METHOD STATEMENT FOR FOUNDATION WORK

TABLE OF CONTENTS

1. SCOPE

2. GENERAL REQUIREMENTS FOR FOUNDATIONS

3. SOIL PIER FOUNDATIONS

4. ENVIRONMENT CONTROL PLAN

5. SAFETY PRECAUTION

6. QC PLAN

7. EXCAVATION, AUGERING & CASING

8. REINFORCING STEEL CAGE

9. FORM BOX/ SHUTTERING INSTALLATION

10. STUB ANGLES

11. CONCRETE

12. CONSTRUCTION JOINT

13. CURING

14. PROTECTIVE COATING

15. TEST CYLINDERS

16. BACKFILL

17. QUALITY ASSURANCE

1.0 SCOPE

This document provides general recommendations for selection of

methods and procedures that have been found practical for the
installation of steel structure Pad & Chimney foundations with stub
angles for Construction of Double Circuit 380KV OHTL between JRP/JEC
to Al-Fara BSP and Al-Fara BSP to Abha East.

1.1 References
SEC Standards
 TCS-P-122-05 Rev 0 – Steel Structure Foundation
 TES-P-112-11 Rev 0 - Transmission Structure Foundation
 PTS-13SO375

2.0 GENERAL REQUIREMENTS FOR FOUNDATIONS

It is the responsibility of NCC to locate underground facilities such as

gas, water, sewer lines, drain lines, electric power and telephone
cables, etc., which may be encountered in digging or drilling holes and
to perform work in such a manner as to prevent damage to such
facilities. In case of any damage, the Contractor shall repair
immediately all such facilities, to the satisfaction of the facility Owner.

The foundations for tangent structures shall be placed so that the

longitudinal axis of the structure cross arms will be lie in a plane
perpendicular to the centre line of the transmission line. The
foundations for angle structures except the terminal structures shall be
placed so that the cross arms will be lie in a plane bisecting the interior
angle formed by the two intersecting centre lines. The footings for
terminal structures shall be placed so that the transverse axis of the
structure cross-arms shall be parallel to the transverse axis of the
gantry structures placed in the substation.

Excavation of the Pad & Chimney holes shall be to the depth and
dimensions indicated on the approved drawings.

Top soil, stumps, bad material shall be removed. All excavated

materials suitable for backfill shall be placed in graded embank in the
immediate area of the structure. Materials found to be unsuitable for
backfill or grading shall be disposed off at an approved disposal facility
SEC.

3.0 PAD & CHIMNEY FOUNDATIONS

One proto type Pad & Chimney foundation for the proposed line shall
be carried out prior to regular foundation works at the suggested /
desired location by SEC Representative, to confirm the load testing
with it.

The load testing shall be as per the below mentioned ASTM standards
& in guide lines with the PM. & Project Specifications PTS-13SO375.
  ASTM D 1143 - Static Axial Compression load test.
 ASTM D 3966 - Lateral load test.
 ASTM D 3689 - Staxial axial load test.
 ASTM D 5882 - Impact Integrity test.
 ASTM D 6760 - Crosshole integrity testing.

Pad & Chimney Pits shall be drilled with suitable types of Excavation
equipment to produce the required depth of excavation. The methods
and equipment used shall be such as to leave the sides of the
Excavation free from appreciable quantities of loose material, which
would prevent intimate contact of concrete with firm soil and/or rock.
The bottom of excavation shall be clean so that end bearing of the
footings will be on the firm soil and rocks.

4.0 ENVIRONMENT CONTROL PLAN:

The Approved Guidelines for the Noise Level shall be maintained during
the execution of soil investigation and related activities.

During Foundation Works care should be taken to avoid disturbing the

natural sources such as tree/ plant cutting.

Removal of Waste material form the work spot to the store yard shall
be monitored, during and after completion foundation activities.

5.0 SAFETY PRECAUTION:

Light vehicle shall have 4 wheel drive mode towards tough terrain
access.

Qualified and Trained personnel are assigned as per the job

requirement.

Required PPE safety shoes, safety goggles inclusive of High visibility

Vest shall be strictly adhered for all working personnel at job site.

Prior to each construction activity, Pre-task will be prepared and issued

to the concerned personnel

The Pre-task will be clearly explained to every individual involved.

The Pre-task will be signed by the involved personnel and a copy to be

kept at the work spot for any time verification.

6.0 QC PLAN:

Availability of current approved Route Plan drawings indicating

revisions shall be issued to the key personnel at job site.
The proposed Excavator Machine should be third party certified before
induction at the site.

The markings along the route shall be cleared indicated in the plotted
tower site locations.

The structure/ tower spotting shall be with required ground & road,
power and pipe line clearances.

