Construction of Solid Cargo Port Terminal

Project Training 07-08 Construction Of Solid Cargo Port Terminal
CHAPTER 1. INTRODUCTION
1.1 BACKGROUND OF THE PROJECT
Considering inherent potential of Dahej for developing facilities for handling dry cargo, in the year
1997, Government of Gujarat through Gujarat Maritime Board commissioned International Finance
Corporation to advise for the development of two Green field Ports in South Gujarat viz., Dahej &
Hazira. IFC assessed the potential of both these ports by conducting a traffic assessment study
which revealed huge potential for Dahej port.
Thereafter Government of Gujarat decided to develop the Dahej port complex and asked the
interested to bid for a cargo handling port.
The project was thus envisaged by Adani Petronet (Dahej) Port Pvt Ltd (APPPL), joint Venture of
Petronet Ltd. and Adani Port Ltd. in order to develop a “MULTIPURPOSE BERTH” at Dahej.
In the Phase I it is proposed to develop a berth with the associated material handling system to
handle panamax vessel for imported coal, Fertilizer, FRM and steel, along with the approach trestle.
In the Phase II, it is proposed to develop another berth in continuation to the Phase – I berth of about
230m for export cargo and some expansion in back up yard facilities.
1.2 THE PROJECT

The “MULTIPURPOSE BERTH” includes construction of Y type structure having 2 jetties (one for
coal handling and other for general cargo) in the sea about 2.4 km from shoreline. The following are
the major component of works:
¾ Main Structure consisting of 2 no. jetties for berthing for Panamax Vessels of about 80,000 DWT
and cargo handling.
¾ Jetty -I is for handling coal and is to be equipped with 2 Nos. of rail mounted mobile Harbour
Cranes for a planned throughput of 12.5 MTPA
¾ The Construction of Jetty -II has been planned for handling multi purpose cargo to be equipped
with 2 Nos. rail mounted mobile harbour cranes.
¾ Approach of about 1170m length consisting of RCC (reinforced concrete) bridge with 8.0m
carriageway spanning on pile caps supported on piles to approach the berth. The pile cap is 13m
long to support approach bridge and steel trestles supporting conveyer galleries.
¾ Approach of about 1200m length in the initial portion of land side consisting of rubble bund.
¾ Conveyor system capable of handling 4200 tph will be installed on the rear section of the jetties
and one side of the approach.
¾ Railway System Consisting of loading line complete and engine escape line, railway line at
marshalling yard, loop line, level crossings, locomotive and shunters, signaling and
telecommunication as per Railway norms, central control cabin and In motion weigh bridge. The
whole project is divided into to 15 packages out of which the marine construction is 15th package.
Sr. No. Package No. Description Sr. No. Package No. Description
1 Package-1 Mobile Harbour Cranes 9 Package-9 Dust Suppression System
2 Package-2 Conveyors & Foundations 10 Package-10 Fire Fighting System
3 Package-3 Stacker Cum Reclaimer 11 Package-11 Railway Systems
4 Package-4 Rapid Loading System 12 Package-12 Diesel Loco 1200 HP
5 Package-5 Buildings & Utilities 13 Package-13 Power & Water facilities
6 Package-6 Electricals , High Mast 14 Package-14 Mechanical Works
7 Package-7 Communication System 15 Package-15 Marine Works
8 Package-8 Yard Development 16 Package-16 Mooring Winches
Suril Shah (2704).School of Building Science & Tech.,CEPT University

1
The project cost of the marine works in phase 1 of the project is 250 crores and the major
component of works in this are as follows:
¾ Construction of 640m X 15m rubble bund

¾ Widening of 600m long existing GMB bund
¾ Construction of 1270x15m Approach Bridge supported on bored cast-in situ piles.
¾ Bored Cast in – situ piles with pre cast pile muff, precast capping beams, longitudinal beams and
in situ & pre-cast deck slab.
¾ Pre-cast deck slab is at the bottom so that no shuttering is required for the top slab.
¾ Construction of 619m X 30m Main Jetty, with two numbers of rigid mooring Dolphins.
¾ The Approach Bridge is divided into 7 units.
¾ Construction of back yard facilities and cargo handling facilities (Stacker, Reclaimer, Conveyor
System, Office buildings, etc.)
1.3 OBJECTIVES OF THE PROJECT

¾ As discussed earlier the main objective behind the development of the terminal is to create a
multipurpose solid cargo handling facility at Dahej due to its potential for developing into at port
complex.
¾ The project has been envisaged in order to develop the material handling system and port back
up development for “MULTIPURPOSE BERTH” at Dahej.
¾ The new facility will add to the existing facilities at Dahej and make it a complete port complex.
¾ Presently Dahej is having four facilities to handle the cargo.
1. Petronet LNG terminal for LNG receiving and Regasification. It’s a captive terminal of Petronet,
which became operational in the year 2002-03.
2. IPCL’s captive jetty for handling the Naphtha and other petro chemicals for its plant at
Vadodra.
3. Dahej Harbour and Infrastructure Private Limited has a solid cargo terminal upto a capacity of
5 million tones. Birla Copper has commissioned a copper smelter plant at Dahej. This terminal
is for captive use of Birla Copper but at present it is allowed to handle outside cargo equivalent
to the volume of captive cargo handled.
4. GCPTCL has a terminal in Dahej ports, for handling hazardous liquid and chemicals.
1.4 NEED OF THE PROJECT

¾ With the fast growing economy of the country, India’s maritime traffic is growing. Out of this traffic
lion’s share is handled by the ports on the western coast mainly due to nearness to Mid-east
countries and Europe.
¾ Gujarat state has developed many ports in last 15 years and the maritime traffic handled by these
ports has grown by leaps & bounds.
¾ The overall Traffic in the GMB managed port has gone up from 89.36 million tones in 2003-04 to
97.13 million tones in 2004-05 and is expected to go on rising in the coming future.
¾ Based on the studies conducted and envisaging the competition from other ports the dry bulk
cargo forecast for the hinterland is as follows:
Table No. 1:- Dry Bulk Cargo Forecast for Hinterland (Million Tones)
Year Coal DOC Fertilizers FRM Cement Steel Wheat/Rice Total
2006-07 6.9 1.77 0.31 1.28 0.21 1.30 6.00 17.7
2007-08 7.4 1.76 0.30 1.32 0.25 1.31 6.00 18.3
2008-09 7.9 1.75 0.30 1.36 0.29 1.32 6.00 18.9
2009-10 8.5 1.74 0.29 1.40 0.33 1.33 6.00 19.6
2010-11 9.1 1.73 0.28 1.44 0.38 1.35 6.00 20.3
2011-12 9.8 1.72 0.27 1.49 0.44 1.36 6.00 21.1
2012-13 10.6 1.70 0.27 1.53 0.51 1.38 6.00 21.9
2013-14 11.3 1.69 0.26 1.58 0.59 1.39 6.00 22.8
2014-15 12.2 1.68 0.25 1.63 0.68 1.40 6.00 23.8
CAGR 7.4% -1.0% -2.7% 3.0% 15.6% 1.0% 0.0% 3.6
¾ Based on the studies conducted and envisaging the competition from other ports the dry bulk
cargo forecast for the Dahej is as follows:

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Table No. 2:- Dry Bulk Cargo Forecast for Dahej (Million Tones)
Year Coal DOC Fertilizers FRM Cement Steel Wheat/Rice Total
2006-07 2.5 0.47 0.05 0.20 0.21 0.17 0.67 4.3
2007-08 3.0 0.52 0.05 0.26 0.25 0.20 0.77 5.0
2008-09 3.6 0.59 0.06 0.35 0.29 0.23 0.89 6.0
2009-10 4.2 0.66 0.06 0.47 0.33 0.27 1.02 7.0
2010-11 4.9 0.74 0.06 0.49 0.38 0.32 1.18 8.1
2011-12 5.3 0.83 0.06 0.50 0.44 0.37 1.36 8.9
2012-13 5.7 0.93 0.06 0.52 0.51 0.42 1.57 9.7
2013-14 6.1 1.04 0.06 0.53 0.59 0.49 1.81 10.6
2014-15 6.6 1.17 0.06 0.55 0.68 0.57 2.09 11.7
CAGR 15.2% 12.2% 6.2% 17.5% 15.6% 15.9% 15.4% 15.0%
¾ From the above figures the need of the project both is well satisfied.
¾ More over the project is financially sound with an Internal rate of Return (IRR) at 19.04% and
Pay back period of 7.08 years.
1.5 PROJECT BREAKDOWN STRUCTURE:
1.6 GENERAL PROJECT INFORMATION:

Name Of The Project Construction of Approach Jetty, Main jetty, & mooring
Dolphins For Solid Cargo Port Terminal
Project Code 1005.201.001
Employer Adani Petronet Port Pvt. Ltd. (APPPL)
(Client) Plot No.604, At &Post Lakhigam
Taluka: Vagra, Dist.: Bharuch
Project Management PMC Projects India Pvt. Ltd.
Consultants “Infrastructure House”, Nr. Mithakali Six Roads,
Navrangpura, Ahmedabad – 380009
Ph : +91(079) 25555801
Structural Consultants L & T Rambol
Contractor Simplex Infrastructure Limited (SIL)
Type Of The Project Infrastructure Project (Marine project)
Contract Type Item Rate Contract
Contract Value Rs. 84, 00, 00,000 (Rs. 84.00 Cr.)
Estimated Project Value Rs. 250, 00, 00,000 (Rs. 250.00 Cr.)
Contract Period 38 months From the date of commencement
Commencement of Project 01/04/07 (1st April 2007)
Expected Date of Completion 01/06/10 (1st June 2010)
End Use Of The Project Loading & Unloading of Dry Bulk Cargo
Defect Liability 365 days from the date of Taking Over

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1.01 LAYOUT PLAN OF THE PROJECT circle approach & main jetty

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1.7 LOCATION OF THE PROJECT:
¾ The site of the Project is situated on the East Coast of Gulf of Khambhat in Bharuch District.
¾ The total area for the project is around 575 hectares and it also includes a part of land required for
storage facilities.
¾ The Jetty under construction is located between the jetties of Petronet LNG & GCPTCL
¾ Latitude: 21°47′00′′ North
¾ Longitude: 72°32′00′′ East
¾ The Site Office is situated at approximately 2 kms from the jetty site.
¾ Another site office is also situated in Bharuch city which around 45 kms from the site.
Solid Cargo Port Terminal

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Access To Site
Mode Of Transportation Description
¾ A 42Kms long two lane highway connects Dahej with
the district head quarters at Bharuch.
Road Link
¾ Bharuch lies on the National Highway No.8 from
Mumbai to Ahmedabad.
¾ Dahej is a part of Western Railway network of Indian
Railways.
¾ Dahej railway station which is around 2Kms from the
GMB port site, is connected by narrow gauge rail upto
Rail Link Samni (40kms) and then to Bharuch(25Kms).
¾ As a part of the project, the same rail line is going to be
converted into a broad guage line and it will be extended
till the port premises.
¾ The nearest airport is at Baroda which is about 135 Kms

Air Link
away by road.
1.8 CLIMATIC CONDITIONS & SEISMIC ZONE
1.8.1 Wind
The wind regime is dominated by monsoon:
¾ SW monsoon (June to August) - Moderate to strong winds, monsoon rains and possibility of
cyclones.
¾ Post-monsoon period (Sept. to Nov.) - Light winds from varying directions.
¾ Winter season (Dec. to March) – Light winds from North East, Cyclones are rare.
¾ Pre-monsoon (March to May) – Moderate winds from South West.
From the earlier studies of the site, the wind climate is summarized as given in table below.
Table No. 3:- Wind Climate Summary

Pre-dominant wind speed
Duration Pre-dominant wind direction
(km/hr)
October to March NW 13-19
April to May NW 13-19
June to September SW 30-50
1.8.2 Rainfall
¾ The South West monsoon from June to September contributes about 92% of annual rainfall of
1000 mm.
¾ The heaviest rainfall in 24 hours is 480mm recorded on 15th September 1958.
1.8.3 Temperature
¾ The variation in temperature is significant, month of April and May are hottest with mean
maximum temperature of about 40ºC.January is coldest with a mean minimum temperature of
about 13ºC.
1.8.4 Waves
HR Wallingford (HRW) has studied the wave climate in the area at the Dahej Coast and the results
of the study carried out by HRW are presented below:
Table No. 4:- Wave Climate Summary
Parameter Return Period (100 Yr.)
Hs (mts.) Tp (Seconds)
o
180 N 1.2m 7 to 11 secs
210o N 3.5m 10.0 secs
240o N 2.7m 9.0 secs
270o N 2.6m 8.9 secs

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¾ The significant wave heights are 1.5mts and it has an exceedance probability of approximately 2
to 5 %.
1.8.5 Tides
The tides are semi-diurnal and the levels are as below:
Mean Highest High Water of Spring MHHWS +10.1mCD
Mean High Water Spring MHWS +9.1mCD
Mean High Water Neap MHWN +7.1mCD
Mean Sea Level MSL +5.1mCD
Mean Low Water Neap MLWN +2.4mCD
Mean Low Water Spring MLWS +0.9mCD
Mean Lowest Low Water of Spring MLLWS +0.7mCD
1.8.6 Currents
¾ The tidal currents are very strong at Dahej site.
¾ Reports indicate that the flood current runs at 6 knots, and the ebb current at 4 knots.
¾ The current velocity at the north of this location can reach upto 7.5 knots.
¾ The current direction reverses approximately 180 degrees.
¾ The Tidal currents at Dahej are second highest in the whole world.
1.8.7 Morphology
¾ The morphological processes in the Gulf of Khambhat are complicated.
¾ From the previous studies carried out at site, it appears that the overall system is in a state of
dynamic equilibrium.
¾ Main characteristics are moving channels requiring regular adjustment of navigation buoys.
¾ The Dahej site is located just north of the point
where the Narmada River enters the Gulf.
¾ The river brings large quantities of sediment to
the Gulf, estimated at more than a million tons
of material per year.
1.8.8 Seismic Zone

¾ Moreover the site falls in seismic Zone V.
¾ The site falls near a principal deep seated fault
line and is located at a moderate risk zone.
¾ Kim and Surat Fault lines which are minor
Faults can also be said to be near, but the
impact due to them is considered to minimal.
1.9 DESIGN CONSIDERATIONS

The key factors that forms the basis of the geometry, structural configuration and design of
the approach bridge and the berth includes:
¾ The berth is designed for rail mounted cranes on rail on rail gauges. Also provision is kept for
Mobile Harbor mounted cranes.
¾ As a part of future expansion a conveyor system capable of handling 4000 tph will be installed on
the rear section of the berth and one side of the approach.
¾ The berth and approach will be two separate structures completely independent of each other.
¾ The design Draft RL of -15m is adopted.
¾ The berth is designed to handle 80000DWT vessels.
¾ The berth is designed to handle two cranes working side by side.
¾ Load intensity of 5t/m2 is considered for designing the berth.
¾ At the time of construction 100 T cranes can be brought on the Approach Bridge and berth and
hence should be designed for its loads.

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1.9.1 Design Criteria for Approach & Main Jetty
Design Life:
Main Berth – 50yrs
Fender & ladders – 8yrs
1.9.1.1 Vessel Parameters:
Table No. 5:- 80000DWT Bulk Carrier Vessel’s Parameters
Parameter Dimensions
Displacement Tonnage 106667T
Length Overall 259m
Width 36.6m
Depth 19.9m
Draught 13.2m
Environmental Criteria Considered:

Table No.6:- Operating Conditions during Table No. 7:- Survival Conditions during
Berthing/Vessel Approaching Berthing/Vessel Approaching
Parameter Consideration Parameter Consideration
Wave Height (Max.) 4.5m Wave Height (Max.) 6.5m
Direction Of Approach 180o-270o N Direction Of Approach 210o N
Significant Wave Height 2.41m Significant Wave Height 3.5m
Time Period (Peak) 6-8 sec Time Period (Peak) 10 sec
1.9.1.2 Currents
¾ The design Current parameters considered for designing are as follows:
¾ Current Velocity at Surface - 3.85 m/sec
¾ Current Velocity at Mid depth - 2.25 m/sec
¾ Current velocity at Bottom - 1.80 m/sec
1.9.1.3 Wind
¾ Basic Wind speed of 19m/sec is considered for mooring of any vessel.
¾ Basic wind speed of 44m/sec is considered for survival condition without any vessel mooring.
1.9.1.4 Earthquake
¾ The seismic loading is considered in accordance with IS 1893 (Part-1): 2002.
¾ The maximum live load considered in combination with seismic loading is 50% of the total overall
live load.
1.9.2 Design load:

Table No. 8:- Self Weight Considered Table No. 9:- Live Loads Considered
Parameter Consideration Parameter Value
3
Density Of Concrete 2500 Kg/m Deck Live Load (operational Conditions) 2.5 T/m2
Density Of Steel 7850 Kg/m3 Deck Live Load (Maximum Design Load) 5.0 T/m2
1.9.2.1 Foundation of Piles

¾ Pile capacity of Bored Cast in situ piles are counted as per IS 2911.
1.9.2.2 Scour
¾ A minimum scour of 4m in deep water and 1m in the shallow water is considered in design.

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1.10 COST BREAKDOWN STRUCTURE
1.10.1 Cost Breakdown Structure for Project

Table No. 10:- Cost Breakdown Structure for
Project
Sr.
Elements Cost(Rs.)
No.
1 Approach Jetty 278509364.00
2 Main Jetty 1 263199913.00
3 Main Jetty 2 229061072.00

Mooring dolphins for Main
4 Jetty1 19767158.00
Mooring dolphins for Main
5 Jetty2 49462520.00
Total - 840000027.00
1.10.2 Cost Breakdown Structure for Approach Jetty
Table No. 11:- Cost Breakdown Structure for

Approach Jetty
Sr
Items Cost
No.
1 Pile Foundations 198517300.00
Precast Works & Cast In
2 76321564.00
Situ Works
3 Miscellaneous 3670500.00
Total 3278509364.00

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CHAPTER 2. CONSTRUCTION & METHODOLOGY
2.1 WORK BREAKDOWN STRUCTURE
Client: Adani Petronet Port Pvt. Ltd. (APPPL)

It is a Joint Venture company of Adani Port & Petronet LNG Ltd. (PLL)
Structural Consultants: Contractor: Project Management

L & T Ramboll Simplex Infrastructures Consultants:
The structural Design for the Limited. (SIL) PMC Projects India Ltd.
marine works is carried out SIL is the main contractor for Project Management,
by L & T Ramboll the Marine works. Procurement, Design,
Supervision & Planning
Sub- Structure Super Structure
Geo technical Labor

Investigation: Contractor:
Fugro Geotech M. Panikar
Ltd. For All the works
related Gantry Piling
Sub Contractor: Labor Contractor: Quality Testing

Joy Construction JPPL Laboratories
For Pre cast Works Miscellaneous AERI (Ahmedabad
& Cast In Situ Deck Works, Engineering
Works & Fabrication Formwork Design & Research Institute)
of Temporary Decks preparation, Liner KCT
fabrication For Testing of
Materials

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2.2 ORGANIZATION CHART OF PMC AT SITE

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2.01 BASIC DRAWINGS – PLAN, SEC, ELEV, GAD,

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2.02 BASIC DRAWINGS – PLAN, SEC, ELEV, GAD, JOB LAYOUT

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2.03 JOB LAYOUT

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2.3 CONSTRUCTION SCHEDULE

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2.4 ACTIVITY WISE PROJECT BREAKDOWN

Construction of Solid
Cargo Port terminal
Phase-1 Phase-2
Scope of Phase 2 Will be finalized
after completion of Phase-1
Marine Works Back Up Facilities

1) Approach Trestle 1) Storage Yard
2) Main Berth 2) Office & Other
Buildings
3) Road Works
Sub Super Sub Super

Structure Structure Structure Structure
Sub Structure Activities for Super Structure Activities

Formwork Sub Structure Activities for Sub Structure Activities for
Marine Works for Marine Works
Back Up Facilities Back Up Facilities
1. Piling Liner Reinforcement
1. Pre casting Works
Fabrication 1) Pile Muff 1. Structural Works
2) Capping Beam Concreting Earth Work 1) Storage Yard, High
3) Longitudinal Beam Mast
Reinforcement
2. JUB 4) Deck Slab 1. Foundation Work 2) Stacker & Reclaimer Fabrication
Fabrication Erection of
Piling 1) Storage Yard, High Formwork 3) Conveyor System
Precast
Elements Mast 4) Rail Mounted Crane Erection
Boring & Liner 2) Stacker & Reclaimer on Main Berth
3. Gantry Driving 3) Conveyor System Reinforcement
Formwork
Piling 2. Cast In Situ Works
Concreting 2) Stage – 1 Works 2. Services
Reinforcement Concreting
3) Stage – 2 Works 1) Mechanical 2) Electrical
4) Insert Plate Fixing 3) Fire fighting 4) Plumbing
Concreting 4) Dust suppression
5) IT Facilities
3. Rock Bund Formation
1) Laying Rubbles in
Gantry Shifting
profile as per design
3. Finishes
4. Erection of Fender 1) Plastering
System 2) Flooring
3) Painting
5. Services
1) Mechanical 2) Electrical
2) Fire fighting 4) Plumbing

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2.04 Over all construction sequence of approach and rock bund to be added in it

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2.5 WORK METHODOLOGY
2.5.1 Construction Methodology
¾ First of all the expansion of the existing rock bund shall be done followed by construction of new
rock bund.
¾ Initial 4 piles shall be done with the help of tripod and the Piling gantry shall be made ready in the
meanwhile.
¾ Piling shall then be done with the help of Gantry using End on method.
¾ Piling for main jetty shall be completely done using Jack up Barge.
¾ For Gantry Piling with End on method, Liners shall be fabricated on the shore and brought to the
gantry for driving.
¾ After the arrival of Jack up Barge the liners of the approach trestle shall be pitched and driven by
jack up barge and the boring and completion of the pile shall be done by the Piling Gantry.
¾ The Liners shall then be filled with Reinforced Cement Concrete.
¾ The piling work of main jetty shall completely be done by Jack up barge.
¾ Hydraulic Rig, Vibro hammer & 150 Ton capacity crane shall be mounted over the jack up barge
to facilitate the piling works through jack up barge.
¾ Precast Elements include Precast Pile Muffs, Precast Pile capping Beams, Precast Longitudinal
beams & Precast Deck Planks.
¾ All the Precast Elements are to be manufactured in the precast yard and then transported to the
site for the purpose of erection.
¾ All the junctions are cast in situ and shall be casted in one go along the length and two layers in
height.
¾ The cast in situ works involve the junction of pile & pile muff, the junction between two pile
capping beams, and also between the longitudinal beams of consecutive grids.
¾ After the erection of the slab is completed, the in-situ slab will be casted. This will involve the
casting near the expansion joint & placing of the crane rail.
¾ After the casting of the in situ deck, a wearing coat has to be laid with a slope of 1%.
¾ All the services like water line, fire hydrant, crane & berth electrical & communication lines will be
done after the completion of the berth construction but conduits and provisions for the services
shall be kept during the construction.
2.5.2 Justification of Methodology Used

¾ The existing rock bund was extended in order to reduce the cost of the project.
¾ As all the piles are marine piles, end-on method (piling using Gantry) is preferred.
¾ As there is no hard rock available, Majorly Friction Piles are used. The piles are designed in such
a way that 80% of the load is transferred through friction & 20% through End Bearing.
¾ Precast Elements are used to reduce the time to a large extent and hence also the cost.
¾ Pre-cast slabs (portion of overall slab) are used to reduce the complexity of shuttering & staging
of the in-situ slab works. Moreover, it reduces the cost of formwork of the slab & increases the
speed of construction.
¾ Slope protection is provided in form of Rock Bund which reduces the washing away of bed.
Table No.12 :- Degree Of Mechanization

Sr No. Items Tools ,Equipments & Plants Used Scale
1 Gantry Piling Gantry, Piling Winch
Piling With Jack Up Barge & Hydarulic Jack Up Barge, DGPS, Hydraulic Rig,
2
Piling Vibro- Hammer
3 Liner Fabrication Liner Bending Machine
4 Reinforcement Fabrication Reinforcement Cutting Machine
20T Gantry, Needle Vibrators,
5 Pre cast Works
Batching Plant & Transit Mixers
Erection Gantry 20 T, 75 T Crane &
6 Erection Works
150 T Crane
Batching Plant, Needle Vibrators,
7 Cast in Situ Works
Concrete Pump & Transit mixture
Fully Mechanized More Mechanized Partly Mechanized More Manual Manual

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2.6 STATUS OF SITE
Total Status at the Status at the Time

Sr.No Description unit
Job Time of Joining Of Leaving
1 Piling works
a Approach Piling Nos. 188 104 54
2 Precast works
a Slab Nos. 2790 1377 1072
b C Beams Nos. 564 279 181
c Pile Muff Nos. 188 93 66
d Longitudinal Beams Nos. 744 368 277
3 Erection works
a Slab Nos. 2790 222 282
b C Beams Nos. 564 62 100
c Pile Muff Nos. 188 94 44
d Longitudinal Beams Nos. 744 67 88
4 Cast In Situ Works
a Stage 1 Nos. 376 36 30
b Stage 2 Beams only Nos. 94 9 9
c Stage 2 Slabs only Rmt. 1106 54 58

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2.7 PLANTS & MACHINERY
Table No. 13:- Plants & Machinery

Sr. Fuel of
Plant and Machinery Company Capacity Nos.
No. Operation
For Piling Works
1 B.P. Winch c/w 6 YDA Engine Siemens Diesel 7.5 Ton 6
2 B.P. Winch c/w 6 YDA Engine Greaves Diesel 5 Ton 2
3 Hydraulic Rotary Rig IMT Diesel -- 1
4 Crawler Crane Sany Diesel 150 Ton 1
5 DGPS System -- -- 1
6 Vibro-Hammer with Powerpack -- Diesel 400KN 1
7 Lighting DG Set Sudhir Diesel 125 kVA 1
10 Submersible Pump -- Electricity 5 HP 3
11 Vacseal Pump -- Diesel 4
12 Welding Transformer Greaves Electricity 125 kVA 10
13 Diesel Welding Generator Greaves Diesel 75 kVA 2
For Concrete
14 Batching Plant Mecon Electricity 30m3/Hr. 2
15 Transit Mixer Greaves Diesel 6 Cum. 6
16 Concrete Pump Sany Diesel 43 Cum. 3
For Civil Works
18 Vibrator -- Electricity 12
19 Tailor made Yard Gantry -- Electricity 15 Ton 2
20 Tailor made Erection Gantry -- Electricity 25 Ton 2
21 Lighting DG Set Kirloskar Diesel 75 kVA 4
23 Welding Transformer Greaves Diesel 125 kVA 9
25 JCB/Loader JCB Diesel 0.9 Cum. 1
For Common Works
26 Crawler Crane Sany Diesel 75 Ton 1
27 Hydra Crane Escorts C-8000 Diesel 8/10 Ton 2
28 Twin Screw Tug -- Diesel 1500BHP 1
29 Air Compressor Sany Diesel 365 cfm 2

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30 Tractor Trailer -- Diesel -- 3
31 Lighting DG Set Kirloskar Diesel 75 kVA 3
34 Welding Transformer Greaves Diesel 125 kVA 10
10/5/3/2
36 Water Pumps Local Electricity
HP 12
Battery
37 Total Station Trimble --
Operated 1
38 Tug Boat -- Diesel 800 BHP 1
39 Dumper TATA Diesel 8 Ton 2
2.8 Material Details

Table No.14 :- Material Details
Sr No. Material Unit Cost/Unit Transport Code
Cement 50 Kg.
1 Rs. 210 Trailer 500 Bags IS 12269
(OPC 53 Grade) Bag
2 Fly Ash MT. Rs. 1500 Bulker IS 1489
3 Aggregate (20mm) Cum. Rs. 700 Dumper - 5 brass IS 369
4 Aggregate (10mm) Cum. Rs. 700 Dumper - 5 brass IS 383
5 Sand MT. Rs. 450 Dumper - 5 brass IS 383
6 Reinforcement Steel MT. Rs. 31850 Truck – 20T IS 1786
7 ISMB MT. Rs. 35700 Truck – 20T IS 432
8 ISMC MT. Rs. 26800 Truck – 20T IS 432
9 ISA MT. Rs. 31263 Truck – 20T IS 432
10 MS Plates MT. Rs. 27750 Truck – 20T IS 432
11 Admixture Kg. Rs. 105 Truck IS 9103
Rs.
Tanker – 8000
12 Water Liters 100/1000 IS 456
Ltrs.
Ltrs.
Bags
13 Bentonite Rs. 512 Truck – 24 bags IS 6186
(1MT.)
2.9 SPECIFICATIONS
2.9.1 Cement
¾ Cement conforming to IS: 12269 may be used provided the minimum cement content mentioned
elsewhere from durability considerations is not reduced.Strength tests shall be carried out for 56
and 90 days to fine tune the mix design from strength considerations.
¾ Total chloride content in cement shall in no case exceed 0.05 percent by mass of cement. Also,
total sulphur content calculated as sulphuric anhydride (SO3) shall in no case exceed 2.5 percent
and 3.0 percent when tricalcium aluminium percent by mass is upto 5 or greater than 5
respectively.
¾ Each consignment shall accompany with manufacturers certificate stating that the cement offered,
is tested and it complies with the Indian Standard Specifications in all respect.
¾ Cement in bags shall be unloaded under cover and stored in a perfectly watertight & well
ventilated building accommodating sufficient cement to ensure continuity of the work & having a
floor raised not less than 30cms from the ground.
¾ Each consignment shall be stacked separately.
¾ The age of cement at the site of delivery to the site shall not be more than 2 months old and shall
be used in the works within 3 months thereafter.

