General Method Statement: CPMG Format No - QF 9949 03

GENERAL METHOD STATEMENT JOB NO.
2264
CPMG FORMAT NO.QF 9949 03
(Central Planning & Methodology
Group)
PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01

DOCUMENT TITLE : General Method Statement DATE : 3-Feb-2011
DOCUMENT NO. 2264-CPMG-100-PRO-111 Page No. : 1 / 69
1 Job Name : Dahej Standby LNG Jetty
2 Job No. : 2264
3 Document Name : General Method Statement
4 Document No. : 2264-CPMG-100-PRO-111
5 Total Pages :
6 Date Of Release : 03.Feb.2011
7 Revision No. : 01
8 Revision For :
9 Document Status : Issued For Information (IFI)
Issued For Approval (IFA)
Issued For Construction (IFC)
10 Remarks / Notes :
11 Enclosure : 1. Construction Programme
Prepared By Checked By Approved By
Mr. Shivaraju SA Mr. Mathi Sekharan Mr. Giridhar R

GENERAL METHOD STATEMENT JOB NO.2264
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Contents
1 BRIEF SCOPE, PURPOSE AND LOCATION OF SITE .................................................................... 4
1.1 SCOPE ....................................................................................................................................................4
1.2 PURPOSE ................................................................................................................................................6
1.3 LOCATION OF SITE .................................................................................................................................6
2 REFERENCES....................................................................................................................................... 7
3 SITE INSTALLATIONS......................................................................................................................... 9
3.1 SITE OFFICE .........................................................................................................................................10
3.2 CONCRETE BATCHING PLANT..............................................................................................................10
3.3 QUALITY CONTROL LABORATORY.......................................................................................................11
3.4 STORES.................................................................................................................................................11
3.5 PRE-CASTING & STACKING YARD .......................................................................................................11
3.5.1 FABRICATION OF PRE-CAST ELEMENTS ..............................................................................................12
3.5.2 FORMWORK ..........................................................................................................................................12
3.5.3 CASTING OF PRE-CAST UNITS .............................................................................................................13
3.5.4 CURING OF PRE-CAST UNITS ...............................................................................................................13
3.5.5 CASTING & STACKING OF PRE-STRESSED LONGITUDINAL BEAMS....................................................14
3.5.6 FIXING REINFORCEMENT & HTS STRANDS.........................................................................................15
3.5.7 FIXING OF FORMWORK .........................................................................................................................15
3.5.8 CONCRETE PLACING ............................................................................................................................15
3.5.9 CURING .................................................................................................................................................16
3.5.10 DE-SHUTTERING ...................................................................................................................................16
3.5.11 TRANSPORTATION OF PRE-STRESSED BEAMS ...................................................................................17
3.5.12 PRE-CASTING OF ROADWAY SLABS ....................................................................................................17
3.6 PILE SPLICING YARD / PREFABRICATION Y ARD .................................................................................17
3.6.1 STEEL PILE TRANSPORT ......................................................................................................................20
3.6.1.1 FOR LAND PILES: APPROACH TRESTLE .............................................................................................20
3.6.1.2 FOR ZONE 1 - 5 PILES OF APPROACH TRESTLE .................................................................................20
3.6.1.3 FOR OFFSHORE STRUCTURES.............................................................................................................21
3.7 WORKSHOP ..........................................................................................................................................22
3.8 REINFORCEMENT BENDING & CUTTING YARD ....................................................................................22
3.9 LOAD OUT JETTY .................................................................................................................................22
4 CONSTRUCTION METHODOLOGY OF MAJOR ACTIVITIES ...................................................... 23
4.1 CONSTRUCTION OF APPROACH TRESTLE ...........................................................................................23
4.1.1 GENERAL ..............................................................................................................................................23
4.1.2 LIST OF M AJOR EQUIPMENTS NEEDED ................................................................................................23
4.1.3 SEQUENCE OF CONSTRUCTION ...........................................................................................................24
4.1.3.1 CONSTRUCTION OF ABUTMENT ...........................................................................................................26
4.1.3.2 DRIVING OF LAND STEEL PILES FROM BENT NO 1 – 18. ...................................................................27
4.1.3.3 DRIVING OF M ARINE STEEL PILES USING TRAVELLING UNIT FROM BENT 19....................................31
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4.1.3.4 DRIVING OF PILES AT EXPANSION LOOP USING TRAVELLING UNIT ...................................................41

