874 MW SUKI KINARI

HYDROPOWER PROJECT

Construction Technical Scheme for

Permanent Bridge

CGGC Suki Kinari Hydropower Project Management in Pakistan

Aug, 2018
 Contents
1 Preparation Statement and Basis............................................................................................1

1.1 Preparation Statement..................................................................................................1

1.2 Basis of the Preparation................................................................................................1

2 Project Overview....................................................................................................................1

2.1 Project Profile...............................................................................................................1

2.2 Engineering Quantity...................................................................................................1

2.3 Analysis of Construction Difficulties...........................................................................4

2.3.1 Construction Difficulties....................................................................................4

2.3.2 Countermeasure..................................................................................................4

3 Construction Layout...............................................................................................................4

3.1 Construction Road and T-Beam Casting Area & Steel Yard........................................4

3.2 Layout of Water and Power..........................................................................................5

4 Construction Principle and Procedures..................................................................................5

4.1 Construction Principle..................................................................................................5

4.2 Construction Procedures..............................................................................................5

5 Main Construction Methods...................................................................................................5

5.1 Construction Arrangements..........................................................................................5

5.2 Construction Sequence.................................................................................................6

5.3 Construction Schedule.................................................................................................7

5.4 Resources Allocation Plan............................................................................................7

5.5 Construction Preparation..............................................................................................8

5.6 Construction Methodology & Techniques...................................................................9

5.6.1 Excavation.........................................................................................................9

5.6.2 Abutments & Pier..............................................................................................9

5.6.3 Casting Girders................................................................................................10

 5.6.4 Launching of Girders......................................................................................10

5.6.5 Preparation for Expansion Joints....................................................................12

5.6.6 Casting of Deck Slab.......................................................................................12

5.6.7 Piliing..............................................................................................................13

6 Main Resource Distribution.................................................................................................15

6.1 Main Manpower Plan.................................................................................................15

6.2 Main Construction Equipment Plan...........................................................................15

7 Construction Progress Plan..................................................................................................16

8 Quality, Safety and Environment Assurance Measures.......................................................16

8.1 Personnel Protective Equipment................................................................................16

8.2 Fall Protection............................................................................................................17

8.3 Scaffold......................................................................................................................18

8.4 Excavation..................................................................................................................18

9 Attachments..........................................................................................................................18
1 Preparation Statement and Basis
1.1 Preparation Statement
The Permanent Bridge at Tail Race Area is the critical structure for the transportation and
access to Power House Area. The progress of Pile work directly restricts the progress of the
Permanent Bridge Construction on time. To regulate the construction, the construction
scheme for the project is formulated based on the principles of "technical feasibility, safety
and reliability, and cost saving" to ensure safe, orderly and rapid construction and
production.
1.2 Basis of the Preparation
This scheme shall be prepared on the basis of the following contents:
(1) Construction Contract for SK Hydropower Project in Pakistan;
(2) Construction Organization Plan of SK Project;
(3) Overall Progress Schedule of SK Project;
(4) Design Drawing of Permanent Bridge at tail Race Area;
2 Project Overview
2.1 Project Profile
The Permanent Bridge is constructed on Left Bank of MNJC Road Project (N-15) at Km
70+300 (N-15). The length of the bridge 80m, with 2 spans, the Deck slab elevation of the
bridge is EL.1323.0m, pile cap elevation at center pier is EL.1307.934m. Piles at left
Abutment are 13m deep and that on center pier are 11m deep. The bridge consists of T
Beams of 40m length and 12 in numbers.
2.2 Engineering Quantity
The main construction contents include: excavation of covering layer, earthwork excavation,
stonework excavation, slope support, etc. Please refer to Table 1 for the main engineering
quantity.
Table 1 Main Engineering Quantity of Permanent Bridge

Sr .No Item of Work Unit Quantity

1 Earth & rock excavation

1.1 Rock excavation m3 2400

1.2 Earth excavation m3 13600

2 Sandy gravel backfill m3 3140

3 Substructure

3.1 1# pier

3.1.1 Cap beam and binder concrete m3 68.8

3.1.2 pier column concrete m3 94.25

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3.1.3 bearing platform concrete m3 143

