Methodology : CD Works: Box, Slab & Pipe Culvert

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Methodology: CD WORKS: BOX, SLAB & PIPE

CULVERT

HINDUSTAN CONSTRUCTION CO. LTD

LMNHP-WB-4, Madan Lal Camp, Po- Darshan Nagar, Ayodhya Road, Faizabad

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TABLE OF CONTENT

Clauses Description Page

PURPOSE
1.0   3
SCOPE
2.0   3
DEFINITION
3.0   3
CROSS REFERENCE
4.0   4
RESPONSIBILITIES
5.0   4
CONSTRUCTION METHODOLOGY
6.0   5-7
6.1   Site clearance work 5
6.2   SuSurvey & setting out works 5
6.3   Construction of Box & Slab culvert 5-6
6.4   Construction of Pipe culvert 6
    Inspection & testing process 6-7
OHS & ENVIRONMENTAL MANAGEMENT
SYSTEM
7.0   7
ATTACHMENT
8.0   7

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1.0 PURPOSE :
The purpose of this Segment Quality Plan for Construction of Cross Drainage
Works is to provide details of the Construction Methodology, Quality Assurance &
Control System/Procedures adopted by H.C.C. and its Sub-
contractor’s/Supplier’s etc. in execution of Cross Drainage Works i.e., Box, Pipe
and Slab Culverts etc. at various locations/stretches as shown in the
Construction Drawings.

This Segment Quality Plan for Flexible Pavement also consists a brief note on
proposed Traffic Safety and Environmental Management Practices/Plans
adopted by HCC and provides list of cross reference documents on the subject
matter for more details.

2.0 SCOPE :
The Scope of this Segmental Quality Plan covers the following activities:

 Cutting, removing and disposing of all materials such as trees, bushes,

shrubs, stumps, roots, grass, weeds, top organic soil etc., which in opinion of
the Engineer are unsuitable for incorporation in the works, from the area
within Toe line containing road embankment drains, cross drainage
structures and such other areas as may be specified on the drawing or by the
Engineer.
 Excavation necessary for construction of CD Works complete as per
Technical Specification Clause 301 & loosening and re compaction of the
original ground /sub grade up to the required depths as directed by the
Engineer and as per M.O.R.T.H. Clause 305.3.4.
 Selection of various Construction Materials, Testing of Materials, Approvals
and Quarry Selection, testing and approval of various grades of materials etc.
 Construction of Cross Drainage Works i.e., Box, Pipe and Slab Culverts etc.
with approved materials/methods etc. complete as per M.O.R.T.H. Section
2900 and also as per other relevant sections of M.O.R.T.H applicable for
Concrete Works as specified in Construction Methodology.

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

PCC : Plain Cement Concrete
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RCC : Reinforced Cement Concrete
BOQ : Bill of quantities

4.0 CROSS REFERENCES :

This Segment Quality Plan shall be read in conjunction with the following
documents:

 M.O.R.T.H – Specifications for Road and Bridge Works ( Third Revision )

 Contract Bid Document, Volume – II ( Technical Specifications )
 Construction Programme and Cash Flow –
 Various BIS/ASTM/ BS Standards/Codes cross referred elsewhere in this
Segment Quality Plan.

5.0 RESPONSIBILITIES :
Responsible personnel for execution of the Segment of Cross Drainage Works
are as per the following Responsibilities Matrix and also as per the Project
Organization Chart:

S. Activity Description Performing Checking/ Approving

No. Verifying

01 Preparation Construction Works Manager (Quality Engineer

Methodologies. Mgr./Section-in- Management)
charge
02 Identification of Source for Works Manager (Quality Engineer
Construction Materials for CD Mgr./Section-in- Management
Works. charge
03 Testing of Samples & Approval QC Engineer Manager / Engineer
and Trial Mixes etc. /Lab Technician QC Engineer
04 Survey & Setting out works. Surveyor Works Engineer
Mgr./Section-in-
charge
05 Preliminary/Excavation Ground Section-in-charge Works Engineer
preparation Works. / Site Engineer Mgr./Section-in-
charge
06 Trial Mixes and QC Engineer Manager (Quality Engineer
Sampling/Testing of Cubes and Management )
Design Mix
07 Preparation of BBS/ Placing of Section-in-charge Works Engineer
Reinforcement in place etc. / Site Engineer Mgr./Section-in-
charge
08 Placing Shuttering and all other Section-in-charge Works Engineer
fixtures/embedment/ / Site Engineer Mgr./Section-in-
pipes etc. as per drawing charge
09 Placing of Concrete and Post- Section-in-charge Works Engineer
concrete activities, curing, / Site Engineer Mgr./Section-in-
finishing etc. charge
10 Testing of Soils/Cubes / Pipes Lab Technician QC Engineer Engineer
etc.
11 Clearance to release/final Section-in-charge QC Engineer Engineer

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approval / Site Engineer

6.0 CONSTRUCTION METHODOLOGY:

6.1 Site Clearance Works:

Site Clearance, Grubbing, Dismantling of existing structures and disposal of
unserviceable materials at designated areas and stacking of serviceable
materials for use in Embankment Construction works etc. shall be carried out as
per M.O.R.T.H Technical Specification, Section – 200.

6.2 Survey and Setting Out Works:

After the Site has been cleared as per Clause 201, the limits of excavations shall
be set out true to lines, curves, slopes, grades and sections as shown on the
drawings or as directed by the Engineer and as per established Bench Marks /
Co-ordinates.

All the Survey Instruments used shall be calibrated periodically as per Calibration
Plan. Survey Check Reports / other relevant data shall be maintained in relevant
Inspection formats.

