4th Term - Summer Training Report at Nicmar Hyderabad

SUMMER INTERNSHIP REPORT
For
CONSTRUCTION OF NATURAL DRAFT COOLING TOWER (NDCT) & CHIMNEY

IN 2 X 600 MW SHREE SINGAJI THERMAL POWER PLANT,
KHANDWA, MADHYA PRADESH.
By
GAMMON INDIA LIMITED
Submitted By
AMOGH SHRIVATSAVA T.SHREEDHAR

R.NO:233004 R.NO:233084
23rd BATCH PGP-ACM 23rd BATCH PGP-ACM
NATIONAL INSTITUTE OF CONSTRUCTION MANAGEMENT & RESEARCH

KONDAPUR, HYDERABAD. A.P
ACKNOWLEDGMENT
Before we get to more important things, We would like to thank numerous people,
without whom our summer training would have been very difficult.
We would like to thank Gammon India Limited for providing us with the necessary,
whole-hearted guidance and valuable suggestions throughout our training period, without
which this endeavor would not have been possible.
We are very grateful to Mr. I.S.Mane, Regional Manager & Mr. A.K.Dey, Project In-
charge, for their continuous support. We thank Mr. Milind M. Gaikwad (AM II) & Mr. Vishal S
Kuwar(AM II), Planning & SMR, for guiding us right from the start.
We profoundly express our gratitude to Mr. R.N.Rai(D.M-I), Executive In-Charge of
NDCT, Mr. Vinay Cheerala(AM II) & Mr. Vaibhav A. Tungidwar(AM II) at NDCT & Mr. Jayant
Mankar(AM-II), Section In-charge of Chimney, for being kind & helpful throughout our
training period.
Finally, We acknowledge each and every member of staff at the 2 x 600 MW SHREE
SINGAJI THERMAL POWER PLANT, KHANDWA,M.P, for their wholehearted co-operation,
which made our summer training comfortable and successful.
AMOGH SHRIVASTAVA T.SHREEDHAR

23rd PGP-ACM 23rd PGP-ACM
CERTIFICATE
This is to certify that Mr. Amogh Shrivasatava R.No: 233004 and
Mr.T.Shreedhar, R.No: 233084 students of NATIONAL INSTITUTE OF CONSTRUCTION
MANAGEMENT AND RESEARCH (NICMAR),HYDERABAD have successfully completed
their Summer Internship on our Project, Malwa 8826/27 NDCT and Chimney under my
guidance and supervision at 2x600MW SHREE SINGAJI THERMAL POWER PLANT,
STAGE-I, KHANDWA, MADHYA PRADESH.
For Gammon India Ltd.
A.K.DEY
(PROJECT IN-CHARGE)
INDEX
Chapter No. Contents Page No.
1 Company's Profile
1.1 Introduction 1
1.2 History 2
1.3 Gammon Mission, Vision, Quality policy 3
1.4 Management Team 4
1.5 Subsidiaries 4
1.6 PPP 5
1.7 Other Clients 5
1.8 Health, Safety & Environment 6
1.9 Areas of specialization 6
1.10 Current projects 7
2 Project Profile 11
2.1 Location 11
2.2 Importance of the project 13
2.3 Introduction to the Project 14
2.4 Salient features of the Contract 15
2.5 Terms & Conditions of contract 16
3 Cooling Tower 21
3.1 Introduction 21
3.2 Types of Cooling Tower 21
3.3 Photograph 22
3.4 Categorization by Air to Water flow 25
3.5 Operation Principle of NDCT 26
3.6 Technical Specification & general Parameters 28
3.7 Codes & standards 30
3.8 Design Criteria of Cooling Tower 31
3.9 Scheme, Sequence and Method of Construction 32
4 Chimney 62
4.1 Inroduction 63
4.2 Technical Specification & general Parameters 65
4.3 Method of Construction 66
5 Quality Plan 87
5.1 Scope 87
5.2 Normative Reference 91
5.3 Terms & Definations 92
5.4 Quality Management System 93
5.5 Management Responsibility 96
5.6 Resource Management 103
5.7 Product Realization 106
5.8 Measurement, Analysis & Improvement 111
6 Construction Site Organization & Management 115

6.1 Site layout 115
6.2 Site Offices & Building 117
6.3 Site Mobilization 119
6.4 Site Manager (Execution) 121
7 Project Management 123

7.1 Importance Of Planning 123
7.2 Steps In Project Mangement 124
7.3 Four Basic Elements of Project Management 127
7.4 Project Management Life Cycle 128
8 Maintainance of Site Document 134
9 Administration/Management 135
9.1 Site Organization Chart 135
9.2 Responsibilities 135
10 Accounting 137
11 Store Management 138

11.1 Defination of material Management 138
11.2 Aims of Material Management 138
11.3 Scope of Material management 138
11.4 Objectives of Material Management 138
11.5 Purpose of Material Management 139
11.6 Classification of Materials 139
11.7 Purchasing 141
11.8 Store Functions 143
11.9 Store Accounting 145
12 Safety 151
GIL, NDCT & Chimney Package for S.S.T.P.P, Khandwa, M.P Summer Internship Report-2010.
CHAPTER 1: COMPANY PROFILE
1.1 INTRODUCTION
Gammon India is not only the largest civil engineering construction company in India, but can lay
claim for the largest number of bridges built in the whole of Commonwealth. With over seventy
years of tradition in the field of construction. Gammon is a name that is inextricably woven into
the fabric of India.
As builders to the nation, Gammon has made concrete contributions by designing and
constructing bridges, Cooling towers, Chimney ports, harbors, thermal and nuclear power
stations, dams, high-rise structures, chemical and fertilizer complexes environmental structures,
cross country water, oil and gas pipelines. Gammon has accomplished this by fusing
tremendous engineering knowledge with innovative skills, harnessing men and materials to build
structures.
Structures that stand out as living testimonies to the victory of man over nature. Structures
conceived and built by minds in constant search of new methods, ideas, applications and
solutions. Because Gammon believes that today's solutions will not be adequate tomorrow.
This insatiable quest has led Gammon to pioneer Reinforced and Prestressed Concrete, Long
span bridges, Under water concreting using the Concrete process, Thin shell structures, Non-
Shrinking concrete, Aluminum trusses for launching precast, prestressed beams and many
more.
These resounding achievements have won Gammon the status of an R&D Institution - an
unequalled honor for an unmatched Performance.
The planners, designers and construction specialists at Gammon have proved their competence
and innovative skills here and abroad. And driving them to seek, to build and not to yield, is a
team of professionals at the Head Office led by the Chairman & Managing Director, Mr. Abhijit
Rajan.
"Reaching out to heights of excellence"

Nicmar Hyderabad. Page 1
1.2 HISTORY
In the beginning was a man and his vision a colossus throbbing with dynamism and pulsating
with energy. A man born to build. A man whose very presence was a source of inspiration.
Mr. John C. Gammon. The founder of Gammon India Limited. A Civil Engineer who can more
aptly be called 'The Sculptor of Concrete in India'. A man who preached and practiced order
and functional expression in structures - the enduring values that helped build the Gammon
edifice.
From monuments and bridges to reservoirs and jetties, his innovative vision and
engineering skill, his intuitive understanding of the materials and systems of construction
sought and fought answers to some of the most challenging examples in civil engineering
projects.
His abiding faith in people and their abilities inspired them to meet challenge after
challenge.
Mr. Gammon had several firsts to his credit. The RCC pile foundations for the Gateway of
India, the thin shell structures of the Meerut Garages, the colloidal grouting process at
Mundali Weir, the hyperbolic cooling towers at Sabarmati - are but a few of his
outstanding achievements. Bridges like Bonum and Patalganga, built by him have stood
the test of time as monuments to his ingenious skill.
Today, Gammon India Ltd., not only carries his name and vision, but stands out as a
Gateway for technological excellence in civil engineering.
“Excellence built on the foundations of perfection”

1.3 GAMMON MISSION, VISION & QUALITY POLICY
MISSION
VISION
QUALITY POLICY

1.4 MANAGEMENT TEAM
The Management team at Gammon is led by the Chairman and Managing Director,
Mr. Abhijit Rajan. He is assisted by his able team of the following directors:
Mr. Peter Gammon (Chairman Emeritus)

Mr. Rohit Modi (Deputy Managing Director)
Mr. Himanshu Parikh (Executive Director)
Mr. Rajul A. Bhansali (Executive Director- International Operations)
Mr. Digambar C. Bagde (Transmission And Distribution) Business)
Mr. Chandrahas C. Dayal (Director)
Mr. Atul Dayal (Director)
Dr. Naushad Forbes (Director)
Mr. Jagdish C. Sheth ( Additional Director )
Mrs. Urvashi Saxena ( Additional Director )
Mr. Naval Choudhary (Additional Director)
Mr. Parvez Umrigar ( Additional Director )
Mr. Atul Kumar Shukla ( Additional Director )
Each segment of construction that the Company engages in is looked after executives with a
deep commitment to quality, timeliness of completion and inherent expertise and skill sets that
assist Gammon in being a leader in the construction arena.
1.5 SUBSIDIARIES
As on 31st March 2009
1. Gammon Infrastructure Projects Ltd. GIPL

2. Gammon Cooling Towers Ltd.
3. Gammon and Billimoria Ltd.
4. Rajahmundry Expressway Ltd. (REL)
5. Andhra Expressway Ltd. (AEL)
6. Cochin Bridge Infrastructure Co. Ltd. (CBICL)
7. Mumbai Nasik Expressway Ltd. (MNEL)
8. Sikkim Hydro Power Ventures Ltd. (SHVPL)
9. Gammon Project Developers Ltd. (GDPL)
10. Gammon Realty Limited (GRL)
11. Kosi Bridge Infrastructure Company Ltd. (KBICL)
12. Gorakhpur Infrastructure Company Ltd. (GICL)
13. Marine Projects Services Ltd.

1.6 PPP
Presence in Public Private Partnership Projects
The Government is actively pursuing Public Private Partnerships (PPP) to bridge the
infrastructure deficit in the country. Several initiatives have been taken during the last three
years to promote PPP in sectors like ports, highways, power, roads, bridges etc. Having been in
the field of Infrastructure project contracting for a number of years, it was natural that the
Gammon group moved into the business of Infrastructure Projects Development. The resources
constraint with the Government and an immediate need of developing Infrastructure in the
Country were the primary drivers in the Gammon group reaching this logical conclusion.
Gammon Infrastructure Projects Limited, a subsidiary Company of Gammon India Limited, has
been leading the Gammon Group's forays into development of infrastructure projects on Public
Private Partnership (PPP) format. GIPL is among the first companies in India to be modeled as
an infrastructure development company and currently developes roads, bridges, ports and hydro
power and has also identified the following areas for project development and infrastructure
investment: urban infrastructure, airports, special economic zones, water and waste water
management, railways, power transmission lines and agricultural infrastructure. GIPL also offers
services in other areas of project development, such as project advisory services and sector
specific O&M activities.
1.7 OUR CLIENTS

Since we have a strong presence across all segments of the construction industry we
have a variety of clients including:
Delhi Metro Rail Corporation Limited

GAIL India Limited
Godrej Properties
Gorakhpur Infrastructure Company Limited
Government of Andhra Pradesh
Government of West Bengal
Kosi Bridge Infrastructure Company Limited
Ministry of Housing, Electricity and Water, Sultanate of Oman
Municipal Corporation of Amritsar
National Highway Authority of India
National Hydroelectric Power Corporation Limited
Nuclear Power Corporation of India
Sabarmati River Front Development Corporation Limited
Satluj Jal Vidhyut Nigam Limited and others.

1.8 HEALTH, SAFETY AND ENVIRONMENT
1. We at Gammon are committed to provide a safe and healthy working environment for our
employees by adopting a proactive approach, prior to commencement of any project.
2. It is part of our work ethic to ensure that safety, health and environment safeguards are in
place right from the inception to the execution stage.
3. We accept the need for constant up gradation of safety & health standards
commensurate with the rapid changing technology in construction.
1.9 AREAS OF SPECIALISATION:
Transportation Engineering Projects
 Bridges - River/Creek Bridges,
 Special Bridges
 Flyovers
 Viaducts
 Aqueducts
 Roads
 Highways
 Railways
Power Projects
 Thermal:
 Thermal Power stations.
 Natural draft Cooling Towers.
 Counter flow Cooling Towers.
 Chimneys.
Hydro:
 River Valley/Irrigation Projects
 Dams
 Tunnels
 Power House
 TBM Tunneling
Major Buildings, Industrial & Commercial Structures
Marine Projects
 Jetties, Wharfs, Berths
Ground Engineering Works
 Piling works
 Diaphragm wall
Environmental Projects
 Water Treatment Plant
 Effluent Treatment Plant
 Integrated Water Supply Project
Pipeline Projects
 Oil & Gas
 Water Pipeline

1.10 CURRENT PROJECTS
Group-3 Job List
Sr. No. Job No. Job Description CMS Name of PMS Champion
1 8107 Parbati HE stage 2 ABB SNN
2 8208 Sewa HEP ABB SNN

3 8302 Koldam HE project ABB SNN
4 8437 Parbati HE stage 3 ABB SNN
5 8525 Rampur HEP ABB SNN
6 8735 Bhutan HEP ABB SNN
7 8303 Kalpakkam (All Jobs) BRKN PPA

8 8612 Jindal Civil Works-Coke Oven GSP AN
9 8633 Ennore Civil Works GSP PPA
10 8640 Ennore Chimney GSP PPA
11 8715 Bellary NDCT-2 GSP AN
12 8716 Tiroda Chimney GSP PAS
13 8717 Tiroda Civil Works GSP PAS

14 8730/31 Ennore IDCT GSP PPA
15 8813 Vallur Chimney and Civil Works GSP PPA
16 8820 Tuticorin Civil Works GSP AN

17 8821 Tuticorin Chimney GSP AN
18 8834 Tiroda Chimney ( Unit 4 & 5) GSP PAS

19 8842 Tiroda Civil Works (Unit 4 & 5) GSP PAS
20 8845 NLCL Chimney, Tuticorin GSP AN
21 8846 Tuticorin Warehouse GSP AN

22 8849 Tuticorin NLC NDCT's GSP AN
23 Godrej Estate, Kalyan PKB SNN
24 8447 Neelkanth Kingdom PKB SNN
25 8603 Pebble Bay, Bangaluru PKB AN

26 8606 Leela palace Hotel, Chennai PKB PPA
27 8815 GSTAAD Hotel Project, Bangaluru PKB AN

28 8843 Galleria Mall, Bangaluru PKB AN
29 8844 Isckon Temple, Mayapuri PKB PAS
30 New Ozone/Lucknow/ Raheja/Runway PKB SNN
31 8609 Korba Chimney RBS MS

32 8616 Jaipur Civil Works for JSSL RBS MS
33 8619 Jaigad Chimney RBS ISM
34 8624/25 Korba IDCT RBS MS

35 8628 Simhadri Chimney RBS AN
36 8631 Aravali Chimney RBS ISM
37 8634/35 Aravali NDCT RBS ISM
38 8636-38 Bhusawal NDCT & Chimney RBS ISM

39 8641/42 Kadappa Chimney & IDCT RBS AN
40 8704/05 Simhdri NDCT RBS AN
41 8706 Mundra Chimney RBS ISM
42 8711 Mundra Civil Works RBS ISM
43 8724 Bongaigaon Chimney RBS MS
44 8733/34 Ukai NDCT RBS ISM

45 8804-07 Krishnapatnam NDCT & Chimney RBS AN
46 8814 Sasan Chimney RBS MS

47 8818 BARH Chimney RBS ISM
48 8819 Rosa Chimney RBS ISM
49 8826/27 Malwa NDCT & Chimney RBS ISM

50 8829/30 Korba NDCT RBS MS
51 8831 Raghunathpur Chimney RBS MS

52 8832 Mauda Chimney RBS ISM
53 8835 Raigarh Chimney RBS MS
54 8838/39 Parli NDCT Unit -8 RBS ISM

55 8840 Raigarh NDCT RBS ISM

CHAPTER 2 PROJECT PROFILE
2.1 LOCATION
Malwa NDCT
MAP OF INDIA

Malwa NDCT
District Map of Madhya Pradesh
Malwa NDCT

2.2 IMPORTANCE OF THE PROJECT
Electricity is one of the most essential entities known to us. Life without electricity sends us back
by many centuries. It has played a major role in the development of the state, the country and
the world. It has, in short, become a necessity to us.
The power consumption is increasing day by day and so is the demand for more electricity.
There is a severe need to construct bigger and better power stations all across the world to meet
the demands of both Industrial and Domestic purposes.
The Madhya Pradesh Government has taken the initiative to increase the electric power
generation across the state.
As a result, Madhya Pradesh Power Generation Co. Ltd. (MPPGCL) has taken the decision for
to construction of Shree Singaji Thermal Power Station (2x 600MW).

2.3 INTRODUCTION TO THE PROJECT
Shree Singaji Thermal Power Station ( 2 X 600 MW) is situated in the Khandwa District,
Khandwa, State Madhya Pradesh. The site location is around 40 km from Khandwa Railway
Station. The total cost of 2 X 600 MW Shree Singaji T.P.S STAGE-I is Rs.8000 Crores.
The scope of work for Gammon India Ltd. in the S.S.T.P.S is as follows:
 For supply of equipments for NDCT and Multi-flue Chimney package including supply of
mandatory spares.
 For erection, testing and commissioning of NDCT and Multi-flue Chimney.
 For construction of NDCT, Multi-flue Chimney including associated civil and structural
works.
The total cost of project for Gammon India Ltd. is Rs.169.77 Crores.

2.4 SALIENT FEATURES OF THE CONTRACT
OWNER MADHYA PRADESH POWER GENCO COMPANY LTD
SHREE SINGAJI THERMAL POWER PLANT STAGE-I

PROJECT
( 2 X 600MW)
OWNER’S CONSULTANT L&T SARGENT & LUNDY LTD
EPC CONTRACTOR L & T EPC POWER LTD
CONTRACTOR’S
DEVELOPMENT CONSULTANT LTD
CONSULTANT
SUB-CONTRACTOR GAMMON INDIA LTD
CONSTRUCTION OF 2NO‟S COOLING TOWERS(170m) &

PACKAGE
1NO CHIMNEY (275m)
CONTRACT VALUE Rs 169,77,00,000/-
TYPE OF CONTRACT LUMP SUM CONTRACT
CONTRACT AWARD 10/12/2009
CONTRACT PERIOD 26 MONTHS
NDCT 1 : 10/10/2011
SCHEDULED
NDCT 2: 10/02/2012
COMPLETION
CHIMNEY:10/10/2011
10% OF CONTRACT VALUE AS MENTIONED IN LETTER OF

MOBILIZATION ADVANCE AWARD
SECURITY MONEY 10% OF CONTRACT VALUE AS MENTIONED IN L.O.A
0.5% OF CONTRACT VALUE PER WEEK OF DEALY & MAXIMUM

LIQUIDITY DAMAGES
UPTO 10% OF CONTRACT VALUE
STATUTORY VARIATION IN WILL BE CONSIDERED BY MPGCOL AFTER SUFFICIENT

TAXES SUBMISSION OF DOCUMENTS
R.A. BILLS AS PER BBU.

2.5 TERMS AND CONDITIONS OF THE CONTRACT
2.5.1 TERMS OF PAYMENT
1. Terms of payment shall be back to back basis.
2. L&T EPC POWER Limited shall raise its bill to MPPGCL against bill received from GIL and
shall make it within 45 days. GIL is not entitled to any claim for any delay in payment.
3. Payment terms for Civil Works portion (Including construction materials but excluding cost
of Structural of Natural Draft cooling Tower)
1. 10% of the amount of total civil works shall be paid to contractor in advance.
1.1. Acceptance of letter of acceptance & Signing the contract agreement.

1.2. On Establishment of site office.
1.3. Receipt of invoice.
1.4. Submission of unconditional and Irrecoverable Bank Guarantee(s) against
performance security at 10% of contract amount.
1.5. Submission of detail PERT networks for Schedules.
2. 80% of the progressive payments of total civil works portion on installation services
components of contract price along with 100% taxes and duties.
3. 5% of civil works portion of installation services “ on completion of facilities including all
associated auxiliary and ancillary works”
4. 5% of Civil works of installation services “on issue of operational acceptance certificates.
4. Payment terms for Structural Works portion of Natural Draft cooling Tower.
1. 10% of the amount of total Structural works shall be paid to contractor in advance
against performance security

2. 40% of the amount of total structural work shall be paid to contractor for procurement of
the steel material at site.
3. 18% of the amount of total structural work shall be paid to contractor for fabrication work
of the structural work.
4. 12% of the amount of total structural work shall be paid to contractor for Erection works of
the NDCT.
5. 10% of the amount of total structural work shall be paid to contractor for final alignment,
bolting and welding.
6. 5% of the amount of total structural work shall be paid to contractor for associate
auxiliaries and auxiliary works
7. 5% of the amount of total structural work shall be paid to contractor for Guarantee test
and issue of operation.
5. Payment terms for Civil Works portion (Including construction materials but excluding
cost of Structural of chimney)
1. 10% of the amount of total civil works shall be paid to contractor in advance.