4.1.3.5 DRIVING OF ANCHOR POINT PILES USING TRAVELLING UNIT ............................................................44
4.2 CONSTRUCTION OF OFFSHORE STRUCTURES ....................................................................................47
4.2.1 GENERAL ..............................................................................................................................................47
4.2.2 LIST OF EQUIPMENTS ...........................................................................................................................47
4.2.3 CONSTRUCTION OF BREASTING DOLPHIN ...........................................................................................48
4.2.3.1 PILE FOUNDATION ................................................................................................................................48
4.2.3.2 PRECAST SLABS INSTALLATION ..........................................................................................................51
4.2.3.3 PROCEDURE FOR IN-SITU CONCRETING ...............................................................................................52
4.2.4 CONSTRUCTION OF MOORING DOLPHIN ..............................................................................................54
4.2.5 CONSTRUCTION OF UNLOADING PLATFORM .......................................................................................55
4.2.5.1 PILE FOUNDATION ................................................................................................................................55
4.2.5.2 SUPERSTRUCTURE ...............................................................................................................................57
4.2.6 INSTALLATION OF CATWALKS ..............................................................................................................61
4.2.7 CONSTRUCTION OF TUG BERTH ..........................................................................................................62
5 JOB SAFETY ANALYSIS................................................................................................................... 63
6 MILESTONES ...................................................................................................................................... 67
7 TIME CYCLES OF MAJOR ACTIVITIES .......................................................................................... 68
7.1 TIME CYCLE FOR APPROACH TRESTLE ...............................................................................................68
7.2 TIME CYCLE FOR UNLOADING PLATFORM...........................................................................................68
7.3 TIME CYCLE FOR BREASTING DOLPHINS ............................................................................................68
7.4 TIME CYCLE FOR MOORING DOLPHINS ...............................................................................................68
7.5 TIME CYCLE FOR TUG STORM MOORING ............................................................................................68
7.6 TIME CYCLE FOR WALKWAY PILLING ..................................................................................................68
8 CONSTRUCTION PROGRAMME...................................................................................................... 69
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1 Brief Scope, Purpose and Location of Site

1.1 Scope
The Scope of this Project consists of Construction of following Marine Structures:
• Approach Trestle.
• Unloading Platform.
• Mooring Dolphin.
• Breasting Dolphin.
• Catwalks.
• Tug Storm Mooring.

The scope of above major activities has been summarized in the form of table as shown below:
Sl Approach Unloading Mooring Breasting Tug Storm

Item Catwalks
No Trestle Platform Dolphin Dolphin Mooring
43m x
2.4 km 10m x 9m x
39.5m x
1 Size Length, 10m x 12.75m x NA NA
2.25m
9.5m Wide 2.5m Thick 2.5m Thick
Thick
2 No. of Bents. 102 NA NA NA NA NA
Type 1 - 4
Total No. as a Whole Type 2 - 8
3 1 1 8 4 4
Unit Type 3 - 2
Type 4 - 4
4 Total No of Piles. 264 38 112 64 4 12
Spacing between the

5 24 NA NA NA NA NA
Bents.(meters)
Diameter of the Not

914 - 1168 1168 1168 1168 914
6 Piles.(mm) Mentioned
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Sl Approach Unloading Mooring Breasting Tug Storm

Item Catwalks
No Trestle Platform Dolphin Dolphin Mooring
Length of Not
7 30.5 - 56 55 - 69 52.7 - 60 50 - 61 50 - 54
Piles(meters) Mentioned
Not
8 Wall Thickness (mm) 20 - 30 18 - 30 18 - 30 18 - 30 18 - 30
Mentioned
Not
9 Slope of Raked Piles 3.5 V: 1H 4V: 1H 3V: 1H 3V: 1H 20V: 1H
Mentioned
Varies
from
+13.54m +18.75m +13.5m Not
10 Pile Cut Off Level +9.5m CD +10.5 m CD
CD to CD CD Mentioned
+18.1m
CD
Pile Cap Beams/Deck

