PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
JOB PROCEDURE FOR CONCRETING
DOCUMENT NO : PECL/TIL – MSC- 006Rev. 0
PROJECT NAME : PTA PROJECT
COMPANY : JBF PETROCHEMICAL LTD.
PMC : TECHNIP KT INDIA LTD.
CONTRACTOR : PETRON ENGINEERING CONSTRUCTION LTD.
LOCATION : PTA PROJECT, JBF – MANGALORE
08/05/2014 JOB PROCEDURE FOR
CONCRETING
Rev. Date DESCRIPTION PREPARED BY ACCEPTED BY APPROVED BY JBF
DD/MM/YY PECL TECHNIP
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
INDEX
1.0 PURPOSE
2.0 SCOPE
3.0 REFERENCES
4.0 RESPONSIBILITY
5.0 EQUIPMENTS
6.0 MATERIALS
6.1 FINE AND COARSE AGGREGATE
6.2 CEMENT
6.3 REINFORCEMENT BARS
6.4 FORM WORKS
6.5 WATER, ADMIXTURE, CORROSION INHIBITOR, , WATER
PROOFING COMPOUND
6.6 EPOXY PAINT
7.0 PROCEDURE
7.1 STAGING/SCAFOLDING AND FORM WORK
7.2 RE-BAR WORK
7.3 PLAIN AND REINFORCEMENT CONCRETE
8.0 SAMPLING AND TESTING
9.0 INSSPECTION AND TESTING
10.0 HEALTH SAFETY AND ENVIRONMENT
11.0 QUALITY ASSURANCE AND QUALITY CONTROL
12.0 APPENDICES/FORMATS
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
1.0 PURPOSE:
The purpose of this procedure is to state the requirements of materials, construction
methodology to be followed during concreting works at site as per specification,
codes and drawings.
2.0 SCOPE:
The scope covers the type of materials, equipments, concreting methodology, and
test to be carried out for PCC and RCC works.
3.0 REFERENCES:
Technip Specification, IS:456, IS:383, IS:8112, IS:6461, IS:2502, IS:2386, IS:455,
IS:10262, IS:1786, IS:4925, IS:4926, IS:9103, 0814-B000-DW-1702-001, Approved
Construction Drawing.
4.0 RESPONSIBILITY:
Following are the responsibilities and reporting structure of personnel involved in
execution of the job.
Project Manager – Shall report to Project Co-coordinator, Project Management
Division, Mumbai.
- Shall be responsible for overall activities going JBF, PTA plant.
Construction Manager – Shall report to the Project Manager.
- Shall will be responsible for day to day work planning,
- Co-ordination and progress.
Site Engineers - Shall report to Construction Manager.
- Shall be responsible for site works, Progress as per planning and
day to day site activities.
QA/QC Engineer - Shall Report to Construction Manager.
- Shall be responsible to implement quality plan and carry out the
relevant to tests.
Safety Officer - Shall Report to Construction Manager.
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
-Shall be responsible for all HSE Related activities.
5.0 EQUIPMENTS
5.1 Transit Mixture
Transit mixture shall be used for transportation of concrete from Batching plant to
construction site. One or more than one transit mixture shall be used as per requirement.
5.2 Concrete Pump
Where the pouring point is not approachable by transit mixture, a concreting pump shall be
used. Concreting pump shall be installed in a suitable place where transit mixture can
reach. Concreting In elevated structures also will be done through the pipe of concreting
pump.
5.3 Vibrator
A Concrete vibrator shall be used to consolidate freshly poured concrete so that trapped air
and excess water are released and the concrete settles firmly in place in the formwork.
Concrete will be compacted by mechanical vibrator.
6.0 MATERIALS
6.1 Fine& Coarse Aggregates
Aggregates will be obtained from the approved sources to produce the same satisfactorily.
These will chemically inert, hard, durable, clean and free from veins, adhering coating,
injurious amount of alkalis, vegetable matters and other deleterious substances. coarse and
fine aggregates for concreting work will confirm to all the requirements specified in IS 383.
Grading of coarse aggregates will be checked periodically as per QA/QC plans for
conformity with the required grading.
6.2 Cement
Approved cement shall be Portland slag cement conforming to IS: 455. For each
consignment of cement, manufacturers test certificate will be obtained and submitted for
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
acceptance. Further all the test as required will be conducted in approved laboratory as
directed by engineer in charge. Cement bags will be stored above ground in a suitable
watertight godown at site to protect from dampness and will be made easily accessible for
proper inspection. First in first out process shall be followed. For each lot of cement, IMIR
shall be made and certified by PMC before use.