6.3 Construction of Box Culvert and Slab Culvert:

After the site has been cleared according to clause 201, the limits of excavation
shall be setout true to lines, curves and slopes to clause 301.3.1.The excavation
shall be carried out as per M.O.R.T.H clause 304.3.2. The depth to which
excavation shall be as shown on the drawings, where water is met with in
excavation due to stream flow, seepage, springs etc, adequate measure shall be
taken to pump out water to keep foundation trenches dry. The bottom foundation
shall be leveled both longitudinally and transversely and compacted by suitable
method. . Over the compacted bed, a leveling course of concrete of required
thickness and grade as specified in drawing shall be laid. Reinforcement steel of
Grade Fe 415 confirming to IS Specification 1786 shall be used. Bar Bending
Schedule shall be prepared and got approved from Engineer. Bars shall be
placed accurately in position as shown on drawings. The bars crossing one
another shall be tied together at every intersection with binding wire conforming
to IS 280. Necessary stays, cover blocks metal chair spacer etc. shall be
provided to fix the reinforcement in its correct position. Placing and fixing of
reinforcement shall be inspected and approved by Engineer before placing of
concrete.

Standard shuttering plates shall be used for inside and outside wall shuttering,
vertical props and cross bracings of sufficient strength shall be used to protect
any bulkage/deformation of concrete. All the joints will be properly sealed. PVC
joints, sealing tapes, foam, Rubber will be used in order to prevent leakage of
slurry. Weep holes shall be provided as per drawing and specification. Concrete

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of required grade and specification shall be mixed at batching plant of capacity
30 Cu.M erected at 109 Km and transported to site by using Transit
Mixers/Tippers.

Concrete will be poured in the erected formwork by using Chutes/ manually/or by

any other approved method and compacted by using needle vibrators. Second
phase of shuttering and false work shall be erected for the top slab and
remaining portion of wall. Tying of slab reinforcement steel shall be done as per
drawing. Then concrete shall be poured and compacted. Concrete shall not be
freely dropped in to place from a height exceeding 1.5 M. Curing shall be done
for 14 days by keeping surface moist. Cubes shall be taken and tested for
compressive strength. Slump shall be taken at delivery point to check the
workability of the concrete.

6.4 Construction of Pipe Culvert:

The foundation bed for Pipe Culverts shall be excavated true to the lines and
grades as per the drawings. In case of high embankment where the height of
filling is more than three times the external diameter of the pipe. The
Embankment shall first be built to an elevation above the top of the pipe equal to
the external diameter of the pipe, and to width on each side of the pipe not less
than five times the diameter of the pipe, after which the trench shall be
excavated. For the construction of head wall, setting for the excavation shall be
done as per M.O.R.T.H Clause 301.3.1 and excavation shall be carried out as
per M.O.R.T.H Clause 304. Granular sand filling in foundation shall be done. Bed
PCC ( M 15 Grade nominal Mix ) for head wall shall be done over compacted
sand bedding. Head wall shall be constructed by using P.C.C and all the material
used in the work shall confirm to the requirements laid down in section 1000 of
M.O.R.T.H. . Bedding for pipe shall be prepared by granular filling. Over the
compacted granular fill 100mm thick M 15 grade PCC shall be laid. Slope of the
bedding shall be as per drawing.

The Hume pipes shall be laid, as per drawing, where two or more pipes shall be
laid adjacent to each other; they shall be separated by distance as mentioned in
the drawing. The laying of pipe shall be carried out as per specification laid in
M.O.R.T.H clause 2904. The newly laid pipe shall be placed in such a way that
these will be joining gap of 13mm to 18mm.The our side and inside jointing gap
shall be filled with cement mortar in 1:2 ratio. Care shall be taken to fill all voids
of the joints from inside and outside and surplus mortar shall be removed. After
jointing of pipe as per M.O.R.T.H Clause 2906, the pipe shall be in a cradle
constructed of concrete in M 15 conforming to section 1700. The shape and
dimensions of the cradle shall be as per the drawing.

6.4 Inspection and Testing Process:

All the Inspection and Testing requirements for various activities in the present
segment shall be carried out as per relevant M.O.R.T.H Specifications & Contract
Technical Specifications, other Codes/Standards as mentioned in References
Chapter are identified in the form of Inspection and Test Plans.
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These Inspection and Test Plans shall consists of type of Inspection and name of
the Test to be conducted for Product Realization, frequency of testing,
acceptance criteria and category of Inspection as mentioned in the legend of ITP.

Inspection and Test Plans shall be revised whenever there is any change in
methodology and specifications etc. Various Field and Laboratory Test Formats
referred in Inspection and Test Plans shall be maintained as per the frequency
mentioned in respective ITP’s for various activities.

Any Non-Conformity observed during Field Inspection and also during Testing of
Materials the same Non-Conformity shall be recorded in the specified Format
and necessary Corrective/Preventive actions shall be initiated to prevent such
things in future.

All Product Non-Conformities shall be observed, recorded, corrective/preventive

actions and closing of NCR’s shall be as per the established documented
procedure described in Project Quality Plan.

Various Document/Records required to be maintained for the present segment

has been presented in the subsequent chapter.

7.0: OHS & ENVIRONMENT MANAGEMENT PLAN:

The OH & Safety and Environmental Management Plan for the Project has been
prepared to meet the various Safety and Environmental Management
requirements as mentioned in Contract documents and also as per the
established OH & Safety and Environmental Management Systems and
Procedures of HCC.

8.0: ATTACHMENTS:
ITP for the Inspection of the segment:
ITP for the Testing of the segment: .

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