11 102 36 NA NA NA NA
Beams (Nos.)
12 Deck Pile Cap (Nos.) NA 29 NA NA NA NA
Pre-stressed Beams
13 362 NA NA NA NA NA
(Nos.)
14 Precast Slabs (Nos.) 808 155 8 4 2 4
15 In-Situ Concrete NA A A A NA NA
16 Fenders NA NA 8 4 NA 8
17 Quick Release Hooks NA NA 8 4 NA NA
A – Applicable
NA – Not Applicable
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1.2 Purpose
The Purpose of this document is to give the General information on Construction Methodologies
and Schemes with necessary sketches that are required to carry out the Major activities that are
listed in the Scope of this document.
1.3 Location of Site
500 m
New LNG Standby Jetty
The Site is located about 500 m directly south of the existing jetty.
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2 References
Sl. No Description Drawing No.
1 Overall Plot Plan - General Arrangement Layout PR-M1005-GN-01
2 General Plant and Elevation LNG Terminal PR-M1005-GN-02
3 JETTY HEAD - General Arrangement Layout PR-M1005-GN-03
4 General Structure - Pile Schedule PR-M1005-GN-04
5 General Structure - Pile 3D View PR-M1005-GN-05
6 Approach Trestle - Pile Layout PR-M1005-AT-01
7 Approach Trestle - Typical Elevation PR-M1005-AT-02
8 Approach Trestle - Typical Cross Section PR-M1005-AT-03
9 Approach Trestle - Typical Cross Section Zone 2 PR-M1005-AT-04
10 Approach Trestle - Typical Cross Section Zone 3 PR-M1005-AT-05
11 Approach Trestle - Anchor Point Zone 2 PR-M1005-AT-06
12 Approach Trestle - Anchor Point Zone 3 PR-M1005-AT-07
13 Approach Trestle - Expansion Loop Zone 1 PR-M1005-AT-08
14 Approach Trestle - Expansion Loop Zone 2 & 3 PR-M1005-AT-09

Approach Trestle - Expansion Loop and Passing Bay Zone 2 &
15 PR-M1005-AT-10
3
16 Approach Trestle - Expansion Loop Platform Plan PR-M1005-AT-11
Approach Trestle - Expansion Loop Platform and Passing Bay

17 PR-M1005-AT-12
Plan
18 Approach Trestle - Precast Plank PR-M1005-AT-13
19 Approach Trestle - Roadway Wet Joints PR-M1005-AT-14
20 Approach Trestle - Prestressed Beams PR-M1005-AT-15 & 16
21 Approach Trestle - Beam/Pile Connection Detail Zone 2 PR-M1005-AT-17
Approach Trestle - Beam/Pile Connection Detail Zone 2 and

22 PR-M1005-AT-18
Tug Berth
23 Unloading Platform - Plan General Arrangement PR-M1005-UP-01
24 Unloading Platform - Longitudinal Cross Sections PR-M1005-UP-02
25 Unloading Platform - Transversal Cross Sections PR-M1005-UP-03
26 Unloading Platform - Steel Piles PR-M1005-UP-04
27 Unloading Platform - Details PR-M1005-UP-05
28 Unloading Platform - Handrail & Stair Detail PR-M1005-UP-06
29 Mooring Dolphins MD1 to MD6 General Arrangement PR-M1005-MD-01.1
30 Mooring Dolphins MD1 to MD6 General Arrangement PR-M1005-MD-01.2

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31 Mooring Dolphins Hand Railing Details & Step Ladder Details PR-M1005-MD-02
32 Breasting Dolphins BD1 & BD2 General Arrangement PR-M1005-BD-01.1
33 Breasting Dolphins BD1 & BD2 General Arrangement PR-M1005-BD-01.2
34 Breasting Dolphins Elevated Platform Details PR-M1005-BD-02
35 Breasting Dolphins Typical Fender and Skirt Details PR-M1005-BD-03
36 Catwalks General Arrangement Plan & Elevation PR-M1005-CW-01
37 Catwalks Detail Plan & Sections PR-M1005-CW-02.1
38 Catwalks Detail Plan & Sections PR-M1005-CW-02.2
39 Catwalks Support Details PR-M1005-CW-03
40 Abutment General Plan & Sections PR-M1005-OC-01.1
41 Abutment Geometric Definition PR-M1005-OC-01.2
42 Tug Berth Plan and Elevation PR-M1005-TB-01

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3 Site Installations
To carry out the construction of the scope of work following temporary site facilities are required
to setup:
• Site Office
• Concrete Batching Plant
• Quality Control Laboratory
• Stores
• Pre-casting and Stacking Yard
• Pile splicing Yard
• Workshop
• Electric Supply
• Reinforcement Bending and cutting yard.
• Load Out Jetty
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3.1 Site Office
The site Office will be constructed immediately after receiving the LOA. Site Office will be of semi
– pakka type. Suitable required furniture and equipment would be provided at the site office.
Electrical and water network system will be provided at site office. Facility for proper sewerage
and drinking water system will be maintained at the site office. Land levelling and necessary
filling shall be carried out before any Installations
3.2 Concrete Batching Plant
To carry out the necessary Civil Works both on Land and Marine, 2 Nos. of Concrete Batching
Plant of different capacity as listed below will be Mobilized and Erected at Site.
1. Concrete Batching Plant of capacity 30 cum/Hr (approximately) on Land for Land

