Document No:

TATA STEEL LIMITED TPL2-CVL-ASU-03-R0

TATA STEEL KALINGANAGAR PROJECT

ASU
SHEET 1 OF 20
SITE MANAGEMENT PLAN

TSK PHASE II
CONSTRUCTION SITE MANAGEMENT PLAN
OF
ASU

Name ……………… …………………….. …………….

Designation ……………… ……………… …………….

Prepared by Checked by Authorized by

CONFIDENTIALITY
The information contained in this document is confidential to Tata Steel. Accordingly, copyright of
this document is retained with Tata Steel and no copying in any format of this document is permitted
without the written permission from the approver of this document.
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INDEX

S. No. Description Page-No.

1 Index 2
2 Objective & Construction philosophy 3
3 Scope of work 4
4 Site layout 5
5 Site Infrastructure 6
6 Power requirement 7
7 Emergency Contact No 7
8 Organization Chart 7
9 Communication Method 8
11 Site Amenities 8
12 Do’s & Don’ts 9 – 10
13 Site Management Plan 11 - 14
14 Construction & Survey Preparedness 14 - 15
15 Material Logistics Plan 15 -16
16 Manpower Plan 17
17 Machinery 18
18 Annexure 1 – Hold & Check Points 19 - 20
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1. Objective & Construction Philosophy:

To complete the civil work of ASU in 9 months. The objective of preparing construction
methodology to ensure that there should be the strategy to start the construction
activities smoothly on site. This project is being driven based on following construction
philosophies (6 KPI’s):

 Discipline
 Quality
 Safety
 Benchmark level of productivity.
 Cost
 Time
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2. Scope of Work

S. No. Description
1 Air Filter
2 MAC
3 BAC
4 Common Silencer
5 IA Comp Foundation
6 MP / LP Cold Box, Exchange cold, Argon cold box foundation,
7 Pump Casting Foundation
8 Turbine Casing Foundation
9 Air Purification Vessel Foundation
10 Water Chiller Tower ( E 60 )
11 Gox Barrier
12 Reactivation Heater Foundation
13 Water Chiller Pump Foundation
14 Liquid Disposal System Foundation
15 Booster after Cooler
16 LAR Storage Tank
17 LOX Storage Tank
18 LIN Storage Tank
19 LIN Storage Tank Pump
20 LOX Atmospheric Vaporizer Foundation
21 LIN Atmospheric Vaporizer Foundation
22 LAR Atmospheric Vaporizer Foundation
23 Compressor Shelter Steel Column Foundation
24 Pipe Racks Steel Column Foundation
25 Pipe Cable Tray & Platform Steel supporting Foundation
26 Cooling Tower
27 ECR, Office and Sub – Station Building
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28 Cable Trenches
29 Paving, Road & Drain works

3. Site Layout of ASU

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Site Infrastructure:

Initial site mobilization will start with the:

 Main site Office - Operational
 Site Office (Portable)
 Site store
 Covered storage
 LPG storage
 O2 Storage
 Diesel storage
 Open storage space
1. Reinforcement steel
2. Structural steel
3. Form work materials

 Fabrication yard
 Vehicle Parking Zone
 Office vehicles
 Equipment’s i.e. excavator, boom placer
 Assembly Point – at site
 Workmen Rest shed & Toilet Block
 Labour Camp at Plot 2
 Training Centre at Plot 2
 Canteen – At Labour Camp
 Batching Plant centralized at Plot 1
 QC Lab – Centralized at Plot 1
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Power Requirement:

Office area : DB – 63 Amp

Fabrication area : DB – 63 Amp

Project Area : DB - 125 Amp at 6 points

Batching Plant : DB - 125 Amp at 1 point

Organization Chart

Attached separately

Emergency Contact Number:

During emergency following person to be contacted:

1. Mr J.L.N. Murty, Mobile - 9937132136

2. Mr Sahid Hussain, Mobile - 7328847019

3. Mr Shri Ram Giri, Mobile - 7328847081

4. Mr Murali G Rao, Mobile - 7328847008

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Communication Method:
All communication will be addressed to Mr J. L. N. Murty – Project Director ( TPL)
related to project and method will be:

 Digital ( Thru Email )

 Letter
 Minute of Meeting
 Site register

Site Amenities For Workmen:

Site will facilitate workmen to work round the clock by providing:

 Container office with work stations

 Rest Shed
 Bus for Pick & Drop ( labour camp to Site )
 Working time ( 8:00 AM to 8:00 PM)
 First AID Kit Centre
 Drinking Water point
 Parking Area for Vehicles

Culture Building:

Project will be executed with” ZERO” harm goal and TATA culture 6
KPI’s will be developed among all the site team, workmen at site by
the thru following activities:
 Skill Assessment
 Safety Training
 Tool Box Talk
 First AID Training at site
 Routine health check-up
 Gate pass for ASU Area
 Displaying signage at work place
 Utilizing Modular formwork
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 Mechanized work thru Auto rebar cut & bend plant, cranes,
boom placer etc.

