Risk Assessment / Method Statement (RAMS) for

Plain Cement Concrete (Overt and Invert Lining) Repair Works in

Head Race Tunnel.

Note: HCCPL will make sure this RAMS reaches the Site supervisor and safety
officer who will looking after the works. The supervisor and safety office than
should make sure the workmen know the bullet points in RAMS for the works.

APPENDIX -1: Method Statement Cover Sheet

Document No: MS-HCC-TPG-001_RAMS for Plain Cement Concrete (Overt
and Invert Lining) Repair Works in Head Race Tunnel.

Document History:

Revision: Date: Prepared Checked By: Authorized By: Reason for

By: Revision:
00 13/06/19 HCCPL Vinay Khetarpal Manjit Singh
01 24/06/19 HCCPL Vinay Khetarpal Manjit Singh TPGPL Code-3
dated 20/6/19

TPGPL Review Status

☐ Code 1 Accepted: Work may proceed
☐ Code 2 Work May Proceed: subject to the incorporation of
changes indicated on the RAMS.
☐ Code 3 Rejected: Revise and Re-submit. Work may not
proceed. Please check PDF Comments and make the
necessary amendments.
Received/Accepted/Rejected
By (Signature)
Print Name Date:
Acceptance by TPGPL does not relieve the Contractor from full compliance with their
contractual obligations and does not constitute approval of design details or test
methods.

Page 1 of 14

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

Appendix 2 Method Statement Contents

1. Appendix – 1. Title Page 1
2. Appendix – 2. Contents Page 2
3. List of Figures 3
4. List of Tables 3
5. Introduction/Purpose 3
6. Proposed Works 3-4
7. Location of Works 4
8. Duration of Works 4
9. Responsible Personnel 4 -5
10. Supervisors of Works 5
11. Personnel Competency and Training Requirements 5
12. Interface with Adjacent Activities 5
13. Sequence of work steps 5-6
14. QA/QC of Works 6-7
15. Appendix – 3. Risk Assessment for Works 8-9
16. Hazardous Materials Utilized 10
17. Site Access and Storage 10
18. Emergency Arrangements 10-12
19. PPE Required for the Work 13
20. Briefing Arrangements 13
21. Inspection Test plan format 14

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

3 List of Figures

Figure Page
Description Drawing. No.
No. No.
1 Emergency Evacuation Plan for repair works in 12
HRT through Adit-2, Adit-1 and Adit-5.

4 List of Tables

S. No. Description Page No.

1 Table of document number 1
2 Table of document history 1
3 Table of TPGPL reviews status 1
7 Table of Risk Assessment for Portable tools 8
8 Table of Risk Assessment for scaffold 9
10 Table of Emergency Contact 11
11 ITP Format 14

5 Introduction / Purpose
The purpose is to repair the plain cement concrete (overt and invert lining)
surface to give F-2 finish surface by giving at least three passes of hand steel
trowel over the applied mortar.

6 Proposed Works
The proposed repair works mainly include the followings:

a) a) Treatment of Cold Joints: At locations, where cold joints have formed

due to unscheduled stoppage of concrete, the concrete along the joint shall
be chipped and cleaned, washed with water and cement sand mortar
prepared in 1:2 mix proportion Liquid Integral water reducing cum
waterproofing admixture ‘Plastocrete Super’ shall be applied over the
surface. Finishing of the surface shall be done by giving three passes of
hand trowel. Technical Data Sheet of ‘Plastocrete Super is given on page
15 to 16.
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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

b) Presence of honeycomb in concrete: Where there is honeycomb in

concrete, the honeycomb surface shall be chipped and honeycomb
removed, watered and repaired according to the procedures laid in Clause
No.13 on page no.5 and 6.

7 Location of Works
The works will be carried out in Head Race Tunnel of Tidong -1 Hydro Power
Project

8 Duration of Works
The repair works shall follow the lining concrete and will be completed along
with lining concrete of HRT.

9 Responsible Personnel
a) Project Manager / Project Head
Lead the project team and be properly equipped to effectively manage local
field staff and ensure that the RAMS should be implemented from top to
bottom and bottom up. He will ensure efficient progress is made in repair
works and works are implemented as per approved RAMS and technical
specifications.
b) Construction Manager
He is responsible to ensure RAMS reach to the concerned individuals at site on
time and they are made aware of their obligations in advance. Planning for the
next day is to be done a day previous, so that all issues and problems are not
carried forward to the next day.

c) Safety Officer
The HSE Department will focus on ensuring a safe work environment for all
employees including TPGPL, HCCPL and Sub-Contractor workers in Head
Race Tunnel. He is also to ensure that all personnel follow and respect the
Environment and follow all HSE rules and guidelines.