Based Civil Works.
2. Concrete Batching Plant of capacity 15 cum/Hr (approximately) on Floating Barge

for Marine Based Civil Works.
Aggregates, which are produced at quarry, are stacked near to the onshore Batching Plant as
shown in the Site Installation Plan. Transfer of aggregates is done by wheel loader.
Cement is stored in silo. It is delivered at site in bulk. Water is stored in dedicated tank
connected to the batching plant. Laboratory facilities are made available in the vicinity of the
batching plant.
TYPICAL BATCHING PLANT ARRANGEMENT FOR ONSHORE WORKS
Additional Batching plant of suitable capacity (approx 15 Cum/Hr)will be installed on the floating
barge for carrying out the civil work of the Breasting Dolphin, Mooring Dolphin, and Loading
Platform etc.
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TYPICAL FLOATING BATCHING PLANT ARRANGEMENTFOR OFFSHORE

WORKS
3.3 Quality Control Laboratory
Quality control laboratory will be constructed to the adjacent of site office or Batching Plant. Even
this will be semi – pakka type construction. It will be equipped with the testing equipment
required for the job. Electrical, Water and required furniture will also be provided in the structure.
The laboratory is equipped in order to perform all necessary tests.
3.4 Stores
Stores will be constructed near to the site office. Even this structure will be of semi – pakka type.
Electrical and water connection will also be provided. Open storage will also be provided in front
of the store. Cement Store will be a watertight construction and will be constructed at a higher
elevation.
3.5 Pre-casting & Stacking Yard
Pre-casting yard for casting of capping beams, Pre-stressed longitudinal beams, Slab units will
be constructed. The pre-casting yard will be levelled and compacted for the loads coming on it.
Stacking Yard for Precast units and Reinforcement and other construction materials will be
constructed on levelled ground. It will be open storage yard.
Pre-cast elements are manoeuvred on the yard by a Gantry Crane / EOT with the required lifting
capacity.
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PRECASTING YARD
3.5.1 Fabrication of Pre-cast Elements
The fabrication of pre-cast elements shall be done in the Pre-cast yard. Gantry Crane / EOT of
desired capacity will be used for handling the pre-cast units in the casting yard and stacking
yard.
Casting yard will be equipped with following Equipments:
• Welding machines / Welding Generator
• Compressor 300 CFM
• Concrete pumps of 26 Cu-m/Hr.
• Needle vibrators of 40mm/60mm
• Shutter Vibrators
• 2 No’s of EOT Gantry of approximately 40MT - 60MT capacity.
• Diesel Generator (Standby)
3.5.2 Formwork
It is proposed to provide a formwork with steel plates of suitable thickness fabricated as per the
requirements. A suitable temp-plate/formwork will also be made with steel plates for making of
pockets in the pre-cast units to facilitate lifting and handling of the pre-cast units.
The shutters will be made of modular type so that the length and width can be adjusted in no
time according to the type of pre-cast unit required to be cast.
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Formworks will be erected at the respective casting bed fixed with nuts and bolts. Before
erection of the formwork, the inner faces of the formworks will be applied with suitable de–
shuttering oil.
Handling of the shutters for pre-cast units shall be done by the Gantry Cranes / EOT crane.
3.5.3 Casting of Pre-cast Units
Concrete will be transported using Transit Mixers of 6 Cu m capacity from Batching plant to the
Casting area. Then the Concrete will be poured into the prepared formwork in layers. Vibrating
will be done in each layer with 40/60mm concrete vibrator, diesel or electric operated. Quality
control checks will be carried out by quality personnel, under guidance of quality engineer, as
and when necessary during the concreting operations of the pre-cast units.
After pouring is completed, skilled masons will do finishing of the top surface. Curing compound
will be sprayed immediately over the finished surface for forming an impervious film, which will
reduce the evaporation loss of surface water from green concrete.
Precast Beams Stacking Area Precast Beams Rebar Cutting

