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History of Revisions
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Revision
Date
Reason for
Revision
First Issue
Document Distribution
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INDEX
CHAPTER
1. PURPOSE
2. SCOPE
3. DEFINITIONS
4. CROSS REFERENCES
5. CONSTRUCTION PROCEDURE
5.1
5.2
5.3
PAGE NO.
5
5
5
5
6
Setting out
Island, Cofferdam & Barge Operation
Cutting Edge
Well Curb
Well Steining and Sinking
Plugging of Well and Well Cap
Time Cycle
19
19
21
21
11.
RECORDS
21
1. PURPOSE:
The purpose of this document is to provide detail construction
methodology, resources deployment, and safety & environment
system/procedures to be adopted by GPT and its sub-contractors during
execution of well foundation in connection with construction of Major Bridge
over Yamuna River at Kalpi (1275/2)
2.SCOPE:
The scope of this methodology covers the following activities:
Preliminary works
Selection, testing and acceptance of materials and mixes for
permanent works
Deployment of plants, equipments and machinery etc.
Construction methodology for well foundation.
Quality Assurance and Quality Control during construction work and
post installation checks, tests etc.
Construction Methodology for Well Foundation in water ( Caissons,
details will be submitted separately)
3.DEFINITIONS:
The words like Contract, Contractor, Engineer (Synonymous to Engineers
Representative), Drawing, Employer, Government, Works, Worksite used in
this methodology considered shall be considered to have the meaning as
understood from the definitions of these terms given in the General
conditions of the contract.
4.CROSS REFERENCE:
5.CONSTRUCTION PROCEDURE:
5.1
5.1.1 Cement:
The cement is Ordinary Portland Cement of 43 grade & Portland
Pozzolona Cement conforming to IS 8112 & IS 1489 codes
respectively and shall meet all physical and chemical requirements
as specified in RVNL spec, MORTH spec & Contract Spec.
5.1.2 Coarse & Fine Aggregate:
Coarse & Fine aggregate conforming to IS 383 shall be used.
Gradation of combined aggregates of different sizes (Coarse
Aggregate only) shall be in accordance with IS 383.
Various mechanical properties of coarse aggregates and properties
of fine aggregate are to be conformed to IS 2386 Series and the
tests shall be conducted as per relevant test codes as described in
RVNL spec, Contract Spec.
5.1.3 Water:
Portable water shall be used for concreting and shall be
conforming to RVNL Spec.
5.1.4 Reinforcement Steel:
Reinforcement steel for works shall be Fe 500D grade and
conforming to IS 1786, only TMT bars to be used.
5.1.5 Concrete Admixture:
Admixture to be used shall be conforming to IS 9103 and prior
approval from Engineer shall be obtained for the use of Admixture.
5.2
Concrete mix design shall be carried out as per RVNL Specification and
IS 10262 or any other standard accepted mix design guidelines and
grade of concrete to be used shall be as per drawing / specification.
The concrete shall be designed to achieve desired degree of workability
for specific grade of concrete to facilitate concreting operation. Trials
shall be conducted and cubes shall be cast, tested before acceptance of
Design mix.
5.3
Grade
Grade
Grade
Grade
Grade
of
of
of
of
of
Concrete
Concrete
Concrete
Concrete
Concrete
for
for
for
for
for
Well Curb:
Well Steining:
Bottom Plugging:
Top Plug:
Well Cap:
M 35
M 25
M 25
M 25
M 35
Plant
Description
Make /
Capacity
No
Require
d
02
Crawler Crane
20 T, TATA
2
3
4
Shell Grab
Diesel generator
Welding M/C
0.5 - 0.9
82.5 KVA
02
01
04
Batching Plant
02
6
7
Transit mixer
Concrete pump
8
9
10
Total station
Auto level M/C
JCB
Schwing
Stetter
TATA
Schwing
Stetter
Leica
Sokia
3D
Remarks
04
02
06 cum capacity
01
01
02
For survey
For level work
For handling well
11
Vibrators
Electric
05
excavated soil.
For concreting.
6.1
Setting Out
Necessary reference points shall be fixed, away from the zone of blowups or possible settlements resulting from well sinking operations. Such
reference points shall be connected to the permanent total stations with
the base lines on the banks. Reference points shall be also be fixed to
mark X-X axis (Usually along the traffic direction) and Y-Y axis (Normal to
X-X axis) accurately. A temporary bench mark shall also be established
near to the well, away from the zones of blow-ups and or possible
settlement.
6.2
Wells in water (Above 4.0m depth):- The area is more than 4.5m deep
water, formation of protected island by constructing cofferdam
alternative methods shall be adopted. The material to be used for
construction of cofferdam shall be as per design and drawing depending
on the operating water level with tidal effect.
The material shall be either MS steel shell or Steel Sheet pile of required
size fabricated at centralized yard and shall be transported to site by
trailer or truck.