2. 80% of the progressive payments of total civil works portion on installation services
components of contract price along with 100% taxes and duties.
3. 5% of civil works portion of installation services “ on completion of facilities including all
associated auxiliary and ancillary works”
4. 5% of Civil works of installation services on issue of operational acceptance certificates.
6. Payment terms for Structural Works portion of chimney

1. 10% of the amount of total Structural works shall be paid to contractor in advance
against performance security
1.1. Acceptance of letter of acceptance & signing the contract agreement.

2. 40% of the amount of total structural work shall be paid to contractor for procurement of
the steel material at site.
3. 18% of the amount of total structural work shall be paid to contractor for fabrication work
of the structural work.
4. 12% of the amount of total structural work shall be paid to contractor for Erection works of
the chimney.
5. 10% of the amount of total structural work shall be paid to contractor for final alignment,
bolting and welding.
6. 5% of the amount of total structural work shall be paid to contractor for associate
auxiliaries and auxiliary works.
7. 5% of the amount of total structural work shall be paid to contractor for Guarantee test
and issue of operation.

2.5.2 STATUTORY VARIATION IN TAXES AND DUTIES
Any upward/downward variation of taxes & duties after the record data shall be L&T/
MPPGCL‟S account.
1. If there is any upward variation of taxes & duties after the record date, the additional
financial implication due to variation in taxes would be paid by L&T to GIL on pro-data
basis.
2. For this GIL has to be make and documentary evidence to L&T, which L&T will forward it
to MPPGCL and this claim will be accepted by MPPGCL and the payment will be made in
line.
3. If there is an increase in taxes & duties during the period of work for any reason which the
GIL is responsible then such increase shall be borne by GIL within the quoted to L&T /
MPPGCL if there is any delay from their side.
4. This variation shall not be applicable on procurement of raw materials and on the bought
out items dispatches directly from sub-vendor‟ s work to site.
2.5.3. LIQUIDATED DAMAGES
LIQUIDATED DAMAGES FOR DELAY:
1. L&T shall levy the liquidated damage on GIL at rate of 0.5% of the total contract price per
week of delay or part thereof subject to maximum of 10% of the total contract price.
2. This damage will be collected by GIL from contract price or securities available with L&T.
LIQUIDATED DAMAGES FOR DELAY IN COMPLETION OF INTERMITTENT ACTIVITIES:
Any delay during execution of work under the contract scope that result into delay in execution
of main plant package then it become liable for levy of liquidated damage on GIL at end work.
Final decision about the quantum and work component on which the liquidated damages to be
imposed will be sale discretion of the component authority of L&T/ MPPGCL.

Milestone
S no. Parts of work Liquidated Damages
dates
1 Shell completion –NDCT-1(100m) 31.01.2011 0.2%
2 Shell completion –NDCT-1(up to top) 30.04.2011 0.5%
3 Casting & erection of internal walls & columns –NDCT-1 30.06.2011 0.5%
6 Casting & erection of internal walls & columns –NDCT-2 30.10.2011 0.5%
Milestone
S no. Parts of work Liquidated Damages
dates
1 Chimney shell completion (up to 50m) 14.06.2010 0.1%
2.5.4. PRE-DISPATCH INSPECTION AND TESTING
L&T and MPPGCL authority shall carry out pre-dispatch inspection of equipments as per
approved quality assurance plan, which will be manufactured by L&T & MPPGCL.
2.5.5. DEVIATION IN SPECIFICATION
GIL shall not consent in writing of L&T take any deviation in respect of any equipment, material
etc. otherwise it will be considered to be breach of contract and payment will not be made for
such deviation.
2.5.6. QUALITY CONTROL
GIL is committed to adhere the FQAP strictly.
Maintaining list of Quality related records
Organize quality audits and provide feedback to PM and HQ – QA/QC group

2.5.7. TRAIL OPERATION AND HANDING OVER
1. The period of the trail operation of the system shall be 28 days during which period the entire
system must be operated and investigation.
2. During trail operation if it is found to be un-satisfactory then GIL has to be the modification
and trail operation will be done again.
2.5.8. PERFORMANCE GUARANTEE TESTS
1. This test must be conducted within 45 days after the completion of trail operation or
agreed upon by both the parties.
2. GIL should provide all the instruments requires for the performance guarantee test.
2.5.9. GUARANTEE/WARRANTY PERIOD
1. GIL shall guarantee that equipment supplied shall be new and free from defect for a
period of 12 calendar months after the completion of performance guarantee test.
2. The liability of GIL towards latent defects shall be for a period of 2 years a period from the
date of completion of guarantee/warranty period.
2.5.10. CROSS FALL BREACH AGREEMENT
According to this agreement if there is breach any one of the three contracts then is
automatically considered for the other also and L&T has the right to cancel the other two
contracts.
2.5.11. CONSULTANTS
CONTRACTOR CONSULTANT: Spectrum Techno-Consultant Pvt Limited is the

consultant for design and engineering for NDCT.
L & T POWER CONSULTANT: M/S Development Consultant Pvt. Ltd is the Consultant
for the design and engineering.
MPPGCL CONSULTANT: M/S L & T Sargent & Lundy is the Consultant for the design
and engineering.

CHAPTER 3 COOLING TOWER
3.1 INTRODUCTION
Cooling towers are heat removal devices used to transfer process waste heat to the
atmosphere. Cooling towers may either use the evaporation of water to remove process heat
and cool the working fluid to near the wet-bulb air temperature or solely on air to cool the
working fluid to near the dry-bulb air temperature. Common applications include cooling the
circulating water used in oil refineries, chemical plants, power stations and building cooling. The
towers vary in size from small roof-top units to very large hyperboloid structures that can be up
to 200 meters tall and 140 meters in diameter, or rectangular structures that can be over 40
meters tall and 80 meters long. Smaller towers are normally factory-built, while larger ones are
constructed on site.
3.2 TYPES OF COOLING TOWERS:
There are three main types of cooling towers:
1. Natural draft: This utilizes buoyancy via a tall structure. Warm, moist air naturally rises due
to the density difference to the dry, cooler outside air. Warm moist air is less denser than dry
air at the same pressure. This moist air buoyancy produces a current of air through the
tower.
2. Mechanical draft: which uses power driven fan motors to force or draw air through the
tower.
1. Induced draft: A mechanical draft tower with a fan at the discharge which pulls air through
tower. The fan induces hot moist air out the discharge. This produces low entering and high
exiting air velocities, reducing the possibility of recirculation in which discharged air flows
back into the air intake. This fan/fill arrangement is also known as draw-through.
2. Forced draft: A mechanical draft tower with a blower type fan at the intake. The fan forces
air into the tower, creating high entering and low exiting air velocities. The low exiting velocity
is much more susceptible to recirculation. With the fan on the air intake, the fan is more
susceptible to complications due to freezing conditions.

Another disadvantage is that a forced draft design typically requires more motor horsepower
than an equivalent induced draft design. The forced draft benefit is its ability to work with high
static pressure. They can be installed in more confined spaces and even in some indoor
situations. This fan/fill geometry is also known as blow-through.
3. Fan assisted natural draft. A hybrid type that appears like a natural draft though airflow is
assisted by a fan.
3.3 Photograph

Fig: Natural draft cooling tower
Fig: Forced draft cooling tower

Fig: Induced Draft CT(Counter flow) Fig: Induced Draft CT with fill(Counter flow)
Fig: Induced Draft CT (Cross flow)
Fig: Induced Draft CT single-flow (Cross flow)

3.4 CATEGORIZATION BY AIR-TO-WATER FLOW
Cross flow: Cross flow is a design in which the air flow is directed perpendicular to the water
flow. Air flow enters one or more vertical faces of the cooling tower to meet the fill material.
Water flows (perpendicular to the air) through the fill by gravity. The air continues through the fill
and thus past the water flow into an open plenum area. A distribution or hot water basin
consisting of a deep pan with holes or nozzles in the bottom is utilized in a cross flow tower.
Gravity distributes the water through the nozzles uniformly across the fill material.
Counter flow: In a counter flow design the air flow is directly opposite to the water flow. Air
flow first enters an open area beneath the fill media and is then drawn up vertically. The water is
sprayed through pressurized nozzles and flows downward through the fill, opposite to the air
flow.
Common to both designs:
 The interaction of the air and water flow allows a partial equalization and evaporation of
water.
 The air, now saturated with water vapor, is discharged from the cooling tower.
 A collection or cold water basin is used to contain the water after its interaction with the air
flow.
Both cross flow and counter flow designs can be used in natural draft and mechanical draft
cooling towers.
Counter flow & Cross Flow

3.5 OPERATION PRINCIPLE OF NDCT
The cooling tower operation is based on evaporative condensation and exchange of sensible
heat. Cooling effect is accomplished by transferring apportion of liquid into vapor state there by
releasing latent heat of vaporization.
Hot water is pumped to a certain height and then distributed through piping system and
discharged through nozzles to splash over a system called filling (or) stacking. The water
splashes, drips and flows downwards through the filling.
The ascending air which enters to tower through the open space between the supporting
columns rises through the open space between the supporting columns rises through the
droplets of hot water through evaporation and consequently cools the water through evaporation
and convection. The cooled water collected in a pond and re circulated by adding loss of water.
3.5.1 COMMONLY USED TERMS
 Drift - Water droplets that are carried out of the cooling tower with the exhaust air. Drift
droplets have the same concentration of impurities as the water entering the tower.
 Blow-out - Water droplets blown out of the cooling tower by wind, generally at the air
inlet openings. Water may also be lost, in the absence of wind, through splashing or
misting
 Plume - The stream of saturated exhaust air leaving the cooling tower. The plume is
visible when water vapor it contains condenses in contact with cooler ambient air.
 Blow-down - The portion of the circulating water flow that is removed in order to maintain
the amount of dissolved solids and other impurities at an acceptable level.

 Leaching - The loss of wood preservative chemicals by the washing action of the water
flowing through a wood structure cooling tower.
 Noise - Sound energy emitted by a cooling tower and heard at a given distance and
direction. The sound is generated by the impact of falling water, by the movement of air
by fans, the fan blades moving in the structure, and the motors, gearboxes or drive belts.
 Approach - The approach is the difference in temperature between the cooled-water
temperature and the entering-air wet bulb temperature.
 Range - The range is the temperature difference between the water inlet and water exit.
 Fill - Inside the tower, fills are added to increase contact surface as well as contact time
between air and water. Thus they provide better heat transfer. The efficiency of the tower
also depends on them. There are two types of fills that may be used:
 Film type fill (causes water to spread into a thin film)
 Splash type fill (breaks up water and interrupts its vertical progress)

3.6 TECHNICAL SPECIFICATIONS AND GENERAL PARAMETERS
General Parameters of NDCT
S.NO Description
1 Quantity 2 No‟s
2 Height 170m
3 Type of Tower Counter flow with P.V.C film fill
4 Water flow rate 75,000 Cum/hr
5 Cooling Range 10 Degree Celsius
6 Hot Water Temperature 43 Degree Celsius
7 Cooled Water temperature 33 Degree Celsius
8 Design Dry bulb temperature 39.78 Degree Celsius
9 Relative Humidity 40 ˚c
10 Design Capacity 18,750 cum/hr (flow through strainers)
11 Design Pressure 1 kg/cm2
12 Ratio of water to air weight 28 Degree Celsius
13 Location N 22˚ 06‟ 08” & E 76˚ 32‟ 45”
14 Coal Required 8.18 Million tons Annually
15 Heavy fuel & HDS Required 15,000 kilolitres
16 Proposed Plant zone Seismic Zone-III
Indra Sagar Reservoir construction on

17 Water Resource
Narmada river ( 6km away from site)
18 Construction method Jump Form method
19 Cooling Tower Shell Hyperbolic Paraboloid shape
20 Cooling Tower Manufacture M/S Gammon India Ltd

TECHNICAL SPEICIFICATION OF NDCT
S.NO Description
1 Tower Capacity 75000 Cum/Hr
2 Cooling Range 10°C
3 Diameter at sill Level 132M
Design atmospheric Wet Bulb

4
Temperature 28°C
5 Relative Humidity 60%
6 Cooled water temperature 33oC
7 Hot water temperature 43oC
8 Drift Loss 0.005% (Maximum)
9 Excavation 49390X2 cum (Approx.)
10 PCC 3028X2 cum (Approx.)
11 RCC 28500X2cum (Approx.)
12 Reinforced Steel 3896x2 MT (Approx.)
13 Nozzles 11700x2 Nos (Approx.)
14 Shuttering Quantity 136605x2 Sqm (Approx.)
15 Bituminous painting 140510x2 Sqm (Approx.)

3.7 CODES AND STANDARDS

IS:11504
Criteria For Structural Design of Reinforced Concrete Natural Draft
(Re-Affirmed 1992) Cooling Towers.
IS:1786
Specification For High Strength Deformed Steel Bars And Wires For
(Re-Affirmed 1990) Concrete Reinforcement.
IS:456-2000 Plain And Reinforced Concrete –Code of Practice.
IS:10262
(Re-Affirmed 1990) Recommended Guidelines For Concrete Mix Designs.
Specifications For Coarse And Fine Aggregates From Natural

IS:383-1997 Sources For Concrete.
IS:2386
(Re-Affirmed 1997) Methods of Test For Aggregates For Concrete.
IS:1199
(Re-Affirmed 1999) Methods of Sampling And Analysis of Concrete
IS:12269 Specification For 53 Grade Ordinary Portland Cement.
IS:269 Specification for 33 grade ordinary Portland cement
Specification for mild steel and medium tensile bars and hard drawn
IS:432 steel wire for concrete reinforcement.
IS:516 Methods of tests for strength of concrete.
IS:800 Code of practice for General Construction in steel.
IS:875 Code of practice for Design Loads for Buildings and Structures.
IS:650 Specification for standard sand for testing of cement.
IS:2210 Criteria for the design of RC shell structures and folded plates.
BS:4485 Specification for Water Cooling Towers (Part 1 to 4).

3.8 DESIGN CRITERIA OF COOLING TOWER
The following loads shall be considered for the design of cooling tower which are as follows: -
1) Dead Loads: - For assessing the self weight of the structure, the specific weight of the
concrete shall be taken as 2500 Kg/sqm. All other loads shall be assessed in accordance
with relevant codal provision.
2) Seismic/Earthquake load: - According to IS: 1893(part1&4) using the spectrum method

and 5% damping shall be considered for analysis.
3) Thermal effect: - Due to this effect stresses are developed. It shall not exceed value
given in IS: 4998(part1)-1975.
4) Permissible stresses for shell: - It shall not exceed as prescribed in clause 7.0 of IS:
4998(part1)-1975 for various combination. Except for the case of dead load + wind load
the maximum permissible stress in concrete shall not exceed 0.32FC (FC: - compressive
strength of concrete in Kg/sq.cm).
5) Wind load: - Wind load loading shall conform of IS: 875(part3)-1987. Dynamic analysis
shall be carried and stability must be ensured under such condition.
Wind pressure at given height shall be compute theoretically by
Pz = 0.6Vz^2 N/m2 (IS: 875(part3)-1987)
Wind parameter for calculating wind speed:
6) Basic wind speed: - 39m/s (up to 10m above normal ground level). Same in Bhusawal
According to IS: 875(part3)-1987.
And various pressure K1, K2 & K3 from IS: 875(part3)-1987.

3.9 SCHEME, SEQUENCE & METHOD OF CONSTRUCTION
3.9.1 SCHEME OF CONSTRUCTION
1. Excavation.
2. P.C.C.
3. Footing and pond wall.
4. Pond floor and grillage column footing.
5. Diagonal column.
6. Ring beam and hyperbolic shell.
7. Pre-casting of laths.
8. Pre-casting of bearer beam, pipe supporting beam, tie beam, bear block.
9. Pre-casting of grillage column, main and cross beams.
10. Erection of pre-casting of grillage column, main and cross beams.
11. Casting of bracing site.
12. Casting of main and secondary ducts.
13. Erection of laths.
14. Hot water inlet pipe.
15. Hot water distribution A.C pipes.
16. Finishing item.
17. Testing and commission.

3.9.2 SEQUENCE OF OPERATIONS

3.9.3 METHOD OF CONSTRUCTION
1. Open excavation for foundations
1.1 Sequence:
1.1.1 Take the block levels with clients.
1.1.2 Mark the outer line of excavation considering side slopes.
1.1.3 Excavate the soil.
1.1.4 After meeting soft/hard rock, take the block levels with clients.
1.1.5 Finalize the level by excavate the soft/hard rock up to the required level by chiseling,
drilling and blasting.
Excavation

Blasting

2 (a) PCC below foundation
2.1 Sequence:
2.1.1 Clean the surface.

2.1.2 Check the required level and slope before concreting.
2.1.3 Prepare the mix design well in advance.
2.1.4 Stock the raw material for concreting like aggregate, sand, water and cement as per
plan near the mixer.
2.1.5 Place the mixer as per plan with necessary chutes.
2.1.6 Prepare walkway arrangement for carrying and pouring the concrete.
2.1.7 Weigh the material as per mix design and convert it to corresponding volume.
2.1.8 Pour the concreting as per pouring pattern layer by layer.
2.1.9 At the end check the proper slope and make smooth finishing the surface of PCC.
2.1.10 Prepare the proper curing arrangements.

2(b) PCC on Pond floor
2.1 Sequence:
2.1.1 Clean the surface.
2.1.2 Remove the black cotton soil present and use plumb to fill the extra depth.
2.1.3 Stock the raw material for concreting like aggregate, sand and cement.
2.1.4 Ready the machinery.
2.1.5 Prepare walkway arrangement for pouring the concrete.
2.1.7 Pour the concreting as per pouring pattern layer by layer.
2.1.8 At the end check the slope of PCC.

3. Foundation
Salient Features:
3.1 (a) Salient Features:
3.1.1 Concrete Quantity (for 1 Node.) : 48.6 m3

3.1.2 Time required (for 1 no.) : 06 Hr.
3.1.3 Peak hour production (for 1 no.) : 4 m3
3.1.4 Grade of concrete : M 25
3.1.5 Maximum size of concrete : 20 mm
3.1.6 Mix Proportion : 1:1.91:3.31
3.1.7 Water cement : 0.5
3.1.8 Production of concreting : using concrete mixer conventional
3.1.9 Method of concreting : manually by wheel barrow.
3.1 (b) Sequence:
3.1.1 Clean the surface if any mud or dust is present there.

3.1.2 Mark out center line of footing and center of individual footing.
3.1.3 Mark layout of footing.
3.1.4 Cut and bent the reinforcement steel as per bar bending schedule.
3.1.5 Shift the reinforcement near the footing.
3.1.6 Lay the bottom reinforcement and fix the reinforcement steel as per drawing.
3.1.7 Fix temporary support for fixing of vertical reinforcement.
3.1.8 Fix spacer bars for maintaining the distances.
3.1.9 Check the spacing of bars as per drawing.
3.1.10 Fix shuttering Plates as per the size of footing.
3.1.11 Align and Fix temporary support to shuttering..
3.1.12 checks the slope of vertical reinforcement steel.
3.1.13 Clean the foundation areas by Air Jet or Water jet .
3.1.14 Marks the required level and slope before concreting.
3.1.16 Stock the raw material for concreting like aggregate, sand, water and cement as per plan
near the mixer.
3.1.17 Place the mixer as per plan with necessary chutes.

3.1.20 Pour the concreting as per pouring pattern layer by layer ensuring proper compaction.
3.1.21 At the end check the proper slope and make smooth finishing of the surface.
3.1.22 makes the proper curing arrangements.
Fig: Foundation Concreting

4. Pond Wall
4.1 Salient Features:
4.1.1 Concrete Quantity (for 1 Node) : 18.269 m3

4.1.2 Time required : 04 Hr.
4.1.3 Peak hour production : 05 m3
4.1.6 Mix Proportion : 1:1.296:2.864
4.1.8 Production of concreting : Single pours using conventional concrete mixer.
4.2 Sequence:
4.2.1 Mark out center line of wall.
4.2.3 Fix scaffolding as per drawing and Fabricate the shuttering plates as per drawing.
4.2.4 Shift the reinforcement near the wall.
4.2.5 Fix the reinforcement steel as per drawing.
4.2.6 Fix temporary support for vertical reinforcement.
4.2.7 Fix spacer bars for maintaining the Thickness.
4.2.9 Fix shuttering plates as per the size of wall.
4.2.10 Fix vertical and horizontal water stopper in Construction and expansion Joints.
4.2.11. Align the shuttering plates as per slope, radius and level.
4.2.12.Fix the temporary support to shuttering plates
4.2.13 Clean the construction joint.
4.2.14 Mark the required level and slope before concreting.

plan
near the mixer.
4.2.17 Place the mixer as per plan with concrete unloading tray.
4.2.22 Make the proper curing arrangements.
Pond Wall Concreting

5. Raker Columns Concrete
5.1.1 Concrete Quantity (for 2 No.) : 9.985 m3

5.1.6 Mix Proportion : 1:1.05:2.59
5.1.8 Production of concreting : Single pours using conventional concrete mixer.
5.2 Sequence:
5.2.1 Mark out center line of Raker columns pair.