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2.9.2 Aggregates
¾ Aggregates shall comply with the requirements of IS: 383 “ Coarse & Fine Aggregates from
Natural Source for Concrete”
¾ Aggregates shall be from approved quarries.
¾ The aggregates shall be hard, strong, durable, clean &free from any adherent coating or
deleterious matter.
¾ Aggregates which are not clean shall be washed in clean fresh water to the satisfaction of the
employer.
¾ Coarse aggregates having coloured layer shall not be used in the permanent works.
¾ All aggregates shall be subjected to inspection and testing.
¾ Sampling shall be in accordance with IS: 2386 (Part I to Part Viii) “Methods of Test for Aggregates
for Concrete”.
¾ Aggregates shall be stored on site on clean well drained area which is not flooding.
¾ Aggregates of different size shall be stored separately.
¾ The maximum value for flakiness index for coarse aggregate shall not exceed 35 %.
¾ The fineness modulus of the aggregate shall neither be less than 2.00 nor greater than 3.50.
2.9.3 Water
¾ Clean fresh water only shall be used for mixing all concrete, grout and mortar.
¾ The water shall be free from any deleterious matter in solution or in suspension and be obtained
from an approved source.
¾ The quality of water shall confirm to IS: 456 and chloride content of water should not be more than
300 ppm irrespective of IS: 456 specifications.
¾ Contractor shall make adequate arrangements to deliver and store sufficient water at the works
for use.
¾ Contractor shall make arrangements for daily checking PH value of water at site.
2.9.4 Reinforcement steel

¾ Reinforcing bars for concrete shall be round bars of Grade 1 quality complying to IS: 432 “Mild
Steel& Medium Tensile Steel Bars & Hard Drawn Steel Wires for Concrete Reinforcement” or
High Yield Strength Deformed Round Bars confirming to IS: 1786 “Specifications for Cold Twisted
Steel Bars for Concrete Reinforcement”.
¾ Reinforcing steel to be used for various different structures shall be as given below:
Table No. 15:- Type Of Reinforcement Used in Different Structures

Structure Type Of Steel Grade Of Steel
Jetty HYSD as per IS: 1786 Fe 500
Other Structures Main Bars HYSD as per IS: 1786 Fe 500
Placement Bars, Ties, Saddles MS as per IS: 432 Fe 250
¾ Binding wire shall comply to IS: 280 “Mild Steel Wire for General Engineering Purpose” with size
1mm or over.
¾ Reinforcing bars shall be stored at site on timber or concrete supports suitably spaced and of
sufficient height to keep steel clear of the ground.
Table No. 16 :- Cover To Reinforcement
Sr. No. Elements Tolerances
1 Piles 75 mm
2 Pile Muff 60 mm
3 Pile Beam 50 mm
4 Longitudinal Beam 50 mm
5 Deck Plank 50 mm
2.9.5 Structural steel

¾ Structural steel used for works shall comply to IS 2062 “Weldable structural steel”.

22
¾ Irrespective of the manufacturers’ certificate, samples must be collected and sent to external
laboratory test for one set/100MT.
¾ The steel shall be stored on timber or concrete supports suitably spaced.
¾ The steel should be stored section wise.
2.9.6 Specifications For Concrete

¾ All underwater concrete works shall have minimum cement content of 400kg/cum.
¾ All concrete works above pile cut off level in jetty shall have minimum cement content of 360
kg/cum.
¾ Minimum 25% of cement shall be replaced by Fly Ash. Fly-ash shall be as per IS: 3812.
¾ Test cubes shall be made in accordance with IS: 516 “Method of Tests for Strength of Concrete”,
except that all test cubes unless otherwise ordered by the Employer, shall be compacted by
vibration.
¾ All Sampling and testing of concrete shall be carried out in accordance with IS: 1199 “Method of
Sampling and Analysis of Concrete”.
¾ Three out of each batch of nine cubes will be tested by the employer for crushing strength and
weight at seven days and remainder at 28 days or at such other time as the Employer may
determine.
¾ A fully qualified & experienced quality control engineer shall be always present at the time of
concreting.
¾ No deviation from the declared proportions will be allowed unless and until the employer shall give
his written authorization for the adoption of revised proportions for any class of concrete.
¾ All loose materials, grease, oil, dirt, etc. shall be removed from the concrete surface, which is to
receive grout.
¾ The surface shall be left rough but not so rough as to interfere with proper placing of the grout.
¾ The contractor shall agitate the placed concrete thoroughly by means of sufficient number of
mechanical vibrators of adequate power and having a frequency of 6000 impulses per minute.
¾ In no case shall concrete be dropped or thrown from a height more than 1.5mts.
¾ Concrete Beams, slabs & similar structures shall be carried out in continuous.
¾ Slump for Cast in Situ Elements should be in range of – 150mm to 190mm.
¾ All exposed faces of concrete shall be kept continuously moist for a period of 10 days.
¾ In places where water curing is not possible compound shall be applied by the procedure
approved by the employer.
Table No. 17 :- Tolerances in Concrete Elements
Sr. No. Elements Tolerances
1 Variation in Piles from their Location ±75mm
2 Shape & Dimension of Precast Elements ±3mm
3 Variation In Erection Of Elements ±25mm
2.9.7 Precast Concrete

¾ No precast element shall be lifted from the bed till it attains 50% of design strength.
¾ The casting tolerances, unless otherwise specified, shall be within 3mm of true dimension.
¾ The method and time after casting of units of striking side shutters shall be subject to approval of
the Employer.
¾ Slump For Precast Elements- 75mm
2.9.8 Specifications For Formwork

¾ Form shall be true to shape, lines and dimensions of the concrete works.
¾ The contractor shall fix all the form work in perfect alignment and it shall be securely braced so as
to be able to withstand, without appreciable displacement, deflection or movement of any kind, the
weight of construction or movement of persons, material and plant.
¾ Form shutters shall not be disturbed until the concrete has sufficiently hardened.
¾ Any damage resulting from premature removal of shutters or from any other cause shall be made
good by contractor at his own expense.
¾ All formwork has to be made by the contractor and the drawings of the formworks are to be
submitted to the client and approved.

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CHAPTER 3. CONSTRUCTION ACTIVITIES
3.1 PILE FOUNDATION USING PILING GANTRY

3.1.1 Scope
¾ There are in all 188 nos. of piled foundations in Approach Trestle. Depending upon the change in
reinforcement, 188 nos. of pile foundations can be divided into two types i.e. P-11 & P-12.
3.1.2 Specification
¾ Construction and testing of bored piles shall be in accordance with IS: 2911(Part 1) “Code of
practice for Design and Construction of Pile Foundations”.
¾ To avoid deflection of piles during construction stage, contractor shall provide temporary structural
steel bracings immediately after casting of bored cat in situ piles till the piles are interconnected
with RCC deck beams.
¾ Liners have to go 5 to 10 mts. below the sea bed level or as per the requirement of the client.
¾ In soils liable to flow the bottom of the liners should be kept ahead of boring in all cases.
¾ The size of the cutting tool shall not be less than 75mm of the diameter of the pile.
¾ Where stabilization of the sides of the bore hole is effected by the use of drilling fluids, the fluid
level shall be maintained at a level not less than 1.5 mts above the level of the sub soil water or
high water level as the case may be and the hole shall always then kept full with it till the
concreting is completed.
¾ For determining the founding strata, standard penetration test shall be carried out in the bore hole
by “Nordmeyer Standard Penetrometer” for 2 piles in every 50m length of the berth and the
approach.
¾ A sample of bentonite suspension shall be taken from the base of the boring using an approved
sampling device. If specific gravity of the suspension exceeds 1.5, the placing of the concrete
shall not proceed.
¾ The concrete shall be placed through a tremie pipe of 20-25 cm in dia. with a suitable hopper.
¾ The tremie pipe joints shall be air tight and the hopper must such that it produces a build up of
atleast 2m concrete in pile.
¾ Placing of concrete shall be continuous.
¾ At all times a shaft of 1.5 mts as per IS specifications shall be maintained between the tremie pipe
opening and the concrete or as may be directed by the employer.
¾ Any short fall in actual consumption of concrete in pile shall not be more than 5 % of the
theoretical volume.
¾ The clear concrete cover to main reinforcement shall be 75 mm and suitable spacer blocks shall
be provided at intervals not exceeding 2mts and wired to the reinforcement.
3.1.3 Standard of acceptance for piles
¾ The head of the pile shall be within 75mm of the specified position.
¾ The pile shall not be out of plumb by more than 2%.
¾ The toe of the pile shall always be at the approved bearing level in each case.
¾ The total volume of concrete shall not be less than 95% and not more than 120% of the calculated
volume.
¾ The concrete shall be of design strength.

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3.1.4 General Information
¾ Location : Approach Trestle (Approach Jetty)

¾ Type of Pile : Bored Cast In – situ Pile.
¾ Method of piling : End on Method.
¾ Total Approach piles : 188 nos.
¾ Pile Diameter : 1000mm, 1100mm & 1200 mm
¾ Founding Level : (-) 30.00m, (-) 34.00m, (-) 38.00m
¾ Pile Cut-off Level : (+) 12.395m.
¾ Reinforcement Cut-off Level : (+) 14.495m.
¾ Load Transfer Mechanism : 80% - Friction, 20% - End Bearing
¾ Designed Capacity Of Piles : 300 Tonnes
¾ Liner Tip Level : Till Refusal level
(Between (-) 5m to (-) 10m as per Tender Specifications)
¾ Liner Material : 6mm & 8mm M.S. Plate.
¾ Grade of Concrete : M 40.
¾ Planned no. of piles/month : 16
¾ C/C distance between piles : 12.00 m (1-2) 9.00m (A-B) ( Refer Drawing 2.01 & 2.02)
¾ Reinforcement used : Thermo Mechanically Treated (TMT) Bars
¾ Type Of Gantry : 6 Pile Gantry ( 4 Permanent Piles & 2 Temporary Piles )
¾ Self Weight Of Gantry : 850 Tones

25
3.01 Layout Of Piles

26
3.1.5 Flowchart for Gantry Piling
Survey Works
Liner Fabrication
Liner Lifting, Guide Welding,

Shifting To Site Liner Joining, Liner Pitching
Liner Driving
Till Founding
Lvl. is achieved Boring, Chiseling
R/F Cage Fabrication
Bailing
Checking the Shifting To Site
Reinforcement Cage
Checking By Apppl Engineer

Lowering Of R/F
Cage
P
A
R
Lowering Of Tremie Cutting & Shifting R
Pipe Of Rolling Bracing A
L
E
Fixing Of Steel L
If Sp. Gravity > Flushing of the Capping Beam
1.25, Reflushing To Borehole with A
Be Done Bentonite Slurry & Air C
T
Placing Of Wheels I
on the Capping V
Concrete Placing Beam I
T
I
E
Cutting Of Liner to S
Gantry Shifting the Required Level

27
3.02EnaBling Structure Gantry Plan Section Elevation

28
3.03 General Job Layout Of Gantry

29
3.1.6 Liner fabrication
¾ Liner is a circular hollow tube made up of steel plate which is driven in the sea bed up to desired
depth to act as a guide in piling operation & left permanently at the place.
3.1.6.1 Advantages of Liner

¾ It is casing/extra anti corrosive layer to the piles.
¾ It prevents any collapse inside the bore hole at the time of piling.
¾ It acts as a formwork and doesn’t allow sea water to mix with the fresh concrete at the time of the
concreting.
¾ It prevents deterioration of concrete due to direct contact with the sea water.
¾ First liner gets corroded, than concrete gets deteriorated due to contact with sea water and at last
reinforcing steel inside the pile come in contact with the sea water. Thus it increases the life span
of pile.
¾ Its rate of corrosion is very slow – 1mm / 10 years in sea water.
Table No. 18 :- Details Of Liner Studied

Sr. No. Parameter Description
1 Location Unit-1 & Unit-2
2 Internal diameter 1000 mm
3 External diameter 1012 mm
4 Length of single unit 1510 mm
5 Liner Cut Off Level +12.395m
6 Material for liner 6 mm Ms plates
7 Type of weld Metal arc weld
8 MS Shoe Of 8 mm Thickness 1000 mm long
9 No. of Lifting Plates 2 Nos.
3.1.6.2 Equipment Details For Liner Fabrication
1. Plate Bending Machine:

Purpose : Bending of plate
Quantity : 1 no.
Motor capacity : 7.5 HP
Power consumption : 6.00 KW/Hr.
Electricity Source : Diesel Generators
2. Diesel Generator:
Purpose : Alternate source of electricity
Quantity : 1 no.
Capacity : 180 KVA
3. Welding Machine:
Purpose : Welding of joints
Quantity : 2 no.
Current Capacity : 210 Amp.
4. Hand Gas Cutter:
Purpose : Cutting 6mm thick plates
Quantity : 1 no.
Machine cost:
¾ Welding machine: Rs. 30,000 / machine (approx)
¾ Plate bending machine: Rs. 50,000 / machine (approx)
¾ Gas cutting machine: Rs 5000 / machine (approx)
Maintenance detail of machines:
¾ Gear oil : once every fortnight
¾ Consumption : 1-1.3 Liter approx.

30
¾ Cost : Rs. 150 / Lt.
¾ Grease : once a week

¾ Consumption : 1.5-2 Kg. approx.
¾ Cost : Rs. 105 / Kg
3.1.6.3 Material Details For Liner Fabrication
1. Steel Plates:
Purpose : Raw material for liner
Type : Mild Steel
Size : 6300 x 1500 x 6mm
Cost : Rs.26000/MT
2. Oxygen cylinder:
Purpose : Gas-cutting
Capacity : 50 Kg.
Consumption : 50 rmt. Cutting (approx.) / cylinder for 6mm plate
Cost : Rs.175/cylinder
3. LPG Cylinder:
Company : HP Gas
Capacity : 14 Kg.
Consumption : 250-300 rmt. Cutting (approx.) / cylinder for 6mm plate
Cost : Rs. 450
4. Welding rods:
Company : ESAB Electrodes Pvt. Ltd.
Type : Metal – Arc Welding
Code reference : IS 4111
Size : 3.15 x 350 mm & 4.00 x 350mm
Cost : Rs. 275/ packet (55 rods).
Consumption : 170mm weld length /rod (4mm x 350mm)
120mm weld length /rod (3.15mm x 350mm)

31
3.1.6.4 Construction Sequence For Liner Fabrication
Unloading of Mild Steel Plates
Stacking in Fabrication Yard
Cutting of Plates in required
Placing if plates in bending

machine to get the circular shape
Tack Welding along the length of

the plate from both the sides
Bending it again in bending

machine to get perfect circular
shape
Removal of Liner unit from the

bending machine
Welding Throughout the length of

the liner
Joining With another Member
Stacking in Fabrication Yard

32
3.04 Bending machine Drg.

33
3.1.6.5 Unloading
¾ MS plates are brought to site in the trailer of 20 ton capacity.
¾ It is unloaded from the trailer by sliding it over the roller, at the place of the storage.
Transportation to the fabrication yard from the Material storage area is done through cranes
(Hydra).
3.1.6.6 Cutting
¾ MS plates are available in size: 6320 X 1510 mm.
¾ Length of each liner unit is same as the width of the plate and it is 1510 mm.
¾ The length of the plate required for fabrication of liner is.
L = π x (T +NB)
Where,
L = length of plate required
T = thickness of plate
NB = nominal bore
So to fabricate 1000 mm liner length of plate required is:
L = π x (6 + 1000)
= π x 1006
= 3160.44 mm
≈ 3161 mm
Length provided on site at the time of cutting is 3164 mm.
To fabricate 1200 mm liner length of plate required is:

L = π x (6 + 1200)
= 3.14 x 1206
= 3788.76 mm
¾ Length provided on site at the time of cutting is 3790 mm.
¾ Extra length is provided as cutting allowance.
¾ Size of full plate is: 6330 X 1510 mm.
¾ Plate length required for 1000 mm liner is 3164 mm. So 2 nos. of plates of 3164 X 1510 mm can
be cut from 1 full size plate without any wastage.
¾ Before cutting plate diagonal check is carried out to check the proper geometry of plate.
¾ Then required distance is measured from both the ends of one side and that point is marked on
the plate. Than again diagonal check is provided for that marked points to check proper geometry.
¾ Then line is marked with the help of chalk and string between those two points.
¾ Then the plate is cut with manual gas cutting machine. Oxygen and L.P.G. are the gases used for
the cutting of the plates.
Table No. 19 :- Liner Dimensions

Liner Liner Length
Sr. Unit Weight Total Weight
Type Length (m) (m)
No. (Kg. / M) (Kgs.)
(Theoretical) (Studied)
1 Shoe 1.00 1.00 201.32 201.32
2 Bottom Liner 12.08 12.06 148.917 1818.37
3 Middle Liner 9.6 9.6 148.917 1429.603
4 Top Liner N x 3.02 5x3.02=15.1 148.917 2248.646
Total 5557.96Kgs.
3.1.6.7 Bending
¾ After cutting the plate in required size it is taken to the plate bending machine with the help of
labourers as it is not far from the cutting site.
¾ Total three nos. of rollers are there. Two bottom roller and one top roller.
¾ First the top roller of the plate bending machine is loosened.
¾ The plate is then kept over the two bottom circular rollers. After this, the top roller is tightened to
the required amount.

34
¾ Then plate is allowed to pass 2 to 3 times for proper straightening.
¾ Then initial curvature is given to the plate with the help of wedge. It is inserted between top roller
and plate at three locations center and at the ends of the plate.
¾ Then top roller is tightened as per the marking they have marked on the tightening screw to get
proper profile. Curvature of the liner is continuously checked with the help of piece of steel plate
cut in an exact fashion of internal diameter of the liner.
¾ Whole circular shape is obtained in one rotation after inserting wedge block.
¾ Once the circular shape is formed tack welding of 100mm @ 200 C/C is done on both the sides of
plate.
¾ After tack welding it is rotated in the machine for additional 3 to 4 minutes to get exact curvature.
¾ Then liner is removed from the machine by withdrawing the movable side from the machine.
3.1.6.8 Welding
¾ Each liner unit is then welded along the length with 6mm shielded metal arc welding on both the
sides.
¾ Two liner units are welded along their circumference such that welded joints along the length are
not in the same alignment (staggered).
¾ For bottom most liner of the pile 7 such units are welded together. And at the bottom most portion
shoe is created by providing additional plates of 8 mm of the varying length 1000 mm.
¾ For other member 3 to 4 units are welded.
¾ Then this assembly is stacked properly with the help of hydra crane.
3.1.6.9 Quantities (Theoretical)

1. Steel Plate (6mm Thk.)
Length of one unit : 1500mm.
No. of Units required : 2 Nos.
Length of plate required for one unit : L = π x (6 + 1000) = π x 1006 = 3.161 m
But provided at site = 3.164 m
Now assuming 15 mts as Liner Refusal Level

Pile Cut off level is +12.395m
Including 5% wastage due to cutting of Liner while driving = 1.37mts
Therefore Total Length of Liner = 15 +12.395 + 1.37 = 28.76 mts
To Fabricate 28.77 mts of Liner Length the amount of units required are
= 28.76/1.51
= 19 units approx.
Therefore Total Quantity of MS Plate Required
= No. of liner units x Length of each liner unit x
Width of each unit x Thickness of plate
= 19 x 1.51 x 3.164 x 0.006
=0.5446 m3
Now, Density of steel is 7850 Kg / m3

Therefore, Quantity of 6mm plate = 0.5466 x 7850 = 4275.51Kg.
Adding 2% wastage in cutting = 85.51 Kg
Therefore,
TOTAL QUANTITY OF 6 mm PLATE = 4275.51 + 85.51
= 4361.02 Kg (4.361 MT)
2. Shoe of the liner (8mm Thk.)

