cage Fabrication

1. Reinforcement: Diameter : 10, 20, 25, 32mm TMT bars Source : SAIL Cost : Rs. 24500 / MT

2. Welding rods: Company : ESAB Electrodes Pvt. Ltd. Type : Metal – Arc Welding Code reference : IS 4111

Table No. 21:- Time Cycle For Liner Fabrication Sr. No. Type Time

1 Unloading (once) 2 Hours

2 Marking 0.25 Hours (15 minutes)

3 Cutting 0.25 Hours (15 minutes)

4 Bending 0.33 Hours (20 minutes)

5 Welding 0.33 Hours (20 minutes)

Total Time Taken For Liner Fabrication of One Pile 19 x (0.25+0.25+0.33+0.33) + 2 = 24.17 Hours



Size : 3.15 x 350 mm & 4.00 x 350mm Cost : Rs. 275/packet. (55Nos.)

Consumption : 170mm weld length/rod (4mm x 350mm) 120mm weld length/rod (3.15mm x 350mm) Above Consumptions are for 6mm weld.

3. Binding Wire: Thickness : 19 gauge Cost : Rs. 28/kg Availability : 50 Kg rolls Code : IS 814 Amp : 115 – 265 Size : 4 x 450 mm

3.1.7.4 T.E.P Details For Reinforcement Cage Fabrication

1. Bar cutting machine :

Use : cutting and bending of bars Company : Spartan Quantity : 2 no. Motor capacity : 8 HP Power consumption : 6.25 KW / Hr. Fuel : Electricity

2. Gas cutter:

Use : Cutting plates Quantity : 2 no. Company : Asha Pvt. Ltd.

3. Welding Machine: Use : Welding Company : ESAB Model no : Arc – 400 Input : 42 amp, 415 volts, 50 Hz Range of weld amp : 30 – 400 amps. Quantity : 8 no. Weight : 115 Kgs

4. Goliath crane : Use : To transfer fabricated cage Capacity : 20 tones Oil change : 200 to 250 hr

Capacity Of Bar Cutting Machine No. of Bars It Can Cut in a Single Go

1 1 2 3 5

Bar Diameter 36 32 25 20 16



3.05 Details of Pile Reinforcement Cage



3.1.7.5 Construction Sequence of Reinforcement Cage Fabrication

3.1.7.6 Construction Methodology For Reinforcement Cage Fabrication

First of all, Bar Bending schedule is prepared & approved by engineer. Then R/F bars are cut as per approved bar bending schedule.

R/F bars are cut to suit the length of pile & the length of bars available. R/F bars are available in 12m length on the site. They are cut to the required size with the help of Gas cutting tool.

A bed of ISMC 250 is made by keeping 4 ISMC250. Helical stirrups are made with the help of tailor made assembly. But this procedure doesn’t give them shape and the diameter required.

Placing of main bars

Bending of R/F for Helical Rings

Preparation of B.B.S

Approval of B.B.S

Cutting of bars according to B.B.S

Marking of location of inner stiffener ring

Positioning of inner stiffener ring

Welding of main bars with stiffener ring

Inserting helical stirrups and cover blocks

Welding of lap of helical stirrups

Welding to main reinforcement

Lifted to stacking yard

Checking by clients engineer

Fabrication of helical stirrups

Preparation of leveled platform

Cutting of bars for inner stiffener ring

Fabrication of inner stiffener ring



The inner guide ring is made at the bar benders bench. The whole process is manual and does not involve any machinery.

Firstly two main Bars are kept on the ISMC 250 at appropriate space as per the drawing. Now, Guide rings are placed in their respective locations and welded. Main bars are marked on them at the required spacing as per the drawing. Then one bottom R/F bars is welded to the inner stiffener rings. Then, the top R/F bars is welded to the inner stiffener ring. In the same way, all the R/F bars are welded to the inner stiffener ring. But care is taken that two opposite pairs are tied at a time in order to prevent the imbalance in the assembly.

Now the positions of helical stirrups are marked at 250mm c/c with the help of chalk and measuring tape on the main R/F.

Helical stirrups along with already inserted 6 cover blocks (75mm) are then slide over the main R/F bars along their length. But care is taken that c/c distance between two helical stirrups is not more than 250mm.

In this way, all the R/F cages are prepared on the ground. After that, they transferred to the place of stacking with the help of crane.

After that, they transferred to the place of lowering into the pile with the help of trailers. After the first cage is lowered, it is held at the casing top level by placing reinforcement bars between the rings.

At the same time another cage is lifted according the sequence given to them. Second cage is kept hanging such that it overlaps 2.20 m with the first cage.

This overlapped junction is then strengthened by welding r/f bars of both cages with each other using tack welding.

After that, helical stirrups along with cover blocks are inserted around the junction & are tied with the cage and then tack welded.

This makes both separate R/F cage units into a single strong unit. In the same manner all the cages are lowered in the pile.

3.1.7.7 Labour Requirement For Reinforcement Cage Fabrication

3.1.7.8 Time Cycle For Reinforcement Cage Fabrication

Table No. 22 :- Labour Requirement For Reinforcement Cage Fabrication Sr. No. Type Skilled Unskilled

1 Unloading - 6 2 Cutting Main Reinforcement 2 2 3 Making helical stirrups 1 3 4 Inner stiffener ring bending 1 3 5 Fixing of Reinforcement 3 6 6 Welding 2 - 7 Tying binding wire - 4

Total 9 24

Table No. 23 :- Time Cycle For Reinforcement Cage Fabrication Sr. No. Type Time

1 Unloading 3 Hours 2 Cutting Main Reinforcement 4 Hours 3 Stirrup Making 3 Hours 4 Inner Ring Bending 3 Hours 5 Fixing Reinforcement 8 Hours 6 Welding 3 Hours 7 Tying Binding Wire 3 Hours

Total Time Taken For Reinforcement Cage Fabrication 27 Hours



3.06 Pile Reinforcement Sequence



BBS



3.1.8 Construction Methodology For Piling 3.1.8.1 Survey Works For Piling Equipments Details For Survey Works 1. Total Station with reflectors

Use : Giving Points As per The Co-ordinates and checking the correctness of the points

Company : Trimble Quantity : 1 no. Mode of Operation : Battery Operated

2. Auto Level Use : Checking the Levels Company : Trimble Quantity : 1 no. Mode of Operation : Manually Operated, No need for Battery

Man Power

Methodology Before Shifting of gantry commences, a chalk marking is done on the gantry & at a distance of 24mts from the centerline of the front roller support (i.e new pile support) indicating the gantry movement shall be stopped when that chalk mark reaches the centerline of the front support.

This ensures that the longitudinal spacing of 12mts. between the piles is maintained. Now it is required to give the pile point locations of the next grid over the gantry platform so that the next activities of liner shift and guide welding can commence.

After the gantry is shifted, points for the next piles are given. As it is not possible to give the centre point of the pile, two points on either side of the center point for each pile are given.

These points are marked on the gantry using paint. These points help to check the centre point of the pile.

At the site, these points are marked 1.5m on either side of pile point. Once the pile point marking is done with help of Total station on the Gantry, the location of piling pulley is checked to ensure that the centerline of wire rope matches with the alignment of the pile.

In case of any longitudinal or lateral deviation observed, the pilling pulley is suitably shifted over the pilling tower frame to match the alignment.

Table No. 24 :- Labour Requirement For Survey Works For Piling Sr. No. Type Skilled Unskilled

1 Survey Works 1 -

2 Helpers (For Holding Cross Staff, Prism etc.) - 3



3.08 Job Layout Before Liner Pitching



3.1.8.2 Bottom Liner lifting, Guide Welding & Liner pitching Equipments For Liner Lifting, Guide Welding & Liner Pitching 1. Piling Winch (7.5 Tons & 5 Tons)

Use : In Activities of Lifting & Pitching of the Liner Company : Siemens (7.5 Tons) & Greaves (5 Tons) Quantity : 4 nos.-7.5 Tons & 2 Nos.-5 Tons Mode of Operation : Diesel Operated

2. Welding Transformer Use : In Activities of Welding of Liner Pieces with each other &

Guide Welding Company : Greaves Quantity : 10 Nos.

Man Power

Methodology for Liner Lifting, Guide Welding & Liner Pitching

After the pile point marking, the centre point of the pile is checked. A string is placed along the marked point and chain is lowered from the pulley to check the centre of the pulley.

If there is a difference between the string and the chain, it is to be rectified. If the difference is more, then the welding of the pulley is cut and it is shifted as required and re-welded.

As the gantry cannot move backwards it becomes difficult when the gantry is shifted more than the required length. Hence proper precautions are to be taken will shifting.

The liners are fabricated at the fabrication yard and brought to the site in trailer. Then it is lifted with the help of winch.

These liners are made up of 6mm thick MS plate. There is an extra 8mm thick plate of 1000 mm length at the bottom most part of the liner, which acts as shoe.

The bottom liner is of 12.08m.length, middle liner of 9.6m and then the subsequent liners of 3.025m length are added on as and when required.

The liner is provided with the lifting hooks on the inside face. The guide is made of ISMC 100 box. With the help of the pile point marking done on the gantry, the guide is fixed in its position and welded to the gantry.

There are total of two guide boxes for each pile. The top guides are welded using the points marked on the gantry, whereas the bottom guides are placed in position using the plumb bob from the top guide.

While doing the guide welding, the tip of the bottom piece liner is kept sufficiently above the sea level to prevent swaying of liner due to wave or water current so that guide welding can be done with accuracy and both top and bottom guide are in perfect plumb to check inclination of the liner.

A gap of 2mm is kept on all sides between the outer face of the liner and the inner face of the guide – box to allow the liner with its joint weld to pass through easily.

Once the guide welding is completed, the bottom piece liner is lowered till the top of it remains 500mm above the gantry deck level.

In this position the liner is arrested on the top guide by welding 4 cleat angles at 90º to each other. Once the liner is arrested, the sling is removed and the lifting hook cut and removed.

Table No. 25:- Labour Requirement Per Pile Point Sr. No. Type Skilled Unskilled

1 Winch Operations 1 -

2 Welding Operations 1 -

3 Helpers - 2

4 Signaling (Rigger) 1 -



Thereafter, the second piece of the liner is lifted and placed over the bottom piece, matching the edges.

Initially, the entire periphery is tack welded at few places by using a hammer and wedge to bring the top edge of the bottom liner and the bottom edge of the top liner in line and contact.

When the full welding is done, 4 stiffener plates, each measuring approx 200x100mm, is welded at 90º to each other as a safety measure.

The arresting clit angles are then cut and removed by lifting the liner slightly to release the load. With the release of the winch brake, the liner falls freely and pitches inside the seabed. Liner pitching is done only in the slack tide period (The period between the High Tide and Low tide when the water current is quite low) as the site is located in the region that has world’s 2nd highest water currents.

When liner touches bed level and rests on the bed without any support, it is known as pitching. The liner is allowed to settle on its self-weight for some period.

3.1.8.3 Boring including additional Liner Driving & Joining Equipments for Boring including additional Liner Driving & Joining 1. Piling Winch (7.5 Tons & 5 Tons)

Use : Piling Winch is used for boring operation with the help of Bailor & Chiesel

Company : Siemens (7.5 Tons) & Greaves (5 Tons) Quantity : 4 nos.-7.5 Tons & 2 Nos.-5 Tons Mode of Operation : Diesel Operated

2. Welding Transformer Use : For welding subsequent liners Company : Greaves Quantity : 10 Nos.

3. Water Pump Use : To Collect Sea Water for Cleaning of Bailor & Chiesel Company : Local Quantity : 2 Nos.

4. Vacseal Pump Use : For bentonite mixing and pouring in the borehole. Company : Vatrak Quantity : 2 Nos. Fuel of Operation : Diesel

Man Power

Methodology Before starting the boring operation the existing bed level is measured by sounding chain. The sounding chain is having a light weight (2Kgs) attached to it .The sounding chain is manually lowered inside the liner very slowly so that the difference in weight is felt; the moment the flat bottom of the weight touches the bed level.

The chain is then marked with reference to the top level of the liner and pulled and measured. This operation is carried out through out the boring operation so that the various strata encountered can be recorded as well as progress of boring can be ascertained.

Boring is done with the help of chiesel & bailer.

Table No. 26 :- Labour Requirement Per Pile Point during Boring including additional Liner Driving & Joining

Sr. No. Type Skilled Unskilled1 Winch Operations 1 - 2 Welding Operations 2 - 3 Helpers - 2 4 Riggers 2 -



A cross chiesel of weight 2-2.5 tons is dropped several times and then the bailor is used to remove the material.

At first, chisel is lowered down in the liner unit to start boring. As chiseling continues, bentonite slurry (Density = 1.04 to 1.2 - Fresh Bentonite) is continuously poured in the borehole from the gantry deck with the help of the pipe.

Bentonite slurry is used because of its higher density than seawater. As bentonite is poured, it gradually settles down in the borehole & forms an impermeable (plaster-type) layer, which prevents the surrounding soil to collapse in the borehole.

The bailer is a vertical steel cylinder open at the top and fitted with a one way valve opening to inside at the bottom. It has an approximate wt. of 1ton.

It is hung with the help of a hook that is fixed to the top with a hinge pin. After the chisel is removed, bailer is attached to the wire rope of the winch. Bailer is used to remove the chiseled soil strata. Here, bentonite plays another role. Due to its higher density than mud, it prevents the mud from settling down at the bottom of the borehole. And thus makes the mud easily available for the bailer

The bailer is lowered into the borehole and dropped multiple times so that the soil material enters the bailer.

Then the bailer is lifted out of the bore and tilted to discharge the collected material. At times when sand is encountered at the bottom of the bore, bailing becomes difficult as sand mixes with water and slips form the bailer.

In such times, lumps of clay are thrown into the borehole and bentonite of is also used so that the sand mixes with the clay and can easily be removed.

Thus alternate bailing and chiseling operation continues till the founding level (-34m) is achieved. Simultaneously sounding is also taken at regular intervals to know the depth of the borehole. Soil samples are taken regularly with the help of a sampler to know the soil strata at varying depths.

Once this achieved the, the bailer is lowered for the last time to finally clean the bore of all loose materials before the pile is ready to receive the reinforcement cage.

While the boring progresses, the Liner is driven with help of a square bar inserted through the window of the bailer or with the help of a monkey.

For this a removable driving cap (helmet) is placed on top of the liner, which prevents the Liner plate from buckling due to impact of Square bar or monkey. (Monkey used at the site is a tailor made monkey made by filling concrete in a bailer till the window and welding square bar on all the four sides equally.

The monkey is dropped from a height of 1-1.5 mts over the driving cap to drive the liner. This operation is carried out along with the boring operation.

Further liner pieces are attached to the existing liner when the top of the liner is about 500mm above the guide level.

In case of distortion, that part of the liner is cut. The same procedure is continued upto refusal level. Empty boring for not more than 3-4 mts is permitted. The level of bentonite in the borehole is maintained in such a way that it is always above the seabed level during the low tide and more than the sea water level during the high tide level.

Table No. 27 :- Soil Strata Obtained During Boring Boring Depth (m)

(A14) Soil Strata (A14) Boring Depth (m) (B14) Soil Strata (B14)

-0.37 Very stiff clay with gravels -2.81 Very Stiff clay -7.32 Stiff clay -5.72 Stiff clay -14.87 Soft clay -9.92 Very Stiff clay -15.92 Stiff clay -17.57 Stiff clay with Gravel -20.62 Stiff Clay with gravel -20.64 Stiff clay -21.62 Stiff Clay -23.96 Soft clay with Gravel -24.12 Stiff Clay with gravel -26.15 Sand -25.04 Very Stiff Clay with gravel -32.86 Very Stiff with Gravel -30.22 Silty Sand with small stone -33.08 Sand with Gravel -34.00 Silty Sand with Gravel -34.34 Sand



Problems Encountered During Boring, Liner Joining & Liner Driving Chiesel gets trapped inside the soil if soil is very stiff clay. Chiesel gets trapped in the bottom of the liner if a cavity develops exactly below the liner tip and the chisel tilts.

Collapse of soil occurs if proper quantity of bentonite is not used and the soil strata encountered is loose.

Bailer gets trapped inside the soil when the soil encountered is very stiff. Liner gets pressed (Bend) form the bottom due to very high soil pressure. Bailer gets trapped in the bottom of the liner if a cavity develops exactly below the liner tip and the bailer tilts.

Winch Breakdown occurs if the Chiesel or bailer gets trapped inside the borehole and winch is overloaded.

Sounding Chain gets trapped when the collapse occurs at the time of sounding.

Probable Solutions As visual inspection is not possible, measures taken are totally based on trial and error method. If chisel or Bailer gets trapped inside the borehole the first thing done is to give jerks to them with the help of piling winch and try to get it out.

The last method for taking it out the chisel or bailer is to drive out the liner with the help of a square bar.

To prevent the soil collapse bentonite mix of proper quality should be regularly supplied. Bailing is to be done to remove the collapsed material.

The last thing that is done when a Chiesel or bailer gets stuck beneath the liner is to send Diver inside the Borehole with all safety measures like Oxygen cylinder, Ropes etc..

The diver goes with a hook and tries or D shackle and tries to fit it in the safety sling attached with the Chiesel or bailer. It is a highly undesirable method as it is very risky and hence it is adopted as a last resort.

Table No. 28:- Liner Details For Pile A14Sr. No. Type Liner Length (m) Unit Weight (Kg./m) Total Weight (Kgs.)

1 Shoe 1.00 201.32 201.32 2 Bottom Liner 12.06 148.917 1818.37 3 Middle Liner 8.66 148.917 1309.226 4 Top Liner 4 x 3.02 = 12.08 148.917 124.351 5 Cutting (-) 0.48 148.917 (-) 71.48

Total 5081.787 Kgs.

Table No. 29:- Liner Details For Pile B14Sr. No. Type Liner Length (m) Unit Weight (Kg./m) Total Weight (Kgs.)

1 Shoe 1.00 201.32 201.32 2 Bottom Liner 12.06 148.917 1818.37 3 Middle Liner 8.66 148.917 1309.226 4 Top Liner 5 x 3.02 = 15.1 148.917 2280.438 5 Cutting (-) 0.00 148.917 (-) 0.00

Total 5609.354 Kgs.

Bend Liner



3.1.8.4 Lifting, Joining & Lowering the Pile Reinforcement Cages Equipments for Lifting, Joining & Lowering the Pile Reinforcement Cages 1. Piling Winch (7.5 Tons & 5 Tons)

Use : Piling Winch is used for lifting the Reinforcement Cages & for lowering them into the pile bore


2. Welding Transformer Use : For welding subsequent liners Company : Greaves Quantity : 10 Nos.

Man Power

Methodology Reinforcement cages are fabricated in sections with provision of lapping (36D) the site. There were 5 no. of sections for the pile type P-11 having 34 mts. depth. The cages are brought to the site by tractor-trailor and lifted with the help of gantry EOT and kept on the top of the girder.

Before lowering the bottom cage the borehole is thoroughly cleaned from the muck by a bailer. The top of the liner is then cut and removed in such a way that the full-length reinforcement cage can be held vertically below the pulley with its bottom above the top of the liner.