3.1.4 Pile foundation concrete m3 155.43

3.1.5 supporting pad concrete m3 1.13

3.1.6 Plain concrete cushion layer m3 7.6

3.1.6 Reinforcement G60 t 94.47

3.1.7 steel t 8.09

3.2 0# bridge abutment

3.2.1 cap beam concrete m3 13.97

3.2.2 foundation concrete m3 0

3.2.3 supporting pad concrete m3 0.53

3.2.4 blinding concrete m3 18.51

3.2.5 Reinforcement G60 t 141.86

3.2.6 Pile foundation concrete m3 298.5

3.2.7 bearing platform concrete m3 269.47

3.2.8 retaining wall m3 283.3

3.2.9 Abutment concrete m3 346.4

3.2.10 steel t 2.3

3.3 2# bridge abutment

3.3.1 Cap beam and ear wall concrete m3 114.04

3.3.2 abutment concrete m3 188.3

3.3.3 foundation concrete m3 248.64

3.3.4 supporting pad concrete m3 0.53

3.3.5 blinding concrete m3 12.92

3.3.6 Reinforcement G60 t 52.36

3.4 Laminated rubber bearing,40×45×8.75cm pcs 24

3.4.1 Laminated rubber bearing,40×40×2cm pcs 12

3.4.2 Laminated rubber bearing,40×20×2cm pcs 8

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3.5 lime trinity mixture fill waterproofer m3 6.3

3.6 clay impervious m3 28.7

3.7 gravel or grait pervious m3 39

3.8 riprap blind ditch m3 3.1

3.9 gravel cushion m3 137.5

2cm thick. Three floors of tarred felt and four
3.10 m2 9.62
floors of tar
3.11 2cm thick. rubber sheet m2 6.9

4 Superstructure

4.1 T beam

4.1.1 Precast concrete m3 771

4.1.2 Cast-in-situ concrete for anchor m3 4.6

4.1.3 Cast-in-situ concrete for wet juncture m3 57.3

4.1.4 Reinforcement G40 t 25.2

4.1.5 Reinforcement G60 t 50.4

4.1.6 prestress wire（1860MPa） t 25.1

4.1.7 Corrugated pipe（Diameter.70mm） m 1893.2

4.1.8 Corrugated pipe（Diameter.80mm） m 950

4.1.9 Anchorage device Set 144

4.2 bridge deck pavement

4.2.1 Cast-in-situ waterproof concrete m3 181.2

4.2.2 Reinforcement G60 t 10.1

4.3 Expansion joint

4.3.1 Cast-in-situ concrete m3 3.8

4.3.2 Reinforcement G60 t 1

4.3.3 Expansion joint, The type: CQ50 m 34.4

4.4 Precast sidewalk

4.4.1 Cast-in-situ concrete m3 40.4

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 4.4.2 Reinforcement G60 t 3.8

4.5 crash bearer

4.5.1 Cast-in-situ concrete m3 67.6

4.5.2 Reinforcement G40 t 1.57

4.5.3 Reinforcement G60 t 5.53

4.5.4 Steel t 3.42

4.6 approach slab

4.6.1 Cast-in-situ concrete m3 42.7

4.6.2 Reinforcement G60 t 4.07

4.6.3 Asphalt Concrete m3 44.8

5 Test pile

5.1 Reinforcement G60 t 7.3408

5.2 Steel t 0.22

5.3 27.6MPa Concrete m3 26.51

Note: Excavation quantities will be subjected to actual site condition

2.3 Analysis of Construction Difficulties
2.3.1 Construction Difficulties
(1) Boring of Piles in Rock and Flowing Water.
(2) Launching of 40m long Girders weighing 144 tons.
2.3.2 Countermeasure
(1) Boring of piles will be done from top to bottom initially with 760mm diameter. Hammer,
than with 1000mm after that with 1200mm and finally 1500mm.Before starting with the
boring, coffer dam will be made to divert the flowing water and platform for tripods will be
prepared.
(2) Launching of T Beam will be performed carefully and safety measures will be insured.
Detail method is explained T beam section.
3 Construction Layout
3.1 Construction Road and Steel Yard and T Beam Casting Area
Permanent Bridge is located at the left bank N15 National Highway, and the construction
equipment and materials are transported to the Camp Area mainly through N15 National
Highway, 7# Bailey bridge and the temporary construction road to Permanent Bridge.
The excavated materials from right Bank Abutment will be used for construction of coffer
dam and platform for Tripods of Percussion Machines.

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3.2 Layout of Water and Power
(1) Water supply system
Water supply pipe line will be laid from source of water on right bank to camp site, where it
will store in tanks and utilized.
(2) Power supply and lighting
In the construction of Permanent Bridge, the electricity there is mainly used as power for
small machines such as Bending Machine, Cutting Machine, welding machine, and for
lighting. A 35KW diesel and 25KW diesel generators are installed at the Camp and steel
Yard Area
4 Construction Principle and Procedures
4.1 Construction Principle
We start will piling and excavation at right Abutment followed by right abutment steel &
concrete. For Left Abutment and Center Pier after piling, pile cap will be done followed by
Abutment wall and wing walls at left Abutment and Pier shaft, bond beam and transom at
center pier. Meanwhile T Beams will be casted during this period.
4.2 Construction Procedures
The main construction procedures of Open Channel are shown in Figure 1.