Quantity of 8 mm thick liner shoe = (1 X3.164 X0.008)
= 0.02531 m3
= 199 kg.
Adding 2% wastage = 202.97 Kg

35
3. Quantity of oxygen and L.P.G. required:
¾ Available length of 6mm steel plate : 6.33m
¾ Length required for single liner unit : 3.164m
¾ No. of liner units / 6.33m plate : 2
¾ Total no. of 6mm liner units required : 19
¾ Total no. of 6mm steel plates required : 9.5
Therefore,
Length of cutting required = No. of 6mm steel plates required x Width of plate
= 9.5 x 1.51m = 14.345 m
Quantity of Oxygen cylinders required

= Length of cutting required
Approx. cutting / cylinder
= 14.345m / 45 m
= 0.319 no. of Oxygen cylinders
Quantity of LPG cylinders required
= Length of cutting required
Approx. cutting / cylinder
= 14.345 m/ 280 m
= 0.051 no. of LPG cylinders
4. Quantity of welding: (thickness – 6MM)

¾ For 6 mm thick Liner units on external face:
Along the length = No. of units x Length of single unit
= 19 x 1.51m
= 28.69 m
Along the circumference = (No. of units – 1) x 3.164m
= (19 – 1) x 3.164
= 18 x 3.164
= 56.952 m
¾ For 6 mm thick Liner unit on internal face:
Along the length 100 mm weld is provided @ 200 C/C.
Along the length = 1+ (total length/ (100+200))
= 1 + 100 = 101
= 101 X 0.1
= 10.1 m
¾ For shoe plate 8 mm thick
Along the length =1m
Along the circumference = 2 X 3.2 = 6.4 m
¾ Total welding length = 28.69 + 56.952 + 10.1 + 6.4 = 102.142 m

¾ Quantity of rods = Total length of welding
Length of welding / rod
= 102.142 m / 0.170 m
= 601 rods (approx)
3.1.6.10 Labour Requirement For Liner Fabrication
Table No. 20:- Labour Requirement For Liner Fabrication

Sr. No. Type Skilled Unskilled
1 Unloading (once) - 6
2 Marking 1 1
3 Cutting 1 -
4 Bending 2 4
5 Welding 2 -
Total 6 11

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3.1.6.11 Time Cycle For Liner Fabrication
Table No. 21:- Time Cycle For Liner Fabrication

Sr.
Type Time
No.
1 Unloading (once) 2 Hours
2 Marking 0.25 Hours (15 minutes)
3 Cutting 0.25 Hours (15 minutes)
4 Bending 0.33 Hours (20 minutes)
5 Welding 0.33 Hours (20 minutes)
19 x (0.25+0.25+0.33+0.33) + 2
Total Time Taken For Liner Fabrication of One Pile
= 24.17 Hours
3.1.7 Reinforcement Cage Fabrication
3.1.7.1 Scope of Work

Supplying, cutting, bending, welding the reinforcement bars and placing in position
reinforcement cage including cleaning, wire brushing, straightening, tack/lap/but welding
with approved electrodes including material and labour. etc, complete.
3.1.7.2 General Information
¾ Diameter of pile : 1000 mm

¾ Pile Type : P 11
¾ Depth of pile : (-) 30 m
¾ Pile cut off level : 12.395 m
¾ R/F cut off level : 14.395 m
¾ Tip level of R/F : 29.925 m
¾ Total length of R/F cage : 44.955 m
¾ Main reinforcement : 25/32mm TMT bars
¾ No of R/F cage : 4 nos
¾ Lap length : 2200 (mm)
¾ Dia of inner stiffener ring : 20 mm TMT bars
¾ Lap for inner stiffener ring: : 300 mm
¾ Helical stirrups : 12 mm TMT bars 150 c/c
¾ Clear cover to main R/F : 75 mm
¾ Type of weld : lap weld
3.1.7.3 Material Details For Reinforcement Cage Fabrication
1. Reinforcement:
Diameter : 10, 20, 25, 32mm TMT bars
Source : SAIL
Cost : Rs. 24500 / MT
2. Welding rods:

37
Size : 3.15 x 350 mm & 4.00 x 350mm
Cost : Rs. 275/packet. (55Nos.)
Consumption : 170mm weld length/rod (4mm x 350mm)
120mm weld length/rod (3.15mm x 350mm)
Above Consumptions are for 6mm weld.
3. Binding Wire:
Thickness : 19 gauge
Cost : Rs. 28/kg
Availability : 50 Kg rolls
Code : IS 814
Amp : 115 – 265
Size : 4 x 450 mm
3.1.7.4 T.E.P Details For Reinforcement Cage Fabrication
1. Bar cutting machine :

Use : cutting and bending of bars
Company : Spartan
Quantity : 2 no.
Motor capacity : 8 HP
Power consumption : 6.25 KW / Hr.
Fuel : Electricity
Capacity Of Bar Cutting Machine
No. of Bars It Can
1 1 2 3 5
Cut in a Single Go
Bar Diameter 36 32 25 20 16
2. Gas cutter:
Use : Cutting plates
Quantity : 2 no.
Company : Asha Pvt. Ltd.
3. Welding Machine:
Use : Welding
Company : ESAB
Model no : Arc – 400
Input : 42 amp, 415 volts, 50 Hz
Range of weld amp : 30 – 400 amps.
Quantity : 8 no.
Weight : 115 Kgs
4. Goliath crane :
Use : To transfer fabricated cage
Capacity : 20 tones
Oil change : 200 to 250 hr

38
3.05 Details of Pile Reinforcement Cage

39
3.1.7.5 Construction Sequence of Reinforcement Cage Fabrication
Preparation of B.B.S
Approval of B.B.S
Cutting of bars according to B.B.S
Placing of main bars Preparation of leveled platform
Marking of location of inner stiffener ring Cutting of bars for inner stiffener ring
Positioning of inner stiffener ring Fabrication of inner stiffener ring
Welding of main bars with stiffener ring Bending of R/F for Helical Rings
Inserting helical stirrups and cover Fabrication of helical stirrups

blocks
Welding of lap of helical stirrups
Welding to main reinforcement
Lifted to stacking yard
Checking by clients engineer
3.1.7.6 Construction Methodology For Reinforcement Cage Fabrication
¾ First of all, Bar Bending schedule is prepared & approved by engineer. Then R/F bars are cut as
per approved bar bending schedule.
¾ R/F bars are cut to suit the length of pile & the length of bars available. R/F bars are available in
12m length on the site. They are cut to the required size with the help of Gas cutting tool.
¾ A bed of ISMC 250 is made by keeping 4 ISMC250.
¾ Helical stirrups are made with the help of tailor made assembly. But this procedure doesn’t give
them shape and the diameter required.

40
¾ The inner guide ring is made at the bar benders bench. The whole process is manual and does
not involve any machinery.
¾ Firstly two main Bars are kept on the ISMC 250 at appropriate space as per the drawing.
¾ Now, Guide rings are placed in their respective locations and welded.
¾ Main bars are marked on them at the required spacing as per the drawing.
¾ Then one bottom R/F bars is welded to the inner stiffener rings.
¾ Then, the top R/F bars is welded to the inner stiffener ring. In the same way, all the R/F bars are
welded to the inner stiffener ring. But care is taken that two opposite pairs are tied at a time in
order to prevent the imbalance in the assembly.
¾ Now the positions of helical stirrups are marked at 250mm c/c with the help of chalk and
measuring tape on the main R/F.
¾ Helical stirrups along with already inserted 6 cover blocks (75mm) are then slide over the main
R/F bars along their length. But care is taken that c/c distance between two helical stirrups is not
more than 250mm.
¾ In this way, all the R/F cages are prepared on the ground. After that, they transferred to the place
of stacking with the help of crane.
¾ After that, they transferred to the place of lowering into the pile with the help of trailers.
¾ After the first cage is lowered, it is held at the casing top level by placing reinforcement bars
between the rings.
¾ At the same time another cage is lifted according the sequence given to them. Second cage is
kept hanging such that it overlaps 2.20 m with the first cage.
¾ This overlapped junction is then strengthened by welding r/f bars of both cages with each other
using tack welding.
¾ After that, helical stirrups along with cover blocks are inserted around the junction & are tied with
the cage and then tack welded.
¾ This makes both separate R/F cage units into a single strong unit. In the same manner all the
cages are lowered in the pile.
3.1.7.7 Labour Requirement For Reinforcement Cage Fabrication
Table No. 22 :- Labour Requirement For Reinforcement Cage Fabrication

Sr.
Type Skilled Unskilled
No.
1 Unloading - 6
2 Cutting Main Reinforcement 2 2
3 Making helical stirrups 1 3
4 Inner stiffener ring bending 1 3
5 Fixing of Reinforcement 3 6
6 Welding 2 -
7 Tying binding wire - 4
Total 9 24
3.1.7.8 Time Cycle For Reinforcement Cage Fabrication
Table No. 23 :- Time Cycle For Reinforcement Cage Fabrication

Sr. No. Type Time
1 Unloading 3 Hours
2 Cutting Main Reinforcement 4 Hours
3 Stirrup Making 3 Hours
4 Inner Ring Bending 3 Hours
5 Fixing Reinforcement 8 Hours
6 Welding 3 Hours
7 Tying Binding Wire 3 Hours
Total Time Taken For Reinforcement Cage Fabrication 27 Hours

41
3.06 Pile Reinforcement Sequence

42
BBS

43
3.1.8 Construction Methodology For Piling
3.1.8.1 Survey Works For Piling
Equipments Details For Survey Works

1. Total Station with reflectors
Use : Giving Points As per The Co-ordinates and checking the
correctness of the points
Company : Trimble
Quantity : 1 no.
Mode of Operation : Battery Operated
2. Auto Level
Use : Checking the Levels
Company : Trimble
Quantity : 1 no.
Mode of Operation : Manually Operated, No need for Battery
Man Power
Table No. 24 :- Labour Requirement For Survey Works For Piling

1 Survey Works 1 -
2 Helpers (For Holding Cross Staff, Prism etc.) - 3
Methodology
¾ Before Shifting of gantry commences, a chalk marking is done on the gantry & at a distance of
24mts from the centerline of the front roller support (i.e new pile support) indicating the gantry
movement shall be stopped when that chalk mark reaches the centerline of the front support.
¾ This ensures that the longitudinal spacing of 12mts. between the piles is maintained.
¾ Now it is required to give the pile point locations of the next grid over the gantry platform so that
the next activities of liner shift and guide welding can commence.
¾ After the gantry is shifted, points for the next piles are given.
¾ As it is not possible to give the centre point of the pile, two points on either side of the center point
for each pile are given.
¾ These points are marked on the gantry using paint. These points help to check the centre point of
the pile.
¾ At the site, these points are marked 1.5m on either side of pile point.
¾ Once the pile point marking is done with help of Total station on the Gantry, the location of piling
pulley is checked to ensure that the centerline of wire rope matches with the alignment of the pile.
¾ In case of any longitudinal or lateral deviation observed, the pilling pulley is suitably shifted over
the pilling tower frame to match the alignment.

44
3.08 Job Layout Before Liner Pitching

45
3.1.8.2 Bottom Liner lifting, Guide Welding & Liner pitching
Equipments For Liner Lifting, Guide Welding & Liner Pitching

1. Piling Winch (7.5 Tons & 5 Tons)
Use : In Activities of Lifting & Pitching of the Liner
Company : Siemens (7.5 Tons) & Greaves (5 Tons)
Quantity : 4 nos.-7.5 Tons & 2 Nos.-5 Tons
Mode of Operation : Diesel Operated
2. Welding Transformer
Use : In Activities of Welding of Liner Pieces with each other &
Guide Welding
Company : Greaves
Quantity : 10 Nos.
Man Power
Table No. 25:- Labour Requirement Per Pile Point
1 Winch Operations 1 -
2 Welding Operations 1 -
3 Helpers - 2
4 Signaling (Rigger) 1 -
Methodology for Liner Lifting, Guide Welding & Liner Pitching
¾ After the pile point marking, the centre point of the pile is checked.
¾ A string is placed along the marked point and chain is lowered from the pulley to check the centre
of the pulley.
¾ If there is a difference between the string and the chain, it is to be rectified.
¾ If the difference is more, then the welding of the pulley is cut and it is shifted as required and re-
welded.
¾ As the gantry cannot move backwards it becomes difficult when the gantry is shifted more than
the required length. Hence proper precautions are to be taken will shifting.
¾ The liners are fabricated at the fabrication yard and brought to the site in trailer. Then it is lifted
with the help of winch.
¾ These liners are made up of 6mm thick MS plate. There is an extra 8mm thick plate of 1000 mm
length at the bottom most part of the liner, which acts as shoe.
¾ The bottom liner is of 12.08m.length, middle liner of 9.6m and then the subsequent liners of
3.025m length are added on as and when required.
¾ The liner is provided with the lifting hooks on the inside face. The guide is made of ISMC 100 box.
¾ With the help of the pile point marking done on the gantry, the guide is fixed in its position and
welded to the gantry.
¾ There are total of two guide boxes for each pile.
¾ The top guides are welded using the points marked on the gantry, whereas the bottom guides are
placed in position using the plumb bob from the top guide.
¾ While doing the guide welding, the tip of the bottom piece liner is kept sufficiently above the sea
level to prevent swaying of liner due to wave or water current so that guide welding can be done
with accuracy and both top and bottom guide are in perfect plumb to check inclination of the liner.
¾ A gap of 2mm is kept on all sides between the outer face of the liner and the inner face of the
guide – box to allow the liner with its joint weld to pass through easily.
¾ Once the guide welding is completed, the bottom piece liner is lowered till the top of it remains
500mm above the gantry deck level.
¾ In this position the liner is arrested on the top guide by welding 4 cleat angles at 90º to each other.
¾ Once the liner is arrested, the sling is removed and the lifting hook cut and removed.

46
¾ Thereafter, the second piece of the liner is lifted and placed over the bottom piece, matching the
edges.
¾ Initially, the entire periphery is tack welded at few places by using a hammer and wedge to bring
the top edge of the bottom liner and the bottom edge of the top liner in line and contact.
¾ When the full welding is done, 4 stiffener plates, each measuring approx 200x100mm, is welded
at 90º to each other as a safety measure.
¾ The arresting clit angles are then cut and removed by lifting the liner slightly to release the load.
¾ With the release of the winch brake, the liner falls freely and pitches inside the seabed.
¾ Liner pitching is done only in the slack tide period (The period between the High Tide and Low
tide when the water current is quite low) as the site is located in the region that has world’s 2nd
highest water currents.
¾ When liner touches bed level and rests on the bed without any support, it is known as pitching.
¾ The liner is allowed to settle on its self-weight for some period.
3.1.8.3 Boring including additional Liner Driving & Joining
Equipments for Boring including additional Liner Driving & Joining

Use : Piling Winch is used for boring operation with the help of
Bailor & Chiesel
Use : For welding subsequent liners
Company : Greaves
Quantity : 10 Nos.
3. Water Pump
Use : To Collect Sea Water for Cleaning of Bailor & Chiesel
Company : Local
Quantity : 2 Nos.
4. Vacseal Pump
Use : For bentonite mixing and pouring in the borehole.
Company : Vatrak
Quantity : 2 Nos.
Fuel of Operation : Diesel
Man Power
Table No. 26 :- Labour Requirement Per Pile Point during Boring including additional
Liner Driving & Joining
3 Helpers - 2
4 Riggers 2 -
Methodology
¾ Before starting the boring operation the existing bed level is measured by sounding chain.
¾ The sounding chain is having a light weight (2Kgs) attached to it .The sounding chain is manually
lowered inside the liner very slowly so that the difference in weight is felt; the moment the flat
bottom of the weight touches the bed level.
¾ The chain is then marked with reference to the top level of the liner and pulled and measured.
¾ This operation is carried out through out the boring operation so that the various strata
encountered can be recorded as well as progress of boring can be ascertained.
¾ Boring is done with the help of chiesel & bailer.

47
¾ A cross chiesel of weight 2-2.5 tons is dropped several times and then the bailor is used to
remove the material.
¾ At first, chisel is lowered down in the liner unit to start boring. As chiseling continues, bentonite
slurry (Density = 1.04 to 1.2 - Fresh Bentonite) is continuously poured in the borehole from the
gantry deck with the help of the pipe.
¾ Bentonite slurry is used because of its higher density than seawater. As bentonite is poured, it
gradually settles down in the borehole & forms an impermeable (plaster-type) layer, which
prevents the surrounding soil to collapse in the borehole.
¾ The bailer is a vertical steel cylinder open at the top and fitted with a one way valve opening to
inside at the bottom. It has an approximate wt. of 1ton.
¾ It is hung with the help of a hook that is fixed to the top with a hinge pin.
¾ After the chisel is removed, bailer is attached to the wire rope of the winch. Bailer is used to
remove the chiseled soil strata. Here, bentonite plays another role. Due to its higher density than
mud, it prevents the mud from settling down at the bottom of the borehole. And thus makes the
mud easily available for the bailer
¾ The bailer is lowered into the borehole and dropped multiple times so that the soil material enters
the bailer.
¾ Then the bailer is lifted out of the bore and tilted to discharge the collected material.
¾ At times when sand is encountered at the bottom of the bore, bailing becomes difficult as sand
mixes with water and slips form the bailer.
¾ In such times, lumps of clay are thrown into the borehole and bentonite of is also used so that the
sand mixes with the clay and can easily be removed.
¾ Thus alternate bailing and chiseling operation continues till the founding level (-34m) is achieved.
¾ Simultaneously sounding is also taken at regular intervals to know the depth of the borehole. Soil
samples are taken regularly with the help of a sampler to know the soil strata at varying depths.
¾ Once this achieved the, the bailer is lowered for the last time to finally clean the bore of all loose
materials before the pile is ready to receive the reinforcement cage.
¾ While the boring progresses, the Liner is driven with help of a square bar inserted through the
window of the bailer or with the help of a monkey.
¾ For this a removable driving cap (helmet) is placed on top of the liner, which prevents the Liner
plate from buckling due to impact of Square bar or monkey. (Monkey used at the site is a tailor
made monkey made by filling concrete in a bailer till the window and welding square bar on all the
four sides equally.
¾ The monkey is dropped from a height of 1-1.5 mts over the driving cap to drive the liner. This
operation is carried out along with the boring operation.
¾ Further liner pieces are attached to the existing liner when the top of the liner is about 500mm
above the guide level.
¾ In case of distortion, that part of the liner is cut.
¾ The same procedure is continued upto refusal level.
¾ Empty boring for not more than 3-4 mts is permitted.
¾ The level of bentonite in the borehole is maintained in such a way that it is always above the
seabed level during the low tide and more than the sea water level during the high tide level.
Table No. 27 :- Soil Strata Obtained During Boring

Boring Depth (m) Boring Depth (m)
Soil Strata (A14) Soil Strata (B14)
(A14) (B14)
-0.37 Very stiff clay with gravels -2.81 Very Stiff clay
-7.32 Stiff clay -5.72 Stiff clay
-14.87 Soft clay -9.92 Very Stiff clay
-15.92 Stiff clay -17.57 Stiff clay with Gravel
-20.62 Stiff Clay with gravel -20.64 Stiff clay
-21.62 Stiff Clay -23.96 Soft clay with Gravel
-24.12 Stiff Clay with gravel -26.15 Sand
-25.04 Very Stiff Clay with gravel -32.86 Very Stiff with Gravel
-30.22 Silty Sand with small stone -33.08 Sand with Gravel
-34.00 Silty Sand with Gravel -34.34 Sand

48
Problems Encountered During Boring, Liner Joining & Liner Driving
¾ Chiesel gets trapped inside the soil if soil is very stiff clay.
¾ Chiesel gets trapped in the bottom of the liner if a cavity develops exactly below the liner tip and
the chisel tilts.
¾ Collapse of soil occurs if proper quantity of bentonite is not used and the soil strata encountered is
loose.
¾ Bailer gets trapped inside the soil when the soil encountered is very stiff.
¾ Liner gets pressed (Bend) form the bottom due to very high soil pressure.
¾ Bailer gets trapped in the bottom of the liner if a cavity develops exactly
below the liner tip and the bailer tilts.
¾ Winch Breakdown occurs if the Chiesel or bailer gets trapped inside the
borehole and winch is overloaded.
¾ Sounding Chain gets trapped when the collapse occurs at the time of
sounding.
Bend Liner
Probable Solutions
¾ As visual inspection is not possible, measures taken are totally based on trial and error method.
¾ If chisel or Bailer gets trapped inside the borehole the first thing done is to give jerks to them with
the help of piling winch and try to get it out.
¾ The last method for taking it out the chisel or bailer is to drive out the liner with the help of a
square bar.
¾ To prevent the soil collapse bentonite mix of proper quality should be regularly supplied. Bailing is
to be done to remove the collapsed material.
¾ The last thing that is done when a Chiesel or bailer gets stuck beneath the liner is to send Diver
inside the Borehole with all safety measures like Oxygen cylinder, Ropes etc..
¾ The diver goes with a hook and tries or D shackle and tries to fit it in the safety sling attached
with the Chiesel or bailer. It is a highly undesirable method as it is very risky and hence it is
adopted as a last resort.
Table No. 28:- Liner Details For Pile A14
Sr. No. Type Liner Length (m) Unit Weight (Kg./m) Total Weight (Kgs.)
1 Shoe 1.00 201.32 201.32
2 Bottom Liner 12.06 148.917 1818.37
3 Middle Liner 8.66 148.917 1309.226
4 Top Liner 4 x 3.02 = 12.08 148.917 124.351
5 Cutting (-) 0.48 148.917 (-) 71.48
Total 5081.787 Kgs.
Table No. 29:- Liner Details For Pile B14

Sr. No. Type Liner Length (m) Unit Weight (Kg./m) Total Weight (Kgs.)
1 Shoe 1.00 201.32 201.32
2 Bottom Liner 12.06 148.917 1818.37
3 Middle Liner 8.66 148.917 1309.226
4 Top Liner 5 x 3.02 = 15.1 148.917 2280.438
5 Cutting (-) 0.00 148.917 (-) 0.00
Total 5609.354 Kgs.

49
3.1.8.4 Lifting, Joining & Lowering the Pile Reinforcement Cages
Equipments for Lifting, Joining & Lowering the Pile Reinforcement Cages
Use : Piling Winch is used for lifting the Reinforcement Cages & for
lowering them into the pile bore
Use : For welding subsequent liners
Company : Greaves
Quantity : 10 Nos.
Man Power
Table No. 30:- Labour Requirement Per Pile Point during Lifting, joining & Lowering
The Pile Reinforcement Cage
3 Helpers - 4
4 Riggers 2 -
Methodology
¾ Reinforcement cages are fabricated in sections with provision of lapping (36D) the site.
¾ There were 5 no. of sections for the pile type P-11 having 34 mts. depth.
¾ The cages are brought to the site by tractor-trailor and lifted with the help of gantry EOT and kept
on the top of the girder.
¾ Before lowering the bottom cage the borehole is thoroughly cleaned from the muck by a bailer.
¾ The top of the liner is then cut and removed in such a way that the full-length reinforcement cage
can be held vertically below the pulley with its bottom above the top of the liner.
¾ While lifting the cage with the help of the wire rope of a piling winch, a guide rope is tied to the
bottom of the cage to control the lifting operation. First the bottom cage is lowered into the bore of
the pile and rested on top of the liner with the help of resting bars (2-32φ).
¾ Thereafter the subsequent cages are lifted and placed vertically over the bottom section in such a
manner that the respective bars in each section are in line with each other for proper lapping.
¾ Each pair of bars in the lap is tack welded to each other at minimum 2places for an approximate
length of 1inch (25mm).
¾ The lapped sections are now ready to be lowered into the pile bore.
¾ This is done by first lifting the jointed cages by about 100mm with the help of a winch in order to
remove the holding (resting) bars on which the bottom reinforcement cage was resting.
¾ After removing the resting bars, the jointed cages are slowly lowered into the pile in such a
manner that the cover blocks do not get damaged.
¾ After the entire cage length barring the further lap portion from the top is lowered, the jointed
sections are again rested over the liner top with help of resting bars and the next section is lifted
and fixed in the same manner as described above.
¾ When all sections of the cage are fixed and lowered into the pile bore, the top level of the pile
cage is checked and measured with tape w.r.t to the deck level of the gantry to ensure that the
cage has attained the required levels.
¾ The top cage of the pile is fabricated in such a manner that it also includes the development
length for embedment into the headstock.
¾ The liner during the construction stage of the pile is extended above the top of these straight bars
to suit the placement of wheels of the piling gantry for the movement over the installed piles.

50
3.09 Job Layout Of Gantry Before R/F Lowering

51
3.1.8.5 Lowering Of Tremie & Flushing the Bore Hole
Equipments for Lowering Of Tremie & Flushing the Bore Hole

Use : Piling Winch is used for lifting & Lowering of Tremie Pipes
2. Vacseal Pump
Use : For bentonite mixing and pouring in the borehole.
Company : Vatrak
Quantity : 2 Nos.
3. Air Compressor Pump
Use : For Air Flushing of the Pile Borehole
Capacity : 365 cfm
Quantity : 2 Nos.
Man Power
Table No. 31:- Labour Requirement Per Pile Point during Lowering of Tremie &
Flushing of Borehole
2 Tremie Pipe Fixing - 3
3 Helpers (Signal Givers) - 2
Methodology
¾ Diameter of tremie is 200mm & length of the pipe varies from between 1.00m to 1.24m.
¾ The tremie pipes are attached to each other with the help of male female socket joints and
lowered into the pile.
¾ Grease is applied to all the threaded joints while attaching one tremie to another to keep the joints
watertight.
¾ The tremie pipe is lowered in such a way that it is kept 300 mm above the bottom of the pile.
¾ Flushing is done to clean the bore shaft for concreting. Fresh slurry of Bentonite having specific
gravity of 1.04 to 1.11 is circulated inside the Borehole.
¾ Bentonite, when mixed with water forms a suspension, which has a tendency to attract the mud
particles.
¾ It forms a colloidal suspension, which comes out of the bore. Till the slurry reaches the bottom of
the bore its specific gravity increases by 0.1, thus becoming 1.14 to 1.21.
¾ Now in the process of flushing the borehole, the density of bentonite increases. For smooth finish
and sound concrete the specific gravity of Bentonite should not be more than that of the concrete.
Moreover it should be less than half the specific gravity of concrete.
¾ The specific gravity of the Bentonite mix at the bottom of the borehole is checked by lowering the
Mud Sampler. Hydrometer is used to check the specific gravity & mud sampler is used to take the
sample from the bottom of the borehole.
¾ If the density of bentonite sample collected is more than 1.25 than flushing is continued.
¾ The proportion or the requirement of the bentonite is given by
Yc= 1 + 0.006(C)
Where,
Yc = Specific Gravity of Fresh Bentonite
C = Concentration of Bentonite Slurry
¾ After the bentonite flushing is over, Air flushing done. Air flushing is done using air compressors.
¾ Now in place of the bentonite pipe air pipe is attached and the bentonite is supplied to the bore
with the help of canvas pipe directly kept into the liner.