5.2.3 Fabricate the shuttering plates well in advance and fix scaffolding as per drawing.
5.2.4 Shift the reinforcement near the Raker columns.
5.2.5 Fix the reinforcement steel as per drawing.
5.2.6 Align the reinforcement as per required radius and slope.
5.2.7 Fix temporary support for fixing of vertical reinforcement.
5.2.9 Fix shuttering plates as per the size of columns.
5.2.10 Make proper arrangement for support fixing in pond floor.
5.2.11 Mark the radius of saddle on which support has to be rest.
5.2.12 Align the shuttering as per radius and level.
5.2.13 Fix inclined and horizontal support for column shuttering sets.


5.2.15 marks the required level before concreting.
5.2.17 Stock the raw material for concreting like aggregate, sand, water and cement as per plan
Near the mixer.
5.2.18 Place the mixer as per plan with concrete unloading tray.
5.2.19 makes walkway arrangement for carrying and pouring the concrete.
5.2.21 Pour the concrete simultaneously in both columns layer by layer ensuring proper
Compaction.
5.2.23 Remove columns shuttering after 12 hr of pouring concrete without disturbing the inclined
and horizontal support.
5.2.24 makes the proper curing arrangements.
Raker Columns Staging

Raker Columns Shuttering

Typical Elevation View of Raker Columns

6. Ring Beam
6.1.1 Concrete Quantity (for 1 No.) : 7.267 m3

6.1.6 Mix Proportion : 1:1.05:2.59
6.1.8 Method of concreting : By concrete pump.
6.2 Sequence:
6.2.1 Fabricate the shuttering and Fix the scaffolding as per drawing.
6.2.2 Make wooden Bottom shuttering..
6.2.3 Fix the level pin, then ISMB section on the staging pipe and place ring beam wooden
Bottom shuttering.
6.2.4 Align the bottom shuttering as per radius and level.
6.2.5 Fix GP sheet on the bottom to maintain the outer curvical shape of ring beam by putting
the wooden angular pieces.
6.2.6 Fix the reinforcement steel as per drawing and provide temporary support to vertical
bars.
6.2.7 Make the alignment of reinforcement which is protruding from ring beam.
6.2.8 Check the radius of reinforcement steel at the lift top level.
6.2.9 Fix the shuttering plates at inner and outer face.
6.2.10 Align the shuttering plates as per radius and level and fix temporary supports.
6.2.11 Maintain the thickness of ring beam by fixing through bolts one meter c/c.

6.2.13 Marks the required level and slope before concreting.
6.2.16 Place the mixer and concrete pump & pipe line as per plan with concrete unloading
tray.
6.2.17 Make walkway arrangement for carrying and pouring the concrete.
6.2.21 Make the proper curing arrangements.

Ring Beam concrete by Concrete Pump

7. Shell By Conventional Method
7.1 Sequence:
1. Fabricate the shuttering plate, Shoulders and other accessories.

2. Fix the scaffolding with staging pipe joint pin and sufficient bracings as per drawing.
3. Fix walkway on staging.
4. Fix the reinforcement steel as per drawing.
5. Make alignment of reinforcement steel and provide temporary support to vertical bars.
6. Fix the main shutter, make up shutter and pan shutter at inner and outer face.
7. Fix the shoulders with the shuttering plates by J-bolts and through bolts.
8. Align the shuttering plates in required radius and level by rotating radius bolts and
maintain thickness by through bolt.
9. Fix four number of anchor screw with bolt in inner face of main shutter for anchoring
Jump form bracket as per Jump form drawing.
10. Clean the construction joint.
11. Marks the required level and slope before concreting.
12. Prepare the mix design well in advance.
13. Stock the raw material for concreting like aggregate, sand, water and cement as per
14. Weigh the material as per mix design and convert it to corresponding volume.
15. Pour the concreting as per pouring pattern layer by layer ensuring proper compaction.
16. At the end check the proper slope and make smooth finishing of the surface.
17. Make the proper curing arrangements.

8. Shell by Berrium Jumpform Method
8.1 Sequence:
1. Fix the Jumpform brackets on inner faces of shell.

2. Assemble Jumpform rigs set at ground level.
3. Lift Jumpform rig set by TATA 320 crane.
4. Fix Jumpform rig in the bracket already fixed on inner face of shell.
5. Fix the ladder beam on the top of vertical Jumpform post.
6. Fix the outer hanging platform on ladder beam.
7. Place and fix the wooden planks on the all Jumpform platform.
8. Fix the safety nets at all inner and outer platforms of Jumpform, bottom and both side
approach walkway on plumb staging.
9. Fix the vertical and meridian reinforcement with cover blocks as per drawing.
10. Align the reinforcement steel in desired radius as per drawing and provide temporary
support to vertical bars.
11. Lift the main shutter, make up shutter and pan shutter along with shoulder by chain pulley
blocks (0.5 MT capacities) and fix at inner and outer face.
12. Align the shuttering plates in required radius and level by rotating radius bolts and
maintain thickness by through bolt.
13. Fix four number of anchor screw in inner face of main shutter as per drawing for
anchoring Jumpform bracket.
15. Marks the required level and slope before concreting.
17. Stock the raw material for concreting like aggregate, sand, water and cement as per plan
near the mixer.
18. Place the mixer and power winches as per plan
19. Make walkway arrangement for carrying concrete on plumb staging.
21. Lift the Concrete bucket by power winch at desired level and unload the bucket in the tray
on the plumb staging platforms.
24. Make the proper curing arrangements by placing high Lift water Pumps.

8.2 Sequences for Jumpform Lifting
1. Lift the shuttering after 12 hrs of casting.

2. Lift the Jumpform rig by 150 mm for releasing load on bottom brackets.
3. Remove bottom brackets and fix on top in next lift.
4. Lift Jumpform rig to next lift by contraction the both Jacks uniformly by power pack.
5. Lift guide channel to next lift by extension the jacks
6. Give load on next top brackets which is recently fixed.



9. PRECAST BEAM
9.1 Sequence:
1. Prepare bar bending schedule as per drawing.

2. Cut and bent steel as per bar bending schedule
3. Fix the reinforcement steel cages as per drawing.
4. Fabricate the shuttering plate as per drawing and Fix the shuttering.
5. Place the reinforcement steel cages in the shuttering pharma with cover.
7. Stock the raw material for concreting like aggregate, sand, water and cement as per plan near
the mixer.
8. Place the mixer as per plan with necessary chutes and Tray.
9. Prepare walkway arrangement for carrying and pouring the concrete.
12. Make smooth finishing of the surface.
13. Mark identification marks immediately after casting.
14. Make the proper curing arrangements.
15. Plug lifting hole with cement mortar after erection.
Typical view of Precast beam shuttering

10. POND FLOOR RAFT
10.1 Sequence
1. Clean the surface if any dust or material is present on floor.
2. Prepare Bar bending schedule and fabricate Pond floor Side Shutter plate
3. Fix the reinforcement as per drawing and provide cover blocks.
4. Fix footing & column (internal) reinforcement at the location as per drawing .
5. Fix 150 mm water stopper at construction joint & 230 mm at expansion joints.
6. Fix the Bituminous joint filler board at expansion joints.
7. Follow the alternate check box pattern of casting.
8. Fix the shuttering on the sides of floor.
9. Marks the levels at the four corner of floor..
10. Cleans the surface by Water jet or air jet.
11. Check the required level and slope before concreting.
13. Stock the raw material for concreting like aggregate, sand, water and cement as per plan
near the mixer.
14. Place the mixer as per plan with necessary chutes and Tray.
17. Pour the concreting as per pouring pattern layer by layer ensuring proper compaction. At the
end check the proper slope and make smooth finishing of the surface. Make mortar bund for
curing .

Typical View of Pond floor reinforcement

11. Internal Column:
11.1. Sequence:
1. Prepare bar bending schedule and fabricate the shuttering plates as per drawing.
2. Fix the scaffolding .
3. Cut and bent steel as per bar bending schedule
4. Fix the reinforcement as per drawing.
5. Fix the shuttering.
6. Make the alignment of Shuttering
8. Mark the required level of concreting.
10. Stock the raw material for concreting like aggregate, sand, water and cement as per plan near
the mixer.
11. Place the mixer as per plan with necessary chutes and tray.
16. Prepare the proper curing arrangements.


12. PVC film fill:
Necessity/Purpose: PVC fill is made of Poly Vinyl Chloride sheets which play a vital role in the water
cooling process by increasing the path of water droplet.
12.1 Sequence:
1. Place the gluing machine and modules pharmas as per plan.

2. Mix the cyclohexane and polyvinyl chloride (PVC) thoroughly in mixing drum by mechanical
mixer.
3. Pour the mixer of (cyclohexane and PVC) liquid in gluing machine tray.
4. Place one PVC sheet in gluing machine and start the machine.
5. Take out the PVC film from other side.
6. Place the sheet in pharma.
7. Place second sheet in gluing machine and take out from other side.
8. Place the 2nd sheet on 1st sheet in such a way that the flute should be cross each other.
9. Repeat the action from 4 to 8 to get the desired depth that is 0.300 m.
10. Place the full pharma in sun light to get dry.
11. Remove the film fill module from the pharma.
12. Stack the fill module near the errection location.
13. makes walkway arrangement on intermediate beam.
14. fixes the pulley on upper level beam
15. Lift the film module manually by pulley.
16. places the film module layer by layer as per drawing on the fill supported beam.

13. Bituminous painting on concrete surfaces
Necessity/Purpose: - Prevent the entry of moisture in to the concrete which may leads to the
corrosion.
1. Clean the surface by wire brush or air blowing.

2. Apply the primer coat on the surface
3. Apply one coat of bituminous paint.
4. then apply second coat.
14. AC pipe
Necessity/Purpose: AC pipe are act as Hot water Distribution system through which hot
water can be easily distributed over a large area of cooling tower and sprinkled through nozzles
on PVC fill media
.
14.1 Sequence:
1. Place the drilling machine as per plan.

2. Mark the hole center on the AC pipe.
3. Place the pipe in drilling machine.
4. Drill the hole on the pipe as per drawing.
5. Stack the pipe near the erection location.
6. Prepare walkway arrangement on PVC fill.
7. Place the pipe in lines and joint the pipes by couplers on upper level cross beam.
8. Make alignment as per drawing.
9. Check line and levels.
10. Prepare cements mortar 1:4 for casting the saddle.
11. Plug the gap between the duct wall and embedded AC pipe.
12. cast the saddle on upper level cross beam to rest the AC pipe.
13. Make arrangement for curing.

Holes for AC pipes

CHAPTER 4 CHIMNEY

4.1 INDTRODUCTION
A chimney is a structure for venting hot flue gases or smoke from a boiler, stove, furnace or
fireplace to the outside atmosphere. Chimneys are typically vertical, or as near as possible to
vertical, to ensure that the gases flow smoothly, drawing air into the combustion in what is
known as the stack, or chimney, effect. The space inside a chimney is called a flue. Chimneys
may be found in buildings, steam locomotives and ships. In the US, the term smokestack
(colloquially, stack) is also used when referring to locomotive chimneys. The term funnel is
generally used for ships' chimneys and sometimes to refer to locomotive chimneys. Chimneys
are tall to increase their draw of air for combustion and to disperse pollutants in the flue gases
over a greater area so as to reduce the pollutant concentrations in compliance with regulatory or
other limits.
4.1.1 Features:
1. Type of Chimney : RCC High Multi Flue Chimney

2. Number of Chimney : One
3. Height of Chimney : 275 meters
4. Client : Larsen & Turbo Ltd.
5. Employer : M.P.Power Gen.Co.Ltd.
6. Contract value : Rs.48, 88, 00, 000
7. Contractor : M/S Gammon India Ltd
8. Date of LOA : 9th Dec, 2009
9. Type of contract : EPC
10. Completion period : 22 Months

4.1.2 SCOPE OF WORK
1. The scope of work covered in this specification in general, comprises the Design
Construction & Commissioning of 275 M. High Twin Flue RCC Chimney required for 2
x500 TO 600 MW Shree Singaji T.P.P.
a. Preparation of design basis report, design and construction drawings and obtaining
approval.
b. All excavation works in all types of soils / rocks including dewatering as necessary.
c. Construction of raft foundation.
d. Backfilling around the foundation.
e. RCC shell.
f. Internal platforms with flue restraint bearing and top internal platform with support
bearing & External platforms.
g. Stainless steel flues of suitable height.
h. Chimney cap.
i. Companion flange and brackets including inserts on the shell for the flue duct
connection.
j. Access, maintenance and clean out doors.
k. Staircase, ladders and hand railings.
l. Insulation material.
m. Platforms, inserts & miscellaneous bolts and anchors required for instrumentation of
chimney.
n. Lightning protection and grounding systems.
o. All painting work including for aviation,
p. Aviation night warning lights, lighting system inclusive of all accessories and cabling
work from power supply point.

4.2 TECHNICAL SPECIFICATION.
Description Value
Total Height of Chimney. : 275 Mtr
RCC Wind shield (shell) enclosing
Two flues, one for each Boiler.
No. of Boilers. : Two
Volume of Gas per Boiler. : 1280 M3/Sec
Mass flow of Gas : 4000 T/h
Density of gases. : 0.85 Kg/M3
Excavation : 16350 cum (Approx.)
PCC : 190 cum (Approx.)
RCC For raft and Grade slab : 8230.00 cum (Approx.)
For shell, corbels, enclosure wall : 8600.00 cum (Approx.)
Reinforced Steel : 1355.00 MT (Approx.)
Shuttering Quantity : 40980.00 sqm (Approx.)
Bituminous painting : 22100.00 sqm (Approx.)

4.3 METHOD OF CONSTRUCTION
4.3.1. EXCAVATION
Procedure:
a) Take the block levels with Clients.
b) Mark the outer line of excavation considering side slopes.
c) Excavate the soil.
d) Again take the block level with clients after meeting soft/hard
e) Finalize the level by excavating the hard/soft rock upto the required level.
f) Trenches shall be backfilled with the suitable material as per specification in layers not exceeding
750 mm loose depth.
g) Each layer of fill shall be adequately consolidated throughout its full depth immediately after
placement and prior to placement of additional layer.
h) Source: Approved borrow Excavated soil shall be checked up for the suitability for reuse. If it is
suitable then use in back filling.
i) Laboratory test: Before starting of fill work in Laboratory to determine of Maximum Dry
Density/Optimum Moisture Content relationship as per IS: 2720.
j) Field test: Field density test shall be carried out as per IS: 2720 till the minimum 95% compaction
achieved.
k) Work will be carried out from 8:00 am to 8:00 pm & 8:00pm to 8:00am every day excluding
Sundays.
l) For access to pit, stock rock location and direction of the vehicle movement please refer Fig No:
4
m) Frequency of Field test:
n) Areas of fill in excess of 1000 Sq. m.: 3 test per layer.
o) Areas of fill in less than 1000 Sq. m.: 2 test per layer.
p) Trenches for each 100 m or less: 1 test per layer.
Details of setting out
RAMP
SURVEY PILLARS
CENTRAL PILLAR
BOUNDARY OF CHIMNEY

Figure 1 Layout of Excavation

4.3.2. PCC BELOW CHIMNEY RAFT FOUNDATION
a) 2.1 Sequence:
b) Clean the surface.
c) Check the required level and slope before concreting.
d) Prepare the mix design well in advance.
e) Stock the raw material for concreting like aggregate, sand, water and cement as
per plan near the mixer.
f) Place the mixer as per plan with necessary chutes.
g) Prepare walkway arrangement for carrying and pouring the concrete.
h) Weigh the material as per mix design and convert it to corresponding volume.
i) Pour the concrete uniformly and the thickness of the PCC can be checked by using 75 mm
structural steel angle or any other material of 75mm.
j) At the end check the proper slope and make smooth finishing the surface of PCC.
k) Prepare the proper curing arrangements.

4.3.3. Raft foundation
1. Sequence of Chimney Foundation activity
1. After completing the PCC, area on it are marked for the laying of bottom reinforcement of
Raft Foundation.
2. Bottom steel are cutted and layed on PCC according to the Bar Bending Schedule submitted
to the Clients.
3. Cover Blocks are provided to the bottom steel so that reinforcement should not touch the
PCC.
4. Once laying of Bottom steel is completed temporary supporting arrangement i.e. scaffolding
pipes will erected for supporting the vertical bars or chairs and the dowels coming out of at
intermediate and top levels.
5. After that intermediate dowels are tied up with the vertical bars or chairs.
6. After that top reinforcement will be tied up according to the drawing.
7. Once the reinforcement is completed, we can proceed for shuttering.
8. Before proceeding for shuttering, care should be taken that we are going to fix shuttering on
the top layer of reinforcement steel. What about the gap between PCC and top layer if steel.
9. For that remaining portion, in the beginning only Mix of M-40 is layed and on that Shuttering
Plates are erected with the help of H-frames.
10. Before the start of shuttering cover blocks will be tied up to the whole reinforcement with
proper spacing so as to maintain the cover of 75mm throughout and the steel should not
protrude out of the concrete under any circumstances.
11. Making shuttering plate 12mm thick ply & fixing (3” X 2”) runner, shuttering which shall be
checked and approved by (Client) and then it shall be placed to the proper position with the
help of supports.
12. Supports provided to the shuttering should be strong enough so that concrete should not flow
out of it during concreting under any circumstances.
13. GI sheet shuttering is provided for shear key at bottom and top.
14. As the top surface will be exposed the one, to maintain proper cover of 75mm on the top
surface also, scrap bars will be tied to top mesh vertically at intervals and 75mm from the
face of the main bar is marked on it in the vertical direction.
15. Get the whole pour checked by the clients.
16. Care should be taken that fixing of formwork and reinforcement adequately secured in
correct position, leaving sufficient access for vibrator.
17. After getting it checked from the clients, now segment is ready for concreting:

1. The segment to be concreted is to be get cleaned before concreting.

2. Vibrator needles ,Transit Mixers or Batching Plant or any other PNM using for the concreting
is to be checked well in advance not at the time of concreting whether it is properly working
or not.
Fig: Showing the first layer of reinforcement
Fig: 1st Segment Before Concreting.

Fig: Showing completion of first pour and reinforcement of other pours
Fig: Showing the completion of 4 pours of raft foundation

4.3.4 SLIPFORM FABRICATION & ERECTION
4.3.4.1 INTRODUCTION
Slip form is a method of construction that requires custom built set forms for each project. Unlike
jumpforming, slip forming usually proceeds 24 hours per day during the pouring stage of the
project. Large diameter silos RCC chimney, square or irregular configuration or clusters of two
or more silos are usually slip form silos.
In this method, a complete and unique form system is fabricated and built on site. The inside
and outside wall forms are constructed of EN 8 MS plates shutter. These forms are held
together and supported by a system of yokes and by the slipform deck. The deck is constructed
of structural steel members, which are covered with wooden planks to provide an area to work
off .Normally, the structural steel members consist of the roof support beams for the actual
structure .Once the slip form is complete, these members are attached to or supported by the
wall. They are left in place to support the roof.
This whole system of deck and wall forms is raised, or slipped as one integral unit by a series of
either hydraulic jack. Each jack is centered between the wall forms and climbs on a steel jack
rod that is left in place in the concrete wall. The jacks are attached to the yokes to tie the whole
system together.
The entire slip forming operation is usually continuous from start to finish .The rate of slip will be
dependent on several factors, including wall thickness ,complexity of structure ,weather ,quantity
of embeds, and block outs to be placed in the walls. Most slips will average between 10” & 15”
per hour. The initial “set time” for the concrete being poured in the walls, which reinforces the
jack rods that support the structure, is another critical factor.
After slip is completed, or “topped –out”, the form system is still supported by the jacks and jack
rods. The finished wall is then given a day or two to gain sufficient strength .When ready, the
deck structural support system is attached to the walls to support the roof to be constructed
later, and the forms, yokes, jacks, etc are removed. The balance of the work to be performed on
the project can then proceed under normal construction methods and practices.

SKETCH OF MODERN SLIP FORM EQUIPMENTS:
Sketch of Slip form arrangement.

SLIPFORM ARRANGEMENT AT EL ( + ) 0 M LEVEL

4.3.4.2 LIST OF SLIPFORM MATERIAL FOR 48 YOKE SYSTEM
Qty for 28 Post for inside waler 48

Sr
Description 48 Yoke
No.
Nos. 29 Inside waler 96
1 Outside yoke leg normal 24 30 Support tube for inside waler 48
2 Outside yoke leg for main yoke 8 31 End piece for inside waler 192
3 Outside yoke leg normal with U 16 32 Clamp for waler 192
4 Inside yoke leg normal 40 Outside intermediate form support

33 48
left
5 Inside yoke leg for main yoke 8
Outside intermediate form support
34 48
6 Yoke beam lower left 24 right
7 Yoke beam lower right 24 Support tube for outside interned.