While lifting the cage with the help of the wire rope of a piling winch, a guide rope is tied to the bottom of the cage to control the lifting operation. First the bottom cage is lowered into the bore of the pile and rested on top of the liner with the help of resting bars (2-32φ).

Thereafter the subsequent cages are lifted and placed vertically over the bottom section in such a manner that the respective bars in each section are in line with each other for proper lapping.

Each pair of bars in the lap is tack welded to each other at minimum 2places for an approximate length of 1inch (25mm).

The lapped sections are now ready to be lowered into the pile bore. This is done by first lifting the jointed cages by about 100mm with the help of a winch in order to remove the holding (resting) bars on which the bottom reinforcement cage was resting.

After removing the resting bars, the jointed cages are slowly lowered into the pile in such a manner that the cover blocks do not get damaged.

After the entire cage length barring the further lap portion from the top is lowered, the jointed sections are again rested over the liner top with help of resting bars and the next section is lifted and fixed in the same manner as described above.

When all sections of the cage are fixed and lowered into the pile bore, the top level of the pile cage is checked and measured with tape w.r.t to the deck level of the gantry to ensure that the cage has attained the required levels.

The top cage of the pile is fabricated in such a manner that it also includes the development length for embedment into the headstock.

The liner during the construction stage of the pile is extended above the top of these straight bars to suit the placement of wheels of the piling gantry for the movement over the installed piles.

Table No. 30:- Labour Requirement Per Pile Point during Lifting, joining & Lowering The Pile Reinforcement Cage

Sr. No. Type Skilled Unskilled 1 Winch Operations 1 -

2 Welding Operations 3 -

3 Helpers - 4

4 Riggers 2 -



3.09 Job Layout Of Gantry Before R/F Lowering



3.1.8.5 Lowering Of Tremie & Flushing the Bore Hole Equipments for Lowering Of Tremie & Flushing the Bore Hole

1. Piling Winch (7.5 Tons & 5 Tons) Use : Piling Winch is used for lifting & Lowering of Tremie Pipes Company : Siemens (7.5 Tons) & Greaves (5 Tons) Quantity : 4 nos.-7.5 Tons & 2 Nos.-5 Tons Mode of Operation : Diesel Operated 2. Vacseal Pump Use : For bentonite mixing and pouring in the borehole. Company : Vatrak Quantity : 2 Nos. Fuel of Operation : Diesel 3. Air Compressor Pump Use : For Air Flushing of the Pile Borehole Capacity : 365 cfm Quantity : 2 Nos. Fuel of Operation : Diesel

Man Power

Methodology

Diameter of tremie is 200mm & length of the pipe varies from between 1.00m to 1.24m. The tremie pipes are attached to each other with the help of male female socket joints and lowered into the pile.

Grease is applied to all the threaded joints while attaching one tremie to another to keep the joints watertight.

The tremie pipe is lowered in such a way that it is kept 300 mm above the bottom of the pile. Flushing is done to clean the bore shaft for concreting. Fresh slurry of Bentonite having specific gravity of 1.04 to 1.11 is circulated inside the Borehole.

Bentonite, when mixed with water forms a suspension, which has a tendency to attract the mud particles.

It forms a colloidal suspension, which comes out of the bore. Till the slurry reaches the bottom of the bore its specific gravity increases by 0.1, thus becoming 1.14 to 1.21.

Now in the process of flushing the borehole, the density of bentonite increases. For smooth finish and sound concrete the specific gravity of Bentonite should not be more than that of the concrete. Moreover it should be less than half the specific gravity of concrete.

The specific gravity of the Bentonite mix at the bottom of the borehole is checked by lowering the Mud Sampler. Hydrometer is used to check the specific gravity & mud sampler is used to take the sample from the bottom of the borehole.

If the density of bentonite sample collected is more than 1.25 than flushing is continued. The proportion or the requirement of the bentonite is given by

Yc= 1 + 0.006(C) Where, Yc = Specific Gravity of Fresh Bentonite C = Concentration of Bentonite Slurry

After the bentonite flushing is over, Air flushing done. Air flushing is done using air compressors. Now in place of the bentonite pipe air pipe is attached and the bentonite is supplied to the bore with the help of canvas pipe directly kept into the liner.

Table No. 31:- Labour Requirement Per Pile Point during Lowering of Tremie & Flushing of Borehole

Sr. No. Type Skilled Unskilled 1 Winch Operations 1 - 2 Tremie Pipe Fixing - 3 3 Helpers (Signal Givers) - 2



Air flushing is done only for 10min. Air flushing is important for the removal of sand particles from the borehole. But care should be taken as excessive air flushing may cause collapse of the sides.

3.1.8.6 Concreting Tools, Equipments & Plants Used for Concreting the Pile Borehole 1. Piling Winch (7.5 Tons & 5 Tons)

Use : Piling Winch is used for lifting of the Hopper & giving Up & Down motion to the same for the compaction of the concrete


2. Batching Plant Use : For Production of the Concrete as Per the Design Mix. Use : For production of Concrete as per Design Mix Company : MACON. Type : Star type automatic batching plant Capacity : 30Cu.m/hr. Batch capacity : 0.5 Cu.m Quantity : 2 Nos.

3. Transit Mixer Use : For Transporting the concrete from the Batching Plant to

the site Company : Greaves Capacity : 6 Cum. Quantity : 6 Nos. Fuel of Operation : Diesel

4. Water Pump Use : To Collect Sea Water for Cleaning of Bailor & Chiesel Company : Local Quantity : 2 Nos.

5. Concrete Pump Use : For pumping the concrete into the borehole Company : Sany Capacity : 43 Cum. Quantity : 2 Nos. Fuel of Operation : Diesel

Man Power

Table No. 32:- Quantity of Bentonite Mix Added Pile No. During Boring (Cum.) During Flushing (Cum.)

A-14 35 39

B-14 34 48

Table No. 33:- Labour Requirement Per Pile Point during Concreting Sr. No. Type Skilled Unskilled

1 Batching Plant Operations 3 5 2 Transit Mixer Operations (Per Transit Mixer) 1 1 3 Helpers (Signal Givers) - 2 4 Concrete Pump Operations 1 1 5 Concrete Pouring - 3



Methodology

The concrete of M40 grade and slump of 150 to 190mm is mixed as per the design mix in a batching plant of 30m3/hr rated output capacity. As there is no media of compaction at the bottom of the borehole, the slump is kept 150 to 190mm.

Once the pile is ready to receive the concrete, the pile supervisor sends the requisition for concrete to the batching plant supervisor indicating the approximate quantity & location of the pour.

Thereafter, the concrete is prepared in the Batching plant. The concrete is then unloaded into the transit mixers, which transports the concrete to the location of the concrete pump arranged for the concreting.

The concrete pumps are stationed over the temporary deck made for the movement of man and materials. The Transit mixers are placed besides the pump for the unloading of the concrete.

Once the flushing is over, a hopper is fitted to the top of the tremie pipe. The gap between the borehole bottom and the bottom end of the tremie pipe is kept around 300mm.

The tremie pipe is held in position by slinging the hopper by the wire rope of the piling winch. The bottom opening of the hopper (i.e. where the hopper joins the tremie pipe) is initially plugged by a removable plug plate.

The tremmie hopper is applied with oil. The plug is attached to separate winch wire rope. The tremie hopper is filled with concrete. When the hopper is completely full with concrete, the plug is pulled and removed using the winch. This allows the concrete to rush through the tremie pipe downwards displacing the bentonite inside the tremie pipe through its bottom end.

This result’s in concrete getting deposited at the bottom of the pile bore enclosing the tremie pipe and the air in the tremie pipe also gets removed through the air pipe.

Now when further concrete is poured, it will result in Pile shaft build up. A build up of 4-5mts is always maintained in the pile.

The theoretical height of the build up can be calculated from the quantum of concrete pumped into the pile and the length of the tremie pipe lowered, obtained from the number of tremie pipes.

Once the build up of 4-5 mts is obtained then the tremie pipe is lifted with the help of piling winch in such a way that the top most tremie pipe comes above the gantry deck.

The tremie pipe is then rested on the gantry deck with help of tremie fork. First the hopper is removed and then the top most tremie pipe is removed. The hopper is than again fixed to the next tremie pipe and the whole system is lowered into the pile.

While lifting the whole system above, care should be taken to keep the bottom of the tremie pipe at least 1.5 m inside the concrete.

The process of filling the hopper with concrete and removal of tremie pipes is continued till the bore is filled with concrete.

At the cut-off level of the pile, a window of size approximately 200x200mm is cut on the liner. Through this window, the contaminated concrete gets removed. Approximately 1m3 concrete is allowed to over flow so that the concrete obtained at the cut-off level is sound concrete.

Table No. 34:- M:40 Grade Mix Design Details

Material Quantity Cement (OPC 53 Grade) 347 Kgs. Fly Ash 116 Kgs. Aggregate (20mm) 874.65 Kgs. Aggregate (10mm) 267.75 Kgs. Sand 704.55 Kgs. Admixture (Retarder) 4.63 Water 185.20 Kgs.



Quantity of concrete Theoretical quantity of concrete (As per Drg.) = 3.14 x (0.50)2 x H = 3.14 x (0.50)2 x (34+12.395+1) = 3.14 x (0.50)2 x (47.395) = 37.22 m3 Theoretical quantity of concrete (As per Actual Boring) = 3.14 x (0.50)2 x H = 3.14 x (0.50)2 x (35.88+12.395+1) = 3.14 x (0.50)2 x (49.275) = 38.70 m3 Actual quantity of concrete = 42 m3 (Because of washing out of impure concrete at cut-off level.)

Table No. 35 :- Quantity of Concrete Pile No. Theoretical Quantity (Cum.) Actual Quantity (Cum.)

A-14 38.70 42

B-14 39.21 45

Table No. 36 :- Actual Consumption of Materials Pile No. Pile A-14 (Kgs.) Pile B-14 (Kgs.) Remarks

Cement (OPC 53 Grade) 14574 15615 Concrete Qty. x 347 Fly Ash 4872 5220 Concrete Qty. x 116 Aggregate (20mm) 36735.3 39359.25 Concrete Qty. x 874.65 Aggregate (10mm) 11245.5 12048.75 Concrete Qty. x 267.75 Sand 29591.1 31704.75 Concrete Qty. x 704.55 Admixture (Retarder) 194.46 208.35 Concrete Qty. x 4.63



3.10 Job Layout At the Time Of Concreting & Flushing



3.11a Piling Sequence



3.11bPiling Sequence



3.11cPiling Sequence



3.12 General Equipments used in Piling



3.1.8.7 Welding of Bracing, Placing of Grillages & Placing of Wheels Equipments for welding of Bracing, Placing of Grillages & Placing of Wheels 1. Piling Winch (7.5 Tons & 5 Tons) & Chain Pulley

Use : For Lifting the Bracings and keeping them in position Company : Siemens (7.5 Tons) & Greaves (5 Tons) Quantity : 4 nos.-7.5 Tons & 2 Nos.-5 Tons Mode of Operation : Diesel Operated

Man Power

Methodology Rolling bracing is a grid of bracings tied together and connected to rollers for easy and fast movement.

They are used to brace the piles on which the gantry is going to rest. Welding of the Rolling bracing is cut with the help of Gas cutters.

Then the rolling bracing is shifted with help of winches situated on the gantry. Fours stoppers are provided on the Rolling bracing which are opened when the Rolling bracing comes near to the pile to which it is to be fixed.

The rolling bracing is shifted 24mts. Liner is projected above the pile cut off level to give a clear space between the reinforcement dowels and the capping beam.

The projected portion of the liner is filled with M25 grade concrete. The liner is properly cut and trimmed to get a uniform level. The capping beam is then placed on the piles on which the gantry will be resting and its level is checked and cross checked with the help of tube level and auto level respectively.

The wheel is then placed on the capping beam. Proper alignment and levels are checked and than it is welded temporarily with capping beam.

Table No 37:- Labour Requirement during Welding of Bracings, Placing of Grillages & Wheels

Sr. No. Type Skilled Unskilled 1 Winch Operations 1 - 2 Cutting 2 - 3 Welding 4 - 4 Helpers - 4 5 Riggers - 2



3.13 Rolling Bracing Details



3.1.8.8 Shifting of Gantry Equipments used for Gantry Shifting 1. Shifting Winches (5 Tons)

Use : For Lifting the Bracings and keeping them in position Company : Greaves (5 Tons) Quantity : 2 Nos.-5 Tons Mode of Operation : Electrically Operated

Man Power

Methodology

Piling is done by end-on method in which piling gantry rests on previously done piles and does piling work of next row.

After concreting is done for a particular pile, it is allowed to gain adequate strength for at least 24 hours so that it can easily withstand the load of movable gantry shifting on it.

After the piling work gets over, first thing done is to cut the liner at required level same as the level of the previous pile, which supports capping beam.

Over flow window is welded again. Concreting is done up to 1m more than cut off level. So rest of liner is also filled with M40 so that proper load transfer takes place.

Points are marked on the main girder of the gantry with the help of total station. Simultaneously live loads on gantry like chisels, bailers, tremie pipes etc. are shifted to the locations assigned to them for the stability of the gantry.

Moreover the water tanks & aggregate tanks on the gantry are to be kept full for the stability purpose whereas the bentonite tanks are kept empty.

Two shifting winches are provided on the gantry. Shifting of gantry is done very slowly with great care and in presence of engineer-in-charge. Continuous eye is kept on the position of the gantry with the help of total station.

The shifting is done for 24mts and the c/c distance between two piles is 12mts. Shifting winches have wire rope connected to pulleys out of which one is tied to the gantry & other is tied to the second last pile.

Then the gantry is checked as per the checklist. When the shifting winches are rotated, wire rope gets collected in the winch. Due to this the length of the wire rope decreases & ultimately the gantry starts moving forward.

The gantry shifting is done on the odd numbered piles (i.e. the load transfer occurs on odd numbered piles)

As the gantry reaches nearby the desired point, it is slowly moved forward. When the gantry is shifted 24m, further shifting is stopped.

The locks are placed on the gantry in such a way that they will obstruct the gantry movement by colliding with the wheel.

Once the Gantry is in the correct position, the brakes of the wheels are tightened to prevent any movement of the gantry.

Proper position of gantry is finally checked with the help of total station from the fixed temporary points on the Rock bund.

If side shifting is observed than it has to be rectified.

Table No 38 :- Labour Requirement during Shifting Of Gantry Sr. No. Type Skilled Unskilled

1 Winch Operations 1 - 2 Cutting 2 - 3 Welding 4 - 4 Helpers - 4 5 Riggers - 5



3.14 Gantry Movement Details



Problems Encountered During Gantry Shifting

The welding of the Rolling bracings breaks. Side shifting of the gantry takes place. Main girders of the gantry bends. Winch Breakdown takes place. Most critical period of gantry shifting is when the gantry leaves the back wheels. Pile settlement takes place.

Reasons for the Above Problems

Improper survey & point establishment. Level difference-if prior to shifting the pile on one side has settled or there is difference in casting than side shifting may occur.

If the Gantry loads are more than that calculated for gantry stability then it may lead to settlement of the piles on which the gantry is resting.

Eccentric Loading on the Gantry Unskilled Winch Operator leads to winch breakdown and minute side shifting. Long Cantilever Portions of the Gantry (Gantry Design) is a major factor causing the Side Shifting.

Solutions for the Above Problems

Jacking the wheels in the direction opposite to the shifting direction and bringing the gantry in required position.

Jacking the girder by supporting the jack on the capping beam if there is level difference If the shifting is very less than the pulley can be shifted in order to get in the correct position exactly above the pile center point rather than shifting the whole gantry with the help of Jacks.

Jacking Operation

Jacking operation in case of side shifting is carried out by placing jacks of 7.5 tons capacity before the wheels on the capping beam.

ISMC 400/ ISMC300 is welded behind the jack in order to support the Jack.

After each shifting of the wheel by some millimeter, survey is carried out to check the shifting of the gantry, as the shifting in the wheel & that of the gantry is not same.

The same procedure of the shifting and surveying is continued till the Shifting comes under the permissible limits.

Jacking is also done to raise the level of the Gantry, if there is settlement of the pile or tilting of gantry.

In this case, the jacking of Main girders of the Gantry is done.

Jacking Operation In Progress



School of Building Science & Technology

Project Training `07 - `08 RATE ANALYSIS

Name of the Project: Multi Purpose Berth, Dahej Student Name: Suril Shah

Code No: 2704 Item

Item Description Unit Quantity Rate Amount No.

3.1.6

Fabricating and delivering to the site 1000mm ID liners made of 6mm thick Steel plates for bored cast-in-situ piles including bending, welding, etc complete.

MT

FOR 5.558 MT

A MATERIALS

Steel Plates MT 5.558 27750.0 154234.50

Welding Rods Nos. 601.00 2.20 1322.20

Oxygen Cylinder Nos. 0.32 200.00 63.80

LPG Cylinder Nos. 0.051 500.00 25.50

B LABOUR

Skilled Nos. 6 126.57 759.42

Unskilled Nos. 11 104.70 1151.70

TOTAL A + B 157557.1

C T, E, P @2% of A + B 3151.14

D.G. Set (Approx.) 15000.00

Welding Transformer (Approx.) 3000.00

D Scaffolding @2% of A + B ---

E Water & Electricity @2% of A + B 3151.14

TOTAL A + B + C + D + E 181859.4

F Profits & Overheads @15% of A+B+C+D+E 27278.91

TOTAL Rs. 209138.3

UNIT RATE Rs.37628.34 / MT.




Project Training 2007 - `08 RATE ANALYSIS

Name of the Project: Student Name: Suril Shah

Construction of Multipurpose Berth, Dahej Code No:2704 Item


3.1.7

Fabricating and erecting of reinforcement cage as per design for bored cast-in-situ piles including bending, welding, binding, etc complete.

MT

FOR 6.799 MT

A MATERIALS

Reinforcement Bars MT 6.799 25400.0 172695

Welding Rods Nos. 440.00 2.1 915

Oxygen Cylinder (Approx.) Nos. --- --- 100

Binding Wires Kgs. 26.00 25.0 650

B LABOUR

Skilled Nos. 30.0 110.0 3300

Unskilled Nos. 60.5 90.0 5445

TOTAL A + B 183105

C T, E, P @2% of A + B 3662

D.G. Set (Approx.) 1000

Welding Transformer (Approx.) 300


E Water & Electricity @2% of A + B 3662

TOTAL A + B + C + D + E 191729

F Profits & Overheads @15% of A+B+C+D+E 28759

TOTAL Rs. 220488

UNIT RATE Rs. 32430




Project Training 2007 - `08

RATE ANALYSIS


Code No:2704 Item


3.1.8.3

Boring of 34m deep bore shaft of 1000mm dia. For bored cast in-situ pile including cleaning, flushing, etc. complete.

Rmt

For 1 Rmt.