52
¾ Air flushing is done only for 10min.
¾ Air flushing is important for the removal of sand particles from the borehole. But care should be
taken as excessive air flushing may cause collapse of the sides.
Table No. 32:- Quantity of Bentonite Mix Added

Pile No. During Boring (Cum.) During Flushing (Cum.)
A-14 35 39
B-14 34 48
3.1.8.6 Concreting
Tools, Equipments & Plants Used for Concreting the Pile Borehole
Use : Piling Winch is used for lifting of the Hopper & giving Up &
Down motion to the same for the compaction of the concrete
2. Batching Plant
Use : For Production of the Concrete as Per the Design Mix.
Use : For production of Concrete as per Design Mix
Company : MACON.
Type : Star type automatic batching plant
Capacity : 30Cu.m/hr.
Batch capacity : 0.5 Cu.m
Quantity : 2 Nos.
3. Transit Mixer
Use : For Transporting the concrete from the Batching Plant to
the site
Company : Greaves
Capacity : 6 Cum.
Quantity : 6 Nos.
4. Water Pump
Use : To Collect Sea Water for Cleaning of Bailor & Chiesel
Company : Local
Quantity : 2 Nos.
5. Concrete Pump
Use : For pumping the concrete into the borehole
Company : Sany
Capacity : 43 Cum.
Quantity : 2 Nos.
Man Power
Table No. 33:- Labour Requirement Per Pile Point during Concreting
1 Batching Plant Operations 3 5
2 Transit Mixer Operations (Per Transit Mixer) 1 1
3 Helpers (Signal Givers) - 2
4 Concrete Pump Operations 1 1
5 Concrete Pouring - 3

53
Methodology
¾ The concrete of M40 grade and slump of 150 to 190mm is mixed as per the design mix in a
batching plant of 30m3/hr rated output capacity. As there is no media of compaction at the bottom
of the borehole, the slump is kept 150 to 190mm.
¾ Once the pile is ready to receive the concrete, the pile supervisor sends the requisition for
concrete to the batching plant supervisor indicating the approximate quantity & location of the
pour.
¾ Thereafter, the concrete is prepared in the Batching plant.
¾ The concrete is then unloaded into the transit mixers, which transports the concrete to the location
of the concrete pump arranged for the concreting.
¾ The concrete pumps are stationed over the temporary deck made for the movement of man and
materials. The Transit mixers are placed besides the pump for the unloading of the concrete.
¾ Once the flushing is over, a hopper is fitted to the top of the tremie pipe.
¾ The gap between the borehole bottom and the bottom end of the tremie pipe is kept around
300mm.
¾ The tremie pipe is held in position by slinging the hopper by the wire rope of the piling winch.
¾ The bottom opening of the hopper (i.e. where the hopper joins the tremie pipe) is initially plugged
by a removable plug plate.
¾ The tremmie hopper is applied with oil.
¾ The plug is attached to separate winch wire rope.
¾ The tremie hopper is filled with concrete. When the hopper is completely full with concrete, the
plug is pulled and removed using the winch. This allows the concrete to rush through the tremie
pipe downwards displacing the bentonite inside the tremie pipe through its bottom end.
¾ This result’s in concrete getting deposited at the bottom of the pile bore enclosing the tremie pipe
and the air in the tremie pipe also gets removed through the air pipe.
¾ Now when further concrete is poured, it will result in Pile shaft build up. A build up of 4-5mts is
always maintained in the pile.
¾ The theoretical height of the build up can be calculated from the quantum of concrete pumped into
the pile and the length of the tremie pipe lowered, obtained from the number of tremie pipes.
¾ Once the build up of 4-5 mts is obtained then the tremie pipe is lifted with the help of piling winch
in such a way that the top most tremie pipe comes above the gantry deck.
¾ The tremie pipe is then rested on the gantry deck with help of tremie fork.
¾ First the hopper is removed and then the top most tremie pipe is removed.
¾ The hopper is than again fixed to the next tremie pipe and the whole system is lowered into the
pile.
¾ While lifting the whole system above, care should be taken to keep the bottom of the tremie pipe
at least 1.5 m inside the concrete.
¾ The process of filling the hopper with concrete and removal of tremie pipes is continued till the
bore is filled with concrete.
¾ At the cut-off level of the pile, a window of size approximately 200x200mm is cut on the liner.
Through this window, the contaminated concrete gets removed. Approximately 1m3 concrete is
allowed to over flow so that the concrete obtained at the cut-off level is sound concrete.
Table No. 34:- M:40 Grade Mix Design Details

Material Quantity
Cement (OPC 53 Grade) 347 Kgs.
Fly Ash 116 Kgs.
Aggregate (20mm) 874.65 Kgs.
Aggregate (10mm) 267.75 Kgs.
Sand 704.55 Kgs.
Admixture (Retarder) 4.63
Water 185.20 Kgs.

54
Quantity of concrete
Theoretical quantity of concrete (As per Drg.) = 3.14 x (0.50)2 x H
= 3.14 x (0.50)2 x (34+12.395+1)
= 3.14 x (0.50)2 x (47.395)
= 37.22 m3
Theoretical quantity of concrete (As per Actual Boring) = 3.14 x (0.50)2 x H
= 3.14 x (0.50)2 x (35.88+12.395+1)
= 3.14 x (0.50)2 x (49.275)
= 38.70 m3
Actual quantity of concrete = 42 m3
(Because of washing out of impure concrete at cut-off level.)
Table No. 35 :- Quantity of Concrete
Pile No. Theoretical Quantity (Cum.) Actual Quantity (Cum.)
A-14 38.70 42
B-14 39.21 45
Table No. 36 :- Actual Consumption of Materials

Pile No. Pile A-14 (Kgs.) Pile B-14 (Kgs.) Remarks
Cement (OPC 53 Grade) 14574 15615 Concrete Qty. x 347
Fly Ash 4872 5220 Concrete Qty. x 116
Aggregate (20mm) 36735.3 39359.25 Concrete Qty. x 874.65
Aggregate (10mm) 11245.5 12048.75 Concrete Qty. x 267.75
Sand 29591.1 31704.75 Concrete Qty. x 704.55
Admixture (Retarder) 194.46 208.35 Concrete Qty. x 4.63

55
3.10 Job Layout At the Time Of Concreting & Flushing

56
3.11a Piling Sequence

57
3.11bPiling Sequence

58
3.11cPiling Sequence

59
3.12 General Equipments used in Piling

60
3.1.8.7 Welding of Bracing, Placing of Grillages & Placing of Wheels
Equipments for welding of Bracing, Placing of Grillages & Placing of Wheels

1. Piling Winch (7.5 Tons & 5 Tons) & Chain Pulley
Use : For Lifting the Bracings and keeping them in position
Man Power
Table No 37:- Labour Requirement during Welding of Bracings, Placing of Grillages
& Wheels
2 Cutting 2 -
3 Welding 4 -
4 Helpers - 4
5 Riggers - 2
Methodology
¾ Rolling bracing is a grid of bracings tied together and connected to rollers for easy and fast
movement.
¾ They are used to brace the piles on which the gantry is going to rest. Welding of the Rolling
bracing is cut with the help of Gas cutters.
¾ Then the rolling bracing is shifted with help of winches situated on the gantry.
¾ Fours stoppers are provided on the Rolling bracing which are opened when the Rolling bracing
comes near to the pile to which it is to be fixed.
¾ The rolling bracing is shifted 24mts.
¾ Liner is projected above the pile cut off level to give a clear space between the reinforcement
dowels and the capping beam.
¾ The projected portion of the liner is filled with M25 grade concrete.
¾ The liner is properly cut and trimmed to get a uniform level.
¾ The capping beam is then placed on the piles on which the gantry will be resting and its level is
checked and cross checked with the help of tube level and auto level respectively.
¾ The wheel is then placed on the capping beam.
¾ Proper alignment and levels are checked and than it is welded temporarily with capping beam.

61
3.13 Rolling Bracing Details

62
3.1.8.8 Shifting of Gantry
Equipments used for Gantry Shifting
1. Shifting Winches (5 Tons)
Use : For Lifting the Bracings and keeping them in position
Company : Greaves (5 Tons)
Quantity : 2 Nos.-5 Tons
Mode of Operation : Electrically Operated
Man Power
Table No 38 :- Labour Requirement during Shifting Of Gantry

2 Cutting 2 -
3 Welding 4 -
4 Helpers - 4
5 Riggers - 5
Methodology
¾ Piling is done by end-on method in which piling gantry rests on previously done piles and does
piling work of next row.
¾ After concreting is done for a particular pile, it is allowed to gain adequate strength for at least 24
hours so that it can easily withstand the load of movable gantry shifting on it.
¾ After the piling work gets over, first thing done is to cut the liner at required level same as the level
of the previous pile, which supports capping beam.
¾ Over flow window is welded again.
¾ Concreting is done up to 1m more than cut off level. So rest of liner is also filled with M40 so that
proper load transfer takes place.
¾ Points are marked on the main girder of the gantry with the help of total station.
¾ Simultaneously live loads on gantry like chisels, bailers, tremie pipes etc. are shifted to the
locations assigned to them for the stability of the gantry.
¾ Moreover the water tanks & aggregate tanks on the gantry are to be kept full for the stability
purpose whereas the bentonite tanks are kept empty.
¾ Two shifting winches are provided on the gantry. Shifting of gantry is done very slowly with great
care and in presence of engineer-in-charge. Continuous eye is kept on the position of the gantry
with the help of total station.
¾ The shifting is done for 24mts and the c/c distance between two piles is 12mts.
¾ Shifting winches have wire rope connected to pulleys out of which one is tied to the gantry & other
is tied to the second last pile.
¾ Then the gantry is checked as per the checklist.
¾ When the shifting winches are rotated, wire rope gets collected in the winch. Due to this the length
of the wire rope decreases & ultimately the gantry starts moving forward.
¾ The gantry shifting is done on the odd numbered piles (i.e. the load transfer occurs on odd
numbered piles)
¾ As the gantry reaches nearby the desired point, it is slowly moved forward. When the gantry is
shifted 24m, further shifting is stopped.
¾ The locks are placed on the gantry in such a way that they will obstruct the gantry movement by
colliding with the wheel.
¾ Once the Gantry is in the correct position, the brakes of the wheels are tightened to prevent any
movement of the gantry.
¾ Proper position of gantry is finally checked with the help of total station from the fixed temporary
points on the Rock bund.
¾ If side shifting is observed than it has to be rectified.

63
3.14 Gantry Movement Details

64
Problems Encountered During Gantry Shifting
¾ The welding of the Rolling bracings breaks.

¾ Side shifting of the gantry takes place.
¾ Main girders of the gantry bends.
¾ Winch Breakdown takes place.
¾ Most critical period of gantry shifting is when the gantry leaves the back wheels.
¾ Pile settlement takes place.
Reasons for the Above Problems
¾ Improper survey & point establishment.

¾ Level difference-if prior to shifting the pile on one side has settled or there is difference in casting
than side shifting may occur.
¾ If the Gantry loads are more than that calculated for gantry stability then it may lead to settlement
of the piles on which the gantry is resting.
¾ Eccentric Loading on the Gantry
¾ Unskilled Winch Operator leads to winch breakdown and minute side shifting.
¾ Long Cantilever Portions of the Gantry (Gantry Design) is a major factor causing the Side Shifting.
Solutions for the Above Problems
¾ Jacking the wheels in the direction opposite to the shifting direction and bringing the gantry in
required position.
¾ Jacking the girder by supporting the jack on the capping beam if there is level difference
¾ If the shifting is very less than the pulley can be shifted in order to get in the correct position
exactly above the pile center point rather than shifting the whole gantry with the help of Jacks.
Jacking Operation
¾ Jacking operation in case of side shifting is carried out by

placing jacks of 7.5 tons capacity before the wheels on the
capping beam.
¾ ISMC 400/ ISMC300 is welded behind the jack in order to
support the Jack.
¾ After each shifting of the wheel by some millimeter, survey
is carried out to check the shifting of the gantry, as the
shifting in the wheel & that of the gantry is not same.
¾ The same procedure of the shifting and surveying is
continued till the Shifting comes under the permissible
limits.
¾ Jacking is also done to raise the level of the Gantry, if there Jacking Operation In Progress
is settlement of the pile or tilting of gantry.
¾ In this case, the jacking of Main girders of the Gantry is done.

65
School of Building Science & Technology

Project Training `07 - `08
RATE ANALYSIS
Name of the Project: Multi Purpose Berth, Dahej Student Name: Suril Shah
Code No: 2704
Item
Item Description Unit Quantity Rate Amount
No.
Fabricating and delivering to the
site 1000mm ID liners made of
6mm thick Steel plates for bored
3.1.6
cast-in-situ piles including bending, MT
welding, etc complete.
FOR 5.558 MT
A MATERIALS
Steel Plates MT 5.558 27750.0 154234.50
Welding Rods Nos. 601.00 2.20 1322.20
Oxygen Cylinder Nos. 0.32 200.00 63.80
LPG Cylinder Nos. 0.051 500.00 25.50
B LABOUR
Skilled Nos. 6 126.57 759.42
Unskilled Nos. 11 104.70 1151.70
TOTAL A + B 157557.1
C T, E, P @2% of A + B 3151.14
D.G. Set (Approx.) 15000.00
Welding Transformer (Approx.) 3000.00
D Scaffolding @2% of A + B ---
E Water & Electricity @2% of A + B 3151.14
TOTAL A + B + C + D + E 181859.4
Profits & Overheads @15% of

F A+B+C+D+E 27278.91
TOTAL Rs. 209138.3

UNIT RATE Rs.37628.34 / MT.

66

Project Training 2007 - `08
RATE ANALYSIS
Name of the Project: Student Name: Suril Shah
Construction of Multipurpose Berth, Dahej Code No:2704
Item
No.
Fabricating and erecting of
reinforcement cage as per design for
3.1.7
bored cast-in-situ piles including MT
bending, welding, binding, etc
complete.
FOR 6.799 MT
A MATERIALS
Reinforcement Bars MT 6.799 25400.0 172695
Welding Rods Nos. 440.00 2.1 915
Oxygen Cylinder (Approx.) Nos. --- --- 100
Binding Wires Kgs. 26.00 25.0 650
B LABOUR
Skilled Nos. 30.0 110.0 3300
Unskilled Nos. 60.5 90.0 5445
TOTAL A + B 183105
C T, E, P @2% of A + B 3662
D.G. Set (Approx.) 1000
Welding Transformer (Approx.) 300
Water & Electricity @2% of A + B

E 3662
TOTAL A + B + C + D + E 191729

F A+B+C+D+E 28759
TOTAL Rs. 220488

UNIT RATE Rs. 32430

67

RATE ANALYSIS
Code No:2704
Item
No.
Boring of 34m deep bore shaft of
1000mm dia. For bored cast in-situ
3.1.8.3 pile including cleaning, flushing, etc.
complete.
Rmt
For 1 Rmt.
A MATERIALS
Bentonite kgs. 50.00 1.20 60.00
Water lit. 785.00 0.02 15.70
B LABOUR
Skilled Nos. 2.00 126.57 253.14
Unskilled Nos. 6.00 104.70 628.20
TOTAL A + B 881.34
C T, E, P @2% of A + B 16.71
Winch (Diesel Operated) Hr. 2.00 650 1300
DG set (Diesel Operated) Hr. 2.00 500 1000
2316.71
D Scaffolding @2% of A + B
TOTAL A + B + C + D + E 3214.76

F 175.37
A+B+C+D+E
TOTAL Rs. 3390.13

UNIT RATE Rs.3390.13 / Rmt.

68

RATE ANALYSIS
Construction of Multipurpose berth Code No: 2704
Item
No.
Providing & laying R.C.C. with given
design mix proportion including
3.1.8.6
compaction, placing for piling work
etc. complete.
cu.m.
For 1 cu.m.M40 grade conc.
A MATERIALS
Cement kgs. 347.00 4.19 1453.93
Sand kgs. 874.65 0.18 157.44
Coarse Aggregate (10mm.) kgs. 267.75 0.40 107.10
Coarse Aggregate (20mm.) kgs. 704.55 0.40 281.82
Admixture kgs. 4.63 90.0 416.70
FlyAsh kgs. 116.00 1.25 145.00
Water kgs. 185.20 0.01 1.85
B LABOUR
Skilled Nos. 2.00 126.57 253.14
Unskilled Nos. 5.00 104.70 523.50
TOTAL A + B 3340.48
C T, E, P @2% of A + B 66.81
Batching plant
Transit Mixer
Pump
Winch
TOTAL A + B + C + D + E 3474.10
F Profits & Overheads @15% of

521.11
A+B+C+D+E
TOTAL Rs. 3995.21

UNIT RATE Rs.3995.21 / Cum.

69
Project Training `07 - `08
RATE ANALYSIS
Multi Purpose Berth, Dahej Code No: 2704
Item Rem
Item Description Unit Qty. Rate Amount
No. arks
Providing & Constructing
bored cast in-situ pile of
1000mm dia. Including
3.1 boring, reinforcement,
concreting, etc., complete. Nos.
For 1 No.
A MATERIALS
Boring (36.52 - 2.18(Bed Level))
= 34.34rmt) rmt 34.34 7200 247248. Ref.
Individ
Liner / Casing MT 5.08 38007.76 193117.43
ual
Reinforcement MT 7.99 32430.00 259115.70 Rate
Analys
is
Concrete cu.m. 45. 3995.21 179784.45
B LABOUR
Skilled Nos. --- --- ---
Unskilled Nos. --- --- ---
TOTAL A + B 879265.58
C T, E, P @2% of A + B ---
Water & Electricity @2% of A

E +B ---
TOTAL A + B + C + D + E 879265.58

F A+B+C+D+E 131889.84
TOTAL Rs. 1011155.4

Rs. 1011155 /
UNIT RATE Pile

70
3.2 HYDRAULIC RIG PILING
3.2.1 Introduction
¾ Method of piling: Piling With A hydraulic Rig

¾ Pile studied: A- 1
¾ Pile diameter of piles studied: 1250 mm
¾ Founding level for piles studied: -34.00 m
Table No. 39 :- Details Of Pile Studied

Description Pile A-1
Sea – Bed level (+) 2.258m
Liner Tip Level (-) 17.442m
Total liner length 29.837m
Total Liner embedment in soil 19.70m
Total Boring Depth 32.22m
Actual Founding Level (-) 29.962m
Founding Level as per Drg. (-) 30.00m
Note: A casing of 1600mm dia. was kept at the location of
the pile at the time of construction of the rock bund.
Table No. 40 :- General Information On Hydraulic

Rig (IMT)
Working
Sr. No. Features
Capacity
1 Base
Name CAT345CL
Under Carriage 5370/3490/7
Length/Width/Shoe 50
2 Rotary
Installed Torque 260 kNm
3 Winches
Main Pull Force 240 KN
Main Winch Speed 73 m/min
Cable Dia. 28 mm
Auxiliary Winch 120 KN
Speed 80 m//min
Cable Dia. 22 mm
4 Crowd System
Kelly Crowd Push 300 KN
Kelly Crowd Pull 390 KN
5 Mast
Mast Raking Forward 5º
Mast Side Raking ±8º
Mast Raking Backward 15º
Pile Max. Dia. 2000 mm
6 Kelly Bar
Operating Wt. of Std. 70 T
Kelly Bar
Standard 4/46
Options Available 4/52 5/50

71
3.2.2 Flow Chart Of Piling With Hydraulic Rig
Survey Works
Liner Lifting, Guide Welding, Liner Joining,

Liner Pitching, Checking Plumb
Boring Liner Driving
Cleaning The Bore Hole

Changing Rock & Soil
With The Help Of Auguring Augur As Per The
Bucket
Strata
Lowering Of R/F
Cage
Lowering Of Tremie
Pipe
If Sp. Gravity > Flushing of The

1.2, Reflushing To Borehole With
Be Done Bentonite Slurry and
Air
Concrete Placing
Survey Works Cutting Of Liner To

The Required Level

72
3.2.3 Survey Works
¾ The equipments & manpower required for survey works are as mentioned in 3.1.8.1.
3.2.3.1 Methodology
¾ At the time of construction of rock bund, a 1600 dia. Casing was already kept at the pile point
location. But the pile diameter being 1250 centre point of the 1600 diameter casing was to be
identified.
¾ As it is not possible to give the centre point of the pile, two points on either side of the center point
for each pile were given.
¾ These points were marked on the 1600mm diameter casing using paint. These points help to
check the centre point of the pile.
¾ Once the pile point marking is done with help of Total station, the positioning of IMT rig is checked
to ensure that the centerline of wire rope of the IMT rig matches with the alignment of the pile.
3.2.4 Bottom Liner lifting, Guide Welding & Liner pitching

3.2.4.1 Equipments
¾ Hydraulic Rig and Welding Transformer.
¾ The Details of hydraulic rig are as mentioned in Table 40 & that of Welding Transformer is as
mentioned above.
3.2.4.2 Man Power
Table No 41 :- Labour Requirement Per Pile Point during Bottom Liner Lifting,Guide
Welding & Liner Pitching using Hydraulic Rig
1 IMT Rig Operations 1 2
2 Welding 1 2
3.2.4.3 Methodology
¾ The methodology of bottom liner lifting, Guide welding & Liner pitching is same as that mentioned
in 3.1.8.2. The use of cable of auxiliary winch of hydraulic rig in place of wire rope of the winch is
the only difference.
3.2.5 Boring including additional Liner Driving & Joining

3.2.5.1 Equipments
¾ Kelly Bar, Welding Transformer & Vacseal Pump. The details of the
same are as mentioned above in previous sections.
¾ Kelly Bars of the IMT rig carries out the boring operation with the help
of Augurs & Bucket.
¾ Welding Transformer is used for welding subsequent liners.
¾ Vacseal pump is used for bentonite mixing and pouring in the
borehole.
3.2.5.2 Man Power Rock Augur

Table No 42 :- Labour Requirement Per Pile Point
during Boring including additional Liner driving &
joining
Sr.
Type Skilled Unskilled
No.
2 Welding 1 2
3.2.5.3 Methodology
¾ Before starting the boring operation the existing bed level is measured
with the help of sounding chain.
Soil Augur

73
¾ This operation is carried out through out the boring operation so that
the various strata encountered can be recorded as well as progress of
boring can be ascertained.
¾ Boring is done with the help of Augur & bucket.
¾ There are different augurs for different strata. Rock augur is used in
the rocky strata and soil augur is used in the soil strata.
¾ Rock augur has bullet shaped diamond bids. Diamond bids are made
from Boron Carbide (BC4) a material used for cutting diamonds.
¾ The Diameter of the Augur was 1200mm.
¾ Before starting the auguring the Kelly of the rig is lowered into the
casing and centered with the help of computerized display given in the
operator’s cabin which shows the alignment of the Kelly.
¾ At first, augur was slowly lowered down in the liner unit to start boring.
Care was taken to see that the augur does not scratch the liner on its
Aligning Equipment
way inside. Of IMT Rig
¾ As soon as the augur touches the bed, the operator gives some
pressure on the bed by increasing the
¾ Kelly height slightly and starts rotating the augur and the Kelly in 2nd
gear and then after sometime in 3rd gear.
¾ Large amount of muck sticks to the augur during the cutting operation.
¾ The rotations of the augur are stopped and it is slowly brought out of
the pile by taking up the Kelly.
¾ The muck and other materials sticking to the augur are removed by
rotating the augur in 4th gear and suddenly stopping it and there by
giving jerks to the augur.
¾ As auguring continues, bentonite slurry (Density = 1.04 to1.2 -Fresh
Bentonite) is continuously poured in the borehole with the help of the
hosepipe. Liner Lifting
¾ Bentonite slurry is used because of its higher density than seawater.
As bentonite is poured, it gradually settles down in the borehole & forms an impermeable (plaster-
type) layer, which prevents the surrounding soil to collapse in the borehole.
¾ The bucket is a vertical steel cylinder closed at the top and fitted with a one way valve opening to
inside at the bottom. It has teeth at its bottom to collect the muck.
¾ It was connected to the Kelly with help of a pin & socket joint.
¾ Bucket is used to clean the borehole from the material chiseled by the augur.
¾ The bucket is also lowered in the same as the augur and rotated to collect the muck.
¾ Then it is slowly brought out side the pile bore and cleaned by opening the lower flap of the
bucket and then giving jerks to the bucket in the same way, as was case with augur cleaning.
¾ The liner goes inside the soil on its own during the operation of boring. If the liner does not go,
then it is driven with the help of front mast of the rig.
¾ Thus alternate Auguring and bucketing operation continues till the founding level of -34mts is
achieved.
¾ Simultaneously sounding is also taken at regular intervals to know the depth of the borehole. Soil
samples are also taken regularly from the soil cleaned from the augur and bucket.
¾ Further liner pieces are attached to the existing liner when the top of the liner is about 500mm
above the guide level.
¾ Before joining each piece of liner, the dimension of the top of the already fixed liner is checked for
any distortion caused due to driving operation.
¾ In case of distortion, that part of the liner is cut.
¾ The same procedure is continued upto refusal level. After this liner units are not inserted in the
borehole because the surrounding soil has enough strength to hold itself.
¾ Empty boring for not more than 3-4 mts is permitted at the site.
¾ Regular bentonite recharging is also done.
¾ The level of bentonite in the borehole is maintained in such a way that it is always above the
seabed level during the low tide and more than the sea water level during the high tide level.

74
Table No. 43 :- Soil Strata Obtained During Boring

Boring Depth (m)
Sr. No. Soil Strata (A1)
(A1)
1 -3.842 Very stiff clay
2 -10.742 Stiff clay
3 -25.102 Dense silty clay
4 -27.302 Dense silty clay
5 -29.962 Stiff silty clay with sand
3.2.6 Lifting, Joining & Lowering the Pile Reinforcement Cages

3.2.6.1 Equipments
¾ Auxiliary Winch & Welding Transformer. The details of the same are as mentioned previously.
¾ Auxiliary Winch of the IMT rig carries out the operation of Lifting & lowering the reinforcement
cages.
¾ Welding Transformer is used for welding subsequent liners.
¾ Prefabricated cages are brought to the site in trailers and unloaded with the help of cranes.
3.2.6.2 Man Power

Table No. 44 :- Labour Requirement Per Pile Point during Bottom R/F Lifting, Joining &
Lowering using Hydraulic Rig
2 Welding 3 4
3.2.6.3 Methodology
¾ The methodology is same as that mentioned in 3.1.8.4. The lifting of pile reinforcement cages is
done with the cable of auxiliary winch in place of wire rope is the only difference.
3.2.7 Lowering of Tremie & Flushing the Borehole

3.2.7.1 Equipments
¾ Auxiliary Winch of IMT rig is used for lifting and lowering of the tremie pipes. The details of the
same are as mentioned previously.
¾ Bentonite flushing is done with help of vacseal pump.
¾ Air flushing is done with help of Air compressors, the details of which are as mentioned in 3.1.8.5.
3.2.7.2 Man Power

Table No. 45 :- Labour Requirements per Pile Point during Lowering of Tremie & Flushing of
Borehole
2 Pipe fixing - 3
3.2.7.3 Methodology
¾ Diameter of tremie is 200mm & length of the pipe varies from between 1.00m to 1.24m.
¾ The tremie pipes are attached to each other with the help of male female socket joints and
lowered into the pile.
¾ Grease is applied to all the threaded joints while attaching one tremie to another to keep the joints
watertight.
¾ The tremie pipe is lowered in such a way that it is kept 300 mm above the bottom of the pile.

