NAME OF THE PROJECT : CONSTRUCTION OF FOUR LANE FLY OVER

BETWEEN JAGDEO PATH MORE TO

SHEIKHPURA MORE AT BAILY ROAD, PATNA
HAVING LENGTH 2350 M ( 2 X 7.5 MT. CARRAIGE
WAY WITHOUT FOOTPATH) 350 MT. APPROACH
ROAD WITH RETAINING WALL / R.E. WALL AND
2 X 2625 MT. SERVICE ROAD WITH JUNCTION
IMPROVEMENT.

NAME OF THE CLIENT : BIHAR RAJYA PUL NIRMAN NIGAM LIMITED.

NAME OF THE CONSULTANT :

NAME OF THE CONTRACTOR : RANJIT BUILDCON LIMITED.

METHOD STATEMENT FOR CASTING

OF SEGMENT

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 METHOD STATEMENT FOR CASTING OF SEGMENTS

1. PREAMBLE

Box – shaped having one inner cell pre-cast segments have been proposed for
construction of Project
It is proposed to precast the segments on long line beds.
Detailed Method Statement is presented herein for casting of these segments.

2. CASTING YARD

Casting yard is located at Sand collection center Sone river, Village Pareb, on Bihta-
Koilwar Road, North side of NH-30 and East bank of Sone River, Dist. Patna with an
area of 260m x 240m approximately. Layout of casting yard is shown in drawing
enclosed.

 Casting Bed
3 nos Long Line casting bed for casting segments of straight spans up to 41.30 mt.

Moulds for casting of segments

1. Mould for casting of pier segment S1
2. Mould for casting of intermediate segments S2 to S7
 Pier Segment Beds – 2 Nos.
 Rebar Tying Area (having 8 Rebar Jigs)
1. Rebar Jig for pier segment S1 – 2 Nos.
2. Rebar Jig for intermediate segment S2 to S7 – 08 Nos.
 Batching Plant including Cement store
 Rebar Yard

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  Stacking Pedestals
 Stores for Aggregate, Cement, Prestressing Materials, general civil & mechanical
items
 Water Tank
 Laboratory
 Office blocks
 Area for load testing
 Sand Blasting Pedestals
 Sheds for keeping Generator sets and miscellaneous activities
 Survey Towers
 Access Roads
 Gantry 80 T capacity (1 Nos.) and 10T capacity (1 Nos.)

3. LIST OF MOULDS AND EQUIPMENTS IN CASTING YARD

S. No. Description No.

1. Long Line Casting Beds for Straight Span 03
2. Casting Moulds for Pier Segment S1 02
3. Casting Moulds for Intermediate Segment S2 to S7 08
4. Batching Plant 01
5. Transit Mixers 04
6. Goliath Crane with 80 T capacity and 25 M span 01
7 Goliath Crane with 10 T capacity and 25 M span 01
8. Shutter Vibrators 06
9. Needle Vibrators 10
10. Concrete Placer Boom (Radius 36 mt.) 01
11. Sprinkler system for curing 02
12. Curing Pump 01
13. Welding set 03
14. Total Stations 02
15. Auto Levels 02
16. Rebar Cutting Machine 03
17. Rebar Bending Machine 03

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5. MOULDS:
There are three types of mould for casting of segments
(a) Pier Segment Mould – S1
(b) Intermediate Segment Mould for segment S2 to S7
Each mould comprises 3 major components – Outer Shutter, Bottom shutter and Inner
shutters. Bottom Shuttering is supported on casting bed pedestals. Outer & Inner shutters
are supported on a Movable Trolley.
5.1 BOTTOM SHUTTERING
Bottom Shuttering is supported on 3nos of concrete long pedestals cast in the casting
beds provided in longitudinal direction of the casting bed at a distance of 4.4m c/c.
Bottom shuttering is fabricated in the form of panels of 1500 x 5000 mm approximate
sizes. Shutters shall be fixed for all segments on the Long Line casting bed except for
pier segments S1 which shall be cast elsewhere on pier segment beds and brought &
placed on movable trolleys to match with the edge of the Long Line Bed for match
casting of segment no. S2.
5.2 SIDE SHUTTERS
Side shutters are mounted on a movable trolley. Each Long Line casting bed shall have
two such moulds in each casting bed so that two intermediate segments are casted
simultaneously.

6. SEQUENCE OF CASTING
6.1 LONG LINE BEDS
Three Long Line casting beds shall be provided .The width of bed for straight spans shall
be 41.30 mt. for the River Bridge. However both the spans can be utilized for casting of
straight spans when ever required to do so. In a typical casting sequence of Span two pier
segments shall be casted on two pier segment beds simultaneously and brought and
placed with the help of 80T crane placed at their final locations on either side of long line
bed. Two intermediate segments are match cast almost simultaneously starting from
either end on each bed.
7. TIME CYCLE FOR CASTING:

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 Both the pier segments of a span shall be casted simultaneously in advance. The casting
of further segments may advance on long line bed. The Time cycles for casting of
intermediate segments on Long Line bed are presented in Table-1

