Method Statement - 20 Bridges

Page 1 of 109
METODOLOGY FOR MAJOR ACTIVITIES IN

20 BRIDGES ON NH-60 PACKAGE OR/WB-I
A. Table of contents for BR-38/1 [Subarnareka]
1. LAYING CUTTING EDGE...........................................................3
2. WELL CURB:.............................................................................7
3. WELL STEINING......................................................................10
4. WELL SINKING:.......................................................................13
5. BOTTOM PLUGGING & INTERMEDIATE PLUGGING...........16
6. WELL CAP:..............................................................................19
7. ABUTMENT WALL & CAP, PIER CAP....................................21
8. PSC Beam Casting , Stressing & Grouting...........................33
9. LAUNCHING & SIDE SHIFTING OF PSC BEAMS.................46
9. LAUNCHING & SIDE SHIFTING OF PSC BEAMS.................47
10. DIAPHRAGM & DECK SLAB CASTING...............................57
11. CASTING OF VOID SLAB.....................................................65
12. INSTALLATION OF EXPANSION JOINTS............................70
B. OPEN FOUNDATION........................................................................74
C. BORED CAST IN SITU PILES..........................................................78
D. PILE CAP CONSTRUCTION (for ROB-4)........................................81
E. CONSTRUCTION OF EMBANKMENT.............................................85
F. STONE PITCHING IN EMBANKMENT SLOPES..............................90
G. REINFORCED EARTH WORK.........................................................92
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PROCESS INVOLVED IN CONSTRUCTION OF

MAJOR BRIDGE SUBARNAREKA [BR-38/1]
SALIENT FEATURES OF SUBARNAREKHA BRIDGE (BR
38/1) IS AS FOLLOWS:
Foundation type : Well foundation
Shape
: Circular
Substructure (RCC)
: Well cap, Pier, Pier cap, Abutment,
Abutment cap
Superstructure : 11 spans of PSC Beam of length 48.7 M
2 spans of RCC Voided slab at the ends
Span details
: 1x20.5 + 11x48.7 + 1x20.5
Total Length
: 576.7 M
The detailed construction methodology for Laying of Cutting edge and Curb
concreting is as follows:
1. LAYING CUTTING EDGE

PRELIMINARY SURVEY:
The preliminary survey has been carried out with reference to existing
Subarnarekha Bridge taking 40 M c/c distance on down-stream side to carry
out confirmatory boreholes.
As per general condition of contract (Ref. Page No:- 5 of 96), it has been
decided to take one no of confirmatory bore holes at each location of
foundation. Detailed method statement for confirmatory boreholes shall be
submitted separately.
DETAILED SURVEY:
A traverse has been closed referring control point C-2 & 36 Km. Stone and
subsequently C/L of proposed bridge has been established.
The survey scheme shall be enclosed for reference. The reference pillars
have also been made @ Balasore & Jaleshwar end for further reference.
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LIST OF PLANT & MACHINERY SHALL BE DEPLOYED FOR
FABRICATION AND CONCRETING:
FABRICATION MACHINERY:
i) Welding Transformer
ii) Drilling Machine (pedestal)
iii) Drilling Machine (Magnetic)
iv) Cutting Set
v) Grinder
vi) Welding Generator(Electric)
vii) Power Generator (60 KVA)
viii) Welding cables, Holder etc
ix) Hydraulic Jack 50 T
- 5 Nos.
- 2 Nos.
- 1 No.
- 2 Nos
- 2 Nos
- 1 No.
- 1 No.
- 4 Set
- 1 No.
CONCRETING MACHINERY:
i) Batching Plant ( 30 Cu.M./ hr)

- 1 No
ii) Crane & Bucket
- 1 No
iii) Transit Mixer ( 6 Cu.M./ 4 Cu.M)
- 2 Nos
iv) Concrete Tremie & Funnel or chutes
- 2 Nos ( In 4 quadrants
of well)
v) Immersion type Vibrator (Electric)
with 60mm needle
- 3 Nos
vi) Cube moulds
- 30 Nos
vii) Slump Cone
- 1 No
viii) Immersion type thermometer (metallic) - 1 No
(for noting ambient temperature and relative humidity)
ix) Generator ( 55, 110 KVA)
- 1 No
x) Water Pump 5 HP
- 2 Nos
xi) HM Loader
-1 No
LIST OF MANPOWER
Supervisory Staff:
Project Engineer
Assistant Engineer
Senior Engineer
Foreman
OTHER STAFF:
i) Q.C.Engineer - 1 No
ii) Supervisor (Civil)
- 1 No
iii) Foreman (Mech)
- 1 No
iv) Electrical Foreman
- 1 No
1 No
- 2 Nos
- 1 No
- 1 No.
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v) Electrician
- 2 Nos
vi) Mechanic
- 4 Nos
vii) Mechanical Helper- 2 Nos
viii) Store keeper - 2 Nos
ix) Purchase Officer
- 1 No
x) Store Helper - 3 Nos
SKILLED / UNSKILLED LABOURS:
i) Gas Cutter
- 4 Nos.
ii) Fitter - 3 Nos.
iii) Welder - 8 Nos.
iv) Khalasi- 8 Nos.
v) Mason - 8 Nos
vi) Q.C.helper
- 2 Nos.
vii) Unskilled labors 60 Nos.
CUTTING EDGE:
It is circular in shape and it is the bottommost component of the foundation
made up of structural steel plates. It is provided for cutting the soil strata
coming below the well during sinking operation. It also accelerates the
process of sinking.
MATERIAL PROCUREMENT:
Materials required for the fabrication of cutting edge shall be procured from an
authorized supplier and the same shall be received at the site fabrication yard.
RECORDS/DOCUMENTS:
Test Certificates of Structural Steel procured shall be submitted for each
consignment received at site.
The received material shall be fabricated as follows:
FABRICATION OF CUTTING EDGE:

The MS Cutting Edge shall be fabricated from structural steel sections as per
drawings.
Cutting edge for 8m & 9m dia wells shall be fabricated in 5 parts
Fabrication shall be carried out at fabrication yard at Subarnarekha bridge site
over a rigid platform.
METHODOLOGY FOR FABRICATION OF CUTTING EDGE:

In order to ensure accuracy, fabrication templates, zigs, calibrated steel tapes
& other appurtenances shall be used.
First MS plate of 12 mm thick shall be cut for 300mm width by Manual Flame
cutting method
The edges of the plates shall be made smooth and regular by removing slags
with the help of chipping hammer.
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The smoothened plate shall be bent using 50t hydraulic jack for the required
curvature.
Similarly, ISA 150X150X10 shall be cut and bent with Zig hudraulic jack to the
required curvature.
A lay out shall be made on fabrication sheet floor for welding the plates with
angles. Fillet welding shall be done using Esab Ferroking Electrodes of size
4x450mm (6013 ) conforming to IS 814.
After completion of first run, welding surface shall be chipped off by chipping
hammer and followed by second coat of welding to get the specified thickness
( 8mm/6mm)
8mm thick stiffeners plates shall be welded with a spacing of 700mm c/c in
position to the cutting edge with the specified shape as per drawing.
The whole cutting edge can be split in to 5 segments and all the segments
shall be assembled over a platform to check the diameter of cutting edge.
Holes of 17.5mm dia shall be made on the angle at a spacing of
300mm c/c with magnetic drill
Cross bracing made of ISMC channel shall be put in position on each
segment to prevent bent/ovality.
Joint number shall be assigned and all the segments shall be taken to site for
in situ welding.
RECORDS/DOCUMENTS:
Progress Card for structural fabrication
Checklist for structural fabrication
SAFETY MEASURES:
Welder shall be provided goggles for eye protection and protective clothings.
It shall be ensured arc welding cables are completely insulated, flexible and
capable of handling the maximum current requirements of the work in
progress and free of exposed cuts.
ISLAND:
Making an artificial Island to provide a dry surface for placing the cutting edge
therein and carrying out further operation as per sinking on ground. This
method can be adopted in water where depth varies from 2 to 6m depth which
is stagnant or flowing water.
ERECTION OF CUTTING EDGE:

The fabricated parts shall be taken to the location and segments of cutting
edge shall be erected over leveled and firm ground and wherever situation
arises over Island. The segments of cutting edge shall be laid at the existing
ground level or 300mm above prevailing water level in case of an Island over
wooden sleepers placed below the cutting edge at spacing of 500mm c/c .
Prefabricated segments of cutting edge shall be laid over wooden sleepers
and after keeping it in true level and alignment, the in-situ welding shall be
done as per MOST specification with Esab Ferroking rods size 4x450mm
(6013). The segments shall be spliced by fillet welding of a single cover plate
of size 400 x 280x12 mm at the junctions (in the outside periphery) of 300mm
width MS Plate. The angle sections shall be spliced by fillet welding at the
junctions of segments (in the inside periphery) with a rectangular plate of size
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295 x 120x12mm.The splices shall also be made as per MOST requirement
using cover plates (280x400x12), wherever it is necessary.
2. WELL CURB:
SHUTTERING MATERIAL:
For 9m Curb Inside shuttering shall be of timber and the outside shuttering
shall be of steel shuttering plates.
For 8m Curb both Inside and outside shuttering shall be of steel shuttering
plates.
ERECTION OF INSIDE SHUTTERING OF CURB:

Inside shuttering shall be of 9mm (minimum) thickness to avoid warping and
easy placing of units.
Before fixing inside curb shuttering, it shall be ensured that the center of
assembled cutting edge matches with the center of foundation surveyed
earlier.
Prefabricated curb shuttering shall be erected and supported by wooden
battens / ballies of which one side shall rest upon the cutting edge by bolting
arrangements.
ANTI CORROSIVE COATING OF REINFORCEMENT:

Reinforcement Bars shall be procured from authorized agency
(SAIL/TISCO/RINL or authorized agency etc) and it is taken to treatment
yard.. Anti Corrosive treatment by CPCC method shall be done at the yard &
shall be shifted to site for fixing.
FIXING OF REINFORCEMENT IN CURB:
CPCC Treated Reinforcement bars shall be cut and bent as per approved Bar
Bending Schedule and also washers & GI binding wires shall be used for tying
in position. Outside treated & threaded vertical bars shall be bolted and fixed
with the cutting edge as per drawing with two nos. of nuts and metal washers
as per MOST relevant clause and there after the stirrups and other inside
reinforcement bars shall be fixed as per drawing and specification. Coating
repair shall be done if required when peeling off and other damages occur
during fabrication or handling by using same coating materials.
ERECTION OF OUTSIDE SHUTTERING:

After completion of reinforcement fixing work, outer shuttering will be erected
on clit angles of 65x65x6-150mm long welded to the cutting edge and the
same will be bolted by M12 bolts at bottom at 610 c/c. Shuttering component
will be tied around by 2 nos. of 16mm dia wire rope with turn buckles (@
900mm c/c). Top radial support will be provided for maintaining uniformity of
the well dimensions. Stay bolts (J) MS12mm dia 600 c/c will be fixed on top
channel for resting 1st lift Steining shuttering on inside faces.
INSPECTION AND CHECKING:
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After completion of fixing of reinforcement and shuttering work, the curb shall
be inspected and checked as per drawing, specification and checklist formats
as mentioned below. For inspecting and movement of supervising staff, a
detachable inspection deck with guardrails shall be provided at the top of the
well curb/ Steining level. After completion of casting, the whole unit
comprising several segments shall be detached for reuse in the next lift of
casting.
DOCUMENTS/RECORDS
Checklist for reinforcement
Steel Register
Checklist of Staging and Formwork
CONCRETING OF CURB:
MIX DESIGN:
The grade of Concrete M-35 using 20mm aggregate shall be produced as per
the method statement submitted earlier.
TESTING OF MATERIALS:
The suitability of ingredient materials of concrete shall be tested at the Quality
control laboratory and shall be approved by Engineer as per specification.
PRODUCTION OF CONCRETE:
The concrete shall be produced by computerized SMM-40 batching plant
having capacity of 30 cum. per hour at Subarnarekha Bridge Site.
The established Batching plant shall be calibrated and got checked by
Engineer well before commencement of production of concrete.
TRANSPORTATION AND PLACING:

The concrete shall be transported from batching plant to the location by
means of Transit Mixer having capacity of 4/6 cubic meter. Before placing of
concrete, Concrete pour card shall be submitted. The placing of concrete
shall be done over a well-prepared surface by crane bucket arrangement
providing chutes/hopper. Alternatively, concreting may also done manually
maintaining following sequence:
Detachable firm walk way/ ramp will be made ready for placing of
concrete manually.
Fresh Concrete will be poured over a rigid platform beside ramp.
The same will be delivered manually over the hopper using iron pan.
The placed concrete shall be compacted properly with the help of immersion
type needle vibrator having 60mm dia. Finally top of the concrete surface shall
be roughened and the key block shall be left over to have a proper
construction joint with Steining well. All the concrete shall be done in one
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single operation. If concreting is carried out at night, sufficient flood lighting
arrangement shall be provided for smooth functioning.
Concrete Quantity well Curb:
Pier well
= 59.25 cum
Abutment well
= 66.67 cum
PROPOSED TIME FOR COMPLETION OF WELL CURB:

Pier Well
= 8 hours
Abutment well
= 9 hours.
for abutment S1 S5 lifts = 2.625 M and the final lift S6 = 2.245M.
for Pier well Steining there shall be S1-S7 lifts= 2.615 M and the final lift shall
be 0.885 M
QUALITY CHECKS:
SLUMP TEST:
Slump shall be taken continuously for first 3 loads and thereafter slump shall
be taken periodically as directed by engineer at site. The same shall be
recorded in slump and temperature register.
CUBE TEST:
Cubes of size 150x150x150mm shall be taken. Number of cubes shall be
taken as per Table No.1700 in most specification. The same shall be tested at
the Q.C.lab for 7 days strength and 28 days strength and it will be entered in
the cube test register.
REMOVAL OF SHUTTERING:
Outside shuttering plates shall be removed after 24 hours and inner shuttering
plates shall be removed after 72 hours.
CURING:
Bore well/River water shall be used for curing.
If river water is used for curing, also it shall be tested for quality in the lab, to
ensure that curing water would not effect the coloration and quality of concrete
surface.
Necessary pipeline arrangement shall be provided for carrying water for curing
the structures.
Hessian cloth shall be tied all over the periphery of the wells for continuous
curing.
SAFETY MEASURES:
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Technical personnel and workers are engaged during concreting operation
both at batching plant and Site shall be equipped with helmets, and safety
shoes shall be provided to masons and khalasis engaged for vibrator
operations.
There shall be safety signs painted on boards displayed at
locations at the time of work with barricading / fencing to bar outsiders
entering the area. There shall be security guards posted at suitable locations.
For night concreting, sufficient flood lighting as appropriated shall be provided
with red light danger signs at vantage locations. First Aid Counter shall be
maintained separately in stores throughout the working hours.
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3. WELL STEINING
WELL STEINING:
It is uniformly circular in shape and it completely rests over well curb.
STEINING OF ABUTMENT:
No. of Abutments
: 2 Nos.
Outside Diameter of well

: 9.0 M
Inside Diameter of well

: 6.5 M
Steining Thickness : 1.250 M

STEINING OF PIER:
No. of Piers
: 12 Nos.
Outside Diameter of well

: 8.0 M
Inside Diameter of well

: 5.4 M
Steining Thickness : 1.30 M

PLANT , MACHINERY AND MANPOWER PROPOSED TO BE DEPLOYED
FOR WELL STEINING & SINKING:
LIST OF PLANTS AND MACHINERY:
Crane RB 38
- 1 No.
Tata 320 crane
- 1 No.
Cu. Yd. Grab
- 1 No.
Dumper/Tipper
- 1 No.
Winch derrick arrangement
- 1 No.
MANPOWER:
Supervisory staff:
Project Engineer
Assistant Engineer
Sr.Foreman
- 1 No.
- 1 No.
- 2 Nos.
Other Staff:
Supervisor (Civil)
Supervisor (Mech)
Foreman ( Mech)
Electrician
Mechanic
Mechanical Helpers
SKILLED/UNSKILLED LABORS:
- 1 No.
- 1 No.
- 1 No.
- 2 Nos.
- 2 Nos.
- 4 Nos.
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Crane Operator - 2 Nos.
Sinking Khalasi - 30 Nos.
Masons
- 4 Nos.
Concreting labors
- 50 Nos.
The detailed construction methodology for Well Steining
MATERIAL PROCUREMENT:
Reinforcement bars of required diameter as specified in the drawing shall
be procured from authorized agency (SAIL/TISCO/RINL or other authorized
agency) Conforming to IS:1786.
DOCUMENTS/RECORDS:
Checklist for inspection of materials (Cement/Structural Steel/ Reinforcement
Steel)
ANTI CORROSIVE TREATMENT OF REINFORCEMENT BARS:
Reinforcement Bars shall be procured from authorized agency
(SAIL/TISCO/RINL or authorized agency etc) and it is taken to treatment
yard.. Anti Corrosive treatment by CPCC method shall be done at the yard &
shall be shifted to site for fixing.
FIXING OF REINFORCEMENT IN STEINING:
Treated reinforcement bars shall be cut and bent as per approved Bar
Bending Schedule .Outside threaded vertical bars shall be bolted and fixed
with the cutting edge at the time of laying of cutting edge. Thereafter other
reinforcement bars shall be fixed for the 1st lift of steining as per the drawing
with GI binding wires.
DOCUMENTS/RECORDS:
i) Checklist for reinforcement
SHUTTERING AND SUPPORTING ARRANGEMENTS:
Both Inside and Outside shuttering for Abutment well steining and Pier well
steining shall be fabricated to the required curvature by using MS plates of
3.15mm thick. And MSA 50X50X6.
Radial Supporting arrangement shall be done for Inside shuttering supporting.
DOCUMENTS/RECORDS:
Checklist for staging and Formwork
CONCRETING:
After completion of well curb concreting and thereafter deshuttering Inner and
Outer surfaces, gauge marking is to be done on the outer surface, taking
bottom of the cutting edge as 0.0 M. This marking shall be continued till top
level of concreting and further be done after deshuttering of each steining lift.
DOCUMENTS/RECORDS:
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i) concrete Register
MIX DESIGN:
The grade of Concrete M-35 using 40mm aggregate shall be produced as per
the method statement submitted earlier.
TESTING OF MATERIALS:
The suitability of ingredient materials of concrete shall be tested at the Quality
control laboratory and shall be approved by Engineer as per specification.
PRODUCTION OF CONCRETE:
The concrete shall be produced by computerized SMM-40 batching plant
having capacity of 30 Cu.M. per hour at Subarnareka Bridge Site.
The established Batching plant shall be calibrated once in a fortnight and got
checked along with Engineer.
TRANSPORTATION AND PLACING:
The concrete shall be transported from batching plant to the location by
means of Transit Mixer having capacity of 4/6 cubic meter . Before placing of
concrete, Concrete pour card shall be submitted. The placing of concrete
shall be done over a well prepared surface manually by providing chute if
required. Alternatively crane bucket arrangement may also be used for well
Steining concreting. Concrete shall be placed layer by layer of each 300mm
depth. The placed concrete shall be compacted properly with the help of
immersion type needle vibrator having 60mm dia. Finally top of the concrete
surface shall be roughened and the key block shall be left over to have a
proper construction joint with the further lifts.
QUALITY CHECKS:
Slump Test:
be taken for every one hour. The same shall be recorded in slump and
temperature register.
Cube Test:
taken as per Table No.1700 in most specification.
The same shall be tested at the Q.C.lab for 7 days strength and 28 days
strength and it will be entered in the cube test register.
Outside shuttering plates shall be removed after 12 hours and inner shuttering
plates shall be removed after 24 hours.
CURING:
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Bore well/River water shall be used for curing.
A Bore well of 6 dia shall be bored on the bank of river .For Lifting the water
5HP submersible water pump shall be installed on the well. A main pipe of
1 dia (GI pipe) shall be laid along the axis of the bridge to carry the water
from the pump. The pipe shall run parallel to all the well foundation and at
each well location nipple shall be fixed to the main pipe for continuous
curing of the structure. Hassian cloth may also be tied along the periphery of
both inner and outer surfaces to get continuous curing.
4. WELL SINKING:
METHODOLOGY:
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After gauge marking done on the outer surface, the removal of wooden
sleepers underneath the cutting edge shall be started. Initially alternate
sleepers are removed one after one. Then sleepers are removed opposite to
each other in order to prevent tilt/shift.
Likewise all the sleepers shall be removed without disturbing the positioned
cutting edge.
Inner portion of the well curb shall be manually excavated till the possible
depth (approximately 2 M), there after excavation shall be started
mechanically with Cu.Yd.Grab using Crane or Winch.
Sinking Operation shall be continued till the well is approximately 0.5 M to 1.0
M above bed level. After completion of I stage sinking tilt/shift to be measured
& recorded.
Likewise other steining lifts shall be concreted and sunken
STEINING FINAL LIFT:

Salient Features:
Concrete Quantity for in Final Lift 2.245M of
Abutment well steining : 66.70M3
Concrete Quantity in Final Lift 0.935M of Pier well steining
Concrete Method: By Crane Bucket.
: 24.87 M3
In order to facilitate the well cap construction, steining final lift shall be
modified as follows:1) for bottom non-recoverable well cap shuttering.
Grooves shall be provided in the final lift steining wall to enable RCC beams to
lock into the steining wall. Size of grooves and number of grooves shall be
fabricated as mentioned in Drawings. After placing pockets, Steining final lift
shall be concreted with Crane Bucket arrangement. In order to have proper
construction joint with well cap, timber key blocks shall be left over the surface
of concreting.
FINAL STEINING LIFT SINKING:

The final lift of Steining shall be sunk until ground level. Still if the well does not
reach the Founding level, a false wall of 200mm thick of M35 grade concreting
shall be done around the periphery of wells. The height of false wall shall be
1.2 M. For Pier, wells on the banks i.e. P1, P2, P11 and P12 two lifts of 1.2 m
false wall shall be constructed. Then Sinking shall be continued till the well
reaches the founding level. After sinking the well to the foundation level, tilt
and shift shall be recorded. It shall be ensured within the tolerance of 150mm
shift and 1 in 80mm (vertical). Then sump shall be made to a maximum of
1/8th Dia of well below the cutting edge. Finally, the founding level and sump
shall be checked jointly with Engineer for proceeding concreting for bottom
plug.
DOCUMENTS/RECORDS:
Tilt/Shift report
Page 15 of 109
FURTHER SINKING:
During Final Stage of sinking of wells, grabbing operation shall be done slowly
to prevent excess sinking. A sump shall be made to a maximum of 1/6th Dia
of well below the cutting edge. Finally, the founding level and sump shall be
checked jointly with clients and permission for bottom plugging shall be
obtained in writing.
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5. BOTTOM PLUGGING & INTERMEDIATE

PLUGGING
SALIENT FEATURES:
ABUTMENT WELLS:
Concrete Quantity in Bottom plugging for a well

Sand filling Quantity for a well
Concrete Quantity in Intermediate
Plugging for a well
Concrete Quantity in Well cap for a well
: 130 M3
: 322 M3
: 16.6 M3
: 83 M3
PIER WELLS:
Concrete Quantity in Bottom plugging for a well

: 105 M3
Sand filling Quantity for a well
: 166 M3
Concrete Quantity in Intermediate
Plugging for a well
: 11.5 M3
Concrete Quantity in Well cap for a well
: 60 M3
Reference Drawing No
: NH-60/B-3/B-38/1-01-17
DOCUMENTS:

Steel Register
PLANT, MACHINERY AND MANPOWER PROPOSED TO BE

DEPLOYED:
List of Plants and Machinery:
Batching Plant (30 Cu.M. / Hr)

Crane RB 38
Tata 320 crane
Cu. Yd. Grab
Concrete Pump
Transit Mixer (6 Cu.M./ 4 Cu.M)
Immersion type Vibrator (Electric)
with 60mm needle
- 1 No.
- 1 No
- 1 No.
- 2 Nos
- 1 No
- 3 Nos
- 3 Nos
Man Power:
Supervisory staff:
Project Engineer
Assistant Engineer
Junior Engineer
Sr.Foreman
- 1 No
- 1 No
- 2 Nos
- 2 Nos
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Q.C.Engineer
Other Staff:
Supervisor (Civil)
Supervisor (Mech)
Foreman (Mech)
Electrical Foreman
Electrician
Mechanic
Mechanical Helpers
- 1 No
- 1 No
- 1 No
- 1 No
- 1 No
- 2 Nos
- 2 Nos
- 4 Nos
Skilled/Unskilled Labors:
Crane Operator
Masons
Khalasis
Labors
- 2 Nos
- 4 Nos
- 10 Nos.
-15 Nos.
CONSTRUCTION METHODOLOGY:
BOTTOM PLUG CONCRETING:
Salient Features:
Concrete Quantity for Abutment: 130 M3

Concrete Quantity for Pier
: 105 M3
Concrete Method:
Under water Tremie pipe concreting.
Major Equipment: 2 set Tremie pipes, Crane and Bucket.
Concrete Grade :
M25
Required Slump :
150mm 200mm
Minimum Cement Content: 363 Kg/M3
Rate of concreting
: 10 M3/hr.
After the sump is jointly measured, Erection of precast RCC beams shall be
started. First the center beam is erected exactly in the pockets of steining.
Then two side beams on either side of the center beams shall be erected.
Beam dimensions and reinforcement details are clearly mentioned in the
drawing (Drawing No.:8007/TS/102/A for pier and Drawing No.: 8007/TS/103
for abutment). Then platform shall be made with channels and planks on the
beams. Tremie pipes shall be used for bottom plugging concreting.
POURING SEQUENCE:
First two tremie pipes shall be placed diagonally in the position A & A1. Then it
shall be shifted again diagonally in the position B & B1. Then one pipe shall
be placed at the center of wall. Two Tremie pipes shall be erected in position
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with crane and it is held in position by spanner arrangement. The whole
Concreting shall be done continuously without any interruption by deploying
sufficient work force and Machineries.
After Concreting, the next day percolation test shall be conducted.
Dewatering shall be done and the rate of rise of water level shall be
measured. It shall be ensured within the tolerance of 10cm/hr.
SAND FILLING:
After 3 days of bottom plug, sand filling shall be started manually/ by crane.
Cleaned Fine Sand shall be filled to the required level as shown in the
drawings in the presence of water. This sand layer forms a supporting layer
for immediate plugging.
INTERMEDIATE PLUG CONCRETING:

Concrete Quantity in Intermediate Plugging for an abutment well: 16.6
M3
Concrete Quantity in Intermediate Plugging for a pier well : 11.5 M3
Required Slump :
150mm 200mm
Minimum Cement Content : 363 Kg/M3
Rate of concreting
: 10 M3/hr.
Concrete Grade : M25
Over the sand layer intermediate plug concreting shall be done for a layer of
500mm thickness by tremie pipe and by Crane bucket method.
WATER FILLING
Potable river water shall be filled up to top level of steining.
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6. WELL CAP:
Salient Features:
Well cap depth for Abutment well
: 1.3 M
Well cap depth for Pier well

: 1.2 M
Concrete Quantity in Abutment well cap : 83 M3
Concrete Quantity in Pier cap

: 60 M3
Concrete Method
: Concrete Pump / Crane
Bucket
Major Equipment
: 1. Concrete Pump
Crane
2. Tata 320/ RB 38
Concrete Grade
: M25
Rate of concreting
: 10 M3/hr.
After water filling, precast RCC slabs shall be placed over the beams as per
the enclosed drawings (Drawing No: 8007/TS/102/A for pier well cap and
Drawing No.:8007/TS/103 for abutment well cap), as non-recoverable bottom
shuttering for well cap. Initially built false wall shall forms the outer shuttering
for well cap casting.
For well steining and well cap permissible tolerances shall be as follows: Variation in dimension
: +50 mm to 10mm
Misplacement from specified
Position in Plan
: 15mm
Variation of levels at the top
: +/- 25mm
Placing of concrete shall be done by concrete pump/by crane with concrete
bucket. Mix design for Pumpable mix shall be done at the Q.C.Lab and were
approved from Engineer. Wherever the GL is above (+) 9.0 M, excavation
& backfilling shall be done on surroundings of well surface for maintaining
slopes out side of well cap.
Concrete of M25 with Maximum Size of 40mm aggregate shall be produced
by SMM-40 Shirke, Batching plant of capacity 30 Cu.M. Per hour installed at
Subarnarekha bridge site. The concrete shall be carried by 2 Nos of transit
mixers from batching plant to the pouring point location (BR-38/1). Slump shall
be maintained between 50-70mm throughout the concreting. Before placing
of concrete, Concrete pour card shall be submitted. From Transit Mixer the
concrete shall be poured either with Concrete Pump or with Crane Bucket.
The concrete shall be compacted thoroughly by immersion type vibrator and it
shall be ensured that no honeycombing should be produced.
On the top
surface of well cap at the contact area of Pier wall & Abutment wall shall be
roughened and key blocks shall be left over the surface after concreting to
avoid construction joints.
CURING OF CONCRETE:
Bore well water shall be used for curing.
the structures. Water Ponding shall be done over the surface of well cap for
continuous curing. In addition, Hessian cloth shall be tied all over the
Page 20 of 109
periphery of the walls for continuous curing. Curing shall be continued for 14
days.
TESTING & SAMPLING PROCEDURES:

Slump Test:
be taken periodically as per the direction of Engineer. The same shall be
recorded in Concrete Pouring Report.
Cube Test:

The same shall be tested at the Q.C.Lab for 7 days strength and 28 days
SAFETY MEASURES:
operations. There shall be safety signs painted on boards displayed and
barricading / fencing shall be done. There shall be security guards posted at
suitable locations. For night -concreting, sufficient flood lighting shall be
provided with red light danger signs at vantage locations. First Aid Counter
shall be maintained separately in stores throughout the working hours.
Page 21 of 109
7. ABUTMENT WALL & CAP, PIER CAP

ABUTMENT, ABUTMENT CAP & DIRT WALL :
SOURCE & QUALITY ASSURANCE OF CONSTRUCTION
MATERIALS:
Utmost quality shall be maintained for the following construction materials
Cement
Reinforcement Steel
Coarse Aggregate
Fine Aggregate
Admixture
CEMENT:
Source: 43 Grade GRASIM / AMBUJA / CENTURY.
Material shall be tested at the manufacturing source and Test certificate shall
be collected for each lot. In every batch the following test shall be conducted
at Q.C.Lab (Subarnareka site) to ensure Test certificate results are matching
Q.C.Lab result.
Consistency
Initial Setting Time
Final Setting time
Fineness of Cement
Compressive strength
Soundness test.
Acceptance Criteria: Test results shall conform to IS 8112.
REINFORCEMENT STEEL:
Source: TISCO / SAIL / RINL / SRMB.
Chemical and Mechanical properties shall be tested as per IS 1786 at the
manufacturing source & test certificates shall be collected along with the every
consignment of steel. Also steel samples shall be tested randomly in outside
laboratories to check whether the test certificate results match the laboratory
test result.
Acceptance Criteria: Test result shall conform to IS 1786.
COARSE AGGREGATE:
Source: Tarini crusher / Durga crusher
Material 40mm / 20mm / 10mm shall be received beside batching plant at
Subarnareka site. Sample shall be collected for every 200 M3 of aggregate or
any change of source, the following test shall be conducted in Q.C.Lab as per
IS 2386
Gradation of single size aggregate
Page 22 of 109
Gradation for graded aggregate
Elongation Index, Flakiness index & compression index.
FINE AGGREGATE:
Source: Gobar ghata
Material shall be received and screened at the stacking yard at Subarnareka
site. Sample shall be collected for every 200 M3 of aggregate or any change
of source, the following test shall be conducted in Q.C.Lab
Gradation
Silt content shall be estimated as per IS 2386 & ensured less than 3%.
ADMIXTURE:
Source: Fosroc
Admixtures expedient for different mix grades shall be procured from
approved agencies. Test certificates shall also be collected along with the
every consignment. The following tests are conducted in Q.C.Lab to verify
with Test certificate result.
Relative density as per IS 6925
Chloride content Test result shall conform to IS 9163.
CONSTRUCTION METHODOLOGY FOR ABUTMENT, DIRT WALL & ABUTMENT

CAP
Concrete quantity for one column
: 7.75 M3
Height of abutment column
: 6.2 M
Proposed lift of concreting
: 3 lift
Concrete quantity for I lift (2.865 m height)
: 3.967 M3
Concrete quantity for II lift ( 2.74 m height)
: 3.783 M3
Concrete quantity for III lift ( 0.62 m height)
: 0.75 M3
( But along with III lift also Abutment cap & dirt wall concreting shall be
done)
Grade of Concrete
: M25
SHUTTERING SCHEME:
Shuttering material shall be fabricated with 3.15mm thick plate & angles. For
each lift one set shall be fabricated.
Shuttering plate shall be fabricated as per column dimensions for I lift, II lift &
III lift separately.
Page 23 of 109
METHOD OF CONSTRUCTION:
First Centre point of Column shall be marked with Total Station

Instrument.
Then Column layout shall be made with line dory
drenched in red oxide paint.
Over that layout ISMC 125 X 65 shall be placed on all 4 sides in

appropriate to the column size. Bottom channel shall be supported by
Sleeve nut arrangement.
Shuttering Plates of I lift column size shall be placed as per drawing

over ISMC 125 X 65 by bolting arrangement.
Above shuttering plates ISMC 125 x 65 top channel shall be placed by

bolting arrangement & sleeve nut arrangement. This top channel shall
form the bottom channel of II lift concreting.
Staging shall be done on either side 3m away from the center line of
well cap. Vertical & Horizontal bracings of 1.2m spacing shall be done
with staging pipes on either side from the center line of well cap.
Shuttering plates shall be supported through Rivel Pin support as

shown in Annexure-1.
I lift concreting shall be done in 6 layers of each layer 500 mm

compacted thickness. First two layers shall be poured with funnel like
chute to avoid segregation.
Since each lift of minimal concrete quantity, funnel like chute shall be
fed by wheel barrow / Crane bucket with a workability of 60mm slump.
Then shuttering plate shall be removed after 24 hours and other 3

columns I lift shall be concreted in a similar manner.
For II lift concreting, shuttering plates shall be placed over the top
channel of I lift concreting & a top channel ISMC 125 placed over the
shuttering plates which will form the bottom channel for III lift
concreting.
For supporting arrangements of II lift concreting, Trestles shall be

placed on either side of the abutment column as shown in Annexure-1.
Page 24 of 109
Staging pipes shall be clamped with the trestle & rivel pin support shall
be given similar to I lift concreting.
SHUTTERING SCHEME:
Shuttering material shall be fabricated with 3.15mm thick plate, angles & MS
Flat.
For I lift : C set (mentioned in Annexure-2 )1.0 x 2.953 m
= 6 Nos x 2 (sides) = 12 Nos.
A set (mentioned in Annexure-2 ) = 4 Nos
For II lift : C set 1.0 x 2.953m = 8 Nos. x 2 (sides ) = 16 Nos.
B set (mentioned in Annexure-2 ) = 4 Nos.
First Center point of Column shall be marked with Total Station

Instrument. Then Pier layout shall be made with line dory drenched in
red oxide paint.
First ISMC 125 shall be placed on the layout area by sleeve nut
arrangement.
Then shuttering plates shall be placed over the channel.
Staging shall be done, from which shuttering plates shall be supported

rivel pin support.
For additional support through bolt shall be connected in 2 layers of 1.0

m c/c.
Over the shuttering plates, a top channel of ISMC 125 shall be placed
which will acts as a bottom channel for II lift concreting.
In round portion on either sides, channel shall be placed and shuttering

plates fabricated for dia of 600mm shall be placed.
Concrete shall be done using Crane bucket.
After I lift concreting, the shuttering plates shall be placed over the tope
channel of I lift concreting and the supporting shall be rivel pin support
from sides and through bolt connection of 2 layers 1 m c/c.
Pier III lift of 0.3 m height and Pier cap concreting shall be done in a
single pour.
CURING OF CONCRETE:
Bore well water shall be used for curing. Necessary pipeline arrangement
shall be provided for carrying water for curing the structures.
In addition,
Hessian cloth shall be tied all over the periphery of the walls for continuous
curing. Curing shall be continued for 14 days.
Page 25 of 109

Slump Test:
Cube Test:
The same shall be tested at the Q.C.lab for 7 days strength and 28 days
SAFETY MEASURES:
Technical personnel and workmen are engaged during concreting operation
suitable locations. For night concreting, sufficient flood lighting shall be
PLANT, MACHINERY AND MANPOWER PROPOSED TO

BE DEPLOYED:
Batching Plant ( 30 Cu.M./ hr) - 1 No.