75
¾ Flushing is done to clean the bore shaft for concreting. Fresh slurry of Bentonite having specific
gravity of 1.04 to 1.11 is circulated inside the Borehole.
¾ After the bentonite flushing is over, Air flushing done. Air flushing is done using air compressors.
¾ Now in place of the bentonite pipe air pipe is attached and the bentonite is supplied to the bore
with the help of canvas pipe directly kept into the liner.
¾ Air flushing is done only for 10min.
¾ Air flushing is important for the removal of sand particles from the borehole. But care should be
taken as excessive air flushing may cause collapse of the sides.
Table No. 46 :- Bentonite Mix Quantity Used

Sr. No. Pile No. During Boring (Cum.) During Flushing (Cum.)
1 A-1 42 48
3.2.8 Concreting
¾ The complete concreting procedure is similar to that done in the Gantry piling but in place of wire
rope used in gantry piling, cable of auxiliary winch is used here.
Table No. 47 :- Concrete Consumption For Pile A-1

Sr. No. Pile No. Theoretical Qty. (Cum.) Actual Qty. (Cum.)
1 A-1 53 54
3.2.9 Time cycle Comparison between Piles A-14, B-14 & A-1
Table No. 48 Time Cycle Comparison Between Piles A-14, B-14 & A-1
Pile A-1
Sr. Pile A-14 Pile B-14
Activity (Hydraulic Rig
No. (Gantry Piling) (Gantry Piling)
Piling)
1 Liner Joining 7 hrs 45min 10hrs 25min 11hrs 45 min
2 Boring 120 hrs 5min 78hrs 5min 12hrs 5min
Reinforcement 6hrs 15min 7hrs 6hrs 50min
3
Cage Lowering
4 Bentonite Flushing 1 hr 10min 1 hrs 15min 1 hr
5 Concreting 2 hrs 30min 3 hrs 45min 2hrs 45min
6 Miscellaneous 16hrs 55min 10hrs 55min -
7 Idle Time 28 hrs 45min 58hrs 35min 6hrs
TOTAL 183 hrs 25 min 170 hrs 40hrs 25min
TOTAL IN DAYS 7.64 Days 7.08 Days 1.68 Days

76
3.15 Piling Sequence

77
3.16Piling Sequence

78
3.17Piling Sequence

79
3.3 PILE INTEGRITY
3.3.1 Principle
The method is based on measuring the frequency and amplitude response of a pile known
as impulse. This response, known as Mechanical Admittance (or mobility), contains all the
information necessary to check pile integrity and to analyze soil influences.
3.3.2 Scope
The scope of the method is as follows:
¾ Pile Toe Level
¾ Cracks
¾ Reductions in section
¾ Zones of poor quality concrete
3.3.3 Apparatus and Materials

¾ Hammer (Wt. varies from 400 Grams to 1.4 Kgs. Depending on the depth
of the pile).
¾ Wax or Vaseline is applied to the hammer surface and used to seal the
space between the hammer and the concrete surface
¾ Pile Integrity Tester - Collector Model – it is a compact built in data
collector with finger touch screen.
Pile Integrity Tester
3.3.4 Test Preparation
In order to obtain the very best data possible, it is essential that the pile head is prepared
properly prior to testing. Without good data any interpretation carried out is meaningless. It is
essential that the measurement transducers are mounted in the correct position and on
sound concrete. The essentials of pile head preparation for integrity testing are given below:
¾ Piles are tested at the cut-off level and trimmed to sound concrete. Any weak, broken concrete
that sounds hollow is removed and the pile top is left roughly horizontal over the complete cross
section.
¾ Two areas are prepared for the transducers, one for the hammer in the centre of the pile and the
other for the probe close to the pile perimeter. The areas are approximately 100 mm in diameter
and prepared as flat and level as possible and then brushed free of debris with a wire brush.
¾ If at first, valid results are unavailable, the area is to be re-prepared and re test is to be carried
out, as cracking in the pile head is not always apparent but can affect the test result significantly.
3.3.5 Pile Integrity Testing and Measurement

¾ The testing involves attaching an accelerometer onto
the pile top (not near its edge) with the help of
bonding material like candle wax, Vaseline etc. After
this, the pile is impacted with a hand held hammer (1
to 2% of the capacity of the pile). This generates low
stress wave into the pile. The resultant strains are of
extremely low magnitude, and the method is hence
known as Low Strain Method.
¾ The accelerations generated by the impact are
measured by the accelerometer attached on the pile
top and are converted to velocity form for display
onto the collector screen. Reflections from pile toe,
pile discontinuities, cross-sectional changes, etc.,
are graphically displayed.
¾ The test involves no. of blows during the stage of
testing. All such similar blows are averaged before display. This averaging technique tends to
cancel random signals in any particular blow.

80
3.3.6 No. of readings
¾ 6 Blows per 1 reading

¾ 5-6 Readings per pile
3.3.7 Data Interpretation

¾ Discontinuities, cross-sectional changes, material
property changes, such as between concrete and
surrounding strata etc., cause reflections at the pile
top. Such reflections are measured and checked. Thus
any defect in the pile shaft can be easily detected. By
measuring the travel time of any such reflection, the
location of defect in the pile can be located.
¾ The wave speed is determined from the response of
the pile toe. This measured wave speed by itself is an
important test result, from which the general condition
of concrete can be estimated.
Complete Graph of Pile A12
3.3.8 Test Limitations
¾ One of the most apparent limitations of this test is the depth to which the method can prove pile
continuity or assess shaft anomalies. On very long piles with a length/diameter ratio, say, in
excess of 30:1, the toe response is usually very faint.
¾ Where a toe response is not visible it is not possible to infer shaft continuity. The same applies to
shaft irregularities, in that the deeper they are the more difficult they are to detect and assess.
¾ Apparent changes in shaft section of less than 10% will generally not be detected. In the case of
multiple shaft irregularities, the test is usually only able to locate the first, although in the case of
closed, horizontal cracks near the pile top it is sometimes possible to detect continuity below the
crack.
¾ The interpretation of results relies heavily on supplementary data such as geotechnical conditions,
construction technique, pile geometry etc.
3.4 DYNAMIC PILE LOAD TEST

3.4.1 Introduction
High strain dynamic testing is used to evaluate pile capacity and is standardized as per ASTM
D4945-96.
3.4.2 Principle
Testing through Pile analyzer obtains and analyzes records of shaft force and velocity under drop
weight impacts. The field results are further analyzed with a signal matching technique (Case Pile
Wave Analysis Program-CAPWAP) to refine the soil parameter assumptions.
3.4.3 Objective
The Objectives of the test are as follows:
¾ Static capacity of the pile at the time of testing.

¾ Simulated static load test curve.
¾ Total skin friction and end bearing of the pile.
¾ Total skin friction variation along the length of the pile.
¾ Compressive and tensile stresses developed in the pile during testing.
¾ Net and total displacement of the pile.
¾ Pile integrity
3.4.4 Background
¾ The piles A-12 & B-12 showed settlement at the time of gantry shifting when the loads were
transferred onto the gantry.
¾ So it was decided to resort to pile load test.

81
¾ The aim of testing was to evaluate pile static capacity and measure settlement under this
measured load.
Table No. 49 :- General Pile Details

Sr. No. Parameter A12 B12
Pile Length Below
1 41.6 mm 41.7 mm
Gauges
2 Pile Diameter 1000mm 1000mm
3 Hammer Wt. 7.1 tons 7.1 tons
4 Drop Height 1-3mts. 1-3mts.
5 Design Load 300 300
6 Test Load 450 450
3.4.5 Pile and Test Preparation

¾ The testing is conducted by fixing strain sensors and accelerometer to the sides of the pile at a
depth of 1.5 X Pile diameter (1.5 x 1000 =1500mm) from the top and then connecting them to the
measuring equipment.
¾ The pile is extended to 1.6 times the pile diameter (1600mm) after chipping top loose concrete.
¾ The extended pile head concrete is M60 and that of the pile is M40.The 7 day strength of M60
obtained was 47N/mm2 and the required strength was 42N/ mm2.
¾ The re-bars and the helical reinforcement are also extended to avoid cracking of the concrete
under the hammer impact. The diameter of the bars is same as that of the pile reinforcement.
¾ The surface of the concrete at the sensor level should be smooth, hard and uniform.
¾ A pile top cushion consisting of Plywood is placed.
¾ A steel helmet of 25 mm Ms Plate is also placed.
¾ A hammer of 1-2% of test load or 5-7% of the dead weight of the pile (whichever is higher) is used
for testing the pile. Thus, here the hammer of 7.1 tons was used for a test load of 450 tons. The
fall of height varies from 1-3 mts.
¾ A guide consisting of ISMC 150 was also made to ensure concentric fall of the hammer.
3.4.6 Test Procedure, Monitoring & Analysis
¾ The hammer is lifted and given a free fall with the help of wire rope connected to the 7.5-ton winch
situated at the back of the gantry. The arrangement is as shown in drg. 3.18.
¾ Power source for the sensors was taken form the gantry but for the equipment, the power was
taken from the car battery.
¾ The net displacement in this method is obtained after double integration and hence it may have
errors. So the displacement is also measured with the help of a surveyor.
¾ The hammer is then again lifted and given a free fall from another height.
¾ The test is conducted at least 21 days after the pile is completed and the concrete has achieved
desired strength.
¾ Dynamic pile testing (High strain Testing) was conducted by attaching strain transducers and
accelerometers to the sides of the pile approximately 1.5 times (1500 mm) below the pile top.
¾ Pair of transducers was fixed onto the opposite sides of the pile to detect the capacity of the pile.
¾ The transducers were connected through the main cable to measuring equipment, which was a
state of Art Computer System with ability to record strain and acceleration measurements and
convert them from analog to digital form and display them on screen.
¾ The testing was done by impacting the pile with blows of hammer of wt. 7.1 tons starting with a
height of 1mt. This is test fall to check the proper functioning of the instruments.
¾ Then the hammer was allowed to fall from a height of 2, 2.5,3 and 3.5 mts.. All the heights were
marked on the guide made for the hammer with the help of a chalk so that measurements are not
required to be taken every time and the winch operator can be easily guided.
¾ For each hammer blow, the strain transducers measure strains where as the accelerations were
measured by the accelerometer. These were then converted into force and velocity respectively
by integration.

82
¾ For each hammer blow the field results were immediately displayed in the form of capacity of the
pile, pile top compression, integrity, stresses etc..
¾ The pile capacity is generally considered to be fully utilized if the energy levels due to hammer
impact are sufficient so as to cause a measurable net displacement of at least 3-4 mm per blow
for a minimum three successive impacts. If the pile set is less than 3-4 mm and the pile achieves
required capacity, then it implies that not all the static pile resistance has been utilized and that
the pile still has some capacity that was not required to be measured at the time of testing.
¾ A typical blow is then selected for Signal Matching Analysis. The program is a method that
combines measured field data with pile wave equation type procedures, to predict the pile static
bearing capacity and soil resistance distribution.
¾ Measured force and velocity data is directly input as obtained from the field measurements.
Based on the measured velocity data, the program computes the force required to induce the
imposed velocity.
¾ Both measured and computed forces are plotted as a function of time and iterative analysis is
continued till there is good agreement between both the curves.
¾ If the agreement is not satisfactory, the soil resistances at the pile point and along the pile are
adjusted until a good match is obtained.
¾ This gives a better estimate of the actual static pile capacity measured during field-testing, and
also the friction and end bearing components.
3.4.7 Test Limitations

¾ Although the method can be used to predict skin friction and end bearing along the length of the
pile, these values should be used with caution as the signal matching is an iterative procedure.
¾ Unlike static testing, evaluation of dynamic pile test results requires an experienced engineer
trained in interpretations of the results.
3.4.8 Test Results
Table No. 50 :- Summary Of Field Results

Net Total Comments
Sr. Pile Height of Pile Capacity
Settlement Settlement
No. No. Fall (m) (Tons)
(mm) (mm)
1 1 198 0.0 1.0 --
2 1.5 308 1.0 2.0 --
PILE
Used for
3 A12 2.5 332.4 0.0 2.0
Analysis
4 3 308.3 2.0 3.0 --
1 1 230.7 0.0 1.0 --
2 PILE 1.5 242 0.0 2.0 --
3 B12 2.5 235 0.0 2.0 --
4 2.5 268.1 0.0 2.0 --
Table No. 51 :- Summary of Analysis

Sr. No. Parameter A12
1 Pile Capacity 317.0 Tons
2 Skin Friction 220.4 Tons
3 End Bearing 96.6 Tons
4 Net Displacement 2 mm
5 Total Displacement 9.5 mm
6 Compressive Test 7 N/mm2
7 Tensile stress 1.8 N/mm2
8 Pile Integrity From Test Level (Sensor Level) OK

83
3.18 Dynamic Pile Load Test

84
3.4.9 Conclusion
Pile No. A12

¾ The analysis results on Pile No. A12 shows that the pile had achieved an activated capacity of
317.0 tons at the time of testing. Further testing could not be continued due to site limitations.
Note that this is not the ultimate capacity of the pile.
¾ The results showed that the maximum compressive stress experienced by the pile at the hammer
impact was about 7.0 N/mm2. This stress is within the allowable stress limits. The pile integrity
was observed to be OK.
Graph 1: Force Obtained From Sensors on Both Sides of the Pile A-12
Graph 2: Load Vs Displacement for For Pile A-12
Pile
No.
B12
¾ No meaningful interpretation was possible for Pile No. B12 as the hammer was not centered
properly onto the pile resulting in incorrect data collection. As the hammer was not centered
properly, the falls resulted in eccentric force and hence it was suggested to retest the pile.

85
3.5 PRECAST WORKS
3.5.1 Scope of the work
Providing and casting of Precast units of design mix concrete grade M:30 including vibrating,
mixing, curing, etc. complete, inclusive of providing, fixing & striping of form work.
3.5.2 Introduction
Different types of Precast members are as follows:
1) Pile muff (PM) - 2 types (PM-11 & PM-12)
2) Longitudinal beam (LB) - 7 types (LB1- LB7)
3) Pile Capping Beam (PB) - 6 types (PB1- PB6)
4) Pre-cast Deck Slab (DP) - 4 types (DP1- DP4)
Pile Muff:
¾ It is provided on the Bored cast In situ Piles.
¾ Each bored cast in situ pile has one pile muff over it.
¾ There are in all 188 pile muffs in approach jetty construction.
¾ There are 4 nos. of pre-casting beds for Pile capping beams and 1 set of shuttering.
Pile Capping Beam:
¾ It is provided on the Precast Pile Muff.
¾ Over the two pile muffs of Grid A & B rests pile capping beams PB-1 & Pb-2 and the cantilever
portions on both sides of the trestle has PB-3 & PB-4 on one side and PB-5 & PB-6 on the other.
They transfer the load from Longitudinal beams to the pile muff.
¾ There are in all 564 pile capping beams in approach jetty construction.
¾ There are 14 nos. of pre-casting beds for Pile capping beams and 5 sets of shuttering.
Longitudinal beam:
¾ It is provided on the Precast Pile Capping Beam.
¾ They rest on two pile capping beams and transfers load from slab to pile capping beam.
¾ There are in all 744 longitudinal beams in approach jetty construction.
¾ There are 13 nos. of pre-casting beds for longitudinal beams and 9 sets of shuttering.
Deck Planks:
¾ Precast Deck planks are placed over the longitudinal beams.
¾ Precast deck planks increase the speed of construction and also act as formwork for the cast in
situ deck.
¾ There are in all 2790 numbers of deck planks.
¾ There are 50 nos. of pre-casting beds for deck planks and 15 sets of shuttering.
Precast Yard:
¾ Precast members are manufactured in pre cast yard which has an over all area of around 2720
Sq.mts. (170mx16m.).
¾ The pre casting beds are made with PCC of 75mm thickness.
¾ The Goliath crane spans throughout precast yard and the rails are placed at a distance of 16mts
from each other.
Concrete Grade:
¾ M:30 grade of concrete is used for all the precast works without addition of any admixture.
¾ At site, admixture is mainly added to increase the setting time.
¾ As precast yard & Batching Plant are in same premises no admixture is required.
Slump Required – 75-90 mm

86
3.19 Precast Yard Layout

87
Table No. 52 :- M:30 Grade Mix Design Details

Material Quantity
Cement (OPC 53 Grade) 320 Kgs
Fly Ash 106 Kgs
Aggregate (20mm) 340.8 Kgs
Aggregate (10mm) 681.6 Kgs
Sand 766.8 Kgs
Water 187.44 Kgs
3.5.3 Tools, Equipments & Plants used for Precasting works

1. Batching plant:
Use : For production of Concrete as per Design Mix
Company : MACON.
Type : Star type automatic batching plant
Capacity : 30Cu.m/hr.
Batch capacity : 0.5 Cu.m
Quantity : 2 Nos.
2. Transit Mixer
Use : For Transporting concrete from the Batching Plant to the site
Company : Greaves
Capacity : 6 Cum.
Quantity : 6 Nos.
3. Goliath crane:
Capacity : 20 tones
Company : Tailor Made
Span : 16mts
Quantity : 1 No.
4. Needle vibrator:
Diameter of Needle : 60mm & 40mm
Range : 300mm Radius - for 60mm & 200mm Radius- for 40mm
Fuel : Electrically operated
Quantity : 6 – 60mm needles, 5- 40mm needles & 9 Vibrators
5. Bar cutting machine :
Use : Cutting and bending of bars
Company : Spartan
Motor capacity : 8 HP
Fuel : Electricity
Quantity : 4 Nos.
Capacity Of Bar Cutting Machine
No. of Bars It Can
1 1 2 3 5
Cut in a Single Go
Bar Diameter 36 32 25 20 16
6. Gas cutter:
Use : Cutting plates
Quantity : 2 no.
Company : Asha Pvt. Ltd.
7. Welding Machine:
Use : Welding
Company : ESAB
Model no : Arc – 400
Input : 42 amp, 415 volts, 50 Hz
Range of weld amp : 30 – 400 amps.
Quantity : 8 no.

88
3.5.4 Materials used for Precasting works
1. Reinforcement:
Diameter : 10, 20, 25, 32mm TMT bars
Source : SAIL
Cost : Rs. 24500 / MT
2. Welding rods:
Size : 3.15 x 350 mm & 4.00 x 350mm
Cost : Rs. 275/packet. (55Nos.)
Consumption : 170mm weld length/rod (4mm x 350mm)
120mm weld length/rod (3.15mm x 350mm)
Above Consumptions are for 6mm weld.
3. Binding Wire:
Binding wire : 19 gauge
Cost : Rs. 28/kg
Availability : 50 Kg rolls
Code : IS: 814
Amp : 115 – 265
Size : 4 x 450 mm
4. Oxygen cylinder:
Capacity : 50 Kg.
Consumption : 50 rmt. Cutting (approx.) / cylinder for 6mm plate
Cost : Rs.175/cylinder
5. LPG Cylinder:
Company : HP Gas
Capacity : 14 Kg.
Consumption : 250-300 rmt. Cutting (approx.) / cylinder for 6mm plate
Cost : Rs. 450
3.5.5 General Information of Construction Methodology

3.5.5.1 Pre Requisites for Reinforcement Fabrication
¾ First of all the Bar Bending schedule is prepared by the contractor & it is approved by the
Engineer in charge of client.
¾ Before starting the reinforcement cage binding, the steel bed is thoroughly cleaned and the
sticking concrete is completely removed with the help of wire brush.
¾ Simultaneously, reinforcement straightening, cutting, bending is done at pre cast yard as per
approved bar bending schedule.
¾ The reinforcement steel is cut & bent as required & is shifted to the place of fabrication manually.
¾ Care is taken that the reinforcement going to be used is rust free, & if it is not it is cleaned & made
rust free with the help of wire brush.
3.5.5.2 Post Reinforcement Checks

¾ Alignment and verticality is maintained with the help of string and plumb bob. Level is checked
with the help of level tube.
¾ Reinforcement cage is prepared as per the drawing and it is checked by the engineer-in-charge of
contractor.
¾ Checking of reinforcement by client is done only after the member is completely ready for
concreting.
¾ Checking whether the cover blocks placed are of required size and in adequate numbers.

89
3.5.5.3 Pre requisites for Formwork
¾ The shuttering plates are fabricated at site in required size & shape.
¾ Shuttering plates are made up of 3.15mm Ms steel plates & 65 x 65 x 6mm angles.
¾ Simultaneously along with the reinforcement cage fabrication, shuttering is done.
¾ The inside face of shutters which is going to be in contact with concrete is oiled properly before
erecting so as to achieve easy removal of shutters & achieve smooth surface.
3.5.5.4 Post Formwork Steps

¾ After the shuttering plates are erected and fixed with the help of nut bolts lateral bracing is
provided with the help of reinforcement bars.
¾ The gap between two shutter plates if any is sealed with putty & cement mix.
¾ After the formwork is erected its linearity, horizontality, verticality & diagonals are checked with
the help of string, level tube, plum bob & measure tape & if required the nut bolts are loosened or
tightened to get the exact line/dimension.
¾ Concreting is not carried out unless and until R/F cage & formwork is inspected by the engineer in
charge of client.
3.5.5.5 General Steps for Concreting

¾ All the materials in required quantity are stacked in storage place of batching plant.
¾ In star type batching plant there are three divisions for stacking of material. 20 mm aggregate,
sand, 10 mm aggregate are saved in their respective partition.
¾ Required quantity of cement is taken out of the storage yard and kept near the cement hopper of
the batching plant.
¾ Admixture is kept in to barrel near the batching plant and it is pumped to the mixing drum.
¾ First mixing drum of the batching plant is cleaned with the water so as to prevent absorption of
water from the cement slurry at the time of mixing.
¾ Than transit mixture is placed in position.
¾ In automatic type of batching plant mix designs are pre feed. At the time of concreting quantity of
required concrete is fed and its mix design number is fed in the batching plant.
¾ Mixing capacity at a time of batching plant is 0.5 Cu.m and mixing time is 30 seconds.
¾ Slump of each transit mixture is checked when it is loaded with desired amount of concrete.
¾ The member to be concreted is thoroughly cleaned before the concreting.
¾ Slump is also checked at the site of concreting by the Clients Engineer.
¾ Now the method of concreting depends upon the location of the casting bed. If the bed is located
at a place where free movement of the Transit mixer is possible, than concreting is done directly
with the chute of the Transit Mixer.
¾ Where the movement of the transit mixer is not possible, Concreting is done with the help of
bucket and goliath crane. Bucket of capacity 0.9 Cum. is used and the crane capacity is 20 tons.
¾ The concreting of pre cast members is generally done at night as in day time the crane is utilized
in shifting of the precast members from their respective beds to curing yard.
¾ Concrete is filled in the layers of 300mm approx. and after each layer vibrations are given by
needle vibrator.
¾ After the required amount of concreting is done, the open layer of concrete is finished with the
help of trowel.
¾ Side formwork of the pre-cast elements is opened after 24 hours.
3.5.5.6 Pre-concreting checks:

¾ Whether the reinforcement is according to bar bending schedule or not.
¾ Whether the reinforcement bars are free from rusting.
¾ Bars are free from de-shuttering oil.
¾ Proper numbers of cover blocks are provided or not.
¾ Formwork is free form dust and is properly lubricated with de-shuttering oil.
¾ Dimensions of the member are proper or not.
¾ Line, level and plumb of the member.
¾ Weather the joints and opening in the formwork are leak proof or not.

90
3.5.5.7 Checks at the time of concreting

¾ Cement consumption, water cement ratio of each batch of concrete.
¾ Slump of concrete (to check workability). Workability of each and every transit mixture is checked.
¾ Required numbers of cubes are casted in batching plant in presence of engineer.
¾ Concrete is placed from appropriate height (less than 1.5mts to prevent segregation of concrete).
¾ Weather the concrete is placed in the layers of 300 mm.
¾ Vibration to concrete is provided after every layer or not.
¾ Checking of leakages of cement slurry from shuttering joints.
3.5.5.8 Post-concreting checks

¾ Member is properly cured.
¾ Member is kept wet all the time for 10 days or not.
¾ Cubes are kept for curing in the curing pond.
¾ 9 Cubes are taken.
¾ Cubes are tested after 3, 7 & 21 days.
3.5.5.9 Curing
¾ The member is cured for 3 days on the bed itself.
¾ Curing is done by ponding method.
¾ Ponding is done by creating edges in 1:10 mortar around the top surface of the member.
¾ Within 3 days the member gains at least 50% of the strength and hence it is lifted and shifted to
the curing yard.
¾ In curing yard it is cured for 4 -7 more days and the cube strength are observed.
¾ The member is lifted from the curing yard and transported to the stacking yard after 10 days.
Table No. 53 :- Strength Requirements For Concrete

Sr. No. Activity Strength (%) Min. Days
1 Lifting Min. 50% 3 Days
2 Shifting to Stacking Yard Min. 65% 10 Days
3 Erection Min. 80% 14 Days

91
3.20 Batching Plant Layout

92
3.5.6 Construction Methodology for Precast Pile Muff
3.5.6.1 Flowchart Showing Construction Methodology of precast Pile Muff
Preparation of BBS & Getting it approved by the client Procuring Material
Binding Of The Reinforcement Cage Cleaning the shutters
Fixing of side shutter & placing Liner Piece in the Applying Shuttering Oil to Sides
Lifting & placing the reinforcement Cage in the

Formwork Checking by clients engineer
2 bars are fixed at top till casting Taking cubes
Concreting Slump Test
Making Indents on the surface which will have in situ
Stripping of form work after 12 hrs & curing
Curing By the method of ponding & Sprinkling
Lifting of the muff from casting bed after 72 hrs.

93
3.21 Numeration & R/F Details Of Pile Muff

94
3.22 Layout Of Pile Muff

95
3.5.6.2 Reinforcement
¾ First of all the pre requisite steps for reinforcement fabrication as mentioned above in 3.5.5.1 are
carried out.
¾ A temporary Stand of reinforcement bars is made to support the pile muff reinforcement.
¾ Reinforcement cage for the muff is prepared just besides its shutter to facilitate easy
transportation of the cage.
¾ Reinforcement cage is prepared on leveled ground.
¾ Refer Drg. No. 3.23-3.24 for reinforcement Sequence.
¾ Cover provided in precast pile muff is 60mm and hence the covers blocks of 60 mm are then
placed at regular intervals.
¾ The line of the reinforcement is maintained with the help of string.
¾ The post reinforcement checks as mentioned above in 3.5.5.2 are then carried out.
3.5.6.3 Formwork
¾ Now in case of Pile Muff, the formwork & reinforcement are carried out separately and then the
reinforcement cage is placed inside the formwork & hence they are simultaneous activities.
¾ First of all the Pre Requisites for Formwork as mentioned above in 3.5.5.3 are carried out.
¾ The formwork sequence for pile muff is as follows:
1. Placing of Bottom Steel Shutter.
2. Placing of Side Shutter.
3. Then the reinforcement is placed inside the formwork shutter.
4. Placing of Internal Form. (MS Liner Piece as per the required Diameter.)
¾ The Post Formwork Steps as mentioned above in 3.5.5.4 are then carried out.
Table No. 54 :- Formwork Quantity Calculations For Pile Muff (PM-11 of 1000dia.)
Sr. Remarks
Description Unit Nos. L B H/D Quantity
No.
(1.5+2.4)/2
1 Slant Face Sqm. 1 1.95 0.57 1.112
= 1.95
Sqm. 2 1.725 0.57 1.967
2 Vetrical Portion Sqm. 1 2.400 0.35 0.840
Sqm. 2 1.950 0.35 1.365
3 Plain Face Sqm. 1 1.725 0.35 0.604
Sqm. 1 2.400 0.35 0.840
1000 Dia Hole P=22/7x1.0
4 Sqm. 1 0.70 1.98
face =3.143m
Total 8.927 Sqm.