The HSE Department of HCCPL will work hand-in-hand with the TPGPL safety
managers to enforce safety regulations and policies. In addition to being the
safety enforcer, the HSE Department will also help construction managers to

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

think proactively, so that accidents are prevented and that the HSE team will
be the first to reach the scene, in the event an accident occurs.

10 Supervisors of Works
The approved RAMS for Repair works of Head Race Tunnel concrete lining
will be handed over to experienced concrete engineer / supervisor who will be
deployed at work location. He is to make sure RAMS is made understandable
to the workers on ground in terms of what works are required from them. He
will ensure that the works are carried out as per approved RAMS and technical
specifications. He will also ensure that the required grade, line and levels as
per approved drawings and technical specifications are maintained.

11 Personnel Competency and Training Required

Though the Masons and workers deployed will be well experienced in
Concrete repair works, still prior to start of work they will be trained and
made familiar with the works’ requirements and safe operations procedures
along with the precautions to be observed during execution of the works. Their
training will mainly include works’ procedure, how to maintain good quality
repair and what steps they should follow for carrying out the repair works
safely.

12 Interfaces with Adjacent Activities

The repair works will follow the HRT concrete lining activities. There will be no
interface with any adjacent activities as men, materials and repair tools can be
taken to site through the CIFA Shutter.

13 Sequence of work steps

Note: Prior to start of any repair works RFI will be issued to TPGPL. No
repair work will be taken up without approval from TPGPL.

a) For Chipping : Grinder / light chipping hammers weighing approximately

7 kg or less with chisel shall be used to remove a minimum of 15 mm
depth of concrete, because impact hammers can fracture the surface of
the concrete that remains.

Page 5 of 14

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

b) Chipping will be followed with water washing to remove the loose

surface.
c) Cement slurry shall be applied on the washed surface.
d) A suitable mix containing 1 part Portland cement and 2 parts sand, a
water-cement ratio of about 0.35 shall be prepared and mixed with
Plastocrete Super (A SIKA Liquid Integral water reducing cum
waterproofing admixture) shall be applied in the chipped portions by
hand packing or by steel trowel over the rough surface.
e) To complete the repair, rough surface/ voids shall be overfilled slightly.
After the material has hardened slightly excess materials shall be
trimmed off with the edge of a steel trowel, shaved off the excess
material.
f) While finishing the repair, care shall be taken to avoid impairing the
bond.

Sufficient quantity of following tools shall be kept at all work fronts.

 Steel Trowel and Float

 Plumb Bob
 Spirit level/Bubble level
 Mason thread
 Head Pan
 Mason Square
 Measuring tape
 Gas cutting set

14 QA /QC of works and Inspection and Tests Plan, Check list to be

maintained

i) SCOPE
This procedure establishes the methods, responsibilities and requirements for
reinforced cement concrete repair works and Inspection and test plan to be
carried out on regular basis as per format on page no. 14, and check list to be
maintained.

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

ii) RESPONSIBILITY

a) The Construction Manager is responsible for implementing these

procedures as per the approved RAMS.
b) The Construction Manager is responsible for assigning the repair works
and for providing the requirements as per the latest approved RAMS
and Technical Specifications.

iii) APPLICATION

a) This procedure applies to repairing works for plain cement concrete lining
in Head Race Tunnel for quality assurance that includes required finish
class, grade, line and levels of finishing of the concrete surface.
b) For controlling the quality of work, routine inspection shall be carried out as
per the ITP format provided on page no. 14.

iv) INSPECTIONS

The following activities shall be inspected and monitored on regular basis to

verify that they have been in accordance with the requirements of this
procedure:

 Initial checking of cold joint / honeycomb,

 Marking of areas where chipping is required,
 Proper chipping is done,
 Repair mortar is mixed in required proportion,
 Mortar is applied properly,
 Final checking of repaired surface,
 Required finish of the repaired surface,
 Curing is done properly, if no curing compound is used,
 Experienced workers, operators and technical staff are deployed.

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

15 Appendix -3, Risk Assessment of Works

a) For Portable Tools

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

b) For Scaffold

Page 9 of 14

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

16 Hazardous Materials Utilized

Personnel using or working with cement and chemical shall be informed and
trained about potential Health, safety and environmental hazards during
execution of the repair works.

