M/s Ram kripal singh Dhruv Consultancy

Construction Pvt. Ltd. Services Ltd.in

Method of Statement - Association with M/s
Box Girder Designilla

1.0 PURPOSE :
The purpose of this document is to lay down the procedure for Construction of cast in situu pe
Box girder Rail over bridge Structure at Chainage 18+172,37+085
,53+632 km.

2.0 SCOPE:

The Scope of box girder Quality Plan covers the following activities:

 Survey and Setting out works marking superstructure girder.

 Selection, Testing and acceptance of Materials and Mixes for Cast-in-situ super -
structure box girder .
 Deployment of Plant/Equipment/Machinery etc.
 Construction Methodology for superstructure box girder.
 Cutting of HT strands
 Placing of HT strands
 Cutting & placing HDPE seething pipe
 Initial adjustment, checking of profile
 Fixing of anchor cone.
 Stressing of strands by multi-pulling jacks.
 Pre-stress to cast unit.
 Cutting the excess length of strands at either ends of the girder and applying grouting inside the
HDPE pipe.

3.0 DEFINITIONS:
The words like Contract, Contractor, Engineer (Synonymous to Engineer’s
representative), Drawing, Employer, Government, Works, Worksite used in this Quality
Plan shall be considered to have the meaning as understood from the definitions of these
terms given in the General conditions of the contract.
The following abbreviations shall have the meaning as set forth below:
M.O.R.T.H : Ministry Of Road Transport & Highways
&
 M/s Ram kripal singh Dhruv Consultancy
Construction Pvt. Ltd. Services Ltd.in
Method of Statement - Association with M/s
Box Girder Designilla

5.0 RESPONSIBILITIES:

Responsible personnel for execution of construction of Bridgeworks are as per the

following Responsibilities Matrix:

Sr. Activity Responsible Personnel for Remarks

No
. Performing Checking/ Approvin
Verifying g
01 Preparation of Works Planning Engineer
work plan Mgr./Section-in- Mgr.
charge
02 Survey & setting Surveyor Site Engineer
out Engineer.
03 Mix design QC Engr./Lab Q.C.Mgr. Engineer
Tech.
04 Preparation of Design engineer Works Engineer
construction Mgr./Sectio
drawing for final n-in-charge
approval
06 Formwork for Site Engineer/ Section-in- Engineer
structures Foreman charge

07 Cutting & binding Site Engineer/ Site Engineer

of reinforcement Foreman Engineer, /
QC
Engineer
08 Laying of Site Engineer Site Engineer Equip. Dept.
Concreting Engineer, responsible to
QA/QC provide
Engineer infrastructure.
09 Curing Site Engineer Section-in- Engineer
charge
 M/s Ram kripal singh Dhruv Consultancy
M/s Ram kripal singh
Construction Pvt. Ltd. Services Ltd.in
Dhruv Consultancy
Construction
Method of StatementPvt.
- Ltd. Association with M/s
Services Ltd.in
MethodBox of Girder
Statement – Association with
Designilla
M/s Designilla
Pile Cap
6.1.2: Detail Methodology.

6.0 PROCEDURE:
6.1.2.1 Preliminary works: During the previous stages of construction i.e. up to the
sub-structure level the supporting earth is in undulated condition. The entire area of soil
supporting the staging, the loose topsoil is removed. The ground is leveled and
6.1 Construction
compacted. Prior toMethodology:
the whole operation the bearing capacity of the soil checked whether
it 6.1.1
satisfies the
General design criteria of 15t/sqm adopted in the design of formwork. If the bearing
capacity is lesser than required, same shall be improved by preparing sand bed. Sand bed
shall be fully saturated to achieve the maximum density.
The R.O.B.(Rail Over Bridge) of the project consists of 4 spans at chainage 18+172, 5
The detail
span att design
chainageof 37+085,
staging, formwork
9 span at shall be submitted
chainage 53+632 &to20 Engineer
span atfor prior approval.
chainage 66+270,
The approved staging/ formwork shall be fabricated at yard.
The superstructure would be cast in situ and would be cast in two
Temporary fence of C.G.I.sheets shall be erected
stages. During first stage concreting on either
of longitudinal side ofand
girders existing railwayshall
diaphrams track.
be
The minimum clear distance of 2.5 m shall be maintained from center of railway
carried out up to bottom of deck and than second stage concreting shall be carried out track.
for deck
6.1.2.2 portion.
Survey works: The survey work would be carried out along the alignment to fix
theTobridge beam
cast the and center line
superstructure of the
steel bridge axis.
formwork is used, supported on the ground staging
comprising of cribs. The adjustments to the formwork i.e. lowering and raising are
made by providing the adjustable stirrup heads fixed to the staging. The crins rest on
All the levels and coordinates of the points to be checked
the bed block.
10.
TheThe contractor
grounding for inspection
supporting at predetermined
the staging andcompacted.
is leveled and pre-marked points shall offer
checking of levels and coordinates. The same would be submitted to the engineer before
The reinforcement
hand. is cut,
The beam soffit bent
profile in and kept
all the ready.
spans Before
would fixationwith
be aligned of reinforcement the and
the bearing levels
6mm foam is used.
keeping in the provision of pre-camber above the bearing surface.
The placement of the concrete would be through concrete pump and concreting of end
When the deck concrete is complete the survey points established in the ground and on
diaphram is done in layers of about 400 mm thickness. The placed concrete is vibrated
the towers are transferred to the centerline of the casted deck, which would be used for
using
the needle
survey vibrators.
of the future spans.