The Pre-task will be prepared, issued and get signed by every

individual before every allied activities involved in the foundation work.

QA/QC shall monitor & maintain following activities:

Qualified and motivated manpower.

Dependable construction equipment.

Required personnel selected on the basis of their skills and

experience.

Suitable personnel shall be physically and mentally fit.

Training/ Testing of craftsmen.

Preparation of procedures and job instructions.

Construction equipment maintenance/ materials control.

7.0 AUGERING & EXCAVATION.

7.1 AUGERING WITH CASING

In areas, where sufficient ground water is encountered to cause

standing water in the boreholes, if possible water shall be pumped out
from the borehole to the elevation of the top of the hole and pumping
shall be continued as necessary to ensure placement of all concrete
under dry conditions if possible.

Temporary casings shall be required at all locations of high water table

in layers of fine, collapsible sand. Casings shall also be required at
locations where the soil will not stand alone without support. Casings
shall be of sufficient strength and rigidity to maintain the required
verticality of the boreholes against the earth and water pressures that
may be encountered, and shall be installed carefully to assure that soil
around casing is not disturbed. The method of holding casing in the
pier hole shall be such that it will not allow the casing to sink in the
ground.

The vibrator-driving hammer shall be used for installation & removal of

casings if the casing depth is more than 10m & in subkha areas. While
driving by vibrator-driving hammer the casing shall be checked for 90 0
verticality. When casing top is at the proper elevation and the vibrator-
driving hammer is removed, the auger shall be centered over the hole
and the soil in the casing shall be removed. The casing shall be driven
until the top is about 500 mm above the structure pad.

It shall be ensured that concrete inside the temporary casing is

sufficient to fill level up to the construction joint before removal of
casing and tremmie required up to the bottom of the borehole is used
for concreting.

The steel casing is to be removed; the concrete shall be poured up to

the construction joint. The steel casing shall be removed concurrently
with the placement of concrete.

7.2 AUGERING WITHOUT CASING

If the pier does not require a steel casing, the auger operator can set
up the center of the cutting blades of the auger so it is centred over
the nail or tack of the foundation center and after checking that it is in
plumb both ways on the Kelly bar, drilling can begin. If the soil is
satisfactory and no caving occurs, the hole can be completed to the
required depth and the other holes completed in a similar manner. The
excavated soil shall be kept away from around the boreholes to permit
working and shoring, as well as to keep the soil from slipping back into
the borehole. After completion of the borehole, the steel-reinforcing
cage shall be placed carefully and concreting shall be poured using
tremmie required up to the bottom of the borehole.

7.3 AUGERING & CONCRETING WITH PERMANENT CASING

When Soil is subkha (frequently water logged) type which is very weak
( SPT < 6) and dicing chemicals are present in high concentration in
soil and ground water, then auguring will be done with permanent
casing based on the soil investigation reports & recommendations.

7.4 EXCAVATION.

The excavated soil shall be kept away from around the Pits to permit
working and shoring, as well as to keep the soil from slipping back into
the Excavated Pits. After completion of the excavation, the steel-
reinforcing cage shall be placed carefully and concreting shall be
poured using tremmie required up to the bottom of the footing
excavation and pedestal.

7.4.1 Lean Concrete

Lean concrete mat 100 mm thick with 20 MPa shall be laid under
Structural foundations, unless stated otherwise in design drawings. A
vapor
Barrier, two (2) layers of polyethylene sheet with 150 microns thick
each,
Shall be laid on top of this lean concrete mat before placing the
structural
Foundation.
8.0 REINFORCING STEEL CAGE

The installation of steel reinforcement shall be in accordance with the

referenced specifications.

The steel rebar shall be covered with tarpaulins at storage yard and at
the job site.

The steel reinforcing bar cage shall either be assembled at the storage
yard and hauled to the job site or the proper steel bars be hauled and
assembled at the job site. Both of these methods shall be acceptable
and satisfactory. The vertical reinforcing bars and horizontal ties shall
be spaced and assembled as shown on the approved construction
drawings

The reinforcing bar cage shall be properly located and held in position
by using concrete blocks of proper dimensions 75 x 75mm Size and
wired into place at about 750 mm to 1000 mm intervals on the outside
of the cage. They shall be placed in several locations around the cage
to position the cage in the center of the hole.

Reinforcement bars (re-bars) shall be carefully formed to the

dimensions indicated on the approved construction drawings. All re-
bars shall be bent cold before being placed in the forms. Re-bars with
kinks and bends shall not be used. No heating of re-bars shall be
permitted. Re-bars shall be accurately positioned and secured against
displacement by using annealed iron wire of suitable size at all
intersections.
Pier cages shall be made, as described in the approved construction
drawings. No visible deformation of the cage shall be allowed. The
cages shall be accurately positioned and secured against displacement
during the placement of concrete. The method of securing pier cages
shall be such that it will not allow the reinforcement to sink in the
ground.