DO’s for Workmen:

As per TSK guidelines workmen must be following instructions during
working at site:
 Proper PPE must be ensured.
 Workers will enter in swing area of equipment’s after prior &
proper communication to the operator
 Worker should ensure that they are present in working area
maintaining safe distance from equipment’s & barricade.
 Workers must wear hand gloves during changing of cutting
tools and lowering of reinforcement binding or shifting.
 Concreting shall be done wearing hand gloves.
 Workers can take rest at designated rest shed.

DON’Ts :
As per TSK guidelines workmen must be following instructions during
working at site:
 Never enter work place without PPE.
 Workers must not enter in swinging area of the equipment
without prior & prior communication to operator.
 No workmen should enter in the equipment’s working area.
 Workers must not touch with bare hand any equipment’s or
reinforcement steel.
 No workers should enter into guarded area without safety
harness or suitable PPE’s.
 Without wearing gloves no workers should be allowed for
concreting process to avoid chemical attack.
 Never take rest under / around the equipment’s even if it is
stopped or in breakdown condition
 Mobile phone should not be used during operation at work
site
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DO’s for Operators:

As per TSK guidelines Operators must follow instructions during
working at site:
 Always carryout “Pre-Use Check”
 Ensure guarding is correctly adjusted and used.
 Ensure any emergency stop devices are in good condition.
 Report any defect promptly to the concerned supervisor.
 Inspection of machine to be done on shift wise and checklist
to be filled as per machine condition.
 Machine swing area barication to be ensured before start the
machine.
 Keep work area clean and free of obstruction and hazards.
 Follow signalman / supervisor signal only during machine
operation.
 Maintenance of machine to be followed as per manual.

DON’Ts for Operators:

TSK guidelines Operators must follow instructions during working at
site:

 Cell phone must not be used while operating machine.

 Never follow other people signal except deployed concern /
signal man / supervisor.
 Never start the machine if workman moving or standing in
swing area.
 Never start the machine before regular inspection or proper
checklist.
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Construction Management Plan:

1. Man & Machinery Movement Plan
 All roads will be one way; no reversal is allowed.
 Pedestrians to follow the pathway only.
Hard copy of above to be communicated to all driver / Operators.
2. Work Schedule
 Working days : Monday to Saturday
 Maintenance Day : Sunday

3. Working Time & Shift Details

 Day Shift :8:00 AM to 8:00 PM
 Night Shift :8:00 PM to 8:00 AM
 Lunch Break :1:00 PM to 2:00 PM
 Dinner Break :10:00 PM to 11:00 PM

4. Rest Time for Workmen

 No specific time for rest is allowed during working hour, however on approval of
supervisor during time gaps when manpower supports are not required workman
may go to the rest shed for taking rest.

5. Amenities
 Transportation of TPL staff : By Bus / LMV
 Transportation of Workmen & Operator : By Bus
 Pick & drop of workmen Lunch at site : By Bus
 Pick & drop of lunch box : ASU site

6. Equipment Deployment Plan

Equipment’s planned for the execution of ASU structures are mentioned below
with two shift operators:

 Boom Placer – 1 no, centralized

 Transit Mixer – 3 nos, centralized

 Concrete pump – 1 nos, centralized

 Vibrator ( Electric ) – 2 nos

 Vibrator ( Diesel ) – 2 nos

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 Needle- 10 nos

 Excavators - 2 nos

 Hywa- 8 nos

 Hydra- 1 no

 Trailer- 1 nos

 Welding Machine- 2 nos

 Cutting set- 2 sets

 Batching Plant (30 cum) Plot-2

Note: Excavator, Hywa, Transit mixer, rock breaker, Boom Placer etc
available at site and can be deployed as per requirement.

7. Administrative Issues
 Grievance redressal – Level I – Section In-charge – 3 days for resolution
 Grievance redressal – Level II – RCM – 3 days for resolution
 Grievance redressal – Level III – Head Admin – 3 days for resolution
 Grievance redressal – Level IV – Project Director – 3 days for resolution

8. Statutory Compliance

 Head Admin - Mr Muralimohana Rao Gunta

9. Health & Hygiene

 Periodical Health Checkup Labour Camp Quarterly
 Collection of Garbage Site / Labour colony Use Dustbin
 Cleaning of Dustbins Site / Labour colony Regularly
 Cleaning of Toilets Site / Labour colony Regularly

10. Infrastructure Provided by TSL

 Approach road,
 Water & Power point
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11. Emergency Preparedness Plan & Procedure