6.3 Reinforcement Bars
Reinforcement bars for cement concrete works will be high yield strength deformed steel
bar of grade Fe 500 conforming to IS: 1786. Only approved manufacturers test certificate
will be produced for all types of reinforcement steel and for all the consignments coming to
site. Further Physical and chemical test will be conducted for each diameter and each
sources at any NABL approved laboratory.
All reinforcement bars will clean and free from dirt, oil, paints, grease, mill scales, and loose
rust. They will be stored in such a way as to avoid and prevent deterioration, corrosion and
twisting, bar bending schedule will be prepared and will get it approved by PMC before
cutting. For each lot of Reinforcement bars, IMIR shall be made and certified by PMC
before use.
6.4 Form Work
Formwork will be of plywood confirming to IS: 6461or steel plate and will give smooth and
even surface after removal of the same. The surface of shuttering in contact with concrete
will give a coating of shuttering will be as per IS 456. The completed form work will be
inspected as per QA/QC plans. The shuttering will be supported on batten and props of
pipes cross bracing together. The form work shall be true rigid & adequately braced both
horizontally & diagonally. Form work shall be sufficiently rigid to carry the dead weight and
side pressure of green concrete and wind load without deformation. All joints shall be leak
proof and strong enough to withstand the thrust of vibrator. A third party certificate shall be
obtained for heavy concreting formwork, for its load carrying capacity.
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
6.5 Water
Potable water shall be used for concrete work. The water shall be clean and free from
harmful chemical and organic materials. To ascertain the same a sample of water will be
tested in the approved laboratory prior to the commencement of work and later on in case if
any visible change is found. The water will be in general confirm to the requirement of
IS:456.
Admixture
Technip approval shall be taken for an admixture to reduce water cement ratio and to
increase workability and retention time. Admixture shall be conforming to IS: 9103.
Corrosion inhibitor
An approved corrosion inhibitor shall be added to the concrete for the use of below ground
level. Corrosion inhibitor shall be used as per manufacturer’s recommendation.
Water proofing compound
For underground water retaining structure an approved waterproofing compound shall be
added to concrete as per manufacturer’s recommendation and as per instruction of
Engineer in charge.
6.6Asphalt Epoxy paint
All concrete surfaces in direct contact with earth shall be coated with minimum two coats of
approved bituminous asphalt epoxy paint. This paint shall be procured and checked
visually, review with original MTC & Traceability. Coating shall be done as per
manufacturer’s recommendation on buried concrete surface and up to 300mm above the
grade level. The surface should be dry and clean, blow holes and other surface defects if
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
any should be rectified before painting. Back filling shall be done only after proper curing. A
painting clearance register shall be maintained at site for backfilling.
7.0. PROCEDURE
7.1 Staging/Scaffolding and form work
Staging/scaffolding will be properly planned and designed. Only steel tubes with clamps
shall be used for the purpose. Sufficient number of horizontal and diagonal braces shall be
provide to make scaffolding very rigid. The scaffolding will be erected to plumb. The
adjustable bases will be provided to compensate for uneven ground. Care will be taken to
ensure that all bolts and nuts, clamps/couplings are firmly tightened to avoid slippage. Base
will be completed to take care of the scaffolding load. The form work will be true rigid and
adequately braced. The form will be smooth and even surface and sufficient strong to carry
the dead weight and side pressure of green concrete, working load and to with stand the
effect of vibration without any deflection/deformation. The joints in the form works will be not
permit any leakage.
7.2 Fabrication and Typing of Reinforcement
Reinforcement will be cut, bent to shape and dimension as per approved bar bending
schedule. Reinforcement will be fixed in correct position and will be properly supported to
ensure that displacement will not occur when the concrete is placed and compacted. The
bars will be tied at every intersection by two stands of 16SWG black soft annealed binding
wire. Cement concrete block of suitable size and thickness equal to specified cover and
same grade of concrete will be cast in advance and made available during the tying of
reinforcements. These cover block will be placed firmly in between the bar and form so as
to secure and maintain the specified cover to reinforcements. The spacer bar and chair
wherever required will be provided. The bar of full length only will be used unless the same
cannot be done over lapping of bars will be staggered to different bars and located at points
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
along the span where neither shear or bending moment maximum. Welding of rebar will not
be done without written permission of engineer in charge. In case of overlapping the lap
length and lap position shall be as per drawing.
7.3 Plain cement concrete and Reinforcement cement concrete
Design Mix
Construction of PCC and RCC works will be accordance with IS 456 and Technip Technical
specification. Grade and type of concrete will be as per the Approved Drawings. The mix
will be design in advance to produce the grade of concrete having the required workability
characteristic strength and specified minimum cement content and water cement ratio.
Mixing of Concrete
For all the PCC and RCC works the concrete will be produced in batching plant. Batching of
concrete ingredients will be done by approved weigh batcher only. Concrete by mechanical
concrete mixer with approved weigh batcher will be produced in case of exigency or smaller
quantity not viable with batching plant.