8. REBAR JIG
Eight Rebar jig for intermediate segments and two Rebar Jigs for pier segments shall be
fabricated to meet the requirement of 40mm clear cover from all sides of concrete
surface. Each casting mould shall have a dedicated jig which shall provide cage for their
respective casting moulds. The jig shall be got checked at mutually agreed frequent
intervals.
9. REBAR CAGE
The rebar cage shall be cut & bent by using cutting & bending machine at the centralized
reinforcement yard adjacent to the casting yard as per approved BBS.
The bars shall then be shifted to the respective rebar jigs where they shall be tied by using
binding wire in the required position according to approved drawings. The sheathing
shall be fitted inside the rebar cage at the required dimension as detailed in approved
tendon profile drawings and held in position using suitable chairs and hooks. The cage
shall be lifted with a structural frame holding the cage in a manner to prevent any
distortion while lifting and placing in position inside the casting mould. The cage shall be
lifted and placed in the casting mould by the Goliath Crane.
10. COVER BLOCKS
The cover blocks shall be cast from the same grade of concrete as used in segment i.e.
M-45. The cover blocks shall be provided to ensure a clear cover of 40mm. These shall
be cast and cured in advance to ensure that the cover block does not crush under the rebar
weight while placing the cage in the casting mould.
11. CONCRETING
The sequences of concrete shall be as follows:
1) Soffit Slab
2) Half height of web – 1
3) Half height of web –2
4) Remaining height of web –1
5) Remaining height of web –2

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 6) Deck Slab including Cantilevers on both sides
The concrete of M-45 grade with a slump of 110mm to 130mm shall be produced at the
centralized Batching plant, and transported to location by transit mixers. The concrete
shall be placed in sequence mentioned above by concrete boom placer. The chute of the
boom placer shall be positioned to allow direct pour of concrete. The concrete shall be
vibrated by both shutter vibrators fitted to the web shutter as well as needle vibrators of
various diameters like 40mm, 60mm etc. should be used. Cubes is required number shall
be cast from respective concrete pours. Roughing of top flange and soffit slab of the
segment shall be done in required locations were secondary pour is to be carried out. For
separation of match-cast segments a suitable concrete de-bonding material (such as
Fasroc, Basf and sika etc. equivalent) shall be used on the surface of previously cast
segment.

12. FIXTURES IN SEGMENT

All other fixtures such as profile locator in Bulk Head, rubber bunk, sponging tube fixing
and Hole for Pre Stressing frame, lifting beam etc. shall be provided at specified locations
as detailed in the drawings.
13. GEOMETRY CONTROL
A survey tower on one side and target pole on the opposite side of the casting bed shall
be constructed to exercise geometric control. A plate of size 100mm x 100mm x 4mm
shall be embedded along center line of segment, one at each end of the segment over the
crown. After casting the segment, its centre line shall be clearly marked on these plates.
Nail / bolt shall be embedded at the center of each of top flanges for measurement of
levels. In casting on long line bottom shuttering is fixed to the pedestals as per actual
soffit profile. Thus the only control required is matching of centre line along the crown
and top levels of the top flanges during subsequent casting operations.
14. Provision of Pockets for Bearing.
Following Pockets has to be provided before casting of Pier Segment S1 & S9 (S1)
Sr. Height of Bearing
Pocket Size
No Bearing Type In mm
In mm
.
1 Type-I (Fixed Type) As per Drawing +50mm As per Drawing
2 Type-II (Free Type) (T-T) -Do- As per Drawing
3 Type-III (Free Type) (L-L) -Do- As per Drawing
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 Type-IV (Free Type) (Bi-
4 -Do- As per Drawing
Directional)
The above pocket will be filled by grouting material when bearing will be placed in its position
as per proof checked drawing.

15. CURING OF SEGMENTS

Curing of concrete shall be complete and continuous with water. Minimum wet curing
shall be for seven days followed by moist curing by spraying water over hessian cloth
which shall be maintained up to a total period of at least 14 days from the date of casting.
16. DESHUTTERING
The shuttering shall be removed after the concrete has attained 25 Mpa Crushing
Strength. The internal form shall be collapsed using the turn buckles provided for
movement of shutter. The outer form shall be released by using jacks and moved
outwards as shown in sketch. The frame supporting internal and outer shutters shall be
shifted to next location by moving it on 50x50 mm rails.
17. LIFTING OF SEGMENTS
The match cast segment shall be fitted with a lifting frame through the lifting holes
provided at the time of casting of the segment. The segment shall be lifted from the soffit
face of top slab by the 100 ton capacity Goliath Crane and placed at the stacking yard.
The lifting of segment shall be done after it attains minimum cube strength of 25 Mpa.
18. GENERAL INSPECTION
Inspection of pier segments before dispatch to the site for erection at stacking yard. Pier
segment requires thorough inspection in respect of anchorage cones, ducts, holes and
bearing pedestals etc. which need to be cleaned before transportation to the site.

Table No – 1

Total Time for

Sr. Time Required for
Activity Casting of Each
No Each Activity
Segment
1 Bottom Shutter Cleaning & Oiling
4.00 Hr
2 Outer Shutter Cleaning &Oiling
3 Outer Shutter Alignment 4.00 Hr
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 4 Debonding agent application 2.00 Hr
4 Cage wiring and cover block adjustment 3.00 Hr. 3.41 Day
5 Bulk head Fixing 4.00 Hr.
6 Duct Profile & support 6.00 Hr.
Inner Shutter Fixing ( 2Hrs. Each cell)x 2
7 4.00 Hr.
gang
8 Insert Fixing 6.00 Hr.
9 Concreting 3.00 Hr.
10 Waiting for remolding strength 40.00 Hr.
11 De Shuttering 6.00 Hr
Total
82.00 Hrs.
hours