Display
Emergency Contact,
First Aid Entrance & Assembly Point
Route Map
Contingency Plan During Emergency Including onsite & Offsite
Preparedness Plan & Procedure attached
First AID First AID box & First Aider will be
available
Major Injury In case of Major Injury patient to be
taken to the TSK First AID center
Severe Injury Patient to be taken to the nearest
Hospital with required facilities by CCU
ambulance available at TSK

12. Safety During Work

Man machine Interface periods Detailed already covered in Safe

Excavation in Earth & Rock Working Procedure however specific
Reinforcement binding training will be provided to the
Formwork fixing Operator & Workmen periodically
Concreting during Tool Box Talk
Specific training to Operator for man & No workmen to take rest / shelter
Machine interface under & around any vehicle /
Specific training to Workmen for man & equipment’s in any condition.
Machine interface
Whistle blowing Whistle to be blown for all kind of
unsafe acts
Monthly Safety Activity Plan To be shared with TSL on monthly
basis
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13. Execution of Work

Approach Road Access road upto site shall be

provided by TSLwhich to be
maintained by TPL, approach to
working area shall be maintained by
TPLTSL will help by providing
adequate slag, transportation will be
arranged by TPL.

Disposal of soil / rock Excavated earth shall be disposed in

allocated dumping yard.

Closer of Work All protocols / register shall be signed /

approved by TSL on daily basis, in
case any protocol pending due to any
unforeseen condition shall be closed
within 24 hours.

Material Reconcilation TPL will submit monthly reconciliation

of materials along with bill, however
TSL wishes for physical stock
verification at any point of time.

Construction Preparedness:
For excavation and disposal of earth Construction methodology document
No. TSL/TSK/Civil/Standard/01 shall be followed. refer to doc
TSL/TSK/civil/methodology/03 in annexure This standard cover following
aspects.

 Preparation of excavation scheme

 Sequence of work
 Excavation in different type of soils.
 Disposal of excavated soil
 Backfilling and compaction
 Type of equipment used.
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 Improving equipment utilization.

Readiness for starting the work

 Survey bench mark and level to be established by standard survey

traversing procedures.
 Before start of the job Safe Work Procedure will be prepared and
submitted for approval by TSK.
 All reinforcement cages shall be fabricated at the Centralized steel
yard and shall be shifted to site 24 hrs in Advance. Insert Fabrication
will be done at site as shown in proposed site layout plan.

5. Material Logistics and Equipment

5.1 Construction Material Flow
Civil work Materials Logistics
Availability Remarks/
Scope of Intermediate
Sl. Description Source before Proposed
Supply storage at
activity Control
Batching plant Site storage for
External
1 Cement TSk and contractors 03 days brickwork and
Purchase
site store plastering
Batching
2 RMC TPL None 30 Min  
plant
Rebar
3 TMT TSK TSJ 24 Hrs.  
Processing yard
Rebar
Contractor's site
4 Cut Bent TMT TPL Processing 24 Hrs.
store
Yard
External
4 Sand TPL Batching plant 07 days  
Purchase
External
5 Aggregate TPL Batching plant 07 days  
Purchase
6 Granulated blast TSK TSK Slag Batching plant 07 days To be used as
furnace slag yard partial
substitute of
sand in
concrete
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production.

Availability Remarks/
Scope of Intermediate
Sl. Description Source before Proposed
Supply storage at
activity Control

within 07
Contractor's days of
Raw structural External
7 TSK machining and issuing  
steel Purchase
fabrication yard construction
drawings
Foundation Bolts Fabrication Contractor's site
8 TPL 24 Hrs.
and embedment Yard store
MS inserts and Fabrication Contractor's site
9 TSK 24 Hrs.
Embedment Yard store
Shuttering raw External Contractor's
10 TPL 07 days  
Materials Purchase shuttering yard
Contractor's
Contractor's site
11 Shuttering boards TPL shuttering 03 day  
yard
yard
Scaffolding External Contractor's site
12 TPL 05 Days  
Material Purchase yard
Non Shrink
External Contractor's site
13 Grouting TPL 04 days  
Purchase yard
Material.
Concrete External
14 TPL Batching plant 07 days  
Admixtures Purchase

5.2 Machinery

Civil work Machinery Logistics

Scope Availability Remarks/
Working
Sl. Description of Storage area before Proposed
Area
Supply activity Control
Site/ Dumping
1 Excavator TPL Site 24 Hrs.  
yard
Site & Contractors'
2 Dumpers TPL dumping Central yard 12 Hour  
yard parking
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Site & Contractors'