Sand shall be filled into the cofferdam by grab or manually. In plan
dimension there shall be minimum 2m working place in protected island
formation. (For reference please refer annexure drawing for cofferdam
with sheet pile and sheet shell)
Barge Operation
To tackle the well foundation works in water spans, deployment of
flatbed floating barge shall be required to approach for transportation of
materials and machineries to well foundation and as well as to execute
the well sinking works.
The barge shall be designed for operating water level taking into
account for draft requirement and freeboard with anticipated operating
dead load consists of well sinking crane, crew, and dredged muck and
self-load. Well sinking barge shall be feed up with materials and services
to be provided by another barge. Tug boats shall be for movement and
anchoring/mooring of barges. Total 2 sets of well sinking barge with
required number of Tugboats to complete the well sinking works in time.
Please refer schematic drawing of well sinking by Barge.
6.3
Cutting Edge
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Description
Location Used
Outer Tee
Brackets
Cutting Edge Plate
Bent Plate & Stiffeners
Skin Plate
The cutting edge shall be fabricated with mild steel structural sections
and plated of specified grade as per approved drawings. Fabrication of
cutting edge may be carried out at site or at a shop. The cutting edges
shall be fabricated in pieces / segments. During the process of
fabrication and handling / erection suitable temporary supports are to
provided / maintained to render rigidity and to keep shape of the
segments and / or parts thereof. Number of segments shall be decided
prior to start of fabrication depending on easement of handling and
transport. Checks are to be made on dimension and shape of the
segments.
For bending the structural members, V cuts may be made and after
bending such V cuts are to be closed by welding. Joints in the length of
structural sections shall be made with fillet welds with a single cover
plate or as shown in the drawings.
Tools and Plants for Cutting Edge Fabrication:
Fabrication:
Working Platform
The working platform is made up of used plain steel plates welded to
each others over levelled concrete surface at the central fabrication
yard. The fabrication of the cutting edge involved the following steps.
Preparation of back angles:
Preparation of MS plates:
The required width and length of the plate as per drawing shall be
marked and cut using pug cutting machine.
Plate shall be bent to the required radius.
The same shall be checked with curvature template and corrected
if required.
Preparation of Brackets:
Assembly:
6.4
Well Curb
Accurate survey shall be carried out by Total Station for fixing the
well locations.
Permanent reference pillars are to be provided at the four sides i.e.
along and across centre line of bridge.
The ground is levelled by removing the top loose soil and
compacted and rescued levels are recorded jointly with the
Engineers representative.
Centre point of well is marked.
The fabricated cutting edge segments shall be shifted to site by
truck / trailer up to the jetty location the same shall be shifted to
well location by barge.
Wooden sleepers are placed at a interval of 1.50m along the
circumference of the cutting edge.
Cutting Edge is placed over wooden sleepers using crane aligned
and joined with respect to centre lines. After alignment joints are
to be welded.
Inner form panels are first cleaned and standard form releasing
agent is applied on the surface.
To make the shutter joints leak proof suitable foam sheets between
shuttering joints and/or masking tape at joints are used to seal the
joints.
Inner formwork shall be erected and all the form panels shall be
joined to form the true shape as per the concrete profile,
horizontal and diagonal supports erected. The erection of inner
formwork shall be as per enabling drawing issued by enabling
dept. The formwork shall be handled by crane.
Fixing of Rebar:
Rebars are cut and shaped at the central rebar yard as per the
approved bar bending schedule and transported to site using
truck/trailer up to the jetty location. The bars shall be transported
to well location by barge.
Adequate number of 75 mm cement concrete cover blocks shall be
placed to maintain cover along the periphery of formwork and also
at the bottom to maintain specified cover.
Outer vertical bond bars shall be welded with angle. All other
reinforcement bars along with any stiffeners / spacers are fixed in
position as per drawing and approved bar bending schedule.
The rebar are checked jointly with Engineers representative.
Concreting:
Curing:
After removal of inner form panel, gunny bags filled with sand shall
be placed in between wooden sleepers along the periphery at the
bottom of cutting edge.
Grounding of the curb shall be done after removing the inner
forms.
The curb is sunk to the ground level by manual dredging in the
dredge hole. When the dredging is partially complete, the loose
6.5
material is removed from the dredge hole using the plate gran and
is dumped outside the area of well, later this dredged material
shall be disposed to nearby area provided by engineer.
The sinking history would be recorded in the format as provided in
the technical specification (Appendix 1200/I, MoRT&H).
The sinking level is monitored at regular intervals of 500mm.
Rebar fixing:
Re bar are cut and bent at the central rebar yard as per the
approved bar bending schedules and transported from the yard by
truck/ trailer.
Re bars are fixed as per drawing and schedule.
Adequate cement concrete cover blocks shall be provided along
the periphery of the formwork to maintain the cover of rebar.