Casting Area and Bending
Area
Precast Slabs Precast Slabs Rebar

Stacking Area Casting Area Work
3.5.4 Curing of Pre-cast Units
Removal of formwork will start only after 12 hrs of pouring of concrete or as stipulated in the
specification.
Curing compound will be sprayed upon the exposed surface of the newly cast pre-cast units.
Curing of the pre-cast units will be done by wrapping with moist Hessian cloth along with
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polythene sheet. Intermittent pouring of water will be done to keep the Hessian cloth moist
always. The pre-cast units will be cured up to 3 days in the casting bed or till the required
strength.
COVERING OF PRECAST UNITS BY POLYTHENE SHEETS AND NUMBERING OF

UNITS FOR EASY IDENTIFICATION
After 3 days of curing or achieving the desired strength suitable for lifting the precast units, the
pre-cast units will be transported to the stack yard for a brief period of time.
Suitable identification marks will be painted on the block surface so that at any point of time, the
pre-cast unit type and the manufacturing date and concrete batch details can be ascertained.
And also this will ensure to identify the right block type for placing at the proper location.
3.5.5 Casting & Stacking of Pre-stressed Longitudinal Beams
The approach trestle has pre-stressed longitudinal beams. These shall be cast at casting yard.
CASTING OF PRE-STRESSED BEAMS STACKING OF PRE-STRESSED BEAMS

After required strength gain, the Pre-stressed beams are stacked in the Stacking yard. The
beams will be lifted by the EOT / Gantry crane at casting yard using nylon sling/belts on either
end of the beam.
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3.5.6 Fixing Reinforcement & HTS Strands
The bar bending schedule shall be prepared as per approved drawings and jointly checked.
Before starting of formwork all the reinforcement bars required for the girder shall be cut and
bent to the required length and shape as per released bar bending schedule. Reinforcement
bars shall be fixed in position on the reinforcement tying bed, alongside the Casting Bed. The
HTS Strands shall be cut using grinding machine to the required length. After insertion of
sheathing pipes, the strands shall be inserted in to the reinforcement cage as per approved
drawings. Once all the above operations are over, the cage shall be hoisted with the help of EOT
Gantries and lowered over the casting bed. After lowering the cage over the casting bed the HTS
strands shall be coupled.
3.5.7 Fixing of Formwork
Side shutter for Girders will be fabricated at site or pre-fabricated shutters will be procured
directly. The bottom of shutter will be hinged to the sides of the casting bed. The shutter shall be
fixed by means of turnbuckles and tied with tie rods of approximately 16-mm / 22 mm diameter,
in between the two turnbuckles. The side bottom bulb and web shutter shall be fixed first;
following this the top slab side shutter shall be fixed with help of nuts & bolts. The shutters will
also have inclined supports along the length. The shutters will be handled with assistance from
EOT / Gantry crane as required.
SHUTTERING & REBAR ARRANGEMENT FOR PRECAST UNITS
3.5.8 Concrete Placing
Concrete shall be placed directly into the moulds from the Transit mixers or shall be placed with
concrete pump & pipeline. Concrete shall be compacted using needle vibrators and shutter
vibrators.
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3.5.9 Curing
Once concreting is completed, the top surface will be covered with multi layer of gunny bags or
jute fabric, well trenched in water and shall be kept moist for the next 5 hours and thereafter
steam curing will be done if required depending on the strength required and the time available
for strength gain.
CURING OF PRE-STRESSED BEAMS
3.5.10 De-shuttering
Once the girder has gained requisite strength, it shall be de-shuttered. The shuttering will be
moved to the next bed for use. The girders will then be lifted from the casting bed with help of 2
nos. EOT / Gantry Crane and will be shifted to stacking beds. In the stack beds the girders will
be cured further using gunny bags / Hessian cloth.
LIFTING OF PRE-STRESSED GIRDER

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3.5.11 Transportation of Pre-stressed Beams
After the pre-stressed beams have been sufficiently cured and gained sufficient strength at the
stacking yard, these will be shifted to the installation location. The beams will be lifted by the
EOT / Gantry crane at casting yard using nylon sling/belts on either end of the beam. The beams
will be loaded on to self travelling trolleys. These trolleys will carry the beams upto the bent just
before the bent of installation.
TRANSPORT OF PRECAST BEAM.
3.5.12 Pre-casting of Roadway slabs
The pre-casting of the roadway slabs shall be casted in the similar way as described above.
Dedicated Casting yard for these slabs is to be prepared next to the Prestressed Longi beams
casting area.
3.6 Pile Splicing Yard / Prefabrication Yard
Pile splicing yard / Prefabrication yard for pile lengthening needs to setup for the following
activities:
• Joining of piles to form the required total length of the steel piles
• Painting of piles
• Radiography testing of the pile joints
For this purpose equipments required for welding operation and system with rollers to allow easy
pile manoeuvring will be supplied.
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SPLICING YARD
The steel piles received from the suppliers/vendors will be stacked in groups at the pile splicing
yard. Pile jointing will be done by full penetration single V-joint. Qualified welders will be
deployed for this activity.
The piles will be spliced at the splicing yard to achieve full length. Once the piles splicing is
completed for a pile, radiography will be carried out on the pile joints. After radiography is
completed positively, the fabricated pile will be shifted onto adjacent area where, touch-up
painting and painting at splicing will be done.
Finally the completed pile ready for installation will be shifted and stacked separately at the
splicing yard. Each pile will be clearly and indelibly marked to show its serial number and also
location. Also, the piles will be calibrated on the outer side for convenience in measurement
while driving.
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Following are the photographs showing the various activities in the pile Splicing Yard.
GRINDING OF PILE JOINTS PILE JOINTING WITH CLAMPS
RADIOGRAPHY TESTING OF PILES TOUCHUP PAINTING OF PILES