3 Roller TPL dumping Central yard 01 Hour  
yard parking
Site &
Site/ Dumping
4 Dozer TPL dumping 12 Hrs.  
yard
yard
Contractors'
5 JCB TPL Site Central yard 01 Hour  
parking
Site and Contractors'
6 Trailers TPL contractor's Central yard 01 Hour  
Central yard parking
Site and Contractors'
7 F-15 TPL contractor's Central yard 01 Hour  
Central yard parking
Concrete breaking Contractors'
8 TPL Site 24 hours  
equipment Site store
9 Welding machines TPL Site Site 24 hours  
Contractors'
10 Gas cutting sets TPL Site 24 hours  
Site store
Surveying Contractors' Always
TPL Site
11 equipment Site store available  
12 Concrete Pumps TPL Site Batching plant 01 Hours  
Contractors'
Dewatering pumps TPL Site
13 Site store As required  
Concrete Vibrators Contractors'
TPL Site
14 and needles Site store 01 Hours  
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5.3 Manpower

Civil work Manpower Logistics

Mode of
S. No. Type of Manpower Scope Residence transport to Remarks
site
Workers, operators, Plot -2 Labour Bus/ Four
1 TPL  
technicians & Supervisors Colony wheelers
Bus/ Four
TPL
2 Contractor's Site engineers JJKR/ Duburi wheelers  
TPL Line Managers and Company/ self- Company/self-
TPL
3 construction supervisors accommodation transport  
Company/self For Cross
TPL Plot 2 Labour -transport checking
4 TPL Surveyor Team Camp ( bus/4 wheeler) line/levels

Workforce
S. No. Discipline Work Description Skill Level
1 Rod fitter Rebar cutting, Bending, Cage making Skilled
2 Helper Muck cleaning, Helpers for fitters and riggers Skilled
3 Mason Concrete pouring Skilled
Cage & tremie pipe lifting, placing, loading and Skilled
4 Rigger
unloading
5 Mechanic For Equipment repair Skilled
6 Supervisor For supervision of all jobs being executed at site. Skilled

Annexure – 1(Base document index)

S. No. Methodology Documents Doc. No.
1 Surveying TSL/TSK/Civil/Methodology/01
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2 Piling TSL/TSK/Civil/Methodology/02
3 Excavation TSL/TSK/Civil/Methodology/03
4 Shuttering TSL/TSK/Civil/Methodology/04
5 Reinforcement TSL/TSK/Civil/Methodology/05
6 Inserts and embedment TSL/TSK/Civil/Methodology/06
7 Concrete TSL/TSK/Civil/Methodology/07
8 Curing TSL/TSK/Civil/Methodology/08
9 Backfilling TSL/TSK/Civil/Methodology/09
10 Brickwork TSL/TSK/Civil/Methodology/10
11 Plaster TSL/TSK/Civil/Methodology/11
12 Painting TSL/TSK/Civil/Methodology/12
13 Grouting TSL/TSK/Civil/Methodology/13
14 Floor finish TSL/TSK/Civil/Methodology/14
15 False ceiling TSL/TSK/Civil/Methodology/15
16 Sanitary & Plumbing TSL/TSK/Civil/Methodology/16
17 Waterproofing TSL/TSK/Civil/Methodology/17
18 Scaffolding TSL/TSK/Civil/Methodology/18
19 Road work TSL/TSK/Civil/Methodology/19
S. No. Code of Practice Doc. No.
1 Earthwork TSL/TSK/Civil/Standard/01
2 Concrete TSL/TSK/Civil/Standard/02
3 Road Construction TSL/TSK/Civil/Standard/03
4 Storage TSL/TSK/Civil/Standard/04
5 Plastering TSL/TSK/Civil/Standard/05
6 Painting TSL/TSK/Civil/Standard/06
7 Brickwork TSL/TSK/Civil/Standard/07
8 Survey TSL/TSK/Civil/Standard/08
9 Formwork TSL/TSK/Civil/Standard/09
10 Reinforcement TSL/TSK/Civil/Standard/10

S. No. Hold points checkpoints Doc. No.

1 Excavation work TSL/TSK/QSR/Civil/0
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1
TSL/TSK/QSR/Civil/0
2 Concrete site work 2
TSL/TSK/QSR/Civil/0
3 Design mix of concrete 3
TSL/TSK/QSR/Civil/0
4 Concrete batching plants 4
TSL/TSK/QSR/Civil/0
5 Reinforcement work 5
TSL/TSK/QSR/Civil/0
6 formwork 6
TSL/TSK/QSR/Civil/0
7 Masonary work 7
TSL/TSK/QSR/Civil/0
8 Plastering work 8
TSL/TSK/QSR/Civil/0
9 Painting work 9
TSL/TSK/QSR/Civil/1
10 False ceiling work 0
TSL/TSK/QSR/Civil/1
11 Ceramic & vitrified tile work 1
TSL/TSK/QSR/Civil/1
12 Road work 2
TSL/TSK/QSR/Civil/1
13 Railway formation 3
TSL/TSK/QSR/Civil/1
14 Piling work 4

………..END………….