Excavation of Right Abutment

Pilling for Pier1 and Left Abutment

Foundation Base,Abutment Wall, Wing Wall of R Abt

Transom

T Beam Launching

Deck Slab, Approcah Slab, Barriers

Figure 1 Main Construction Procedures of Permanent Bridge

5. Main Construction Methods
5.1 Construction Arrangement
This permanent bridge right Abutment will be made accessible with the help of Bailey bridge
(#07) on the downstream of this bridge. 80m long permanent bridge at tail race area of Suki
Kinari Hydropower Project located on Kunhar River in Kaghan Valley, Mansehra District,
Khyber Pakhtunkhuwa mainly comprises of Sub-structure and Superstructure.
5.1.1 Substructure
Substructure includes all the structures under the T-Beam level. In case of this bridge,
substructure consists of following:

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5.1.1.1 Abutment at Grid 0 (Left side)
Abutment 0 has following activities
a. Pilling (12Nos Diameter 1.5m depth 13m) (at least 3m into weak weathered rock)
b. Pile Cap
c. Abutment Wall and Wing Walls
d. Transom
e. Approach Slab
5.1.1.2 Pier at Grid 1 (Mid Span)
a. Formation of platform for pilling
b. Piles (6Nos 1.5m diameter depth 11m) (at least 5m into weak weathered rock)
c. Pile Cap
d. Steel liner (of 16mm wall thickness)
e. 3 Nos. of Pier Shaft (2m diameter) and 01 Nos. of Bonding Beam at interval over pier
shaft
f. Transom over pier shaft
5.1.1.3 Abutment at Grid 2 (Right side)
a. Excavation for Abutment Beam
b. Foundation Beam
c. Abutment Beam
5.1.2 Super structure
Superstructure includes all activities above transom level comprises of following as in table
Below:

SERIAL NO. DESCRIPTION SPECIFICATIONS/QUANTITY

1 T-Beam 40m Long/ 12 in No.
2 Deck Slab 40mx13.80m, 2 in No.
3 Approach Slab 5.0x13.80 & 6.0mx13.80m , 2 in No.
4 Wing walls 2 in left and right side.
5 Barrier & Side walk 80m long/ on both sides
6 Expansion joints 3x13.8m
Table 2 Description and Specifications/Quantity

5.2 Construction sequence

Construction sequence will comprise of 2 main activities, as listed below:
Table 3 Critical and Subsequent Activities
CRITICAL ACTIVITIES Subsequent Activities
Piles: 12 piles having diameter of 1.5m and 13m Excavation for abutments 2,Preparation of 12 Nos T-
of depth & 6 plies diameter 1.5m and 11m depth Beam
Pier shafts: 3 pier shafts each joined by Binding Abutment#2 base

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 beam
Transom Beam: Transom consists of 13m x 2m
Wing walls (Abumtment#0&2)
and 2.5m in height.
Launching of Girders Abutments Transom
Deck Slab and Diaphragm concrete
Barrier and side walk/ Approach Slab

5.3 Construction schedule

Please refer to attachment
5.4 Resources allocation plan
The resource allocation plan for the project is devised in two categories
a. Mechanical Resources：
①. 1.No. of Excavators along with Jack Hammers.
② 1. No. Loader (3.6 m3)
③ 1. No. Roller (2 Tons)
④ Batching Plant (of 1 m3 capacity)
⑤ 04 No. Transit Mixer (6 m3)
⑥ 2.No Percussion machine for pilling/boring.
⑦ 1.No Crane of 5 ton capacity for shifting of formwork, steel etc.
⑧ 02 No. Gen set (138KVA for batching plant, 20KVA for bridge site)
⑨ 01 No. Concrete pump 42m boom length
⑩ Small tools and equipment will be available as per site requirement
Note: Item No. ④, ⑤ and ⑨ will be provided by CGGC
b. Material Resources:
Cement: Cement used will be used upon approval of OE however following are suggested
due to their availability i.e. Fauji, Bestway, Askari, Dewan Cement Company
①.Sand: Sand will be purchased from Qibla Bandi (Block#04, the only coarse sand source
in the radius of 250KM), Lawrencpur (Distt. Attock, Punjab)
② Aggregate: Aggregate will be purchased from approved source (i.e. Margalla )
③ Admixtures: Admixtures will be of approved brands
④ Steel: Steel will be purchased from approved source (from Fazal, Nomee and Mujahid
Steel)
⑤ Formwork: Special form work of required size will be arranged for T-beam Girders, Pier
Shaft and Bonding Beam
Note: As per new development CGGC will provide ready concrete and Steel, so Item I to V
are with CGGC.