Hazard identification and risk assessment is described in S. No15 a) and b)

above and hazards associated with these activities and control measures to be
taken to mitigate risk of hazards are also detailed. Risk Assessment is drawn up
in accordance with Risk Assessment procedure.

Job Safety Analysis (JSA) was conducted for each phase of operation defined
under this method statement. JSA was prepared in accordance with Job Safety
Analysis Procedure.

17 Site Access and Storage

Adit-2 is accessible by road from Power house camp. Adit-1 and Adit-5 are
accessible from PWD Road to Intake road and through HCCPL Camp at near
Adit-5. Necessary scaffolding shall be erected (as per approved RAMS of
Power House) wherever required to access the top of formwork. Sufficient
quantity of sand, cement, plastocrete plus admixture, water and grinding
wheels etc. shall be kept in stock for smooth and continuous operation of
repair work.

18 Emergency Arrangements

a) OBJECTIVE

The main objective of Emergency arrangement is to rescue the site staff

and workers to safe area, if any emergency situation arises at works in
Head Race Tunnel.

b) OUR EMERGENCY PREPAREDNESS PLAN

The following measures shall be taken to ensure that in case of emergency

of any kind at work site, our people are evacuated safely to safe area.
 Hazards identified and assessed and measures will be taken to
overcome the hazards.

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

 Emergency resources such as fire extinguisher, Ambulance, Doctor,

first aid box shall be kept ready and rescue vehicle shall be kept
available at work site.
 Communication systems such as Intercom / mobile phones shall be
used in case of emergency
 Emergency response procedure shall be followed, which shall be
informed to all staff and workers prior to start of work.
 Post-traumatic stress procedure shall be explained to staff and
workers, prior to start of work.

c) Emergency Contact

HIMALAYA CONSTRUCTION CO. PVT. LTD.

Emergency Contacts
S.No. Name Telephone No.
1 Ambulance 102
2 Fire 101
3 Police 100
4 Doctor (TPGPL) 07303594968
5 Project Director (TPGPL) 09717085007
6 Construction Manager (TPGPL) 08448589972
7 Safety Manager (TPGPL) 09667390466
08448798551
8 Project Head (HCCPL) 06239657923
9 HCCPL Site In Charge 09557174804
10 HCCPL Medical Dispensary 08894428997
11 HCCPL Safety Officer 07987277369

Route for Emergency Evacuation:

The works shall be carried inside Head Race Tunnel. In case of

emergency, workers will be brought outside the Adit-2, Adit-1 and Adit-5
respectively, from where they will be rescued with the help of rescue
vehicle.

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

Figure - 1. Emergency Evacuation Plan for repair works inside Head Race
Tunnel through Adit-2, Adit-1 and Adit-5

Page 12 of 14

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

19 PPE Required for the Work

The following PPEs shall be used during grouting operation.
 Safety helmet
 Safety shoes/Rubber shoes
 Dust mask
 Safety Harness
 Safety goggles
 Safety gloves/PVC glove
 Reflector jacket

20 Briefing Arrangement
JSA that has been done prior to work shall be communicated to workforce by
Safety Officer and this will be done on daily basis.

Prior to start of work, the work force shall be assembled at work area.
Construction Manager and Safety Officer will brief everyone with the
procedures of repair works to be executed, safety measures to be followed
and the precautions to be taken for good quality work.

Page 13 of 14

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 Risk Assessment / Method Statement (RAMS) for
Plain Cement Concrete (Overt and Invert Lining) Repair Works in
Head Race Tunnel.

Inspection and Test Plan format.

Inspection and test Plan for Concrete repair works in Head Race Tunnel
Signature of
S.No. Description Yes No
HCCPL TPGPL
1 Survey Inspection to pour
a Initial checking of cold joint / honeycomb,
b Marking of areas where chipping is required,
c Proper chipping is done,
d Repair mortar is mixed in required proportion,
e Mortar is applied properly,
f Surface is finished properly,
g Final checking of repaired surface,

h Curing is done properly if no curing compound is used

3 Cement Sand Mortar

a Mortar prepared as per approved RAMS
b Minimum three passes of steel trowel given
c Approved Admixture used
d Others (if any)