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3.6.1 Steel Pile Transport
After splicing & painting, pile will be stacked in the yard. As and when required the piles will be
shifted to the piling location. Crawler crane of sufficient capacity will lift the pile with nylon
sling/belts on either end of the pile and will load the pile on the truck with dolly arrangement. The
truck along with pile will move to the location.
3.6.1.1 For Land Piles: Approach Trestle
For this Zone i.e. from Bent No. 1 to 18 the piles will be transported directly to the Pile driving
location where the crane will be parked. The piles will be transported on truck with dolly
arrangement.
PILE LOADING ON TRUCK WITH DOLLY ARRANGEMENT
3.6.1.2 For Zone 1 - 5 Piles of Approach Trestle
For Zone 1 to 5, the piles will be transported on truck with dolly arrangement from pile splicing
yard to the pile location on the travelling unit / Gantry. The piles will be lifted with the help of the
two Gantry Cranes / EOT assembled on the Travelling unit / Gantry. The piles will be transported
in front i.e. towards the end of the Travelling unit / Gantry with these Gantry Cranes / EOT.
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3.6.1.3 For Offshore Structures
These piles will be transported to the location with the help of Material pontoon towed with tugs.
TOWING OF MATERIAL PONTOON CARRYING STEEL PILES BY TUG

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3.7 Workshop
Workshop for maintenance of construction of plant and equipment will be constructed at the site.
Even this will be a temporary type of construction. Sufficient number of workshop equipment will
be provided at the workshop. Proper arrangement for electricity and water will be provided.
3.8 Reinforcement Bending & Cutting Yard
Reinforcement fabrication Yard, for cutting and bending of reinforcement shall be carried out as
per the bar bending schedule. The area for this activity shall be near to the casting yard.
3.9 Load Out Jetty
Load out jetty needs to be erected for the transportation of the steel piles and the pre-cast slab
units of the Mooring dolphin and Breasting dolphin.
LOAD-OUT JETTY
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4 Construction Methodology of Major Activities

4.1 Construction of Approach Trestle
4.1.1 General
The entire work will be carried out strictly as per tender conditions and specifications and to the
complete satisfaction of the client.
Survey will be jointly carried out with client to mark the alignment, Pile locations, to establish the
benchmark, etc.
The entire work will be carried out giving due cognizance to the safety, health and environment
aspects.
Bracings for all the Marine Piles shall be provided to control the Sway of Piles due to heavy
Currents and Waves.
4.1.2 List of Major Equipments needed
For Land Based Piling

Numbers
Name of Plant / Equipment Capacity Required / Purpose
Similar
Land Based Piling and Cap-
Crawler Crane 200 MT 1
beam Placing.
Trailer and Dolly 60 MT 1 Steel Pile Transportation
Vibro Hammer + Power Pack 50HD 2 Steel Pile Driving
Hydraulic Hammer + Power Pack HHK18A/20S 2 Steel Pile Driving
a. Assembling the Traveling
Unit &
b. Assembling the
Crawler Crane 200 MT 1 approximately 450 MT Crawler
crane.
c. Erection of 2 Nos. of EOT
(To be confirmed).
Longi Beams and Roadway
EOT 60 MT 2
Slabs Placing.
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For Marine Based Piling