Crane RB 38
- 1 No
Tata 320 crane
- 1 No.
Cu. Yd. Grab
- 2 Nos.
Concrete Pump
- 1 No
Transit Mixer ( 6 Cu.M./ 4 Cu.M)
- 3 Nos.
Immersion type Vibrator (Electric) with 60mm needle - 3 Nos.
MAN POWER:
Supervisory staff:
Project Engineer
Assistant Engineer
Junior Engineer
Sr.Foreman
Q.C.Engineer
- 1 No
- 1 No
- 2 Nos
- 2 Nos
- 1 No
Page 26 of 109
Other Staff:
Supervisor (Civil)
Supervisor (Mech)
Foreman ( Mech)
Electrical Foreman
Electrician
Mechanic
Mechanical Helpers
- 1 No
- 1 No
- 1 No
- 1 No
- 2 Nos
- 2 Nos
- 4 Nos
Skilled/Unskilled Labors:
Crane Operator
Masons
Khalasis
Labors
- 2 Nos
- 4 Nos
- 10 Nos
-15 Nos
ABUTMENT CAP
Concrete quantity for Abutment cap ( 0.65 m height) : 10.12 M3
Concrete quantity for dirt wall
III lift abutment column concreting, abutment cap & dirt wall shall be
cast in a single pour.
Trestles shall be fabricated upto a height of 5.175 m. Then trestle cap

shall be placed with ISMC 125. Also 2 ISMB 400 cross girders shall be
placed over the trestle cap as shown in figure. This cross girder shall
extended 3m beyond trestles T1, T4, T5 & T8.
Then 8 Nos. of ISMB 300 (Longitudinal girders ) shall be placed at

proper spacing from which enable bottom shuttering for dirt wall and
also supports shall be given for cantilever portion of abutment cap &
dirt wall portion.
Supporting arrangement between abutment columns for dirt wall

bottom shuttering is shown in figure.
Concreting shall be done with concrete bucket.
: 7.24 M3
SHUTTERING SCHEME:
Shuttering scheme will be according to drawing.
Shuttering material shall be fabricated with 3.15mm thick plate, angles, MS
Flat & ISMC25
No. of sets to be used : 1 set
Page 27 of 109
ABUTMENT COLUMN
TRESTLE TYPE
T8
T1
A
T7
T2
T6
T3
T5
T4
FIG: PLAN
TRESTLE SUPPORTING ARRANGEMENT FOR ABUTMENT CAP, ABUTMENT IIIrd LIFT &
DIRT WALL CONCRETING
Page 28 of 109
IIIRD LIFT
I I
I I
IIND LIFT
IST LIFT
FIG 1: SECTION A-A

TRESTLE SUPPORTING ARRANGEMENT FOR ABUTMENT CAP, ABUTMENT IIIrd LIFT &
DIRT WALL CONCRETING
Page 29 of 109
After completion of 1st and 2nd lift, column shuttering arrangements for 3rd lift
and Abutment cap is to be made as shown in above fig I.
During casting of 2nd lift of the Pier, sleeve bolts of diameter 125mm are to be
embedded in casting for fixing of bracket, to cast pier cap
3rd lift of Abutment column concreting and abutment cap shall be cast in a
single pour.
Trestles shall be fabricated upto a height of 5.175 m. Then trestle cap shall be
placed with ISMC 125. Also 2 ISMB 400 cross girders shall be placed over
the trestle cap as shown in fig-1. This cross girder shall extend 3m beyond
trestles T1, T4, T5 & T8.
Then 8 Nos. of ISMB 300 (Longitudinal girders ) shall be placed at proper
spacing from which enable bottom shuttering for dirt wall and also supports
shall be given for cantilever portion of abutment cap & dirt wall portion.
Supporting arrangement between abutment columns for dirt wall bottom
shuttering is shown in fig-1.
Separate steel shuttering sets shall be fabricated as per drawing to cast
bearing pedestal monolithically with pier cap in a continuous operation.
Casting of pedestal (M-35) to be done by using concrete bucket.
Proper care should be taken for finishing top surfaces maintaining proper line
and level
Concreting shall be done with crane concrete bucket/ concrete pump taking
due care of slump and compaction.
Drainage slopes 1:100 towards edge to be provided towards Jaleshwar side
of Abutment cap to prevent stagnation of water.
The surface of cap shall be finished smooth and shall have a slope of 1:100
for draining of water.
PIER & PIER CAP:

Total No. of Piers
: 12
Concrete Quantity of a Pier
: 71.84 M3
Height of Pier
: 6.582 M
Proposed lift of concreting
: 3 lifts
Concrete quantity for I lift of 3.203 m height : 31.68 M3
Concrete quantity for II lift of 3.078 m height : 36.26 M3
Concrete quantity for III lift of 0.3 m height
: 3.9 M3
Since all pier wells shall not receive the I lift concreting at a time, we have
proposed only 1 set of shuttering for each I Lift, II lift concreting.
Pier cap concrete quantity
: 35.6 M3
Height of Pier cap
: 1.0 M
Shuttering set for Pier cap
: 1 set
Page 30 of 109
SHUTTERING SCHEME:
Shuttering scheme will be according to enclosed drawing.
Shuttering material shall be fabricated with 3.15mm thick plate, angles, MS
Flat & ISMC25
No. of sets to be used: 1 set. The number of shuttering set shall be increased
depending upon requirement.
BEARING PEDESTAL
TIE ANGLE
SIDE
SHUTTERING
3600
ISMC125 X 65
SIDE SUPPORT WTH
STAGING SUPPORT
PIER & PIER CAP
BRACKETS ISMC125 X 65
@ 1m C/c
20mm DIA
SLEEVE
BOLT, 1.0m
C/C
FIG: TRESTLE SUPPORTING ARRANGEMENT
FOR PIER CAP & PIER CAP WALL
2000
Page 31 of 109
During casting of IInd lift of the pier, slip bolts of diameter 125mm to be
embedded in casting for fixing of bracket, to cast pier cap.
Pier III lift of 0.3 m height and Pier cap concreting shall be done in a single
pour.
Bearing Pedestals (M35) shall be monolithically cast with pier cap (M25) in a
continuous operation.
drainage slopes 1:100 towards edge to be provided on both sides of pier cap
to prevent stagnation of water
Casting of pedestal (M-35) to be done by using concrete bucket.
Proper care should be taken for finishing top surfaces maintaining proper line
and level
Concreting shall be done with crane concrete bucket/ concrete pump.
Drainage slopes 1:100 towards edge to be provided towards Jaleshwar side
of pier cap to prevent stagnation of water.
CURING OF CONCRETE:
the structures. Also Hessian cloth shall be tied all over the periphery of the
walls for continuous curing. Curing shall be continued for 14 days.

Slump Test:
Cube Test:

SAFETY MEASURES:
Technical personnel and work men are engaged during concreting operation
operations. There shall be safety signs painted on boards displayed and also
Page 32 of 109
PLANT , MACHINERY AND MANPOWER PROPOSED TO

BE DEPLOYED:
Batching Plant (30 Cum./ hr)

- 1 No.
Crane RB 38
- 1 No.
Tata 320 crane
- 1 No.
Concrete Pump
- 1 No.
Transit Mixer ( 6 Cu.M./ 4 Cu.M)
- 2 Nos.
Immersion type Vibrator (Electric)With 60/40 mm needle
MAN POWER:
SUPERVISORY STAFF:
Project Engineer 1 No.

Assistant Engineer
1 No
Junior Engineer 2 Nos.
Foreman
2 Nos.
Q.C.Engineer
1 No.
OTHER STAFF:
Supervisor (Civil) 1 No.

Supervisor (Mech)
1 No.
Foreman ( Mech) 1 No.
Electrical Foreman
1 No.
Electrician
2 Nos.
Mechanic
2 Nos
Mechanical Helpers
4 Nos.
SKILLED/UNSKILLED LABORS:
Crane Operator
Masons
Khalasis
Labors
2 Nos.
4 Nos.
10 Nos.
15 Nos.
- 3 Nos.
Page 33 of 109
8.
PSC Beam
Grouting
Casting
Stressing
&
Source & Quality Assurance of Construction Materials:

o Cement
o Reinforcement Steel
o Coarse Aggregate
o Fine Aggregate
o Admixture
o HT Strands
o Sheathing Strip
o Pre-stressing Hardware
Cement:
Source: 53 Grade L&T / Grasim / Ambuja / Century.
at Q.C. Lab (Subarnarekha site) to ensure Test certificate results are matching
Q.C.Lab results.
o Consistency
o Initial Setting Time
o Final Setting Time
o Fineness Of Cement
o Compressive Strength
o Soundness Test.
Reinforcement Steel:
Source: TISCO / SAIL / RINL / SRMB/ IISCO
test result.
Coarse Aggregate:
Source: Tarini crusher / Durga crusher/ ECI crusher
Material 40mm / 20mm / 10mm shall be received at Subarnarekha site.
Samples shall be collected for every 200 m3 of aggregate or for any change
of source, the following test shall be conducted in Q.C.Lab as per IS 2386
Page 34 of 109
o Gradation Of Single Size Aggregate
o Gradation For Graded Aggregate
o Elongation Index, Flakiness Index & Compression Index.
Fine Aggregate:
Source: Gobar ghata
Material shall be received and screened at the stacking yard at Subarnarekha
of source, the following test shall be conducted in Q.C.Lab
Gradation
Admixture:
Source: Fosroc
HT Strands:
Source: M/s Indore Wire & Tata SSL
12.7mm dia low relaxation 7 ply strands of class II conforming to IS 14268
1995+ 2.
Random inspection of the materials shall be done by consultants engineer at
factory.
Sheathing Strips/ Ducts

Source: M/s Standard Engineers, Mumbai
Bright material flexible Sheathing strip of .4mm thickness and 36mm width.
Cold rolled cold annealed mild steel mild steel conforming to IS 513 (Bright
Material) or strip 36mm width and 0.40mm thickness shall be brought at site.
Sheathing pipes of 75mm dia shall be manufactured at Balasore Batching
Plant site and the same will be transported to Br38/1 site as per requirements.
Physical tests of ducts shall be conducted at site as per MOST 1800 /I
Pre-stressing Hardware
Source: M/s Freyssinet Pre-Stressing Concrete Company Ltd., Mumbai 12
T 13-anchorage cone & cir clip.
FPCC will supply 12 T 13 anchorage cones, which will be as per
specifications and drawings.
Page 35 of 109
Construction Methodology:
A: Preparation Of Casting Yard:After completion of embankment filling up to required filling further filling will be
continued to reach up to desired casting yard level
Pre-Casting yard shall be constructed behind abutment A1 at Balasore side. Casting
Bed, Stacking Bed and shifting track shall be constructed as per enclosed drawing
8007 / TS / 201A & 203 & sketch.
B: Plant/Machinery & Manpower Proposed to be Deployed for PSC

Girder Casting:PSC Beam Shuttering Beam Bottom
Beam Side Shuttering
Shuttering Handling Gantry
Concrete Conveyor/mobile chute
Hydra
Transit Mixer
Shutter Vibrator/transformers
Immersion Vibrator & Needle (60mm )
Beam Lifting Jack 150T
Beam Shifting Trolley
Pre stressing Jack S-6 & Hydraulic Pump (Electrically
Operated):
Grouting pump
o
Manpower:
Project engineer
Assistant engineer
Junior engineer
Foreman
Supervisor
Surveyor
01
01
01
01
01
01
Skilled/ Unskilled Labor:
2 Set
1Set
01 No
01 No
01 No
02 Nos
10Nos.& 2Nos
03 Nos
02 Nos
02 Nos
02each
01No
Page 36 of 109
Carpenter
Fitter
Khalasis
Helper
Male Coolie
Method of Concreting:
35
35
50
10
15
Form Work:
Formwork for the beam is being fabricated at site as per enclosed
drawing 8007/T3/211.
It is fabricated in 12 panels for one beam of 2 sides, for the
alignment of formwork adjustable struts & through bolt shall be
used.
Rigid working platform shall be made at beam top level with
scaffolding Pipes, clamps and 1 planks shall be used
Shuttering handling gantry shall be erected & shall be put in
operation for shifting, handling and dismantling operations and for
shifting of one side beam from one bed to other whenever
required.
STEP 1:
After completion of casting bed and pedestals, fabricated beam bottom shall
be erected and fixed as per our drawings. Uniform level of beam bottom shall
be made.
STEP 2:
One side-shuttering panel shall be erected and placed over beam bottom as
per drawings and true plumb of side shuttering to be made to start marking of
cable profile.
STEP 3:
Cable profile
Cable profile shall be marked by paint over beam bottom and side shuttering
as per drawing no. NH60-3/B38/104
STEP 4:
Reinforcement
Treated bar shall be fabricated in advance as per bar bending schedules.

Fabricated reinforcement shall be shifted by trailer/manually to casting yard
Fabricating of reinforcement cage:
In order to maintain quality, reinforcement cage shall be fabricated in advance
outside the bed and Pre-fabricated cage shall be rolled over bed as soon as
bed is ready to receive reinforcement cage for next beam.
Initially for one/two beams reinforcement will be tied over bed itself.
Page 37 of 109
STEP 5:
Laying of Sheathing Pipe
Seating pipe of 75mm dia of various lengths (9 to 6m) shall be laid over
marked profiles (ref: STEP 3). Then the pipes shall be accurately located and
tied as per drawings in both direction of vertical and horizontal
Ladders, spacers @ 2m C/C shall be provided to keep Sheathing duct in
position. 78mm dia 150mm long coupler shall be provided for joining
Sheathing ducts and at both junctions of end block. Joints in between couplers
and pipes shall be sealed with adhesive ceiling tape to prevent ingress of
cement slurry in to ducts during concreting. In addition, couplers of adjacent
ducts shall be staggered whenever possible
DIMENSION & CABLE POSITION OF BEAM
Cable No.11
500
Cable No.10
300
Cable No.9
300
Cable No.8
300
Cable No.E
300
Cable No.7
Cable No.6
300
300
Cable No.5
3550 mm
300
Cable No.3,4
300
Cable No.1,2
250
165
165
250
FIG: SECTION AT END OF PSC BEAMS
C
aC
C
ba
b
la
b
Cel
le
e
175
175
175
175
Cable No. 6,E,7
175
115
830 mm
FIG: SECTION AT THE CENTRE OF PSC BEAMS

Cable No. 1, 2, 3, 4,5
115
150
150
150
150
115
oN
o
.N
o
.
1.
18
9
STEP 6:
Page 38 of 109
Casting & Erection Of End Block:
In order to achieve good quality of casting and to reduce waiting time to get
desired compressive strength for first stage stressing, end blocks shall be cast
prior to beam casting independently.
Separate shuttering shall be fabricated for End-Block casting as per drawing.
End-blocks should be cast well in advance as per drawing TS111A
After cleaning and leveling of casting bed, pre-cast end-block shall be erected
either by Tripod or by Hydra crane.
STEP 7:
Threading of Cables:
Cutting of cables and trimming of HT strands shall be done with angle grinder
after uncoiling of HT Strands. Proper care shall be taken to avoid damage,
kinks or bents and stacking shall be done properly preventing ground contact.
As soon as the Sheathing duct profile is completed threading of cables shall
be started from one end to the other end. Bundle of 12nos. HT strand be
made and same to be inserted manually inside the Sheathing duct. Proper
care shall be taken to avoid damage to Sheathing duct while threading.
STEP8:
Closing of Shuttering:
After checking of reinforcement and threading of cables, other side of beam

shuttering shall be erected over adjustable struts. Shuttering shall be closed
by side bolting as well as by fixing of tie angle and by adjustable props.
STEP 9:
Concreting Of PSC Beam
:
o Concrete Qty
: 81 cum
o Concrete Mix
: M40
o Time for completion of concreting
: 10 hrs
Proposed Plan for Concreting of PSC Beam:
o Concrete pump/ conveyor:/mobile chute 1no
o Transit mixer
o Shutter Vibrator
o Needle Vibrator
: 2nos
: 10nos
: 3nos
Page 39 of 109
Concrete shall be produced at Br38/1 batching plant and will be
transported by transit mixers to the casting yard.
Placing of concrete shall be done by concrete pump/concrete
conveyor/mobile chute @ rate of 10cum/hr
Concreting shall be done up to a depth of 400 mm and the same layer will
be continued until completion of the beam.
Compaction of concreting at bottom flange, web shall be done by using
shutter vibrator and with immersion vibrator simultaneously.
Proper care shall be taken to ensure all the cables are free from concrete.
During concreting and up to 3 to 4hrs after completion of concreting, the
cables shall be checked manually for free movement.
Finally, surface hacking shall be done at the beam top surface for proper
construction joint with deck slab.
Step 10 : Curing & De-Shuttering

Normal curing shall be commenced after final setting of concrete i.e.
6hours (approx) depending on cement. Curing shall be continued until the
concrete reaches strength 34N/mm2
After completion of final setting, the vertical shuttering of PSC girder shall
be removed and taken out of the bed to be used in the second bed by
shuttering handling gantry.
Alternatively, steam curing shall be used for accelerated curing to reduce
cycle time.
Step 11: Pre-Stressing

Method of Stressing:
FPCC System
Important Points
o First Stage stressing will be done when the concrete achieves
strength of 34 MPa and total 8nos. cables in each girder shall be
stressed in first stage.
o Second Stage stressing will be done after completion of
diaphragms and deck slabs and attains specified strength of
40MPa. 3nos. of cables shall be stressed in each beam in second
stage.
o Dummy Cable (No.E) to be stressed after stressing of 2nd stage
cables if required as advised by the Engineer (Consultants)
o The extensions specified in the table account for effect of slip up to
9mm at each end hence no extra allowance of slip should be made.
Page 40 of 109
o Extension at each end during stressing operation should be equal
as far as possible, max. Difference should not exceed 5% of the
prescribed extensions at each end. In case the required extensions
are not obtained at the specified pressure stressing should be
continued till the required extensions are obtained subjected to jack
pressures not exceeding 585kg/cm2
o difference
between
calculated
and
observed
tension
and
elongations during the pre-stressing operations shall be regulated

as per MOST sec. 1807 under post tensioning head as per point a,
b, c, d .
Table i: Cable Elongation Chart

CABLE
NO.
11
7
8
9
10
E
SIZE OF
CABLE
STAGE OF
PRESTRESSING
ELONGATION
AT EACH END
1.
12 T 13
1ST STAGE
162
FORCE IN
CABLE IN
JACK ENDS
BEFORE
ANCHORING
172
2.
12 T 13
1ST STAGE
162
172
3.
12 T 13
1ST STAGE
162
172
4.
12 T 13
1ST STAGE
162
172
5.
12 T 13
1ST STAGE
166
170
6.
12 T 13
1ST STAGE
163
177
12 T 13
12 T 13
12 T 13
12 T 13
12 T 13
DUMMY
1ST STAGE
166
169
1ST STAGE
162
169
2ND STAGE
165
169
2ND STAGE
165
171
2ND STAGE
156
168
To be stressed as per advice of Consultants Engineer.
Table ii: Sequence Of Stressing

SL.NO
.
1.
ACTIVITY
Casting of girder
MINIMUM
DURATION
0 day
REMARKS
Page 41 of 109
2.
1st stage stressing

for normal curing
3.
4.
for steam curing
Casting of deck slab and

diaphragms
2nd stage stressing
72hrs
24hrs
14th day
28th day
Requirement of Stressing Hardware per Beam:

o Anchorage cone: 24 nos.
o Cir clip: 288 nos.
o Bearing Plate: 24 nos.
Requirement of Stressing Equipment & Hardware per
Beam:
o Stressing Jack, S6 Model: 2nos.
o Hydraulic Pump electrically operated 2nos.
o Barrel & Grip: 24 nos.
Method of Stressing
o During curing of PSC beam, arrangements for pre-stressing shall
be started
o Place the tripod on both end of PSC beam

o HT Strands to be physically checked to ensure the strands are free
from any concrete blockage.
o Keep all strand ends at particular point approx 450mm from the
anchorage cone.
o Clean all projected HT strands by petrol and afterwards give a

coating of wax for smooth operation place the bearing plate on the
outer face of each of the anchorage cone of PSC Beam.
o Fix the cir clip in each hole of bearing plates by means of a pipe.
o Erect the pre-stressing jacks and place the jacks first in cable-1 of
both end and then fix the barrel and grip in pre-stressing jacks.
Page 42 of 109
o Initial force shall be applied for tightening of jacks, for gauge
marking for measuring extensions of cables.
o Stressing to continue till it reaches its final extensions as per table i.

o Afterwards all the other cables to be stressed in 1st stage as per
sequence as given above.
o Slip of each cable shall be measured and recorded.