A MATERIALS

Bentonite kgs. 50.00 1.20 60.00

Water lit. 785.00 0.02 15.70

B LABOUR

Skilled Nos. 2.00 126.57 253.14

Unskilled Nos. 6.00 104.70 628.20

TOTAL A + B 881.34

C T, E, P @2% of A + B 16.71

Winch (Diesel Operated) Hr. 2.00 650 1300

DG set (Diesel Operated) Hr. 2.00 500 1000

2316.71

D Scaffolding @2% of A + B


TOTAL A + B + C + D + E 3214.76


TOTAL Rs. 3390.13

UNIT RATE Rs.3390.13 / Rmt.



School of Building Science & Technology Project Training 2007 - `08

RATE ANALYSIS Name of the Project: Student Name: Suril Shah Construction of Multipurpose berth Code No: 2704

Item Item Description Unit Quantity Rate Amount

No.

3.1.8.6

Providing & laying R.C.C. with given design mix proportion including compaction, placing for piling work etc. complete.

cu.m.

For 1 cu.m.M40 grade conc.

A MATERIALS

Cement kgs. 347.00 4.19 1453.93

Sand kgs. 874.65 0.18 157.44

Coarse Aggregate (10mm.) kgs. 267.75 0.40 107.10

Coarse Aggregate (20mm.) kgs. 704.55 0.40 281.82

Admixture kgs. 4.63 90.0 416.70

FlyAsh kgs. 116.00 1.25 145.00

Water kgs. 185.20 0.01 1.85

B LABOUR

Skilled Nos. 2.00 126.57 253.14

Unskilled Nos. 5.00 104.70 523.50

TOTAL A + B 3340.48

C T, E, P @2% of A + B 66.81

Batching plant

Transit Mixer

Pump

Winch



TOTAL A + B + C + D + E 3474.10

F Profits & Overheads @15% of A+B+C+D+E

521.11

TOTAL Rs. 3995.21

UNIT RATE Rs.3995.21 / Cum.




Project Training `07 - `08RATE ANALYSIS


Multi Purpose Berth, Dahej Code No: 2704 Item

Item Description Unit Qty. Rate Amount Remarks No.

3.1

Providing & Constructing bored cast in-situ pile of 1000mm dia. Including boring, reinforcement, concreting, etc., complete.

Nos.

For 1 No.

A MATERIALS

Boring (36.52 - 2.18(Bed Level)) = 34.34rmt) rmt 34.34 7200 247248.

Ref.

Individual

Rate Analys

is

Liner / Casing MT 5.08 38007.76 193117.43

Reinforcement MT 7.99 32430.00 259115.70

Concrete cu.m. 45. 3995.21 179784.45

B LABOUR

Skilled Nos. --- --- ---

Unskilled Nos. --- --- ---

TOTAL A + B 879265.58

C T, E, P @2% of A + B ---


E Water & Electricity @2% of A + B ---

TOTAL A + B + C + D + E 879265.58


TOTAL Rs. 1011155.4

UNIT RATE Rs. 1011155 / Pile



3.2 HYDRAULIC RIG PILING 3.2.1 Introduction Method of piling: Piling With A hydraulic Rig Pile studied: A- 1 Pile diameter of piles studied: 1250 mm Founding level for piles studied: -34.00 m

Note: A casing of 1600mm dia. was kept at the location of the pile at the time of construction of the rock bund.

Table No. 39 :- Details Of Pile Studied Description Pile A-1

Sea – Bed level (+) 2.258m Liner Tip Level (-) 17.442m Total liner length 29.837m Total Liner embedment in soil 19.70m Total Boring Depth 32.22m Actual Founding Level (-) 29.962m

Founding Level as per Drg. (-) 30.00m

Table No. 40 :- General Information On Hydraulic Rig (IMT)

Sr. No. Features Working Capacity

1 Base Name CAT345CL Under Carriage

Length/Width/Shoe 5370/3490/750

2 Rotary Installed Torque 260 kNm 3 Winches Main Pull Force 240 KN Main Winch Speed 73 m/min Cable Dia. 28 mm Auxiliary Winch 120 KN Speed 80 m//min Cable Dia. 22 mm 4 Crowd System Kelly Crowd Push 300 KN Kelly Crowd Pull 390 KN 5 Mast Mast Raking Forward 5º Mast Side Raking ±8º Mast Raking Backward 15º Pile Max. Dia. 2000 mm 6 Kelly Bar Operating Wt. of Std.

Kelly Bar 70 T

Standard 4/46 Options Available 4/52 5/50



3.2.2 Flow Chart Of Piling With Hydraulic Rig

Survey Works

Liner Driving

Survey Works

Liner Lifting, Guide Welding, Liner Joining, Liner Pitching, Checking Plumb

Boring

Auguring

Lowering Of R/F Cage

Lowering Of Tremie Pipe

Concrete Placing

Flushing of The Borehole With

Bentonite Slurry and Air

If Sp. Gravity > 1.2, Reflushing To

Be Done

Changing Rock & Soil Augur As Per The

Strata

Cleaning The Bore Hole With The Help Of

Bucket

Cutting Of Liner To The Required Level



3.2.3 Survey Works The equipments & manpower required for survey works are as mentioned in 3.1.8.1.

3.2.3.1 Methodology At the time of construction of rock bund, a 1600 dia. Casing was already kept at the pile point location. But the pile diameter being 1250 centre point of the 1600 diameter casing was to be identified.

As it is not possible to give the centre point of the pile, two points on either side of the center point for each pile were given.

These points were marked on the 1600mm diameter casing using paint. These points help to check the centre point of the pile.

Once the pile point marking is done with help of Total station, the positioning of IMT rig is checked to ensure that the centerline of wire rope of the IMT rig matches with the alignment of the pile.

3.2.4 Bottom Liner lifting, Guide Welding & Liner pitching 3.2.4.1 Equipments Hydraulic Rig and Welding Transformer. The Details of hydraulic rig are as mentioned in Table 40 & that of Welding Transformer is as mentioned above.

3.2.4.2 Man Power

3.2.4.3 Methodology The methodology of bottom liner lifting, Guide welding & Liner pitching is same as that mentioned in 3.1.8.2. The use of cable of auxiliary winch of hydraulic rig in place of wire rope of the winch is the only difference.

3.2.5 Boring including additional Liner Driving & Joining 3.2.5.1 Equipments Kelly Bar, Welding Transformer & Vacseal Pump. The details of the same are as mentioned above in previous sections.

Kelly Bars of the IMT rig carries out the boring operation with the help of Augurs & Bucket. Welding Transformer is used for welding subsequent liners. Vacseal pump is used for bentonite mixing and pouring in the borehole.

3.2.5.2 Man Power

3.2.5.3 Methodology Before starting the boring operation the existing bed level is measured with the help of sounding chain.

Table No 41 :- Labour Requirement Per Pile Point during Bottom Liner Lifting,Guide Welding & Liner Pitching using Hydraulic Rig

Sr. No. Type Skilled Unskilled 1 IMT Rig Operations 1 2 2 Welding 1 2

Table No 42 :- Labour Requirement Per Pile Pointduring Boring including additional Liner driving &

joining Sr. No. Type Skilled Unskilled

1 IMT Rig Operations 1 2 2 Welding 1 2

Soil Augur

Rock Augur



This operation is carried out through out the boring operation so that the various strata encountered can be recorded as well as progress of boring can be ascertained.

Boring is done with the help of Augur & bucket. There are different augurs for different strata. Rock augur is used in the rocky strata and soil augur is used in the soil strata.

Rock augur has bullet shaped diamond bids. Diamond bids are made from Boron Carbide (BC4) a material used for cutting diamonds.

The Diameter of the Augur was 1200mm. Before starting the auguring the Kelly of the rig is lowered into the casing and centered with the help of computerized display given in the operator’s cabin which shows the alignment of the Kelly.

At first, augur was slowly lowered down in the liner unit to start boring. Care was taken to see that the augur does not scratch the liner on its way inside.

As soon as the augur touches the bed, the operator gives some pressure on the bed by increasing the

Kelly height slightly and starts rotating the augur and the Kelly in 2nd gear and then after sometime in 3rd gear.

Large amount of muck sticks to the augur during the cutting operation. The rotations of the augur are stopped and it is slowly brought out of the pile by taking up the Kelly.

The muck and other materials sticking to the augur are removed by rotating the augur in 4th gear and suddenly stopping it and there by giving jerks to the augur.

As auguring continues, bentonite slurry (Density = 1.04 to1.2 -Fresh Bentonite) is continuously poured in the borehole with the help of the hosepipe.

Bentonite slurry is used because of its higher density than seawater. As bentonite is poured, it gradually settles down in the borehole & forms an impermeable (plaster-type) layer, which prevents the surrounding soil to collapse in the borehole.

The bucket is a vertical steel cylinder closed at the top and fitted with a one way valve opening to inside at the bottom. It has teeth at its bottom to collect the muck.

It was connected to the Kelly with help of a pin & socket joint. Bucket is used to clean the borehole from the material chiseled by the augur. The bucket is also lowered in the same as the augur and rotated to collect the muck. Then it is slowly brought out side the pile bore and cleaned by opening the lower flap of the bucket and then giving jerks to the bucket in the same way, as was case with augur cleaning.

The liner goes inside the soil on its own during the operation of boring. If the liner does not go, then it is driven with the help of front mast of the rig.

Thus alternate Auguring and bucketing operation continues till the founding level of -34mts is achieved.

Simultaneously sounding is also taken at regular intervals to know the depth of the borehole. Soil samples are also taken regularly from the soil cleaned from the augur and bucket.

Further liner pieces are attached to the existing liner when the top of the liner is about 500mm above the guide level.

Before joining each piece of liner, the dimension of the top of the already fixed liner is checked for any distortion caused due to driving operation.

In case of distortion, that part of the liner is cut. The same procedure is continued upto refusal level. After this liner units are not inserted in the borehole because the surrounding soil has enough strength to hold itself.

Empty boring for not more than 3-4 mts is permitted at the site. Regular bentonite recharging is also done. The level of bentonite in the borehole is maintained in such a way that it is always above the seabed level during the low tide and more than the sea water level during the high tide level.

Aligning Equipment Of IMT Rig

Liner Lifting



3.2.6 Lifting, Joining & Lowering the Pile Reinforcement Cages 3.2.6.1 Equipments

Auxiliary Winch & Welding Transformer. The details of the same are as mentioned previously. Auxiliary Winch of the IMT rig carries out the operation of Lifting & lowering the reinforcement cages.

Welding Transformer is used for welding subsequent liners. Prefabricated cages are brought to the site in trailers and unloaded with the help of cranes.

3.2.6.2 Man Power

3.2.6.3 Methodology

The methodology is same as that mentioned in 3.1.8.4. The lifting of pile reinforcement cages is done with the cable of auxiliary winch in place of wire rope is the only difference.

3.2.7 Lowering of Tremie & Flushing the Borehole 3.2.7.1 Equipments

Auxiliary Winch of IMT rig is used for lifting and lowering of the tremie pipes. The details of the same are as mentioned previously.

Bentonite flushing is done with help of vacseal pump. Air flushing is done with help of Air compressors, the details of which are as mentioned in 3.1.8.5.

3.2.7.2 Man Power

3.2.7.3 Methodology

Diameter of tremie is 200mm & length of the pipe varies from between 1.00m to 1.24m. The tremie pipes are attached to each other with the help of male female socket joints and lowered into the pile.

Grease is applied to all the threaded joints while attaching one tremie to another to keep the joints watertight.

The tremie pipe is lowered in such a way that it is kept 300 mm above the bottom of the pile.

Table No. 43 :- Soil Strata Obtained During Boring

Sr. No. Boring Depth (m) (A1) Soil Strata (A1)

1 -3.842 Very stiff clay 2 -10.742 Stiff clay 3 -25.102 Dense silty clay 4 -27.302 Dense silty clay 5 -29.962 Stiff silty clay with sand

Table No. 44 :- Labour Requirement Per Pile Point during Bottom R/F Lifting, Joining & Lowering using Hydraulic Rig

Sr. No. Type Skilled Unskilled 1 IMT Rig Operations 1 2 2 Welding 3 4

Table No. 45 :- Labour Requirements per Pile Point during Lowering of Tremie & Flushing of Borehole

Sr. No. Type Skilled Unskilled 1 IMT Rig Operations 1 2 2 Pipe fixing - 3



Flushing is done to clean the bore shaft for concreting. Fresh slurry of Bentonite having specific gravity of 1.04 to 1.11 is circulated inside the Borehole.

After the bentonite flushing is over, Air flushing done. Air flushing is done using air compressors. Now in place of the bentonite pipe air pipe is attached and the bentonite is supplied to the bore with the help of canvas pipe directly kept into the liner.

Air flushing is done only for 10min. Air flushing is important for the removal of sand particles from the borehole. But care should be taken as excessive air flushing may cause collapse of the sides.

3.2.8 Concreting The complete concreting procedure is similar to that done in the Gantry piling but in place of wire rope used in gantry piling, cable of auxiliary winch is used here.

3.2.9 Time cycle Comparison between Piles A-14, B-14 & A-1

Table No. 46 :- Bentonite Mix Quantity Used Sr. No. Pile No. During Boring (Cum.) During Flushing (Cum.)

1 A-1 42 48

Table No. 47 :- Concrete Consumption For Pile A-1 Sr. No. Pile No. Theoretical Qty. (Cum.) Actual Qty. (Cum.)

1 A-1 53 54

Table No. 48 Time Cycle Comparison Between Piles A-14, B-14 & A-1

Sr. No. Activity Pile A-14

(Gantry Piling) Pile B-14

(Gantry Piling) Pile A-1

(Hydraulic Rig Piling)

1 Liner Joining 7 hrs 45min 10hrs 25min 11hrs 45 min 2 Boring 120 hrs 5min 78hrs 5min 12hrs 5min

3 Reinforcement Cage Lowering

6hrs 15min 7hrs 6hrs 50min

4 Bentonite Flushing 1 hr 10min 1 hrs 15min 1 hr 5 Concreting 2 hrs 30min 3 hrs 45min 2hrs 45min 6 Miscellaneous 16hrs 55min 10hrs 55min - 7 Idle Time 28 hrs 45min 58hrs 35min 6hrs TOTAL 183 hrs 25 min 170 hrs 40hrs 25min TOTAL IN DAYS 7.64 Days 7.08 Days 1.68 Days



3.15 Piling Sequence



3.16Piling Sequence



3.17Piling Sequence



3.3 PILE INTEGRITY 3.3.1 Principle The method is based on measuring the frequency and amplitude response of a pile known as impulse. This response, known as Mechanical Admittance (or mobility), contains all the information necessary to check pile integrity and to analyze soil influences. 3.3.2 Scope The scope of the method is as follows: Pile Toe Level Cracks Reductions in section Zones of poor quality concrete

3.3.3 Apparatus and Materials Hammer (Wt. varies from 400 Grams to 1.4 Kgs. Depending on the depth of the pile).

Wax or Vaseline is applied to the hammer surface and used to seal the space between the hammer and the concrete surface

Pile Integrity Tester - Collector Model – it is a compact built in data collector with finger touch screen.

3.3.4 Test Preparation In order to obtain the very best data possible, it is essential that the pile head is prepared properly prior to testing. Without good data any interpretation carried out is meaningless. It is essential that the measurement transducers are mounted in the correct position and on sound concrete. The essentials of pile head preparation for integrity testing are given below: Piles are tested at the cut-off level and trimmed to sound concrete. Any weak, broken concrete that sounds hollow is removed and the pile top is left roughly horizontal over the complete cross section.

Two areas are prepared for the transducers, one for the hammer in the centre of the pile and the other for the probe close to the pile perimeter. The areas are approximately 100 mm in diameter and prepared as flat and level as possible and then brushed free of debris with a wire brush.

If at first, valid results are unavailable, the area is to be re-prepared and re test is to be carried out, as cracking in the pile head is not always apparent but can affect the test result significantly.

3.3.5 Pile Integrity Testing and Measurement The testing involves attaching an accelerometer onto the pile top (not near its edge) with the help of bonding material like candle wax, Vaseline etc. After this, the pile is impacted with a hand held hammer (1 to 2% of the capacity of the pile). This generates low stress wave into the pile. The resultant strains are of extremely low magnitude, and the method is hence known as Low Strain Method.

The accelerations generated by the impact are measured by the accelerometer attached on the pile top and are converted to velocity form for display onto the collector screen. Reflections from pile toe, pile discontinuities, cross-sectional changes, etc., are graphically displayed.

The test involves no. of blows during the stage of testing. All such similar blows are averaged before display. This averaging technique tends to cancel random signals in any particular blow.

Pile Integrity Tester



3.3.6 No. of readings 6 Blows per 1 reading 5-6 Readings per pile

3.3.7 Data Interpretation Discontinuities, cross-sectional changes, material property changes, such as between concrete and surrounding strata etc., cause reflections at the pile top. Such reflections are measured and checked. Thus any defect in the pile shaft can be easily detected. By measuring the travel time of any such reflection, the location of defect in the pile can be located.

The wave speed is determined from the response of the pile toe. This measured wave speed by itself is an important test result, from which the general condition of concrete can be estimated.

3.3.8 Test Limitations One of the most apparent limitations of this test is the depth to which the method can prove pile continuity or assess shaft anomalies. On very long piles with a length/diameter ratio, say, in excess of 30:1, the toe response is usually very faint.

Where a toe response is not visible it is not possible to infer shaft continuity. The same applies to shaft irregularities, in that the deeper they are the more difficult they are to detect and assess.

Apparent changes in shaft section of less than 10% will generally not be detected. In the case of multiple shaft irregularities, the test is usually only able to locate the first, although in the case of closed, horizontal cracks near the pile top it is sometimes possible to detect continuity below the crack.

The interpretation of results relies heavily on supplementary data such as geotechnical conditions, construction technique, pile geometry etc.

3.4 DYNAMIC PILE LOAD TEST

3.4.1 Introduction High strain dynamic testing is used to evaluate pile capacity and is standardized as per ASTM D4945-96. 3.4.2 Principle Testing through Pile analyzer obtains and analyzes records of shaft force and velocity under drop weight impacts. The field results are further analyzed with a signal matching technique (Case Pile Wave Analysis Program-CAPWAP) to refine the soil parameter assumptions. 3.4.3 Objective The Objectives of the test are as follows: Static capacity of the pile at the time of testing. Simulated static load test curve. Total skin friction and end bearing of the pile. Total skin friction variation along the length of the pile. Compressive and tensile stresses developed in the pile during testing. Net and total displacement of the pile. Pile integrity

3.4.4 Background The piles A-12 & B-12 showed settlement at the time of gantry shifting when the loads were transferred onto the gantry.

So it was decided to resort to pile load test.

Complete Graph of Pile A12



The aim of testing was to evaluate pile static capacity and measure settlement under this measured load.

3.4.5 Pile and Test Preparation The testing is conducted by fixing strain sensors and accelerometer to the sides of the pile at a depth of 1.5 X Pile diameter (1.5 x 1000 =1500mm) from the top and then connecting them to the measuring equipment.