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Following Table shows the resources for different activities and their allocation Plan:
Table 4: Resources
Activity Machine No. Model
Excavation Excavator 2 EX -200

Steel Bending & Cutting Machine 1 (each)

Batching Plant 1
Transit Mixer 2
Concrete
Loader 1
Generator 100 KVA 1
Scaffolding pipes 500
Joints 1000
Formwork Steel Plates 200
Ply Sheets 150
Wooden planks 250
Percussion Machine (option#1) 2
Pilling
Tripods 2
T-Beam Formwork 1
Pier Shaft+Bonding
Special Formwork 1
Beam
Shifting of Heavy
Crane (5 Ton capacity) 1
loads
Concreting Concrete Pump (42m Boom length) 1

5.5 Construction preparation

5.5.1 Site office
Site office comprising field and technical staff (in over 10 rooms comprising of 2
compounds) has been established in Paras near to the permanent access bridge location.
5.5.2 Site Laboratory
Laboratory for QA/QC and other testing is established within the vicinity of batching plant
area comprising of laboratory office and a functional lab consist of concrete compressive
strength machine, concrete cylinder & sieves of various sizes, weighing scale, thermometer.
5.5.3 Steel yard & Labor Residence
Steel yard (03 Kanal out of 7.50) is established near the work site. Proper electricity facilities
will be provided not only for cutting / bending machine and welding plants but for general
labor as well.
5.5.4 Concrete Batching Plant
Concrete batching plant has been installed in 7.50 Kanal area. The batching plant capacity is
1m3. Keeping in view the impact on environment and local population, the batching plant is
located 1.5KM range from site. The batching Plant staff will be provided accommodation at
the plant site. The Contractor will also prepare the stock pile for the aggregates (coarse and
fine) with in the vicinity of batching plant. Also, laboratory is established within the plant

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having compressive strength machine. Calibrations of all machinery and equipment will be
carried out and prior approval will be taken.
Note: Contractor Batch Plant will be used.
5.5.5 Electricity
Nonstop electricity is required for the steel yard and batching plant. The Contractor will
ensure that, through WAPDA and stand by Generator (100KVA).
5.5.6 Security
Security at the site will be made sure through proper surveillance and security.
5.6 Construction Methodology and Techniques
5.6.1 For Excavation
Excavation works at site will be carried out by following methods:
1. Excavator EX-200 & Jack Hammer
2. here required blasting will be done
(Note: The blasting will be carried out by taking care of all safety measures and protocols.
Before every blast, a pattern will be submitted to OE not only for the information about the
blasting area but also elaborating the diameter of hole, depth of hole and its charge depth,
amount of total explosive, the formation of blasting and total tentative pull of blast. As, the
site is located near population, the instruments to record the shock wave will be installed
along with sand bags and mats will be placed on charged holes in order to avoid/minimize
the flying rock and timely sprinkling of river water to control airborne dust)
Initial plan is to arrive at Abutment “2” (RHS of D/S) and start its excavation, at the same
time excavation of Abutment “0” (LHS of D/S) will be carried out.
Initially, there will be an access road starting from the Bailey bridge and will lead towards
the Abutment#0. This will be done by doing the excavation on right bank and preparing
girder casting area with excavated material up to the start of Abutment#2. Then the
excavation of abutment#2 will be done through jack hammer/blasting. The excavated
material of abutment#2 will be used to make a platform in the river edge for pier#1. This
excavation material will enable the contractor to develop a platform on middle pier for piles
boring. This excavation will be made on stable slope “1:0.3” (as per Dwg# SKP-CGGC-CD-
04-UZA-13-103-D2).
5.6.2 Abutments (Grid#0&2) Pier (Grid#1)
Construction of Abutment base will be done by two methods.
Abutment 2: it consists of:
a. Abutment base
b. Abutment wall
c. Wing walls
d. Abutment beam
Taking advantage of belly bridge, the reinforcement and concrete of Abutment#2 will be
transported to the location through belly bridge.
Upon the completion of reinforcement and formwork of above mentioned (a-d) structures,
concreting for individual structures will be done through pump.

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Abutment 0: As it is located on road side and it consists of following:
a. Piles (12 Nos of 1.5m diameter)
b. Abutment Cap Beam/ Back Wall / wing wall
Concreting of piles has already been mentioned below at (3.2, 5 Concreting).
After the completion of reinforcement and formwork of abutment cap beam, concreting will be done
either by installing a temporary chute and pouring the concrete directly from the transit mixer or concrete
delivery pump in order to minimize the traffic blockade.
Pier 1: it is consist of following structures
a. Piles (6 Nos of 1.5m diameter)
b. Pile Cap
c. 3 Nos Pier Shaft and 1 No Bonding Beam
d. Pier Transom
As per approved design, specific formwork will be fabricated for pier shaft and bonding
beam. Initially, the formwork will be placed for pier shaft only, upon reaching the required
segmental height, the prefabricated job specific formwork will be placed on site for
concreting of both boding beam and pier shaft simultaneously with the help of crane. The
concreting will be done with the help of concrete delivery pump.
Moreover bending & cutting activity of steel will be done at steel yard and transported to site
for fixing.
For transporting steel from yard to site, vehicle will be used. The reinforcement cages for
Pier 1 piles will be prepared at site.
5.6.3 Casting of Girders
The Girders will be casted on site upon the approved drawings and mix design. Initially, the
surface will be made level and the ground will be compacted, if necessary. Then, starter of
girder will be poured on leveled ground to form the bed of girder. The thickness of starter
will be at least 10cm of A-1 concrete. Profile of the girder will be marked along the length of
starter. Afterwards, the steel fixing of approved brand will be started and upon completion of
it, approved corrugated pipe of 70 and 80mm respectively will be inserted in fixed steel as
per profile. After casting of girder, its stressing will be done of approved source and as per
schedule (Ref Dwg# SKP-CGGC-CD-04-UZA-13-109-D2) and its grouting with approved
mix will also be insured before preparing to launch.
5.6.4 Launching of Girder by Derrick System
Power winch operated Derrick system will for launching of 40m pre-stressed concrete girder,
adequate steps will be taken for the safety, health and welfare of persons for the prevention
of damage to works, material and equipment for the purpose of or in connection with the
Contract. The equipment involved will be:

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 Table 5 Equipment for Derrick System
Serial Item Qty. Specification/Purpose
No.
1 Winches 2 100-ton capacity each.
Height: 3 x 15 ft. = 45 ft.
Derrick towers 2 Sectional Dimensions: 600 x 600 mm.
2
Main L-Section: 155 x 155 x 15 mm thick
Top & bottom plates: 635 x 635 x 20 mm thick
3 Crane 1 With mechanical boom of capacity 25 Tons
4 Tractor with trolley 1 For shifting and launching of equipment
5 Chain blocks 2 Five tones capacity, to control horizontal movement of Girders
6 Hand winches 2 Capacity 40 Tons, to control horizontal movement of Girders
2 Mechanical Jacks with 100 tones capacity
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Jacks 4 Hydraulic jacks with 50 tones capacity
And following methodology will be involved:
1. Two Derricks (steel towers) will be separately erected vertically over two adjacent
transoms of a span along-with their steel ropes, pulleys, hooks/anchors, shackles, wheel
pulley and chain block etc. Diesel engine (lay land 6 cylinders’ engine of 100 ton capacity)
driven winches will also be installed at the required position and attached to the derrick
network system to provide working arrangements for lifting of girders.
2. Verticality of the Derrick tower will be controlled with four stay ropes fixed with the head
of the tower. Stay rope will be tightened with columns, abutments or end concrete blocks.
3. Girder will travel over the rail track consisting steel rails over wooden sleepers, a built-up
rails beam (5 rails in 2 rows) fixed under the Girder drags over the track with horizontal pull
Surface of steel rails will be greased for smooth movement of Girders.
4. Girder will be lifted with the help of steel pins of diameter. 8” diameter inserted through
lifting hole of Girders.
5. Girders will be properly tied between the supports mounted on the trollies to avoid any
overturning of girders during their transportation.
6. Girders will be loaded on trollies with the help of wheel pulleys (upper & lower) & bipod
(steel pipe consisting of 8” internal diameter. ½” thick).
7. Dozer or Loader shall be used to pull the trollies and transport the girders to the required
span where it has to be launched.
8. Girder will be pulled to their location by Derricks, Winches and Chain blocks.
i). Over the end span when deck slab has attained 80% of 28 days strength.
ii). Over the 4 m span when girders are connected with all the diameterphragms having
attained 80% of 28 days strength.
9. Elastomeric Bearing pads of required size will be placed at the bearings.
10. Girders from the ends will be hooked and gradually lifted with pulley block and launched
at the required location.
11. Similarly other girders of the span will be transported to site and launched at the required
location.

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12. Girders on all spans will be launched one by one through the same derrick system till
launching of whole girders is completed.
After launching and prior to casting of diameterphragms, the girders shall be temporarily
interconnected so as to secure them against tilting and overturning.
5.6.5 Preparation for Installation of Expansion Joints (CQ50)
Wearing Course will be placed prior to installation of expansion joints. The following steps
shall be adopted for installation of road expansion joints:
1. Locate the opening between the abutment and the deck or between two decks.
2. Mark the center line of the opening.
3. Mark the edge line of opening.
4. Cut the wearing course and concrete with cutter/ chisel up to required depth and width.
5. Remove all loose material.
6. Check the height of recess.
7. If height is less than required, remove concrete by a bush hammer.
8. Clean the recess using compressed air.
9. Place the formwork, polystyrene, and reinforcement.
10. Check the levels.
11. Place rebar and install the joint elements.
12. Install the element on supporting devices.
13. Put grease on bottom side of them
For installing, adjusting and concreting of recess the following sequence will be used:
1. An installation device is fixed to each joint element. The assembling of elements is carried
out in the recess starting at one end and using two supporting bars for the first element.
2. The next element is placed by fixing one end on the first element and using the supporting
bar at the other end.
3. The opening of each element is adjusted to the required value as defined by the designer.
Adjust the joint in the longitudinal as well as In vertical direction using shims if necessary to
complete final tightening of the joint elements.
Similarly, for concreting, the sequence will be:
4. After placing of joints, concreting and vibration must be carried out progressively to avoid
deformation of Formwork.
5. When the concrete starts setting, unscrew the nuts very slightly to remove arms, joints and
gap forms.
6. Curing of concrete is performed as required and directed
5.6.6 Casting of Concrete Deck System
The procedure for the casting of concrete deck slabs will be as follows:
1. After concreting of diameterphragms and their stressing a working platform will be made
under the deck slab with the help of scaffolding pipes resting on the bottom flange of girders