96
3.23 Reinforcement Sequence

97
3.24 Reinforcement Sequence

98
3.25 Formwork Sequence

99
3.5.6.4 Concrete
¾ First of all the pre concrete checks are done as mentioned above in 3.5.5.6.
¾ After pre concrete checks, the Pre cast supervisor sends the requisition for concrete to the
batching plant supervisor indicating the approximate quantity & location of the pour.
¾ The checks at the time of concreting as mentioned above in 3.5.5.7are done.
¾ The concreting is done as per General Steps of concreting 3.5.5.5
¾ The Post concreting checks as mentioned above in 3.5.5.8 are done.
Table No. 55 :- Concrete Quantity Calculations For Pile Muff (PM-11 of 1000dia.)
Sr.
Description Unit Nos. L B H/D Quantity
No.
Bottom upto (1.5+2.4)/2=1.95
1 Cum. 1 1.95 1.725 0.35 1.177
350mm ht.
Above 350mm
2 Cum. 1 2.4 1.95 2.016
to 700mm 0.35
Deduction 22/7 x 0.9 x 0.9/4
3 Cum. -1 0.786 0.70 -0.550
(1000mm dia.) = 0.636 Sq. m
Total 2.797 Cum.
Actual consumption = 3 Cum.
Table No. 56 :- Actual Material Consumption For Pile Muff (PM-11 of 1000dia.)
Cement Fly Aggregate Aggregate Sand Water
Material (Kg.) Ash (20mm) (10mm) (Kg.) (Kg.)
(Kg.)
Theoretical 895.04 296.48 953.22 Kg. 1906.43 Kg. 2144.74 524.27
Consumption Kg. Kg. Kg. Kg.
Actual 960 318 1022.4 Kg. 2044.8 Kg. 2300.4 562.32
3.5.6.5 Man Power Requirement

Table No 57 :- Labour Requirement For Precasting Of Pile Muff (PM-11 of 1000dia.)
1 Formwork 0.75 1.5
2 Reinforcement 1 2
3 Concreting 2 3
TOTAL 3.75 6.5
3.5.6.6 Time Cycle
Table No. 58 :- Time Cycle For Precast Pile Muff manufacturing (PM-11 of 1000dia.)
Sr.
Type Time
No.
1 Shuttering 4 Hours
2 Reinforcement 5 Hours
3 Concreting 40 Minutes
4 De Shuttering 50 Minutes
5 Curing 10 Days
Total Time Taken For Precast Pile Muff = 10.43 Days

100
3.5.7 Construction Methodology For Precast Longitudinal Beam
3.5.7.1 Flow chart of Construction Methodology of Longitudinal Beam
Placing of bottom reinforcement bars Preparing BBS and getting it

approved
Placing of vertical stirrups

Cutting the reinforcement as
per BBS
Placing of top bars
Placing of lifting hooks
Applying Shuttering Oil To Sides
Fixing of sides
Placing of Cantilever (fin) R/F
Thoroughly cleaning the

2 bars are fixed at top till casting formwork
Checking by clients engineer

Placing of sides for fin
Requisition For Concrete

Placing of lifting hooks
Taking Cubes & Checking For

Concreting
Slump
Making Indents on the surface which will

have in situ conc.
Stripping of form work after 12 hrs and

curing
Lifting from casting bed after 72 hrs.

101
3.26 Numeration Details

102
3.27 Rc Detail Of Longitudinal Beam

103
3.28 Layout Of Longitudinal Beam

104
3.5.7.2 Formwork & Reinforcement
¾ In Case of Precast Longitudinal Beam, Reinforcement cage fabrication and formwork goes on
simultaneously but not separately.
¾ First of all the pre requisites of formwork erection (as mentioned above in 3.5.5.3) and
reinforcement fabrication (as mentioned above in 3.5.5.1) are carried out simultaneously.
¾ The bottom steel shutter is placed first placed over the concrete bed prepared for it.
¾ Then the side shutter on the small cantilever side is erected and fixed with the bottom shutter with
nut & bolt assembly.
¾ Two ISA 50x50x6mm are placed at two ends of the bottom shutter.
¾ The reinforcement placing is then started.
¾ Refer Drg. No: 3.29 – 3.30 for reinforcement sequence.
¾ Before Placing of Bar Mark 7, the side shutter on other side i.e. on the longer cantilever side is
fixed.
¾ Cover provided in precast longitudinal Beam is 50mm.
¾ The reinforcement cage is lifted with the help of reinforcement rods manually and cover blocks are
inserted and the ISA 50X50X6mm sections placed at both the ends are removed.
¾ The side stoppers are fixed and hence on the completion of formwork, the post formwork checks
(as mentioned above in 3.5.5.4) are done.
¾ The post reinforcement checks (as mentioned above in 3.5.5.2) are then carried out.
Table No. 59:- Formwork Quantity Calculations For Longitudinal Beam (LB-5a)
Sr. No. Description Unit Nos. L B H/D Quantity
Side Face Longer Sq. m. 1 10 1.287 12.87
1
Cantilever Side
Side Face Shorter Sq. m. 1 10 0.940 9.4
2
Cantilever Side
Face Central Sq. m. 2 0.400 0.725 0.580
3
Portion
Face Cantilever Sq. m. 2 0.250 0.175 0.088
4
portion
Sq. m. 2 0.6 0.175 0.210
Total 23.148 Sq. m
3.5.7.3 Concrete
¾ First of all the pre concrete checks are done (as mentioned above in 3.5.5.6).
¾ The checks at the time of concreting (as mentioned above in 3.5.5.7) are done.
¾ The concreting is done as per General Steps of concreting (3.5.5.5).
¾ The concreting is done in two stages.
¾ In first stage the rectangular bottom part is concreted. Second stage concrete involves concreting
the two cantilever portion known as fins on the site.
¾ Concrete is filled in the layers of 300mm approx. and after each layer vibrations are given by 60
mm needle vibrator.
¾ The Post concreting checks ( as mentioned above in 3.5.5.8) are done.
¾ The surface of concrete which will have cast in situ concrete works is then made rough by making
indents on it. Side formwork of the pre-casted elements is opened after 24 hours.

105
3.29 RF Fabrication

106
3.30 RF Fabrication

107
3.31 Formwork

108
3.32 Over all Construction Sequence

109

110

111

112
Table No. 60 :- Concrete Quantity Calculations For Longitudinal Beam (LB-5a)

Sr.
Description Unit Nos. L B H/D Quantity Remarks
No.
Central
1 Cum. 1 10 0.4 0.725 2.9
Portion
Deduction for
2 Cum. -1 10 0.025 0.025 -0.006
Chamfer
Long
3 Cantilever Cum. 1 10 0.6 0.175 1.050
Portion
Short
4 Cantilever Cum. 1 10 0.25 0.175 0.438
Portion
Total 4.381 Cum.
Actual consumption = 4.4 Cum.

Table No. 61 :- Actual Material Consumption For Longitudinal Beam (LB-5a)
(Kg.)
Theoretical 1401.92 464.39 1493.04 Kg. 2986.09 Kg. 3351.35 821.17
Actual 1408 Kg. 466.4 1499.51 Kg. 2999.04 Kg. 3365.88 824.73
Consumption Kg. Kg. Kg.
3.5.7.4 Manpower Requirements

Table No 62 :- Labour Requirement For Longitudinal Beam (LB-5a)
1 Formwork 0.75 1.5
2 Reinforcement 1 2
3 Concreting 2 3
TOTAL 3.75 6.5
3.5.7.5 Time Cycle
Table No. 63 :- Time Cycle For Precast Longitudinal Beam (LB-5a)

Sr. No. Type Time
5 Curing 10 Days

113
3.5.8 Construction Methodology For Precast Deck Planks
3.5.8.1 Flow chart of Construction Methodology of Deck Planks
Preparation of BBS & Getting it approved by the client
Laying of PVC Sheet on the bottom steel shutter Procuring Material
Placing of Bottom Main Reinforcement Cutting of Reinforcement As per BBS
Placing of Vertical Stirrups
Placing of top main Reinforcement
Placing of lifting hooks Cleaning the shutters
Fixing of side shutter Applying Shuttering Oil to Sides
Concreting Checking by clients engineer
Making Indents on the surface which will have insitu Taking cubes
Stripping of form work after 12 hrs & curing Slump Test
Lifting from casting bed after 72 hrs.

114
3.36 Numeration & RC Details

115
3.5.8.2 Reinforcement
¾ First of all the pre requisite steps for reinforcement fabrication (as mentioned above in 3.5.5.1) are
carried out.
¾ In case of deck planks, reinforcement cages are prepared separately and then placed inside the
shutter.
¾ The reinforcement cage preparation & shuttering are hence a simultaneous activity.
¾ Reinforcement cage is prepared on leveled ground.
¾ Refer drg. No. 3.37-3.38 for reinforcement sequence.
¾ The main bottom reinforcement is first binded and then only shear reinforcement is binded.
¾ Now before placing the reinforcement cage in the shutter, cover blocks are placed at regular
intervals.
¾ Cover provided in precast deck planks is 50mm.
¾ The post reinforcement checks (as mentioned above in 3.5.5.2) are then carried out.
3.5.8.3 Formwork
¾ Now in case of Deck Planks, the formwork & reinforcement are carried out separately and then
the reinforcement cage is placed inside the formwork & hence they are simultaneous activities.
¾ First of all the Pre Requisites for Formwork (as mentioned above in 3.5.5.3) are carried out.
¾ The formwork sequence for pile muff is as follows:
1. Placing of Bottom Steel Shutter.
2. Placing of Side Shutter of two opposite sides.
3. Then the reinforcement is placed inside the formwork shutter.
4. Placing of side shutter of another two sides
¾ The Post Formwork Steps (as mentioned above in 3.5.5.4) are then carried out.
Table No. 64:- Formwork Quantity Calculations For Deck Plank (DP-1)
1 Shorter Side Face Sq. m. 2 1.45 0.15 0.435
Longer Cantilever
2 Sq. m. 2 1.725 0.15 0.5175
Side Face
Total 0.9525 Sq. m
3.5.8.4 Concreting
¾ First of all the pre concrete checks are done (as mentioned above in 3.5.5.6).
¾ Now generally a large number of deck planks are casted together or concreting of deck oplank is
combined with concreting of some other element as the concrete requirement of a single deck
plank is very less.
¾ The checks at the time of concreting (as mentioned above in 3.5.5.7) are done.
¾ The concreting is done as per General Steps of concreting (3.5.5.5).
¾ The concreting is done in a single stage without stopping.
¾ The Post concreting checks (as mentioned above in 3.5.5.8) are done.
¾ The surface of concrete which will have cast in situ concrete works is then made rough by making
indents on it. Side formwork of the pre-casted elements is opened after 12 hours or next morning.
Table No. 65 :- Concrete Quantity Calculations For Deck Plank (DP-1)

Sr.
No.
Central
1 Cum. 1 1.725 1.345 0.15 0.348 LxBxH
Portion
Total 0.348 Cum.
Actual consumption = 0.4 Cum.

116
Table No. 66 :- Actual Material Consumption For Deck Plank (DP-1)

(Kg.)
Theoretical 111.36 36.89 118.6 237.2 Kg. 266.85 65.23
Consumption Kg. Kg. Kg. Kg. Kg.
Actual 128 Kg. 42.4 136.32 Kg. 272.64 Kg. 306.72 74.98
Consumption Kg. Kg. Kg.
3.5.8.5 Man Power Requirements

Table No 64 :- Labour Requirement For For Deck Plank (DP-1)
1 Formwork 0.5 1
2 Reinforcement 1 2
3 Concreting 2 2
TOTAL 3.5 5
3.5.8.6 Time Cycle

Table No. 68 :- Time Cycle For Precast Deck Plank (DP-1)
Sr. No. Type Time
1 Shuttering 30 Minutes
5 Curing 10 Days
3.5.9 General Problems Encountered In Precast Works

¾ Smooth Finish is not achieved.
¾ Falling of slurry while concreting.
¾ Formwork Sticks to concrete.
¾ Joggle is provided on the side other than it should have been provided.
¾ Segregation of Concrete.
¾ Development of Surface cracks.
¾ While transporting and lifting, the edges break.
3.5.10 Reasons For Above Problems

¾ Slurry leaks due to improper joining of two shutters.
¾ Improper Curing (Only 7 Days) leads to development of surface cracks.
¾ Lack of supervision leads to providing of joggle on the wrong side of the member.
¾ The main reason for the breaking of edges while transportation is that wooden battens are not
placed while transporting beams.
3.5.11 Probable Solutions

¾ Wooden Battens should be placed below the beams while transporting them for proper support in
order to prevent the breaking of edges
¾ The gaps between the shutters should be avoided and if unavoidable they should be filled with U
foam or putty (cement & grease mix).
¾ Proper Supervision and adopting a method like always joggle one side of the beam can prevent
improper joggling of the beam reinforcement.
¾ Proper curing (atleast till 10-14 days) can prevent the surface cracks.

117
3.37 R/F Fabrication For deck Planks

118
3.38 R/F Fabrication For deck Planks

119
3.39 Formwork For deck Planks

120
3.6 ERECTION WORKS
3.6.1 Flowchart Showing Erection Sequence of Precast Elements
Transporting the Pre cast member from Stacking Yard to
Site
Tie the sling /Spreader Beam with the Lifting Hooks
Tie Additional ropes for controlling the movement of

precast member
Lifting Of the Precast Element Checking the Functioning of

Erection Gantry as per Checklist
Cutting the temporary support

Making temporary Supporting arrangements
members as per required sizes.
Placing the Precast member at its location
Survey Works to check the Line & level of the Precast

Element
Readjusting by making adjustments in the temporary Cutting of the welding

support
Re-welding of the temporary supports

121
3.6.2 Erection Methodology of Pile Muff
¾ Pile Muff which has been cured for atleast 14 days can be erected.
¾ So the muff which is minimum of14 days old is brought to the site of erection from the stacking
yard through trailer.
¾ A sling is then tied with the two lifting hooks of the pile muff.
¾ Two more ropes are tied to the pile muff at two opposite corners for controlling the movement of
the muff at the time of lifting of the muff.
¾ The muff is lifted with the help of EOT in the back of the Gantry which is of 15 tons capacity.
¾ Now the muff is slowly lifted and brought above the pile over which it is to be placed.
¾ Muff is slowly lowered till the bottom of the muff is approximately 50 mm above the pile.
¾ It is held in this position and then supporting brackets of ISMC 150 are welded at four places
around the pile.
¾ Then the muff is lowered and allowed to rest on the pile.
¾ Surveying is carried out to check the position of the muff and its levels are checked.
¾ For checking the position of the muff, four points are taken on the four sides of the muff 1.5mts
from the centre of the muff.
¾ The co-ordinates are then matched and the variation is then calculated.
¾ The variation has to be within the tolerance of ±75mm and if it is more then the tolerance limit
then the muff is readjusted.
¾ Now levels are taken with help of Auto level.
¾ Levels are taken at four corners of the muff.
¾ Now if any variation in the level of the muff is found then the Supporting brackets on that side of
the muff is adjusted and the levels are corrected.
NOTE: All other precast elements are erected in similar manner except in case of Pile
capping beam & Longitudinal Beams are lifted with the help of spreader beam and Erection
Gantry, and precast deck planks are erected by 75 ton capacity crane & erection Gantry.
3.6.3 Manpower Requirements

Table No. 69 :- Labour Requirement For Erection Of Pile Muff
1 Gantry/EOT/Crane Operator 1 -
2 Signal Giver - 2
3 Welders 2 4
Helpers for Erection (For Controlling
4 - 3
Member Movement, tying Sling, etc.)
TOTAL 3 9
3.6.4 Time Cycle
Table No. 70 :- Time Cycle For Erection Of Pile Muff

Sr.
Type Time
No.
1 Loading 20 Minutes
2 Transportation 30 Minutes
3 Unloading 20 Minutes
4 Placing (Erecting) 25 Minutes
5 Enabling Works for Support 1 Hour 20 Minutes
6 Survey Works 15 Minutes
7 Readjustments 40 Minutes
Total Time Taken For Precast Pile Muff = 3 Hours 50 Minutes

122
3.40 Alignment Details For Pile Muff

123
3.41 Layout at the time of erection

124
3.42 Erection Sequence

125
3.43Erection Sequence

126

127

128
3.7 CAST IN SITU WORKS
3.7.1 Introduction
Cast in situ works is divided into two parts on the basis of their order of construction:
1) Stage – 1
2) Stage – 2
Stage -1 consists of two phases.

¾ 1st phase involves casting of the junction between Pile muff and pile.
¾ 2nd Phase involves casting of the junction between two pile capping beams.
Phase-1 involves M 40 Grade concrete.

Phase-2 involves M 30 Grade Concrete.
Stage -2 consists of two phases.
¾ 1st phase involves concreting of junction over the pile capping beam between longitudinal beams
and also cast in situ slab.
¾ 2nd Phase involves concreting of Cast In situ Deck slab
¾ Both the phases of Stage -2 involves M40 Grade of Concrete
Location Cast In situ Stage -1 Works Studied: Grid 13

Location Cast In situ Stage -2 Works Studied: Between Grid 3, 4 & 5.
¾ The location of phase 1 concrete of Stage 2 is at grid 4
¾ The location of Phase 2 Cast in situ deck is between Grid 3 & 4. The area selected for concreting
was 4 mts away from the grid 3 and it extended upto 8mts. away from grid 4 towards Grid 5.
¾ Thus the construction joint was provided at L/3 mts., thereby assuring that the joint is provided at
a place where there is minimum Bending and Shear stresses.
3.7.2 Tools, Equipments & Plants used for Cast In Situ works
1. Concrete Pump
Use : For pumping the concrete into the borehole
Company : Sany
Capacity : 43 Cum.
Quantity : 2 Nos.
2. Air Compressor :
Use : For cleaning the surface to be concreted
Company : Sany
Capacity : 365 cfm
Quantity : 2 Nos.
Rest of TEP is same as that used in precast works
3.7.3 Materials used for Cast In Situ works

Materials used are same as that used in precast works

129
3.46 Numeration& Rc Details

130
3.7.4 Flowchart Showing Construction Sequence of Stage -1 Cast In Situ Works:
P Preparation of BBS by contractor & getting it approved

from the client
Procuring Materials
H
A Providing rings in the junction of Pile muff and pile Bending Reinforcement as per
the BBS
S
E Concreting the junction
1 Curing the junction and waiting for the junction to Preparing the BBS & Getting
mature Approved by Client
Sealing of the Gaps between the pile capping beams Procuring Material
with Fly ash Masonry (Lost Form)
P
H Placing of Reinforcement Cutting of Reinforcement As
per BBS
A
S
Procuring Material for
Fixing Of Formwork & checking its line level and Formwork
plumb
E
Cutting of Wooden and ply
Concreting the junction wood members in proper sizes
2
Curing by means of heissan clothes

131
3.7.4.1 Construction Methodology of Phase 1 of Stage 1 of Cast in Situ Works

Phase- 1
¾ First of all as per the approved BBS of the client, rings are bent and prepared.
¾ The rings are then tied to the pile reinforcement as per the drawings.
¾ Clients Engineers checks the rings and gives approval for the concreting of the junction between
the precast pile muff and pile.
¾ Simultaneously preparations for concreting are made and tremie pipe is fixed.
¾ Once the pile muff-pile junction is ready to receive the concrete, the supervisor sends the
requisition for concrete to the batching plant supervisor indicating the approximate quantity &
location of the pour.
¾ Now as soon as the Transit mixer arrives at the site cubes (9 in nos.) are casted and taken for
cube testing.
¾ Slump test is done in presence of the client’s engineer.
¾ Once approved then concreting is done with the help of the chute of the transit mixer (wherever
possible) or with help of pump and tremie.
¾ Needle vibrator is also used for vibrating the concrete.
¾ Then curing is done by sprinkling of water and also with heissan clothes.
In case of Phase 2 works before placing of the pile capping beams of the opposite side
reinforcement bars with bar mark 2, 3 & 4 are to be kept in position as it would not be possible to
place the bars.
Formwork
¾ Before starting the reinforcement binding, formwork is done.
¾ Formwork done is of Fly ash masonry which is lost after concreting is done and hence can be said
as lost form.
¾ The area between the two adjacent pile capping beams i.e between PB-1& PB-2 has fly ash
masonry as formwork.
¾ The Fly Ash Masonry is done in 1:4 cement mortars.
¾ After completion of the masonry, the surface is leveled by plastering the surface in Cement mortar
1:6.
Reinforcement
¾ First of all the area that is going to receive the reinforcement is thoroughly cleaned.
¾ Simultaneously the Bar Bending schedule is prepared by the contractor & it is approved by the
¾ Then reinforcement straightening, cutting, bending is done at pre cast yard as per approved bar
bending schedule.
¾ The reinforcement steel is cut & bent as required & then is shifted to the place of binding through
trucks.
¾ Reinforcement is placed as per the drawing & BBS.
contractor.
¾ Practice of binding the reinforcement with two binding wires is followed.
¾ Checking of reinforcement by client is done before concreting of a member.
¾ Cover blocks are inserted at required places at the bottom & sides of the reinforcement cage.

132
Formwork
¾ The shuttering is Prepared at site in required size & shape.
¾ The shuttering is made up of Plywood sheets and wooden battens.
¾ After the reinforcement cage fabrication, shuttering is done.
¾ After the shuttering is erected and fixed with the help of tie rods of 20mm dia.
¾ The gaps if any are sealed with U-foam.
¾ After the formwork is erected its linearity, horizontality & verticality & are checked with the help of
string, level tube & Plumb bob & if required the tie rods are loosened or tightened to get the exact
line/dimension.
charge of client.
Table No. 71 :- Formwork Quantity For Phase 2 of Stage -1 Cast in Situ Works
1 Side Face Sq. m. 2 1.5 1.7 5.1
Total 5.1 Sq. m
Concreting
¾ Pre concreting checks (as mentioned above in 3.5.5.6) are carried out first
¾ The surface to be concreted is thoroughly cleaned with the help of air compressor
¾ Concreting is done as per the general procedure of concreting ( as mentioned in 3.5.5.5)
¾ From the transit mixture, concrete is unloaded into the concrete pump. Then it is transported to
the place of the concreting through tremie pipes.
¾ Before pouring the new concrete, water is sprinkled on old concrete.
mm needle vibrator.
¾ Concrete checks at the time of concreting as mentioned above in XXX are carried out.
¾ Concreting is done in a single go to get monolithic concrete without any construction joints.
¾ After the required amount of concreting is done, the open layer of concrete is made rough with the
help of broom as it will have cast in situ stage 2 concrete over it.
¾ Cover provided to concrete is 50 mm.
¾ After the completion of concreting, the post concrete checks (as mentioned above in 3.5.5.8) are
carried out.
Table No. 72 :- Concrete Quantity For Stage -1 Cast in Situ Works

Sr.
No.
1 Phase - 1 Cum. 1 10 0.4 0.5 0.392 3.14x0.5x0.5x0.5=0.392
Phase - 2 Cum. 1 1.5 1.7 1.2 3.06
Total 3.452 Cum.
Actual consumption Phase – 1 = 0.445 Cum.
Table No. 73 :- Actual Material Consumption For Stage -1 Cast in Situ Works
Cement Fly Ash Aggregate Aggregate Sand Water
Material
(Kg.) (Kg.) (20mm) (10mm) (Kg.) (Kg.)
Phase – 1 154.415 51.62 389.22 119.15 313.52 82.41
(M:40 Grade) Kg. Kg. Kg. Kg. Kg. Kg.
Phase – 2 1045.76 346.408 1113.73 Kg. 2227.47 Kg. 2505.90 612.55
(M:30 Grade) Kg. Kg. Kg. Kg.
Total 1200.175 398.028 1502.95 Kg. 2346.62 Kg. 2819.42 694.96
Kg. Kg. Kg. Kg.
Curing is done by ponding for 14 days and method is same as in precast works.