Steel cage should be bind tightly and balance installation of lifting sling
to prevent deformation and displacement during lifting activity. Upon
insertion of the steel cage to the steel casing, steel hook is being used
to support steel cage attached to steel casing to prevent settling.

Fabrication and bending, where required, shall be in accordance with

the approved drawings and within the tolerances cover as -12.5mm
and longitudinal location + or – 50mm for bends and discontinuous end
shall be + or -12.5mm.

9.0 FORMBOX / SHUTTERING INSTALLATION

Form box/ Shuttering shall be installed before concreting. Structural

calculation shall be done before the fabrication of form box/ shuttering
to determine the thickness of the steel plate, the capacity of the block
out and the capacity of the bolts as stiffeners. After all calculation are
made and probed to be safe, fabrication shall start.

Installation of form box/ shuttering shall be supervised by a competent

person. The plumbness of the shuttering shall be checked and all the
block out shall be checked if properly installed based on approved
structural calculations. Scaffolding shall be installed for easy access of
the workers.

10.0 STUB ANGLES

Stub angles shall be placed in the tower footings as shown on the
approved drawings, and shall be supported in proper position by means
of a rigid template. The stub angles shall be held rigidly in a manner to
prevent displacement during placing of the concrete. All stub angles
shall be set accurately to the grade and alignment indicated on the
approved drawings with a tolerance of horizontal distance between
stubs of 10 mm in diagonal and 5 mm in tower face.

The stub angles and the setting template shall be assembled together
into place to obtain proper setting location for each stub angle. The
stub angle setting template shall be furnished as part of the steel
furnished by the steel supplier or shall be fabricated separately for the
intended purpose. The templates shall be adjustable for different
spacing and batter as required for tower type under construction.

The concrete shall be poured after all the adjustments and checks have
been made as required. The top surface shall be crowned and given
trowel finish.

11.0 Grounding:

All grounding requirements shall be in accordance with the SEC

Standards TES-P-122.10 and TCS-P-122.21. All grounding materials
shall be Copper clad steel.

The conductor for bonding foundation stub angle with the rebars and
ground rod prior to concreting shall be coated with two (2) coats of coal
tar epoxy and mastic taped. Grounding conductor connected from the
stub angle to the ground rod shall be embedded in the concrete
foundation and buried 500mm from the ground level.

The grounding of the terminal structure (last structure before the

gantry take-off structures) shall be connected to the substation

12.0 CONCRETE

References;
Project Specification; PTS-13SO375

Approved ready mix supplier shall be providing the required concrete for
Ist stage & 2nd stage concreting.
The measuring mixing and placing of concrete shall conform to the
latest requirements of ACI 318 and ACI 304. Concrete shall have a
minimum 28-day compressive strength of 38 MPa based on testing of
cylinders by third party testing agency. Required slump shall be 125 +
25mm. Water cement ratio shall be 0.36 (maximum).
For Ist stage concreting hopper with tremmie pipe up to the bottom of
the excavation and pier shall be used for directing the flow of concrete
down the center. Concrete shall be consolidated by use of vibrators of
required size up to the bottom of the excavation in dry condition.
For 2nd stage concreting, the form shall be kept in good condition until
placement of concrete is completed. The placing of concrete shall be
accomplished with 1.0m. tremmie pipe to prevent segregation of the
aggregates. Concrete shall be consolidated by use of vibrators of
required size to ensure good compaction of the concrete into a dense
homogeneous mass without honeycombs.
If groundwater is up to 2m head from the bottom of the pier, it will be
pumped out with a dewatering pump, before starting of pouring
concrete with tremmie or using concrete pump. If groundwater is more
than 2m head from the bottom of the pier, or not able to drain out the
water with dewatering pump, concrete will be poured continuously with
tremmie or using concrete pump, the excess water/concrete slush will
be flow off at ground level till good mass concrete is seen at top of pier.
Stability of boreholes shall be ensured during concreting & prior to
poring. The overflow water shall be discharged to settling pit and
allowed to recharge / evaporate as explained in the attached method
statement.

Excess water and concrete sludge will be drained to settling pit. The
dimension of the settling pit will be having an approximate dimension
of 3 meter width, 4 meter length and 1 meter depth.

All concrete, which has not been placed within the allowable time after
all the ingredients have been introduced into the mixer, shall be
rejected. The temperature of the mixed concrete shall not exceed
32°C.