6.1.2.3 ERECTION
The placement OF STAGING
of concrete AND
for deck FORMWORK:
portion shall be carried out in 3.0 m wide horizontal

strips.
(A) Erection of cribs, ismb & ismc.
The final top surface is given a broom finish by using brooms. Adequate lighting
The design of staging and formwork shall be submitted to Engineer for prior approval.
arrangements would be provided for concreting during nights.

For curing of the deck shall be made by sand cement mortar. The formwork and
 M/s Ram kripal singh Dhruv Consultancy
Construction Pvt. Ltd. Services Ltd.in
Method of Statement - Association with M/s
Box Girder Designilla

(A) Erection of cribs, ismb, ismc as per staging design.

To provide safety during construction, Staging of girders shall be carried out

using cribs.
Minimum clear horizontal distance between two cribs is 2m. cribs shall be
supported on RCC bed block. Longitudinal & cross bressing shall be placed over
cribs.

When the bracing of the cribs is completed, the beams are fixed in the cribs. The
shuttering panels are held in position by bolting arrangement and joints of top
panel shall be sealed of using 6 mm thick foam sheet and sealing compound. To
meet the requisite levels of the form panel with one end other minor adjustments
i.e. small rise in the stirrup head is carried.
When the entire staging and formwork is ready the same is checked and
approved by Engineer. The deck profile is checked and approved by Engineer
before concreting .Any minor adjustments to the deck profiles are made by rising
or lowering stirrup heads or by placing packing material.
6.1.2.4 Placement of reinforcement:
The BBS shall be prepared and got approved from Engineer. The reinforcement
are cut and bent at the site. The reinforcement work would be carried in two
phases
Box reinforcement
Before placement of reinforcement the entire formwork is cleaned using
compressed air. The reinforcement is fixed in position and tied using binder steel.
Suitable cover blocks are provided to provide cover to the reinforcement. When
the entire reinforcement of bridge deck is completed the same is got approved by
Engineer.
The top reinforcement is fixed in position as described earlier. The reinforcement
projecting into crash barrier & Railing is also provided. When the entire
reinforcement work is completed the same is again got checked by Engineer.
Pockets for the fixing expansion joints would left by using thermo coal (insulation
material). The reinforcement in the location of the drainage spouts is moved
locally to accommodate the recess of the drainage hole. The drainage spouts are
fixed at their respective locations. The drainage spouts are packed with sand so
that the concrete doesn’t get filled in.
 M/s Ram kripal singh Dhruv Consultancy
Construction Pvt. Ltd. Services Ltd.in
Method of Statement - Association with
Box Girder M/s Designilla

6.1.2.5 CONCRETING:
The deck superstructure is of the design mix concrete of grade M-40 and is cast
in situ.
PSC box-girder
Before the concreting operations are planned the entire checking with the
supervision consultants would be completed. All the loose materials are
removed/blown using air compressor. The concreting operations would be done
in single pour from end diaphragm to end diaphragm. Prior to concrete, the
arrangements for concreting are checked so that no interruption occurs during
concreting. Approved mix design would be followed during concreting. The
placement of the concrete would be through concrete pump/crane & bucket
arrangement. The placed concrete is vibrated using needle vibrators of
appropriate diameters.
The concrete shall be vibrated using 65mm/40mm/25mm vibrators. The 40 mm
needle vibrator is used in the non-congested area, in the bottom of girders,
where reinforcement congestion is present the vibration would be carried out by
25/40 mm needle vibrators.
6.1.2.6 CURING:
Immediately after concrete is hardened, curing shall be started. For the curing
purpose we will have a flexible pipe, which is connected to the main line from
which continuous curing is carried out. Bunds of size 2.0x2.0 m2 shall be made
using sand cement mortar. Curing shall be carried out for period of 14 days.

6.2.7 DE-SHUTTERING:
The de-shuttering of the girder would be completed in stages.

staging along with soffit panels underneath box girders are removed after 21
days of concreting of deck slab.
 M/s Ram kripal singh Dhruv Consultancy
Construction Pvt. Ltd. Services Ltd.in Asso-
Method of Statement - ciation with M/s De-
Box Girder signilla

6.2.8 MATERIALS FOR SUPERSTRUCTURE : -

All the basic materials shall be used for bridge works shall confirm to the section
1000 of MOST specification.
The QC-laboratory will test to confirm the acceptability of the materials proposed
shall use in the works.
A Project quality plan was submitted for quality control & quality assurance along
with the clause 14 programs.
All the materials from various sources will be tested & got approved by the
Engineer Prior to use.
Routine testing on stacked materials will be carried out from time to time as
directed by the Engineer.
The frequency of tests will confirm to requirements of Technical specifications.
The approved sources will not be changed without prior approval of the Engineer.
Stockpiles of aggregates will be inspected intermittently. Construction water and
curing water will be tested & approved by the Engineer. With the approved
materials and mix design concrete will be produced at batching plant and
transported to site through transit mixers as per site requirement.

7. Safety & Environmental Requirements :

Hazard Identification, Risk assessment and Risk control measures for each and
every activities and sub-activities involved in the present Segment shall be
identified and necessary action plan shall be initiated.
C.G.I. sheet fencing shall be erected on either side of railway track at a distance
of 2.5 M from centre of existing track .No manpower /equipments shall be
allowed to cross the fencing.
All workmen shall use personal protective equipment like hardhat &safety shoes.