Slump Test:
Cube Test:
Cubes of size 150x150x150mm shall be taken. Number of cubes shall
be taken as per Table No.1700 in most specification.
The same shall be tested at the Q.C.lab for 7 days strength and 28
days strength and it will be entered in the cube test register.
RECORDS:
Documents/Records
o Format for checklist for reinforcement
o Format for checklist of Staging and Formwork
o concrete pour card
o concrete pouring formats
o Record of Pre-stressing operation along with elongations and jack
pressure data shall be maintained as per format 1800/ii of MOST.
SAFETY MEASURES:
suitable locations. For night concreting, sufficient flood-lighting shall be
Page 43 of 109
SAFETY DURING STRESSING:
o Use hydraulic equipments supplied with a relief valve

o Place safely valve in between jacks and connection high-pressure
hose.
o Use hosepipes in good conditions and avoid using worn out hosepipes.
o Check the concrete around bearing plate and anchorage to see
whether there are any voids /honeycombing
o Do not allow anybody behind stressing devices, in line with tendon, or

near hydraulic hoses.
o When the stressing works are in progress no other work should

continue in the vicinity
o Health of safety systems incorporated in the stressing equipment shall

be ascertained once a week.
o Provide safety barriers during stressing operations

o Display a clearly visible sign DANGER..PRESTRESSING WORKS
IN PROGRESS
GROUTING OF CABLES IN PRESTRESSED CONCRETE

Grouting of cables shall be conducted preferably within 14days of stressing of cable.
Materials:
Water: clean, potable water free from impurities will be used.
Cement: OPC as mentioned above
Sand: sand conforming to IS:383 will be used
Admixture: admixture if required conforming to IS:9102 will be used.
Equipment:
Grout Mixer & Agitator: the grout shall be maintained in a homogeneous state
with uniform consistency to avoid any separation of cement.
Grout Pump: Positive displacement type grout pumps capable of ejecting
grout in a continuous operation shall be used.
Grout Screen: grout should be passed through this screen, having a mesh
size of 106microns prior to introduction in to the grout pump.
Connections & Air Vents: all the connections shall be of the Quick Couple
type and at change of diameters suitable reducers will be provided.
Page 44 of 109
Mixing of Grout:
Proportions of the required materials will be measured by weight before
starting of mixing operation.
Water shall be added to the mixer followed by cement, sand & admixture/
readymade grout mixture.
Mixing shall be done for approximately 2 to 3 minutes until uniform and
thoroughly blended grout is achieved.
Adequate care shall be taken to prevent any addition of water to mixed grout
to increase fluidity.
Cubes of 100mm shall be taken for verification of Compressive Strength
Grouting Operations:
Grouting shall be carried out within 2 weeks of stressing of cables.
Ducts shall be flushed with water for cleaning as well as for wetting the
surfaces of the duct walls. Water used for flushing should be of same quality
as used for grouting.
After cleaning all water shall be drained thoroughly by vent pipe or by blowing
compressed air through duct.
During and after 3 to 4 hours of grouting other non stressed cables shall be
checked manually for free movements.
All outlet points including vent openings should be kept open before to
commencement of grouting.
Injection of Grout
After mixing grout should be kept in continuous movement and injection of
grout must be continuous without any interruptions.
Grouting shall be commenced initially with a low pressure of injection of up to
0.3MPa increasing it until the grout come out through the other end with same
consistency as that of the grout @ injection end.
Full injection pressure (approx 0.5MPa) shall be maintained for a minimum of
1 minute before closing the injection pipe.
RECORDS
Grouting records shall be maintained as per format conforming to MOST,
Appendix 1800/IV
Methodology of Steam Curing of PSC Beam at

Subarnarekha Bridge Casting Yard
Objective:
GIL has proposed to install steam-curing plant to obtain accelerated strength in high
performance concrete in PSC Girder for Subarnarekha Bridge Casting Yard.
The main purpose of proving steam curing is to reduce cycle time of casting of PSC
beam.
Page 45 of 109
Plant/Machinery & Manpower Proposed to be
deployed for Steam Curing @ Rajghat Casting Yard: List of Plant & Machinery:
Super therm non IBR fully automatic, 4 Pass circulation, having 02 nos.
evaporation capacity of 600kg/hr with a working pressure of
10.54kg/cm2 (150 psi)
Water purifying system (softener plant)
02 nos.
Water tank and diesel tank:
02 nos.
Pipe line
GI pipeline for water

MS pipeline for steam
Canvas tarpaulin
100m
100m
14 nos.
Thermometer for measuring temperature within the girder 3 nos.

enclosure
Manpower:
Assistant engineer
Foreman
Supervisor
01
01
01
Skilled/ Unskilled Labour:

Mechanic
Electrician
Labour
1
1
10
Method of Curing:
1. After placement and compaction, concrete shall be allowed to attain initial set
prior to steam application. Initial set requires 4 hours normally and 6 hours if
retarders are used.
2. Initially boiler, softener plant, Water Line Chimney shall be installed as per
sketch enclosed and thereafter MS pipes shall be laid to transport steam from
boiler. Proper care to be taken to reduce loss of temperature by providing
asbestos rope over MS pipe and proper flange joint. After casting of girder, it
shall be covered by tarpaulin. The sides to be packed properly by sand bags
to reduce loss of steam. The steam shall be at 100% relative humidity.
3. Ambient temperature around the concrete shall be increased gradually at a

rate not exceeding 50C/hr to reach a maximum temperature of 60-700C
(which corresponds to a pressure of 1 Mpa).
Page 46 of 109
4. The maximum temperature shall be maintained for a maximum period of 3 to
4hrs during which only representative cubes stored at either end of girder and
at center of girder shall be tested for the desired strength.
5. Steam curing cycle shall be maintained in order to get concrete strength of

340kg/cm2. Free circulation of steam around the top, bottom and sides of
member shall be maintained for a minimum period of 3 to 4 hours..
6. when steam curing is discontinued the ambient air temperature shall drop at a
rate of 50c/hr until a temperature of about 10oc above air temperature, and
will be exposed (Cl. 1713.2 of MOST Spec)
7. After completion of steam curing tarpaulin to be removed from PSC Girders

and representative cubes, which has been cured along with the beam, are to
be tested to ascertain concrete strength in order to start pre-stressing activity.
All cubes shall be placed within the enclosure along the girder length and
representative sample shall be picked from each end and at center and
testing during maximum temperature steady state period.
8. Pre-Stressing shall be started as soon as de-shuttering of girder is over.

Normal curing by water shall be continued for 14 days from the day of casting
to achieve 100% strength gain.
9. In case of short fall in targeted strength of girder during prestressing it is

required to adopt the following methods:
de-shuttering
Continue with normal curing till girder reaches strength of 34 Mpa.
Page 47 of 109
Typical time vs. temperature curve is given for reference for adopting steam
curing
DELAY
PERIOD
TIME
VS.
TEMPERATURE
STEADY
STATE
MAXIMUM
CURVE
HEATING PERIOD
TEMPERATURE PERIOD
COOLING PERIOD
70
60
TEMPERATURE IN 0C
50
40
AIR TEMP
10OC
30
20
10
4 (approx)
10
DELAY HEATING PERIOD

PERIOD @50C/hr
4 hrs
minimum 6 7 hrs
TIME IN HOURS
CONSTANT TEMP. TO BE
MAINTAINTED DURING CURING
(60-700C) min 3 to 4 hrs
14
19
COOLING PERIOD
4 to 5 hours approx.
DATA RECORDS:
Separate register for steam curing operation shall be maintained on a approved
format by the Bridge Engineer and Field Engineer with due signatures of
Consultant and Contractor.
SAFETY MEASURES:
Technical personnel and workmen who are engaged during curing operations should
be equipped with helmets. Safety shoes shall be provided to all the workers engaged
in steam curing operations.
There shall be safety signs painted on boards displayed and also barricading /
fencing shall be done. There shall be security guards posted at suitable locations.
First Aid Counter shall be maintained separately in stores throughout the working.
Also no outside visitors shall be permitted inside the steam curing and boiler
premises.
Page 48 of 109
9. LAUNCHING & SIDE SHIFTING OF PSC

BEAMS
INTRODUCTION
After completion of casting, 1st stage stressing and grouting PSC girder shall
be shifted over to stacking pedestal or directly over launching track through
side shifting trolley. Subsequently all the PSC girders shall be launched over
the respective spans.
PLANT/MACHINERY & MANPOWER

FOR PSC GIRDER SIDE SHIFTING & LAUNCHING
Launching Truss Cap (225T cap) with auto launching
trolley
01 No.
Beam Shifting Trolley with drive mechanism (T1& T2)
02 Nos.
Side Shifting Trolley
02 Nos.
Beam Shifting Trolley with drive mechanism (T3, T4)
02 Nos.
Lifting devices Jack & Power-cap of 100T capacity each
01 No.
Beam Lifting Jack & Power Cap (100T capacity)
04 Sets.
Hand Winch/ Rope Pulley for beam shifting @ Casting

yard
02 Nos.
Miscellaneous like ropes and hooks for suspending of

PSC beam with trolleys.
01 No.
MANPOWER:
Project engineer
Assistant engineer
Junior engineer
Foreman
Supervisor
SKILLED/ UNSKILLED LABOUR:

Rigger
Welder, Cutter
Fitter
Khalasis (skilled)
01 no.
01 no.
01 no.
01 no.
02 nos.
20 nos.
05 nos.
05 nos.
10 nos.
Page 49 of 109
Helper
05 nos.
MATERIALS:
STRUCTURAL STEEL:
Source: TISCO / SAIL / RINL / SRMB/ IISCO
Structural steel shall be used for fabrication of launching truss, A1P1
supporting arrangement and other ancillary structure. Chemical and
Mechanical properties shall be tested as per IS 1786 at the manufacturing
source & test certificates shall be collected along with the every consignment
of steel. Also steel samples shall be tested randomly in outside laboratories to
check whether the test certificate results match the laboratory test result to
carry out fabrication of launching truss A1P1 supporting arrangement and
other ancillary structures.
Acceptance Criteria: Test result shall conform to IS Specifications.
POT CUM PTFE BEARINGS:

Source: Steel Auto Industries
Acceptance Criteria: Test result shall conform to MOST Specifications and
subject to approval after inspection and necessary testing at workshop.
SIDE SHIFTING OF PSC BEAMS:

Transverse track shall be made as per approved drawings
After stressing and grouting, PSC girders shall be lifted by 4 nos. of Hydraulic
jack & Pump (100 T capacity) by placing 2 nos. on each side of the girder
taking due care of plumb & packing providing side support etc.
After placing of PSC girder over trolley, turnbuckle arrangement shall be
provided on each side of the girder to prevent any lateral movement.
Then beam on trolley shall be shifted either up to stacking bed or up to
longitudinal track by hand winch with side pulley arrangement over rail track.
Unloading of girder over stacking bed/over trolley, T1 & T2 for launching
purpose & lifting shall be done by hydraulic jack (100T capacity) as mentioned
above in Point No2.
While transportation of girders proper care shall be taken as mentioned below
Before starting of transportation on transverse direction, marking on the rails
at 100 mm interval shall be given to monitor uniform movement at both ends.
Rail/wheel path shall be free from any obstruction.
2 nos. supervisors will be appointed to watch and keep track of both side
movements and also to take care of the wheel movement.
FABRICATION OF LAUNCHING TRUSS:

Details of Truss:
Launching truss length: 96m
Height of L/T panel: 4.5m
Page 50 of 109
Weight of truss: 250T
Rail distance in Launching Truss T5 Trolley: 6.5m
Launching truss shall be fabricated at site as per Drawing and other detailed
specifications. The launching truss comprises of two box trusses connected at
the front end. These are supported over a trolley, which is used for moving the
truss to the next span.
The launching truss has been designed for a maximum beam load of 225T
and a span of 50m. The truss shall be fabricated in modular form. In addition
to the self-weight of truss, beam load, live loads etc, & the effects of wind
loads have also been considered. The design also accounts for effects due to
the gradient in the longitudinal profile of bridge.
Fabrication of the truss shall be done at site under strict quality control
measures. Tested quality structural steel shall be used for the fabrication.
Wherever required, third party testing shall be arranged for quality standards.
Critical components like suspenders; pins etc shall be ultrasonically tested to
ensure them to be free from laminations. Butt welds and fillet welds shall be
tested by DPT. Field tests shall also be carried out for welds at critical
junctions applying equivalent loads using hydraulic jacks, to which they are
designed.
The truss shall be fabricated in the fabrication yard in modules of
approximately 9m lengths. Mock assembly of adjoining panels shall be done
in the fabrication yard to check the matching of connection details.
A1P1 SUPPORTING ARRANGEMENT

As the first span A1P1 (20.5m) is of voided slab which is not designed for
taking the launching load, the gap(A1P1) is provided with structural steel
supporting arrangements in place of shall be fabricated and erected over
trestle as per drawing
SHIFTING & ERECTION OF LAUNCHING TRUSS:

After fabrication, the truss panels are to be shifted and erection shall be done
over staging arrangement over A1P1 & P1P2 with the front leg resting on pier
cap P2 (located at A1P1 & P1P2) as per drawing
The erection of the truss shall be done over temporary staging from A1 & P1
LOAD TEST OF LAUNCHING TRUSS:

After erection of Launching truss, load testing will be done as indicated in the
drawings.
After completion of erection of launching truss, it shall be inspected thoroughly
for compliance of all the critical aspects. Member sizes, plate thickness,
number and diameter of bolts, locking of pins, gauge distance between the
rails etc shall be checked. Trolleys shall be checked for their free movements,
electrical circuits etc. hydraulic jacks to be checked for their operations. Trolley
stoppers, side-shifting arrangements over pier cap, stools/packing below
beam, inclined struts etc shall be kept ready at their respective locations.
AUTO LAUNCHING CONDITION
Page 51 of 109
Initially the truss shall be tested for the auto launching condition. Bolts
connecting the front leg with the pier were removed and the front leg was lifted
up by attaching the beam at the rear end of the truss. Deflections were
recorded at various points (such as L/2, L/4, L/3). The truss was kept under
this condition for about 4 hours and deflections were recorded again after
unloading. All the members were carefully observed for any distress.
BEAM LAUNCHING CONDITION

The truss shall be checked for beam launching condition by actually moving
the beam over the truss. Front end of beam was brought over the truss up to
predetermined points like quarter span, mid span etc. deflections ere
measured at these points and compared with the theoretical values. Then the
beam shall be lowered over the side-shifting track fixed over pier cap and
shifted to desired location and placed on bearing. After ensuring satisfactory
results actual launching operations shall be continued.
ERECTION DETAIL OF GIRDER:

The launching truss comprises of two box trusses connected at the front end.
These are supported over a trolley, which is used for moving the truss to the
next span. During the launching of precast beam, the truss is supported at
front end also by its front leg, resting over pier cap. The beam is carried over
the truss using overhead trolleys, which run over box trusses. These are fully
mechanized and equipped with hydraulic jacks for raising or lowering of the
precast beam. The truss is provided with well-protected walkways and ladders
keeping in view the safety of working personnel.
The rails provided for the movement of Trolleys & Launching Truss is having a
gradient of 1in100 from casting yard to Pier P1 and thereafter no slope is
provided up to the end i.e. Pier P12.
The speeds of travel for the various trolleys involved in the launching
operations are as follows:
Trolley T1 & T2:
8m/min
Trolley T1 & T2:
8m/min
The launching truss has been designed for a maximum beam load of 225T
and a span of 50m.
Erection of PSC Girders shall be done as per the following sequence:
Page 52 of 109
SEQUENCE OF GIRDER MOVEMENT & PLACEMENT

BALASOR
E SIDE
Pier
1
U/
S
KHARAGP
UR SIDE
PSC
Girders
D/S No. 1, 2,
3&4
Pier
Rails
PLAN
Tracks shall be laid on PSC Girder Nos. 1 & 3 (as shown in fig. Above)
The launched girder is always unloaded at no.2 location
1st girder unloaded at no.2 location & side shifted to no.4 position on D/S end
2nd girder unloaded at no.2 location & side shifted to no.1 position on U/S end
3rd girder unloaded at no.2 location & side shifted to no.3 position on D/S end
4th girder unloaded at no.2 location and then paced on bearing at no.2
location
Page 53 of 109
STAGE I (PSC GIRDER SHALL BE MOVED UP TO T5

TROLLEY POSITION)
Trolley T3 & T4 shall be placed over launching truss.
The PSC beam supported over trolley T1 & T2 over span A1P1 shall be
brought till trolley T1 comes near trolley T5.
TOP OF RAIL
LAUNCHING
TROLLEY T3TRUSS
DIRECTION OF LAUNCHING
KHARAGPUR SIDE
TROLLEY T1
PSC BEAM 47.3m
A1
STAGING
ARRANGEMENT
S
FOR
ERECTING
TRESTLES
@
3m INTERVAL
Page 54 of 109
TROLLEY T4
TROLLEY T2
Trolley T3 shall be moved over launching truss until it comes over trolley T1.
Connect suspenders to Trolley T3 and PSC beam is offloaded from Trolley T1 and
the beam is resting on T2 & T3.
STAGE II (LIFTING OF PSC BEAM AT BOTH END)
KHARAGPUR SIDE
Page 55 of 109
TROLLEY T1
ABUTMENT A1
Page 56 of 109
TROLLEY T4
TROLLEY T3
TROLLEY T2
TOP OF RAIL
LAUNCHING TRUSS
TROLLEY T5
PIER P2
PSC Beam shall be moved forward and trolley T2 comes near the trolley support
T5.
Trolley T4 shall be brought over Trolley T2.
Connect suspenders to trolley T4, operate jacks over T4 so that the PSC beam is
off loaded from Trolley T2, so now beam is resting on Trolleys T3 & T4.
STAGE III (MOVEMENT OF PSC BEAM UP TO NEXT

PIER)
TOP OF RAIL
KHARAGPUR SIDE
Page 57 of 109
TROLLEY T1
Page 58 of 109
TROLLEY T3
TROLLEY T4
ABUTMENT A1
LAUNCHING TRUSS
TROLLEY T2
PIER P2
FRONT LEG
TROLLEY T5
Fix side shifting arrangements over pier P1 and P2 as per drg. no. TS/761
The PSC beam shall be moved over the longitudinal movement trolley till it
reaches near the trolley support of the launching truss (T5)
The front end of the PSC beam shall be lifted by the first overhead trolley (T4) and
then lower front-end trolley (T2) gets released
The PSC beam then shall be moved further with its front end hanging from
overhead trolley T4 and rear end resting on lower trolley T2 till the rear end of the
beam comes to trolley position 9T5)
Page 59 of 109
Then the rear end of the PSC beam shall be lifted by the second overhead trolley
T3.
Now the PSC beam shall move in fully hanging condition over the two overhead
trolleys (T3 & T4) till it reaches its exact location over pier and locked. The beam
is then lowered cautiously by hydraulic jack over the side-shifting track fixed over
the pier cap and shifted laterally to the desired location.
Lowering of the beam from the suspended position shall be done cautiously by
2sets of lifting devices placed at trolley T3 & T4 as described in drg.TMS/710.
After lowering of the beam over side shifting arrangement, side shifting of the
beam shall be done.
Details of Lowering
Length of Travel In Launching Truss: 47.60m
Time taken for Travel: 10 min
Time for lowering of Girder: 5 hrs
Similar procedure shall be under taken for launching of the other beams by
repeating the above operations in sequence as at stage I(e)
The diaphragms shall be cast in situ.
STAGE IV (FINAL LAUNCHING)

Side Shifting of PSC Girder over Pier Cap:
After lowering of PSC Beam at 2nd pedestal position, girder shall be shifted
over pier cap as per drg. No. TS/761 on wooden skid up to bearing location by
help of 50T capacity Jack and then the girder shall be placed on bearing by
Hydraulic Jack of capacity 100T. Detailed time required for side shifting of
girder over pier cap
For Girder B4: 18hrs
Fixing of Bearing:
During casting of end blocks and pedestals on pier-caps, 90mm diameter
pockets shall be provided as per drawings and specifications.
Bearings shall be placed at location as per drawings and shall be aligned
properly before placing of beams.
THE FOLLOWING SEQUENCE SHALL BE ADOPTED FOR

FIXING OF POT CUM PTFE BEARINGS:
End Block casting leaving pocket of 90mm dia along with PVC hose (3/4) for
grouting of pockets after both bearing sleeves (60mm dia) are fixed in position.
Girders casting with above End Blocks ensuring the pockets are not ingressed
with cement slurry/concrete.
Pedestal over cast leaving pockets for grouting after bearing sleeves are fixed in
position
Positioning of bearing on pedestal shall be done matching project and bearing
centerline in both axes keeping preset line of bearing towards next span.
Pedestals shall be cast 10mm down or else 10mm chipped. The products of
sleeves shall be grouted using Conbex/Cebex-100 @ 225 g per 50 Kg of Cement
Page 60 of 109
(w/c ratio 0.4) by natural pouring to get a uniform thickness (i.e. 10mm) mortar
in between bearing and pedestal.
Erection and launching of girder
Side shifting of girder & placing over bearings
Fixing of bolt sleeves in top plates of bearing, ensuring bearing sleeves are in
vertical position
Lower the girder over grouted bearing after 48 hours when required strength is
attaining.
Grout the top pockets as in item no. 1 &2 for fixing bearing by plasticized
expanding grout admixture i.e. Conbex100 @ 225 g per 50 Kg of Cement with the
help of Hand Grouting Pump through PVC hose.
STAGE V (AUTO LAUNCHING), MOVEMENT OF LAUNCHING