13.0 CONSTRUCTION JOINT

During 1ST Stage concreting the concrete shall be poured and stopped at
the level of construction joint &the construction joint key shall be
installed as shown in the approved drawings.
Nitobond EP or equivalent approved bonding agent shall be used for
the cold joint during 2nd stage concreting in compliance with approved
manufacturer’s Data Sheet.

14.0 CURING

The curing shall be carried out in accordance with project specification

PTS-13SO375

Once the second stage is completed and form box is completely

stripped, the concrete pedestal will undergo curing. The concrete
pedestal will be wrapped with 2 layers of burlap sacks and water will be
sprayed on it. To maintain the moisture of the burlap sacks, a plastic
drum full of water with a very small hole in it for the water to drain in
form of drops. The plastic drum will be refilled daily. The concrete
pedestal will be cured for 21 days

15.0 PROTECTIVE COATINGS

The protective coating shall be carried out in accordance with project
specification PTS-13SO375 and SEC Specification.

Concrete foundation shall be applied with the following concrete

protective coating materials, a minimum of thirty-five (35) days after
concrete placement. Manufacturer’s recommendation shall be strictly
followed in all aspects of surface preparation, priming, coating
application (first and succeeding coats and interval therein) and curing
and safety practices.

The protective coating shall be prepared with the following steps:

15.1 SURFACE PREPARATION

The surface to be coated shall be prepared prior to application of the

coating material. Surface cracks, shallow spalls and holes on the
concrete surface shall be filled with mortar. It shall be repaired by
cutting “U” grooves using chisel or similar tools. The surface shall be
free of dirt, loose materials, laitance, oil, grease, wax black-white
carbonate deposits and yellow-white sulphate deposits and other
deleterious materials shall be removed from the surface to reach solid
gray concrete underneath.

15.2 COATING APPLICATION

15.2.1 CONCRETE SURFACE BELOW GRADE

Below grade surface of concrete shall be coated with minimum of two

(2) coats of coal tar epoxy. The second coat shall be applied within the
time interval (between successive coating application) specified by the
manufacturer.
The application of coal tar epoxy will depend upon the type of
concrete foundation adopted by the contractor. For open excavation
(spread footing, pile cap), all concrete surfaces in direct contact with
the earth shall be applied with coal tar epoxy. For augured pier type
foundation, coal tar epoxy shall be applied from the last construction
joint or bottom level of the anchor bolt or stub angle up to the structure
pad finished grade level.

15.2.2 CONCRETE SURFACE ABOVE GRADE

All exposed surfaces above structure pads grade level shall be coated
with elastomeric materials (polyurethane water-proofing membrane).
The coating application shall extend continuously down to 500 mm
below structure grade level. This coating shall be applied after curing
of the coal tar epoxy. Coating materials shall be either spray-applied or
brush applied.

The interface between the steel monopole and the concrete foundation
shall be properly coated with polyurethane coating membrane and
shall extend 500 mm above the top of the non-shrink grout. Similarly,
the steel stub angles/concrete foundation interface shall be covered
with polyurethane coating membrane and it shall extend 500 mm
above the top of foundation.
15.3 FILM THICKNESS AND TESTING

The total dry film thickness (DFT) shall be obtained upon application
and subsequent curing shall be:

 Above Grade Application: 1 mm for the specified material

(Priming Coat and Subsequent Coats (except top coats),
Aromatic Formulation = 500 microns DFT. Top Coat, Aliphatic
Formulation = 500 microns DFT.
 Below Grade Application: 0.6 mm for the specified material ( A
two-component, high-solids coal tar and epoxy resins).

16.0 TEST CYLINDERS

Concrete cylinders shall be filled and witnessed by the Project Manager

& NCC QC and testing shall be made by Third Party Independent
Testing Laboratory M/s. SAFCO Ltd., Al Khamis Mushait in accordance
with ASTM C39, 'Standard Test Method for Compressive Strength of
Cylindrical Concrete Specimens" & as per project specification PTS-
13SO375

17.0 BACK FILL

The backfilling shall be in accordance with project specification PTS-

13SO375.

18.0 QUALITY ASSURANCE

NCC QC personnel should ensure the inspections of both materials and

workmanship at each stage of the work, focusing attention on such
items:

 a. Establishment of correct location for the structure (span

length,
radial distance, elevation etc.)

 b. Type of structure, height of basic body and leg/body

extensions etc.

 c. Suitability of location for the proposed type of

foundation

 d. RFI will be submitted to the SEC Representative on each

stage of concrete

 e. Suitability of excavated material for backfill

 f. Excavation depth, casing depth

 g. Setting of templates and placement of stub

angles/anchor bolts
 h. Distance between adjacent and diagonally opposite stub
angles

 Stub angle slope / batter

 j. Quality of concrete and pouring & curing

 k. Concrete Testing.