Numbers
Name of Plant / Equipment Capacity Required / Purpose
Similar
Traveling Unit with Hydraulic Supporting Unit for Crawler
2-span 1
Guide. Crane.
For Pile Driving and Placing of
Crawler Crane on Traveling Unit Approx 400 MT 1
Cap-beam
Same Used
Steel Pile ,Capbeam and Longi
Trailer and Dolly 60 MT in Land
beam Transportation
Based Piling
Vibro Hammer + Power Pack 50HD - Do - Steel Pile Driving
Hydraulic Hammer + Power Pack HHK18A/20S - Do - Steel Pile Driving
Longi Beams / Roadway Slabs
EOT 60 MT
Placing.
4.1.3 Sequence of Construction
For the purpose of the piling work of the Approach Trestle, the Approach Trestle is divided into
following zones considering the average sea bed level so as to arrive at the accurate duration
required for driving of steel piles.
APPROACH
TRESTLE
Land Piles Marine Piles

(Bent no 1-18) (Bent no 19-102)
Zone 1 Zone 2 Zone 3 Zone 4 Zone 5

(Bent no 19-55) (Bent no 56-68) (Bent no 69-80) (Bent no 81-90) (Bent no 91-102)
FLOWCHART SHOWING THE ZONE WISE DIVISION OF APPROACH TRESTLE

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The Approach Trestle is divided into 6 Zones considering the average sea bed level, which is
mentioned in the below table.
No of
Sr. No. Zones Bents Avg. Bed Level
Bents
1. Land Piles Zone 1 – 18 18 9.00 m
2. a Zone 1 19 – 25 7 3.50 m
3. b Zone 1 26 – 55 30 3.50 m
4. Zone 2 56 – 68 13 2.00 m
5. Zone 3 69 – 80 12 -3.00 m
6. Zone 4 81 – 90 10 -8.50 m
7. Zone 5 91 - 102 12 -13.00 m
102
The Following Activities are involved in construction of the Approach Trestle:
• Construction of Abutment
• Driving of Land Steel piles from Bent No 1 – 18.
• Driving of Marine Steel Piles from Bent No 19 – 102.
• Cutting of Steel Piles as per the Cut-off level of the piles.
• Placing of Capping Beams.
• Welding Bottom plate embedded in Capping beams to the pile
• Placing of Prestressed longitudinal beams
• Placing of Pre-cast Roadway slabs

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4.1.3.1 Construction of Abutment
The main purpose of this structure is to connect the Approach trestle with shore. The below
photograph shows the construction of the abutment for the Approach Trestle:
CONSTRUCTION OF ABUTMENT
CROSS SECTION OF ABUTMENT

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4.1.3.2 Driving of Land Steel Piles from Bent No 1 – 18.
These piles will be driven with the help of 250 MT Capacity crane on land with Vibro hammer
and Hydraulic hammer.
Following are some of the photos showing the activity of driving of steel piles with crane on land.
DRIVING OF STEEL PILES WITH CRANE ON LAND
Step 1: Temporary Gravel Filling
Temporary Gravel Filling till the Grid 18 has to be done before carrying out the Piling Works. The
purpose of Gravel Filling is to provide the stable base for the Crawler Crane which will be used
for Pile driving. The Piling is started from the Grid 18 and moved in the direction of Abutment.
Before starting the Piling work, the survey has to be carried out for Pile Locations.
Step 2: Pre-boring at Pile Locations before Driving.
After the Surveyor gives the exact driving location of piles, Pre boring has to be carried to a
depth of 5m approximately from the top level of Gravel fill. The Pre-boring is carried out using a
Piling Rig in advance.
The purpose of Pre-boring is to keep the Pile stable and Vertical after insertion into the guide.
Group)

Step 3: Positioning of Guides and Insertion of the Pile into the Guides
Once the Pre-boring is done, guides are lifted by Crawler crane and positioned at the piling
location. The guide will be fabricated in two halves to ease the fixing and removing before and
after pile driving. Surveyor shall assist in all the necessary survey works. The transportation of
Pile shall be done by Trailer and Dolly arrangement as shown in the below sketch. The Crane
will lift the Pile and inserts into the surveyed guide. The top end of the pile will be provided with
Self Releasing Shackle and shall be released only after inserting completely into the Pre-bored
hole.
Step 4: Driving of Pile with Vibro Hammer

Group)

Lift the Vibro Hammer by Crane and drive the Pile till the Refusal. Once the pile reaches refusal,
lay back the Vibro Hammer at its position allotted near to the Crane. Engineer In-Charge shall
take care of all the necessary equipments and accessories required for the driving shall be
quickly available.
Step 5: Driving of Pile with Hydraulic Hammer

Group)

Once after the Vibro Hammering, lift the Hydraulic hammer and lay it onto the pile. Start driving
the Pile till the Design Founding Level. Lay back the Hydraulic hammer back to its position
allotted near to the Crane.
The Rigger shall be available at all the times during any lifting activities carried out by Crane.
Step 5: Cutting of Pile at the Cut-Off Level
Once the pile is driven completely till the design founding level, the pile is cut at the cut off level.
The cutting of the pile shall be done by the cutters standing on the Guide.
Step 6: Placing of Capping Beam on the Prepared Piles
The transportation of the Cap beam shall be done using Trailer. The crane will lift the cap beam
from the trailer and will place on the prepared piles.
Step 7: Removal of Guide Frame and Shifting to new location.

