Methodology - Hydro Project

SUBANISIRI LOWER H.E.
PROJECT
CONSTRUCTION OF SURFACE WORKS (ADIT PORTALS, HRT

INTAKE STRUCTURES, SURGE CHAMBER, SURFACE POWER
HOUSE & TAIL RACE CHANNEL) FOR SUBANISIRI LOWER HYDRO
ELECTRIC PROJECT (LOT SSL-2 GROUP A)
CONSTRUCTION METHODOLOGY
GENERAL
The main works covered under this package include:
i) HRT Intake Structures and their Adit Portals. – 8 Nos.

ii) Surge Chamber – 8 Nos. (26 m x 16 m x 62 m).
iii) Surface Power House (285.16 m x 61 m x 64 m).
iv) Tail Race Channel (206.16 m x 26 m).
v) Roads (5.3KM)
vi) Water Supply & Sewerage Works, Slope Protection Works &
Finishing works.
Access road to power house and HRT intake structure sites shall be made
available by the owner The construction of approx. 5.3 km long permanent
approach road as per BOQ provisions has been considered in the scope
of the Bidder. Land for infrastructure facilities, Camp facilities, Dump
yards etc. shall be arranged free of cost at suitable location in the vicinity
of project site.
We have considered that the proposed works are to be carried out

continuously, broadly as indicated in Construction Programme annexed to
the Tender document. In case, continuous working is not possible due to
any site constraint or any restrictions imposed during execution of the job,
the intermediate milestones are likely to get shifted and suitable
readjustment accordingly shall be necessitated.
Mobilization of equipments, manpower, materials etc. shall be commenced

immediately on receipt of the work order. Initial Mobilization is proposed to
be completed within a period of 2 months. Construction of approach road
works as per BOQ provisions, infrastructure facilities, camp facilities etc.
shall also be commenced along with mobilization. The improvement as
well as protective works to the road shall be continued as required during
the construction period.
The excavation works of Adit Portals and Power House shall be

commenced simultaneously as and when the access road to respective
sites is made available to us. Necessary arrangements for dewatering of
surface and sub surface water shall be done as per BOQ provision. The
excavation works including portal stabilization of Adits shall be completed
by 5th month of commencement of works.
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Excavation shall be carried out mechanically (methods like

chiseling/blasting or equivalent means) and we shall have an option to do
open blasting when hard rock/hard strata are encountered. The disposal of
surplus earth and unsuitable materials shall be done at the designated
disposal areas identified by the department. The stabilisation and
protection works of rock surface shall be carried out according to site
requirements by rock bolting and shotcreting.
Surge Chambers
The excavation of Surge Chambers shall be carried out from the surface
level El 225.00 to EL 160.00. The excavation is proposed to be carried out
by the conventional drill and blast method using Jack Hammers and
compressed air for drilling and also by road headers. The excavated and
blasted material shall be removed manually / by mechanical means. The
excavated material shall be conveyed to suitable location and further
disposal of unsuitable material to designated areas shall be done through
dumpers. Seepage water in the shaft shall be pumped out using Electric
Pumps. For the control survey and keeping the verticality of the surge
shaft, necessary reference points shall be established on the sides and
roof of the shaft.
The excavation of surge chamber (approx. 4,10,000 cum) shall be

completed in a period of 24 months from the date of start of work. The
surface of the excavated face shall be prepared and the staging and
shuttering shall be carried out commensurating with the progress of the
work as per drawings. Grouting as well as foundation-concreting works
shall be carried out using Concrete produced from batching plant set up
near the site and conveyed to the pouring point or/nearest approachable
location through transit Mixers. Suitable admixtures shall be used as per
requirement. The placing of concrete shall be done by using concrete
pumps/placer boom or using crane buckets/chutes. The concreting of
surge chamber shall be completed by the end of 36 months from the date
of commencement. Finishing work shall be completed thereafter in a
period of 2 months.
Power House
The excavation work at Power House will be commenced immediately

after the construction of approach road and other infrastructure facilities.
Excavation shall be done in stages as per the construction programme
annexed with the tender document. Initially, excavation shall be done from
NSL to EL 84.50 using benching and widening operations sequentially.
The excavation in soil shall be done by mechanical means and excavation
in rock will be done using conventional drill and blast method / chiseling /
equivalent means. Simultaneously, rock protection works of rock bolting,
shotcreting etc. as required shall be done. The first stage excavation shall
be completed by the end of 18th month and the excavation for the second
stage from EL 84.5 to EL 76.0 for turbine pits shall be taken up
subsequently and the same will be completed in 6 months thereafter.
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After completion of excavation and surface preparation, concreting shall