35 96
form support
8 Yoke beam lower left for main yoke 24
36 Screw for form support 192
9 Yoke beam lower right for main yoke 24
37 Inside intermediate form support left 48
10 Yoke beam upper right 48
38 Inside intermediate form support right 48
11 Yoke beam upper left 48
Support tube for inside intermed.
39 96
12 Steering arm 8 form support
13 Adjusting screw for wall thickness 125 40 Clamp for form panel 96
14 Top screw 55 41 Console for turn buckle 100
15 Special nut for top screw 55 42 Upper turn buckle 96
16 Guide for normal yoke 180 43 Lower turn buckle 96
17 Guide for main yoke 32 44 Lower catch with spring 96
18 Slide bar 35 45 Pusher with spring 192
19 Clamp for yoke 384 46 Upper catch with spring 96
20 Radius screw 55 47 Hydraulic piston jack 100
21 Form support 96 48 Drawing bar 192
22 Outside form panel 48 49 Piston screw 192
23 Inside form panel 48 50 Screw for drawing bar 192
24 Post for outside waler 48 51 Split pin dia.5mmX30mm 768
25 Outside waler 96 52 Protecting cover 96
26 Support tube for outside waler 48 Inside spindle right M24X2P

53 110
L=850mm
27 End piece for outside waler 192

54 Inside spindle left M24X2P L=850mm 110 84 Outside guard railing 288
Outside spindle right M24X2P 85 Inside guard railing 240

55 110
L=950mm
86 Spacing sleeve 144
Outside spindle left M24X2P
56 110
L=950mm 87 Taper tube 32 mm Dia 100
57 Nut for spindle M24X2P right 200 88 Taper tube 25 mm Dia 0
58 Nut for spindle M24X2P left 200 89 Console handle LH 200
59 Special nut for spindle M24X2P right 200 90 Console handle RH 200
60 Special nut for spindle M24X2P left 200 Elephant hose 200 mm dia, 2 mtr
91 48
long
61 Beam for bracing of main yoke 16
92 Starnut 400
62 Stretching screw 16
93 Cleat for form panel A Top 120
Protecting hose flexible dia.35mm
63 384
L=800mm 94 Cleat for form panel B Bottom 120
64 Screw for catch 192 95 Reinforcement clamp 100
65 Split pin dia.2mmX25mm 384 Pulley 250mm dia, 20mm rope,

96 16
Guide
66 Hanging frame for pump unit 2
Pulley 350mm dia, 16mm rope,
97 8
67 Counter flange for 6 ton jack 200 Concrete Bucket
68 Wing beam type A 4 Pulley 350mm dia,13mm rope, Pass /

98 9
Mat Hoists
69 Frame work beam type A 4
99 Cover plate for pulley 66
70 Wing beam type B 4
100 Bearing 6210Z for pulleys 66
71 Frame work beam type B 4
Pin MS, 250mm long 50mm dia for
101 33
72 Centre ring 1 pulley
73 Suspension clamp 8 Jack rod 32mm dia, 10 feet or 3 mtr

102
long
74 Washer 16
Jack rod 25mm dia, 10 feet or 3 mtr
103
75 Spider beam left 40 long
76 Spider beam right 40 Stud 3/4" BSW, 50mm long for 32mm
104 2000
jack rod
77 Distance bar 48
Stud 5/8" BSW, 45mm long for 25mm
105 0
78 Inside console for working deck 48 jack rod
79 Outside console for working deck 48 106 Shoe for 32 dia taper tube 100
80 Inside hanging scaffold 48 107 Shoe for 25 dia taper tube 0
81 Outside hanging scaffold 48

108 Slipform Power Pack SSP0110 2 Nos.
Upper outside console for normal
82 40
yoke
83 Upper outside console for main yoke 8+8

4.3.4.3 PROCEDURE FOR ERECTION OF SLIPFORM

1. All The materials shall be collected, checked and stocked before start of erection as per
list.
Sr. No Description
1 Yoke Leg (Outer)

2 Yoke Leg (Inner)
3 Yoke Beam & Shell Thickness screw
4 Outside Hanging Platform
5 Inside Hanging Platform
6 Waler Assembly
7 Waler post
8 Intermediate Form Support
9 Working Platform (Normal Post ) For Wing Beams
10 Working Platform (Normal Post ) For Spider Beams
11 Sleeve Pipe ,Shoe Pipe ,Jack Rod& Radius screw
12 Reinforcement Guide Clamp & Cover Block
13 Hopper & Chute Assembly for concreting
14 Turn buckle & mason Jullah
15 Details of Shuttering Plate.
16 Details of Steering Arm.
17 Hydraulic pressure pipe Connections Through 6T & 3T Jacks
18 Hydraulic pressure pipe Connections Through Piston Jacks
2. From centre point as a reference periphery of shell will divide in to 48 equal parts each at
angle 8.
3. Layout of staging shall be drawn on concrete surface of foundation.
4. According to layout staging shall be fixed, center staging should be strong as heavy load of
mainframe will come over it.
5. Assembling of main center truss, ring beam and wing beam shall be carried out at ground
level.
6. Before erection all required equipments and materials (like D-Shackle, sling, P.P.Rope)
shall be kept ready.
7. Erection of mainframe shall be carried out by crane of suitable capacity to lift main beam at
12.75 radius.
8. Main truss with wing beam shall be placed at predetermined center and level as per site
requirement.
9. Spider beam shall be connected into the ring beam channel, provided for fixing spider
beam.

10. After completion of erection work wing beam with central truss and spider beams, the
bottom level of all the wing beams and spider beams shall be maintained constantly.
11. Check the centre of chimney with the center of center frame and adjust the same if frame
is not in position.
12. Check all the connections for the proper tightness and location.
13. Erect the outer yoke leg with the help of guide angle.
14. Erect the inner Yokel leg ,Distance bar and continue erection of yoke beam, Internal &
External platform frame with hand railing ,fixing of inner and outer shuttering plates, fixing
of Waler support ,Waler ,fixing of Intermediate form support ,fixing of piston jacks, inside
the console ,fixing of top platform frame with hand railing ,fixing of Right and Left hand
horizontal Turnbuckle both side inside and outside with console and intermediate Waler
support ,fixing of diagonal turnbuckle with Wing Beam and outer Yoke ,fixing of steering
arm in Wing beam between Yoke legs shall be carried out.
15. Fix Shell Thickness Screw with Inner and outer yoke leg and radius Screw with inner Yoke
Leg, Wing Beam & Spider Beam.
16. Fix the planks of 50 mm thickness over Wing beam, Spider beam, Inner and outer Hanging
Platform and outer top platform.
17. Alignment of Yoke legs with Shuttering shall be carried out by keeping
„G‟-value= Thickness of shell × No. of Yokes.
1000
The „G‟-value shall be measured between top Yoke leg and Wing Beam/Spider
Beam.
18. Keep all the Yoke legs in position with shuttering by adjusting the radius screw, which has
provided for the adjustment radius at different elevations.
19. Fix the Hydraulic Pressure pipe with piston jack both inside & outside continuously .
20. Both ends of the hydraulic pressure hosepipes shall be connected to power pack .
21. Fix the batten of size 2”×3”×4” with the inner Yoke leg at the location
22. Fix the monometer tubes on each battens provided in inner Yoke leg by keeping the
constant distance between the lower yoke beam and draw a line on the battens.
23. Fix all the jack rod shoes at the locations marked on starter of shell. Fixing of reinforcement
guide clamp on wing beam /spider beams and cover blocks with shuttering plates.
24. Fix the jack rods with jacks and sleeve pipe ,please ensure ,the gap between the sleeve
pipe and shoe pipe shall be tightly closed be means of cello tape/shuttering tape to restrict
the flow of concrete /grout in between the shoe pipe and sleeve pipe which leads to
grouting of jack rod inside the shoe .
25. Fix pressure hosepipes with jacks and power pack
26. Check all the joints /Nipples of hydraulic hose pressure pipe by operating power pack.

FIRST STEP:
1. 2 Nos of wing beams with centre frame has been erected by tyre mounted crane of suitable
capacity to lift the truss.
2. If the whole assembly of centre frame & wing beams have to erect in as step the crane capacity
needed to be 13 T.
ERECTION PROCEDURE WITH THE HELP OF SKETCHES
Ring beam
Wing beam
Wing beam
Crane
Reinforcement bar GL.
Raft foundation
Backfilled soil
SECOND STEP:
1. After the erection of 2 nos of Wing Beams with centre frame the other 6 parts of wing beams were
erected one by one and properly connected to centre frame with an angle of 45 degree between
them.
ERECTION PROCEDURE SHOWN WITH THE HELP OF SKETCHES:
Ring beam
Wing beam
Wing beam
Crane
Backfilled soil

Spider beam Erection
Wing beam
Ring beam
Crane
Raft foundation
Backfilled soil
PROCEDURE SHOWN WITH THE HELP OF SKETCHES:
THIRD STEP:
1. After the erection of all 8 nos wing Beams and connecting it to centre frame with all care of dimension
and adequate checking ,the spider beams are erected one by one and get connected with ring beam with
an angle of 8 degree in between them.

4.3.5 CONCRETING OF CHIMNEY SHELL USING SLIPFORM
4.3.5.1 INTRODUCTION
The Concreting of Chimney Shell includes Concreting, Formwork/Shuttering, Reinforcement,

Slipform Operation, Curing, Finishing and all safety measures taken into consideration.
4.3.5.2 Sequence of Concreting
After erection of wing beam, spider beam, central frame and all other peripherals
associated with slipform assembly, the lifting operation can be started.
At present the slipform is resting on the staging pipes with all parts in assembled manner.
As the lifting operation starts the total weight of the assembly will be transferred to jack
rods inserted in concrete .
The other members of slipform such as the Wing Beam ,Center frame, Spider Beams
,Yoke Leg & Yoke Beams are designed in such a manner so that the load transfer and
stress distribution must be in a uniform manner .
All the hydraulic jacks are connected in series connection through Power pack,
manifold,Tee & hydraulic pressure distribution hose.
The piston jacks are also connected in series through power pack ,4 way direction control
valve distribution and hydraulic pressure distribution hose.
Upto 25m Truck Mounted Boom Placer will transfer the concrete in the tray kept on the
slipform deck.
From there concrete will be poured to the shell using trolleys through the funnels kixed
around the periphery of the deck so as to avoid segregation of concrete.
Concreting is done from one end simultaneously with one by one layer of 200mm.
Depending on the initial setting time of concrete, slipform shall be lifted up to 100mm in 1
hour.
Vibrating and leveling will be maintained.
After 25m concreting will be done by concrete buckets which will be lifted with help of
winches.
Observe the levels of each Yoke leg and if levels are not matching then adjust the lifting of
jacks with the help of bolt provided at the top of jacks.
The above process shall be continued for lifting of slipform.
Simultaneously operate all the screw like shell thickness screw, Radius screw and
horizontal turnbuckle as per the reading given in slipform operation chart.

4.3.5.3. Procedure For Extraction of Jack Rods
Jack rods shall be extracted after concreting a height of 25m of shell, initially and at 65m,
105m, 155m, 200m and 245m.
A free Board of 900mm shall be kept in shuttering by lifting the slipform as
required without concreting.
Staging shall be provided to support total slipform .The loads shall be taken be staging
pipes provided below wing beam and spider beams.
Remove the jacks by dismantling bolts provided for fixing jacks with lower yoke beam.
If there are two jacks at a location then one can be dismantled first and jack rod shall be
extracted.
If there is only one jack below spider/Wing beams the after transferring total load of
slipform on staging provided on shell for the purpose, jack rods shall be extracted.
Fix the extraction jacks at the predetermined locations in bottom of yoke beam.
Connect the extraction jacks as per the dia of jack rods with power pack and operate the
jack to extract jack rods.
In one operation 300mm jack rod will be extracted .Continue the operation till you extract
the joint of jack rod above jack top level.
Continue the above procedure for extracting total length of jack rod at each location.
Location of extraction shall be followed by setting, alternate locations.
Grout the holes left out at jack rods extracted location by cement mortar.
4.3.5.4 RESETTING OF SLIPFORM.
1. Fix the pipe shoe at the extracted locations of jack rods with sleeve pipe, jack rod and
jacks.
2. Alignment of shuttering and slipform shall be readjusted as per the drawing.
3. Concrete pouring shall be started after adjustment /setting of slipform.
4. Operation process shall be followed for further height as per slipform program.

4.3.5.5 PROCEDURE FOR SETTING SHIFT / TWIST.
1. Layout shall be drawn on floor by selecting any two wing beam opposite to each other.
2. Plumb shall be hanged at both the locations and initial reading shall be noted down and
also with help of laser instrument
3. Observe the shift /twist at every one hour and note down the readings.
4. If the slipform is shifted to any one direction it shall be brought to original direction by
controlling the lifting of jacks.
5. In extreme cases chain pulley block shall be used by raking reaction from inserts provided
in shell for the purpose.
6. If the slipform is twisted to any one direction, it shall be brought to original position by
operating diagonal turnbuckle provided in wing beams.
7. On extreme twist chain pulley blocks shall be used to control the twist of slipform.


4.3.6 FLUE CAN FABRICATION
4.3.6.1 Method of Fabrication

First of all raw structural steel received from APML will be stacked on a wooden battens in
a proper manner.
Then the plates will be straightened so that before bending they should be in a proper
shape.
Then the plates will be cut for the proper dimension as mentioned in the drawings
Using the pug cutters, plates will be cut horizontally and vertically as per the angle
mentioned in the drawing.
Then the plates will be bend half round with the help of plate bending machine.
Then the two halves will be welded together keeping a gap of 2mm.
Weld size will be 6mm butt weld as mentioned in the drawing.
The end of butt joints shall be welded so as to provide full throat thickness. This may be
done by the use of extension pieces, cross-runs.
Firstly the root run will be applied using filler material of ER-70-S-6 and after that back
gauging will be carried out from inner surface.
After back gauging Liquid Penetrant Inspection will be carried out and if any flaws appears
will be rectified as per standard welding practice.
Once the Liquid Penetrant Test is carried out and the gaps are located final filling run will
be applied.
After each run of weld, slag will be removed (Deslagging).
Both cans will be mounted on rotator and cans will be welded automatically from the top.
Again the above procedure should be repeated for the third can.
Then the 75x75x8 angle top one having 120 holes of 22mmǾ and bottom having 18mmǾ
shall be welded respectively and one angle of 75x75x8 shall be bend and welded to the
assembly.
After fabricating one canT1, two angles of 90x90x8 are welded diametrically opposite
points below 1000mm from top and above 1000 mm from bottom so as to maintain the
shape of can which can be removed later on.
Similarly, fabrication of stainless plates of 6mm is to carried out.


4.3.7 Tests to be carried out.
1. Liquid Penetration Inspection will be carried out after root run conforming
2. Magnetic Particle Test will be carried out for fabrication of Stainless
Steel
3. Radiography may be done 10% if required.

CHAPTER 5 QUALITY PLAN

1.0 SCOPE
1.1 General:
Project Quality Plan is a systematic document serving as a basis for assuring quality
execution of the project at each stage for full satisfaction of Client/ Employer ensuring
timely completion of the project by avoiding any cost and time over runs.
It aims at ensuring timely completion of the project by avoiding any cost and time over
runs and ensuring quality construction at all stages of the project.
The Project Quality Plan contains requirements of quality assurance programme for
Complete Design, Detailed Engineering, Supply, Construction, Erection, Testing and
Commissioning of 2Nos,Natural Draft Cooling Tower for 2x600MW, Shree Singaji
Thermal Power Plant, Village Dongalia, Dist. KHANDAWA, MADHYA PRADESH. This
Project Quality Plan is in conformance with requirements of Company‟s Corporate QAM,
ISO9001-2000 and L&T Technical specification for Construction.
1.1.1. Project Profile:
This Project includes Construction of Two no‟s of Natural Draft Cooling Tower for
2x600MW SINGHAJI THERMAL POWER PLANT KHANDAWA, MADHYA PRADESH.
Features:
Type of Cooling Tower : Natural Draft Counter Flow, Splash

type Cooling Tower
Number of Cooling Tower : Two (one for each unit)
Height of Cooling Tower : 170M (shell height)
Client : Larsen & Turbo Ltd.
Employer : M.P.Power Gen.Co.Ltd.
Contract value : Rs.120, 89, 00,000.00
Contractor : M/S Gammon India Ltd
Date of commencement : 9th Dec, 2009
Type of contract : Lump Sum contract.
Completion period : 22 and 26 Months.

1.1.2 Scope of Work:
2. The scope of work covered in this specification in general, comprises the Design
Construction & Commissioning of 2 No of Natural Draft Counter Flow Cooling Tower
required for 2 x500 TO 600 MW Shree Singaji T.P.P.
The scope of this work shall consist of, but not limited to, the design and construction of
reinforced concrete double curvature hyperbolic shell, Raker columns, ring beams, cold
water basin with partition walls, hot water pipeline, drain sumps, external drain chamber
with associated pipe work, cold water channels with sluice gates and removable screens
as specified elsewhere, hoists & monorails, primary and secondary hot water distribution
troughs, fill support systems including columns & beams, drift eliminators (if required),
testing of cold water basin for water tightness, external stairs, cage ladders, handling
facilities at tower top with walkway platform and CW channel, platforms, walkways as
specified or required for operation and maintenance, access doors, MS handrails, steel
fittings, fixtures, inserts including fabrication, galvanizing and erection of associated steel
work and other chemicals on the completed structures etc. all complete as per functional
requirements and as per directions of Owner. The scope of work under this specification
shall include providing thermal design, structural engineering design and drawings, all
labour, supervision, materials, shuttering and scaffolding, construction equipments
including tower cranes, hoists, batching plants etc. tools and plant, supply and
transportation of all incidental items not shown or specified but reasonably implied for
successful completion of the work. The nature of the work shall generally involve
foundation, excavation, dewatering, shoring and strutting, backfilling around
underground structures and plinth filling, sand filling, disposal of surplus soil outside
plant boundary, concreting of grade as specified, formwork including automatic climb
form, laser beam instruments, fabrication, galvanizing and erection of steel structures
and inserts, finishing anchor bolts, RCC sump, laying and testing of hot water pipe line,
water proofing, providing PVC water stops and joint filters, drainage and other ancillary
items connected with cooling towers as approved. The surface protection that would
include all inner face of hyperbolic shell, Raker column faces, inner faces of cold water
basin, fill support structures, hot water distribution pipes & channels, cold water

channels etc. This list is indicative and the scope shall also include the preparation and
supply of all working drawings required for this work.
2.1.3 TECHNICAL FEATURES OF COOLING TOWER

Description Value
Tower Capacity : 75000 Cum/Hr
Cooling Range : 10°C
Diameter at sill Level : 132M
Design atmospheric Wet
Bulb Temperature : 28°C
Relative Humidity : 60%
Cooled water temperature : 33oC
Hot water temperature : 43oC
Drift Loss : 0.005% (Maximum)
Excavation : 49359 cum
PCC : 3028X2 cum
RCC : 28500X2cum
Reinforced Steel : 3896x2 MT
Nozzles : 11700x2 Nos
Shuttering Quantity : 136605x2 Sqm
Bituminous painting : 140510x2 Sqm

1.2 Structure of Quality Plan (QP):
Project Quality Plan is structured into four parts conveying the Quality Policy, Quality
Objectives and Governing Procedures for the execution of the above job in a clear, accurate
and complete manner, applying sound engineering practices.
First Section deals with the structure of QP, responsibility of preparation and upkeep of
QP, and distribution list of QP.
Second section covers the purpose & scope of QP.
Third Section details of project are briefly furnished for ease of reference and
understanding the scope of work.
Fourth section Quality System elements as enshrined in QP are dealt with in conformity
with ISO 9001-2000
1.3 Responsibility for execution and upkeep of QP:
The Site In-charge in consultation with the Contract Management Section (CMS)
concerned shall be responsible for execution of the project as per this QP.
The Site In-charge in co-ordination with the QA Engineer In-charge shall be responsible
for the preparation, distribution, and upkeep of this QP including revising by issuing
approved revised pages/ amendments as necessary.
All copies of QP shall be numbered and issued to a person as specified in the distribution
list.
1.4 Distribution List:
The master copy of this document will be with the Project Manager. The copy shall be
distributed to the following personnel:
Sr. No. Copy Holder Copy No.
1. QA/QC Department L&T 1
2. Civil Department L&T 2
3. Q.A/QC Engineer, GIL 3
4. CMS Section 4
5. ISO Section, HO 5
6. SMR 6

2.0 NORMATIVE REFERENCE

Following reference codes are to be referred which are as follows:
Reference Code Title
IS:11504 Criteria For Structural Design of Reinforced Concrete Natural Draft

(Re-Affirmed 1992) Cooling Towers.
IS:1786 Specification For High Strength Deformed Steel Bars And Wires For
(Re-Affirmed 1990) Concrete Reinforcement.
IS:456-2000 Plain And Reinforced Concrete –Code of Practice.
IS:10262
Recommended Guidelines For Concrete Mix Designs.
(Re-Affirmed 1990)
Specifications For Coarse And Fine Aggregates From Natural Sources

IS:383-1997
For Concrete.
IS:2386
Methods of Test For Aggregates For Concrete.
(Re-Affirmed 1997)
IS:1199
Methods of Sampling And Analysis of Concrete
(Re-Affirmed 1999)
IS:12269 Specification For 53 Grade Ordinary Portland Cement.
Specification for mild steel and medium tensile bars and hard drawn
IS:432
steel wire for concrete reinforcement.
IS:516 Methods of tests for strength of concrete.
IS:800 Code of practice for General Construction in steel.
IS:875 Code of practice for Design Loads for Buildings and Structures.
IS:650 Specification for standard sand for testing of cement.
IS:2210 Criteria for the design of RC shell structures and folded plates.
BS:4485 Specification for Water Cooling Towers (Part 1 to 4).