The pile is extended to 1.6 times the pile diameter (1600mm) after chipping top loose concrete. The extended pile head concrete is M60 and that of the pile is M40.The 7 day strength of M60 obtained was 47N/mm2 and the required strength was 42N/ mm2.

The re-bars and the helical reinforcement are also extended to avoid cracking of the concrete under the hammer impact. The diameter of the bars is same as that of the pile reinforcement.

The surface of the concrete at the sensor level should be smooth, hard and uniform. A pile top cushion consisting of Plywood is placed. A steel helmet of 25 mm Ms Plate is also placed. A hammer of 1-2% of test load or 5-7% of the dead weight of the pile (whichever is higher) is used for testing the pile. Thus, here the hammer of 7.1 tons was used for a test load of 450 tons. The fall of height varies from 1-3 mts.

A guide consisting of ISMC 150 was also made to ensure concentric fall of the hammer. 3.4.6 Test Procedure, Monitoring & Analysis The hammer is lifted and given a free fall with the help of wire rope connected to the 7.5-ton winch situated at the back of the gantry. The arrangement is as shown in drg. 3.18.

Power source for the sensors was taken form the gantry but for the equipment, the power was taken from the car battery.

The net displacement in this method is obtained after double integration and hence it may have errors. So the displacement is also measured with the help of a surveyor.

The hammer is then again lifted and given a free fall from another height. The test is conducted at least 21 days after the pile is completed and the concrete has achieved desired strength.

Dynamic pile testing (High strain Testing) was conducted by attaching strain transducers and accelerometers to the sides of the pile approximately 1.5 times (1500 mm) below the pile top.

Pair of transducers was fixed onto the opposite sides of the pile to detect the capacity of the pile. The transducers were connected through the main cable to measuring equipment, which was a state of Art Computer System with ability to record strain and acceleration measurements and convert them from analog to digital form and display them on screen.

The testing was done by impacting the pile with blows of hammer of wt. 7.1 tons starting with a height of 1mt. This is test fall to check the proper functioning of the instruments.

Then the hammer was allowed to fall from a height of 2, 2.5,3 and 3.5 mts.. All the heights were marked on the guide made for the hammer with the help of a chalk so that measurements are not required to be taken every time and the winch operator can be easily guided.

For each hammer blow, the strain transducers measure strains where as the accelerations were measured by the accelerometer. These were then converted into force and velocity respectively by integration.

Table No. 49 :- General Pile Details Sr. No. Parameter A12 B12

1 Pile Length Below Gauges

41.6 mm 41.7 mm

2 Pile Diameter 1000mm 1000mm 3 Hammer Wt. 7.1 tons 7.1 tons 4 Drop Height 1-3mts. 1-3mts. 5 Design Load 300 300 6 Test Load 450 450



For each hammer blow the field results were immediately displayed in the form of capacity of the pile, pile top compression, integrity, stresses etc..

The pile capacity is generally considered to be fully utilized if the energy levels due to hammer impact are sufficient so as to cause a measurable net displacement of at least 3-4 mm per blow for a minimum three successive impacts. If the pile set is less than 3-4 mm and the pile achieves required capacity, then it implies that not all the static pile resistance has been utilized and that the pile still has some capacity that was not required to be measured at the time of testing.

A typical blow is then selected for Signal Matching Analysis. The program is a method that combines measured field data with pile wave equation type procedures, to predict the pile static bearing capacity and soil resistance distribution.

Measured force and velocity data is directly input as obtained from the field measurements. Based on the measured velocity data, the program computes the force required to induce the imposed velocity.

Both measured and computed forces are plotted as a function of time and iterative analysis is continued till there is good agreement between both the curves.

If the agreement is not satisfactory, the soil resistances at the pile point and along the pile are adjusted until a good match is obtained.

This gives a better estimate of the actual static pile capacity measured during field-testing, and also the friction and end bearing components.

3.4.7 Test Limitations Although the method can be used to predict skin friction and end bearing along the length of the pile, these values should be used with caution as the signal matching is an iterative procedure.

Unlike static testing, evaluation of dynamic pile test results requires an experienced engineer trained in interpretations of the results.

3.4.8 Test Results

Table No. 50 :- Summary Of Field Results

Sr. No.

Pile No.

Height of Fall (m)

Pile Capacity (Tons)

Net Settlement

(mm)

Total Settlement

(mm)

Comments

1

PILE A12

1 198 0.0 1.0 -- 2 1.5 308 1.0 2.0 --

3 2.5 332.4 0.0 2.0 Used for Analysis

4 3 308.3 2.0 3.0 -- 1

PILE B12

1 230.7 0.0 1.0 -- 2 1.5 242 0.0 2.0 -- 3 2.5 235 0.0 2.0 -- 4 2.5 268.1 0.0 2.0 --

Table No. 51 :- Summary of AnalysisSr. No. Parameter A12

1 Pile Capacity 317.0 Tons 2 Skin Friction 220.4 Tons 3 End Bearing 96.6 Tons 4 Net Displacement 2 mm 5 Total Displacement 9.5 mm 6 Compressive Test 7 N/mm2 7 Tensile stress 1.8 N/mm2 8 Pile Integrity From Test Level (Sensor Level) OK



3.18 Dynamic Pile Load Test



3.4.9 Conclusion Pile No. A12 The analysis results on Pile No. A12 shows that the pile had achieved an activated capacity of 317.0 tons at the time of testing. Further testing could not be continued due to site limitations. Note that this is not the ultimate capacity of the pile.

The results showed that the maximum compressive stress experienced by the pile at the hammer impact was about 7.0 N/mm2. This stress is within the allowable stress limits. The pile integrity was observed to be OK.

Graph 1: Force Obtained From Sensors on Both Sides of the Pile A-12 Graph 2: Load Vs Displacement for For Pile A-12

Pile No.

B12 No meaningful interpretation was possible for Pile No. B12 as the hammer was not centered properly onto the pile resulting in incorrect data collection. As the hammer was not centered properly, the falls resulted in eccentric force and hence it was suggested to retest the pile.



3.5 PRECAST WORKS 3.5.1 Scope of the work Providing and casting of Precast units of design mix concrete grade M:30 including vibrating, mixing, curing, etc. complete, inclusive of providing, fixing & striping of form work. 3.5.2 Introduction Different types of Precast members are as follows: 1) Pile muff (PM) - 2 types (PM-11 & PM-12) 2) Longitudinal beam (LB) - 7 types (LB1- LB7) 3) Pile Capping Beam (PB) - 6 types (PB1- PB6) 4) Pre-cast Deck Slab (DP) - 4 types (DP1- DP4) Pile Muff: It is provided on the Bored cast In situ Piles. Each bored cast in situ pile has one pile muff over it. There are in all 188 pile muffs in approach jetty construction. There are 4 nos. of pre-casting beds for Pile capping beams and 1 set of shuttering.

Pile Capping Beam: It is provided on the Precast Pile Muff. Over the two pile muffs of Grid A & B rests pile capping beams PB-1 & Pb-2 and the cantilever portions on both sides of the trestle has PB-3 & PB-4 on one side and PB-5 & PB-6 on the other. They transfer the load from Longitudinal beams to the pile muff.

There are in all 564 pile capping beams in approach jetty construction. There are 14 nos. of pre-casting beds for Pile capping beams and 5 sets of shuttering.

Longitudinal beam: It is provided on the Precast Pile Capping Beam. They rest on two pile capping beams and transfers load from slab to pile capping beam. There are in all 744 longitudinal beams in approach jetty construction. There are 13 nos. of pre-casting beds for longitudinal beams and 9 sets of shuttering.

Deck Planks: Precast Deck planks are placed over the longitudinal beams. Precast deck planks increase the speed of construction and also act as formwork for the cast in situ deck.

There are in all 2790 numbers of deck planks. There are 50 nos. of pre-casting beds for deck planks and 15 sets of shuttering.

Precast Yard: Precast members are manufactured in pre cast yard which has an over all area of around 2720 Sq.mts. (170mx16m.).

The pre casting beds are made with PCC of 75mm thickness. The Goliath crane spans throughout precast yard and the rails are placed at a distance of 16mts from each other.

Concrete Grade: M:30 grade of concrete is used for all the precast works without addition of any admixture. At site, admixture is mainly added to increase the setting time. As precast yard & Batching Plant are in same premises no admixture is required.

Slump Required – 75-90 mm



3.19 Precast Yard Layout



3.5.3 Tools, Equipments & Plants used for Precasting works 1. Batching plant: Use : For production of Concrete as per Design Mix Company : MACON. Type : Star type automatic batching plant Capacity : 30Cu.m/hr. Batch capacity : 0.5 Cu.m Quantity : 2 Nos. 2. Transit Mixer Use : For Transporting concrete from the Batching Plant to the site Company : Greaves Capacity : 6 Cum. Quantity : 6 Nos. Fuel of Operation : Diesel 3. Goliath crane: Capacity : 20 tones Company : Tailor Made Span : 16mts Quantity : 1 No. 4. Needle vibrator: Diameter of Needle : 60mm & 40mm Range : 300mm Radius - for 60mm & 200mm Radius- for 40mm Fuel : Electrically operated Quantity : 6 – 60mm needles, 5- 40mm needles & 9 Vibrators 5. Bar cutting machine : Use : Cutting and bending of bars Company : Spartan Motor capacity : 8 HP Fuel : Electricity Quantity : 4 Nos.

6. Gas cutter: Use : Cutting plates Quantity : 2 no. Company : Asha Pvt. Ltd. 7. Welding Machine: Use : Welding Company : ESAB Model no : Arc – 400 Input : 42 amp, 415 volts, 50 Hz Range of weld amp : 30 – 400 amps. Quantity : 8 no.

Table No. 52 :- M:30 Grade Mix Design Details Material Quantity

Cement (OPC 53 Grade) 320 Kgs Fly Ash 106 Kgs Aggregate (20mm) 340.8 Kgs Aggregate (10mm) 681.6 Kgs Sand 766.8 Kgs Water 187.44 Kgs

Capacity Of Bar Cutting Machine No. of Bars It Can Cut in a Single Go

1 1 2 3 5

Bar Diameter 36 32 25 20 16



3.5.4 Materials used for Precasting works 1. Reinforcement: Diameter : 10, 20, 25, 32mm TMT bars Source : SAIL Cost : Rs. 24500 / MT 2. Welding rods: Company : ESAB Electrodes Pvt. Ltd. Type : Metal – Arc Welding Code reference : IS 4111 Size : 3.15 x 350 mm & 4.00 x 350mm Cost : Rs. 275/packet. (55Nos.) Consumption : 170mm weld length/rod (4mm x 350mm) 120mm weld length/rod (3.15mm x 350mm) Above Consumptions are for 6mm weld. 3. Binding Wire: Binding wire : 19 gauge Cost : Rs. 28/kg Availability : 50 Kg rolls Code : IS: 814 Amp : 115 – 265 Size : 4 x 450 mm 4. Oxygen cylinder: Purpose : Gas-cutting Capacity : 50 Kg. Consumption : 50 rmt. Cutting (approx.) / cylinder for 6mm plate Cost : Rs.175/cylinder 5. LPG Cylinder: Purpose : Gas-cutting Company : HP Gas Capacity : 14 Kg. Consumption : 250-300 rmt. Cutting (approx.) / cylinder for 6mm plate Cost : Rs. 450 3.5.5 General Information of Construction Methodology

3.5.5.1 Pre Requisites for Reinforcement Fabrication First of all the Bar Bending schedule is prepared by the contractor & it is approved by the Engineer in charge of client.

Before starting the reinforcement cage binding, the steel bed is thoroughly cleaned and the sticking concrete is completely removed with the help of wire brush.

Simultaneously, reinforcement straightening, cutting, bending is done at pre cast yard as per approved bar bending schedule.

The reinforcement steel is cut & bent as required & is shifted to the place of fabrication manually. Care is taken that the reinforcement going to be used is rust free, & if it is not it is cleaned & made rust free with the help of wire brush. 3.5.5.2 Post Reinforcement Checks

Alignment and verticality is maintained with the help of string and plumb bob. Level is checked with the help of level tube.

Reinforcement cage is prepared as per the drawing and it is checked by the engineer-in-charge of contractor.

Checking of reinforcement by client is done only after the member is completely ready for concreting.

Checking whether the cover blocks placed are of required size and in adequate numbers.



3.5.5.3 Pre requisites for Formwork The shuttering plates are fabricated at site in required size & shape. Shuttering plates are made up of 3.15mm Ms steel plates & 65 x 65 x 6mm angles. Simultaneously along with the reinforcement cage fabrication, shuttering is done. The inside face of shutters which is going to be in contact with concrete is oiled properly before erecting so as to achieve easy removal of shutters & achieve smooth surface. 3.5.5.4 Post Formwork Steps

After the shuttering plates are erected and fixed with the help of nut bolts lateral bracing is provided with the help of reinforcement bars.

The gap between two shutter plates if any is sealed with putty & cement mix. After the formwork is erected its linearity, horizontality, verticality & diagonals are checked with the help of string, level tube, plum bob & measure tape & if required the nut bolts are loosened or tightened to get the exact line/dimension.

Concreting is not carried out unless and until R/F cage & formwork is inspected by the engineer in charge of client.

3.5.5.5 General Steps for Concreting All the materials in required quantity are stacked in storage place of batching plant. In star type batching plant there are three divisions for stacking of material. 20 mm aggregate, sand, 10 mm aggregate are saved in their respective partition.

Required quantity of cement is taken out of the storage yard and kept near the cement hopper of the batching plant.

Admixture is kept in to barrel near the batching plant and it is pumped to the mixing drum. First mixing drum of the batching plant is cleaned with the water so as to prevent absorption of water from the cement slurry at the time of mixing.

Than transit mixture is placed in position. In automatic type of batching plant mix designs are pre feed. At the time of concreting quantity of required concrete is fed and its mix design number is fed in the batching plant.

Mixing capacity at a time of batching plant is 0.5 Cu.m and mixing time is 30 seconds. Slump of each transit mixture is checked when it is loaded with desired amount of concrete. The member to be concreted is thoroughly cleaned before the concreting. Slump is also checked at the site of concreting by the Clients Engineer. Now the method of concreting depends upon the location of the casting bed. If the bed is located at a place where free movement of the Transit mixer is possible, than concreting is done directly with the chute of the Transit Mixer.

Where the movement of the transit mixer is not possible, Concreting is done with the help of bucket and goliath crane. Bucket of capacity 0.9 Cum. is used and the crane capacity is 20 tons.

The concreting of pre cast members is generally done at night as in day time the crane is utilized in shifting of the precast members from their respective beds to curing yard.

Concrete is filled in the layers of 300mm approx. and after each layer vibrations are given by needle vibrator.

After the required amount of concreting is done, the open layer of concrete is finished with the help of trowel.

Side formwork of the pre-cast elements is opened after 24 hours.

3.5.5.6 Pre-concreting checks: Whether the reinforcement is according to bar bending schedule or not. Whether the reinforcement bars are free from rusting. Bars are free from de-shuttering oil. Proper numbers of cover blocks are provided or not. Formwork is free form dust and is properly lubricated with de-shuttering oil. Dimensions of the member are proper or not. Line, level and plumb of the member. Weather the joints and opening in the formwork are leak proof or not.



3.5.5.7 Checks at the time of concreting

Cement consumption, water cement ratio of each batch of concrete. Slump of concrete (to check workability). Workability of each and every transit mixture is checked. Required numbers of cubes are casted in batching plant in presence of engineer. Concrete is placed from appropriate height (less than 1.5mts to prevent segregation of concrete). Weather the concrete is placed in the layers of 300 mm. Vibration to concrete is provided after every layer or not. Checking of leakages of cement slurry from shuttering joints.

3.5.5.8 Post-concreting checks

Member is properly cured. Member is kept wet all the time for 10 days or not. Cubes are kept for curing in the curing pond. 9 Cubes are taken. Cubes are tested after 3, 7 & 21 days.

3.5.5.9 Curing

The member is cured for 3 days on the bed itself. Curing is done by ponding method. Ponding is done by creating edges in 1:10 mortar around the top surface of the member. Within 3 days the member gains at least 50% of the strength and hence it is lifted and shifted to the curing yard.

In curing yard it is cured for 4 -7 more days and the cube strength are observed. The member is lifted from the curing yard and transported to the stacking yard after 10 days.

Table No. 53 :- Strength Requirements For Concrete Sr. No. Activity Strength (%) Min. Days

1 Lifting Min. 50% 3 Days 2 Shifting to Stacking Yard Min. 65% 10 Days 3 Erection Min. 80% 14 Days



3.20 Batching Plant Layout



3.5.6 Construction Methodology for Precast Pile Muff 3.5.6.1 Flowchart Showing Construction Methodology of precast Pile Muff

Preparation of BBS & Getting it approved by the client

Binding Of The Reinforcement Cage

Procuring Material

Lifting & placing the reinforcement Cage in the Formwork

2 bars are fixed at top till casting

Applying Shuttering Oil to Sides Fixing of side shutter & placing Liner Piece in the

Concreting

Making Indents on the surface which will have in situ

Stripping of form work after 12 hrs & curing

Curing By the method of ponding & Sprinkling

Cleaning the shutters

Lifting of the muff from casting bed after 72 hrs.

Checking by clients engineer

Taking cubes

Slump Test



3.21 Numeration & R/F Details Of Pile Muff



3.22 Layout Of Pile Muff



3.5.6.2 Reinforcement First of all the pre requisite steps for reinforcement fabrication as mentioned above in 3.5.5.1 are carried out.

A temporary Stand of reinforcement bars is made to support the pile muff reinforcement. Reinforcement cage for the muff is prepared just besides its shutter to facilitate easy transportation of the cage.

Reinforcement cage is prepared on leveled ground. Refer Drg. No. 3.23-3.24 for reinforcement Sequence. Cover provided in precast pile muff is 60mm and hence the covers blocks of 60 mm are then placed at regular intervals.

The line of the reinforcement is maintained with the help of string. The post reinforcement checks as mentioned above in 3.5.5.2 are then carried out. 3.5.6.3 Formwork

Now in case of Pile Muff, the formwork & reinforcement are carried out separately and then the reinforcement cage is placed inside the formwork & hence they are simultaneous activities.

First of all the Pre Requisites for Formwork as mentioned above in 3.5.5.3 are carried out. The formwork sequence for pile muff is as follows:

1. Placing of Bottom Steel Shutter. 2. Placing of Side Shutter. 3. Then the reinforcement is placed inside the formwork shutter. 4. Placing of Internal Form. (MS Liner Piece as per the required Diameter.)

The Post Formwork Steps as mentioned above in 3.5.5.4 are then carried out.

Table No. 54 :- Formwork Quantity Calculations For Pile Muff (PM-11 of 1000dia.) Sr. No. Description Unit Nos. L B H/D Quantity Remarks

1 Slant Face Sqm. 1 1.95 0.57 1.112 (1.5+2.4)/2 = 1.95

Sqm. 2 1.725 0.57 1.967 2 Vetrical Portion Sqm. 1 2.400 0.35 0.840 Sqm. 2 1.950 0.35 1.365 3 Plain Face Sqm. 1 1.725 0.35 0.604 Sqm. 1 2.400 0.35 0.840

4 1000 Dia Hole face

Sqm. 1 0.70 1.98 P=22/7x1.0=3.143m

Total 8.927 Sqm.