be taken up. Concreting works of Power House shall be carried out in
stages as per construction programme annexed with the tender document.
For production of concrete, Batching & Mixing Plant will be installed near
the crushing plant located near the river shoal and conveyed to the
pouring points by using Transit Mixers / concrete trucks. Placement of
concrete will be done by pumping using concrete pump/placer boom and
crane buckets. The progress of concreting shall be such that there is
proper interface with hydro-mechanical works, which is to be taken up by
other agency(s). All inserts and embedded parts in the concrete shall be
done as per requirement of hydro-mechanical/electro-mechanical works.
The staging and shuttering for turbine foundation shall be done as per
relevant detailed hydro-mechanical drawings made available by the owner.
The framed structure above E.L. 110.00 shall be taken up using
conventional staging and shuttering forms.
Grouting and other finishing works shall be taken up in a phased manner

later on. After erection of EOT crane (which is to be taken up by other
agency) the concreting for the balance portion of the substructure from EL
131.00 to EL 136.00 shall be taken up. The entire concreting works of the
Power House shall be completed by 52 nd month. Building and
architectural works, metal works, structural steel works for roof truss and
finishing works shall be completed progressively. The entire powerhouse
shall be completed by the 56th month.
HRT Intake Structures
The construction of 8 Nos. of Intake structures at the upstream of

Headrace tunnel shall be commenced from 29 th month onwards and shall
be progressively completed by the end of 52 nd month. Excavation for 8
intake structures shall be done at two locations (four structures each)
simultaneously. Excavation in soil in the top portion shall be done by
mechanical means and the excavation in rock shall be by
blasting/chiseling etc. Excavation shall be done in stages from EL 210.00
to EL 155.25 using benching and widening operations sequentially. The
unsuitable excavated muck shall be collected and disposed at designated
areas using dumpers. Installation of rock bolts, rock anchors, shotcreting
as required shall be carried out concurrently with excavation. The
excavation for intake structure shall be completed in a period of 6 months.
After surface preparation, concreting shall be taken up progressively from
EL 155.25 to EL 210.00 in two stages. In Stage-I, concreting for four
intake structure shall be completed by 36 th month and subsequently, the
concreting for the balance four intake structure shall be completed
subsequently. The staging and shuttering shall be done as per relevant
hydro-mechanical/electro-mechanical drawings and interface with other
agency(s) responsible for erection of trash racks and stop log gates etc.
Concrete mixing shall be done at the Batching & Mixing Plant installed
near the crushing plant located near river shoal. Concrete will be conveyed
to the pouring site using Transit Mixers. Concrete shall be placed using
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concrete pump/placer boom. All the works of intake structures shall be

completed by 52nd month.
Tail Race Channel
The construction of slope protection works and excavation for the tail race
channel shall be completed in 4 months time. The slope on the riverside
shall be protected using boulder filling in wire crates, random rubble
masonry, rock pitching and using concrete blocks. The excavation shall be
done using conventional methods as described above. The concreting
shall be done on prepared surfaces progressively and shall be completed
in 6 months.
Rock Bolting
Rock Bolting works to protect the excavated rock surface are proposed to
be carried out after removal of excavated material and removal of loose
stones by scaling and tapping. Bolting works shall be done either at
regular spacing or at isolated places and/or wherever required as per
geological conditions of the rock after each excavation cycle, depending
on the stand up time of the excavated rock surface and as per the
instruction of the Engineer – in - charge. If the situation warrants, rock
bolts shall be installed immediately after blasting also, i.e., before removal
of excavated muck.
After drilling the holes and subsequent washing and cleaning the holes
thoroughly with Air & water Jet, Rock Bolts (supplied by the owner) shall
be manufactured with 25 mm dia tor steel with required base plate, nut,
washer etc. shall be installed using an attachment made and fitted on the
Rock Drill for pushing the bolt pneumatically. After installation of rock bolts,
the nuts will be tightened to the required Torque by using a Torque
Wrench.
For testing the strength of Rock Bolts installed, Pull Out Equipment with
required gauge shall be deployed and testing shall be carried out as per
direction of the NHPC.
Grouting of neat cement or specified material in holes drilled in stages of