General Method Statement: CPMG Format No - QF 9949 03

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General Method Statement: CPMG Format No - QF 9949 03

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GENERAL METHOD STATEMENT JOB NO.

PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01

1 Job Name : Dahej Standby LNG Jetty

2 Job No. : 2264

3 Document Name : General Method Statement

4 Document No. : 2264-CPMG-100-PRO-111

6 Date Of Release : 03.Feb.2011

9 Document Status : Issued For Information (IFI)

Issued For Approval (IFA)

Issued For Construction (IFC)

11 Enclosure : 1. Construction Programme

Prepared By Checked By Approved By

Mr. Shivaraju SA Mr. Mathi Sekharan Mr. Giridhar R

PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01

PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01

4.1.3.4 DRIVING OF PILES AT EXPANSION LOOP USING TRAVELLING UNIT ...................................................41

PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01

1 Brief Scope, Purpose and Location of Site

The Scope of this Project consists of Construction of following Marine Structures:

• Tug Storm Mooring.

Sl Approach Unloading Mooring Breasting Tug Storm

2 No. of Bents. 102 NA NA NA NA NA

4 Total No of Piles. 264 38 112 64 4 12

Spacing between the

Diameter of the Not

PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01

Sl Approach Unloading Mooring Breasting Tug Storm

Pile Cap Beams/Deck

12 Deck Pile Cap (Nos.) NA 29 NA NA NA NA

14 Precast Slabs (Nos.) 808 155 8 4 2 4

17 Quick Release Hooks NA NA 8 4 NA NA

PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01

1.3 Location of Site

New LNG Standby Jetty

PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01

1 Overall Plot Plan - General Arrangement Layout PR-M1005-GN-01

2 General Plant and Elevation LNG Terminal PR-M1005-GN-02

3 JETTY HEAD - General Arrangement Layout PR-M1005-GN-03

4 General Structure - Pile Schedule PR-M1005-GN-04

5 General Structure - Pile 3D View PR-M1005-GN-05

6 Approach Trestle - Pile Layout PR-M1005-AT-01

7 Approach Trestle - Typical Elevation PR-M1005-AT-02

8 Approach Trestle - Typical Cross Section PR-M1005-AT-03

9 Approach Trestle - Typical Cross Section Zone 2 PR-M1005-AT-04

10 Approach Trestle - Typical Cross Section Zone 3 PR-M1005-AT-05

11 Approach Trestle - Anchor Point Zone 2 PR-M1005-AT-06

12 Approach Trestle - Anchor Point Zone 3 PR-M1005-AT-07

13 Approach Trestle - Expansion Loop Zone 1 PR-M1005-AT-08

14 Approach Trestle - Expansion Loop Zone 2 & 3 PR-M1005-AT-09

Approach Trestle - Expansion Loop Platform and Passing Bay

19 Approach Trestle - Roadway Wet Joints PR-M1005-AT-14

20 Approach Trestle - Prestressed Beams PR-M1005-AT-15 & 16

21 Approach Trestle - Beam/Pile Connection Detail Zone 2 PR-M1005-AT-17

Approach Trestle - Beam/Pile Connection Detail Zone 2 and

23 Unloading Platform - Plan General Arrangement PR-M1005-UP-01

24 Unloading Platform - Longitudinal Cross Sections PR-M1005-UP-02

25 Unloading Platform - Transversal Cross Sections PR-M1005-UP-03

26 Unloading Platform - Steel Piles PR-M1005-UP-04

27 Unloading Platform - Details PR-M1005-UP-05

28 Unloading Platform - Handrail & Stair Detail PR-M1005-UP-06

29 Mooring Dolphins MD1 to MD6 General Arrangement PR-M1005-MD-01.1

30 Mooring Dolphins MD1 to MD6 General Arrangement PR-M1005-MD-01.2

PROJECT : LNG STANDBY JETTY AT DAHEJ REV. : 01