The site utilizes the following document for Quality Management System based on ISO 9001-
2000:
1. Quality Manual (Apex Manual of the Company)

2. Corporate Procedures
3. Work Procedures for NDCT works.
4. Record generated during the process.
5. Quality Control Plan (QCP)
3.0 TERMS & DEFINITIONS:
Abbreviations Full Form
IMTE Inspection, Measuring And Testing Equipments
ISO International Organization For Standardization
LOA Letter of Acceptance
MR Management Representative
NCR Non Conformity Report
SMR Site Management Representative
QSP Quality System Procedure
QMS Quality Management Systems
QSS Quality Survey Section
TMS Technical Management Section
WSS Work Survey Station
TPIA Third Party Inspection Agency
REV Revision
QCP Quality Control Plan
QP Quality Plan
RT Radiography Testing

4.0 QUALITY MANAGEMENT SYSTEM
Quality management system of the project shall start with the establishing of policy and objectives
to direct and control an organization and it‟s inter related or interacting elements with regard to
quality.
Gammon India Limited has implemented Quality System as per requirements of ISO 9001-2000,
including
1. Quality Manual (QM)

2. Quality System procedures and other procedures
3. Quality Plan (QP) for this project.
4. Work Procedures
5. Safety Management Plan - Safety Manual
6. Procedure of Inspection and testing of incoming materials
7. Inspection and Testing Procedures and Inspection reports
Quality plan is prepared for the project as per quality requirement for ensuring
conformance to lay down specifications.
4.1. General Requirements
QMS of the project shall start with establishing the quality plan of the project at the initial
stage.
Quality Plan shall give process and its details and measurements criteria in the form of
Process Parameters.
Once the job is awarded planning activity for the job starts.
This is done by establishing the Quality Plan, construction methodology and ITP‟s of the
project.
This gives resource requirements and its schedule. Various processes involved in the
project and its construction are established and documented in the quality plan.

4.2 Organization Chart

4.3 Control of Documents
All the processes should be carried out strictly as per approved procedures and specifications.
The following documents are applicable for this procedure.
Document Controlled By
Contract Agreements Planning Engineer
Drawings Planning Engineer
Relevant Codes And Standards Quality Control Engineer
Quality Manual SMR/QA Engineer
Quality Plan With Method Statement And

SMR/QA Engineer
Testing of Incoming Materials
QSP For Job SMR/QA Engineer
Relevant person keeps the master copy of above documents and copies of above are
issued to the users and entered in issue register.
Each controlled document bears a copy number.
Some documents if need to corrected or changed, concern person can change it under an
approval of Project Manager.
If some revision will take place in control document, the Originator will call back the copy
from the users and issue fresh copy.
The old copy will be kept with master copyholder indicating it as obsolete document.
The obsolete copies of the document are kept by person controlling it only for any
contractual or legal issues.
The details of this process are as per corporate procedure for Control of documents
"QSP/MGR/03, copy of which is available with SMR.
4.4. Control of Records:
Records generated during various processes are maintained properly.

The records generated are maintained by QA/QC in charge.
The indexing number given is as: GIL/KHA/NDCT/QP abbreviation of process /Type of
document or record / serial number.
• GIL/ SSTPP/NDCT/QP - Gives location of
• GIL - As Contractor
• SSTPP - Location Shree Singaji Thermal Power Plant.
• NDCT - As the name of the project (NDCT).
• QP – Quality Plan.
The lists of records are made and retention period is mentioned on the same.
Copyholder shall take action regarding disposal of these records on expiry of defect liability
period or afterwards as per instruction of CMS and inform all concerned.
He shall ensure that these records are properly indexed, stored and are retrievable when
required.
The details of this process are as per corporate procedure for Control of Record
"QSP/MGR/04, copy of which is available with SMR.
5.0 MANAGEMENT RESPONSIBILITY
5.1 Management Commitment:
GIL management (HO & Site) shall:
Be in constant contact with site & encourage site to complete the project as per Clients
requirement
Define the quality objectives, mission and establish QMS for Site.
Conduct management reviews of the site once in three months.
Ensure that the resources required for the completion of the project are available on time.
Conduct audit for compliance of QMS and take feedback for continuous improvement.
5.2. Customer Focus:
To adhere safety, quality as per tender, approved procedure, drawings, quality control plan
and QP, and progress as per schedule.
5.3. Quality Policy:
Mission Statement
To develop, build and service physical infrastructure for better living, work Environment &
transportation.
Vision
To be the leader in innovative engineering and timely delivering of our quality Construction
services upholding our tradition of being “Builders to the Nation.”
Quality Policy
Gammon‟s quest for excellence is achieved by its innovative engineering and quality execution of
contracts through continual improvement of technology by its high performance team that takes
pride in being “Builders to the Nation”.

5.4 Planning
5.4.1 Quality Objectives
The QMS is to be implemented at site for achieving following quality objectives
• Quality of works:
To achieve the higher quality standard to the requirements and to reduce the non-
conformance and thereby reworking.
Sr
CORPORATE LEVEL SITE LEVEL
No.
1. The Company will seek to understand Improve customer satisfaction level by
customer satisfaction level in the scale reducing number of complaints and
of 1 to 10 and will take steps to improve satisfaction level based on
continuously improving the satisfaction feedback received from clients.
level.
2. The company will increase the revenue To achieve billing as targeted and
by at least 10% every year in the areas achieve project completion as per
of its core competency. schedule.
3. The company will increase the ROCE by To achieve job profit as per Control
1% every year. Estimate.
4. The company will improve the To maintain the plants in good working
productivity of equipments by 10% conditions and reduce breakdown
every year. percentage by 5%
5. The company will reduce the accident To create safe working environment for
frequency rate by 10% every year. Also individuals at the project and achieve
maintain safe working environment with reduction in time lost by maintaining
proper housekeeping. proper housekeeping and general
cleanliness.

5.5 Responsibility, authority and Communication:
5.5.1 Responsibility and authority
Project Manager shall define the responsibilities & authority of the site personnel.
The responsibilities & authorities of the site personnel shall be as follows:
A) Project In charge:
Responsibility:
To make the estimate, programme, work instruction and monitor the site as
well as QA/QC activities and safety activities. To interact with client, outside
agencies and HO.
Monitoring men and resources required for site i.e. arranging for the staff, plant /
machinery from the sources available at HO.
Follow up for getting the various construction activities started.
Monitoring the daily expenditures incurred at site.
Chair the review meetings to sort out the problems in execution of the job.
To check the accounting, finance consumption, progress report, stock
statements and QA/QC records are prepared properly and sent in time.
Attending the client‟s officials in their site inspection and in meetings.
B) Section-In charge:
Responsibility:
Monitor the site activities as per the programme and schedules made.
Interaction with various parties, outside agencies etc.
Liasioning with clients for necessary permissions and getting approval for
various construction activities.
Follow up for resources required for site as per requirement and equipment
deployment.
Follow up for getting the various construction activities started.
Day to day co ordination with client for necessary clearances.

C) Planning Engineer:
Responsibility:
(1)Planning:
To make Control estimate, cash flow, and programming and review the program
periodically.
Monitoring the stock of materials
Maintaining the drawing register
Estimating the quantities required for the next week & next month and informing
to the stores.
Reconciliation of the materials like cement, steel, aggregates, sand, Bitumen
paint, staging pipes, etc.
Prepare daily / weekly / monthly progress report and submit to Client and H.O.
Preparing work orders for sub contractors as per approved rates and checking
of sub contractor bills.
Making the arrangement of weekly review meetings with client
(2) Billing:
Planning Engineer shall make running account interim bills & escalation bills
monthly.
Reviewing the work done quantities with the quantities of R.A. bills
Authority:
In the absence of Project Manager, he shall have authority as delegated by

Project Manager.
D) Plant in charge:
Responsibility:
Smooth operation, running of the plant and machinery at site.
Prepare monthly plant statement and send it to HO through Project Manager.
Make the weekly schedule for day-to-day maintenance of all plant items and
carry out the maintenance accordingly.
Prepare a list of plant spares required for maintenance of plant and vehicles
weekly.
Do the statistical analysis of breakdowns.
Authority:
To define the duties & responsibilities of all staff of plant section

To place requirements for plants, plant spares.
To declare plants as surplus

E) Store Keeper:
Responsibility:
Prepare stock statement of the materials required for the job and update its
quarterly.
Check weights /measurements of incoming materials.
Carry out visual inspection, check quantity and specification of incoming
material.
Originating the records of materials received.
Storing of materials as required / specified
Authority:
He has the authority to reject material, which is not satisfactory.

To recommend / propose the material suppliers.
To make petty purchases at site with the knowledge of Project Manager.
F) Accounts Officer:
Responsibility:
Record the transactions as soon as they take place make the summaries and
sent to H.O through Project Manager.
Design the forms and procedures for timely accounting with internal control.
Prepare and send MFS statement to H.O duly signed by Project Manager.
Statutory requirements viz. income tax, sale tax etc.
Authority:
Complete cash control of the site in consultation with Project Manager.

To recommend cash payments to suppliers and site personnel
G) Site Engineers:
Responsibility:
Ensuring the proper functioning of the sites
Ensuring the understanding, implementation and maintenance of quality and
safety systems at all levels.
Performing the activities of construction function relating to contract
Ensuring proper documentation and data control.
Ensuring adherence to construction schedule and giving feedback to planning
cell.
Ensuring proper housekeeping at work site.

H) Safety Engineer:
Responsibility:
Ensuring overall safety at site.
Identifying potential hazardous operations and situations and prepare HAZOP
analysis.
Preparing comprehensive and detailed accident report whenever accidents
occur.
Understanding the site conditions at various stages of work from perspective of
safety of personnel and machinery
Evaluating the requirement of safety training programs and carrying out the
safety training programs
Evaluating the effectiveness of the safety-training program.
Conduct safety induction training as and when the situation demands.
I) Administration:
Responsibility:
Arranging facilities such as communication, transportation, accommodation etc.
required at site.
Hiring of plants for project as and when required and getting approval from
Project Manager
Allocating and maintaining accommodation facilities for personnel at site.
Maintaining various personnel records
Maintaining security arrangements for works camp, colony and equipment‟s.
Liaison with local departments like transport, electrical, postal, telegraphs, labor,
provident fund, etc.
Complying with various statutory requirements applicable to the project.
J) Quality Assurance & Quality Control Engineer:
Responsibility:
Maintaining list of Quality related records.
Maintaining of record room
Reviewing QSPs, work procedures, Quality Plan and Inspection and Test Plan.
Conducting various tests as indicated in the Inspection and Test Plan.
Attending day to day site QC activities.
Involving in QA related activities at site before concreting, during concreting and
after concreting.
Organize quality audits and provide feedback to PM and HQ – QA/QC group.

5.5.2 Site Management Representative (SMR)

Responsibility:
Maintain all documents related to ISO 9001:2000.

Initiate the internal audit and conduct Site Management Review meeting and take
corrective action to close all NCR‟s raised in the audit in consultation with Project
Manager.
Implement ISO system in the site.
Ensure that all staff follows quality management system at site.
Maintain list of all quality records maintained at site.
5.6 MANAGEMENT REVIEW

5.6.1 General
Management review shall be done as per company procedure bearing no. QSP/MGR/01. Site
management review meeting shall be conducted once in three months after the Internal Audit is
over. SMR shall fix the date & time in advance in consultation with Site in Charge and inform to all
Section In-charge. SMR is responsible for organizing the meeting. He will prepare the agenda of
meeting and distributed to all the section in charges in advance.
5.6.2 Review Input
The agenda as well as Review Input for the meeting shall be as below:
Audit reports (ISO Audit/Client Audit/DNV Audit), Report of analysis of Non-
conformities, customer complaints, equipment failure etc.
Action plan for corrective and preventive action.
Report of monitoring of corrective and preventive action plan implementation.
Safety records.
Wastage.
Reports of statistical techniques as given in procedure QSP/MGR/07.
Process parameters of various processes are monitored and
Reported and improvement of process carried out.
Achievement of project schedule.
5.6.3 Review Output

Improvement of the effectiveness of the quality management system and its
processes.
Improvement of product/service related to customer requirements.

SMR shall prepare the Minutes of Review Meeting (MOM) and shall distribute among all the
members. SMR shall also send necessary part of the minutes of the meeting to the concerned
person for taking action as per the MOM as required. The copy of the MOM and the report of
monitoring of corrective and preventive action taken shall be sent to M.R at H.O. with a copy to
concern CMS, which shall serve as input for the agenda for Management Review Meeting at H.O.
Management review shall be done as per the company procedure bearing no. QSP/MGR/01
6.0. RESOURCE MANAGEMENT
6.1 Provision of Resources:
To establish hygienic site office and accommodation for staff and workers, sufficient vehicles for
transportation of staff and labors, first-aid center, welfare facilities and etc. at site.
6.2 Human Resources
6.2.1 General
The skilled manpower and technical, non-technical as well as managerial staff deployed are
selected based on their qualification, experience and competency. Masons, Vibrator operator,
PVC water stopper and metal welders and personnel for jump-form shutter alignment etc. are
selected and qualified based on their performance and as per the procedure.
6.2.2 Competence, awareness and training
The training requirements of staff are to be identified by Project In charge. Project In charge
arranges for on job training and routine training based on requirements given by an individual in
the appraisal, client recommendation and job nature. Safety related training is imparted by Safety
Engineer at site. For any other training requirement he informs to H.O. CMS and H.O. HRD &
Training section.
6.3 Infrastructure:
Project Manger prepares requirements for infrastructure while preparing the estimate for the job.
Infrastructure requirements include provision of Site offices,
Plants & equipment like crusher‟s concrete batching plants etc.
Transportation and communication facility

The above is provided during the mobilization of the site. Also during the progress of the project
when necessity is felt for additional infrastructure same is justified and is approved by CMS on
review. The site is provided with adequate transportation facility for commuting. The site is
connected by V-sat for its communication by emails and for procurements through ERP system.
Plant Maintenance:
Site has established a workshop at site for maintenance of its plants. Plant In-charge establishes
preventive maintenance schedule for all the major plants, which follow the manufacturer
guidelines for the same. The plants are thus maintained routinely so as to ensure them in working
condition and for ensuring the productivity. The productivity and breakdown details are monitored
and process parameters of the Plant Maintenance process are reported during the Site
Management Review meetings.
Objective of plant maintenance is to reduce the down time and Repair / maintenance cost of
equipment‟s. For this failure analysis is done and improvements are implemented.
6.4 Work Environment:
A safe work environment is ensured at site by taking adequate measures like adequate access
scaffolds and walkways, railing and PPE for all the staff and workmen as appropriate to nature of
their works.
Company‟s safety manual can be referred for safety policy and standard procedures to be
followed with regards to safe working at site.
SAFETY, HEALTH & ENVIRONMENT MANAGEMENT:

Prior to commencement of work the personnel including sub contractor attend a safety induction
meeting. All personnel who are exposed to hazardous activities are provided with necessary
personnel protective equipment‟s like helmets, safety belts, shoes, goggles etc. Personnel
working in hazards area are trained for fire-fighting training. The relevant safety equipment‟s shall
be made easily accessible to the personnel.
SAFETY, HEALTH & ENVIRONMENT POLICY
We at Gammon are committed to provide a safe and healthy working environment for our
employees by adopting a proactive approach, prior to commencement of any project.
It is part of our work ethic to ensure that safety; health and environment safeguards are in
place right from the inception to the execution stage.
We accept the need for constant up gradation of safety and health standards commensurate
with the rapid changing technology in construction.

HSE – OBJECTIVES AND TARGETS
Sr Objectives Targets
No.
1. Commitment to provide safe, healthy working

Accident Prevention.
environment to the employees.
2. Maintaining safe, health and environmental

Environment Preservation
safeguards at our work sites.
3. Continual improvement in health, safety and

environment standards with rapid change in the Progress with safety.
technology.
Program to implement HSE POLICY and achieve objectives and targets:
1. Conducting Tool box talks:

Toolbox talks are conducted at critical activities like ROW preparation, main line welding,
trenching, lowering, boring, HDD etc.
2. Giving Training to the employees:

Training regarding operation and safety instructions, spill prevention and environment
protection, activity hazards etc. are given to enhance the awareness of HSE.
3. Job Safety Analysis (JSA) / Job Hazard Analysis (JHA) :

Execution staff in consultation with safety section makes the JSA or Hazard analysis of
the work activities before activity is taken up. The execution staff takes care of routine
preventive actions as briefed in JSA or JHA.
4. Auditing:
Safety audits are conducted and reports being maintained. Ratings are given for safety
performance of the month. From the findings of audit, steps to improve the situation can
be taken.
The findings of the Safety Audit are reported to H.O Safety In charge and also to Project
In charge and in SMR meetings.
5. Monitoring:
It is done daily through work place inspections, recording conformances/non-
conformances and issuing inter-office memorandum to rectify the safety related deficiency
(SRD). Process parameters of safety are reported on monthly basis to HO.
7.0 PRODUCT REALIZATION
7.1 PLANNING OF PRODUCT REALIZATION
To establish and maintain procedure for planning and control of construction activities at site. This
Section proposes the methods adopted by the project Manager that will enable him to
Administrate and execute the Contract as per approved Quality Plan, ITP‟s and Job Work
Procedure and to the entire satisfaction of the customers.
7.2 CUSTOMER-RELATED PROCESS
7.2.1 Determination of requirements related to the product
Product conforming to I.S shall be determined as per contract and approval of the same shall be
obtained from customer before use
7.2.2 Review of requirements related to the product
Product requirement as per contract and drawing shall be reviewed & its availability on time shall
be ensured.
7.2.3 Customer Communication
Customer (owner)'s representatives give their instructions to site personnel in the register or in
the approved format. Customer‟s complaints, if any received at site shall be attended with reply
and compliance is maintained in the register or as per approved format by giving the details
related to action taken.

7.3 DESIGN AND DEVELOPMENT
Design and Development of the final product is in the scope of customer.
7.4 PURCHASING
7.4.1 Purchasing Process
To streamline the site, Head Office purchases and defines the boundaries of site and Head Office
purchase limit.
Material purchasing at site is for consumables and small items. The objective of site purchase is
to reduce the lead-time and get the material at the best price. User group will raise an indent for
the material to be procured and the same is reviewed by planning section and Stores will check
for the availability of the material at stock and then the Project- In charge will approve the indent
for procurement.
Stores/Purchase section at site will obtain the Quotations for the materials indented and the
Purchase Officer/Store Keeper will generate comparison statement and proper approval shall be
obtained on the comparative statement and then Purchase order shall be prepared.
Purchase Order shall contain the following details:
Date / P.O. Number / Indent Reference / Quotation Reference

Vendors Name and Address
Details of the Materials to be procured with Quantity and Rate
Sales Tax Registration Number (for both State and Central) or VAT
Specification of the Materials with IS or any other standard requirements
Packaging details / Delivery Details / Validity of the Purchase Order
Insurance / Discount / any other tax details / Transportation details
Signature of the Competent Authority
Purchase of major materials and that of consumables etc are done by HO P&S based on the
indent raised by the user at site and reviewed by planning section at site and approved by the
Project In charge and CMS.
Purchase process and relevant documents are as referred in purchase process chart.
Vendors are to be registered and their ability to supply the product is examined and then
approved. After receipt of material based on each purchase orders, vendor's performance is
viewed and is rated for their performance. Successful vendors are listed in approved vendor list.
This list is reviewed once in three months based on the nature of supply and the product.