Transportation of Concrete
Batching plant/ RMC supplied concrete will be transported through transit mixer. all the
information pertaining to a particular concrete pour will be incorporated in pour cards. PECL
shall raise RFI about the concreting well in advance. The pouring will commences only after
the approval of Technip. Requisite concreting ingredients will be mixed in approved
batching plant. The mixing time will not be less than 2 minute for a mixer of 2.0 cum or less
and 3 minutes above 2.0 cum. Batching Plant/ RMC supplied concrete will be transported
and placed on clean bed as near as practicable to the final position of concreting. The
concrete shall be used within retention time, mentioned in design mix. Concrete will not
dropped from a height of more than 1.5. If required a chute may be used with not greater
than 60° slope. Concrete will be compacted with mechanical vibrator. Concrete shall be
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
placed continuously until completion or up to approved construction joint. Newly placed
concrete will be protected up to 30 minutes after placing from heavy rain. curing will be
started after 8 hours of placement of concrete in normal weather and in hot weather after 6
hours. Curing shall be maintained continuously for at least the first 7 days after placing of
concrete. Exposed surface of concrete shall be maintained continuously in a damp or wet
condition for at least first 7 days after placing the concrete. This may be maintained buy
continuous sprinkling of water on vertical or flat surface. In flat surface weak cement mortar
bunds may provide to retain the water for long time. In vertical surface wet gunny bags may
be used to keep the surface in damp condition.
7.4 Construction Joints
Construction joints, wherever required, will be provided, only as per drawing. This will be in
straight and right angles to the direction of main reinforcements. In column the joint will be
about 100mm to 150mm below the lowest soffit of the beam. In beam and slab if
unavoidable it will be located within 1/3to 1/4 of the span, prior to resuming the further
concreting. The surface of construction joint will be chipped and clean and a thick and rich
coat of cement mortar will be applied before placing the new concrete. All the concrete
structure exposed to the atmosphere including the fire proof structure will be painted with
antifungal paint. Separation joint are to be obtained by using an approved alkathene sheet
stuck on the surface against which concrete shall be placed.
8.0 SAMPLING AND TESTING
Sampling and strength testing of concrete cubes shall be in accordance to IS: 456 and
other relevant codes mentioned therein.
Sampling frequency for concrete for each grade will be as given below:
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
CONCRETE QUANTITY (cum.) CONCRETE CUBE SAMPLE (SET OF 3
CUBES
01-05 1
06-15 2
16-30 3
31-50 4
51 & above 4+one additional for each 50 cum.
At least one sample will be taken from each shift. Three test specimens will be made each
sample. The additional one sample will be taken for testing of 7days.
9.0 INSPECTION AND ACCEPTANCE
Immediately after the stripping of the form work all concrete surfaces will be carefully
inspected and defective work or small defects if any will be removed or good before
concrete has hardened.
On stripping the formwork surface defects such as bulges, ridges and honey combing etc.
observed will be brought to the notice of Engineer in charge and with permission of Technip
necessary rectification will be carried out. Acceptance criteria of concrete will be as
specified in IS 456.
10.0 HEALTH, SAFETY & ENVIRONMENT
Approved JSA for health, Safety & Environment plan will be followed to comply the
Technip’s, Owner’s & ISO standards requirement the following precaution and
measures will be taken care of:
1. All employee working within the battery limit will wear personal protective
equipment.
2. All employee will confirm & follow company’s Health & safety policy Environment
policy, HSE plan and also owner’s/ Technip’s Environment policy and plan.
3. All the critical areas will be cordoned using red and white color zebra tape.
4. All working area shall be easily accessible.
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PETRON ENGINEERING CONSTRUCTION LTD.
JBF MANGALORE
DOCUMENT NO. : PECL/TIL –MSC-006
11.0 QUALITY ASSURANCE AND QUALITY CONTROL
Quality assurance and quality control for earth work in excavation and backfilling works will
be as per quality plan and corresponding inspection and test plan. All records / formats as
appended to this procedure will be maintained for all major activities.
12.0 APPENDICES/ FORMATS
Appendix 1 Inspection and Test Plan for Concreting
FORMAT: 1. Bar bending schedule Format PECL/JBF/QC/CIVIL/002
2. Pour Card CW33
3. Concrete sample compression test format CW17
4. Survey Report PECL/JBF/QC/CIVIL/003/A
5. Concrete mix design approval CW15A
6. Concrete test Summery QC10
7. Construction material approval W12A
8. Concrete slump Test CW35
9. Plain concrete summary reports CW 33R
10. Section excavation summary reports CW 61A
11. Backfilling summary report CW 61B
12. Foundation release reports CW 100
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