3.23 Reinforcement Sequence



3.24 Reinforcement Sequence



3.25 Formwork Sequence



3.5.6.4 Concrete First of all the pre concrete checks are done as mentioned above in 3.5.5.6. After pre concrete checks, the Pre cast supervisor sends the requisition for concrete to the batching plant supervisor indicating the approximate quantity & location of the pour.

The checks at the time of concreting as mentioned above in 3.5.5.7are done. The concreting is done as per General Steps of concreting 3.5.5.5 The Post concreting checks as mentioned above in 3.5.5.8 are done.

Actual consumption = 3 Cum.

3.5.6.5 Man Power Requirement

3.5.6.6 Time Cycle

Table No. 55 :- Concrete Quantity Calculations For Pile Muff (PM-11 of 1000dia.) Sr. No. Description Unit Nos. L B H/D Quantity

1 Bottom upto 350mm ht.

Cum. 1 1.95 1.725 0.35 1.177 (1.5+2.4)/2=1.95

2 Above 350mm to 700mm

Cum. 1 2.4 1.95 0.35

2.016

3 Deduction (1000mm dia.)

Cum. -1 0.786 0.70 -0.550 22/7 x 0.9 x 0.9/4 = 0.636 Sq. m

Total 2.797 Cum.

Table No. 56 :- Actual Material Consumption For Pile Muff (PM-11 of 1000dia.)

Material Cement

(Kg.) Fly Ash (Kg.)

Aggregate (20mm)

Aggregate (10mm)

Sand (Kg.)

Water (Kg.)

Theoretical Consumption

895.04 Kg.

296.48 Kg.

953.22 Kg. 1906.43 Kg. 2144.74 Kg.

524.27 Kg.

Actual Consumption

960 Kg.

318 Kg.

1022.4 Kg. 2044.8 Kg. 2300.4 Kg.

562.32 Kg.

Table No 57 :- Labour Requirement For Precasting Of Pile Muff (PM-11 of 1000dia.)Sr. No. Type Skilled Unskilled

1 Formwork 0.75 1.5 2 Reinforcement 1 2 3 Concreting 2 3

TOTAL 3.75 6.5

Table No. 58 :- Time Cycle For Precast Pile Muff manufacturing (PM-11 of 1000dia.) Sr. No. Type Time

1 Shuttering 4 Hours

2 Reinforcement 5 Hours

3 Concreting 40 Minutes

4 De Shuttering 50 Minutes

5 Curing 10 Days

Total Time Taken For Precast Pile Muff = 10.43 Days



3.5.7 Construction Methodology For Precast Longitudinal Beam 3.5.7.1 Flow chart of Construction Methodology of Longitudinal Beam

Placing of bottom reinforcement bars

Placing of vertical stirrups

Placing of top bars

Placing of lifting hooks

Placing of Cantilever (fin) R/F

2 bars are fixed at top till casting

Applying Shuttering Oil To Sides

Fixing of sides

Placing of sides for fin Checking by clients engineer

Concreting

Making Indents on the surface which will have in situ conc.

Stripping of form work after 12 hrs and curing

Lifting from casting bed after 72 hrs.


Thoroughly cleaning the formwork

Taking Cubes & Checking For Slump

Requisition For Concrete

Preparing BBS and getting it approved

Cutting the reinforcement as per BBS



3.26 Numeration Details



3.27 Rc Detail Of Longitudinal Beam



3.28 Layout Of Longitudinal Beam



3.5.7.2 Formwork & Reinforcement In Case of Precast Longitudinal Beam, Reinforcement cage fabrication and formwork goes on simultaneously but not separately.

First of all the pre requisites of formwork erection (as mentioned above in 3.5.5.3) and reinforcement fabrication (as mentioned above in 3.5.5.1) are carried out simultaneously.

The bottom steel shutter is placed first placed over the concrete bed prepared for it. Then the side shutter on the small cantilever side is erected and fixed with the bottom shutter with nut & bolt assembly.

Two ISA 50x50x6mm are placed at two ends of the bottom shutter. The reinforcement placing is then started. Refer Drg. No: 3.29 – 3.30 for reinforcement sequence. Before Placing of Bar Mark 7, the side shutter on other side i.e. on the longer cantilever side is fixed.

Cover provided in precast longitudinal Beam is 50mm. The reinforcement cage is lifted with the help of reinforcement rods manually and cover blocks are inserted and the ISA 50X50X6mm sections placed at both the ends are removed.

The side stoppers are fixed and hence on the completion of formwork, the post formwork checks (as mentioned above in 3.5.5.4) are done.

The line of the reinforcement is maintained with the help of string. The post reinforcement checks (as mentioned above in 3.5.5.2) are then carried out.

3.5.7.3 Concrete

First of all the pre concrete checks are done (as mentioned above in 3.5.5.6). After pre concrete checks, the Pre cast supervisor sends the requisition for concrete to the batching plant supervisor indicating the approximate quantity & location of the pour.

The checks at the time of concreting (as mentioned above in 3.5.5.7) are done. The concreting is done as per General Steps of concreting (3.5.5.5). The concreting is done in two stages. In first stage the rectangular bottom part is concreted. Second stage concrete involves concreting the two cantilever portion known as fins on the site.

Concrete is filled in the layers of 300mm approx. and after each layer vibrations are given by 60 mm needle vibrator.

The Post concreting checks ( as mentioned above in 3.5.5.8) are done. The surface of concrete which will have cast in situ concrete works is then made rough by making indents on it. Side formwork of the pre-casted elements is opened after 24 hours.

Table No. 59:- Formwork Quantity Calculations For Longitudinal Beam (LB-5a) Sr. No. Description Unit Nos. L B H/D Quantity

1 Side Face Longer Cantilever Side

Sq. m. 1 10 1.287 12.87

2 Side Face Shorter Cantilever Side

Sq. m. 1 10 0.940 9.4

3 Face Central Portion

Sq. m. 2 0.400 0.725 0.580

4 Face Cantilever portion

Sq. m. 2 0.250 0.175 0.088

Sq. m. 2 0.6 0.175 0.210 Total 23.148 Sq. m



3.29 RF Fabrication



3.30 RF Fabrication



3.31 Formwork



3.32 Over all Construction Sequence



Actual consumption = 4.4 Cum.

3.5.7.4 Manpower Requirements

3.5.7.5 Time Cycle

Table No. 60 :- Concrete Quantity Calculations For Longitudinal Beam (LB-5a) Sr. No. Description Unit Nos. L B H/D Quantity Remarks

1 Central Portion

Cum. 1 10 0.4 0.725 2.9

2 Deduction for Chamfer

Cum. -1 10 0.025 0.025 -0.006

3 Long Cantilever Portion

Cum. 1 10 0.6 0.175 1.050

4 Short Cantilever Portion

Cum. 1 10 0.25 0.175 0.438

Total 4.381 Cum.

Table No. 61 :- Actual Material Consumption For Longitudinal Beam (LB-5a)

Material Cement

(Kg.) Fly Ash (Kg.)

Aggregate (20mm)

Aggregate (10mm)

Sand (Kg.)

Water (Kg.)


1401.92 Kg.

464.39 Kg.

1493.04 Kg. 2986.09 Kg. 3351.35 Kg.

821.17 Kg.

Actual Consumption

1408 Kg. 466.4 Kg.

1499.51 Kg. 2999.04 Kg. 3365.88 Kg.

824.73 Kg.

Table No 62 :- Labour Requirement For Longitudinal Beam (LB-5a) Sr. No. Type Skilled Unskilled


TOTAL 3.75 6.5

Table No. 63 :- Time Cycle For Precast Longitudinal Beam (LB-5a) Sr. No. Type Time

1 Shuttering 3 Hours 2 Reinforcement 4 Hours 3 Concreting 50 Minutes 4 De Shuttering 35 Minutes 5 Curing 10 Days




3.5.8 Construction Methodology For Precast Deck Planks 3.5.8.1 Flow chart of Construction Methodology of Deck Planks

Preparation of BBS & Getting it approved by the client

Placing of Bottom Main Reinforcement

Placing of Vertical Stirrups


Applying Shuttering Oil to Sides Fixing of side shutter

Checking by clients engineer Concreting

Making Indents on the surface which will have insitu

Stripping of form work after 12 hrs & curing

Lifting from casting bed after 72 hrs.

Procuring Material

Cutting of Reinforcement As per BBS

Placing of top main Reinforcement

Cleaning the shutters

Taking cubes

Slump Test

Laying of PVC Sheet on the bottom steel shutter



3.36 Numeration & RC Details



3.5.8.2 Reinforcement First of all the pre requisite steps for reinforcement fabrication (as mentioned above in 3.5.5.1) are carried out.

In case of deck planks, reinforcement cages are prepared separately and then placed inside the shutter.

The reinforcement cage preparation & shuttering are hence a simultaneous activity. Reinforcement cage is prepared on leveled ground. Refer drg. No. 3.37-3.38 for reinforcement sequence. The main bottom reinforcement is first binded and then only shear reinforcement is binded. Now before placing the reinforcement cage in the shutter, cover blocks are placed at regular intervals.

Cover provided in precast deck planks is 50mm. The line of the reinforcement is maintained with the help of string. The post reinforcement checks (as mentioned above in 3.5.5.2) are then carried out. 3.5.8.3 Formwork

Now in case of Deck Planks, the formwork & reinforcement are carried out separately and then the reinforcement cage is placed inside the formwork & hence they are simultaneous activities.

First of all the Pre Requisites for Formwork (as mentioned above in 3.5.5.3) are carried out. The formwork sequence for pile muff is as follows: 1. Placing of Bottom Steel Shutter. 2. Placing of Side Shutter of two opposite sides. 3. Then the reinforcement is placed inside the formwork shutter. 4. Placing of side shutter of another two sides

The Post Formwork Steps (as mentioned above in 3.5.5.4) are then carried out.

3.5.8.4 Concreting First of all the pre concrete checks are done (as mentioned above in 3.5.5.6). Now generally a large number of deck planks are casted together or concreting of deck oplank is combined with concreting of some other element as the concrete requirement of a single deck plank is very less.

After pre concrete checks, the Pre cast supervisor sends the requisition for concrete to the batching plant supervisor indicating the approximate quantity & location of the pour.

The checks at the time of concreting (as mentioned above in 3.5.5.7) are done. The concreting is done as per General Steps of concreting (3.5.5.5). The concreting is done in a single stage without stopping. The Post concreting checks (as mentioned above in 3.5.5.8) are done. The surface of concrete which will have cast in situ concrete works is then made rough by making indents on it. Side formwork of the pre-casted elements is opened after 12 hours or next morning.

Actual consumption = 0.4 Cum.

Table No. 64:- Formwork Quantity Calculations For Deck Plank (DP-1) Sr. No. Description Unit Nos. L B H/D Quantity

1 Shorter Side Face Sq. m. 2 1.45 0.15 0.435

2 Longer Cantilever Side Face

Sq. m. 2 1.725 0.15 0.5175

Total 0.9525 Sq. m

Table No. 65 :- Concrete Quantity Calculations For Deck Plank (DP-1) Sr. No. Description Unit Nos. L B H/D Quantity Remarks

1 Central Portion

Cum. 1 1.725 1.345 0.15 0.348 L x B x H

Total 0.348 Cum.



3.5.8.5 Man Power Requirements

3.5.8.6 Time Cycle

3.5.9 General Problems Encountered In Precast Works Smooth Finish is not achieved. Falling of slurry while concreting. Formwork Sticks to concrete. Joggle is provided on the side other than it should have been provided. Segregation of Concrete. Development of Surface cracks. While transporting and lifting, the edges break.

3.5.10 Reasons For Above Problems Slurry leaks due to improper joining of two shutters. Improper Curing (Only 7 Days) leads to development of surface cracks. Lack of supervision leads to providing of joggle on the wrong side of the member. The main reason for the breaking of edges while transportation is that wooden battens are not placed while transporting beams.

3.5.11 Probable Solutions Wooden Battens should be placed below the beams while transporting them for proper support in order to prevent the breaking of edges

The gaps between the shutters should be avoided and if unavoidable they should be filled with U foam or putty (cement & grease mix).

Proper Supervision and adopting a method like always joggle one side of the beam can prevent improper joggling of the beam reinforcement.

Proper curing (atleast till 10-14 days) can prevent the surface cracks.

Table No. 66 :- Actual Material Consumption For Deck Plank (DP-1)

Material Cement

(Kg.) Fly Ash (Kg.)

Aggregate (20mm)

Aggregate (10mm)

Sand (Kg.)

Water (Kg.)


111.36 Kg.

36.89 Kg.

118.6 Kg.

237.2 Kg. 266.85 Kg.

65.23 Kg.

Actual Consumption

128 Kg. 42.4 Kg.

136.32 Kg. 272.64 Kg. 306.72 Kg.

74.98 Kg.

Table No 64 :- Labour Requirement For For Deck Plank (DP-1) Sr. No. Type Skilled Unskilled

1 Formwork 0.5 1 2 Reinforcement 1 2 3 Concreting 2 2

TOTAL 3.5 5

Table No. 68 :- Time Cycle For Precast Deck Plank (DP-1) Sr. No. Type Time

1 Shuttering 30 Minutes 2 Reinforcement 3 Hours 3 Concreting 30 Minutes 4 De Shuttering 20 Minutes 5 Curing 10 Days




3.37 R/F Fabrication For deck Planks



3.38 R/F Fabrication For deck Planks



3.39 Formwork For deck Planks



3.6 ERECTION WORKS 3.6.1 Flowchart Showing Erection Sequence of Precast Elements

Transporting the Pre cast member from Stacking Yard to Site

Tie the sling /Spreader Beam with the Lifting Hooks

Tie Additional ropes for controlling the movement of precast member

Lifting Of the Precast Element Checking the Functioning of Erection Gantry as per Checklist

Making temporary Supporting arrangements

Placing the Precast member at its location

Cutting the temporary support members as per required sizes.

Survey Works to check the Line & level of the Precast Element

Readjusting by making adjustments in the temporary support

Re-welding of the temporary supports

Cutting of the welding



3.6.2 Erection Methodology of Pile Muff Pile Muff which has been cured for atleast 14 days can be erected. So the muff which is minimum of14 days old is brought to the site of erection from the stacking yard through trailer.

A sling is then tied with the two lifting hooks of the pile muff. Two more ropes are tied to the pile muff at two opposite corners for controlling the movement of the muff at the time of lifting of the muff.

The muff is lifted with the help of EOT in the back of the Gantry which is of 15 tons capacity. Now the muff is slowly lifted and brought above the pile over which it is to be placed. Muff is slowly lowered till the bottom of the muff is approximately 50 mm above the pile. It is held in this position and then supporting brackets of ISMC 150 are welded at four places around the pile.

Then the muff is lowered and allowed to rest on the pile. Surveying is carried out to check the position of the muff and its levels are checked. For checking the position of the muff, four points are taken on the four sides of the muff 1.5mts from the centre of the muff.

The co-ordinates are then matched and the variation is then calculated. The variation has to be within the tolerance of ±75mm and if it is more then the tolerance limit then the muff is readjusted.

Now levels are taken with help of Auto level. Levels are taken at four corners of the muff. Now if any variation in the level of the muff is found then the Supporting brackets on that side of the muff is adjusted and the levels are corrected.

NOTE: All other precast elements are erected in similar manner except in case of Pile capping beam & Longitudinal Beams are lifted with the help of spreader beam and Erection Gantry, and precast deck planks are erected by 75 ton capacity crane & erection Gantry. 3.6.3 Manpower Requirements

3.6.4 Time Cycle

Table No. 69 :- Labour Requirement For Erection Of Pile Muff Sr. No. Type Skilled Unskilled

1 Gantry/EOT/Crane Operator 1 - 2 Signal Giver - 2 3 Welders 2 4

4 Helpers for Erection (For Controlling Member Movement, tying Sling, etc.)

- 3

TOTAL 3 9

Table No. 70 :- Time Cycle For Erection Of Pile Muff Sr. No. Type Time

1 Loading 20 Minutes 2 Transportation 30 Minutes 3 Unloading 20 Minutes 4 Placing (Erecting) 25 Minutes 5 Enabling Works for Support 1 Hour 20 Minutes 6 Survey Works 15 Minutes 7 Readjustments 40 Minutes

Total Time Taken For Precast Pile Muff = 3 Hours 50 Minutes



3.40 Alignment Details For Pile Muff



3.41 Layout at the time of erection



3.42 Erection Sequence



3.43Erection Sequence



3.7 CAST IN SITU WORKS 3.7.1 Introduction Cast in situ works is divided into two parts on the basis of their order of construction:

1) Stage – 1 2) Stage – 2

Stage -1 consists of two phases. 1st phase involves casting of the junction between Pile muff and pile. 2nd Phase involves casting of the junction between two pile capping beams.

Phase-1 involves M 40 Grade concrete. Phase-2 involves M 30 Grade Concrete. Stage -2 consists of two phases. 1st phase involves concreting of junction over the pile capping beam between longitudinal beams and also cast in situ slab.

2nd Phase involves concreting of Cast In situ Deck slab Both the phases of Stage -2 involves M40 Grade of Concrete

Location Cast In situ Stage -1 Works Studied: Grid 13 Location Cast In situ Stage -2 Works Studied: Between Grid 3, 4 & 5. The location of phase 1 concrete of Stage 2 is at grid 4 The location of Phase 2 Cast in situ deck is between Grid 3 & 4. The area selected for concreting was 4 mts away from the grid 3 and it extended upto 8mts. away from grid 4 towards Grid 5.

Thus the construction joint was provided at L/3 mts., thereby assuring that the joint is provided at a place where there is minimum Bending and Shear stresses.

3.7.2 Tools, Equipments & Plants used for Cast In Situ works 1. Concrete Pump

Use : For pumping the concrete into the borehole Company : Sany Capacity : 43 Cum. Quantity : 2 Nos. Fuel of Operation : Diesel

2. Air Compressor : Use : For cleaning the surface to be concreted Company : Sany Capacity : 365 cfm Quantity : 2 Nos. Rest of TEP is same as that used in precast works

3.7.3 Materials used for Cast In Situ works Materials used are same as that used in precast works



3.46 Numeration& Rc Details



3.7.4 Flowchart Showing Construction Sequence of Stage -1 Cast In Situ Works:

Preparation of BBS by contractor & getting it approved from the client

Providing rings in the junction of Pile muff and pile

Concreting the junction

Curing the junction and waiting for the junction to mature

Sealing of the Gaps between the pile capping beams with Fly ash Masonry (Lost Form)

Procuring Materials

Bending Reinforcement as per the BBS

Preparing the BBS & Getting Approved by Client

Procuring Material


Placing of Reinforcement

Fixing Of Formwork & checking its line level and plumb


Curing by means of heissan clothes

Procuring Material for Formwork

Cutting of Wooden and ply wood members in proper sizes

PHASE 1

PHASE 2



3.7.4.1 Construction Methodology of Phase 1 of Stage 1 of Cast in Situ Works

Phase- 1 First of all as per the approved BBS of the client, rings are bent and prepared. The rings are then tied to the pile reinforcement as per the drawings. Clients Engineers checks the rings and gives approval for the concreting of the junction between the precast pile muff and pile.