Page 14 of 14

14
 Product Data Sheet
Edition 14/4/2015
Identification no:
02 14 03 01 100 0 000062
® ®
Sika Plasocrete Super

Sika® Plastocrete® Super

Liquid Integral water reducing cum waterproofing admixture

Product Water reducing and waterproofing admixture for all types of concrete and mortar.
Description
Sika® Plasocrete® Super is recommended for use in structural and mass concrete,
Construction

Uses
particularly for the following:
 Sloped Roof Slab
 Flat Roof Slab
 Beams
 Columns
 Slabs etc
Also used in:
 Internal and external plaster of buildings etc.
 Repair and renovation
® ®
Characteristics / Sika Plasocrete Super provides the following beneficial properties :
Advantages  Compatible with all varieties of Portland cement including Slag Cement.
 Required at a very small dosage hence convenient to handle and greater
economy
 Improves water tightness to a great extent.
 Reduced shrinkage, better finish
 Improves workability
 Rebound loss is low
 No added chloride- does not attack reinforcement
Tests
Approvals/Standards IS 9103-1999, IS 2645-1975 and ASTM C-494

Product Data

Form
Appearance / Colour Brown liquid
Packaging 100gm, 500gm, 1kg, 5kg, 10kg, 20kg, 100kg

Storage
Storage Conditions / Best before12 months from date of production if stored properly in undamaged,
Shelf -Life unopened, original sealed packaging in dry conditions at temperatures between
+10°C and +40°C. Protect from direct sunlight and frost.

1 ® ®
Sika Plasocrete Super 1/2
15
 Technical Data
Chemical Base Modified Napthalene Formaldehyde Sulphonate
Specific Gravity ~1.04 at 25°C
pH >6
System
Information
Application Details
Consumption / Dosage 0.2% by weight of cement (100g per 50kg bag of cement)
Applications
conditions/Limitations
® ® ®
Compatibility Sika Plasocrete Super may be combined with many other Sika products.
Important: Always conduct trials before combinig products in specific mixes and
Construction

combinations. Compatible with all types of cement and cementitious material

Application
Instructions
Dispensing For Concrete:
 Mix cement, aggregates and sand and dry mix
 Add 50-70 % of required water and mix the mass to make it moist
® ®
 Add Sika Plasocrete Super to the remaining water and pour it in the mixing
drum and mix the entire quantity for approx. 3 minutes to achieve homogeneous
mix
For Mortar:
 Mix cement and sand and dry mix
 Add 50-70 % of required water and mix the mass to make it moist
® ®
 Add Sika Plasocrete Super to the remaining water and pour in the mixture
 Mix the entire quantity for approx. 3 minutes to achieve homogeneous mix
® ®
Application By use Sika Plasocrete Super concrete of highest quality can be produced.
Method/Tools The standard rule of good concreting practice, concerning production, placing and
testing are to be followed.
Fresh concrete must be cured as per the relevant satndard.
Cleaning of Tools Clean all tools and application equipment with water immediately after use.
Hardened / cured material can only be mechanically removed.
Notes on If frozen and/or if precipitation occur, Sika® Plasocrete® Super may be used after
Applications/Limitations thawing slowly at room temperature and after intensive mixing.
All technical data stated in this Product Data Sheet are based on laboratory tests.
Value Base Actual measured data may vary due to circumstances beyond our control.
Health and Safety For information and advice on the safe handling, storage and disposal of chemical
products, users shall refer to the most recent Material Safety Data Sheet containing
Information physical, ecological, toxicological and other safety-related data.
Legal Notes The information, and, in particular, the recommendations relating to the application
and end-use of Sika products, are given in good faith based on Sika's current
knowledge and experience of the products when properly stored, handled and
applied under normal conditions in accordance with Sika’s recommendations. In
practice, the differences in materials, substrates and actual site conditions are such
that no warranty in respect of merchantability or of fitness for a particular purpose,
nor any liability arising out of any legal relationship whatsoever, can be inferred
either from this information, or from any written recommendations, or from any other
advice offered. The user of the product must test the product’s suitability for the
intended application and purpose. Sika reserves the right to change the properties
of its products. The proprietary rights of third parties must be observed. All orders
are accepted subject to our current terms of sale and delivery. Users must always
refer to the most recent issue of the local Product Data Sheet for the product
concerned, copies of which will be supplied on request.

Registered office: Sika India Pvt. Ltd. Phone +91 33 2447 2448/2449
Commercial Complex II Telefax +91 33 2396 8688
620, Diamond Harbour Road ind.sika.com
Kolkata, 700 034, India info.india@in.sika.com

2 ® ®
Sika Plasocrete Super 2/2
16