TRUSS TO NEXT SPAN
PSC beam shall be brought near the rear end of the launching truss using two
trolley (T1 & T2) which are fully mechanized and power driven and attached to
give counter balancing moment against over turning. For movement of launching
truss to next span, manually operated winches are used. As such, the launching
truss and PSC girder shall move together until the front leg reaches the next pier
cap location. Then the PSC beam is detached from the rear end and front leg is
made to rest on the pier cap and secured in position by bolting arrangements.
The Steps involved in Auto launching operation are:
Extend rail line on wooden sleepers placed on PSC Beams.
Bring trolleys T3 & T4 to the rear end of the launching truss.
Bring PSC beam supported on trolleys T1 & T2 below launching truss till trolley
T1 comes below T3.
Fix front suspender to trolley T3, remove bolts fixing front leg to pier-cap of P2.
Operate jack over Trolley T3 and lift PSC Beam slightly so that front leg of
launching truss is lifted over top of pier cap by at least 25mm. Remove front leg
stool.
Move launching truss forward over span P2-P3 by hand operated winch (reaving
sketch enclosed) taking into consideration that concrete in situ Diaphragm
achieves a minimum strength of 20MPa before launching truss is moved to next
span.
When the front leg of launching truss reaches next pier (P3), jacks at T3 shall be
released and transfer load of PSC girders fully to trolley T1.
Fix the front leg of the launching truss to pier cap at P3.
Move the PSC girders further till the trolley T1 comes near T5
Repeat the steps as mentioned above and complete placement of PSC beams of
all spans i.e. up to P11P12.
STAGE VI (DISMANTLING OF LAUNCHING TRUSS)

1.
After successfully launching of all the girders of all the spans, the
launching truss will be dismantled taking adequate safety measures.
2.
After dismantling, cast voided slab over span P12A2.
Page 61 of 109
Load Test:
Load test of launching truss for launching of PSC Girder shall be done as per
drawings and specifications
Verticality of the PSC girder will be checked during side shifting by plumb bob
PRECAUTIONS DURING SHIFTING/LAUNCHING OF PSC

BEAMS
IN CASTING/STACKING YARD
INSERTS SHALL BE PROVIDED FOR FIXING PROPS,
BRACING ARRANGEMENT ETC.
Holes shall be provided for deck slab supporting arrangement.
During side shifting to stacking yard, props at ends of beams shall be
provided.
DURING CASTING OF PIER CAP/PEDESTAL

Provide inserts in pier cap for fixing props and supporting arrangement in gap
portion.
DURING BEAM ERECTION

The PSC Beam shall be lowered to its required location by resting it over
packing and bearing
Beams shall be strutted by using struts at both ends.
Beams shall be tied by using clamps and tie members
After the diaphragm is cast, the packing under the beam shall be removed by
hammering.
SAFETY MEASURES:
Jacks shall be operated in such a manner and from such a position that the
safety of all concerned is ensured.
Technical personnel and workers engaged during side shifting and launching
operation shall be equipped with adequate safety gears like helmet and safety
shoe.
Helmets, safety belts and safety shoes shall be provided to masons and
khalasis engaged for the operations.
There shall be safety signs painted on boards displayed and barricading /
fencing shall be done.
There shall be security guards posted at suitable locations.
For nightshifting/launching, sufficient flood lighting shall be provided with red light danger
signs at vantage locations.
Page 62 of 109
10. DIAPHRAGM & DECK SLAB CASTING

Source & Quality Assurance of Construction Materials:
Cement
Reinforcement Steel
Coarse Aggregate
Fine Aggregate
Admixture
Cement:
Source: 43/53 Grade Grasim /L&T/ Ambuja / Century.
at Q.C. Lab (Subarnarekha site) to ensure Test certificate results are matching
Q.C. Lab results.
Consistency
Initial Setting Time
Final Setting time
Fineness of Cement
Compressive strength
Soundness test.
Reinforcement Steel:
Source: TISCO / SAIL / RINL / SRMB.
test result.
Coarse Aggregate:
Material 40mm / 20mm / 10mm shall be received beside batching plant at
Haldipada/Subarnarekha site. Sample shall be collected for every 200 M3 of
aggregate or any change of source, the following test shall be conducted in
Q.C.Lab as per IS 2386
Gradation for graded aggregate
Elongation Index, Flakiness index & combined index.
Page 63 of 109
Acceptance Criteria: All course aggregates shall conform to IS 383 and tests
for conformity shall be carried out as per IS 2386, Parts I to VIII.
Fine Aggregate:
Source: Gobar ghata
Material shall be received and screened at the stacking yard at Subarnarekha
of source; the following test shall be conducted in Q.C.Lab
Gradation
Acceptance Criteria: all course aggregates shall conform to IS 383 and tests
for conformity shall be carried out as per IS:2386, Parts I to VIII.
Admixture:
Source: Fosroc/ Chembond/Sika
Plant/Machinery & Manpower Proposed to be deployed for

Diaphragm Slab: List of Plant & Machinery:
Transit mixer
Dumper/ tipper
Crane/ Bucket for concreting
Concrete pump
Electric vibrator
04 nos.
02 nos.
1 set.
02 nos.
04 nos.
Manpower:
Project engineer
Assistant engineer
Junior engineer
Foreman
Supervisor
Surveyor
01
01
01
01
01
01
Skilled/ Unskilled Labour:

Carpenter
Fitter
Helper
Concrete pump operator
35
35
100
02
Page 64 of 109
TM Driver
Male Coolie
03
25
Method of Casting Diaphragm:

After completion of launching operations of PSC girders over the bearings,
Diaphragm casting shall be started.
The detailed arrangement for casting of diaphragm shall be done as per
drawing. No.TS/251(PMS)(Position of holes for outer beams, casting deck
slab & Diaphragm).
Details of Diaphragms:
For single span of the bridge:
End Diaphragms:
Intermediate Diaphragms:
Concrete Quantity:
Grade of Concrete:
Reference Drawing:
drawing)
No of Shuttering Sets to be used:
14 nos. side shuttering
6nos.
15nos.
47cumi.e. Total: 21nos/ span
M40
TS/251(PMS@ Gammon HO
Concrete Pump/Crane, Bucket
21 nos. bottom shuttering
Detailed Sequence & Brief Points about Casting

of Diaphragm:
A1
DIAPHRAGM SPAN C
DIAPHRAGM SPAN B
DIAPHRAGM SPAN A
A2
15
8
1
16
21
14
17
18
10
11
2A4
A3
19
20
12
13
FIG: TYPICAL SCHEMATIC PLAN OF GIRDER AND DIAPHRAGM FOR

ONE SPAN.
PSC Girders shall be launched in the following sequence
Girder A4 aGirder A3 aGirder A1 aGirder A2
Page 65 of 109
Diaphragm no 1-7 in span A shall be cast first, as soon as A4 and A3 beams
are placed.
Preferably casting and shuttering shall be continued except the time when
other beam (A1 & A2) shall be launched on the same span.
Rest diaphragm shuttering and reinforcement can only be started after proper
placing of beam A2 and A1.
Method of Casting Diaphragm:

A. FOR SPANS (9 SPANS)
P1-P2
P9-P10
P2-P3
P10-P11
P3-P4
P11-P12
P4-P5
P7-P8
P8-P9
List of Plant & Machinery:

Transit mixer
Crane/ Concrete bucket
01 nos.
01 nos.
Rigid common platform shall be made on beam top to receive concrete for
diaphragm casting. Walkway with hand railing shall be provided for
conventional pouring inside diaphragm shuttering.
The concrete shall be laid in layer not exceeding 400 mm depth.
Normal curing shall be continued up to 14 days.
Diaphragm shuttering shall be released as follows:
Side shuttering: 16 to 24 hrs.
Soffit of diaphragm: 7 days.
B. FOR SPANS (2 SPANS)

P5P6
P6P7
List of Plant & Machinery:

Transit mixer
Concrete pump
01 nos.
01 nos.
Concrete shall be pumped over rigid platform and then shall be poured
conventionally (mostly) at locations by providing walkways and hand railings
since quantity and thickness of diaphragm is less.
The concrete shall be laid in layer not exceeding 400 mm depth.
Normal curing shall be continued up to 14 days.
Diaphragm shuttering shall be released as follows:
Side shuttering: 16 to 24 hrs.
Page 66 of 109
Soffit of diaphragm: 7 days.
TYPICAL SEQUENCE OF LAUNCHING & CASTING OF

CASTING
LAUNCHING OF GIRDERS
DIAPHRAGMDIAPHRAGM
& DECK
SLAB AUTO LAUNCHING: FRNT. LEG
4NOS. FOR 1 SPAN >> 10
FOR 1 SPAN >> 10 DAYS
ST
ST
OF L/T TO REACH P3 >>
DAYS
AUTO LAUNCHING: FRNT. LEG

OF L/T TO REACH P4 >> 2
DIAPHRAGM CASTING FOR

2ND SPAN 10 DAYS
DAYS
>> 15 DAYS

3RD SPAN >> 10 DAYS
ERECTION
DAYS
OF
GIRDERS
ERECTION
OF
GIRDERS
OVER 2ND SPAN >> 10 DAYS
RAIL TRACK PLACING OVER

DECK SLAB 1ST SPAN &
OVER BEAM AT 3RD SPAN >>
5 DAYS
>> 15 DAYS
OVER 3RD SPAN >> 10 DAYS
RAIL TRACK REMOVING &

DECK SLAB CASTING FOR
1ST SPAN
AUTO LAUNCHING: FRNT. LEG

OF L/T TO REACH P5 >> 2
>> 10 DAYS
DAYS
ERECTION
OF
4TH SPAN >> 10 DAYS
DECK SLAB CASTING FOR 2ND

SPAN >> 10 DAYS
RAIL TRACK PLACING OVER
DECK SLAB 1ST SPAN &
OVER BEAM AT 3RD SPAN >>
5 DAYS
CONTINUE IN SAME SEQUENCE
1 2 3 4 5
TO REACH UPTO SPAN P12
GIRDERS
OVER 4TH SPAN >> 10 DAYS
Page 67 of 109
Concreting of Deck Slab:
After completion of diaphragm casting shifting of launching truss over the
respective spans, Deck Slabs casting arrangements shall be commenced as
per drawing TS/251 (Position of holes for outer beams, casting of deck slab
and diaphragm)
When adjacent span of slab has already been cast, the expansion joint and
filler board shall be placed abutting the already cast span which shall form the
shutter on that side of the new span to be cast. The whole of the slab shall be
cast with reinforcement embedded for the road Kerb and railings.
After the deck slab has been cast, the surface of the slab shall be finished
rough for proper bonding with the wearing coat. Adequate care shall be taken
for maintaining proper lines and levels of the surface as per drawings.
The top of the slab shall be covered with clean moist sand as soon as the top
surface has hardened.
DETAILS OF DECK SLABS

Concrete Quantity:
Grade of Concrete:
Reference Drawing:
Reference Drawing:
167cum
M40
NH60B38-1-02(a)R1
NH60B38-1-03
NH60B38-1-05R1
Concrete Pump
MIX DESIGN: M40 grade of concrete using 20mm aggregates shall be produced as per
approved Mix Design.
TESTING OF MATERIALS: The suitability of ingredient materials of concrete shall be tested in QC

Laboratory and shall be approved by the Engineer as per specifications.
PRODUCTION OF CONCRETE:The concrete shall be produced by Shirke-40 Batching Plant having a capacity
of 30cum/hr @ Subarnarekha Batching Plant. The established batching plant
shall be calibrated and got checked by Engineer well before commencement
of production of concrete.
Page 68 of 109
TRANSPORTATION AND PLACING OF CONCRETE:From Subarnarekha Batching Plant concrete shall be transported for Br No.
38/1 (Subarnarekha Bridge) Deck slab casting.
The concrete shall be transported from above batching plant to the respective
locations by means of Transit Mixers having capacity 4/6cum/hr and having
slump of 80-100mm.
Concrete shall be placed by means of concrete pump for directly pouring over
Deck slab. The concrete shall be compacted by means of immersion type
vibrator having needle diameter of 60mm. The temperature of pouring
concrete after vibration shall be recorded in pouring format.
The concrete shall be compacted thoroughly and it shall be ensured that no
portion to be left out without vibration.
The concreting shall be laid in layers not exceeding 300mm depending on the
next layer shall be laid before initial setting time of previous layer. The
approximate expected rate for pouring of concrete is 15cum/hr. depending on
above number of transit mixer shall be fixed for slab casting.
The concrete shall be laid to the shape, true line and level as shown in
relevant drawings. The top surface shall be finished smooth initially and
afterwards light scratches shall be provided for construction joint for proper
bonding of wearing course over deck slab.
CURING OF CONCRETE:
the structures. Curing of concrete shall be done by water ponding method.

Slump Test:
Slump shall be taken for each batch of Transit Mixer. The same shall be
recorded in Concrete Pouring Format.
Cube Test:
DOCUMENTS & RECORDS

Report For Inspection (RFI)
Check List For Staging And Formwork
Checklist For Reinforcement
Concrete Pour Card
Concrete Pouring Format
Page 69 of 109
SAFETY MEASURES:
Technical personnel and work men who are engaged during concreting
operation both at batching plant and Site shall be equipped with helmets.
Safety shoes shall be provided to masons and khalasis engaged for vibrator
operations. The Planks of the walkway shall be carefully checked for safety
regularly. There shall be safety signs painted on boards displayed and also
shall be maintained separately in stores throughout the working.
Page 70 of 109
11. CASTING OF VOID SLAB
SOURCE & QUALITY ASSURANCE OF CONSTRUCTION
MATERIALS:
Cement
Reinforcement Steel
Coarse Aggregate
Fine Aggregate
Admixture
Void Former
VOID FORMER:
Source: JK Steel & Polymer India, associate of Steel Auto (India) Ltd.
Void formers shall be fabricated at Balasore/ Bhadrak from approved agencies
and same shall be transported by Trailers to respective locations. Details of
void former are enclosed along with this method statement.
Light steel metal strips shall be used to make the void formers by using the
void former machine.
PLANT/MACHINERY & MANPOWER PROPOSED TO BE

DEPLOYED FOR VOID SLAB:LIST OF PLANT & MACHINERY:
Transit mixer
Dumper/
tipper
Concrete
pump
04 nos.
02 nos.
Electric
vibrator
04 nos.
02 nos.
STAGING/ SUPPORTING ARRANGEMENTS:

Trestle
5 sets
Side shuttering of void slab 3 sets
MANPOWER:
Project engineer
Assistant engineer
Junior engineer
Foreman
Supervisor
01
01
01
01
01
Page 71 of 109
Surveyor
01

Carpenter
Fitter
Helper
Concrete pump operator
TM Driver
Male Coolie
35
35
100
02
03
25
BRIDGE WISE VOID SLAB DETAILS
Br. No.
4/1
32/3
Fly1
38/1
25/2
20/2
D
1.50
1.10
1.10
1.50
1.50
1.30
R
0.22
0.22
0.616
0.22
0.616
0.22
D0
1.15
0.75
0.75
1.15
1.15
0.95
D1
0.15
0.15
0.15
0.15
0.15
0.15
D2
0.20
0.20
0.20
0.20
0.20
0.20
W1
0.40
0.40
0.40
0.40
0.40
0.40
W2
2.075
2.075
2.075
2.075
2.075
2.075
D2
D
D1
D0
W2
W1
Fig: Half Section of Void Slab
BRIDGE WISE VOID FORMER DETAILS
W
13.75
13.75
13.75
13.75
13.75
13.75
L
8.80
8.80
8.80
8.80
8.80
8.80
Span Length
20.50
14.50
14.50
20.50
20.50
20.50
Page 72 of 109
Br. No.
Nos.X Units
Dia of Void
former
Span
Length
4/1
32/3
Fly1
38/1
25/2
20/2
6X2X2
9X3X2
9X2
6X2
6X2X2
6X3X2
1.00m
0.60m
0.60m
1.00m
1.00m
0.80m
20.50m
14.50m
14.50m
20.50m
20.50m
20.50m
Length of
void
former
17.50m
11.50m
11.50m
16.70m
17.50m
15.50m
METHOD OF CASTING VOID SLAB:

Preferably after completion of bed block, concreting and stone bedding
pedestals for Trestle to be constructed as per drawings.
After proper curing and others, prior fabricated trustle shall be shifted and
erected @ pedestal location.
Drawings for Trestle supporting arrangement shall be followed as mentioned
below:
For 14.50m obligatory span for Flyover-1, drawing No. TS/511A to be followed
For 20.50 non obligatory span @ Br No. 38/1 (Subarnarekha Bridge), 25/2,
20/2 & 4/1 drawing No. TS/501/B to be followed
For 14.50m non-obligatory span for Br 32/3, sketches as attached along with
to be followed.
After placing of stool over trestle, main girder and cross girder shall be placed
as per referred drawing.
Pre fabricated Acrow shuttering (1.25 X 0.50) shall be lifted and to be placed
for bottom shuttering as per drawing and scheme. Level and slopes shall be
checked before placing reinforcement
Trial section shall be cast along with void form for inspection of quality of
concrete and retention of shape of voided form during and after construction.
Void former shall be fabricated at Balasore/Bhadrak from approved agency
(M/s Steel Auto Ltd.) and same shall be transported by trailer to required
location. Due care shall be taken during the transportation of void formers.
Treated reinforcement cutting, bending shall be made as per BBS and same
shall be brought to location by trailer taking due care during transportation.
After completion of bottom reinforcement, void former of specified diameter
shall be placed over prefabricated chairs to avoid contact with reinforcement.
Clamping and fixing of end cone shall be followed as per the product literature
information supplied by the manufacturer, which is also enclosed here with.
it will be ensured that no seepage of grout/cement slurry occurs inside the void
former. This shall be done by properly sealing the joint of cone and void
former.
After completion of top reinforcement side shall be erected and kept in position
as per enclosed drawing. Afterwards props and supports shall be made for
rigidity and supporting the structure.
Page 73 of 109
Pockets shall be kept for providing drainage spouts between void slab casting
as per drawing by using PVC pipes/ Thermocol. During construction of
wearing coat drainage spout shall be fixed to match with top surface of deck.
MIX DESIGN:M30 grade of concrete using 20mm aggregates shall be produced as per
approved Mix Design.
TESTING OF MATERIALS:The suitability of ingredient materials of concrete shall be tested in QC

Laboratory and shall be approved by the Engineer as per specifications.
PRODUCTION OF CONCRETE:The concrete shall be produced by computerized Shirke-40 Batching Plant

having a capacity of 30cum/hr @ Subarnarekha and Haldipada Batching
Plant. The established batching plant shall be calibrated and got checked by
Engineer well before commencement of production of concrete.
TRANSPORTATION AND PLACING OF CONCRETE:From Batching Plant concrete shall be transported for void slabs casting.
The concrete shall be transported from above batching plant to the respective
locations by means of Transit Mixers having capacity 4/6cum/hr and having
slump of 80-100mm.
Concrete shall be placed by means of concrete pump for directly pouring over
void slab. The concrete shall be compacted by means of immersion type
vibrator having needle diameter of 60mm. The temperature of pouring
concrete after vibration shall be recorded in pouring format.
The concrete shall be compacted thoroughly and it shall be ensured that no
portion to be left out without vibration.
The concreting shall be laid in layers not exceeding 300mm depending on the
next layer shall be laid before initial setting time of previous layer. The
approximate time expected rate for pouring of concrete is 15cum/hr.
depending on above number of transit mixer shall be fixed for void slab use.
The concrete shall be laid to the shape, true line and level as shown in
relevant drawings. The top surface shall be finished smooth initially and
afterwards light scratches shall be provided for construction joint for proper
bonding of wearing course over deck slab.
CURING OF CONCRETE:
the structures. Also Hessian cloth shall be tied all over the periphery of the
walls for continuous curing.
Page 74 of 109
Slump Test:
recorded in Concrete Pouring Format.
Cube Test:
taken as per Table No.1700 in most specification. The same shall be tested at
the Q.C.lab for 7 days strength and 28 days strength and it will be entered in
the cube test register.
DOCUMENTS & RECORDS

Report For Inspection (RFI)
Check List For Staging And Formwork
Checklist For Reinforcement
Concrete Pour Card
Concrete Pouring Format
SAFETY MEASURES:
Technical personnel and work men are engaged during concreting operation
operations. There shall be safety signs painted on boards displayed and also
Page 75 of 109
12. INSTALLATION OF EXPANSION JOINTS