Simultaneously preparations for concreting are made and tremie pipe is fixed. Once the pile muff-pile junction is ready to receive the concrete, the supervisor sends the requisition for concrete to the batching plant supervisor indicating the approximate quantity & location of the pour.

Now as soon as the Transit mixer arrives at the site cubes (9 in nos.) are casted and taken for cube testing.

Slump test is done in presence of the client’s engineer. Once approved then concreting is done with the help of the chute of the transit mixer (wherever possible) or with help of pump and tremie.

Needle vibrator is also used for vibrating the concrete. Then curing is done by sprinkling of water and also with heissan clothes.


In case of Phase 2 works before placing of the pile capping beams of the opposite side reinforcement bars with bar mark 2, 3 & 4 are to be kept in position as it would not be possible to place the bars. Formwork Before starting the reinforcement binding, formwork is done. Formwork done is of Fly ash masonry which is lost after concreting is done and hence can be said as lost form.

The area between the two adjacent pile capping beams i.e between PB-1& PB-2 has fly ash masonry as formwork.

The Fly Ash Masonry is done in 1:4 cement mortars. After completion of the masonry, the surface is leveled by plastering the surface in Cement mortar 1:6.

Reinforcement First of all the area that is going to receive the reinforcement is thoroughly cleaned. Simultaneously the Bar Bending schedule is prepared by the contractor & it is approved by the Engineer in charge of client.

Then reinforcement straightening, cutting, bending is done at pre cast yard as per approved bar bending schedule.

The reinforcement steel is cut & bent as required & then is shifted to the place of binding through trucks.

Care is taken that the reinforcement going to be used is rust free, & if it is not it is cleaned & made rust free with the help of wire brush.

Reinforcement is placed as per the drawing & BBS. Alignment and verticality is maintained with the help of string and plumb bob. Level is checked with the help of level tube.


Practice of binding the reinforcement with two binding wires is followed. Checking of reinforcement by client is done before concreting of a member. Cover blocks are inserted at required places at the bottom & sides of the reinforcement cage.



Formwork The shuttering is Prepared at site in required size & shape. The shuttering is made up of Plywood sheets and wooden battens. After the reinforcement cage fabrication, shuttering is done. The inside face of shutters which is going to be in contact with concrete is oiled properly before erecting so as to achieve easy removal of shutters & achieve smooth surface.

After the shuttering is erected and fixed with the help of tie rods of 20mm dia. The gaps if any are sealed with U-foam. After the formwork is erected its linearity, horizontality & verticality & are checked with the help of string, level tube & Plumb bob & if required the tie rods are loosened or tightened to get the exact line/dimension.

Concreting is not carried out unless and until R/F cage & formwork is inspected by the engineer in charge of client.

Concreting Pre concreting checks (as mentioned above in 3.5.5.6) are carried out first The surface to be concreted is thoroughly cleaned with the help of air compressor Concreting is done as per the general procedure of concreting ( as mentioned in 3.5.5.5) From the transit mixture, concrete is unloaded into the concrete pump. Then it is transported to the place of the concreting through tremie pipes.

Before pouring the new concrete, water is sprinkled on old concrete. Concrete is filled in the layers of 300mm approx. and after each layer vibrations are given by 60 mm needle vibrator.

Concrete checks at the time of concreting as mentioned above in XXX are carried out. Concreting is done in a single go to get monolithic concrete without any construction joints. After the required amount of concreting is done, the open layer of concrete is made rough with the help of broom as it will have cast in situ stage 2 concrete over it.

Cover provided to concrete is 50 mm. After the completion of concreting, the post concrete checks (as mentioned above in 3.5.5.8) are carried out.

Actual consumption Phase – 1 = 0.445 Cum. Actual consumption Phase – 2 = 3.268 Cum.

Curing is done by ponding for 14 days and method is same as in precast works.

Table No. 71 :- Formwork Quantity For Phase 2 of Stage -1 Cast in Situ Works Sr. No. Description Unit Nos. L B H/D Quantity

1 Side Face Sq. m. 2 1.5 1.7 5.1 Total 5.1 Sq. m

Table No. 72 :- Concrete Quantity For Stage -1 Cast in Situ Works Sr. No. Description Unit Nos. L B H/D Quantity Remarks

1 Phase - 1 Cum. 1 10 0.4 0.5 0.392 3.14x0.5x0.5x0.5=0.392

Phase - 2 Cum. 1 1.5 1.7 1.2 3.06

Total 3.452 Cum.

Table No. 73 :- Actual Material Consumption For Stage -1 Cast in Situ Works

Material Cement (Kg.)

Fly Ash(Kg.)

Aggregate (20mm)

Aggregate (10mm)

Sand (Kg.)

Water (Kg.)

Phase – 1 (M:40 Grade)

154.415 Kg.

51.62 Kg.

389.22 Kg.

119.15 Kg.

313.52 Kg.

82.41 Kg.


1045.76 Kg.

346.408 Kg.

1113.73 Kg. 2227.47 Kg. 2505.90 Kg.

612.55 Kg.

Total 1200.175 Kg.

398.028 Kg.

1502.95 Kg. 2346.62 Kg. 2819.42 Kg.

694.96 Kg.



3.47 R/F Fabrication Sequence



3.50 Formwork Sequence



3.7.4.3 Man Power Requirement

3.7.4.4 Time Cycle

Table No 74 :- Labour Requirement For Stage -1 Cast in Situ Works Sr. No. Type Skilled Unskilled


TOTAL 3.75 7.5

Table No. 75 :- Time Cycle For Stage -1 Cast in Situ Works Sr. No. Type Time

1 Shuttering 4 Hours 30 Minutes 2 Reinforcement 14 Hours 3 Concreting 2 Hours 4 De Shuttering 45 Minutes 5 Curing 10 Days

Total Time Taken For Stage -1 Cast in Situ Works

= 10.88 days



3.7.5 Flowchart Showing Construction Sequence of Stage -2 Cast In Situ Works:

Bending Reinforcement as per the BBS

Placing the formwork between the two consecutive

longitudinal beams on the


Filling the gaps between Precast Deck planks with U foam & Sealing Large gaps with Cement Mortar

Fixing Of Formwork & checking its line level and plumb

Concreting the cast in situ Deck Slab

Curing by means of Ponding by creating edges in cement mortar 1:10 around the casted slab

Concrete Requisition

PHASE 2 Arrangements for Concreting

Simultaneous Activity

Preparation of BBS by contractor & getting it approved from the client

Placing of the Reinforcement in the junction above the pile capping beams and between the longitudinal beams


Curing the junction and waiting for the concrete to mature

Placing of Reinforcement

Procuring Materials

Preparing the BBS & Getting Approved by Client

Procuring Material

PHASE 1

Simultaneous Activity



3.51 RC detail Of Stage 2 Concrete



3.54 Area of interest




Formwork (Phase 1) The shuttering is a tailor made shuttering prepared in the pre fabrication yard. The shuttering is made up of 3.15 mm Ms Steel plates and ISA 65X65X6mm. Before the reinforcement cage fabrication, shuttering is done and the gaps between the consecutive Longitudinal Beams are covered.

The inside face of shutters which is going to be in contact with concrete is oiled properly before erecting so as to achieve easy removal of shutters & achieve smooth surface.

The shuttering is then fixed in position by welding 16mm dia rods to the existing reinforcement of the longitudinal beams.

The gaps if any are sealed with U-foam. After the formwork is erected its linearity, horizontality & verticality & are checked with the help of string, level tube & Plumb bob & if required the welded rods are loosened or tightened to get the exact line/dimension.

The sides are placed and fixed only after the reinforcement has been binded. Concreting is not carried out unless and until R/F cage & formwork is inspected by the engineer in charge of client.

Reinforcement First of all the area that is going to receive the reinforcement is thoroughly cleaned. Simultaneously the Bar Bending schedule is prepared by the contractor & it is approved by the Engineer in charge of client.

Simultaneously, reinforcement straightening, cutting, bending is done at pre cast yard as per approved bar bending schedule.

The reinforcement steel is cut & bent as required & then is shifted to the place of binding through trucks and dumpers.

Care is taken that the reinforcement going to be used is rust free, & if it is not it is cleaned & made rust free with the help of wire brush.

Reinforcement is placed as per the drawing & BBS. Alignment and verticality is maintained with the help of string and plumb bob. Level is checked with the help of level tube.


For reinforcement sequence refer Drg.3.55-3.57. Practice of binding the reinforcement with two binding wires is followed. Checking of reinforcement by client is done before concreting of a member. Cover blocks are tied at required places at the bottom & sides of the reinforcement cage.

Concreting Pre concrete checks are first made (as mentioned above in 3.5.5.6). Transit mixtures are covered with wet heissan clothes in order to to protect the concrete from heat and to prevent the reduction in slump of the concrete.

Slump is also checked at the site of concreting by the Clients Engineer. From the transit mixture, concrete is unloaded into the concrete pump. Then it is transported to the place of the concreting through tremie pipes.

Before pouring the new concrete, a bonding agent is applied to the old concrete surface. All the concrete surfaces which will receive Cast in Situ concrete are casted rough in order to have proper bonding.

Before concreting the area, the area is thoroughly cleaned with the help of air blowers. Concrete is filled in the layers of 300mm approx. and after each layer vibrations are given by 60 mm needle vibrator.

60mm needle vibrator is used in order to get proper vibrations through out the beam. Theoretical range of vibrations in 60 mm needle is in diameter of 300mm as compared to 200mm diameter in 40mm needle.

Concreting is done in a single go to get monolithic concrete without any construction joints.



After the required amount of concreting is done, the open layer of concrete is finished with the help of trowel or broom.

Side formwork of the casted elements is opened after 24 hours. Cover provided to concrete is 50 mm.

Actual consumption Phase – 1 = 28.5 Cum.

Curing is done by ponding and by covering heissan clothes for about 14 days.

Man Power Requirements

Time Cycle

Table No. 76 :- Concrete Quantity For Phase-1 of Stage -2 Cast in Situ Works Sr. No. Description Unit Nos. L B H/D Quantity Remarks

1 Phase - 1 Cum. 1 16.4 1.9 0.9 28.044 L x B x H = 28.044

Total 28.044 Cum.

Table No. 77 :- Actual Material Consumption For Phase-1 of Stage -2 Cast in Situ Works


Fly Ash(Kg.)

Aggregate (20mm)

Aggregate (10mm)

Sand (Kg.)

Water (Kg.)


9889.5 Kg.

3306 Kg.

24927.5 Kg.

7630.87 Kg.

20079.67 Kg.

5278.2 Kg.

Table No. 78 :- Labour Requirement For Phase 1 of Stage -2 Cast in Situ WorksSr. No. Type Skilled Unskilled

1 Formwork 0.75 1.5

2 Reinforcement 2 3

3 Concreting 2 4

TOTAL 4.75 8.5

Table No. 79 :- Time Cycle For Phase 1 of Stage -2 Cast in Situ Works Sr. No. Type Time

1 Shuttering 18 Hours 2 Reinforcement 18 Hours 3 Concreting 4 Hours 4 De Shuttering 4 Hours 30 Minutes 5 Curing 10 Days

Total Time Taken For Phase 1 of Stage -2 Cast in Situ Works = 11.85 days



3.55 R/F Fabrication



3.7.5.2 Construction Methodology of Phase 2 of Stage 2 of Cast in Situ Works Formwork The methodology for formwork is same as mentioned in phase 1 of cast in situ stage 2 works.

Reinforcement The genereal steps of reinforcement as mentioned in phase 1 of cast in stage 2 works are first followed.

For reinforcement sequence refer Drg. 3.58-3.61 The insert plates for the conveyor are placed. The level of the inserts is checked with the help of the Auto level. Top level of inserts is +15.00mts which is same as that of the cast in situ deck slab. The inserts are placed in line with the help of string which is tied with the help of erecting temporary supports.

The positions of temporary supports are given with the help of total station.

Concreting The procedure of concreting is same as that mentioned in phase 1 of cast in situ stage 2 works.

Actual consumption Phase – 2 = 45 Cum.

Curing The method of Curing is also same as that mentioned in phase 2 of stage 2 cast in situ works.

Man Power Requirement

Time Cycle

Table No. 80 :- Concrete Quantity For Phase-2 of Stage -2 Cast in Situ Works Sr. No. Description Unit Nos. L B H/D Quantity Remarks

1 Phase – 2 Cum. 1 12 16.4 0.28 55.14 L x B x H = 55.14

2 Deductions Cum. 1 12 7.88 0.13 12.29

Total 42.84 Cum.

Table No. 81 :- Actual Material Consumption For Phase-2 of Stage -2 Cast in Situ Works


Fly Ash(Kg.)

Aggregate (20mm)

Aggregate (10mm)

Sand (Kg.)

Water (Kg.)

Phase – 2

(M:40 Grade)

15615 Kg. 5220

Kg.

39359.25

Kg.

12048.75

Kg.

31704.75

Kg.

8334.0

Kg.

Table No 82 :- Labour Requirement For Phase-2 of Stage -2 Cast in Situ WorksSr. No. Type Skilled Unskilled

1 Formwork 2 3 2 Reinforcement 2 5 3 Concreting 3 11

TOTAL 7 19

Table No. 83 :- Time Cycle For Phase-2 of Stage -2 Cast in Situ Works Sr. No. Type Time

1 Shuttering 10 Hours 2 Reinforcement 68 Hours 3 Concreting 5 Hours 4 De Shuttering 5 Hours 5 Curing 10 Days

Total Time Taken For Phase-2 of Stage -2 Cast in Situ Works = 13.67 days



3.62Concreting Sequence



Owning & Operating Cost



4.1 MATERIAL MANAGEMENT Material Management is the function responsible for the co-ordination of planning, sourcing, purchasing, moving, storing and controlling materials in an optimum manner so as to provide a pre-decided service to the customer at a minimum cost.

` Purchase

Inventory Management

Execution / Commissioning Waste Management The major functions of material management can be stated as under: 1) Materials Planning and Control Based on the sales forecast and production plans, the materials planning and control is done. This involves estimating the individual requirements of parts, preparing materials budget, forecasting the levels of inventories, scheduling the orders and monitoring the performance in relation to production and sales. 2) Purchasing This includes selection of sources of supply, finalization of terms of purchase, placement of purchase orders, follow-up, maintenance of smooth relations with suppliers, approval of payments to suppliers, evaluating and rating suppliers. 3) Stores and Inventory Control This involves physical control of materials, preservation of stores, minimization of obsolescence and damage through timely disposal and efficient handling, maintenance of stores records, proper location and stocking. Stores are also responsible for the physical verification of stocks and reconciling them with book figures. The inventory control covers aspects such as setting inventory levels, ABC analysis, fixing economical order quantities, setting safety stock levels, lead time analysis and reporting. 4.1.1 Purchase The basic objective of purchasing function is to ensure continuity of supply of raw materials, sub contracted items and spare parts and at the same time reduce the ultimate cost of the finished goods, in other words the objective is not so much to procure the materials at the lowest price but to reduce the cost of the final product.

For ensuring this, there are a large no. of well known parameters such as Right price, Right quality, Right contractual terms, Right time, Right source, Right material, Right place, and Right mode of transportation, Right quantity and Right attitude. All these have to be considered jointly.

It also ensures that all purchased products and services conform to specified requirements of the contract. The products may include any sub-contract work and supplies such as materials.

The selection of sub-contractors, and the degree of control exercised, is dependent upon the product type, past supplier’s performance and requirements.

4.1.1.1 Purchasing Process The process involves the following:

1. To ensure that the product which is outsourced, e.g. raw materials, semi processed and/ or the finished product purchased from the supplier or the services procured from the consultant, technical know-how provider or the piece-rate workers and sub-vendors meets the requirement of the client/ customer.

MATERIAL MANAGEMENT Stores

CHAPTER 4. PROJECT MANAGEMENT



2. To ensure conformance of purchased product to specified requirements by supplying control over the supplier of goods or services and the purchased product.

3. To excise the control over suppliers by means of Suppliers Evaluation. 4. To evaluate suppliers on the basis of their ability to supply product or as per requirement. 5. To establish the basis of criteria for selection, evaluation and re-evaluation. 6. To maintain the records 7. Results of evaluation 8. Actions arising from evaluation

4.1.1.2 Responsibility

4.1.1.3 Purchasing Information

Purchasing documents contain a clear description of the product or service required, including any verification requirements for compliance with quality management systems.

All purchasing documents are reviewed prior to release to the sub-contractor, checked and maintained to provide clear, complete and specific information which is as follows: 1. To describe information e.g. technical specification and commercial terms and conditions

including quantity, price, delivery schedule(s) and tests involved for the product to be purchased in the purchase order.

2. To describe the requirements for product, procedures, processes and equipment. 3. To describe requirements for qualification of personnel to be involved in the process. 4. To describe requirements of the Quality Management System.

4.1.1.4 Verification of purchased product

When formalising a purchasing Contract with suppliers, PMC specifies, as necessary, its or the Client’s requirements for access to the supplier’s premises for any verification arrangements and the method of product release by adopting set procedure of quality assurance plans and programs.

The suppliers are specifically advised that this verification activity does not substitute the supplier’s responsibility for effective quality and end use of its products or services.

4.1.2 Steps in Purchase transaction 1. The requirements of purchase of equipment/ materials are identified through:

a) Project Scope Document b) Fortnightly reviews in the project review meeting. c) Project Planning/ Engineering Department: d) Indents.

In all cases the indents are regularized by the Project Manager, who also is responsible to provide schedule and the technical inputs required for floating enquiries and finalizing the orders.

2. Floating of enquiries to approved suppliers, specifying the due date and technical requirements, if available in the Procurement Databank, Otherwise pre-qualification of suppliers is taken up.

3. Vendor is selected from approved vendor list 4. Quotations are received from the bidders along with quality plan and procedures for supply

items. 5. After receipt of quotations from the suppliers comparative analysis statement is made on the

basis of landed cost and other specific terms and conditions offered by the bidders. 6. The offers received are sent to the PMC user department, Engineering, quality and for technical

review as required.

Table No. 84 :- Purchase Responsibilities Sr. No. Purchase Location Personnel Responsible

1 Site Purchases Project Manager 2 Zonal Office Purchases Chief Materials Manager 3 H.O. Purchases Director (Commercial & Purchase)



7. Price negotiation is carried out with the suppliers on the basis of prevailing market rate available in the databank, PMC estimated rates, earlier purchase orders placed etc.

8. Quality plan and procedures for supply item is finalized by quality and sys. in co ordination with commercial and in agreement with suppliers prior to price negotiation.