A) INSPECTION AND TESTING
7.4.2 Purchasing Information
A Purchase order to be issued to supplier mentioning all relevant information of the required
product such as name of the Product and Quantity with the relevant standards and specifications
Against purchase order, material shall be received from supplier at site and the inspection shall
be carried out as per approved Quality Assurance Plan (QAP) or Inspection and Testing Plan
(ITP) on receipt of the material.
7.4.3 Verification of Purchased Product
Store personnel receives the materials and is accepted based on fulfilling requirement of
incoming materials inspection. Quality Control engineer inspects the same materials and conduct
sampling and testing as per approved ITP or QAP.
Receipt Inspection Items received from H.O. like Cement, Reinforcement steel, Admixture etc.
should be accompanied by Manufacturer‟s Test Certificate. Items received from vendors at site
should be inspected / tested by the QC Engineer and records shall be maintained. Rejected
materials are to be returned to the vendor and details are entered in the register. The Inspection
and Test Plan and method of testing for incoming materials is defined in the Quality Assurance
Plan.
a) In process Inspection and testing
In process Inspection and testing shall be carried out as per test/Inspection Plan and test results
shall be recorded. QC Engineer will be responsible for this activity. QA test plan for in process
testing and receiving inspection is detailed in Quality Assurance Plan. List of processes for
Inspection/testing is enclosed.
b) Final Inspection and test
Before asking the Engineer In-charge for joint inspection, thorough check shall be carried out by
QC Engineer. Project In-charge will make request for inspection to Engineer In-charge.
B) INSPECTION AND TEST STATUS
Inspection and Test Status of materials and processes shall be identified by tags, marking or by
documenting the test results indicating the conformance of the material/ processes based on the
inspection/test performed. Non-conforming materials/processes shall be clearly identified to avoid
their unintended use till the non-conformity is removed.
All records shall be maintained by the QA Engineer on completion and acceptance of an activity
by Client. All the measuring test and inspection Equipment‟s shall bear a sticker signed by the site
QA In-charge containing all details related to its identification & calibration. Periodic cross
verification of Equipment shall be done by the site QA In-charge for its accuracy.

7.5 PRODUCTION AND SERVICE PROVISION
7.5.1 Control of Production and Service Provision
To establish, implement and maintain a procedure for control of production and service provision
for all permanent and temporary works in the site. The same is carried out by approved
methodology of the respective activity like excavation, concreting for raft foundation, etc.
7.5.2 Validation of Processes for Production and Service Provision

Validation of process for product shall be done based on the QCP approved by client.
7.5.3 Identification and traceability
Product identification and traceability shall be carried out for critical items. Paperboard shall be
kept near the critical material, which posses expiry date and these shall be depleted in the
“First in First Out” system.
Identification boards shall be displayed near the reinforcement steel/ structural steel indicating
the diameter/size/specification.
All critical materials (other than coarse and fine aggregates) purchased shall be accompanied
by Manufacturer‟s test certificates.
Details of Product Batch no., Lot no., Location, Date of use etc. shall be maintained in product
for all critical materials. Records shall be maintained by QA Engineer.
For example for cement Batch number shall be traced out with manufacturer material test
certificates and Week number shall be traced out from cement bag and related documents.
For steel Lot number shall be traced from manufacturer test certificate and at site from tags
which is tied to the Reinforcement and as well as it will be transferred into issue register and
steel register book, so that the traceability of steel shall be ensured. Product like Precast items
shall have the product identification and traceability.
7.5.4 Customer Property
There is no supply of materials by customer. It is applicable for some embedment parts

and the same shall be controlled in the following manner: -
The indent shall be reviewed and approved by site in charge and submitted to the
customer.
The store In-charge shall verify the quantity of the customer-supplied materials.
Project In-charge shall ensure that the Manufacturer‟s test certificates are supplied by the
customer with each lot of material. In addition, random sampling and independent testing
of customer supplied-product shall be carried out. Non-conforming materials shall be
returned to the customers and record maintained.
7.5.5 Preservation of Product
All the material received at stores is preserved at store. Material is accounted and entered in
stores ledgers. The care is taken to store the material at appropriate place. They are traced
appropriately with their identification of the material.
The main product required for this job is as follows:
a) Cement
b) Aggregate (Coarse & Fine)
c) Admixture
d) Reinforcement
e) PVC Water Stopper
f) Bitumen Paint
g) GI Ladders
h) Structural Steel for ladders, lightening, Earthing etc.
i) M.S.Pipes
a) Cement
Cement shall be stored in closed godown as per Indian standard practices (IS 4082)
and the same cement shall be issued to site as per the requirement. The cement older
than six months will be rejected from its use.
b) Admixture
Admixture shall be stored in Closed Godown and same shall be issued to site as per
requirement.
c) Reinforcement
Reinforcement should be stored diameter wise and stacked over the wooden sleepers
or pedestals. Tags will be used to identify each diameter of reinforcement.
d) PVC Water Stopper

PVC Water Stopper should be stored in open or closed godown as per size and should
be covered. Material code shall be written over it and tags will be used to identify each.
e) Bituminous paint
Bitumen paint shall be stored in closed go down and shall be issued to site as per
requirement.

7.6 CONTROL OF MONITORING AND MEASURING DEVICES
A list of all inspection, measuring and test Equipment‟s shall be maintained with the details
of the Equipment Identification number, Calibration frequency, Date of Calibration, next
due date of calibration, calibration agency (in-house or external lab). In-house calibration
shall be carried out as per equipment manual. QA In-charge shall be responsible for the
calibration of the equipment and maintenance of documents and records. List of
Inspection, Measuring and Test Equipment‟s has been prepared and given in Annexure-4.
All the inspection, measuring and test equipment shall bear sticker signed by the site QA
In-charge containing the details related to its identification and calibration status. Periodic
cross verification of Equipment‟s shall be done by site QA In-charge for its accuracy.
8.0 MEASUREMENT, ANALYSIS AND IMPROVEMENT:

8.1 GENERAL

8.2 Monitoring and Measurement
8.2.1 Customer Satisfaction
Customer‟s feedback shall be taken proactively once in every Three Months for various attributes
of project execution. A customer satisfaction index shall be assessed and corrective action shall
be taken to improve QMS‟s performance
8.2.2 Internal Audit
Management Representative will send quarterly audit plan and SMR will prepare audit schedule
for internal audit before scheduled date of internal audit which includes name of trained internal
auditors, auditor, date & time, duration of audit & location. The same shall be distributed to all
concerned. Internal Quality auditing shall be carried out at the interval of three months.
As soon as audit is over, SMR shall ensure that NCR‟s are duly endorsed with proper corrective
action and data by the auditor and are sent to MR at HO. These non-conformities are brought to
the knowledge of Site In-charge who will conduct and chair the management review meetings
after preparing necessary agenda for the same. During this meeting site In-charge shall discuss
the reasons/causes of non-conformity with all Section In-charges and suggest corrective action.
Corrective action plan shall be finalized with the staff for closure of non-conformity report. SMR
shall maintain a register of non-conformities stating details of non-conformities and corrective
action taken for closing non-conformity.
The following audit records shall be maintained: -
a) Auditor‟s note to MR.

b) NCR Form
c) Audit Plan
d) Audit Schedule
e) NCR Register
f) Report of Site Management Review Meeting.
g) Audit Report.
SSTPP NDCT shall be provided to access all the Quality documents maintained at site for any
audit conducted by them.
8.2.3 Monitoring and Measurement of process
Monitoring and Measurement criteria are decided for various processes at site, which are termed
as "Process Parameters". These are listed for each major process and are as shown in various
activity process plans. The results of the process measurements are assessed with those

planned. If these are found to be not in line with the planed ones suitable corrective actions are
taken.
8.2.4 Monitoring and Measurement of Product
Monitoring and Measurement of product are done at project sites. Inspection and testing
requirements are documented in Inspection and Test plan (ITP). The ITP gives characteristics
to be tested, applicable codes, testing methods, acceptance criteria, variance allowed etc.
The record of test result as evidence of conformity to the acceptance criteria is maintained.
If any deviations in the results are noted then such products are segregated and they are not
used.
Also deviations if any from acceptance criteria are validated from clients and then on its
acceptance only material are used.
8.3 CONTROL OF NON-CONFORMING PRODUCT
a) The site ensures that the nonconforming products are not used in the works and are identified
and are segregated.
b) The non-conformity in the product shall be noted at the time of inspection and testing by
Quality Control Engineer. In case of non-conformity product he shall take appropriate action &
reporting the same to Project Manager.
c) The products, which received from clients, have identified as non-conformity by Quality Control
Engineer shall be segregated and reported to clients through Project Manager.
d) Product found nonconforming after receiving inspection and in-process inspections are
identified and segregated till disposition is decided.
8.4 Analysis of Data

Data generated from the above processes is analyzed for initiating corrective and preventive
action.

8.5 IMPROVEMENT
8.5.1 Continual Improvement
The site has targeted quality objectives based on company‟s Mission-Vision Quality Policy.
Results obtained while analyzing the data shall be used in further improving the Quality
Management System. Results of Internal audits Data shall be analyzed and actions shall be
taken for continual improvement of the Quality Management System. Data from various sources
shall be analyzed and corrective and preventive actions shall be planned.
8.5.2 Corrective Action
Corrective actions are initiated once the nonconformity is detected in view to eliminate its root
cause and to prevent its reoccurrence. The Site In-charge shall initiate the corrective actions as
and when nonconformity is encountered.
Corrective actions include following actions:
Nonconformity are reviewed

Root cause are investigated
Actions are evaluated and decided in view to avoid its re-occurrence
Actions determined are implemented
Records of such actions are recorded and are copied to CMS and MR
Corrective actions so taken are reviewed for its appropriate Implementation.
8.5.3 Preventive Action
The company has a system to initiate preventive actions for the events, which shall result in
nonconformity at later stage. These events can be detected during the safety and quality audits.
The Project Manager shall initiate the preventive actions as and when felt necessary.
The actions taken during the preventive actions are as follows: -
Events of potential nonconformity are reviewed

Actions needed are evaluated and decided in view to prevent its occurrence
Actions determined are implemented
Records of such actions are recorded and are copied to CMS & MR

CHAPTER 6 CONSTRUCTION SITE ORGANIZATION AND MANAGEMENT
6.1 SITE LAYOUT DESIGN

Main items of site layout design
 Building/structure under construction
 Main equipments
 Auxiliary plants, yards, workshops
 Stores and deposits
 Site management offices
 Sanitary/welfare rooms and buildings
 Temporary roads
 Electric power supply
 Water supply
 Storm-water drainage, dewatering
 Waste/contaminated water treatment, sewer.
6.1.1ON-SITE MAIN EQUIPMENTS

Cranes (tower cranes)
Manipulation area to be served/reached
Location of other main equipments, cranes
Height of beam
Dimensions of effective lifting area served/reached
Base frame – fixing (anchoring)
(Pre-)Assembly of beam - spreading
Assembly of crane by auto crane - climbing
Other objects on the area to be served
Elevators
Proper location of feeding/picking area has great effect on performance
Easy delivery of materials into the building should be provided in long period of
Construction
6.1.2 AUXILIARY YARDS, PLANTS AND WORKSHOPS

Rest of work is organized to central production plants. Less on-site processing can
be
performed at (supported by) special on-site plants.
Potential auxiliary plants and yards
Wood yard (formwork, shutter, timbering)
Steel yard (reinforcement processing plant)
Batching (concrete mixing) plant
On-site prefabrication/pre-assembly yard

Lime and mortar plant

Yards and workshops functioning rather as stores
Plumbers yard and workshop
Electricians workshop
HVAC assemblies store
Tinsmith workshop.
6.1.3 WOOD YARD

Its significance is vanishing due to more and more wide-spread use of formwork systems
Irregular/unusual forms in architecture may recover (revitalize) its use
 Storage: On sleepers (e.g. on concrete beams) laid on spacers (ventilation/airing)
 Cutting: Power-saws located under shelter
 band-saw : circular-saw ( properly located for to cut any sizes of log or timber )
 Assembly: in joining yard
 Infrastructure: electric power supply – buried cable
 water supply – fire plug (hydrant)
 road and surface
 gravel-typed dry/hard surface
 access for transportation
 fencing/enclosing needed
6.1.4STEEL YARD
 Central steel yard (reinforcement processing plant) as industrial supply is tending to be
typical
 On-site steel yard
 Storage
 Transport
 straight rods and bars (length ~12 m)
 rods and bars cut and bended (confected)
 rolls of wires (e.g. for stirrups and for bonding)
 Storage
 by size and by mechanical characteristics (type, quality)
 Cutting and bending
 bending equipment(s), power tools
 linear

6.1.5 BATCHING (CONCRETE MIXING) PLANT

On-site batching (radial or tower-system) plants are typical
rather at distant, („Greenfield”)
Investments. At municipal (in-city) sites less frequently applied.
Functional units
 Mixer, stand, dozing partition
 Cement-silos
 Radial deposit for fractions of aggregates (+ dragline excavator/feeder)
Infrastructure
 Electric power supply (high consumption, separated supply)
 Water supply (high/intensive consumption)
Road and surface
 Access around the aggregate-deposit must be provided
 Receiving cement transport – parking/loading bay
 Supply, reach/access/service of mixer – height of stand
 Hard surface (cover) under aggregate-deposit
6.1.6 STORES AND DEPOSITS

 Considerations
 closed (lockable) stores
 shelters : open deposits , special stores, Closed stores, mostly containers, sometimes
store houses, buildings, or parts/sections of some existing on-site buildings
Shelters
Temporary structures (enclosed or fenced)
Open deposits: hard surface (covered and/or enclosed)
Special stores: special storage (safety, protection, hazard) regulations.
6.2 SITE OFFICES AND OTHER BUILDINGS
6.2.1 Temporary building structures

 located close to the only port/gate of site (in a „neutral zone/corner”)
 container
 special ready-made (pre-assembled) building
 (separate section of) existing- or under-construction building
6.2.2Site management offices

 single container
 office rooms, cabinets,
 documents‟ archives, office-technology rooms
 meeting rooms
 lavatory
 refreshment room, tea-kitchen, (drink/food automat)
 sub-contractors offices (as contracted)
 emergency- or „clean” room (first-aid room for case of accidents, wounds)

Changing room, dining room, shelter (if any)
 sized for average workers‟ staff
 container
 shelter van
 special ready-made (pre-assembled) building
 refreshment room, buffet van
 (drink/food automat)
Sanitary
 sized for maximum workers‟ staff
 lavatory/wash-basin as fixture in container or in building
 toilet
 wash-down toilet as fixture in container or in building
6.2.3 TEMPORARY ACCESS ROADS

Even if no any structure was constructed as temporary road free access to all location on site
must be
provided during over-all time-span of accomplishment!
Horizontal alignment
 single-lane
 roundabout access
 controlled only entrance and exit (gate)
 turning and man oeuvres of vehicles
 designed in accordance with the traffic (usually 12-14m)
6.2.4TEMPORARY ELECTRIC SUPPLY

Demand w : engine/equipment (pile driver, batching plant, tower crane, etc.)
w: power tool (power saw, poker vibrator, vibro-hammer, etc.)
w: illumination, lighting (lamp, spotlight, reflector tower, sign, office, etc.)
6.2.5 TEMPORARY WATER SUPPLY

Demand technology (concrete, plaster, paint, earthworks, etc.)
Sanitary (drinking water, cleaning, washing, etc.)
Fire protection (emergency water tank or water reservoir)
6.2.6 WASTE- AND STORM WATER DRAINAGE

To be provided for
 technology wastes and cleaning ( must be collected and treated/transported )
 sanitary ( if possible can be driven to public sewer system, other ways must be collected )
 storm water and ground water ( driven to natural outlet )

6.3 SITE MOBILISATION

 A very important component of site management is the organization.
 Depending upon the size and nature of the project, the organization would coordinate and
carry out activities as determined.
 The success of a project very largely depends upon the commitment,involvement,attitude
and understanding amongst the project team.
 A very close coordination needs to be maintained by the project manager with client/
owner, consultant, vendor/supplier, sub-contractor and local authorities.
 In view of uncertainties, the project manger & his team must rise to the occasion and
innovate ways & means to come out of the crisis or a difficult situation as & when it
develops.
6.3.1 SITE MOBILIZATION INVOLVES THE FOLLOWING
1. Enabling works:
• Under works of this category, structures which would facilitate undertaking the actual
project work are included in the master control network & planning. In a large project
running into cores, enabling works itself will form a mini-project. Enabling works will
include:
(a) Fencing/boundary wall around the project, fixing security check post and gates.
(b) Camp for engineers, supervisors & workmen
(c) Store for materials
(d) Construction plant & equipment:
(1) Static plant such as concrete batching plant, pre-cast concrete element plant, hot mix
plant etc.
(2) Mobile plant such as dumper, bulldozers, transit mixer, concrete, compressor, trucks,
bitumen sprayer, road roller etc.
2) Workshop:
• For maintenance of plant and equipment(static & mobile), it is necessary to have a
workshop which will undertake maintenance, repair, overhauling and major replacement of
equipment.
• The workshop should have a small machine shop attached with lathes, drilling
machines,welding,sheet metal work and also battery charger, tyre repair etc.
3) Quality control laboratory:
• For testing of material and building component, it is essential to set up a quality control
laboratory at site.
• This laboratory should test materials such as cement, sand,aggregate,bricks,concrete etc.
• If any item needs to be tested for which facilities are not available at site, then such
samples are sent to reputed laboratories/research institutions for testing.
4)Stores and stacking yards:
• In the project site, open storage is necessary for maintaining the material in good condition.
• Cement is usually supplied in bags which are stored at site in covered shed.

• If more than 10 bags are stacked, then the lower bags tend to set, making cement non-
usable.
5) Services:
• The site camp is to be provided with services like electric supply, sewage disposal,
communication, power, telephone ,&water supply
• In order to carry out the enabling work which is required at the very initial stage of the project, a
team is sent in advance to the site for building up all temporary structures, services required for
enabling works.
• On the other hand, if a project team that has been assigned with the main work is to first build up
enabling works, a lot of time is lost in the project.
In some international projects and some major projects within the country, structures are being
adopted for the site camp which is of portable nature.
6.3.2 GOOD SITE MANAGEMENT TECHNIQUES
1) Well laid out site:

• A tidy and workmanlike site is important because it helps the contractor to operate more
efficiently and saves wasted time & resources. Secondly, it shows the client that the
contractor takes pride in his work.
2) Site office for supervisor:
• The site supervisor should be provided with an office where he can keep the drawings,
documents, update the bar chart programme and prepare labour, plant and material
returns as required by head office.
• When the project manager or any authorised person as contractor visits the site, he should
make sure that upto date drawings, client‟s instructions and other information is available
3) Training foreman:
• The foreman is in the frontline of management and he will always perform better if he is
made to understand that he is a member of team rather than an as a person to take orders.
• It is worthwhile taking a little time to explain the reasons for requiring them to keep the site
office tidy and submit time sheets regularly rather than simply saying “it has to be got
done”.
4) Reducing waiting time:
• Waiting time is far too common occurrence on many sites e.g. operators wait to be told as
to what to do next, lorry drivers wait while the foreman goes off to the supplier for an
urgent item and the concreting gang has to stop until the fitter comes out to repair the
mixer. „Waiting time‟ is a polite way of describing wasted time and wasted time means
wasted money. This can be eliminated provided a site management plan is prepared in
advance.
5) Reducing movements:
• Half of the man hours that is expended on a construction site are concerned with the
movement and handling of materials. Much of this time could be saved, leading to greater
productivity and lower costs, if the site layout has been planned from the start of job to
minimize unnecessary movements.

6.4 SITE MANAGER (EXECUTION)
• The first step in opening a site is to post a person to be the site in charge.
• Running a site is a full time job and this job must be given to person who is qualified and
has got experience of work at sites.
• He/she should be a competent person with definite direction and strong inspiration, a
natural leader with pleasing personality for leading a team of men successfully.
The following things are expected of a site manager:
1. KNOW THE CONTRACT:: He should thoroughly read the contract and should be knowing
the contractual obligations and specifications so that the quality of performance is improved.
2. STUDY THE PLANS:

 He /she is expected to have the plan before him and ensure that the key men of the site
team look at the plans as often as possible.
 When the target dates of approaching events & milestones stares, it will accelerate the
speed of the whole team.
3. READ THE ERECTION MANUAL

 The erection manual must be read so that whatever is not clear should be discussed
and clarification should be sought in advance.
 In this process, the manager must ensure that his team members become competent
enough to attend to the erection job so that he can concentrate on other activities at
the site
4. MOBILISATION OF RESOURCES:
 Apart from the items mentioned in the mobilisation checklist given by the planning
manager, there are requirements of various registrations under relevant law for starting
a new establishment employing people.
 Resource mobilisation shall be done as per the plan of head office in line with the work
schedule, keeping the time, quality and economy in mind. If something planned by head
office is unnecessary @ site, it is not necessary to do that. But, if something more is to
be done, permission is necessary for budget allocation.
5. DIVIDE THE SITE INTO MANAGEABLE SECTIONS:
If the site is unwieldy, divide it logically into units/sections/divisions and put an

engineer/foreman in charge of each. Allocate the resources according to the needs. In
allocation of resources, diversion should be made possible by ensuring least wastage &
idleness.