SCOPE:
Supplying and fixing of strip seal type of expansion joint under the supervision
of approved manufacturer Sanfield (India) Limited
MATERIAL:
WABO strip seal expansion joint comprises of
Edge beam
Anchorage
Strip seal
Anchor Loops
70m
m
82m
m
EDGE BEAM:
It is claw leg profiled member having
good weldability and made of hot rolled
steel section conforming to RST 37-2 OR
37-3 (DIN), ASTM A 36. It mechanically
locks the sealing element in place
throughout the normal movement cycle.
The height of the edge beam is 82mm
and is placed parallel to the width of the
deck slab.
ANCHORAGE:
The edge beams shall be
anchored
to
deck
by
reinforcement bars & anchor
studs cast in concrete. The
16 dia Anchor
wheel loads acting on steel edge
Studs
members are transferred to
staggered at
bridge deck by means of
anchorage.
It
bonds
the
200 mm c/c
expansion joint to the bridge deck. 16mm dia anchor studs, made of
steel conforming to IS2062 shall be used at 200mm c/c.
Page 76 of 109
STRIP SEAL:
This shall be of chloroprene with high tear
strength. This component is provided to
ensure water tightness. The bulbous shape of
the part of the strip seal is inserted into the
groove provided in the edge beam. The seal shall be vulcanized in
single operation for minimum full length of the joint.
ANCHOR LOOPS:
This shall be welded steel connecting the rigid anchorage with deck
reinforcement.
METHODOLOGY AND SEQUENCE OF INSTALLATION OF

WABO STRIP SEAL EXPANSION JOINT SYSTEM
During deck slab, concreting a recess of size equal to dimensions of the edge
beam shall be made conforming to the approved design data of manufacturer.
The surface of the recess shall be cleaned before installation of joint.
The exposed reinforcement from the deck slab shall be adjusted to permit
unobstructed lowering of the joint into the recess.
The gap between the steel edge members shall be adjusted depending on the
temperature at the time of installation of the expansion joint using clamp plate
arrangement.
Expansion joint is lowered in the predetermined position and the levelling of
Edge beam assembly using U-frame with threaded rod and lock nut
arrangement.
The level and gradient is adjusted matching with the final finish level of the
deck slab at the carriageway.
Anchor studs of 16mm dia shall be welded with the deck slab reinforcement to
support the Edge beam firmly without any side movement. Link bars of
16mm dia @ 200 mm c/c shall also be welded with the deck reinforcement.
Detailed sketch of this and the Methodology of Welding is also provided at the
end.
Shuttering shall be done suitably taking into account of the prevalent site
conditions.
The gap between the edge beam and the central beam shall be covered by
masking tape.
Concreting of Grade M35 shall be done at the recess portion. Good
compaction and careful curing of concrete shall be done.
After concrete has cured, the movable installation brackets shall be removed.
Rolled up neoprene strip seal shall be cut into the required length and inserted
between the Edge beams by using crowbar pushing the bulb of the seal into
the steel grooves of the Edge beams.
Bonlastic shall be applied by brush to the full perimeter on the walls of the
extrusion cavity for proper bonding.
Page 77 of 109
The Neoprene seals shall be installed in continuous lengths spanning the
entire roadway width. To ensure proper fit of the seal, dirt or standing water
shall be removed from the cavity using a brush or compressed air.
The carriage way surfacing shall be finished flush with the top of the steel
sections. The actual junction of the surfacing/wearing coat with the steel edge
section shall be formed by a wedge shaped joint with a sealing compound.
After curing of block-outs for sufficient period, the masking tape shall be
removed and the area cleaned for opening the carriageway to the traffic.
HANDLING & STORAGE

For transportation and storage, auxiliary brackets shall be provided to hold the
joint assembly together.
Expansion joint materials shall be handled with great care. It shall be stored
under cover on suitable wooden platform.
TESTS & ACCEPTANCE CRITERION

All the steel elements used shall be finished properly with corrosion protective
system
For neoprene seal & anchorage system, the manufacturers shall produce test
certificates conducted in recognized independent laboratory
The installed joint shall be checked for water tightness.
WELDING METHODOLOGY
Prepare double V groove for Butt Joint or as required.
Rigidly clamp the two pieces in straight line.
Preheat electrode at 150 170 C for 2 Hrs.
Current value [for AC or DC] should be in between 85 to 120 amps for 3.15
mm electrode [As per relevant specification of IS 814]
After each welding lap, remove slag deposit with the help of sharp Ttype
Chisel and wire brush.
Once the weld deposit filled property, grind off extra weld deposit.
Check quality level by Dye Penetrate Test.
Weld joint must be free from blowhole, pin hole and crack etc.
Clean the Weld Surface by Wire Brush and apply suitable anti corrosive
coating.
WELDING OF ANCHOR STUDS WITH DECK

REINFORCEMENT:
The Anchor Studs are adequately secured into the Deck Slab by welding of
the Anchor Studs with the Exposed Deck Reinforcement by adopting the
following procedure :For this purpose, the Secondary or Transverse Reinforcing Bars provided into
the Deck Slab, if passing by touching the Anchor Studs of the Expansion
Joints are welded / tied to the Anchor Studs.
In case no Transverse Reinforcement is available in the Deck Slab at the
required location, then the Transverse bar of 16 mm Dia is provided
Page 78 of 109
throughout the length of the Joint touching the Anchor studs and then welded /
tied to these Studs.
This Transverse Bar, if not a part of the Deck Reinforcement is also weld
attached or tied with the Deck Reinforcing Bars thus to become an integral
part of the Deck Reinforcement.
In addition to the above, the Anchor Studs [both the straight and staggered one] are
also welded to the main deck reinforcement using link bars of different sizes and
shapes to achieve integrity with the main Deck Reinforcement.
Page 79 of 109
B. OPEN FOUNDATION
SURVEY:
A traverse shall be closed considering intermediate stations and closing
station and the co-ordinates of intermediate station shall be calculated and the
miss-closed shall be adjusted to find the adjusted co-ordinates. From the
traverse, a station on the Centerline of project shall be located for prolongation
of Centerline of proposed project. A Temporary Bench Mark shall be
established on the top of mother pillars. This Temporary Bench Mark shall be
tied with reference benchmarks.
MAKING COFFER DAM:

If the area is water logged, to get a firm and level ground for carrying out the
excavation of foundation, an artificial man made cofferdam is required. A
cofferdam encasing the foundation area shall be made of sand/Earth filling
and sumps of suitable dimension shall be made for collection of water and two
numbers of 5 H.P. Diesel pump shall be installed for dewatering the area.
SETTING OUT THE WORKS:

The plan dimensions of the foundation shall be set out at the bottom of
foundation trench and checked with respect to original reference line and axis.
It shall be also ensured that at no point the bearing surface is higher than the
founding level shown on the drawings.
EXCAVATION OF FOUNDATION TRENCH:

After setting out the plan dimension of foundation, the excavation shall be
done to the required depth i.e. founding level as shown in the relevant
drawings.
The excavation shall confirm to the lines, grades, side slopes and levels
shown on the drawings. After excavation, the sides of excavated area shall be
trimmed and the area contoured to minimize erosion and ponding, allowing
natural drainage to take place.
Excavation of marshes shall begin at one end and proceed in one direction
across the entire marsh immediately ahead of back filling. The method and
sequence of excavating and backfilling shall be such as to ensure, to the
extent practicable, the complete removal or displacement of all marshes from
within the lateral limit called for on the drawing and to the bottom of marsh,
firm support or level indicated
DEWATERING:
If water is met with in the excavation due to springs, seepage, rain or other
causes, it shall be removed, by pumping out through with two numbers of 5
H.P dewatering pump and the excavation kept dry whenever so required. The
pumped out water shall be drained in to the original stream.
Page 80 of 109
DISPOSAL OF EXCAVATED MATERIALS:
Unsuitable and surplus materials not intended for use shall be transported and
dumped in a dumping yard as directed by the Engineer.
PREPARATION OF FOUNDATIONS AND CONCRETING OF

LEVELLING COURSE:
After excavating up to required strata, all the loose materials shall be removed
and the bottom of the foundation shall be leveled both longitudinally and
transversely. Before laying the leveling course, the surface area shall be
slightly watered and rammed. Now a layer of M-15 concrete shall be provided
to the thickness of 100mm as shown in the drawing. The concreting shall be
finished in one single operation to avoid any construction joint. In addition,
during concreting operation the surface area shall be kept dry by continuously
pumping out the water present inside the area.
Documents/Records:
A Checklist for P.C.C
REINFORCEMENT:
The HYSD bars conforming to IS 1786 shall be used in the work. The
reinforcement shall be fabricated as per approved Bar Bending Schedule in
accordance with relevant drawings. The bars shall be bent to specified shape
and dimensions using a proper bar bender operated by hand or power. The
anti-corrosive treatment shall be done by CPCC (Cement Polymer Composite
Coating) method.
PLACING OF REINFORCEMENT:
PVC/Concrete cover blocks of 40mm shall be placed between the bars and
formwork. Laying of reinforcement shall be separated by spacer bars at
approximately one meter intervals. The minimum diameter of spacer bars
shall be 12mm. Necessary blocks, metal chairs, spacers, supporting wires etc
or other subsidiary reinforcement shall be provided to fix the reinforcement
firmly in its convenient position.
Documents/Records:
Format for material inspection
ERECTION OF SHUTTERS:
The contact surface of the forms shall be cleaned and dried. The form
surfaces shall be evenly and thinly coated with release agent. The vertical
surface shall be treated before horizontal surface and the excess shall be
wiped out.
The concreting area shall be cleaned and all the loose materials shall be
removed. The erection of shuttering (Standard plate size 1250mmx600mm)
shall be done manually. All the joints of shuttering shall be provided
Page 81 of 109
waterproof by providing Flaxo Foam between joints. The form works shall be
done in the true line and level in accordance with the drawing. The forms shall
be supported by the pipes from the ground.
The shuttering shall be fixed in the following limit of tolerances:
a. Variation in dimension
+50mm,
-10mm
b. Misplacement from specified position in Plan
15mm
c. Surface irregularities measured with 3m
5mm
straight edge
d. Variation of levels at the top
+/- 25mm
Documents/Records:
Checklist for Shuttering
PRODUCTION, TRANSPORTATION, LAYING OF CONCRETE:

Concrete shall M25 with Maximum Size of 40mm aggregate. The concrete
shall be produced by SMM-40 Shirke, Batching plant of capacity 30 cum per
hour installed at Subarnarekha, bridge site. The concrete shall be transported
to BR-32/3 location by transit mixer of capacity 4 to 6 Cum Capacity. From
Transit Mixer the concrete shall be unloaded to a watertight platform made of
steel plate and concrete shall be placed in foundation manually. The concrete
shall be compacted by means of immersion type vibrator having needle
diameter of 60mm. The concrete shall be compacted thoroughly and it shall
be ensured that no honeycombing should be produced. The concrete shall be
laid in layers not exceeding 500mm and next layer shall be laid before initial
setting time of previous layer. The whole concreting operation shall be done in
one single operation to avoid any Construction joint. The concrete shall be
laid to the shape, true line and level as shown in the relevant drawing. The top
surface shall be finished smooth except the construction joint portion with
Abutments Shaft, where the surface shall be roughened and key blocks shall
be left for proper bonding with foundation.
Documents/Records:
Concrete Pour card
Concrete pouring Format
QUALITY CHECKS:
Slump Test:
Page 82 of 109
be taken for every one hour. The same shall be recorded in slump and
temperature register.
Cube Test:
taken as per Table No.1700 in MOST specification. The same shall be tested
at the Q.C.Lab for 7 days strength and 28 days strength and it will be entered
in the cube test register.
The form plates shall be removed after 12 to 24 hours after concreting and
form shall be cleaned again and staked properly for reuses.
CURING OF CONCRETE:
Curing shall be done with the Bore well water established near the bridge site.
A two H.P. pump shall be installed to lift the water from Bore well and delivery
pipe of 1 diameter shall be installed from pump to bridge location. It shall be
laid parallel to the axis of bridge up to entire length of bridge with nipples at
every foundation location from where pipe shall be installed for curing of
the structure for 14 days.
PLANTS AND MANPOWER PROPOSED TO BE DEPLOYED:

Plants:
Batching Plant (30 cum/ hr)

Transit Mixer (6 cum/ 4 cum)
Immersion type Vibrator (Electric) with 60mm needle
Generator (25 KVA)
Water Pump 5 HP
HM Loader
Dumper / Tipper 6 cum
1 No
Welding Transformer
1 No
1 No
1 No
3 Nos
1 No
2 Nos
1 No
Page 83 of 109
C. BORED CAST IN SITU PILES
Introduction:
The piling for the entire package is proposed to be done by direct mud
circulation method in compliance with the IS 2911. The following is the
construction m procedure for the piling works.
Equipment, Machinery to be Deployed:

1. Diesel operated winch 5T to 10T capacity
2. Tripods for piling
3. Vertical Pump
4. Tripods for suspending pump
5. DMC Pipes (dia 125mm)
6. Tremie Pipes (dia 200mm)
7. Bored bailor (wt. 1400kg)
8. Funnel for concreting
9. Boring chisel
10.
Bore casing & casing caps (internal dia 750mm, length 2.5m)
11.
Welding generator/transformer
12.
Batching plant/ 10/7 mixer machine with weigh batcher facility
13.
Transit mixer (2nos. 6 cum capacity)
Manpower Deployment
1. Winch operator
2. Skilled khalashi
3. Wireman
4. Welder
5. Mechanic
6. Unskilled labour
7. Khalasis
Procedure
Formation of bore hole:
Boring operation shall be done by percussion type drilling rigs using direct
mud circulation of chisel bailor method to extract soil out. A suitable capacitypiling rig operated by power winch diesel engine shall carry out the entire pile
installation
Temporary guide casting of required diameter about 2 to 3 m in length shall be
driven by means of MS bailor accurately on desired pile location which will act
as guide to cutting tools. This shall be removed after concreting of pile.
Page 84 of 109
After driving of guide casing, cutting tools shall be fitted with boring tube
100mm dia with water swivel at top and shall be lowered in the borehole. The
size of the cutting tool shall not be less than the diameter of pile by more than
75mm. The boring of pile shall be done by the free fall of entire cutting tools
from the desired height frequently and the soil shall be removed from the
borehole through circulation of mud by direct mud circulation system or/and by
the use of bailor.
In direct mud circulation system Bentonite slurry shall be pumped through the
boring tube to the bottom of cutting tools with high capacity mud pump from
the Bentonite tank. The soil with the Bentonite slurry comes out from the
borehole shall be taken back to the Bentonite tank through channels to recirculate again in the borehole. As the borehole progresses, boring tubes shall
be added till the required depth is achieved.
Bentonite slurry
Sodium based Bentonite powder shall be used for making slurry. The
Bentonite shall be mixed thoroughly with water to make a suspension, which
will maintain the stability of the borehole for the period necessary to complete
the piling operation. The density of the Bentonite suspension shall be between
1.03 to 1.10g/ml depending on the soil and site conditions and shall be
checked periodically with the help of hydrometer.
Reinforcement work
The CPCC treated reinforcement shall be prefabricated in to cages sufficiently
rigid to withstand handling without damages. The methodology for CPCC
treatment shall be submitted separately reinforcement cages shall be made in
segments and the same shall be lowered in to the borehole and assembled by
providing necessary laps, which shall be staggered. Proper cover of the
reinforcement shall be ensured by use of suitable concrete roller blocks, cast
specifically for the purpose. The full length of reinforcement cage shall be kept
in position. Cover blocks made of concrete of same strength as specified in
the member. This shall be checked by testing of corresponding control cubes
of 7.06 cm size cast simultaneously. Alternatively plastic over blocks approved
by the Engineer shall be used.
Concreting of pile
Concrete for piles is of grade M35, submission and approval of mix design
shall be done separately. Concrete for piling shall be carried using 2nos. of
transit mixers from batching plant located at Subarnarekha. Alternately
concrete shall be produced at site using mini batching plant. Placing of
concreting shall be done manually using concrete trolleys.
Page 85 of 109
Concreting shall be done by Tremie method. Concrete shall be placed through

hopper and 200mm dia Tremie pipes. The first batch of concrete shall be
charged by using charger plate and sliding plug.
The tremie pipes shall be gradually withdrawn as the level of the concrete in
the borehole rises. The top level of concrete in the bore hole shall be brought
up above the cut-off level by 0.6m (as per MOST page 354, cl 1115.1.5) so as
to permit removal of all laitance and weak concrete, to ensure good and
sound concrete at the cut-off level for proper embedment in to the pile cap.
The entire pile installation work shall be carried out in accordance with IS 2911
and sound engineering practice.
Quality Control:
Slump shall be measured at site periodically as directed by the engineer.
Work cubes shall be taken as specified in Table 1700-8 of MOST or as
directed by the Engineer.
Page 86 of 109
D. PILE CAP CONSTRUCTION (for ROB-4)
INTRODUCTION:
National Highway Authority of India has proposed to widen the existing road
between Balasore to Kharagpur. The job of preparing detailed project report
was entrusted to M/s SHELADIA/PBI/MRC and the same was prepared after
carrying out proper topographic and hydrographic survey, pavement condition
investigation, geotechnical investigation etc as required in NHAIS TOR. The
National Highway Authority of India based on the Detailed Project Report has
entrusted to M/s gammon India Limited with the construction of major bridges
in this stretch. Out of these 20 Bridges, one is located at CH: KM 116+888.20
[ROB4].
SURVEY:
Referring control points Z-16 & Z-17 established by LBII, a traverse shall be
closed considering intermediate station A,B and Z-16 & Z-17 as closing station
and the co-ordinates of intermediate station shall be calculate and the missclosed shall be adjusted to find the adjusted coordinates. From the traverse, a
station on the Centerline of project shall be located for projection of Centerline
of proposed project i.e., from CH KM 116+86.604. A sketch for the survey
layout for ROB-4 is enclosed in Annexure-1 and the co-ordinates sheet is
enclosed in Annexure-2 for your reference. A temporary benchmark shall be
established on the top of mother pillar. This temporary Bench Mark shall be
tied with reference benchmarks i.e., 24.237 M1 & P2/R & A1/L having value &
24.319 & 20.049 respectively.
SETTING OUT THE WORKS:

The plan dimensions of the foundation shall be set out at the bottom of
foundation trench and checked with respect to original reference line and axis.
It shall be also ensured that at no point the bearing surface is higher than the
founding level shown on the drawings.
PREPARATION OF FOUNDATIONS AND CONVERTING OF

LEVELING COURSE:
After excavating up to required Depth, all the loose materials shall be removed
form and around the piles and the bottom of the foundation shall be levelled
both longitudinally and transversely. Before laying the leveling course, the
surface area shall be slightly watered and rammed. Now a layer of M-15
concrete shall be provided to the thickness of 100mm as shown in the
drawing. The concreting shall be finished in one single operation to avoid any
construction joint. And during concreting operation the surface area shall be
kept dry by continuously pumping out the water present inside the area.
Document / Records:
i] Checklist for P.C.C
Page 87 of 109
REINFORCEMENT:
The HYSD bars conforming to IS:1786 shall be used in the work. The
reinforcement shall be fabricated as per approved Bar Bending Schedule in
accordance with relevant drawings. The bars shall be bent to specified shape
and dimensions using a proper bar bender operated by hand or power. The
anti corrosive treatment shall be done by CPCC [Cement Polymer Composite
Coating] method. The CPCC treatment shall be done at treatment yard
established at ROB-4 Site. The detailed methodology has already been
submitted to you.
PLACING OF REINFORCEMNT:
PVC/Concrete cover blocks of 50mm shall be placed between the bars and
formwork. Laying of reinforcement shall be separated by spacer bars at
approximately one meter intervals. The minimum diameter of spacer bars
shall be 12mm. Necessary blocks, metal chairs, spacers, supporting wires etc
or other subsidiary reinforcement shall be provided to fix the reinforcement
firmly in its convenient position.
Documents / Records:
1] Checklist for reinforcement
2] materials inspection
ERECTION OF SHUTTERS:
The contact surface of the forms shall be cleaned and dried. The form
surfaces shall be evenly coated with release agent. The vertical surface shall
be treated before horizontal surface and the excess shall be wiped out.
The concreting area shall be cleaned and all the loose materials shall be
removed. The erection of shuttering [Standard plate size 1250 mm x 500mm]
shall be done manually. All the joints of shuttering shall be provided water
proof by providing Flaxo Foam between joints. The form works shall be done
in the true line and level in accordance with the drawing. The forms shall be
supported by the pipes from the ground.
The shuttering shall be fixed in the following limit of tolerances:
Variation in dimension - +50mm, 10mm
Misplacement from specified position in Plan 15mm
Surface irregularities measured with 3m straight edge-5mm
Variation of levels at the top - +/-25mm.
Document / Records:
i] Checklist for staging and formwork
PRODUCTION, TRANSPORTATION, LAYING OF CONCRETE:

Concrete shall be M35 with Maximum size of aggregate 20mm. The concrete
shall be produced partly by four Gamcie installed at different position at site
with total output of 15 Cum/hr and partly by batching Plant of capacity 30 Cum
Page 88 of 109
per hour installed at Debra Site. To take care of concrete mix quality in Transit,
mix design shall be adjusted accordingly.
a] Each Gamcie will by supported by adequate number of manpower and
weighing boxes.
Per batch of production will be with respect to two bags of Cement.
b] Concrete by Batching Plant: The concrete shall be transported to ROB-4 location at a distance of 25 KM by
Transit Mixer of capacity 4 to 6 Cu. M. capacity. From Transit Mixer the
concrete having a slump of 80-100 mm shall be placed in Pile foundation
through a mobile chute to avoid segregation in concrete being poured from a
height. The concrete shall be compacted by means of immersion type vibrator
having needle diameter of 60mm and the temperature of poured concrete
after vibration shall be recorded in the pour card format. The concrete shall be
compacted thoroughly and it shall be ensured that concrete is properly
compacted. The concrete shall be laid in layers not exceeding 300/500mm
depending on the dimension of structure and next layer shall be laid before
initial setting time of previous layer. The whole concreting operation shall be
done in one single operation to avoid any Construction joint. The concrete
shall be laid to the shape, true line and level as shown in the relevant drawing.
The top surface shall be finished smooth except the construction joint portion
with Abutments/Piers Shaft where the surface shall be roughened and key
blocks shall be left for proper bonding with foundation.
Documents / Records:i] Concrete Pour card
ii] Concrete Register
QUALITY CHECKS:
i] Slump Test: - Slump shall be taken continuously for first 3 loads and
thereafter slump shall be taken periodically as directed bythe Engineer. The
same shall be recorded in slump and temperature register. The format for the
slump register is enclosed in Annexure
ii] Cube Test: -Cubes of size 150 x 150 x 150 mm shall be taken.
Number of cubes shall be taken as per Table No. 1700 in most specification.
The same shall be tested at the Q.C. Lab for 7 days strength and 28 days
Format for Cube Testing is enclosed in Annexure
The form slates shall be removed after 12 to 24 hours after concreting and
form shall be re-cleaned and stacked properly for reuses.
CURING OF CONCRETE: Curing shall be done with the Bore well water established near the bridge site
[ROB-4]. A 5 HP pump shall be installed to lift the water from Bore well and
delivery pipe of 1 diameter shall be installed from pump to foundation
location.
Page 89 of 109
PLANT AND MANPOWER PROPOSED TO BE DEPLOYED: PLANTS:
Batching Plant [30 Cu.M / Hr]

Transit Mixer [6 Cu. M / 4 Cu. M]
Immersion type Vibrator [Electric]
with 60mm needle
1 No
Generator [25 /30 KVA]
: 2 No
Water Pump 5 HP
JCB
: 1 No
Dumper / Tipper 6 Cu.M
: 1 No
Welding Transformer
: 1 No & Gamcie 4 Nos

: 5+1 Nos
: 3 Nos
: 2 Nos
: 1 No
MANPOWER
Supervisory Staff: Sr. Engineer
:01 No
Junior Engineer :01 No
Foreman
:01 No
Other Staff:
Q.C. Engineer : 1 Nos

Supervisor [Civil] : 4 Nos
Foreman [Mech] : 1 No
Electrical Foreman
: 1 No
Electrician
: 2 Nos
Mechanic
: 2 Nos
Mechanical Helper
: 2 Nos
Store Keeper
: 2 Nos
Skilled / Unskilled Labours:
Gas Cutter
Fitter
Welder
Khalasi
Mason
Unskilled Labour
Carpenter
Fitter
Helper
: 1 No
: 3 Nos
: 1 No
: 30 Nos
: 4 Nos
: 30 Nos x 2 Shifts
: 3 Nos
: 5 Nos
: 8 Nos
E. CONSTRUCTION OF EMBANKMENT
& Diesel Vibrator
Page 90 of 109
INTRODUCTION:
The work of back filling/embankment forming shall be started only after
ensuring that the work in the abutment/bridge structure is sufficiently
advanced to permit the completion of the filling without any risk of damage to
the structure.
The fill materials shall be deposited in horizontal layers in loose thickness and
compacted thoroughly to the requirement of IS Specifications. For laying filter
media behind abutment, the media shall be laid in layers simultaneously with
the laying of fill materials.
PLANT/MACHINERY & MANPOWER

a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
Loader cum excavator (JCB) 02 Nos.

Excavator
Vibro roller of suitable capacity
Plate compactor
Dumper
Water tanker
Auto level/dumpy level
Total station
Dozer for clearing, grubbing & spreading
Field Test Equipment
MANPOWER:
Assistant engineer
Junior engineer
Foreman
Supervisor
Surveyor
Field Test Assistant
01 no.
01 no.
01 no.
01 no.
01 no.
01 no.

Khalasis
Helper
FILLING MATERIALS:
10nos.
15 nos.
1 No.
1 No.
1 No.
1 No.
8 Nos.
1 No.
1 No.
1 No.
1 No.
1 No.
Page 91 of 109
Predominantly River sand shall be used and Moorum shall be used as
sandwiching layer at side edges for additional stability of embankment.
APPROVAL OF BORROW AREA:

Borrow areas shall be identified and shall be divided in a grid of 25 m.
Each grid shall be exhumed and Bore log data sheet shall be prepared for
each grid and Samples from each grid shall be collected and tested for its
suitability at Q.C.Laboratory at Subarnarekha.
Modified Proctor density test shall be conducted as per IS 2720 for its
suitability.
After approval, before excavation of embankment earth, borrows area, top
surface shall be cleared and grubbed. Excavators & Dumpers shall be
engaged for shifting of material to site.
RIVER SAND:
Source: Subarnarekha River
Acceptance Criteria: Test result shall conform to IS 383 and tests for
conformity shall be carried out as per IS 2386 Part I to VIII
MOORUM/ EARTH:
Source: Material shall be received from approved quarry at Amarda Road and
any change in quarry shall be intimated and approved from the Engineer
before using the same.
MATERIALS FOR FILTER MEDIA:

Coarse Aggregate:
Material 80mm / 20mm shall be received from approved source. Sample shall
be collected for every 200 M3 of aggregate or any change of source, the
following test shall be conducted in Q.C.Lab as per IS 2386
Acceptance Criteria:
Test result shall conform to IS 383 and tests for conformity shall be carried out
as per IS 2386 Part I to VIII
PREPARATORY WORKS:
Initially Trees, roots shall be uprooted behind abutments A1 & A2 manually /
mechanically.
Layout for embankment construction shall be done with Total Station
Instrument / Theodolite. Toe level marking shall be done with lime powder.
Layout shall be marked true to lines, curves, slopes and grades.
Within the marked limit cleaning, grubbing operation shall be done and debris,
deleterious materials and boulders shall be cleared.
Page 92 of 109
Initial Ground level behind abutments up to 30 m from dirt wall shall be
recorded. A cross section of natural ground shall be prepared at
5 M
intervals and the level for the same shall be recorded jointly with the
Engineers representative
Excavator & dumpers shall be deployed for scarifying boulders at sides and
the elevated ground shall be excavated to prepare a uniform ground free from
undulations.
Soil samples from existing natural ground shall be taken jointly with Engineers
representative and the same shall be sent to Q.C.Laboratory at Subarnarekha
to ascertain the maximum dry density and Optimum moisture content.
Leveled ground supporting embankment shall be scarified, watered, and
compacted to 95% density/ 97% density depending upon embankment height
before commencement of Embankment construction.
FILLING WORKS:
Sand filling shall be done wherever furrows are seen to form a supporting
leveled ground.
Earth/Sand from approved borrow areas shall be excavated and placed on
the supporting leveled ground.
The embankment material such as Moorum/earth shall be spread in layers of
uniform thickness not exceeding 250mm-compacted thickness over the width
of embankment. Number of layers of 250mm compacted thickness to reach
the proposed formation level shall be stipulated from beginning of work so as
to maintain density records, levels and date on which tests are done.
Successive layers shall not be placed until the layer under construction has
been properly compacted and which is to be ascertained after field density
tests. Wherever water is required, it shall be added by tankers fitted with
sprinklers. Compaction shall be done by Vibro roller of 10T capacity to achieve
relative compaction as follows:
Embankment up to 6m-height 95% relative compaction
Embankment exceeding 6 m height 98% relative compaction for backfill
Then earth/Moorum shall be sprayed by Tractor/dozer in between two
Moorum layers of two extreme ends to achieve compaction thickness of
250mm.
For additional compaction Vibro roller (10 T) shall be engaged to achieve 97%
of maximum dry density.
Every layer shall be tested for density test by Sand replacement method.
(Field test)
Samples shall be collected from each layer and Modified Proctor density test
shall be conducted at Q.C.Laboratory.
FILTER MEDIA:
The material for filter shall comply with grading zones in Table 400-3 of MOST
and shall consist of sand, gravel, stone or coarse sand to prevent escape of
the embankment material through the voids weep holes in abutments as well
as to allow free movement of water without creating any uplift head.
The filter material shall be laid in two layers:
40mm coarse aggregate of 150mm thickness
10 mm coarse aggregate of 150mm thickness
Followed by crusher dust/sand of 150mm thickness
Page 93 of 109
CONSTRUCTION METHOD FOR FILTER MEDIA
Before starting of work, the weep holes in abutment faces shall be cleared.
Survey lines to be established by lines over ground and pegs at intervals of
2m to ensure clear identification line to be marked over abutment faces to
facilitate layer in filling. Excavation and dressing shall be done prior to start of
laying of filter media.
The weep holes of the abutment shall be blocked temporarily by over size
aggregate to prevent entry of any of the filling materials into the weep holes.
Initially cleaning and grubbing shall be due to prepare bases and then
sufficient rolling with Vibro roller to be done.
The embankment material shall be spread in layers of uniform thickness of
250mm over the entire width of embankment and then compacted by
mechanical means and finished by compactor as per clause 305.3.6 of MOST
specifications.
The embankment filling shall be done up to 450mm from the abutment face of
earth fill to provide for filter media, which shall be filled simultaneously with
filter media of composition as specified.
The filter material shall be laid over the prepared base in three vertical layers:
40mm coarse aggregate of 150mm thickness
10 mm coarse aggregate of 150mm thickness
followed by crusher dust/sand of 150mm thickness
to ensure filling of filter media is done simultaneously a framework(ref.
Annex.3) shall be used where filter media 1,2 &3 are placed in required order
of required width and layer thickness. The framework shall be moved
sideways in each layer to build up the full length of abutment (ref. Annex.2)
The filter media materials shall be filled as per specified thickness and then
compacted as per specification.
The embankment filling and filter media filling shall be done simultaneously as
described above in layers of 250mm up to the specified height. Successive
layers shall not be placed until the layer under construction has been
thoroughly compacted to specified requirement and each compacted layer
shall be finished parallel to the final cross section of the embankment.
TESTING & SAMPLING PROCEDURES

Moisture content
Moisture content of the material shall be checked at the site f placement prior
to commencement of compaction in accordance with IS 2720(Part 2)
SURFACE FINISH
Surface finish of the filling shall be checked in accordance to requirement of
Clause 902 of MOST specifications.
Documents & Records
Request for inspection (RFI)
SAFETY MEASURES:
Technical personnel and workers engaged at site shall be equipped with
helmets and safety shoes. There shall be safety signs painted on boards and
Page 94 of 109
displayed and barricading / fencing shall be done. These shall be security
guards posted at suitable locations. For night, sufficient flood lighting shall be
provided with red light danger signs at vantage locations. First aid counter
shall be maintained separately in store through out the working hours.
Page 95 of 109
F. STONE PITCHING IN EMBANKMENT SLOPES

INTRODUCTION:
Laying of stone pitching and boulder apron are the two major methods used in
bridge construction. This method is adopted in OR/WB-I package in BR-4/1,
BR-17/1, BR-20/2, BR-20/3, BR-24/1, BR-24/2, BR-25/2, BR-32/3 and BR89/1 A. In addition to bed protection, stone pitching helps in guiding the
stream without damaging the abutment walls, whereas boulder apron
provides protection against scouring of river sand.
SALIENT FEATURES OF BOULDER APRON:

It is laid beside the curtain wall on both upstream side and downstream side.
Length:
Width :
Depth :
Varies as bridge length varies

On U/s side 2 m and on D/s side 4 m
1 m uniform for all the bridges
CRITICAL MATERIAL USED:

The size and weight of pitching stones (of minimum sp. Gr. 2.65) shall be
minimum 300mm size & weighing not less than 40 Kg
Filter medium materials: The filter media shall comply with the requirement
mentioned in Cl.2504.2.2 of MOST for which the specific three criteria of
MOST must be satisfied. Laboratory test results and calculations shall be
submitted
MACHINERIES:
Excavator - 1 No
Dumper - 2 Nos
MANPOWER:
Project Engineer - 1 No
Site Engineer
- 1 No
Page 96 of 109
Safety Engineer - 1 No
CONSTRUCTION METHODOLOGY FOR STONE PITCHING:

Boulders of regular rectangular minimum 300mm size & weighing more than
40 Kg shall be received from Mitrapur quarry.
Dumpers shall be used for transporting the boulders to site.
Before stone pitching, backfilling is done as per the drawing from curtain wall
to approach slab maintaining a slope of 1:1.5
In order to prevent escape of the embankment material through the voids of
the stone pitching a layer of 300 mm thick filter material is laid over the backfill
material. This would serve as a sandwiching layer between the boulders and
the backfill material. In addition, this layer enables greater stability and friction
for settlement of boulders firmly without rolling off from top. Thus, we can
preclude any uplift head on pitching by the free movement of water.
Filter material shall be crusher dust and 10mm aggregate. Before laying the
pitching, the sides of the banks shall be trimmed to the slope of 1:1.5. Over
the prepared base filter-material shall be laid over and suitably compacted.
Boulders shall be shifted manually shifted by labors.
It shall be meticulously placed by skilled labors and hammered properly to
avoid any roll off. In addition, the largest stones shall be placed in the bottom
courses and it acts as headers for subsequent courses.
For stone pitching also slope of 1: 1.5 is maintained with lines and levels as
per the drawing. Typical sketch of stone pitching and boulder pitching for BR4/1 is enclosed in Annexure-1.
Voids of stone pitching shall be filled with spalls of minimum 25mm for better
interlocking.
CONSTRUCTION METHODOLOGY FOR BOULDER APRON

ADJOINING RETAINING WALL:
Excavation shall be done by EX-60 for a width of 1m from the curtain wall and
a depth of 1 m for laying boulder apron.
Excavated surface on which apron is laid shall be leveled and prepared
according to dimensions mentioned in the drawing.
Walkway shall be prepared all around the curtain wall to facilitate the laying
process.
Boulders received from the quarry shall be examined visually by the site
engineer and it shall be arranged to place it manually ensuring greater
interlocking characteristics.
SAFETY ARRANGEMENTS:
All stone carrying labors shall be provided hard hand gloves, boots and
helmets.
Acute surveillance shall be done by the safety engineer for smooth execution.
Page 97 of 109
During heavy rain, laying of stones shall be stopped to avoid any casualties
caused due to slippery.
Page 98 of 109
G. REINFORCED EARTH WORK
NAME OF PROJECT
CLIENTS
CONSULTANT
NICE JV
CONTRACTOR
R.E.W. AGENCY
KOREA
:
:
:
20 BRIDGES, PACKAGE OR/WB-1

NATIONAL HIGHWAYS AUTHORITY OF INDIA
LOUIS BERGER INTERNATIONAL INC AND
:
:
GAMMON INDIA LIMITED, MUMBAI

KOLON
INTERNATIONAL
CORPORATION,
METHODOLOGY FOR CONSTRUCTION OF REINFORCED EARTH WORK

(REW) FOR FLY OVER FL-1 ON NH-60
INTRODUCTION:
The concept of Reinforced Earth is similar to reinforced concrete, in which
tensile load carrying elements are introduced in the earth mass to improve its
load carrying properties. Stresses produced with in the earth mass are
resisted by reinforcing strips, which are transferred via friction. The volume of
earth mass thus formed with distributed strips becomes its own supporting
structure. A form of facing cover, consisting of discrete cruciform shaped
precast concrete elements is provided for durability and aesthetic appearance
to the structure. Besides, this unique shape of the panel caters to maximum
transversal, vertical and longitudinal flexibility.
SALIENT FEATURES OF FLY OVER01:
LENGTH OF APPROACHES:
Balasore end
- 67.91 m
Kharagpur End
- 110.7 m
HEIGHT OF REW WALL:

Balasore End
Kharagpur End
Left carriage
Right carriage
Left carriage
Right carriage
way
way
way
way
10.941m
9.735 m
10.81m
9.217 m
TYPE OF RCC FACIA PANELS:
Panel A
: 131 Nos
Panel B
: 137 Nos
Page 99 of 109
Panel C
: 1416 Nos
Panel D
32 Nos
Panel E
6 Nos
Panel F
6Nos
Panel G
125 Nos
Panel H
128 Nos
Panel F
02 Nos
Panel D
08 Nos
Panel E
02 Nos
Panel G
08 Nos
Panel H
06 Nos
Panel C
04 Nos
Total
: 2011 Nos
QUANTITY INVOLVED:
R.E.W at
Starting
Chainage
End
Chainage
Total
Length
(Rm)
Area of
Facia
Panels(Sqm)
Balasore
Side 0+234.625M 0+302.28M 67.655
Approach (L.H.S)
Balasore
Side 0+226.883
0+295.094M 68.166
Approach (R.H.S)
M
750.21
Balasore
Side
Abutment End
Kharagpur
Side
Approach (L.H.S)
Kharagpur
Side
Approach (R.H.S)
Kharagpur
side
Abutment End.
Total
25.066
269.62
111.699
1123.734
0+311.02M
0+420.726M 109.706
1027.536
0+318.251
M
0+318.251
M
25.066
269.62
420.06
4242.54
0+302.28M
0+302.28M
0+318.251M 0+429.95M
REFERENCE DRAWINGS:
Quantity
involved in
earth work
(Cum)
17,225
662.45
28,352
45,577
Page 100 of 109
Following Reference Drawings are to be followed for proper execution of