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in the transverse direction and wooden planks lying on these pipes.
2. Channel bracket provided with 5/8” diameter through bolts 60cm long placed from top of
projected portion of girders with 3”x4”x6” wooden block laid under the channel
transversely.
3. 5/8” diameter through bolts along with nuts & washer are placed from top of C-Channel.
A steel plate under the projected portion between adjacent girders will be used as formwork
for casting of gap slab. For this purpose another C-Channel will also be provided below the
steel plate to receive through bolt & double nuts & washer tightened from the bottom.
4. Wooden blocks under C-Channel -bracket are used to give clearance for leveling and
rough finish to the gap slab.
5. Sleeves have already been provided in the outer projected portion of outer girders to
receive scaffolding pipes used for purpose of erecting formwork. The specified diameter of
PVC pipes (10 cm) will also be provided on regular intervals on outer side of deck slab for
drainage.
6. Starter will be casted for forming the inner side formwork of barrier with the help of an
angle iron tightened together with longitudinal stopper plate of projected slab. The vertical
plate for this purpose has already been kept 2” above the level of projected slabs.
7. Concrete cylinders will be casted for the gap slab to crush on the 4th day if required
minimum strength of concrete is achieved, then the 5th cable of girder will be stressed and
thereafter the stressing of the gap slab cables will be carried out.
8. Formwork for barrier will be placed in position after performing above operation and
finally, the barrier will be concreted.
9. After removal of formwork through bolt holes of 5/8”, in gap slab will be filled with
cement grout. The block out /sleeves in the projected portion of outer girders will be filled
with concrete having a maximum 10mm size of aggregates after removal of PVC pipe and
marking the hole wedge in shape by chipping in its top corners.
5.6.7 For Pile
The Scope is to describe the sequence of execution of the Cast in Situ 2000mm, working Pile
(total 03 Nr) of Bridge at Piwer#1 and 1500mm working pile (04 nr) at Abutment #2. This
will be the base for the selection and definition of the necessary equipment for the
foundation works will be as follows.
Initially with the excavated material of Abutment 0 (RHS of D/S), it’s planned to construct a
platform (Pier#1) in the river bed which will also act as a coffer dam, where the Contractor
can place the drilling machines to start the work on piles.
The sequence of operations will be as follows:
1. Driving of Lining
The cast-in-situ working Pile will be executed by a Percussion machine. The position of
temporary lining is to be adjusted very accurately before driving the temporary lining. The
inside diametermeter of temporary lining will be larger than the outside diametermeter of the
pile.
2. Drilling of Bore
The drilling will be carried out by the percussion machine/auger. The same will be used for
lowering steel reinforcement cages.