133
3.47 R/F Fabrication Sequence

134

135

136
3.50 Formwork Sequence

137
3.7.4.3 Man Power Requirement
Table No 74 :- Labour Requirement For Stage -1 Cast in Situ Works

1 Formwork 0.75 1.5
2 Reinforcement 1 2
3 Concreting 2 4
TOTAL 3.75 7.5
3.7.4.4 Time Cycle

Table No. 75 :- Time Cycle For Stage -1 Cast in Situ Works
Sr. No. Type Time
1 Shuttering 4 Hours 30 Minutes
3 Concreting 2 Hours
5 Curing 10 Days
Total Time Taken For Stage -1 Cast in Situ
= 10.88 days
Works

138
3.7.5 Flowchart Showing Construction Sequence of Stage -2 Cast In Situ Works:
P Preparation of BBS by contractor & getting it approved Procuring Materials S

i
from the client m
H u
l
t
A Placing of the Reinforcement in the junction above the Placing the formwork between
a
n
e
S pile capping beams and between the longitudinal beams the two consecutive
longitudinal beams on the
o
u
s
E A
c
Concreting the junction t
Bending Reinforcement as per
i
the BBS
1
v
i
t
y
Curing the junction and waiting for the concrete to Preparing the BBS & Getting
mature Approved by Client
Placing of Reinforcement Procuring Material
P
H Filling the gaps between Precast Deck planks with U Cutting of Reinforcement As
S
i
foam & Sealing Large gaps with Cement Mortar per BBS m
A u
l
t
S a
n
Fixing Of Formwork & checking its line level and Concrete Requisition
E
e
plumb o
u
s
2 Concreting the cast in situ Deck Slab Arrangements for Concreting

c
t
i
v
i
t
y
Curing by means of Ponding by creating edges in

cement mortar 1:10 around the casted slab

139
3.51 RC detail Of Stage 2 Concrete

140

141

142
3.54 Area of interest

143

Formwork (Phase 1)
¾ The shuttering is a tailor made shuttering prepared in the pre fabrication yard.
¾ The shuttering is made up of 3.15 mm Ms Steel plates and ISA 65X65X6mm.
¾ Before the reinforcement cage fabrication, shuttering is done and the gaps between the
consecutive Longitudinal Beams are covered.
¾ The shuttering is then fixed in position by welding 16mm dia rods to the existing reinforcement of
the longitudinal beams.
¾ The gaps if any are sealed with U-foam.
¾ After the formwork is erected its linearity, horizontality & verticality & are checked with the help of
string, level tube & Plumb bob & if required the welded rods are loosened or tightened to get the
exact line/dimension.
¾ The sides are placed and fixed only after the reinforcement has been binded.
charge of client.
Reinforcement
¾ First of all the area that is going to receive the reinforcement is thoroughly cleaned.
¾ Simultaneously the Bar Bending schedule is prepared by the contractor & it is approved by the
¾ Simultaneously, reinforcement straightening, cutting, bending is done at pre cast yard as per
approved bar bending schedule.
¾ The reinforcement steel is cut & bent as required & then is shifted to the place of binding through
trucks and dumpers.
¾ Reinforcement is placed as per the drawing & BBS.
contractor.
¾ For reinforcement sequence refer Drg.3.55-3.57.
¾ Practice of binding the reinforcement with two binding wires is followed.
¾ Checking of reinforcement by client is done before concreting of a member.
¾ Cover blocks are tied at required places at the bottom & sides of the reinforcement cage.
Concreting
¾ Pre concrete checks are first made (as mentioned above in 3.5.5.6).
¾ Transit mixtures are covered with wet heissan clothes in order to to protect the concrete from heat
and to prevent the reduction in slump of the concrete.
¾ Slump is also checked at the site of concreting by the Clients Engineer.
¾ From the transit mixture, concrete is unloaded into the concrete pump. Then it is transported to
the place of the concreting through tremie pipes.
¾ Before pouring the new concrete, a bonding agent is applied to the old concrete surface.
¾ All the concrete surfaces which will receive Cast in Situ concrete are casted rough in order to
have proper bonding.
¾ Before concreting the area, the area is thoroughly cleaned with the help of air blowers.
mm needle vibrator.
¾ 60mm needle vibrator is used in order to get proper vibrations through out the beam. Theoretical
range of vibrations in 60 mm needle is in diameter of 300mm as compared to 200mm diameter in
40mm needle.
¾ Concreting is done in a single go to get monolithic concrete without any construction joints.

144
¾ After the required amount of concreting is done, the open layer of concrete is finished with the
help of trowel or broom.
¾ Side formwork of the casted elements is opened after 24 hours.
¾ Cover provided to concrete is 50 mm.
Table No. 76 :- Concrete Quantity For Phase-1 of Stage -2 Cast in Situ Works
Sr.
No.
1 Phase - 1 Cum. 1 16.4 1.9 0.9 28.044 L x B x H = 28.044
Total 28.044 Cum.
Table No. 77 :- Actual Material Consumption For Phase-1 of Stage -2 Cast in Situ Works
Material
(Kg.) (Kg.) (20mm) (10mm) (Kg.) (Kg.)
Phase – 1 9889.5 3306 24927.5 7630.87 20079.67 5278.2
(M:40 Grade) Kg. Kg. Kg. Kg. Kg. Kg.
Curing is done by ponding and by covering heissan clothes for about 14 days.
Man Power Requirements
Table No. 78 :- Labour Requirement For Phase 1 of Stage -2 Cast in Situ Works
1 Formwork 0.75 1.5
2 Reinforcement 2 3
3 Concreting 2 4
TOTAL 4.75 8.5
Time Cycle
Table No. 79 :- Time Cycle For Phase 1 of Stage -2 Cast in Situ Works
Sr.
Type Time
No.
4 De Shuttering 4 Hours 30 Minutes
5 Curing 10 Days
Total Time Taken For Phase 1 of Stage -2 Cast in Situ Works = 11.85 days

145
3.55 R/F Fabrication

146

147

148
3.7.5.2 Construction Methodology of Phase 2 of Stage 2 of Cast in Situ Works Formwork
¾ The methodology for formwork is same as mentioned in phase 1 of cast in situ stage 2 works.
Reinforcement
¾ The genereal steps of reinforcement as mentioned in phase 1 of cast in stage 2 works are first
followed.
¾ For reinforcement sequence refer Drg. 3.58-3.61
¾ The insert plates for the conveyor are placed.
¾ The level of the inserts is checked with the help of the Auto level.
¾ Top level of inserts is +15.00mts which is same as that of the cast in situ deck slab.
¾ The inserts are placed in line with the help of string which is tied with the help of erecting
temporary supports.
¾ The positions of temporary supports are given with the help of total station.
Concreting
¾ The procedure of concreting is same as that mentioned in phase 1 of cast in situ stage 2 works.
Table No. 80 :- Concrete Quantity For Phase-2 of Stage -2 Cast in Situ Works
Sr.
No.
1 Phase – 2 Cum. 1 12 16.4 0.28 55.14 L x B x H = 55.14
2 Deductions Cum. 1 12 7.88 0.13 12.29

Total 42.84 Cum.
Actual consumption Phase – 2 = 45 Cum.
Table No. 81 :- Actual Material Consumption For Phase-2 of Stage -2 Cast in Situ Works
Material
(Kg.) (Kg.) (20mm) (10mm) (Kg.) (Kg.)
Phase – 2 15615 Kg. 5220 39359.25 12048.75 31704.75 8334.0
(M:40 Grade) Kg. Kg. Kg. Kg. Kg.
Curing
¾ The method of Curing is also same as that mentioned in phase 2 of stage 2 cast in situ works.
Man Power Requirement
Table No 82 :- Labour Requirement For Phase-2 of Stage -2 Cast in Situ Works

1 Formwork 2 3
2 Reinforcement 2 5
3 Concreting 3 11
TOTAL 7 19
Time Cycle
Table No. 83 :- Time Cycle For Phase-2 of Stage -2 Cast in Situ Works
Sr. No. Type Time
4 De Shuttering 5 Hours
5 Curing 10 Days
Total Time Taken For Phase-2 of Stage -2 Cast in Situ Works = 13.67 days

149

150

151

152

153
3.62Concreting Sequence

154
Owning & Operating Cost

155

156

157

158

159

160
CHAPTER 4. PROJECT MANAGEMENT
4.1 MATERIAL MANAGEMENT

Material Management is the function responsible for the co-ordination of planning, sourcing,
purchasing, moving, storing and controlling materials in an optimum manner so as to provide a pre-
decided service to the customer at a minimum cost.
` Purchase
Inventory Management
MATERIAL MANAGEMENT
Stores
Execution / Commissioning
Waste Management
The major functions of material management can be stated as under:

1) Materials Planning and Control
Based on the sales forecast and production plans, the materials planning and control is done. This
involves estimating the individual requirements of parts, preparing materials budget, forecasting the
levels of inventories, scheduling the orders and monitoring the performance in relation to production
and sales.
2) Purchasing
This includes selection of sources of supply, finalization of terms of purchase, placement of
purchase orders, follow-up, maintenance of smooth relations with suppliers, approval of payments
to suppliers, evaluating and rating suppliers.
3) Stores and Inventory Control
This involves physical control of materials, preservation of stores, minimization of obsolescence and
damage through timely disposal and efficient handling, maintenance of stores records, proper
location and stocking. Stores are also responsible for the physical verification of stocks and
reconciling them with book figures. The inventory control covers aspects such as setting inventory
levels, ABC analysis, fixing economical order quantities, setting safety stock levels, lead time
analysis and reporting.
4.1.1 Purchase
¾ The basic objective of purchasing function is to ensure continuity of supply of raw materials, sub
contracted items and spare parts and at the same time reduce the ultimate cost of the finished
goods, in other words the objective is not so much to procure the materials at the lowest price but
to reduce the cost of the final product.
¾ For ensuring this, there are a large no. of well known parameters such as Right price, Right
quality, Right contractual terms, Right time, Right source, Right material, Right place, and Right
mode of transportation, Right quantity and Right attitude. All these have to be considered jointly.
¾ It also ensures that all purchased products and services conform to specified requirements of the
contract. The products may include any sub-contract work and supplies such as materials.
¾ The selection of sub-contractors, and the degree of control exercised, is dependent upon the
product type, past supplier’s performance and requirements.
4.1.1.1 Purchasing Process

The process involves the following:
1. To ensure that the product which is outsourced, e.g. raw materials, semi processed and/ or the
finished product purchased from the supplier or the services procured from the consultant,
technical know-how provider or the piece-rate workers and sub-vendors meets the requirement
of the client/ customer.

161
2. To ensure conformance of purchased product to specified requirements by supplying control
over the supplier of goods or services and the purchased product.
3. To excise the control over suppliers by means of Suppliers Evaluation.
4. To evaluate suppliers on the basis of their ability to supply product or as per requirement.
5. To establish the basis of criteria for selection, evaluation and re-evaluation.
6. To maintain the records
7. Results of evaluation
8. Actions arising from evaluation
4.1.1.2 Responsibility
Table No. 84 :- Purchase Responsibilities
Sr. No. Purchase Location Personnel Responsible
1 Site Purchases Project Manager
2 Zonal Office Purchases Chief Materials Manager
3 H.O. Purchases Director (Commercial & Purchase)
4.1.1.3 Purchasing Information

¾ Purchasing documents contain a clear description of the product or service required, including
any verification requirements for compliance with quality management systems.
¾ All purchasing documents are reviewed prior to release to the sub-contractor, checked and
maintained to provide clear, complete and specific information which is as follows:
1. To describe information e.g. technical specification and commercial terms and conditions
including quantity, price, delivery schedule(s) and tests involved for the product to be
purchased in the purchase order.
2. To describe the requirements for product, procedures, processes and equipment.
3. To describe requirements for qualification of personnel to be involved in the process.
4. To describe requirements of the Quality Management System.
4.1.1.4 Verification of purchased product
¾ When formalising a purchasing Contract with suppliers, PMC specifies, as necessary, its or the
Client’s requirements for access to the supplier’s premises for any verification arrangements and
the method of product release by adopting set procedure of quality assurance plans and
programs.
¾ The suppliers are specifically advised that this verification activity does not substitute the
supplier’s responsibility for effective quality and end use of its products or services.
4.1.2 Steps in Purchase transaction

1. The requirements of purchase of equipment/ materials are identified through:
a) Project Scope Document
b) Fortnightly reviews in the project review meeting.
c) Project Planning/ Engineering Department:
d) Indents.
In all cases the indents are regularized by the Project Manager, who also is responsible to
provide schedule and the technical inputs required for floating enquiries and finalizing the orders.
2. Floating of enquiries to approved suppliers, specifying the due date and technical requirements,
if available in the Procurement Databank, Otherwise pre-qualification of suppliers is taken up.
3. Vendor is selected from approved vendor list
4. Quotations are received from the bidders along with quality plan and procedures for supply
items.
5. After receipt of quotations from the suppliers comparative analysis statement is made on the
basis of landed cost and other specific terms and conditions offered by the bidders.
6. The offers received are sent to the PMC user department, Engineering, quality and for technical
review as required.

162
7. Price negotiation is carried out with the suppliers on the basis of prevailing market rate available
in the databank, PMC estimated rates, earlier purchase orders placed etc.
8. Quality plan and procedures for supply item is finalized by quality and sys. in co ordination with
commercial and in agreement with suppliers prior to price negotiation.
9. After negotiation, approval of the competent authority is sought.
10. Note for approval for placement of purchase order is sent along with the draft purchase order for
approval.
11. Prior to issue of the order to proposed vendor, commercial (procurement) head ensures to
receive the following from vendors.
a) Manufacturing schedule in line with approved project schedule.
b) Material/equipment inspection schedule
c) Quality Assurance Plan and Inspection test plan
d) Milestone schedule for manufacturing and supply of items.
12. After approval the purchase order is issued to the supplier.
13. For the items, for which the order has been placed recently and the supplier agrees to the same
rate, repeat order is placed.
14. The purchase order includes the following:
a) Purchase Order Number; k) Mode of supply;

b) Supplier’s Name; l) Consignee and address;
c) Supplier’s Address; m) Frequency of supplies and Lot size where
d) Item name; relevant;
e) Item description, part number/drawing n) Delivery schedule;
number where relevant; o) Prices, duties, taxes;
f) Relevant item code if p) Specific instructions on handling, packaging
standardized/specified by company; and delivery;
g) Dimensional Specifications; q) General terms and conditions including
h) Physical and/or Chemical payment terms, warranty, liquidated
characteristics where relevant; damages, force majeure, guarantees;
i) Quantity to be ordered; r) Any other provisions relevant to the supply.
j) Unit and total price;
15. The Purchase Order is reviewed for its adequacy and correctness before issue.
16. Copies of Purchase order are distributed to Supplier, Stores, Q & S, Finance, Contract
Administration, and one copy is retained with Purchase Department.
17. Commercial deptt. prepares cash flow plan for one month and forecast for two month for supply
items on monthly basis and provides it to F & A for compilation of project fund.
18. Amendments are generally issued for any of the following reasons:
a. Quantity variation (Increase / Decrease);
b. Rate variation;
c. Terms and conditions variation;
d. Specification variation.
19. Follow up for the supply of materials till received and accepted at store.
20. Coordination for necessary measure in case of any discrepancies in materials received at
stores. Purchase deptt. ensures for clearance and acceptance of materials.
21. Preparation of GRN is jointly done by the Stores and Construction Manager and forwarding the
GRN along with the invoice and other documents to Commercial Manager.
22. Development of suppliers and maintaining databank.
23. It is ensured that the suppliers’ are periodically evaluated every six months on the basis of
quality, timely delivery and cost for the supplies made in the period.
24. Monthly Review Meeting is conducted by procurement department at HO for all major
procurement items to monitor the progress of manufacturing item as follows:
a) For short term (up to one month) items, normally no review are conducted accept delay or
problem is encountered.
b) For long term delivery items, a monthly review meeting is conducted at Head office, A’bad .
c) For imported long lead items, monthly progress review meeting is held with the Indian
representative of the supplier and in the alternate month the principal supplier is called for
progress review.

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4.1.3 Material Storage & Handling

¾ The received material is registered in the Stock Record Register.
¾ The store department has to store the materials on racks under cover keeping in mind the
manufactures specifications also. The recommended code for this is IS: 4082 "Recommendations
on stacking and storage of construction materials on site" and IS: 7969 "Safety code for handling
and storage of building materials".
¾ The materials are stacked in specified areas with the old stock shifted ahead and new at the back.
¾ The stock, which is not tested, is kept separately with identification.
¾ Stock Statement i.e. daily stock verification report is made stating the quantum of materials in the
beginning & at the end of the day.
¾ Reconciliation of Stock Statement is done on monthly basis.
¾ Periodical Verification of P&M & Tools & Tackles is done.
¾ Issues of delivery challans is also done on arrival of materials.
¾ Safety & Security of all the materials in stock is looked after by the stores department itself.
¾ Review of Insurance Coverage is also done.
¾ The quality of the each supplied lot is checked first and than stored. If the material is found not to
be matching the required specifications, the whole lot is liable for rejection.
¾ The received material is than stored in the appropriate place.
4.1.4 Material reconciliation

¾ Material reconciliation is the process of checking the proper usage of the materials issued for
work. The theoretical material consumption is compared with the actual usage of the materials,
bearing permissible percentage of wastage in handling.
¾ The payment is done for the free/chargeable materials considering the reconciliation.
¾ If the wastage of material exceeded the permissible value, the extra cost is to be borne by the
Contractor.
¾ As Cement, Steel & Fly-ash are provided by the Client as “Free Issue”, material reconciliation of
these materials is done on regular basis. This also forms the base for the clearance & payment of
the RA bill.
A. Cement
¾ Cement is freely issued directly to the contractor at site; the contractor submits reconciliation
statement for cement actually consumed v/s the theoretical consumption. The contractor submits
such reconciliation statement with their running bills or monthly basis whichever is earlier.
B Steel reinforcement/Structural steel

¾ Contractor submits the reconciliation statement as per prescribed format as actual consumption
v/s theoretical consumption at the frequency of three months.
¾ Construction manager and store in charge jointly carries out the physical verification of stock and
reconciliation of material. Allowable wastage and rolling margin are given due consideration
during material reconciliation.
4.2 PROJECT MANAGEMENT INFORMATION SYSTEM (PMIS)

4.2.1 Progress reports
4.2.1.1 Daily Progress report
This report, which is made daily, has all minor progress details of the approach works,
Precast works, erection works & cast in situ works. This report is made by the contractor &
is send to the client the very next day for signing and for client’s record. No daily reports are
made at the site from client’s side. Refer Fomat-1
4.2.1.2 Weekly reports
A weekly progress report is send to the HO from the site office on every Monday. Majorly
weekly progress report contains details of planned works for that week Vis-a Vis achieved
progress in each activity. Contractor also makes a weekly report in more or less similar
format and sends it to client for his records. Refer Format-2

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4.2.1.3 Material procurement, consumption and issue reports
¾ Requirement of material is as given by the Sr. Site engineer on different parts of the project. The
Planning engineer checks this demand with the help of the previous consumption reports (pour
card, bbs, etc.) and also with the target chart to deal with the quantities required for that particular
stretch of time.
¾ After the approval from the Planning engineer, a list of the required materials / machinery /
consumables is made by the store-incharge in a requisition format and is then passed on to the
Project Manager for the final approval.
¾ After the requisition is signed by the PM, the whole purchase procedure is followed.
¾ A material stock Status is generated daily & its summary is sent along with monthly report. Refer
Format-3
4.2.1.4 Wastage reports
¾ As such there is no wastage report separately prepared on the site.
¾ Wastage is calculated as a part of the reconciliation statement
¾ A check is kept on the consumption of the materials so as avoid the misuse of the product. It is
generally found that for materials like cement 5% wastage is considered casual. If it exceeds
beyond this limit, then re-checking is carried out at the godown or calibration of the batching plant
is checked. For steel 2% wastage is considered within limits.
4.2.1.5 Monthly reports
The report is submitted to the HO in the very first week of the month. Following are the
contents of this report:
¾ Important activities carried out in the previous¾ Drawing status statement
month ¾ Plants and equipments deployed in and upto
¾ Shortfalls for the project completion previous month
¾ Site progress report ¾ Manpower at site
¾ Target for the coming month ¾ Photographs of important events
¾ Material procurement statement
4.3 QUALITY MANAGEMENT SYSTEM

4.3.1 Quality Policy (Policy Statement)
¾ PMC-PIPL is committed to deliver zero defect products and services of highest level of quality
within the time schedules at the lowest cost to our Customers including providing safe work
environments.
¾ PMC is committed to the continuous improvement in quality of products and services including the
development of employees at all levels.
4.3.2 Project Quality Management System (PQMS) Planning

¾ Planning activities ensure that adequate resources are available to achieve quality and safety
management objective.
¾ Planning ensures that change is conducted in a controlled manner and that the Integrity of the
Project Management System is maintained during this change.
4.3.3 Quality Objectives

¾ PMC has established Quality Objectives and levels of assurance that are measurable and
consistent with Organisation policy. Quality and safety objectives are defined within the respective
policies and operations procedures forming part of this Project Quality Management System.
Quality Objectives are as follows:

¾ 100% compliance with applicable safety ¾ 0% re-work
and environmental standards. ¾ 100% delivery on time
¾ 100% conformance to customer ¾ 100% completion within budget
specification and expectations.

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4.3.4 Quality Assurance Plan
a. The objective of the QAP is to establish a procedure to plan, monitor and achieve Quality
Management System planning in order to fulfill customer requirements, statutory
requirements and organization objectives based on contractual requirement.
b. There are two types of Quality Assurance Plans.
1) Field Quality Assurance Plans
2) Quality Assurance Plans for Incoming Materials
4.3.5 Quality Monitoring Procedure

4.3.5.1 Management Review (General)
Top management is responsible for reviewing all aspects of the PMC Project Quality
Management System.
¾ The purpose of review is to ensure that the Project Quality Management System is suitable and
effective in satisfying the requirements of the PMC quality environmental and Safety objectives.
¾ Management review meetings are held once in three months. Each process is reviewed in MIS
reports.
4.3.5.2 Management Review At Site

¾ Review Inputs: Results of audits including safety, customer feedback , process performance and
product conformance , status of preventive and corrective action includes Safety, follow-up
actions from earlier management reviews, recommendations for improvement includes Safety,
changes that could effect the Project Quality Management System
¾ Review Outputs: Improvement of QMS, Improvement of process, Resource requirement,
Improvement of Product Quality, Improving Customer satisfaction, Best practices for
implementation.
4.3.5.3 Product Monitoring & Measurement of Processes

¾ To establish, implement and maintain the procedure for monitoring & measurement of the quality
Management system processes to achieve the planned results of the product & to verify that the
requirements have been met as per contract.
4.3.6 Quality Evaluation System

Quality Evaluation system mainly includes
4.3.6.1 Internal Audits
¾ Project quality manager prepares the schedule of internal quality audit for each month for various
projects and conducts quality audits during the project construction. The schedule of internal
quality audit is intimated to each auditee well in advance with copy to project leader. Construction
manager is also an auditee for the audit. The scope of audit is contract documents/PO/QAP and
quality procedures / documentation / construction work at sites etc. as applicable.
¾ Internal Quality audit report is issued to auditees with copy to project manager and project leader.
¾ Issue of Non Conformance Report (NCR) is done for non compliance of products and activities in
concurrence with auditees and the record of the same is maintained. Each NCR also has
stipulated time period to liquidate the same.
¾ Construction manager is responsible for closing of NCR.
¾ Project QC manager does tracking of NCR, follow up and verification for closure of NCR for
relevant projects and MR also has to do the same for Project Quality management system
(PQMS) audits.
¾ Management Representative (MR) conducts the system audit of each department as per
schedule of system audit. Audit report is issued to each department head and copy to CEO.
¾ In case of non compliance to system, MR issues the NCR to department head.
¾ Department head is responsible for closing of NCR.
¾ MR has to keep tracking of NCR, follow up and verification for closure of NCR.
¾ MR also has to co-ordinates for the Management Review Meeting (MRM) at defined interval to
review the PQMS.

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4.3.6.2 Customer Satisfaction
¾ To establish and maintain a system to understand customer perception and meet Customer
requirements & measure Customer satisfaction.
¾ It is done quarterly.
¾ Customer complaints are noted & performance is improved on area of dissatisfaction by
discussing the root causes & replying with action plan & target dates.
4.4 BILLING
4.4.1 Method of Measurement
The method of measurement will be as per IS: 1200 unless otherwise specified.
4.4.2 R.A Bills

¾ R A bills are the interim bills that are made by the contractor at the end of each month. The bill Is
produced every month.
¾ By these bills, the contractors are able to claim the payment of the work they did in the whole
month. After receiving the payment, the contractor pays to the sub-contractors working under
them & also makes orders for the materials required.
¾ Each RA bill has a specific format with a specific number assigned to it, Work order Reference
no., and date of giving it to the client for later reference.
¾ Each RA bill was made in 3 hard copies (one for the client & one for own record & one for
reference).
¾ Within 15 days of receipt of the said bill for the interim payment, it was approved/ amended such
that, in engineer’s opinion, the certificate reflects the amount due to the contractor in accordance
with the contract. In case of difference of opinions as to the value of any item, engineer’s view
prevailed.
¾ The RA bill consist of the following:
1. Estimated contract value of permanent works executed since the submission of last bill,
obtained by applying the base unit rates & prices in the BOQ measured by the engineer.
2. Estimated contract value of permanent works as obtained above executed upon the previous
bill.
3. The cumulative estimated contract value at base unit rates & prices of permanent works upto
the bill in question.
4. The cumulative amount approved in respect of extra items executed up to the bill in question,
obtained by applying the rates approved.
5. An amount reflecting any changes in cost.
6. Any amount to be withheld under the retention provisions (@5% of net bill amount after
discount).
7. Any credit/debit for period in question in respect of materials on site intended for, but not yet
incorporated in, permanent works in the amount.
8. Any amount to be deducted on account of mobilization advances under contract.
9. Deductions of IT- as per the IT act
10. Any amount to be deducted on account of electricity, water or machinery supplied to the
contractor.
11. Reimbursement for difference in rate for steel, cement & flyash as in contract & as procured.
12. Net payable amount of bill for the present month after all additions & deductions.
13. Annexure containing the BOQ of the work executed, Material reconciliation statement, Bill
abstract & Monthly Progress Report (MPR).
4.4.3 Recovery of Cement & Steel

¾ Since cement, Structural steel & Reinforcement steel is provided as free issue by the client, there
is no such recovery applicable.
¾ But penalty is levied if the consumption of cement is less than 97% of theoretical requirement.
Moreover, the wastage should not exceed the permissible limit, if so; the charges are deducted
from the contractor’s bill.

167
¾ This is checked through the reconciliation report of free- issued materials, in which the actual
consumption of material is checked in comparison with the theoretical consumption considering
the wastage.
¾ Replacement of steel reinforcement is provided. (On return of cut pieces larger than 2m length,
same tonnage of full length steel reinforcement is provided back to the contractor).
4.5 SAFETY PROVISIONS

On award of the work & before commencement of work, Simplex Infrastructures (India)
Limited (hereinafter referred as SIL) submitted the health and safety policy
It is the policy of the company to ensure that all reasonable and practicable measures will be
taken to ensure the safety and welfare of all of its employees and all other persons who may
adversely affected by the company activities.
4.5.1 Basic steps

4.5.1.1 Supervision
SIL provides adequate suitably trained, competent, and experienced management and supervision to
ensure safety at site.
4.5.1.2 Reporting of all Fatal and Major Injuries and Dangerous Occurrences
All Fatal, major & minor injuries and dangerous occurrences if any, are to be reported to the SIL
Safety Manager immediately and all other injuries to medical centre/First aid room for recording.
4.5.1.3 Monthly Safety Meeting

Monthly Safety Meeting are attended by the Project Manager, all frontline Engineers, supervisors
and Safety Manager/Officer and representative of labour contractor & all actions discussed &
identified are to be complied within the prescribed time limit.
4.5.1.4 Health and Safety Training

SIL ensures adequate training for all employees and workers to ensure execution of work in safe
manner and also meet all statutory obligations.
4.5.1.5 Induction
All employees including labours and anybody who is associated with the work are given suitable and
sufficient induction training, before the concerned person commences work at site, under following
circumstances:-
¾ Change of responsibility ¾ Introduction of new labour
¾ Introduction of new working equipment ¾ Induction training is given by safety officer of
¾ Introduction of new system of work/technology SIL.
4.5.1.6 Tool Box Talks

Front Line engineers and Supervisors of SIL collect workers and brief them for 5 minutes 'tool
box talks' each day on different topics and keep a record of such talks.
The Other basic Steps include:
¾ Notification of Manpower Deployed ¾ Electrification
¾ Provision of Personal Protective Equipment ¾ Dress of Working
¾ Adequate Lighting arrangement ¾ Emergency plans
4.5.2 Site Safety Plan

4.5.2.1 Hazards/risks involved with the activities envisaged
¾ Confined spaces ¾ Hazards involved during precast member

¾ Work over or adjacent to water shifting from yard to jetty.
¾ Work at night ¾ Fire from LPG/acetylene and oxygen
¾ Fall from height. cylinders
¾ Truck Movement during reclamation works. ¾ Fire
¾ Discipline of drivers & traffic hazard ¾ Demolitions/Dismantling
¾ Hazards during erection of precast slab & ¾ Faulty Cranes and lifting appliances
precast beams. ¾ Rotating part of the Machinery not guarded.