REW work on FL-1 .
S.
Drawing No.
No
1 NH-60/B/T2
Drawing
prepared By
Sheladia
Drawing
approved by
NHAI
Kolon
international
Kolon
international
Kolon
international
LBII
Schematic
Presentation of facia
elevation at Balasore
side (LHS)
P-0/FL-1,BLS (RHS) Schematic
side (RHS)
Kolon
international
LBII
Kolon
international
LBII
P-0/FL-1,KGP(LHS)
Schematic
elevation
at
Kharagpur side (LHS)
Kolon
international
LBII
P-0/FL-1,KGP
(RHS)
Schematic
side (RHS)
9 P-0/FL-1,Abt
Schematic
elevation
for
Abutment for Both
KGPR and BLSR
side (OR WB-1/FL-1)
10 DB-7-OR-WB-I-FL-1 Typical Details of
Corner
column,
Abutment & various
accessories required
for Panel Erection for
FL-01
Kolon
international
LBII
Kolon
international
LBII
DB-2
DB-4/R1
DB-1/R4
P-0/FL-1,BLS (LHS)
Drawing Title
General Arrangement
of FL-1 Fly over
Typical Details of
Precast Panels
Installation
Methodology
Details of Reinforced
Earth Wall
Kolon
International
LBII
LBII
Page 101 of 109

SOURCE & QUALITY ASSURANCE OF CONSTRUCTION MATERIALS: Utmost quality shall be maintained for the following materials.
Backfill Material
Reinforcing Strips
Drainage System [Kony horizontal drain & Kony Pack drain]
RCC Facia Panels
BACKFILL MATERIAL :
Sand from the bed of River Budo Balango near Balasore is tested in
Laboratory and satisfied as fill material for REW zone, fulfilling all design
criteria such as angle, grain size distribution and PI.
Sample shall be collected from the borrow area [sand from Budhabalang
River] and the same shall be tested at any other approved laboratory for
getting approval as a fill material, before starting the work. Borrow area plan
shall be enclosed. The following test shall be conducted.
Peak Friction Angle

Maximum Dry density
OMC
Cohesion C
Gradation
ACCEPTANCE CRITERIA
i) Pick Friction Angle shall not be less than 30 degree.
ii) All Backfill Materials used within the RE wall shall be reasonably free from
organic or other deleterious material
Iii) Gradation shall conform the limits as shown below:
Sieve Size
Percent Passing
25mm
100%
10mm
75% - 100%
75 Micron
0 15 %
This sand will be transported from Budha Balango to site using

Dumpers, trucks or Tractors as per requirement and availability. Filling
shall be done by the sand only between Right & Left RE walls
irrespective of any zone.
Page 102 of 109

REINFORCING STRIPS
Reinforcing strips [Kolo ties] shall be manufactured & supplied by M/s Kolon
International Corporation, Seoul, South Korea in the form of KT-70, KT-50, KT30, KT-20 .
ACCEPTANCE CRITERIA
The test results shall conform to ASTM D5262 & 5261, ASTM D 4595, GRI
- GG4 [b], ASTM D-794, ASTM D-746, ASTM D-543 & ASTM D-4355
Testing facility is not available any where in India however; Test results from
out side India will be submitted.
DRAINAGE SYSTEM [KONY HORIZONTAL DRAIN & KONY PACK DRAIN]

Kony horizontal drain & pack drain shall be manufactured and supplied by M/s
Kolon International Corporation, Seoul, South Korea.
ACCEPTANCE CRITERIA
The material shall conform to MOST Specifications.
RCC FACIA PANELS

The RCC Facia Panel of M35 Grade in cruciform shape 18 Cm thick and
nominal dimension of 1.5 M / 1.5 M shall be cast in our casting yard at ROB-1
[Haldipada] as per specifications,
Drawings & approved methodology.
After 14 days of curing shall be transported to Fly-01 side by means of low
bedded open Trailer / Truck & stack properly.
ACCEPTANCE CRITERIA
The Facia Panel shall be cast for its structural connection and back filling
loading as per IS 456 & IRC 21.
WORK METHOD STATEMENT:
Page 103 of 109

This work method statement is specific for FL-1 fly over but for detailed
installation procedure in general, drawing no. DB-4/R1 is to be referred
simultaneously.
ACTIVITIES INVOLVED :
1. Layout
2. Excavation of trenches
3. Casting of P.C.C
4. Casting of U-Beam
5. Casting of corner Junction Column
6. Erection of pre-cast Facia panel
7. Alignment of pre-cast Panels at 2 degree inclination with vertical.
8. Filling of approved materials up to KONY-Drain level.
9. Compaction of approved materials up to KONY-Drain level
10.
Layout of KONY-Drain & Vertical Pack-Drain.
11.
Fixing of KONY-Drain & Vertical Pack-Drain with Proper
connection between them with 100 micron P.V.C Tape.
12.
Filling of Pack-Drain with graded material as specified in
drawing.
13.
Filling of approved Backfill materials in layers of 300mm thick
upto 1st layer of friction Tie.
14.
Fixing of 20mm dia rod as required considering different
combination factor of Configuration
15.
Laying of friction-tie.
16.
Dumping of approved fill materials within RE walls.
17.
Spreading of dumped material with EX-60 excavator above
friction ties.
18.
Leveling of spread material by Grader/ Dozer & manually.
19.
Compaction of filled material by 10 Ton Vibro-Roller , except
1.5 m patch behind R.E.W Panels.
20.
Compacting the left out 1.5 m width patch behind R.E.W
panels by 1ton compactor or 75 Kg. Plate compactor. In case of
plate compactor will use, layer thickness will be 100 mm.
Otherwise layer thickness will be 250mm.
21.
Laying of Horizontal Pack-Drain as per approved drawing at
an interval of 50m c/c.
22.
Erection of 2nd layer of facia panel after backfilling 3/4 th height
of first layer of pre-cast panel.
23.
other layers of friction-ties will be laid as specified in drawing
at 0.75m interval from 1st tie.
24.
The dimensions of top layer of Facia Panel will be adjusted
considering the vertical curve.
Page 104 of 109

25.
Casting of Cast-in-situ Crash-barrier.
1. ,LAYOUT
The R.E.W in approaches will be in circular curve as well as in transition
curve. Since this Fly over is a part of a 360m radius minute survey deficiency,
physical center of the existing Concrete structure of Fly over is to be matched
with the Road center line of Road contractor on far end. This will give a true
center line and alignment of Fly over. For preliminary alignment to carry out
excavation of trenches for casting of pcc, at every 10 Mtrs interval along the
center line of left side and right side of REW panel lines will be marked. to set
out the center line of R.E.W wall. Before casting of U-Beam a fresh layout will
be given at an offset of 2 metre interval to get a smooth profile of circular
curve. This survey will be done using Total-Station and measuring tape.
2. EXCAVATION OF TRENCHES
After setting preliminary alignment , excavation of trenches will be carried out
upto an approximate depth of P.C.C level by EX-60 Excavator. Dressing of
trenches will be done upto required founding level by manually.
2(a) Trenches in between pile caps and between Pile cap and corner column
shall be dug upto RL 6.125 and shall be filled up with boulders in layers and
voids filled up with sand so as to avoid relative settlement or tilt of the portion
of the standing RE wall. This shall be checked by Engineer before laying
PCC.
3. CASTING OF P.C.C
A thin layer of sand will be placed over the bottom surface and plate compactor will
be used to get a properly leveled surface before casting of PCC with M15 grade of
concrete. As the trenches had made with due care, no shuttering will be placed and
the edges of PCC will touch the trench wall. The PCC will be laid only after test for
SBC has been satisfactory. If required SBC is not achieved, soil stabilization work
shall be carried out.
4. CASTING OF U-BEAM
After getting a fresh layout on P.C.C top, CPCC treated steel will be fixed as per
approved bar bending schedule. Outside shuttering of U-beam will be fixed and
aligned . M35 grade Concrete upto bottom of U-beam wall will be done first . Next
the inner side shuttering of U-beam wall will be fixed and concreting upto required
level will be done.
5. CASTING OF CORNER JUNCTION COLUMN
Page 105 of 109
Detail layout of corner junction column will be done at pcc level RL 5.875. .Shuttering
For a height of 1.5 m will be fabricated at our Fabrication Yard. After placing
reinforcement steel and proper fixing of shuttering, first 1.5m casting will be done by
M35 grade of concrete. Next 1.5m casting will be done in layers only after erection of
first layer of Precast Panels and completion of reinforced earth filling upto 3/4th of
first layer. The base of corner junction column to be done as per Drg.No.DB-1/R4
(Rev 5).
ERECTION OF PRECAST PANELS

25mm thick thermocol will be placed in U-beam bottom & 2sides and corner
junction column groove conforming the approved drawing. After that First
layer of Precast panels will be erected starting from the Corner junction side
i.e the Abutment end side. The first Panel will be E-type as specified in
Drawing. After that alternately B and A Type Panel will be erected with the help
of 5 ton Capacity Crane. The panels shall be placed at 92 degree for RE
walls on LHS & RHS ends and vertically on Abutment face between the
corner columns of LHS and RHS ends.
A temporary spacer bar shall be used for panel to panel centering. , the panel
shall be aligned at an inclination of 92 degree and horizontally intermittently.
The spacer bars will be removed after the erection of one layer of RE panel.
The vertical alignment consists of aligning the panel along the centre line of Ubeam. This shall be done by adjusting the panels by means of crow bar
[Rubber pad shall be used to avoid direct contact crow bar to facia panel] to
match that panel with respect to the control line and sighting both the lines
until all offsets are eliminated. For vertical alignment panel so placed are tilted
to the required batter by means of hard wood wedges inserted at the bottom
of the panel. The 92 degree inclination shall be ascertained by a shopmade
template with a level-tube. When desired inclination is achieved, the bottom
wedges are tightened and consecutive panel is adjusted to the same
inclination.
The panels are secured in the position by a pair of seasoned wooden clamps
and supported by wooden props used only for base course.
The procedure shall be carried up to the last panel of the row. The aligned
panel shall be sighted by the both end and any offset if observed, corrected by
adjusting wooden clamps.
The recess formed at the bottom due to inclination of panels shall be plugged
by cement slurry grouting / thermocol.
The joints between the panels are sealed by non-woven geotextile filter
fabric or closed cell Polyethylene Foam.
Second layer of Panel will only be placed after first layer is covered in
compacted earth up to th height. All subsequent layers of panels will
also be put when its bottom layer is earth filled and compacted upto th
height.
Page 106 of 109

The precast panels for the top layer will be cast at site considering the
vertical Curve profile.
The same template to be used to check the alignment of panels at 92
degree. [Ref Drg. No. DB-7)].
BACKFILLING
Access for tippers & trucks movement:
The following arrangement shall be made for access to tippers, trucks &
other machineries to enter in REW area.
1. In BLS side Approach:
Ramp shall be made in already left 10 M approach in BLS (L.H.S)
R.E.wall, since the R.E.wall level will come up to L&T Road level.
After that L&T Road shall be used for dumping material in side of
the R.E.wall.
2. In KGP side Approach:
A ramp of 4.5m width shall be made at the centre of two RE walls
connecting L&T road by compacting in Layers of 250mm thick.
The ramp shall be used for dumping approved sand in REW area.
As the Koloties is coming upto 7.5 m (max) from both side of RE
wall, there will be no hindrance of work for the Ramp. The ramp
shall be made by approved sand & moorum and will be kept
permanently.
Approved back fill material conforming the requirement of reinforced soil fill
[Budhabalang River sand] shall be laid by means of Tippers / Trucks at a
distance of 1 m to 2 m from the Facia panel and towed by excavators [up to
drainage bay].
It shall be leveled to thickness such that the compacted thickness shall not be
more than 250 mm.
All visible organic impurities and clayey clods shall be removed and disposed
before its spreading. Water shall be sprinkled on the sand near about OMC
[+2% & -1%] and rolled over by Vibro Roller of 10 MT capacity from center to
edges on either side for leaving portion 1.5m from face of facia panel on either
side.
Normally 5 passes shall be given. The compacted soil shall be tested for in
situ density. The patches not confirming to the specification shall be lightly
drenched, rolled and recheck for density i.e., 97% of MDD.
The portion approximately 1.5 m from the facia panel shall be compacted with
the help of 1 Ton Roller normally 10 passes are required to compact the same.
The compaction shall be from inner side to outer side. When the compacted
fill reaches the level of GI hook in the panels the friction ties shall be
connected to panels with the help of anchor bar of 16 dia and vertical pin of 20
dia [600 mm deep].
Page 107 of 109

Any over lapping of friction ties [Kolo Ties] if required, shall be done with the
help of 50 Micron tape [KR wonder 555 make or equivalent, as propriety
product of M/s Kolon is not being manufactured].
The over lap length shall be 1 M. Further back filling operation shall be carried
till the height of 75 cm.
Thereafter the second course of panel shall be erected, with the help of wooden
clamps. The panels shall be placed on a special type of EPDM bearing pads [90mm
x 90mm x 10 mm], which shall be placed on the top of the bottom panel as per
drawing.
LAYING OF KONY DRAIN AND PACK DRAIN
The kony drain shall be provided along the length of bay for drainage system at
bottom at a slope of 1:300, and shall be interlinked by a horizontal pipe at 100 M c/c.
Pack drain pipe[packed with graded material of sizes 19.1mm to 9.1mm] shall be
laid in the same line of kony drain at 750 mm c/c vertically.
Whereas, Kony horizontal drain pipe at every 50 m c/c in transverse direction
shall be provided.
CRASH BARRIER & FRICTION SLAB:A crash barrier & friction slab of M30 Grade concrete shall be cast in situ as
per specification and drawing No 8007/04 R2 along the length of both side
ramps of the Flyover. The crash barrier and friction slab shall be cast in situ in
two operations, at first the friction slab and then the crash barrier.
Testing & Sampling Procedures:
FIELD DENSITY TEST for Back filling materials:Field density test shall be conducted by means of core cutter or sand
replacement method for every 1000 sq..m. earthwork or one test per day.
CUBE TEST for Conc. Panel / U Beam:
Cube of size by 150mm x 150mm x 150mm shall be taken as per table 1700
of MOST speicification.
The same shall be tested at the Q.C.Lab
[Subarnarekha site] for 7 days strength and 28 days strength and shall be duly
entered in the cube test register.
CURING:
Exposed surfaces of Concrete shall be kept continuously in a damp or wet condition
for a period of 14 days by sprinkling water over the hassian cloth covered the
concrete faces.
DOCUMENTS & RECORDS:
Report for inspection:
1. Check list for staging & formwork.

2. Check list of reinforcement.
Page 108 of 109
3. Concrete pour card.

4. Concrete pouring format
5. Field density format
6. Level sheets
7. Approved C/s at every 10m
8. Approved L-section giving layer details.
9. Checklist for physical examination of panels before fixing i.e. surface
finish, edges etc.
6. PRECAUTIONARY MEASURE
The following precautions shall be taken during the progress of the work.
No machinery either tracked or tyred should be allowed to roll over exposed

surface of reinforcing strips.
Any movement of machinery/ plant weighing more than 1 Ton shall not be
allowed within a distance of 1.5 m from the erected panels until the top of wall
level is reached.
No further panel shall be erected until back fill is placed and compacted up to
required grade and level.
Time consumed between erection and back filling should be minimized to

avoid possible misalignment of panels.
Props supporting panels for batter required extra cautions so that they
should not be over run by man, machinery or any other construction
related stresses.
A minimum fill of loose soil thickness shall be 100 mm prior to operation of

compaction equipment on koloties.
SAFETY MEASURES:
Technical persons & workers engaged for the work shall be

equipped with helmets.
Safety shoes shall be provided to the Masons & Khalasis engaged

for erection
operation.
There shall be safety sign painted on boards and displayed.
The area shall be fenced properly.
During night shift, sufficient lighting shall be provided with Red light
danger sign at vantage location and illumination tape.
Page 109 of 109
A First Aid counter shall be maintained in Stores during the working

hours.
PLANT MACHINERIES & MANPOWER PROPOSED TO BE DEPLOYED FOR

REW
1.
2.
3.
4.
5.
6.
7.
8.
10T DUMPERS
10 T CAP VIBRATORY ROLLER
ANGLE DOZER
OR
TRACTOR DOZER
PLATE COMPACTOR
OR
1 T ROLLER
SHALLOW BORE WELL WITH PUMP
5 T CAP. TYRE MOUNTED CRANE
TRACTOR TROLLEY/ OPEN BODY
TRUCK OR TRAILER
:
:
:
5 NOS
1 NO
1 NO
2 NOS
2 NOS
:
:
:
:
1 NO
1 NO
1 NO
1 NO
:
:
:
2 NOS
:
4 NOS
6 NOS
1
EACH
FOR
:
:
1 NO
1 NO. FOR ENTIRE FLY
MAN POWER WORK GROUP (MWG):

1.
SKILLED KHALASI
2.
SEMI SKILLED WORKERS
3.
UNSKILLED LABOURS
4.
OPERATORS FOR EQUIPMENT
EQUIPMENT
5.
SUPERVISOR
6.
GIL ENGINEER
OVER
7.
KOLON ENGINEER
FLY OVER
EACH
1 NO. FOR ENTIRE

Method Statement - 20 Bridges

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Page 1 of 109

METODOLOGY FOR MAJOR ACTIVITIES IN

PROCESS INVOLVED IN CONSTRUCTION OF

1. LAYING CUTTING EDGE

i) Batching Plant ( 30 Cu.M./ hr)

SKILLED / UNSKILLED LABOURS:

FABRICATION OF CUTTING EDGE:

METHODOLOGY FOR FABRICATION OF CUTTING EDGE:

ERECTION OF CUTTING EDGE:

ERECTION OF INSIDE SHUTTERING OF CURB:

ANTI CORROSIVE COATING OF REINFORCEMENT:

FIXING OF REINFORCEMENT IN CURB:

ERECTION OF OUTSIDE SHUTTERING:

INSPECTION AND CHECKING:

TRANSPORTATION AND PLACING:

PROPOSED TIME FOR COMPLETION OF WELL CURB:

Outside Diameter of well

Inside Diameter of well

Steining Thickness : 1.250 M

Outside Diameter of well

Inside Diameter of well

Steining Thickness : 1.30 M

STEINING FINAL LIFT:

FINAL STEINING LIFT SINKING:

5. BOTTOM PLUGGING & INTERMEDIATE

Concrete Quantity in Bottom plugging for a well

Concrete Quantity in Bottom plugging for a well

Checklist for reinforcement

PLANT, MACHINERY AND MANPOWER PROPOSED TO BE

Batching Plant (30 Cu.M. / Hr)

Concrete Quantity for Abutment: 130 M3

INTERMEDIATE PLUG CONCRETING:

Well cap depth for Pier well

Concrete Quantity in Abutment well cap : 83 M3

Concrete Quantity in Pier cap

TESTING & SAMPLING PROCEDURES:

Cubes of size 150x150x150mm shall be taken. Number of cubes shall be

7. ABUTMENT WALL & CAP, PIER CAP

CONSTRUCTION METHODOLOGY FOR ABUTMENT, DIRT WALL & ABUTMENT

First Centre point of Column shall be marked with Total Station

Then Column layout shall be made with line dory

drenched in red oxide paint.

Over that layout ISMC 125 X 65 shall be placed on all 4 sides in

Shuttering Plates of I lift column size shall be placed as per drawing

Above shuttering plates ISMC 125 x 65 top channel shall be placed by

Shuttering plates shall be supported through Rivel Pin support as

I lift concreting shall be done in 6 layers of each layer 500 mm

Then shuttering plate shall be removed after 24 hours and other 3

For supporting arrangements of II lift concreting, Trestles shall be

First Center point of Column shall be marked with Total Station

Then shuttering plates shall be placed over the channel.

Staging shall be done, from which shuttering plates shall be supported

For additional support through bolt shall be connected in 2 layers of 1.0

In round portion on either sides, channel shall be placed and shuttering

Concrete shall be done using Crane bucket.

TESTING & SAMPLING PROCEDURES:

PLANT, MACHINERY AND MANPOWER PROPOSED TO

Batching Plant ( 30 Cu.M./ hr) - 1 No.

Concrete quantity for Abutment cap ( 0.65 m height) : 10.12 M3

Concrete quantity for dirt wall

Trestles shall be fabricated upto a height of 5.175 m. Then trestle cap

Then 8 Nos. of ISMB 300 (Longitudinal girders ) shall be placed at

Supporting arrangement between abutment columns for dirt wall

Concreting shall be done with concrete bucket.