9. After negotiation, approval of the competent authority is sought. 10. Note for approval for placement of purchase order is sent along with the draft purchase order for

approval. 11. Prior to issue of the order to proposed vendor, commercial (procurement) head ensures to

receive the following from vendors. a) Manufacturing schedule in line with approved project schedule. b) Material/equipment inspection schedule c) Quality Assurance Plan and Inspection test plan d) Milestone schedule for manufacturing and supply of items.

12. After approval the purchase order is issued to the supplier. 13. For the items, for which the order has been placed recently and the supplier agrees to the same

rate, repeat order is placed. 14. The purchase order includes the following:

a) Purchase Order Number; b) Supplier’s Name; c) Supplier’s Address; d) Item name; e) Item description, part number/drawing

number where relevant; f) Relevant item code if

standardized/specified by company; g) Dimensional Specifications; h) Physical and/or Chemical

characteristics where relevant; i) Quantity to be ordered; j) Unit and total price;

k) Mode of supply; l) Consignee and address; m) Frequency of supplies and Lot size where

relevant; n) Delivery schedule; o) Prices, duties, taxes; p) Specific instructions on handling, packaging

and delivery; q) General terms and conditions including

payment terms, warranty, liquidated damages, force majeure, guarantees;

r) Any other provisions relevant to the supply.

15. The Purchase Order is reviewed for its adequacy and correctness before issue. 16. Copies of Purchase order are distributed to Supplier, Stores, Q & S, Finance, Contract

Administration, and one copy is retained with Purchase Department. 17. Commercial deptt. prepares cash flow plan for one month and forecast for two month for supply

items on monthly basis and provides it to F & A for compilation of project fund. 18. Amendments are generally issued for any of the following reasons:

a. Quantity variation (Increase / Decrease); b. Rate variation; c. Terms and conditions variation; d. Specification variation.

19. Follow up for the supply of materials till received and accepted at store. 20. Coordination for necessary measure in case of any discrepancies in materials received at

stores. Purchase deptt. ensures for clearance and acceptance of materials. 21. Preparation of GRN is jointly done by the Stores and Construction Manager and forwarding the

GRN along with the invoice and other documents to Commercial Manager. 22. Development of suppliers and maintaining databank. 23. It is ensured that the suppliers’ are periodically evaluated every six months on the basis of

quality, timely delivery and cost for the supplies made in the period. 24. Monthly Review Meeting is conducted by procurement department at HO for all major

procurement items to monitor the progress of manufacturing item as follows: a) For short term (up to one month) items, normally no review are conducted accept delay or

problem is encountered. b) For long term delivery items, a monthly review meeting is conducted at Head office, A’bad . c) For imported long lead items, monthly progress review meeting is held with the Indian

representative of the supplier and in the alternate month the principal supplier is called for progress review.



4.1.3 Material Storage & Handling The received material is registered in the Stock Record Register. The store department has to store the materials on racks under cover keeping in mind the manufactures specifications also. The recommended code for this is IS: 4082 "Recommendations on stacking and storage of construction materials on site" and IS: 7969 "Safety code for handling and storage of building materials".

The materials are stacked in specified areas with the old stock shifted ahead and new at the back. The stock, which is not tested, is kept separately with identification. Stock Statement i.e. daily stock verification report is made stating the quantum of materials in the beginning & at the end of the day.

Reconciliation of Stock Statement is done on monthly basis. Periodical Verification of P&M & Tools & Tackles is done. Issues of delivery challans is also done on arrival of materials. Safety & Security of all the materials in stock is looked after by the stores department itself. Review of Insurance Coverage is also done. The quality of the each supplied lot is checked first and than stored. If the material is found not to be matching the required specifications, the whole lot is liable for rejection.

The received material is than stored in the appropriate place. 4.1.4 Material reconciliation Material reconciliation is the process of checking the proper usage of the materials issued for work. The theoretical material consumption is compared with the actual usage of the materials, bearing permissible percentage of wastage in handling.

The payment is done for the free/chargeable materials considering the reconciliation. If the wastage of material exceeded the permissible value, the extra cost is to be borne by the Contractor.

As Cement, Steel & Fly-ash are provided by the Client as “Free Issue”, material reconciliation of these materials is done on regular basis. This also forms the base for the clearance & payment of the RA bill.

A. Cement Cement is freely issued directly to the contractor at site; the contractor submits reconciliation statement for cement actually consumed v/s the theoretical consumption. The contractor submits such reconciliation statement with their running bills or monthly basis whichever is earlier.

B Steel reinforcement/Structural steel Contractor submits the reconciliation statement as per prescribed format as actual consumption v/s theoretical consumption at the frequency of three months.

Construction manager and store in charge jointly carries out the physical verification of stock and reconciliation of material. Allowable wastage and rolling margin are given due consideration during material reconciliation.

4.2 PROJECT MANAGEMENT INFORMATION SYSTEM (PMIS)

4.2.1 Progress reports 4.2.1.1 Daily Progress report

This report, which is made daily, has all minor progress details of the approach works, Precast works, erection works & cast in situ works. This report is made by the contractor & is send to the client the very next day for signing and for client’s record. No daily reports are made at the site from client’s side. Refer Fomat-1

4.2.1.2 Weekly reports A weekly progress report is send to the HO from the site office on every Monday. Majorly weekly progress report contains details of planned works for that week Vis-a Vis achieved progress in each activity. Contractor also makes a weekly report in more or less similar format and sends it to client for his records. Refer Format-2



4.2.1.3 Material procurement, consumption and issue reports Requirement of material is as given by the Sr. Site engineer on different parts of the project. The Planning engineer checks this demand with the help of the previous consumption reports (pour card, bbs, etc.) and also with the target chart to deal with the quantities required for that particular stretch of time.

After the approval from the Planning engineer, a list of the required materials / machinery / consumables is made by the store-incharge in a requisition format and is then passed on to the Project Manager for the final approval.

After the requisition is signed by the PM, the whole purchase procedure is followed. A material stock Status is generated daily & its summary is sent along with monthly report. Refer Format-3 4.2.1.4 Wastage reports

As such there is no wastage report separately prepared on the site. Wastage is calculated as a part of the reconciliation statement A check is kept on the consumption of the materials so as avoid the misuse of the product. It is generally found that for materials like cement 5% wastage is considered casual. If it exceeds beyond this limit, then re-checking is carried out at the godown or calibration of the batching plant is checked. For steel 2% wastage is considered within limits. 4.2.1.5 Monthly reports

The report is submitted to the HO in the very first week of the month. Following are the contents of this report: Important activities carried out in the previous month

Shortfalls for the project completion Site progress report Target for the coming month Material procurement statement

Drawing status statement Plants and equipments deployed in and upto previous month

Manpower at site Photographs of important events

4.3 QUALITY MANAGEMENT SYSTEM

4.3.1 Quality Policy (Policy Statement) PMC-PIPL is committed to deliver zero defect products and services of highest level of quality within the time schedules at the lowest cost to our Customers including providing safe work environments.

PMC is committed to the continuous improvement in quality of products and services including the development of employees at all levels.

4.3.2 Project Quality Management System (PQMS) Planning Planning activities ensure that adequate resources are available to achieve quality and safety management objective.

Planning ensures that change is conducted in a controlled manner and that the Integrity of the Project Management System is maintained during this change.

4.3.3 Quality Objectives PMC has established Quality Objectives and levels of assurance that are measurable and consistent with Organisation policy. Quality and safety objectives are defined within the respective policies and operations procedures forming part of this Project Quality Management System.

Quality Objectives are as follows: 100% compliance with applicable safety and environmental standards.

100% conformance to customer specification and expectations.

0% re-work 100% delivery on time 100% completion within budget



4.3.4 Quality Assurance Plan a. The objective of the QAP is to establish a procedure to plan, monitor and achieve Quality

Management System planning in order to fulfill customer requirements, statutory requirements and organization objectives based on contractual requirement.

b. There are two types of Quality Assurance Plans. 1) Field Quality Assurance Plans 2) Quality Assurance Plans for Incoming Materials

4.3.5 Quality Monitoring Procedure

4.3.5.1 Management Review (General) Top management is responsible for reviewing all aspects of the PMC Project Quality Management System. The purpose of review is to ensure that the Project Quality Management System is suitable and effective in satisfying the requirements of the PMC quality environmental and Safety objectives.

Management review meetings are held once in three months. Each process is reviewed in MIS reports.

4.3.5.2 Management Review At Site

Review Inputs: Results of audits including safety, customer feedback , process performance and product conformance , status of preventive and corrective action includes Safety, follow-up actions from earlier management reviews, recommendations for improvement includes Safety, changes that could effect the Project Quality Management System

Review Outputs: Improvement of QMS, Improvement of process, Resource requirement, Improvement of Product Quality, Improving Customer satisfaction, Best practices for implementation.

4.3.5.3 Product Monitoring & Measurement of Processes

To establish, implement and maintain the procedure for monitoring & measurement of the quality Management system processes to achieve the planned results of the product & to verify that the requirements have been met as per contract.

4.3.6 Quality Evaluation System Quality Evaluation system mainly includes

4.3.6.1 Internal Audits Project quality manager prepares the schedule of internal quality audit for each month for various projects and conducts quality audits during the project construction. The schedule of internal quality audit is intimated to each auditee well in advance with copy to project leader. Construction manager is also an auditee for the audit. The scope of audit is contract documents/PO/QAP and quality procedures / documentation / construction work at sites etc. as applicable.

Internal Quality audit report is issued to auditees with copy to project manager and project leader. Issue of Non Conformance Report (NCR) is done for non compliance of products and activities in concurrence with auditees and the record of the same is maintained. Each NCR also has stipulated time period to liquidate the same.

Construction manager is responsible for closing of NCR. Project QC manager does tracking of NCR, follow up and verification for closure of NCR for relevant projects and MR also has to do the same for Project Quality management system (PQMS) audits.

Management Representative (MR) conducts the system audit of each department as per schedule of system audit. Audit report is issued to each department head and copy to CEO.

In case of non compliance to system, MR issues the NCR to department head. Department head is responsible for closing of NCR. MR has to keep tracking of NCR, follow up and verification for closure of NCR. MR also has to co-ordinates for the Management Review Meeting (MRM) at defined interval to review the PQMS.



4.3.6.2 Customer Satisfaction To establish and maintain a system to understand customer perception and meet Customer requirements & measure Customer satisfaction.

It is done quarterly. Customer complaints are noted & performance is improved on area of dissatisfaction by discussing the root causes & replying with action plan & target dates.

4.4 BILLING

4.4.1 Method of Measurement The method of measurement will be as per IS: 1200 unless otherwise specified. 4.4.2 R.A Bills R A bills are the interim bills that are made by the contractor at the end of each month. The bill Is produced every month.

By these bills, the contractors are able to claim the payment of the work they did in the whole month. After receiving the payment, the contractor pays to the sub-contractors working under them & also makes orders for the materials required.

Each RA bill has a specific format with a specific number assigned to it, Work order Reference no., and date of giving it to the client for later reference.

Each RA bill was made in 3 hard copies (one for the client & one for own record & one for reference).

Within 15 days of receipt of the said bill for the interim payment, it was approved/ amended such that, in engineer’s opinion, the certificate reflects the amount due to the contractor in accordance with the contract. In case of difference of opinions as to the value of any item, engineer’s view prevailed.

The RA bill consist of the following: 1. Estimated contract value of permanent works executed since the submission of last bill,

obtained by applying the base unit rates & prices in the BOQ measured by the engineer. 2. Estimated contract value of permanent works as obtained above executed upon the previous

bill. 3. The cumulative estimated contract value at base unit rates & prices of permanent works upto

the bill in question. 4. The cumulative amount approved in respect of extra items executed up to the bill in question,

obtained by applying the rates approved. 5. An amount reflecting any changes in cost. 6. Any amount to be withheld under the retention provisions (@5% of net bill amount after

discount). 7. Any credit/debit for period in question in respect of materials on site intended for, but not yet

incorporated in, permanent works in the amount. 8. Any amount to be deducted on account of mobilization advances under contract. 9. Deductions of IT- as per the IT act 10. Any amount to be deducted on account of electricity, water or machinery supplied to the

contractor. 11. Reimbursement for difference in rate for steel, cement & flyash as in contract & as procured. 12. Net payable amount of bill for the present month after all additions & deductions. 13. Annexure containing the BOQ of the work executed, Material reconciliation statement, Bill

abstract & Monthly Progress Report (MPR).

4.4.3 Recovery of Cement & Steel Since cement, Structural steel & Reinforcement steel is provided as free issue by the client, there is no such recovery applicable.

But penalty is levied if the consumption of cement is less than 97% of theoretical requirement. Moreover, the wastage should not exceed the permissible limit, if so; the charges are deducted from the contractor’s bill.



This is checked through the reconciliation report of free- issued materials, in which the actual consumption of material is checked in comparison with the theoretical consumption considering the wastage.

Replacement of steel reinforcement is provided. (On return of cut pieces larger than 2m length, same tonnage of full length steel reinforcement is provided back to the contractor).

4.5 SAFETY PROVISIONS

On award of the work & before commencement of work, Simplex Infrastructures (India) Limited (hereinafter referred as SIL) submitted the health and safety policy It is the policy of the company to ensure that all reasonable and practicable measures will be taken to ensure the safety and welfare of all of its employees and all other persons who may adversely affected by the company activities. 4.5.1 Basic steps

4.5.1.1 Supervision SIL provides adequate suitably trained, competent, and experienced management and supervision to ensure safety at site.

4.5.1.2 Reporting of all Fatal and Major Injuries and Dangerous Occurrences All Fatal, major & minor injuries and dangerous occurrences if any, are to be reported to the SIL Safety Manager immediately and all other injuries to medical centre/First aid room for recording.

4.5.1.3 Monthly Safety Meeting Monthly Safety Meeting are attended by the Project Manager, all frontline Engineers, supervisors and Safety Manager/Officer and representative of labour contractor & all actions discussed & identified are to be complied within the prescribed time limit.

4.5.1.4 Health and Safety Training SIL ensures adequate training for all employees and workers to ensure execution of work in safe manner and also meet all statutory obligations.

4.5.1.5 Induction All employees including labours and anybody who is associated with the work are given suitable and sufficient induction training, before the concerned person commences work at site, under following circumstances:- Change of responsibility Introduction of new working equipment Introduction of new system of work/technology

Introduction of new labour Induction training is given by safety officer of SIL.

4.5.1.6 Tool Box Talks

Front Line engineers and Supervisors of SIL collect workers and brief them for 5 minutes 'tool box talks' each day on different topics and keep a record of such talks. The Other basic Steps include: Notification of Manpower Deployed Provision of Personal Protective Equipment Adequate Lighting arrangement

Electrification Dress of Working Emergency plans

4.5.2 Site Safety Plan

4.5.2.1 Hazards/risks involved with the activities envisaged Confined spaces Work over or adjacent to water Work at night Fall from height. Truck Movement during reclamation works. Discipline of drivers & traffic hazard Hazards during erection of precast slab & precast beams.

Hazards involved during precast member shifting from yard to jetty.

Fire from LPG/acetylene and oxygen cylinders

Fire Demolitions/Dismantling Faulty Cranes and lifting appliances Rotating part of the Machinery not guarded.



Lack of House keeping Electrical hazard in temporary electrification Hazards involved in welding and gas cutting

Specific precautions and control measure needed to reduce accidents.

4.5.2.2 Steps taken for construction tasks

Life Jackets are provided on gantry in adequate amount. They are to be compulsorily worn by the workers when they work below gantry.

Helmets are compulsory to all the personal at the site.

Helmets, gloves, Dark glasses, Safety Harness are provided depending on the variety of work.

No one is allowed to go above 2m of height without wearing Safety harness. Safety harness is also compulsory for working below the gantry.

First-Aid box is provided over the Gantry, at Simplex office on Jetty as well as at the site office of the Simplex.

In case of emergency, an emergency vehicle is always on the stand by mode, the victim is immediately taken to nearby hospital at the Birla Copper for primary treatment.

Proper railing of Steel Pipe is provided throughout the sides of gantry.

Twin-Engine boat is kept in stand-by position in case of emergency.

Buoy with proper lighting were provided at a safer distance from the jetty under-construction in order to guide barges.

A safety meeting is held every morning on each gantry by the Safety Engineer himself.

Safety Stewards are kept on duty on gantry for all the shifts.

Divers are always available on the gantry.

4.5.2.3 Steps taken For Tasks Related to Construction All the vehicles should have a reverse horn which is having adequate level of sound. Each vehicle should have a helper, who guides the driver during reversing of the vehicle or other such related tasks.

All vehicles are to be checked weekly for their brakes, lights, horns, oils, etc. All the electrical items are checked for their earthing, etc. ELCB’s are attached to all the electrical items.

All the oxygen, DA, LPG cylinders & Diesel drums are stored is a safe closed shed having signboards of “No Smoking”.

Membership of Disaster management cell has also been taken. Disaster Management cell is already existing at Dahej which was formed By companies like Birla Copper, IPCL, BASF, Petronet LNG , GCPTCL, Welspun Gujarat and other near by companies.



ANNEXURE FORMAT-1

Ref. No. Material Stock Status

Format No. FPJ/16/05

Date Rev. No. : Date : Pages :

Project User Project Code Contractor Location Consultant / TPIA As on

Sr. No.

Material Unit Opening

Stock Today’s receipt

Total receipt

Today’s consumption

Total consumption

Closing Stock

Flow of format : Store Incharge commercial (purchase) copy to Project manager andproject coordinator (Monthly basis)

Prepared by Reviewed by Approved by Sign Sign Sign FORMAT-2

Ref. No. Weekly Progress Report

Format No. FPJ/07/05


Project User Project Code Contractor Location Consultant / TPIA

Sr. No.

Description of Activities

Unit of Measurement

Total Scope

Achieved till last week

planned for this week

Achieved this week

Cumulative achievement till this week

Constraints : Reason for variance (if any) : Major even (if any) : Major equipment deployed : No. of workmen engaged : A. Skilled B. Unskilled Major Material receipt (if any) : Flow of format : Project manager � Project coordinator � copy to project leader and

project control (weekly basis) Prepared by Reviewed by Approved by Sign Sign Sign



FORMAT - 3 Ref. No.

Daily Progress Report Format No. FPJ/06/05


Project User Project Code Contractor Location Consultant / TPIA

Sr. No.

Activities UOMTotal Scope

Achieved till Yesterday

Planned for today

Achieved to day

Cumulative Achievement

till date Constraints : Reason for variance (if any) : Major even (if any):Major equipment : No. of workmen: A. Skilled B. Unskilled Flow of format : Construction manager � project coordinator � copy to projectmanager (Freq: Daily) Prepared by Reviewed by Approved by Sign Sign Sign



Technically what I have gained in these 18 weeks has made me understand all my basic theories, which I have learnt in the past three and a half years of my college, on stronger basis. Moreover theses 18 weeks have also made me stronger and more confident not only academic wise but also in other aspects of life. I was extremely glad to be a part of SBST, as and when I could see myself proving better on technical aspects compared to the trainee colleagues from other colleges. I am glad to say that I have had an opportunity to be amongst those few lucky ones to witness as well as work on such specialized construction technology. In addition to this, I could also study important activities such as Piling and precasting. I have definitely realized how difficult it is to maintain line and level on site; compared to it being so easily written in ‘checks’ on paper. Precast elements are the ‘in’ technology of the present era. I had been involved in making job completion reports, presentation, planning & designing. To work like an employee with people of great caliber around u to guide you in your project is an extremely great fortune. I will never forget this utmost respect given to me by all my colleagues. Apart from the project, all the people at site and at the office had been overwhelmingly co-operative and kind. In these 18 weeks, I have known what it takes to be an engineer; the amount of devotion and commitment one needs to give.