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The drilling for Cast-in-situ Pile starts with Rotary action through Kelly Bucket with cutting
tools. The cutting are collected and retain is unloaded outside the boreholes. The drilling is
continued up to the required depth through the pull down force of drilling rig as well as its
Rotary Movement. Frequent checks on Plumb of the shaft will be ensured.
Whenever required, bentonite shall be used for the purpose of maintaining the stability of the
walls and base of bore. (The investigatory bore hole as mentioned is Comments in out of
Sub-Contractor scope.)
3. Washing/Cleaning of Hole
Once drilling is complete, the contractor will clean the bore-hole from loose debris. It is
believed that there will be no need washing of the bore-hole because of the terrain. If
however, it becomes necessary, then mud station will be installed on higher level of Bank.
The fresh mud will be supplied to the piles with heavy duty flygt pumps.
If there is no need of washing of hole, the contractor will proceed with the lowering of
reinforcement cage. If, however, it becomes necessary, then the mud mixed with cuttings
will be pumped out from the bottom of the bore hole and at the same time fresh bentonite
slurry coming from the mud treatment unit will be pumped into the hole.
4. Lowering of Permanent Lining and Reinforcement cage
After washing/cleaning of borehole, the permanent liner of the required length will be
placed. Fabrication of pile reinforcement cage will be made near the piles on land in 3
sections according to the drawings.
Prefabricated reinforcement cage in 3 sections will be lowered into the predrilled holes
inside the temporary lining by means of U-Bolts (Sockets) and steel wire rope.
5. Concreting
The concreting operation will take place once the above mentioned operations are
completed. Supersonic checking-measuring pipe will also be places after lowering of steel
cages prior to the concreting. This pipe will be three in number in each pile and consists of 2
pipe i.e. one is 57mm diameter inner pipe which will be further encased by 70mm diameter
pipe at outer. It will be a steel pipe. The Top bottom and the joint shall be sealed and top
shall be closed by wooden plug to prevent mortar, sundries blocking pipe. A series of
interconnected trimme pipes of 200 mm diametermeter, having wall thickness 6mm and 3m
length of each pipe coupled together are lowered into the borehole up to the bottom of the
hole. These trimme pipes are of suitable length and are coupled by screwing system or
male/female type.
When trimme pipe lowering is completed, a funnel is fitted on the top of the trimme column.
Ready mix concrete of required strength with plasticizer and retarder will be delivered at pile
head by means of transit mixer and concrete pump. Sufficient concrete with minimum slump
of approx. 150 mm shall be poured into this funnel volume which is always greater than the
volume of the installed trimme column. The outlet of the funnel is then opened and concrete
goes in through the trimme into the borehole in one continuous motion to ensure maintaining
of interference between concrete and bentonite mud in the borehole, which always remain on
the top of the concrete.
It is always ensured that the bottom of the trimme pipe is always 1.5 m to 2 m inside
concrete so that fresh concrete is always added into the concrete. The concrete is continued
till the good concrete flows out. Trimme pipes will be removed and the concreting
arrangement shifted to the next location.

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The rate of delivering concrete at the funnel of trimme pipes will be minimum of 20 Cum
per hour.
6 Main Resource Distribution
6.1 Main Manpower Plan
Table 6 Main Manpower Plan List
Quantity of Quantity of
S/N Specialty or work type Pakistan Remark
Chinese
personnel
personnel

1 Project Manager 0 1

2 Site Engineer 0 1

3 Surveyor 0 1

4 Quantity Surveyor 0 1

5 Survey Helper 0 1

6 Earthwork Supervisor 0 1

7 Steel Supervisor 0 1

8 Concrete Supervisor 0 1

9 Rebar worker 0 10

10 Concrete labour 0 10

11 Formwork Labour 1 15

12 Generator Operator 0 1

13 Loader Operator 0 1

14 Excavator Operator 0 1
15 Piling Skilled workers 0 10
16 Truck Driver 0 1
Total 0 57

6.2 Main Construction Equipment Plan

Table 7 Main Construction Equipment Configuration List
Activity Machine No. Model
Excavation Excavator 2 EX -200
Bending & Cutting
Steel 1 (each)
Machine
Batching Plant 1
Transit Mixer 1
Concrete
Loader 1
Generator 100 KVA 1
Formwork Scaffolding pipes 500
Joints 1000

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 Steel Plates 200
Ply Sheets 150
Wooden planks 250
Percussion Machine
2
(option#1)
Pilling Tripods 2
Auger Machine
1
(option#2)
T-Beam Formwork 1
Pier Shaft+Bonding Beam Special Formwork 1
Shifting of Heavy loads Crane (5 Ton capacity) 1
Concrete Pump (42m
Concreting 1
Boom length)
7. Construction Progress Plan
According to the actual progress of the SK project, the preliminary plan for construction of
Permanent Bridge is started in Aug 27, 2018 and completed in May 15, 2019.
Construction Schedule Annexed at Annex 2
8. Safety control method
The Contractor will ensure the recommended PPEs of all the working staff and sufficient
amount of stand-by in case of any visitor, Owner or Owner`s Engineer. The Construction
premises will be cordon off with barricade tape, safety cones, informative reflective sign
board in both English and Urdu will be placed on N-15 for smooth traffic flow in both day
and night shift. No permission will be granted for the site staff or any relevant person
without personal protection equipment. First aid box along with paramedic will be readily
available on site to cover any emergency or potential life risk. Proper search lights will be
installed in all construction areas. However, keeping in view the scope and quantum of work,
the safety measures will be adopted and strictly followed as below:
8.1 Personal Protective Equipment
All employees will be provided with appropriate personal protective equipment (PPE) as
necessary to control or eliminate hazardous exposures that may cause injury or illness.
Personal protective equipment includes all clothing and other work accessories designed to
create a barrier against workplace hazards.
To prevent injuries and illnesses, supervisors/foremen will implement and enforce the use of
personal protective equipment within the construction limits.
The description of PPE will consist of following:
A. Head Protection
Head injuries are caused by falling or flying objects, or by bumping the head against a fixed
object. Head protection must resist penetration and absorb the shock of a blow. Recent
standards for protective helmets will be provided.
All employees and visitors will wear protective helmets while on project site unless
otherwise indicated in the site-specific safety plan. Protective helmets are worn to protect
employees and visitors from potential head injury caused from impact, falling or flying
objects, or electrical shock and burns.
If the damage is suspected, helmets will be turned in and a new one issued.