5metres in ascending stages in case of curtain grouting and in descending
stages in case of consolidation grouting will be done.
Before the grouting of hole is taken up the adjoining holes shall be kept
clean and open in case there is a grout connection between these holes
during grouting.
Grout for sealing the foundations shall consist of neat cement and water
measured and mixed to exact proportions, as directed by the EIC. If
necessary suitable admixtures shall be added as specified by the EIC.
The equipment for mixing shall be capable of effectively mixing the grout in
correct and specified proportions, like colcrete mixer. Arrangements shall
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be made for accurately measuring the quantity of water, cement and other
materials to be used. In general two mixing tanks connected in tandem
shall be used. The grout being mixed in the first tank called mixer and kept
agitated to the proper consistency in the second called agitating tank prior
to being pumped into the holes. The later tank shall feed the grout directly
to the pump.
The pump shall enable wide range of pumping speeds to be used and to
maintain a constant flow of grout intake in the hole at the designed
pressure. The mixed grout shall be conveyed to the hole by means of a
suitable pipe or flexible rubber hose, designed to with stand the maximum
pressure required. The circulating system of returning extra grout to the
mixer shall be adopted and the grout shall be kept circulating continuously
at sufficient velocity to prevent undue settlement or clogging at the fittings
in the pipe line.
Pressure control valves shall be installed at the pumps or in the injection

system for adequate control of pressures during the operation.
Initially grout hall be applied at specified pressures with thin mixes. The
actual proportion of cement to water shall be decided at site, depending
upon the strata met with the results of water intake tests, but generally
shall vary between 1:10 to 1:12 (Vol. of dry cement : Vol. of water),
depending upon certain characteristics which may reveal themselves in
the course of injection pumping speed may be increased and mixes
thickened commensurate with resistance to injection. As a hole
approaches refusal the grout shall be progressively thinned, and the
pumping shall be carefully regulated and the grouting continued to refusal.
The pressure at the top 3 metres of the hole to be grouted should not
exceed 0.34kg/sqcm per metre depth of hole measured over the center of
the hole to be grouted.
The grouting shall be deemed to have been completed if the hole or

section refuses to take more than .028 cum of grout mixture in 40 minutes
under the specified grout pressure for the hole under consideration.
Shotcreting
Shotcreting works are proposed to be done with wet mix concrete using
“Aliva Shotcreting Machine AL-285 and Aliva Liquid Dozing Unit Type AL-
403.5”, electrically operated. The hourly output of the equipment is 4 to 20
cum. according to the manufacturers and even at 4 cum. per hour, this
equipment is considered adequate for shotcreting works.
Mixing of concrete for shotcreting shall be done in the Batching and Mixing
Plant erected near the site and shall be conveyed by deploying Transit
Mixers. Pouring/Placement of shotcrete shall be done manually by highly
skilled personnel through the wet mix spraying attachment to the shotcrete
machine. The activities/accelerators as prescribed and approved shall be
added to the concrete at the nozzle, before spraying through the Liquid
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Dozing Unit. Before spraying wet mix shotcrete, the rock surface shall be
thoroughly cleaned with Air and Water Jet.
Shotcreting shall be done depending on the different class of rock mass

and as per requirement. Wherever required, wire mesh shall also be fixed
to reinforce the shotcreted surface.

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SUBANISIRI LOWER H.E.

CONSTRUCTION OF SURFACE WORKS (ADIT PORTALS, HRT

The main works covered under this package include:

i) HRT Intake Structures and their Adit Portals. – 8 Nos.

We have considered that the proposed works are to be carried out

Mobilization of equipments, manpower, materials etc. shall be commenced

The excavation works of Adit Portals and Power House shall be

Excavation shall be carried out mechanically (methods like

The excavation of surge chamber (approx. 4,10,000 cum) shall be

The excavation work at Power House will be commenced immediately

After completion of excavation and surface preparation, concreting shall

Grouting and other finishing works shall be taken up in a phased manner

HRT Intake Structures

The construction of 8 Nos. of Intake structures at the upstream of

concrete pump/placer boom. All the works of intake structures shall be

Tail Race Channel

Grouting of neat cement or specified material in holes drilled in stages of

Pressure control valves shall be installed at the pumps or in the injection

The grouting shall be deemed to have been completed if the hole or

Shotcreting shall be done depending on the different class of rock mass

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