6. TRAIN AND DELEGATE RESPONSIBILITIES:
The manager must train the supervisors to do the work well, guide them in every step until
they become competent enough to take correct decisions at their level independently, and
motivate them by delegating more responsibility in recognition of their competence in their
assignments. All key men @ site must be trained to know the scope, capacity, their use,
maneuverability and use of machines that are used in site. The manager must delegate part
of his authority to subordinates so that they can exercise control over the resources to the
extent necessary for carrying out their responsibilities efficiently.
7. SITE BUDGET:
The head office consolidated budgets of various items of inputs and outputs for the whole
site. It is necessary to break them section wise and delegate responsibility to section heads
so that they learn to work independently & produce results. Measure & compare the
performance every week.
8. REMOVE CONSTRAINTS:
 As a site manager, he /she should ensure that constraints are foreseen by way of advance
planning of drawings, foundations, clearances, material indents,
 Working fronts, erection schemes etc so that they are removed in time. All constraints will
cause delay and delay will cause financial loss to the organization. In construction work,
“time lost is money lost” and hence the site manager is always under emergency.
 Narrating excuses will not help and what stands at the end of the month is figures of
achievements. He should be a “creator” and should not wait for things to happen by
themselves without human effort.
9. CLOSELY MONITOR ACTIVITIES:
 The site manager‟s task doesn‟t end by making resource allocation and holding of
meetings. Instead of team leaders coming to manager for guidance,
 The manager should go to them for monitoring the performance, and where ever
necessary, should guide them before any damage is done.
 No construction manager worth his name should say “Progress is poor because of failure
of an engineer in charge of some activity”. As the boss of site, the manager should know
the daily progress in every area of work, measure it and compare it with the planned
programme and take effective steps for the same.
10. MANAGE TIME
 At the construction site, there is always pressure of work and lack of time. The manager
should learn the art of time management in a better way.

CHAPTER 7. PROJECT MANAGEMENT
Project Definition and Scope
What is a Project?
“A project is a one-shot, time-limited, goal-directed, major undertaking, requiring the
Commitment of varied skills and resources”.
A project is a temporary endeavor undertaken to create a unique product or service. A project is

temporary in that there is a defined start (the decision to proceed) and a defined end (the
achievement of the goals and objectives). Ongoing business or maintenance operations are not
projects. Energy conservation projects and process improvement efforts that result in better
business processes or more efficient operations can be defined as projects. Projects usually
include constraints and risks regarding cost, schedule or performance outcome.
Project management is concerned with the overall planning and co-ordination of a project
from conception to completion aimed at meeting the stated requirements and ensuring
completion on time, within cost and to required quality standards.
Project management is normally reserved for focused, non-repetitive, time-limited activities

with some degree of risk and that are beyond the usual scope of operational activities for which
the organization is responsible.
7.1 IMPORTANCE OF PLANNING
1) project plan clearly defines project scope of work

2) It breaks down project objectives into clear ,identifiable,quantifible,attainable,and
verifiable goals which are assigned to individual &responsibility centers for
accomplishment
3) Project plan aids the management in performing its functions effectively & efficiently.
4) Project plan forms the basis of project operations &directions &shows how the project is
to be run.
5) Project plan identifies critical activities, thus enabling the managing of project by
exceptions.

6) Project plan provides the basis for coordinating the efforts of clients, consultants,
architects, designers, specialists, suppliers,contractors and the quantity surveyors
&project staff.
7) Project plan provides the yard stick for measuring progress and evaluating resources
performance.
7.2 Planning includes
1. Time planning
2. Resource planning
3. Planning control system
7.2 .1.Time planning
 1.Project work breakdown

 2.Drawing project networks
 3.Project work scheduling
7.2.2. Resource planning
 1.Planning construction manpower
 2.Plannnijng construction materials
 3.Selecting construction equipment
 4.Planning construction costs
 5.Planning construction budgets
7.2.3. Planning control system
 1.Resource productivity control
 2.Project cost control
 3.Project time control

7.3 Steps in Project Management
The various steps in a project management are:
Project Definition and Scope
1. Technical Design
2. Financing
3. Contracting
4. Implementation
5. Performance Monitoring
7.3.1. Technical Design
For a project to be taken up for investment, its proponent must present a sound technical
Feasibility study that identifies the following components:
 The proposed new technologies, process modifications, equipment replacements and
other measures included in the project.
 Product/technology/material supply chain (e.g., locally available, imported, reliability of
supply)
 Commercial viability of the complete package of measures (internal rate of return, net
present value, cash flow, average payback).
 Any special technical complexities (installation, maintenance, repair), associated skills
required.
 Preliminary designs, including schematics, for all major equipment needed, along with
design requirements, manufacturer‟s name and contact details, and capital cost estimate.
 Organizational and management plan for implementation, including timetable, personnel
requirements, staff training, project engineering, and other logistical issues.
7.3.2 Financing
When considering a new project, it should be remembered that other departments in the
organization would be competing for capital for their projects. However, it is also important to
realize that energy efficiency is a major consideration in all types of projects, whether they are:
 Projects designed to improve energy efficiency
 Projects where energy efficiency is not the main objective, but still plays a vital role.
The funding for project is often outside the control of the project manager. However, it is
important that you understand the principles behind the provision of scarce funds.

Project funds can be obtained from either internal or external sources.

Internal sources include:
 Direct cash provision from company reserves
 From revenue budget (if payback is less than one year)
 New share capital
Funding can become an issue when energy efficiency projects have previously been given a
Lower priority than other projects. It is worth remembering that while the prioritization of
Projects may not be under our control, the quality of the project submission is.
External sources of funds include:

 Bank loans
 Leasing arrangement
 Payment by savings i.e. A deal arranged with equipment supplier
 Energy services contract
 Private finance initiative
The availability of external funds depends on the nature of your organization. The finance
charges on the money you borrow will have a bearing on the validity of your project.
Before applying for money, discuss all the options for funding the project with your finance
managers.
It is reiterated that energy savings often add substantially to the viability of other non-energy
projects.
7.3.3 Contracting
Since a substantial portion of a project is typically executed through contracts, the proper
Management of contracts is critical to the successful implementation of the project. In this
context, the following should be done.
 The competence and capability of all the contractors must be ensured. One weak link can
affect the timely performance of the contract.
 Proper discipline must be enforced among contractors and suppliers by insisting that
they should develop realistic and detailed resource and time plans that are matching
with the project plan.
 Penalties may be imposed for failure to meet contractual obligations. Likewise,
incentives may be offered for good performance.
 Help should be extended to contractors and suppliers when they have genuine
Problems.
 Project authorities must retain independence to off-load contracts (partially or wholly)
to other parties where delays are anticipated.

If the project is to implemented by an outside contractor, several types of contract may be

used to undertake the installation and commissioning:
 Traditional Contract: All project specifications are provided to a contractor who
Purchases and installs equipment at cost plus a mark-up or fixed price.
 Extended Technical Guarantee/Service: The contractor offers extended guarantees on
the performance of selected equipment and / or service/maintenance agreements.
 Extended Financing Terms: The contractor provides the option of an extended lease
or other financing vehicle in which the payment schedule can be based on the
expected savings.
 Guaranteed Saving Performance Contract: All or part of savings is guaranteed by
the contractor, and all or part of the costs of equipment and/or services is paid down
out of savings as they are achieved.
 Shared Savings Performance Contract: The contractor provides the financing and
is paid an agreed fraction of actual savings as they are achieved. This payment is used
to pay down the debt costs of equipment and/or services.
7.3.4 Implementation
The main problems faced by project manager during implementation are poor monitoring of
progress, not handling risks and poor cost management.
a) Poor monitoring of progress: Project managers sometimes tend to spend most of their
time in planning activity and surprisingly very less time in following up whether the
implementation is following the plan. A proactive report generated by project planner
software can really help the project manager to know whether the tasks are progressing as
per the plan.
b) Not handling risks: Risks have an uncanny habit of appearing at the least expected time. In
spite of the best efforts of a project manager they are bound to happen. Risks need immediate
and focused attention. Delay in dealing with risks cause the problem to
aggravate and has negative consequences for the project.
c) Poor cost management: A project manager's success is measured by the amount of cost
optimization done for a project. Managers frequently do all the cost optimization during the
planning stages but fail to follow through during the rest of the stages of the project. The cost
graphs in the Project planner software can help a manager to get a update on project cost
overflow. The cost variance (The difference between approved cost and the projected cost
should be always in the minds of the project managers).

7.3.5 Performance Monitoring
Once the project is completed, performance review should be done periodically to compare
actual performance with projected performance. Feedback on project is useful in several
ways:
a) It helps us to know how realistic were the assumptions underlying the project
b) It provides a documented log of experience that is highly valuable in decision making in
future projects
c) It suggests corrective action to be taken in the light of actual performance
d) It helps in uncovering judgmental biases
e) It includes a desired caution among project sponsors.
Performance Indicators (PIs) are an effective way of communicating a project‟s benefits,

usually as part of a performance measuring and reporting process. Performance Indicators are
available for a wide range of industries and allow a measure of energy performance to be
assigned to a process against which others can be judged.
Depending on the nature of the project, savings are determined using engineering
calculations, or through metering and monitoring, utility meter billing analysis, or computer
simulations.
7.4 Four Basic Elements of Project Management
A successful Project Manager must simultaneously manage the four basic elements of a
project: resources, time, cost, and scope. Each element must be managed effectively. All these
elements are interrelated and must be managed together if the project, and the project
manager, is to be a success.
7.4.1. Managing Resources

A successful Project Manager must effectively manage the resources assigned to the project.
This includes the labor hours of the project team. It also includes managing labor subcontracts
and vendors. Managing the people resources means having the right people, with the right skills
and the proper tools, in the right quantity at the right time.
However, managing project resources frequently involves more than people management.
The project manager must also manage the equipment (cranes, trucks and other heavy
equipment) used for the project and the material (pipe, insulation, computers, manuals)
assigned to the project.

7.4.2. Managing Time and Schedule

Time management is a critical skill for any successful project manager. The most common
cause of bloated project budgets is lack of schedule management. Fortunately there is a lot of
software on the market today to help you manage your project schedule or timeline.
Any project can be broken down into a number of tasks that have to be performed. To prepare
the project schedule, the project manager has to figure out what the tasks are, how long they
will take, what resources they require, and in what order they should be done.
7.4.3. Managing Costs
Often a Project Manager is evaluated on his or her ability to complete a project within budget.
The costs include estimated cost, actual cost and variability. Contingency cost takes into
account influence of weather, suppliers and design allowances.
7.4.4. How the 80/20 Rule can help a project manager?
The 80/20 Rule means that in anything a few (20 percent) are vital and many (80 percent) are
trivial. Successful Project Managers know that 20 percent of the work (the first 10 percent and
the last 10 percent) consumes 80 percent of your time and resources.
7.5 Project Management Life Cycle
The process flow of Project management processes is shown in Figure 7.1. The various
elements of project management life cycle are
1) Need identification
2) Initiation
3) Planning
4) Executing
5) Controlling
6) Closing out

7.5.1 Need Identification
The first step in the project development cycle is to identify components of the project. Projects
may be identified both internally and externally: Internal identification takes place when the
energy manager identifies a package of energy saving opportunities during the day-to-day
energy management activities, or from facility audits. External identification of energy savings
can occur through systematic energy audits undertaken by a reputable energy auditor or energy
service company. In screening projects, the following criteria should be used to rank-order
project opportunities.
Cost-effectiveness of energy savings of complete package of measures (Internal rate of
return, net present value, cash flow, average payback) Sustainability of the savings over the life
of the equipment. Ease of quantifying, monitoring, and verifying electricity and fuel savings.
Availability of technology, and ease of adaptability of the technology to Indian
conditions. Other environmental and social cost benefits (such as reduction in local pollutants,
7.5.2 Initiation
Initiating is the basic processes that should be performed to get the project started. This starting
point is critical because those who will deliver the project, those who will use the project, and
those who will have a stake in the project need to reach an agreement on its initiation. Involving
all stakeholders in the project phases generally improves the probability of satisfying customer
requirements by shared ownership of the project by the stakeholders. The success of the
project team depends upon starting with complete and accurate information, management
support, and the authorization necessary to manage the project.
7.5.3 Planning
The planning phase is considered the most important phase in project management. Project
planning defines project activities that will be performed; the products that will be produced, and
describes how these activities will be accomplished and managed. Project planning defines
each major task, estimates the time, resources and cost required, and provides a framework for
management review and control. Planning involves identifying and documenting scope, tasks,
schedules, cost, risk, quality, and staffing needs.

The result of the project planning, the project plan, will be an approved, comprehensive
document that allows a project team to begin and complete the work necessary to achieve the
project goals and objectives. The project plan will address how the project team will manage the
project elements. It will provide a high level of confidence in the organization‟s ability to meet the
scope, timing, cost, and quality requirements by addressing all aspects of the project.
7.5.4 Executing
Once a project moves into the execution phase, the project team and all necessary resources to
carry out the project should be in place and ready to perform project activities. The project plan
is completed and base lined by this time as well. The project team and the project manager‟s
focus now shifts from planning the project efforts to participating, observing, and analyzing the
work being done.
The execution phase is when the work activities of the project plan are executed, resulting in the
completion of the project deliverables and achievement of the project objective(s). This phase
brings together all of the project management disciplines, resulting in a product or service that
will meet the project deliverable requirements and the customers need. During this phase,
elements completed in the planning phase are implemented, time is expended, and money is
spent. In short, it means coordinating and managing the project resources while executing the
project plan, performing the planned project activities, and ensuring they are completed
efficiently.
7.5.5 Controlling
Project Control function that involves comparing actual performance with planned performance
and taking corrective action to get the desired outcome when there are significant differences.
By monitoring and measuring progress regularly, identifying variances from plan, and taking
corrective action if required, project control ensures that project objectives are met.
7.5.6 Closing out

Project closeout is performed after all defined project objectives have been met and the
customer has formally accepted the project‟s deliverables and end product or, in some
instances, when a project has been cancelled or terminated early. Although, project closeout is a
routine process, it is an important one. By properly completing the project closeout,
organizations can benefit from lessons learned and information compiled. The project closeout
phase is comprised of contract closeout and administrative closure.
The main roles are Project manager :
1. Figure head role( legal & social head) : The project manager, is the legal and social head of
the project, is the single focal point of making decisions, ceremonial functions and symbolic
duties.
2. Leader ship role (Performance motivator & experienced person): As a leader, the project
manager directs the inter functional efforts through a complex web of relationships created in
the project organization by building a performance-motivated organization a team of skilled
and experienced people who collectively face the challenges posed by the people.
3. Liasioning role (Dealing with the outside agencies): The project manager maintains
contacts outside the organization, deals with those activities which may involve
correspondence and contact with the concerned government officials contract vendors
professionals, and top persons of the construction industry.
4. Monitoring role (Monitoring the relevant information coming from outside agencies): The
project manager focuses a planned approach for performing tasks, land implements of time,
cost and quality planning and monitoring system for the project that highlights the
commitment of the project team to provide assured results.
5. Disseminator’s role (Transfer information to higher & lower ends): The project manager
transmits the relevant information received from external sources and internal systems to the
concerned people in the work place. This information may be written or verbal, formal or
informal.
6. Spokesmen's role: The project manager acts as the sole representative through whom all
communications with the client or other external parties are conducted outside the project
site.

7. Entrepreneur's role (Identifies opportunities to promote to improvements): The project

manager seeks and identifies opportunities to promote improvements and needed changes.
8. Disturbance handling role( The PM resolves conflicts ): The project manager maintains
organizational harmony by resolving conflicts and diagnosing organizational behavior an
time. He applies corrective action when the organization faces important unexpected
disturbances.
9. Resource allocator role : The project manager takes responsibility for allocating/ altering
the project resources and .makes any changes which are necessary to ensure the availability
of adequate resources on time. This role also calls for developing and monitoring budgets
and predicting future resource needs.
10. Negotiator’s role: The project manager negotiates important conflicting issues and
business related matters, both inside and outside of the project environment. He represents
the organization on major negotiations.
Project Mission
The project manager aims to achieve its mission by:
Managing
• Time & progress
• Cost & cash flow
• Quality & performance
• Organization behavior
With  Organization resources by

• Planning resources
• Scheduling resources
• Organizing resources
• Directing resources
• Monitoring resources
• Controlling resources
Within
• Quality constraints
• Time constraints
• Cost constraints
• Environment constraints

Why Projects Fail?

 Failure to align project with organizational objectives
 Poor scope
 Unrealistic expectations
 Lack of executive sponsorship
 Lack of project management
 Inability to move beyond individual and personality conflicts
 Politics.
Project Success Factors

 Project Mission: Initial clarity of goals and general direction.
 Top Mgt Support: Willingness to provide necessary resources and authority / power for
project success.
 Project Schedule/Plans: Detailed specification of steps for project implementation.
 Client consultation: Communication and consultation with and active listening to all
affected parties.
 Human resources: Recruitment, selection and training of necessary personnel for the
project team.
 Technical tasks: Ability of required technology and expertise to accomplish specific
technical action steps.
 Client acceptance: The act of „selling‟ the final project to the intended users.
 Monitoring and feedback: Timely provision of comprehensive control information at
each stage of implementation process.
 Communication: Provision of an appropriate network and necessary data to all key
actors in the project implementation.
 Trouble shooting: Ability to handle crisis and deviations from the plan.

CHAPTER 8. MAINTAINANCE OF SITE DOCUMENTS
List of documents to be maintain at construction project
Latest approved construction programs/schedule & review records.

Detailed layout Plan.
Copy of Contract Documents.
Bar charts/CPM charts.
Works site Order Book.
Works Diary.
Measurement Book.
Valid justification reports for delay if any.
Vendor/sub-contractor evaluation.
Availability of test certificates for all material.
Training records.
Following inspection and testing plans.
All audit reports (client/internal-safety & quality).
Non-conformance reports and its compliances.
Site management review meeting records.
Plant preventive maintenance records.
Design review/validation/change records if any
Wastage control measures & scrap handling.
Accident/incident reporting.
Analysis on audit results/concrete results/plant break-down.
Control of non-conforming products (rejection of material/process).
Valid indent & its approval/comparative statement/product verification
Micro planning records.
Document/drawing controls.
Storage and preservation of materials/documents.
Servicing/repairing documents-(workshops).
Plant transfer or surplus plant declaration record.
Review of quality plan/ABC analysis/control estimate.
ERP entry/validation/ledger posting/status.

CHAPTER 9. ADMINISTRATION/MANAGEMENT
9.1. Site Organization Chart
9.2. Responsibilities
9.2.1. Regional Manager
Co-ordination, monitoring the project under region.

Identify new projects and preparation of estimate and helping in winning this project.
Periodic management, review meeting to ensure profitability, centralize wastage and
optimum utilization of resource.
Impart training to staff and develop culture and right attitude towards work at site.
Create Gammon brand by constant interaction with prospective agency.
Bring about innovation and periodic changes to improve the system.

9.2.2. Project Manager
To achieve projected cash margin.

Resolving the issue w.r.t client, govt bodies and PRW/contractor at his level.
Team building.
Inventory of resources and plant.
Housekeeping and save environment of work.
MIS system implementation.
8.2.3. Section In-charge
To create team plan and execute this work under section within time, budget and
specification.
To create safety awareness and impart daily training w.r.t work hazards and its precaution
and maintaining housekeeping.
To provide time to time information as per MIS requirement to I/C and planning in required
format.
To carry out periodic analysis of various expenses and wastage and to improve upon on
each stage by 10%.
Maintain and update all records at site as per system.
To provide proper guidance to subordinate and sub-contractors.
8.2.4. Engineers
To study and prepare salient features, Qty, schedule of work.

To maintain day to day log book regarding work and measurement book.
To provide time to time information as per MIS requirement to I/C and planning in required
format.
To implement various procedure and QA and safety plan at site.
Maintain proper housekeeping and material reconciliation.
8.2.5. Store Keeper
Proper material management at site includes vendor identification, timely collection of

quotation, timely placement of orders and receiving material as per specifications and
maintaining records thereof.
Proper housekeeping of stores and site.
Timely preparation of company‟s standard statements like ABC analysis, stock statement,
wastage analysis and IRN‟s.
Stage wise demobilization of the site by declaring the surplus material and dispatch of the
same to the respective site in proper manner.

CHAPTER 10. ACCOUNTING

Accounting systems form an integral part of any successful business. Proper
accounting not only helps the organization know its monitory worth, but also works as
leverage to climb the ladders of growth. A construction company is like any other company
and has many responsibilities towards their employees, customers, vendors, investors and
government. They are bound to answer questions or queries that are raised time to time.
Unless, they maintain a sound accounting procedure and proper reporting systems they
cannot fulfill these requirements.
The construction industry has some specific accounting requirements. Apart from
routine receivable and payable accounts, they need systems for project estimating, job
costing, overhead expenses, project schedules and contracts, project billing, vendor
tracking and invoicing, customer management, etc. A typical construction accounting
system includes accounts payable, job cost management, accounts receivable, payroll,
detailed job budgets, time and material billing, general ledger, AIA billing, subcontract
status, custom job reports, certified payroll, over and under billings, purchase orders, union
reports, inventory, equipment tracking, work in progress, etc.
In this computer age, there are many software packages available. Software
specifically developed for the construction industry incorporates their specific requirements
and are user-friendly and can be operated by the personnel with little computer knowledge.
Apart from fulfilling statutory requirements such as balance sheets, profit and loss accounts
for company and outside agencies like sales tax and customs departments, these packages
generate innumerable reports which would be very helpful in company's decision making
process.
Most of this accounting software covers four major areas of construction industries.
Accounting module covers, E.R.P, Tally , A/P, A/R, check writing, financial reports,
inventory, job costs, payroll, project billing, cost estimating module covers assemblies, as
well as unit costs, project management module includes change orders, contract writing,
material takeoffs, punch lists, schedules. Business management module deals with
appointments, customer relations, leads, property management, sales, etc.