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B. Eye and Face Protection
Eye and face protection is required wherever there is a reasonable probability of preventable
injury.
All employees will be provided with appropriate eye and face protection equipment for any
operations that present potential eye or face injury from physical, chemical, or
radiametertion agents.
Employees will wear full face shields, along with safety glasses that are equipped with side
shields whenever involved in grinding, chipping, or where flying particles create hazards to
the eyes and face.
C. Foot Protection
Foot and leg injuries from falling or rolling objects, sharp objects, molten metal, hot
surfaces, and wet slippery surfaces can be prevented using appropriate foot guards, safety
shoes, or boots and leggings.
The following safety practices will be implemented and enforced on project site.
1. All employees and visitors will be required to wear foot protection while on the job site.
2. Safety shoes with an impact resistant toe.
3. Employees engaged in asphalt paving or any other operation that exposes them to hot
surfaces will be required to wear heat resistant soled shoes.
D. Hand Protection
Gloves will be required when employees' hands are exposed to hazards such as skin
permeable harmful substances, severe cuts or lacerations, severe abrasions, punctures,
electrical shocks, chemical burns, thermal burns, and harmful temperature extremes. Gloves
may lessen the ergonomic hazards of many vibrating construction tools by increasing
gripping abilities and insulating the hands and arms from excessive vibration. Therefore, all
the personnel working on site will be wearing industrial grade gloves for better protection.
8.2 Fall Protection
To access high and low places on job sites, a variety of equipment may be used such as
ladders, scaffolding, suspended platforms, aerial lifts, stairways, and climbing lines. The use
of these access systems often presents fall hazards. In addition, employees may be exposed
to falls while working on elevated structures, climbing onto and off equipment, and even
while walking by falling through holes or by slipping or tripping.
To protect employees when they are exposed to fall hazards, some form of fall protection
will be used. The most common forms of fall protection are guardrails, personal fall arrest
systems, hole covers, and safety nets. Any one or all of these forms of fall protection may be
used on construction worksites.
Major Components of a Fall Protection Program
Personal Fall Arrest System: The three main parts of a personal fall arrest system are the
body belt or harness, the lanyard/lifeline, and a suitable anchorage. Attention must be paid to
the anchorage point(s) to ensure that they are capable of supporting 5,000 lb. (22.2 kN) or
two times the maximum load on an engineered system.
Training: All employees will receive training on the nature of the fall hazards at the site and
on how to avoid falls. Employees should be familiar with the use of all personal fall arrest

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systems and must wear the equipment when necessary.
8.3 Scaffolds
Use of scaffolds exposes workers to several different hazards. The falls are most commonly caused by
either the planking or scaffold support structures giving way, or by falling off the edges of the work
platforms. In addition to the fall hazards, workers have been electrocuted when either the scaffold
structures or conductive tools and materials being used on the scaffold have meet electrical sources.
A key requirement in scaffolds is that it can only be erected, moved, dismantled, or altered under the
supervision of a competent person. Such activities can only be performed by experienced and trained
employees selected by the competent person. Other duties of the competent person will include:
1. Determining if scaffold components from different manufacturers can be used together.
2. Determining if galvanic actions are taking place when scaffolding materials of dissimilar metals are
used together.
3. Inspecting the inboard connections of outriggers to support structures be-fore using suspension
scaffolds.
4. Inspecting wire ropes on suspension scaffolds before and after every shift.
5. Providing work skills and safety training to all employees in scaffold work.
8.4 Excavation
Trenching and excavation work presents a serious risk to all employees. The greatest risk is the cave-in of
a trench or excavation. Cave-in accidents are much more likely to result in worker fatalities than any other
excavation -related accidents. Other hazards include contact with buried utilities. Be-cause of the hazards
associated with excavation work, the following safe work practices, and procedures must be implemented
and enforced at all construction site:
1. Remove or support all surface encumbrances whenever their location creates a hazard toemployees.
2. Protect, support, or remove underground installations, as necessary, to safeguard employees working in
open excavations.
3. Structural ramps used by employees as a means of access or egress from excavations must be designed
by a competent person.
4. Structural ramps for access and egress of equipment must be designed by a competent person qualified
in structural design.
5. No employees are permitted underneath loads handled by lifting or digging equipment.
6. A warning system (e.g., barricades, signals, or stop logs) must be used when mobile equipment is
operated adjacent to an excavation.
7. Never work in excavations where water has accumulated or is accumulating unless adequate
precautions have been taken to protect you against the hazards posed by water accumulation.
9 Attachments
Annex 1: Construction layout of Permanent Bridge
Annex 2: Construction Schedule of Permanent Bridge

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