CHAPTER 5. CONCLUSION



Table of Contents CHAPTER – 1 INTRODUCTION

1.1 BACKGROUND OF THE PROJECT................................................................................. 1 1.2 THE PROJECT ............................................................................................................... 1 1.3 OBJECTIVES OF THE PROJECT .................................................................................... 2 1.4 NEED OF THE PROJECT ............................................................................................... 2 1.5 PROJECT BREAKDOWN STRUCTURE: ......................................................................... 3 1.6 GENERAL PROJECT INFORMATION: ............................................................................ 3 1.7 LOCATION OF THE PROJECT: ...................................................................................... 5 1.8 CLIMATIC CONDITIONS & SEISMIC ZONE ..................................................................... 6

1.8.1 Wind ............................................................................................................................. 6 1.8.2 Rainfall .......................................................................................................................... 6 1.8.3 Temperature ................................................................................................................. 6 1.8.4 Waves ........................................................................................................................... 6 1.8.5 Tides ............................................................................................................................. 7 1.8.6 Currents ........................................................................................................................ 7 1.8.7 Morphology ................................................................................................................... 7 1.8.8 Seismic Zone ................................................................................................................ 7

1.9 DESIGN CONSIDERATIONS ........................................................................................... 7 1.9.1 Design Criteria for Approach & Main Jetty ..................................................................... 8 1.9.2 Design load: ...................................................................................................................... 8

1.10 COST BREAKDOWN STRUCTURE ................................................................................ 9 1.10.1 Cost Breakdown Structure for Project .......................................................................... 9 1.10.2 Cost Breakdown Structure for Approach Jetty ............................................................. 9

CHAPTER - 2 CONSTRUCTION METHODOLOGY 2.1 WORK BREAKDOWN STRUCTURE ............................................................................. 10 2.2 ORGANIZATION CHART OF PMC AT SITE ................................................................... 11 2.3 CONSTRUCTION SCHEDULE ...................................................................................... 15 2.4 ACTIVITY WISE WORK BREAKDOWN ............................... Error! Bookmark not defined. 2.5 WORK METHODOLOGY .............................................................................................. 18

2.5.1 Construction Methodology .......................................................................................... 18 2.5.2 Justification of Methodology Used ............................................................................... 18

2.6 STATUS OF SITE ......................................................................................................... 19 2.7 PLANTS & MACHINERY ............................................................................................... 20 2.8 Material Details ............................................................................................................ 21 2.9 SPECIFICATIONS ........................................................................................................ 21

2.9.1 Cement ....................................................................................................................... 21 2.9.2 Aggregates ................................................................................................................. 22 2.9.3 Water .......................................................................................................................... 22 2.9.4 Reinforcement steel .................................................................................................... 22 2.9.5 Structural steel ............................................................................................................ 22 2.9.6 Specifications For Concrete ........................................................................................ 23 2.9.7 Precast Concrete ........................................................................................................ 23 2.9.8 Specifications For Formwork ....................................................................................... 23

CHAPTER - 3 CONSTRUCTION ACTIVITIES 3.1 PILE FOUNDATION USING PILING GANTRY ................................................................ 24

3.1.1 Scope.......................................................................................................................... 24 3.1.2 Specification ............................................................................................................... 24 3.1.3 Standard of acceptance for piles ................................................................................. 24 3.1.4 General Information .................................................................................................... 25 3.1.5 Flowchart for Gantry Piling .......................................................................................... 27 3.1.6 Liner fabrication .......................................................................................................... 30 3.1.7 Reinforcement Cage Fabrication................................................................................. 37 3.1.8 Construction Methodology For Piling .......................................................................... 44

3.2 HYDRAULIC RIG PILING .......................................................................................... 71 3.2.1 Introduction ...................................................................................................... 71 3.2.2 Flow Chart Of Piling With Hydraulic Rig .......................................................... 72 3.2.3 Survey Works .................................................................................................. 73



3.2.4 Bottom Liner lifting, Guide Welding & Liner pitching ....................................... 73 3.2.5 Boring including additional Liner Driving & Joining ......................................... 73 3.2.6 Lifting, Joining & Lowering the Pile Reinforcement Cages .............................. 75 3.2.7 Lowering of Tremie & Flushing the Borehole .................................................. 75 3.2.8 Concreting ....................................................................................................... 76 3.2.9 Time cycle Comparison between Piles A-14, B-14 & A-1 ............................... 76

3.3 PILE INTEGRITY........................................................................................................ 80 3.3.1 Principle ........................................................................................................... 80 3.3.2 Scope .............................................................................................................. 80 3.3.3 Apparatus and Materials ................................................................................. 80 3.3.4 Test Preparation .............................................................................................. 80 3.3.5 Pile Integrity Testing and Measurement .......................................................... 80 3.3.6 No. of readings ................................................................................................ 81 3.3.7 Data Interpretation ........................................................................................... 81 3.3.8 Test Limitations ............................................................................................... 81

3.4 DYNAMIC PILE LOAD TEST ..................................................................................... 81 3.4.1 Introduction ...................................................................................................... 81 3.4.2 Principle ........................................................................................................... 81 3.4.3 Objective ......................................................................................................... 81 3.4.4 Background ..................................................................................................... 81 3.4.5 Pile and Test Preparation ................................................................................ 82 3.4.6 Test Procedure, Monitoring & Analysis ........................................................... 82 3.4.7 Test Limitations ............................................................................................... 83 3.4.8 Test Results .................................................................................................... 83 3.4.9 Conclusion ....................................................................................................... 85

3.5 Pre Cast Works ......................................................................................................... 86 3.5.1 Scope of the work ............................................................................................ 86 3.5.2 Introduction ...................................................................................................... 86 3.5.3 Tools, Equipments & Plants used for Precasting works .................................. 88 3.5.4 Materials used for Precasting works ............................................................... 89 3.5.5 General Information of Construction Methodology .......................................... 89 3.5.6 Construction Methodology for Precast Pile Muff ............................................. 93 3.5.7 Construction Methodology For Precast Longitudinal Beam .......................... 101 3.5.8 Construction Methodology For Precast Deck Planks .................................... 114 3.5.9 General Problems Encountered In Precast Works ........................................ 117 3.5.10 Reasons For Above Problems ...................................................................... 117 3.5.11 Probable Solutions ........................................................................................ 117

3.6 Erection Works ....................................................................................................... 121 3.6.1 Flowchart Showing Erection Sequence of Precast Elements ....................... 121 3.6.2 Erection Methodology of Pile Muff ................................................................. 122 3.6.3 Manpower Requirements .............................................................................. 122 3.6.4 Time Cycle .................................................................................................... 122

3.7 CAST IN SITU WORKS ........................................................................................... 129 3.7.1 Introduction .................................................................................................... 129 3.7.2 Tools, Equipments & Plants used for Cast In Situ works .............................. 129 3.7.3 Materials used for Cast In Situ works ............................................................ 129 3.7.4 Flowchart Showing Construction Sequence of Stage -1 Cast In Situ Works: 131 3.7.5 Flowchart Showing Construction Sequence of Stage -2 Cast In Situ Works: 139

Owning & Operating Cost Tools, Equipments & Plants……………….………………………155 CHAPTER -4 PROJECT MANAGEMENT

4.1 MATERIAL MANAGEMENT .................................................................................... 161 4.1.1 Purchase ....................................................................................................... 161 4.1.2 Steps in Purchase transaction ....................................................................... 162 4.1.3 Material Storage & Handling ......................................................................... 164 4.1.4 Material reconciliation .................................................................................... 164

4.2 PROJECT MANAGEMENT INFORMATION SYSTEM (PMIS) ............................... 164



4.2.1 Progress reports ............................................................................................ 164 4.3 QUALITY MANAGEMENT SYSTEM ....................................................................... 165

4.3.1 Quality Policy (Policy Statement) .................................................................. 165 4.3.2 Project Quality Management System (PQMS) Planning ............................... 165 4.3.3 Quality Objectives ......................................................................................... 165 4.3.4 Quality Assurance Plan ................................................................................. 166 4.3.5 Quality Monitoring Procedure ........................................................................ 166 4.3.6 Quality Evaluation System ............................................................................ 166

4.4 BILLING ................................................................................................................... 167 4.4.1 Method of Measurement ............................................................................... 167 4.4.2 R.A Bills ......................................................................................................... 167 4.4.3 Recovery of Cement & Steel ......................................................................... 167

4.5 SAFETY PROVISIONS ............................................................................................ 168 4.5.1 Basic steps .................................................................................................... 168 4.5.2 Site Safety Plan ............................................................................................. 168

Annexure…………………………………………………………..……………………….……….171 CHAPTER – 5 CONCLUSION LIST OF DRAWINGS

LIST OF DRAWINGS

1.01 Layout Plan of The Project 4 2.01 General Arrangement Drawing Part‐1 12 2.02 General Arrangement Drawing Part‐2 13 2.03 Job Layout 14 2.04 Construction Sequence 17 3.01 Layout Of Piles 263.02 Plan & Sections Of Gantry 28 3.03 General Job Layout Of Gantry 29

3.04 Plate Bending Machine & Its working 33 3.05 Details OF Pile Reinforcement Cage 393.06 Pile Reinforcement Cage Fabrication Sequence & BBS 42 3.07 Job Layout Of gantry Before Liner Pitching 45 3.08 Job Layout Of gantry Before R/F Lowering 51 3.09 Job Layout at the Time Of Bentonite Flushing & Concreting 56

3.10a Piling Sequence ( Part‐1) 57

3.10b Piling Sequence (Part‐2) 58 3.10c Piling Sequence (Part‐3) 59 3.11 General Equipments used in Piling 60 3.12 Retails of Rolling Bracing 623.13 Gantry Movement Details 64 3.14 Hydraulic Rig Piling Sequence (Part‐1) 773.15 Hydraulic Rig Piling Sequence (Part‐2) 78 3.16 Hydraulic Rig Piling Sequence (Part‐3) 793.17 Set Up Details of Dynamic Pile Load Test 84 3.18 Precast Yard Layout 87 3.19 Batching Plant Layout 92 3.20 Numeration & R/F details of Pile Muff 94 3.21 Layout Of Pile Muff 95



3.22 Reinforcement Binding Sequence for Precast Pile Muff(Part‐1) 973.23 Reinforcement Binding Sequence for Precast pile Muff (Part‐2) 98 3.24 Formwork Fixing Sequence & Formwork Details for Precast Pile Muff 993.25 Numeration details of Precast Longitudinal Beam 102

3.26 Reinforcement Details of Precast Longitudinal Beam 1033.27 Layout Of Precast Longitudinal Beam 104 3.28 Reinforcement Binding Sequence for Longitudinal Beam ( Part‐1) 106 3.29 Reinforcement Binding Sequence for Longitudinal Beam ( Part‐2) 107 3.30 Formwork Fixing Sequence & Formwork Details for Longitudinal Beam 108 3.31 Construction Sequence for Longitudinal Beam (Part‐1) 109 3.32 Construction Sequence for Longitudinal Beam (Part‐2) 110 3.33 Construction Sequence for Longitudinal Beam (Part‐3) 111 3.34 Construction Sequence for Longitudinal Beam (Part‐4) 112 3.35 Numeration & Reinforcement Details for Precast Deck Planks 115

3.36 Reinforcement Binding Sequence For Precast Deck Planks (Part‐1) 118 3.37 Reinforcement Binding Sequence For Precast Deck Planks (Part‐2) 1193.38 Formwork Fixing Sequence & Formwork Details for Precast Deck Planks 120 3.39 Alignment Details Of Pile Muff 1233.40 Layout For Erection 124 3.41 Erection Sequence Of Pile Muff ( Part‐1) 125 3.42 Erection Sequence Of Pile Muff ( Part‐2) 126

3.43 Erection Sequence Of Pile Muff ( Part‐3) 127 3.44 Erection Sequence Of Pile Muff ( Part‐4) 128 3.45 Numeration & Reinforcement Details for Stage 1 Cast in Situ Works 130 3.46 Reinforcement Binding Sequence for Stage 1 Cast in Situ Works (Part‐1) 134 3.47 Reinforcement Binding Sequence for Stage 1 Cast in Situ Works (Part‐2) 135 3.48 Reinforcement Binding Sequence for Stage 1 Cast in Situ Works (Part‐3) 1363.49 Formwork Fixing Sequence & Formwork Details for Stage 1 Cast in Situ works 137 3.50 Reinforcement Details of Stage 2 cast in situ Works (Part‐1) 1403.51 Reinforcement Details of Stage 2 cast in situ Works (Part‐2) 141 3.52 Reinforcement Details of Stage 2 cast in situ Works (Part‐3) 142

3.53 Location Of Area Studied for Cast in Situ Stage 2 Concrete 143 3.54 Reinforcement Binding Sequence for Phase 1 of Stage 2 Cast in Situ Works (Part‐1) 146 3.55 Reinforcement Binding Sequence for Phase 1 of Stage 2 Cast in Situ Works (Part‐2) 147

3.56 Reinforcement Binding Sequence for Phase 1 of Stage 2 Cast in Situ Works (Part‐3) 148 3.57 Reinforcement Binding Sequence for Phase 2 of Stage 2 Cast in Situ Works (Part‐1) 150 3.58 Reinforcement Binding Sequence for Phase 2 of Stage 2 Cast in Situ Works (Part‐2) 151 3.59 Reinforcement Binding Sequence for Phase 2 of Stage 2 Cast in Situ Works (Part‐3) 152

3.60 Reinforcement Binding Sequence for Phase 2 of Stage 2 Cast in Situ Works (Part‐4) 153 3.61 Concreting Sequence For Stage 2 Cast in Situ Works 154



LIST OF TABLES

LIST OF TABLES 1 Dry Bulk Cargo Forecast for Hinterland 22 Dry Bulk Cargo Forecast for Dahej 3 3 Wind Climate Summary 6

4 Wave Climate Summary 6 5 80000DWt Bulk Carrier Vessel’s Parameters 8 6 Operating Conditions during Berthing/Vessel Approach 8

7 Survival Conditions during Berthing/Vessel Approach 8 8 Self Weights Considered 8 9 Live Loads Considered 8

10 Cost Breakdown Structure of the Project 9

11 Cost Breakdown Structure of Approach Jetty 9 12 Degree Of mechanization 1813 Plants & Machinery 20 14 Material Details 2115 Type Of Reinforcement Used in Different Structures 22 16 Cover to Reinforcement 22

17 Tolerances in Concrete Elements 23 18 Details of Liner Studied 30 19 Liner Dimensions 34 20 Labour Requirement for Liner Fabrication 36 21 Time Cycle For Liner Fabrication 37 22 Labour Requirement for Reinforcement Cage Fabrication 41 23 Time Cycle For Reinforcement Cage Fabrication 41

24 Labour Requirements For Survey Works of Piling 44 25 Labour Requirements per Pile Point For Liner Lifting, Guide Welding & Liner Pitching 4626 Labour Requirements per Pile Point during Boring including additional Liner Driving & Joining 47 27 Soil strata Obtained during Boring 48

28 Liner Details for Pile A14 49 29 Liner Details for Pile A14 4930 Labour Requirements per Pile Point during Lifting, Joining & Lowering Reinforcement Cage 50

31 Labour Requirements per Pile Point during Lowering of Tremie & Flushing of Borehole 52 32 Quantity of Bentonite Mix added 53 33 Labour Requirements per Pile Point during Concreting 53 34 M:40 grade Mix design Details 54 35 Quantity Of concrete 55 36 Actual Consumption of Materials 5537 Labour Requirement during Welding of Bracings, Placing of Grillages & Wheels 61 38 Labour Requirement during Gantry Shifting 6339 Details of Pile Studied 71 40 General Information On Hydraulic Rig(IMT) 71

41 Labour Requirements per Pile Point For Liner Lifting, Guide Welding & Liner Pitching 73 42 Labour Requirements per Pile Point during Boring including additional Liner Driving & Joining 7343 Soil Strata obtained during Boring 75



44 Labour Requirements per Pile Point during Lifting, Joining & Lowering Reinforcement Cage 7545 Labour Requirements per Pile Point during Lowering of Tremie & Flushing of Borehole 75 46 Quantity Of Bentonite Mix Used 7647 Concrete Consumption For Pile A1 76 48 Time Cycle Comparison Between PilesA14,B14& A1 7649 General Pile Details 82 50 Summary Of Field results 83 51 Summary of Analysis 83 52 M:30 Mix Design Details 88 53 Strength Requirements for Concrete 91 54 Formwork Quantity Calculations for Pile Muff 96 55 Concrete Quantity Calculations for Pile Muff 10056 Actual Material Consumption for Pile Muff 10057 Labour requirements for Precasting Of Pile Muff 100

58 Time Cycle for Precast Pile Muff manufacturing 10059 Formwork Quantity Calculations for Longitudinal Beam 10560 Concrete Quantity Calculations for Longitudinal Beam 11361 Actual Material Consumption for Longitudinal Beam 11362 Labour requirements for Precasting Of Longitudinal Beam 11363 Time Cycle for Precast Longitudinal Beam manufacturing 11364 Formwork Quantity Calculations for Deck Plank 117

65 Concrete Quantity Calculations for Deck Plank 11766 Actual Material Consumption for Deck Plank 11767 Labour requirements for Precasting Of Deck Plank 11768 Time Cycle for Precast Deck Plank manufacturing 11769 Labour requirements for Erection Pile Muff 12270 Time Cycle for Erection Of Pile Muff 12271 Formwork Quantity Calculations for Stage 1 Cast In Situ Works 13372 Concrete Quantity Calculations for Stage 1 Cast In Situ Works 13373 Actual Material Consumption for Stage 1 Cast In Situ Works 13374 Labour requirements for Stage 1 Cast In Situ Works 138

75 Time Cycle for Stage 1 Cast In Situ Works 13876 Concrete Quantity Calculations for Phase 1 of Stage 2 Cast In Situ Works 14577 Actual Material Consumption for Phase 1 of Stage 2 Cast In Situ Works 145

78 Labour requirements for Phase 1 of Stage 2 Cast In Situ Works 14579 Time Cycle for Phase 1 of Stage 2 Cast In Situ Works 14580 Concrete Quantity Calculations for Phase 2 of Stage 2 Cast In Situ Works 14981 Actual Material Consumption for Phase 2 of Stage 2 Cast In Situ Works 149

82 Labour requirements for Phase 2 of Stage 2 Cast In Situ Works 14983 Time Cycle for Phase 2 of Stage 2 Cast In Situ Works 14984 Purchase Responsibilities 162

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