CHAPTER 11. STORES MANAGEMENT
11.1 Definition of Material Management

Materials management is that process of management which co-ordinates, supervises
and executes the tasks associated with the flow of materials to, through and out of an
organization in an integrated fashion.
11.2 AIM OF MATERIAL MANAGEMENT (Objective)
To get
1. The Right quality
2. Right quantity of supplies
3. At the Right time
4. At the Right place
5. For the Right cost
11.3 Scope of Material Management

 Procurement (including Planning & Scheduling)
 Inspection & QC
 Stores & Inventory Control
 Transportation & handling
 Distribution (logistics)
11.4 Objective of material management

Primary
• Right price Secondary
• High turnover • Forecasting
• Low procurement • Inter-departmental harmony
• & storage cost • Product improvement
• Continuity of supply • Standardization
• Consistency in quality • Make or buy decision
• Good supplier relations • New materials & products
• Development of personnel • Favorable reciprocal relationships
• Good information system

11.5 PURPOSE OF MATERIAL MANAGEMENT

• To gain economy in purchasing
• To satisfy the demand during period of replenishment
• To carry reserve stock to avoid stock out
• To stabilize fluctuations in consumption
• To provide reasonable level of client services
11.6 CLASSIFICATION OF MATERIALS
11.6.1 Why should we classify materials?
 We deal with hundreds of different types of inventory items. With so many items,
complexity of managing the process increases.
 To manage these inventories effectively grouping is essential.
 Grouping together of materials of technical affinity is known as classification.
11.6.2 Classification can be based on various attributes:

 By size
 By names
 By values
 By end use
 By product category
11.6.3 ABC Analysis

Is a basic analytical management tool
 It enables management to place efforts where the results will be greatest.
 This technique is popularly known as Always Better Control.
 This technique tries to analyze the distribution of any characteristic by money value of
importance in order to determine its priority.
11.6.4 Principles of ABC analysis:
1. The analysis does not depend upon the unit cost of the items but only on its annual
consumption value.
2. It is independent of the importance of the item.
3. The limits of ABC analysis are not uniform but depend upon the size of the undertaking,
its inventory as well as the number of items controlled.

Applications of this technique
For:
 Inventory Control
 Criticality of items
 Obsolete stock control
 Purchase orders
 Receipt of materials
 Inspection
 Store-keeping
 Verification of bills
 Basis of ABC analysis
 This technique is based on Pareto’s Law ( an Italian Economist) which states the rule of
80:20.
Based on the principle that:
- FEW ARE VITAL

- MANY ARE TRIVIAL
This aims to direct efforts where results are important.
“Use of ABC analysis”
Helps in rationalizing the number of orders and reduce the overall inventory even though
overall purchase orders are the same, the average inventory can be reduced substantially.
Steps for classifying the items into A,B,C categories.

1. List out all the items in the inventory.
2. Ascertain the unit cost of each of the items.
3. Ascertain the number of units issued in a year. Assumption: Issues and consumption are
the same.
4. To obtain the annual consumption value multiply the unit cost of each item with the
number of units issued in a year.
5. Sort the list of consumption value of each item in the descending order.
6. Starting at the top of the list compute the cumulative total of the rupee consumption value.
7. Compute for each item the cumulative percentages for the item count and cumulative
annual value.
This is based on cost criteria.
It helps to exercise selective control when confronted with large number of items it
rationalizes the number of orders, number of items & reduce the inventory.
About 10 % of materials consume 70 % of resources

11.7 PURCHASING
What is purchasing? : Purchasing is a service function
Definition
 Purchasing implies the act of exchange of goods and services for money.
OR
 Purchasing is the process of buying - learning a need , selecting a supplier , negotiating a
price and fixing the terms of delivery and payment.
11.7.1 Basic objectives of Purchasing
1. To maintain continuity of supply to support construction schedules.

2. To ensure minimum investment in stores and materials inventory, consistent with supply and
economy.
3. To avoid duplication of purchases and costly delays.
4. To maintain proper quality standards based on suitability criteria.
5. To procure materials at lowest possible cost, consistent with quality and service requirement.
6. To maintain company‟s competitive position in the market by controlling material costs.
11.7.2 Purchase Procedure

1. Purchase Requisition or Indent from user.
2. Verification of current stock levels by the Stores department.
3. Assessing exact procurement required with detailed specifications.
4. Enquiry / RFQ.
5. Evaluation of Bids received preparation of comparative statement.
6. Negotiations.
7. Placing of the Purchase Order.

11.7.3 Requisition/ indent – key information check list

1. Date & time
2. Material Description
3. Detailed specification, standards or make.
4. Quantity
5. Suggested supplier
6. Purpose
7. Approximate date when required
8. Originating department
9. Authorisation
11.7.4 Purchase Order - definition

A purchase order is a buyer-generated document that authorizes a purchase transaction.
It sets forth the descriptions, quantities, prices, discounts, payment terms, date of performance
or shipment, other associated terms and conditions, and identifies a specific seller.
When accepted by the seller, it becomes a contract binding on both parties. Also called order.
11.7.5 Purchase Order – key information check list

1. P.O. reference no.
2. Date
3. No. of copies
4. Quotation / Offer for supply ref.
5. Description of material
6. Detailed specification – detailed description of characteristics, blue print, drawing, market
grades, brand names or trade names, commercial standards, preference characteristics.
7. Quantity required.
8. Delivery schedule.
9. Price and discounts + taxes and duties.
10. Packing Instructions.
11. Shipping instructions.
12. Place of delivery (Location where material required).
13. Detailed terms and conditions - vendor rating.
14. Payment terms.
15. Price variation / escalation or reduction.
16. Exit terms – order cancellation

11.8 STORES FUNCTIONS

 To receive goods – raw materials, components, tools & equipments and other items and
account for them.
 To provide adequate and proper storage and preservation of the goods in store.
 To meet the demands of the consuming departments.
 To minimize obsolescence, surplus and scrap.
 To highlight stock accumulation, discrepancies, abnormal consumption and effect control
measures.
 To ensure good housekeeping
11.8.1 Design factors for good stores management

 Location – ideally should be as near to the point of consumption as possible so as to
reduce handling and to have timely despatch.
 Layout – should ensure easy movement of materials. Ensure easy retrieval,
ergonomically.
 Sufficient space (for men and material handling equipment) shelves, racks, pallets.
 Proper preservation – rain, light, heat, cold storage, air conditioning.
 Lighting – adequate lighting is essential
 Safety - training safety consciousness, safety appliances, Personal Protective
Equipment (PPE)
 good house keeping
 keep stores equipment in good order, forklifts, cranes, trolleys, conveyors.
 fire fighting equipment
 toilets
11.8.2 Specific Functions of a Store.

A. Receipt
B. Stocking
C. Issues
A) .RECEIPT SYSTEM
Receipts into the organisation or store come from many sources:
a. From outside suppliers
b. From rejected stores
c. From surplus stores
d. From scrap generated
e. From empties
f. From stock transfer from other project sites

 The Receipt system of a store starts much before the actual receipt of materials at the
store. This requires proper planning in advance.
 The Purchase order indicating quantity and delivery date is the starting point. Records
should be maintained in a chronological order to show expected daily receipts. So that
the handling and storage can be planned in advance.
 This helps in planning labour contracts for uploading, stocking etc. and when to take
delivery – demurrage.
 Suppliers send despatch note or advise note to the stores in advance – i.e. Date of
despatch, carrier details, description, value etc.
 Document of transport department – LR/RR or consignment note
 Packaging slip detailing contents in the package.
 Insurance
Actual physical receipts (delivery challan –
a. Verification for quantity, shortages, damages, claims preference.
b. Take open delivery with transporters get shortage or excess or damage endorsed.
Provisional Goods Inward (PGI) – physically received, pending inspection note/report.
Final goods inward note (FGI)
INTERNAL RECEIPTS – transfer note/ return to stores, stock transfer (no sale),
Debit/Credit note, Internal DC (delivery challan) . Where to integrate the quality inspection
dept?
B) .STOCKING
Sorting and storing issues
 when volumes are high, provide separate areas for:-
1) Stores awaiting inspection.
2) Stores which are QC inspected, passed and accepted for use.
3) Storage of rejected materials.
( FG not applicable to construction activity directly)
C) .ISSUES
 For consumption by internal departments as per order or indent.
 To works on returnable basis.
 To outside suppliers for processing or conversion.
 For stock transfer to other divisions or project sites.

11.9 STORES ACCOUNTING

Any inventory item has both physical and financial characteristics. Whereas the physical
characteristics (flow of goods) are factual and measurable, financial characteristics (flow of
costs) are mainly subjective in nature. The financial characteristics associated with the flow of
costs are usually emphasized in stores accounting and valuation.
WHY STORES ACCOUNTING?

Stores accounting plays a very important role for the estimation of the cost of a product for
pricing decisions. Material costing is very important in terms of the valuation of the cost of
materials consumed by say, the production department during a given period of time as well as
in terms of the estimation of the value of materials held in stock. In this context, two important
aspects, viz., costing of the materials receipt and of materials issue, are considered in stores
accounting.
1. Costing of the Receipt of Materials

The factors that are to be included in building up the cost of the materials received are
material price, freight charges, insurance, and taxes. Price usually refers to the price
quoted and accepted in the purchase orders. Prices may often be stated in various ways,
such as net prices, prices with discount terms, free on board (FOB) and cost insurance
and freight (CIF). For costing purposes the actual cost incurred needs to be calculated by
taking price quoted by supplier as the basis, subtracting the discounts and adding any
other expenses not covered.
2. Costing of the Issues of Materials to Production
There are several methods that are in use for costing the issues of materials to the
production and other departments of an organization. First in first out (FIFO), last in first
out (LIFO), average cost, standard cost, base stock method, market price at the time of
issue, latest purchase price, and replacement or current cost methods are a few of the
methods used for this purpose.
Material Costing : Is important for
1) Valuation of the cost of materials consumed, and

2) Estimating the value of materials held in stock. - at various stages

11.9.1 FLOW OF COSTS (or) Pricing material issues

1) ACTUAL COST METHOD.
2) FIFO – FIRST-IN-FIRST-OUT
3) LIFO – LAST-IN-FIRST-OUT
4) HIFO – HIGHEST-IN-FIRST-OUT
5) SIMPLE AVERAGE COST METHOD
6) WEIGHTED AVERAGE COST METHOD
7) PERIODIC AVERAGE COST METHOD
8) STANDARD COST METHOD
9) REPLACEMENT COST METHOD (MARKET PRICE METHOD)
10) NIFO – NEXT-IN-FIRST-OUT METHOD
11) BASE STOCK METHOD

CHAPTER 12 CONSTRUCTION SAFETY
Safety Officer Responsibilities

COMMON RESPONSIBILITIES
The following responsibilities apply to all ICS personnel:

1. Receive assignment, notification, reporting location, reporting time, and travel instructions
from your home agency.
2. Upon arrival at the incident, check in at designated check-in locations. Check-in locations
may be found at: Incident Command Post, Base or Camps, Staging Areas, Helibases,
Division Supervisors (for direct line assignments).
3. Agency representatives from assisting or cooperating agencies report to Liaison Officer at

4. The Command Post after checking in.
5. All radio communications to Incident Communications Center will be addressed:

"(Incident Name) Communications".
6. Use clear text and ICS terminology (no codes) in all radio transmissions.
7. Receive briefing from immediate supervisor.
8. Acquire work materials.
9. Organize, assign, and brief subordinates.
10. Complete forms and reports required of the assigned position and send material through
supervisor to Documentation Unit.
11. Ensure continuity using in/out briefings.
12. Respond to demobilization orders.
13. Brief subordinates regarding demobilization.

A N N E X U R E - I
HAZARD & RISK / CONSEQUENCE IDENIFICATION FOR A FEW

ACTIVITIES IN CONSTRUCTION INDUSTRIES
S.No Activity Hazard Consequences / Risk
1. Excavation (1) Dusts generation Dust Ellergy, Asthama

Exposed to dust, inhalation
(2) Caving in (burying in of person) Injury, Death if a person goes

under high debris / earth.
2. Rock blasting (1) Dust generation (exposure to Dust Ellergy, Asthama,

dust inhalation.
(2) Noise Generation (Exposure to Deafening, Permanent loss of

high noise) hearing.
(3) Hitting by materials Injury / Death
3. Reinforcement Dusts / rusts / Paints / Oils Eye Injury

generation, spreading
a) Cleaning of causing eye injury
bars from (Contact with these materials)
grease, oil, paint,
Dust inhalation
rust, dust Ellergy, Asthama
b) Cutting, 1) Flying of pieces, (Hitting) Injury

bending
2) Hammer not falling correctly on
chisel Injury
c) Bending of Hitting by wire or reinforcement Injury to eye or body.

reinforcement

S.N Activity Hazard Consequences / Risk

o
4. Brick Works Falling of bricks Injury
a) Brick
transport (If
manually
b) Mixing of Dust generation (Inhalation) Dust Ellergy, Asthama

mortar
c) Transport of Falling of mortar / container Injury to leg.

mortar
5. Curing with Water sprinkling back in eyes Eye Injury

water spray (Water splash in eyes)
6. Roofing
(ACC / GI / AC)
a) Handling Falling of sheets (Falls from 1) Injury

shifting & lifting height)
2) Damage to sheets.
b) Roofing fixing Tools falling / damaging hands Injury

– bolting, nailing etc…
Contact with ACC sheet leads to 3) In case of ACC, Skin
skin disease. disease may be there.
7. Fabrication: Falling of materials Injury
a) Loading /
Unloading of
materials
b) Welding Welding rays effecting eyes Eye damage, cancers.

SPECIAL THANKS TO
Sr No. Name Designation Project Site
1 Mr I. S. Mane Regional Manager Malwa NDCT & CHIMNEY

2 Mr A. K. Dey Project Manager Malwa NDCT & CHIMNEY
3 Mr R. N. Rai DM-I Malwa NDCT & CHIMNEY
4 Mr Parvindra Tyagi DM-II Malwa NDCT & CHIMNEY
5 Mr Jayant Mankar AM-II Malwa NDCT & CHIMNEY
6 Mr Vishal S. Kuwar AM-II Malwa NDCT & CHIMNEY
7 Mr Vyankatesh Y AM-II (Safety officer) Malwa NDCT & CHIMNEY
8 Mr Milind Gaikwad AM-II Malwa NDCT & CHIMNEY
9 Mr Swapnil Galave AM-II Malwa NDCT & CHIMNEY
10 Mr Vaibhav A. Tungirwar AM-II Malwa NDCT & CHIMNEY
11 Mr Vinay Cheerala AM-II Malwa NDCT & CHIMNEY
12 Mr Shubham Gupta Engineer Malwa NDCT & CHIMNEY
13 Mr Aniruddha Joshi Engineer Malwa NDCT & CHIMNEY
14 Mr Rakesh Parihar Engineer Malwa NDCT & CHIMNEY
15 Mr Rahul Ruikar Engineer Malwa NDCT & CHIMNEY
16 Mr Gajanand Tiwari AM-II Malwa NDCT & CHIMNEY
17 Mr Sourav Chatterjee Exe. Accounts Malwa NDCT & CHIMNEY
18 Mr Arabinda Jena Asst. Accounts Malwa NDCT & CHIMNEY
19 Mr Chodhury S Store Officer Malwa NDCT & CHIMNEY
20 Mr Soumya Ranjan Store Asst. Malwa NDCT & CHIMNEY
21 Mr Niranjan Swain Supervisor Safety Malwa NDCT & CHIMNEY
22 Ms Sunil Mahadik Project In-charge Bhusaval NDCT & CHIMNEY
23 Mr Ajay Singh Admin & Accounts Bhusaval NDCT & CHIMNEY
24 Mr Shailesh Rakhonde AM-II Bhusaval NDCT & CHIMNEY
25 Mr Jagdish Sarda AM-II Bhusaval NDCT & CHIMNEY
26 Ms Renu Upadhyay Engineer Bhusaval NDCT & CHIMNEY
27 Mr Devidas Sapkale Engineer Bhusaval NDCT & CHIMNEY
28 Mr Vishnu Priyan Engineer Bhusaval NDCT & CHIMNEY
29 Mr Bhushan Sukhode Engineer Bhusaval NDCT & CHIMNEY
30 Mr Prasad Asst.Store Bhusaval NDCT & CHIMNEY
31 Mr Komal Management Trainee NICMAR Pune

NICMAR PGP-ACM, 23RD BATCH, HYDERABAD CAMPUS.
CONTACT US:
1. T.SHREEDHAR,
H.NO 18-13-9-65-A2,
BANDLAGUDA,
PO; KESHAVA GIRI,
HYDERABAD.
ANDHRA PRADESH-500005.
Email: shree0605@gmail.com
a. : er.shreedhar@gmail.com
Tel : +91 9052445996
2. AMOGH SHRIVASTAVA,
IN FRONT OF CCF BUNGLOW,
NEAR PTC GROUND,
GOPALGUNJ,
SAGAR,
MADHYA PRADESH-470001.
Email: amogh.k.shrivastava@gmail.com
: amogh_0999@rediffmail.com
Tel : +91 9926352999

4th Term - Summer Training Report at Nicmar Hyderabad

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SUMMER INTERNSHIP REPORT

CONSTRUCTION OF NATURAL DRAFT COOLING TOWER (NDCT) & CHIMNEY

GAMMON INDIA LIMITED

AMOGH SHRIVATSAVA T.SHREEDHAR

NATIONAL INSTITUTE OF CONSTRUCTION MANAGEMENT & RESEARCH

which this endeavor would not have been possible.

We profoundly express our gratitude to Mr. R.N.Rai(D.M-I), Executive In-Charge of

SINGAJI THERMAL POWER PLANT, KHANDWA,M.P, for their wholehearted co-operation,

which made our summer training comfortable and successful.

AMOGH SHRIVASTAVA T.SHREEDHAR

This is to certify that Mr. Amogh Shrivasatava R.No: 233004 and

Mr.T.Shreedhar, R.No: 233084 students of NATIONAL INSTITUTE OF CONSTRUCTION

MANAGEMENT AND RESEARCH (NICMAR),HYDERABAD have successfully completed

guidance and supervision at 2x600MW SHREE SINGAJI THERMAL POWER PLANT,

STAGE-I, KHANDWA, MADHYA PRADESH.

For Gammon India Ltd.

Chapter No. Contents Page No.

6 Construction Site Organization & Management 115

7 Project Management 123

8 Maintainance of Site Document 134

11 Store Management 138

CHAPTER 1: COMPANY PROFILE

"Reaching out to heights of excellence"

“Excellence built on the foundations of perfection”

Nicmar Hyderabad. Page 2

1.3 GAMMON MISSION, VISION & QUALITY POLICY

Nicmar Hyderabad. Page 3

1.4 MANAGEMENT TEAM

Mr. Peter Gammon (Chairman Emeritus)

As on 31st March 2009

1. Gammon Infrastructure Projects Ltd. GIPL

Nicmar Hyderabad. Page 4

1.7 OUR CLIENTS

Delhi Metro Rail Corporation Limited

Nicmar Hyderabad. Page 5

1.8 HEALTH, SAFETY AND ENVIRONMENT

1.9 AREAS OF SPECIALISATION:

Transportation Engineering Projects

 Bridges - River/Creek Bridges,

 Thermal Power stations.

 Natural draft Cooling Towers.

 Counter flow Cooling Towers.

 River Valley/Irrigation Projects

Major Buildings, Industrial & Commercial Structures

 Jetties, Wharfs, Berths

Ground Engineering Works

 Water Treatment Plant

 Effluent Treatment Plant

 Integrated Water Supply Project

 Oil & Gas

Nicmar Hyderabad. Page 7

1.10 CURRENT PROJECTS

Group-3 Job List

1 8107 Parbati HE stage 2 ABB SNN

2 8208 Sewa HEP ABB SNN

4 8437 Parbati HE stage 3 ABB SNN

5 8525 Rampur HEP ABB SNN

6 8735 Bhutan HEP ABB SNN

7 8303 Kalpakkam (All Jobs) BRKN PPA

11 8715 Bellary NDCT-2 GSP AN

12 8716 Tiroda Chimney GSP PAS

13 8717 Tiroda Civil Works GSP PAS

16 8820 Tuticorin Civil Works GSP AN