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¾ Lack of House keeping ¾ Specific precautions and control measure
¾ Electrical hazard in temporary electrification needed to reduce accidents.
¾ Hazards involved in welding and gas cutting
4.5.2.2 Steps taken for construction tasks

¾ Life Jackets are provided on gantry in ¾ In case of emergency, an emergency
adequate amount. They are to be vehicle is always on the stand by mode,
compulsorily worn by the workers when the victim is immediately taken to nearby
they work below gantry. hospital at the Birla Copper for primary
¾ Helmets are compulsory to all the treatment.
personal at the site. ¾ Proper railing of Steel Pipe is provided
¾ Helmets, gloves, Dark glasses, Safety throughout the sides of gantry.
Harness are provided depending on the ¾ Twin-Engine boat is kept in stand-by position in
variety of work. case of emergency.
¾ No one is allowed to go above 2m of ¾ Buoy with proper lighting were provided at a
height without wearing Safety harness. safer distance from the jetty under-construction
Safety harness is also compulsory for in order to guide barges.
working below the gantry. ¾ A safety meeting is held every morning on each
¾ First-Aid box is provided over the Gantry, gantry by the Safety Engineer himself.
at Simplex office on Jetty as well as at ¾ Safety Stewards are kept on duty on gantry for
the site office of the Simplex. all the shifts.
¾ Divers are always available on the gantry.
4.5.2.3 Steps taken For Tasks Related to Construction

¾ All the vehicles should have a reverse horn which is having adequate level of sound.
¾ Each vehicle should have a helper, who guides the driver during reversing of the vehicle or
other such related tasks.
¾ All vehicles are to be checked weekly for their brakes, lights, horns, oils, etc.
¾ All the electrical items are checked for their earthing, etc. ELCB’s are attached to all the
electrical items.
¾ All the oxygen, DA, LPG cylinders & Diesel drums are stored is a safe closed shed having
signboards of “No Smoking”.
¾ Membership of Disaster management cell has also been taken. Disaster Management cell
is already existing at Dahej which was formed By companies like Birla Copper, IPCL,
BASF, Petronet LNG , GCPTCL, Welspun Gujarat and other near by companies.

169
ANNEXURE
FORMAT-1
Ref. No. Format No. FPJ/16/05
Material Stock Status Rev. No. : Date :
Date
Pages :
Project User
Project Code Contractor
Location Consultant / TPIA
As on
Sr. Opening Today’s Total Today’s Total
Material Unit Closing Stock
No. Stock receipt receipt consumption consumption
Flow of format : Store Incharge commercial (purchase) copy to Project manager and
project coordinator (Monthly basis)
Prepared by Reviewed by Approved by
Sign Sign Sign
FORMAT-2
Weekly Progress Report Rev. No. : Date :
Date Pages :
Project User
Cumulative
Description Achieved planned Achieved
Sr. Unit of Total achievement
of till last for this this
No. Measurement Scope till this
Activities week week week
week
Constraints :
Reason for variance (if any) :
Major even (if any) :
Major equipment deployed :
No. of workmen engaged :
A. Skilled
B. Unskilled
Major Material receipt (if any) :
Flow of format : Project manager Project coordinator copy to project leader and
project control (weekly basis)
Sign Sign Sign

170
FORMAT - 3

Daily Progress Report Rev. No. : Date :
Date
Pages :
Project User
Cumulative
Sr. Total Achieved till Planned Achieve
Activities UOM Achievement
No. Scope Yesterday for today d to day
till date
Constraints :
Reason for variance (if any) :
Major even (if any):
Major equipment :
No. of workmen:
A. Skilled
B. Unskilled
Flow of format : Construction manager project coordinator copy to project
manager (Freq: Daily)
Sign Sign Sign

171
CHAPTER 5. CONCLUSION
Technically what I have gained in these 18 weeks has made me understand all my basic
theories, which I have learnt in the past three and a half years of my college, on stronger
basis. Moreover theses 18 weeks have also made me stronger and more confident not only
academic wise but also in other aspects of life.
I was extremely glad to be a part of SBST, as and when I could see myself proving better on
technical aspects compared to the trainee colleagues from other colleges.
I am glad to say that I have had an opportunity to be amongst those few lucky ones to
witness as well as work on such specialized construction technology. In addition to this, I
could also study important activities such as Piling and precasting. I have definitely realized
how difficult it is to maintain line and level on site; compared to it being so easily written in
‘checks’ on paper. Precast elements are the ‘in’ technology of the present era. I had been
involved in making job completion reports, presentation, planning & designing. To work like
an employee with people of great caliber around u to guide you in your project is an
extremely great fortune. I will never forget this utmost respect given to me by all my
colleagues.
Apart from the project, all the people at site and at the office had been overwhelmingly co-
operative and kind. In these 18 weeks, I have known what it takes to be an engineer; the
amount of devotion and commitment one needs to give.

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Table of Contents
CHAPTER – 1 INTRODUCTION
1.1 BACKGROUND OF THE PROJECT................................................................................. 1
1.2 THE PROJECT ............................................................................................................... 1
1.3 OBJECTIVES OF THE PROJECT .................................................................................... 2
1.4 NEED OF THE PROJECT ............................................................................................... 2
1.5 PROJECT BREAKDOWN STRUCTURE: ......................................................................... 3
1.6 GENERAL PROJECT INFORMATION: ............................................................................ 3
1.7 LOCATION OF THE PROJECT: ...................................................................................... 5
1.8 CLIMATIC CONDITIONS & SEISMIC ZONE ..................................................................... 6
1.8.1 Wind ............................................................................................................................. 6
1.8.2 Rainfall .......................................................................................................................... 6
1.8.3 Temperature ................................................................................................................. 6
1.8.4 Waves ........................................................................................................................... 6
1.8.5 Tides ............................................................................................................................. 7
1.8.6 Currents ........................................................................................................................ 7
1.8.7 Morphology ................................................................................................................... 7
1.8.8 Seismic Zone ................................................................................................................ 7
1.9 DESIGN CONSIDERATIONS ........................................................................................... 7
1.9.1 Design Criteria for Approach & Main Jetty ..................................................................... 8
1.9.2 Design load: ...................................................................................................................... 8
1.10 COST BREAKDOWN STRUCTURE ................................................................................ 9
1.10.1 Cost Breakdown Structure for Project .......................................................................... 9
1.10.2 Cost Breakdown Structure for Approach Jetty............................................................. 9
CHAPTER - 2 CONSTRUCTION METHODOLOGY
2.1 WORK BREAKDOWN STRUCTURE ............................................................................. 10
2.2 ORGANIZATION CHART OF PMC AT SITE ................................................................... 11
2.3 CONSTRUCTION SCHEDULE ...................................................................................... 15
2.4 ACTIVITY WISE WORK BREAKDOWN ............................... Error! Bookmark not defined.
2.5 WORK METHODOLOGY .............................................................................................. 18
2.5.1 Construction Methodology .......................................................................................... 18
2.5.2 Justification of Methodology Used............................................................................... 18
2.6 STATUS OF SITE ......................................................................................................... 19
2.7 PLANTS & MACHINERY ............................................................................................... 20
2.8 Material Details ............................................................................................................ 21
2.9 SPECIFICATIONS ........................................................................................................ 21
2.9.1 Cement ....................................................................................................................... 21
2.9.2 Aggregates ................................................................................................................. 22
2.9.3 Water .......................................................................................................................... 22
2.9.4 Reinforcement steel .................................................................................................... 22
2.9.5 Structural steel ............................................................................................................ 22
2.9.6 Specifications For Concrete ........................................................................................ 23
2.9.7 Precast Concrete ........................................................................................................ 23
2.9.8 Specifications For Formwork ....................................................................................... 23
CHAPTER - 3 CONSTRUCTION ACTIVITIES
3.1 PILE FOUNDATION USING PILING GANTRY ................................................................ 24
3.1.1 Scope.......................................................................................................................... 24
3.1.2 Specification ............................................................................................................... 24
3.1.3 Standard of acceptance for piles ................................................................................. 24
3.1.4 General Information .................................................................................................... 25
3.1.5 Flowchart for Gantry Piling .......................................................................................... 27
3.1.6 Liner fabrication .......................................................................................................... 30
3.1.7 Reinforcement Cage Fabrication................................................................................. 37
3.1.8 Construction Methodology For Piling .......................................................................... 44
3.2 HYDRAULIC RIG PILING .......................................................................................... 71
3.2.1 Introduction ...................................................................................................... 71
3.2.2 Flow Chart Of Piling With Hydraulic Rig .......................................................... 72
3.2.3 Survey Works .................................................................................................. 73

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3.2.4 Bottom Liner lifting, Guide Welding & Liner pitching ....................................... 73
3.2.5 Boring including additional Liner Driving & Joining ......................................... 73
3.2.6 Lifting, Joining & Lowering the Pile Reinforcement Cages .............................. 75
3.2.7 Lowering of Tremie & Flushing the Borehole .................................................. 75
3.2.8 Concreting ....................................................................................................... 76
3.2.9 Time cycle Comparison between Piles A-14, B-14 & A-1 ............................... 76
3.3 PILE INTEGRITY........................................................................................................ 80
3.3.1 Principle ........................................................................................................... 80
3.3.2 Scope .............................................................................................................. 80
3.3.3 Apparatus and Materials ................................................................................. 80
3.3.4 Test Preparation .............................................................................................. 80
3.3.5 Pile Integrity Testing and Measurement .......................................................... 80
3.3.6 No. of readings ................................................................................................ 81
3.3.7 Data Interpretation ........................................................................................... 81
3.3.8 Test Limitations ............................................................................................... 81
3.4 DYNAMIC PILE LOAD TEST..................................................................................... 81
3.4.1 Introduction ...................................................................................................... 81
3.4.2 Principle ........................................................................................................... 81
3.4.3 Objective ......................................................................................................... 81
3.4.4 Background ..................................................................................................... 81
3.4.5 Pile and Test Preparation ................................................................................ 82
3.4.6 Test Procedure, Monitoring & Analysis ........................................................... 82
3.4.7 Test Limitations ............................................................................................... 83
3.4.8 Test Results .................................................................................................... 83
3.4.9 Conclusion ....................................................................................................... 85
3.5 Pre Cast Works ......................................................................................................... 86
3.5.1 Scope of the work ............................................................................................ 86
3.5.2 Introduction ...................................................................................................... 86
3.5.3 Tools, Equipments & Plants used for Precasting works .................................. 88
3.5.4 Materials used for Precasting works ............................................................... 89
3.5.5 General Information of Construction Methodology .......................................... 89
3.5.6 Construction Methodology for Precast Pile Muff ............................................. 93
3.5.7 Construction Methodology For Precast Longitudinal Beam .......................... 101
3.5.8 Construction Methodology For Precast Deck Planks .................................... 114
3.5.9 General Problems Encountered In Precast Works ........................................ 117
3.5.10 Reasons For Above Problems ...................................................................... 117
3.5.11 Probable Solutions ........................................................................................ 117
3.6 Erection Works ....................................................................................................... 121
3.6.1 Flowchart Showing Erection Sequence of Precast Elements ....................... 121
3.6.2 Erection Methodology of Pile Muff ................................................................. 122
3.6.3 Manpower Requirements .............................................................................. 122
3.6.4 Time Cycle .................................................................................................... 122
3.7 CAST IN SITU WORKS ........................................................................................... 129
3.7.1 Introduction .................................................................................................... 129
3.7.2 Tools, Equipments & Plants used for Cast In Situ works .............................. 129
3.7.3 Materials used for Cast In Situ works ............................................................ 129
3.7.4 Flowchart Showing Construction Sequence of Stage -1 Cast In Situ Works: 131
3.7.5 Flowchart Showing Construction Sequence of Stage -2 Cast In Situ Works: 139
Owning & Operating Cost Tools, Equipments & Plants……………….………………………155
CHAPTER -4 PROJECT MANAGEMENT
4.1 MATERIAL MANAGEMENT .................................................................................... 161
4.1.1 Purchase ....................................................................................................... 161
4.1.2 Steps in Purchase transaction ....................................................................... 162
4.1.3 Material Storage & Handling ......................................................................... 164
4.1.4 Material reconciliation .................................................................................... 164
4.2 PROJECT MANAGEMENT INFORMATION SYSTEM (PMIS) ............................... 164

174
4.2.1 Progress reports ............................................................................................ 164
4.3 QUALITY MANAGEMENT SYSTEM ....................................................................... 165
4.3.1 Quality Policy (Policy Statement) .................................................................. 165
4.3.2 Project Quality Management System (PQMS) Planning ............................... 165
4.3.3 Quality Objectives ......................................................................................... 165
4.3.4 Quality Assurance Plan ................................................................................. 166
4.3.5 Quality Monitoring Procedure ........................................................................ 166
4.3.6 Quality Evaluation System ............................................................................ 166
4.4 BILLING ................................................................................................................... 167
4.4.1 Method of Measurement ............................................................................... 167
4.4.2 R.A Bills ......................................................................................................... 167
4.4.3 Recovery of Cement & Steel ......................................................................... 167
4.5 SAFETY PROVISIONS ............................................................................................ 168
4.5.1 Basic steps .................................................................................................... 168
4.5.2 Site Safety Plan ............................................................................................. 168
Annexure…………………………………………………………..……………………….……….171
CHAPTER – 5 CONCLUSION
LIST OF DRAWINGS
LIST OF DRAWINGS
1.01 Layout Plan of The Project 4
2.01 General Arrangement Drawing Part‐1 12
2.02 General Arrangement Drawing Part‐2 13
2.03 Job Layout 14
2.04 Construction Sequence 17
3.01 Layout Of Piles 26
3.02 Plan & Sections Of Gantry 28
3.03 General Job Layout Of Gantry 29
3.04 Plate Bending Machine & Its working 33
3.05 Details OF Pile Reinforcement Cage 39
3.06 Pile Reinforcement Cage Fabrication Sequence & BBS 42
3.07 Job Layout Of gantry Before Liner Pitching 45
3.08 Job Layout Of gantry Before R/F Lowering 51
3.09 Job Layout at the Time Of Bentonite Flushing & Concreting 56
3.10a Piling Sequence ( Part‐1) 57
3.10b Piling Sequence (Part‐2) 58
3.10c Piling Sequence (Part‐3) 59
3.11 General Equipments used in Piling 60
3.12 Retails of Rolling Bracing 62
3.13 Gantry Movement Details 64
3.14 Hydraulic Rig Piling Sequence (Part‐1) 77
3.17 Set Up Details of Dynamic Pile Load Test 84
3.18 Precast Yard Layout 87
3.19 Batching Plant Layout 92
3.20 Numeration & R/F details of Pile Muff 94
3.21 Layout Of Pile Muff 95

175
3.22 Reinforcement Binding Sequence for Precast Pile Muff(Part‐1) 97
3.23 Reinforcement Binding Sequence for Precast pile Muff (Part‐2) 98
3.24 Formwork Fixing Sequence & Formwork Details for Precast Pile Muff 99
3.25 Numeration details of Precast Longitudinal Beam 102
3.26 Reinforcement Details of Precast Longitudinal Beam 103
3.27 Layout Of Precast Longitudinal Beam 104
3.28 Reinforcement Binding Sequence for Longitudinal Beam ( Part‐1) 106
3.29 Reinforcement Binding Sequence for Longitudinal Beam ( Part‐2) 107
3.30 Formwork Fixing Sequence & Formwork Details for Longitudinal Beam 108
3.31 Construction Sequence for Longitudinal Beam (Part‐1) 109
3.35 Numeration & Reinforcement Details for Precast Deck Planks 115
3.36 Reinforcement Binding Sequence For Precast Deck Planks (Part‐1) 118
3.37 Reinforcement Binding Sequence For Precast Deck Planks (Part‐2) 119
3.38 Formwork Fixing Sequence & Formwork Details for Precast Deck Planks 120
3.39 Alignment Details Of Pile Muff 123
3.40 Layout For Erection 124
3.41 Erection Sequence Of Pile Muff ( Part‐1) 125
3.45 Numeration & Reinforcement Details for Stage 1 Cast in Situ Works 130
3.46 Reinforcement Binding Sequence for Stage 1 Cast in Situ Works (Part‐1) 134
3.49 Formwork Fixing Sequence & Formwork Details for Stage 1 Cast in Situ works 137
3.50 Reinforcement Details of Stage 2 cast in situ Works (Part‐1) 140
3.53 Location Of Area Studied for Cast in Situ Stage 2 Concrete 143
3.54 Reinforcement Binding Sequence for Phase 1 of Stage 2 Cast in Situ Works (Part‐1) 146
3.61 Concreting Sequence For Stage 2 Cast in Situ Works 154

176
LIST OF TABLES
LIST OF TABLES
1 Dry Bulk Cargo Forecast for Hinterland 2
2 Dry Bulk Cargo Forecast for Dahej 3
3 Wind Climate Summary 6
4 Wave Climate Summary 6
5 80000DWt Bulk Carrier Vessel’s Parameters 8
6 Operating Conditions during Berthing/Vessel Approach 8
7 Survival Conditions during Berthing/Vessel Approach 8
8 Self Weights Considered 8
9 Live Loads Considered 8
10 Cost Breakdown Structure of the Project 9
11 Cost Breakdown Structure of Approach Jetty 9
12 Degree Of mechanization 18
13 Plants & Machinery 20
14 Material Details 21
15 Type Of Reinforcement Used in Different Structures 22
16 Cover to Reinforcement 22
17 Tolerances in Concrete Elements 23
18 Details of Liner Studied 30
19 Liner Dimensions 34
20 Labour Requirement for Liner Fabrication 36
21 Time Cycle For Liner Fabrication 37
22 Labour Requirement for Reinforcement Cage Fabrication 41
23 Time Cycle For Reinforcement Cage Fabrication 41
24 Labour Requirements For Survey Works of Piling 44
25 Labour Requirements per Pile Point For Liner Lifting, Guide Welding & Liner Pitching 46
26 Labour Requirements per Pile Point during Boring including additional Liner Driving & Joining 47
27 Soil strata Obtained during Boring 48
28 Liner Details for Pile A14 49
29 Liner Details for Pile A14 49
30 Labour Requirements per Pile Point during Lifting, Joining & Lowering Reinforcement Cage 50
31 Labour Requirements per Pile Point during Lowering of Tremie & Flushing of Borehole 52
32 Quantity of Bentonite Mix added 53
33 Labour Requirements per Pile Point during Concreting 53
34 M:40 grade Mix design Details 54
35 Quantity Of concrete 55
36 Actual Consumption of Materials 55
37 Labour Requirement during Welding of Bracings, Placing of Grillages & Wheels 61
38 Labour Requirement during Gantry Shifting 63
39 Details of Pile Studied 71
40 General Information On Hydraulic Rig(IMT) 71
41 Labour Requirements per Pile Point For Liner Lifting, Guide Welding & Liner Pitching 73
42 Labour Requirements per Pile Point during Boring including additional Liner Driving & Joining 73
43 Soil Strata obtained during Boring 75

177
44 Labour Requirements per Pile Point during Lifting, Joining & Lowering Reinforcement Cage 75
45 Labour Requirements per Pile Point during Lowering of Tremie & Flushing of Borehole 75
46 Quantity Of Bentonite Mix Used 76
47 Concrete Consumption For Pile A1 76
48 Time Cycle Comparison Between PilesA14,B14& A1 76
49 General Pile Details 82
50 Summary Of Field results 83
51 Summary of Analysis 83
52 M:30 Mix Design Details 88
53 Strength Requirements for Concrete 91
54 Formwork Quantity Calculations for Pile Muff 96
55 Concrete Quantity Calculations for Pile Muff 100
56 Actual Material Consumption for Pile Muff 100
57 Labour requirements for Precasting Of Pile Muff 100
58 Time Cycle for Precast Pile Muff manufacturing 100
59 Formwork Quantity Calculations for Longitudinal Beam 105
60 Concrete Quantity Calculations for Longitudinal Beam 113
61 Actual Material Consumption for Longitudinal Beam 113
62 Labour requirements for Precasting Of Longitudinal Beam 113
63 Time Cycle for Precast Longitudinal Beam manufacturing 113
64 Formwork Quantity Calculations for Deck Plank 117
65 Concrete Quantity Calculations for Deck Plank 117
66 Actual Material Consumption for Deck Plank 117
67 Labour requirements for Precasting Of Deck Plank 117
68 Time Cycle for Precast Deck Plank manufacturing 117
69 Labour requirements for Erection Pile Muff 122
70 Time Cycle for Erection Of Pile Muff 122
71 Formwork Quantity Calculations for Stage 1 Cast In Situ Works 133
72 Concrete Quantity Calculations for Stage 1 Cast In Situ Works 133
73 Actual Material Consumption for Stage 1 Cast In Situ Works 133
74 Labour requirements for Stage 1 Cast In Situ Works 138
75 Time Cycle for Stage 1 Cast In Situ Works 138
76 Concrete Quantity Calculations for Phase 1 of Stage 2 Cast In Situ Works 145
77 Actual Material Consumption for Phase 1 of Stage 2 Cast In Situ Works 145
78 Labour requirements for Phase 1 of Stage 2 Cast In Situ Works 145
79 Time Cycle for Phase 1 of Stage 2 Cast In Situ Works 145
80 Concrete Quantity Calculations for Phase 2 of Stage 2 Cast In Situ Works 149
81 Actual Material Consumption for Phase 2 of Stage 2 Cast In Situ Works 149
82 Labour requirements for Phase 2 of Stage 2 Cast In Situ Works 149
83 Time Cycle for Phase 2 of Stage 2 Cast In Situ Works 149
84 Purchase Responsibilities 162

178

Construction of Solid Cargo Port Terminal

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Project Training 07-08 Construction Of Solid Cargo Port Terminal

1.2 THE PROJECT

Suril Shah (2704).School of Building Science & Tech.,CEPT University

¾ Construction of 640m X 15m rubble bund

1.3 OBJECTIVES OF THE PROJECT

1.4 NEED OF THE PROJECT

Suril Shah (2704).School of Building Science & Tech.,CEPT University

1.5 PROJECT BREAKDOWN STRUCTURE:

1.6 GENERAL PROJECT INFORMATION:

Suril Shah (2704).School of Building Science & Tech.,CEPT University

Suril Shah (2704).School of Building Science & Tech.,CEPT University

Solid Cargo Port Terminal

Suril Shah (2704).School of Building Science & Tech.,CEPT University

¾ The nearest airport is at Baroda which is about 135 Kms

Table No. 3:- Wind Climate Summary

Suril Shah (2704).School of Building Science & Tech.,CEPT University

1.8.8 Seismic Zone

1.9 DESIGN CONSIDERATIONS

Suril Shah (2704).School of Building Science & Tech.,CEPT University

Environmental Criteria Considered:

1.9.2 Design load:

1.9.2.1 Foundation of Piles

Suril Shah (2704).School of Building Science & Tech.,CEPT University

1.10.1 Cost Breakdown Structure for Project

1 Approach Jetty 278509364.00

2 Main Jetty 1 263199913.00

3 Main Jetty 2 229061072.00

1.10.2 Cost Breakdown Structure for Approach Jetty

Table No. 11:- Cost Breakdown Structure for

Suril Shah (2704).School of Building Science & Tech.,CEPT University

CHAPTER 2. CONSTRUCTION & METHODOLOGY

2.1 WORK BREAKDOWN STRUCTURE

Client: Adani Petronet Port Pvt. Ltd. (APPPL)

Structural Consultants: Contractor: Project Management

Sub- Structure Super Structure

Geo technical Labor

Sub Contractor: Labor Contractor: Quality Testing

Suril Shah (2704).School of Building Science & Tech.,CEPT University

2.2 ORGANIZATION CHART OF PMC AT SITE

Suril Shah (2704).School of Building Science & Tech.,CEPT University

2.01 BASIC DRAWINGS – PLAN, SEC, ELEV, GAD,

Suril Shah (2704).School of Building Science & Tech.,CEPT University

Suril Shah (2704).School of Building Science & Tech.,CEPT University

2.03 JOB LAYOUT

Suril Shah (2704).School of Building Science & Tech.,CEPT University

2.3 CONSTRUCTION SCHEDULE

Suril Shah (2704).School of Building Science & Tech.,CEPT University

2.4 ACTIVITY WISE PROJECT BREAKDOWN

Marine Works Back Up Facilities

Sub Super Sub Super

Sub Structure Activities for Super Structure Activities

Suril Shah (2704).School of Building Science & Tech.,CEPT University

Suril Shah (2704).School of Building Science & Tech.,CEPT University

2.5.2 Justification of Methodology Used

Table No.12 :- Degree Of Mechanization

Suril Shah (2704).School of Building Science & Tech.,CEPT University

Total Status at the Status at the Time

Suril Shah (2704).School of Building Science & Tech.,CEPT University

Table No. 13:- Plants & Machinery

Suril Shah (2704).School of Building Science & Tech.,CEPT University

2.8 Material Details

Suril Shah (2704).School of Building Science & Tech.,CEPT University