De - shuttering:
The inner and outer form panels are removed after 12 hours of the
concrete finished time.
Steining Sinking:
Following the de shuttering of steining lift, gauge marking is carried
out at both axes in line with well curb marking and reference height is
marked on the wall surface. The sinking operation would be started
after 16 hrs of concreting for steining.
Sinking of wells shall be carried out by dredge hole method by using
the following steps:
Sinking operation:
When the wells have sunk close to each other and clear distance
between them is not greater than the diameter of wells, sinking
shall be taken up on all wells and they shall be sunk alternately.
Very deep sump shall not be made below the well curb. The depth
of sump shall not exceed 3.0m below the level of cutting edge
unless otherwise specifically permitted by Engineer.
6.6
False Steining.
Bottom Plug.
Sand Filling.
Intermediate Plug.
Top Plug.
Water Filling.
Well Cap.
False Steining:
False steining is cast wherever required and mentioned as per
drawing.
Bottom plug:
Once the cutting edge has reached the founding level as shown in
the drawing or as decided by the engineer, a sump of required
shape and shape as shown in the drawing or decided by the
Engineer shall be formed. It is desirable to have a good idea of the
shape of the sump either by probing or by sending divers.
After completion soundness test of bottom plug filling inside the
well shall commence after a period of 3 days.
Sand filling:
After the bottom plug and waiting period is over, sand filling shall
be started. Good quality sand shall be filled in dredge hole after 3
days of bottom plug concrete up to required level.
After sand has been filled in the well, water remaining on top of
the sand shall be bailed outers. Top level of sand to be checked
and top plug / intermediate plug of required grade of concrete and
thickness shall be laid as shown in the drawing, and balance work
of well cap shall be taken up.
Intermediate / Top plug:Intermediate / Top plug will be carried out after sand filling as per
drawing.
Water filling:
Water filling in the steining wherever mentioned in the drawing
shall be taken into consideration.
Time cycle
A
i)
ii)
iii)
iv)
v)
vi)
vii)
viii
)
ix)
B
C
Duration (days)
1.0
1.0
5.0
2.0
2.0
1.0
2.0
2.0
De - shuttering
Total duration
Well Sinking 1m / day, so 4 m lift
Well Steining Lift 2.5m
1.0
17
4
i)
ii)
iii)
iv)
D
i)
ii)
iii)
iv)
v)
vi)
vii)
viii
)
Reinforcement fixing
Inner and outer shuttering
Checking and concreting
De shuttering & Sinking
Total duration
Bottom Plug, Sand filling, Well cap
Cleaning, checking 7 clearance for bottom
plugging.
Bottom plugging
Sand filling
Top plugging
Reinforcement for well cap
Outer shuttering for well cap
Checking and concreting
De shuttering
2.0
3.0
2.0
2.0
9.0
Total duration
14.0
1.0
1.0
4.0
1.0
3.0
2.0
1.0
1.0
All employees, workmen and labour of GPT INFRA PROJECTS LTD. And
its subcontractor engaged for bridge work shall be wearing proper
P.P.E before entering the site.
Barricading shall be provided to cover the entire length of working
area. The barricading shall be provided as per the approved scheme.
Painting of barricading shall be done with approved colour scheme for
prominent visibility.
All the vehicles engaged for the work shall be fitted with proper
indicator systems.
Reverse light rear view mirror and reverse horn shall be fitted with all
the vehicles.
Break, steering condition, tire pressure shall be checked periodically.
Proper speed limit shall be maintained within the project site.
Driver shall not drive vehicle when he is not fit mentally and
physically.
Proper caution boards, flag boys be placed to caution the vehicle
movement at unloading points.
Trained supervisors shall be deployed at working sites.
Unauthorized persons and visitors shall not be allowed within the
critical area/hard hat area.
Trained Flag Boy and warning systems shall be provided.
Periodic training shall be provided to drivers, helpers, and bank men
and flag boys. Tool box talks shall be carried at frequent intervals by
safety personnel/site in charge.
Proper supervision and proper planning of the activity shall be done.
Proper illumination shall be provided during night work.
Good housekeeping shall always be maintained nearby working area
to prevent any kind of hazards.
Any lifting equipments shall be engaged in work after proper
checking and load testing as per relevant requirement. Periodic
maintenance shall be done for all lifting equipments/devices
deployed at work. Record shall be maintained in prescribed format.
10. ATTACHMENTS:
Annex 1: Details of Cutting Edge for 19.15 x 9.15 m dia well
curb for Kalpi Yamuna Rail Bridge Project.
Annex 2: Details of Well Steining for 19 x 9 m dia well for
Kalpi Yamuna Rail Bridge Project.
Annex 3: Fabrication details of Inner and Outer formwork for
well curb for Kalpi Yamuna Rail Bridge Project.
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