Standard Operating (Work) Procedure Document No.

KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 1 of 43

PROCEDURE FOR FOUNDATION WITH GUIDELINES

 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 2 of 43

CONTENTS
SL NO. DESCRIPTION PAGE NO.

I COVER SHEET 1
II CONTENTS 2

III ABBREVIATIONS 3

1 PURPOSE 4

2 SCOPE 4
3 EXCLUSION 4
4 APPLICABILITY 4

5 REFERENCE DOCUMENTS 4
6 RESPONSIBILITY 4

7 PREREQUISITE 4

8 EQUIPMENTS 5
9 CONSTRUCTION SEQUENCE 5 to 23

10 ACCEPTANCE CRITERIA 23

11 SAFETY MEASURES/PRECAUTION 23 & 24

12 RECORDS 24

13 ANNEXURE I 25-26

14 ANNEXURE II 27 to 33

15 ANNEXURE II 34 to 40
16 ANNEXURE IV 41 to 43
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ABBREVIATIONS
DFR - Dry Fissure Rock
FQP - Field Quality Plan
PM - Project Manager
QA - Quality Assurance
QCE - Quality Control Engineer
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1 PURPOSE :
This document describes the step wise work procedure to carry out the Foundation work of 11-132 / 220 / 400
/ 765 KV Transmission Line work in planned and controlled manner with reference to the drawings, technical
specification and standards. This is primarily made for T&D & can be used for other units like Water, Solar &
Railways as per need.

2 SCOPE :
It includes Foundation work (Lean Work, Reinforcement, Form Work, Material for Concrete & Storage,
Measurement for Concrete, Batching & Mixing, Transportation of Concrete, Casting, Stripping Time, Form
Work removal & Curing) in substructure work etc. as indicated on Technical Specifications / drawing. The work
shall be carried out in accordance with the specification and corresponding approved drawings.

3 EXCLUSION :
In case of very specific & mandatory customer’s need their processes & formats can be followed as a part or in
full. However in case of any conflict most stringent norms must be followed. Different variable parameters like,
transit time for ready mix, placement & setting (permissible high & low temperature) of concrete, mix ratios
(Water & Cement/ Aggregates & Cement) etc will depend on use of new techniques and different
methodologies as per job requirement.

4 APPLICABILITY:
This procedure is primarily developed for Railways & Transmission & Distribution works however it is also
applicable Waters, sites across all locations as per specification.

5 REFERENCE DOCUMENTS :
Following Documents / Drawings / Codes have been referred for the preparation of this procedure:-
a) IS:383-1970(Specifications of coarse & fine aggregates from natural source for concrete)
b) IS:456-2000(Plain & reinforced concrete code of practice), IS:516-1959 (Method of test for strength of
concrete)
c) IS:2911 (Part 1/ Section 1,2,3) -2010 (Design & Construction of Pile Foundation)
d) IS:10262-2009 (Concrete mix proportioning), IS: 4082-1986 (Storage of construction material at site)
e) IS : 5613 (Part 2 / Section 2) - 1985, IS : 5613 (Part 3 / Section 2) – 1989 (Installation of lines)
f) IS: 7861 (Part1)-1975 (Hot weather concreting) & IS: 7861 (Part2)-1981 (Cold weather concreting)

6 RESPONSIBILITY:
Responsibility of implementation of this procedure rest with below mentioned officials
PRIMARY: Section-In-Charge, Site Supervisor, Site Engineer, Quality Control Engineer (QCE)
SECONDARY: Project Manager (PM)

7 PREREQUISITE:
a) Approved Drawings
b) Generic Contract Documents (as applicable)
c) Field Quality Plan (FQP)
d) Availability of tested handling equipments, tools, tackles.
e) Availability of skilled manpower.
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8 EQUIPMENTS :
 Form Boxes.
 Mixer Machine (In case where mixing of construction material is done mechanically).
 Needle Vibrator.
 Dewatering Pump (In case there is need to pump out water from excavated pits).
 Dumpy Level / Water pipe level.
 Concrete cube moulds.
 Wooden / Steel Shuttering (In case of side collapse).
 Mixing sheets.
 Measuring Box.
 Metal Sieve.
 Sand Sieve.
 Empty Barrel.
 Plumb Bobs.
 Water Tanker.
 Spade.
 Shovel.
 Receptacle.
 Buckets.
 Poking / Ramming Rod (Vibrator).
 Spanner (Ring & Flat).
 Steel Tape.
 Dolly
 Drop Hammer/Single or Double acting Hammer/Hydraulic Hammer
 Kentledge
 Pile Rig
 Additional any as per requirement

9 CONSTRUCTION SEQUENCE:
After Successful Completion of Stubs, Probe & Template Settings Concrete work will be done in a manner as
per approved design & drawing. Sequence for same is as under: -
 MATERIAL FOR CONCRETE & IT’S STORAGE
All the materials such as fine and coarse aggregates, water & cement required, source should be approved
and then tested in approved third party laboratories. Further any change in source shall be intimated to
client and materials shall be tested.
Joint Inspection of fine and coarse aggregates, water & cement should be done at site in presence of
Client. The results are to be filled in FOUNDATION MATERIAL CHECKLIST.
 CEMENT
 Cement shall be adequately protected from moisture or contamination during transportation and
storage at site.
 All bags of cement shall be stored on site in a correct and proper manner such that, those shall be
protected from rain and surface water. Storage of Cement in bags shall be limited within a heap of
7 bags at site. No cement containing lumps or deleterious matter shall be used. Cement shall not
be placed directly on ground.
 Cement should be kept on Wooden / Plastic Pallets with Tarpaulin.
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 COARSE AGGREGATES
 The concrete used for the foundation, chimney portion and slab portion should be downgraded
stone metal as per client requirement for slab / pyramid portions.
 Aggregates shall conform to specifications for coarse and fine aggregates from natural sources for
concrete as per IS: 383.
 The aggregates shall be of clean, broken hard granite or other stone specified or approved by the
client.
 It shall be of hard, closed-grained quality. It shall also be as far as possible cube like, preferably
angular, but not flaky, perfectly clean and free from earth, organic or other deleterious matters.
 Aggregates will pass through a sieve (mesh size should be as per aggregate size) measured in the
clear.
 Aggregates shall be stored in a manner, which prevents contamination by dust, clay, water or any
harmful material as per IS 4082-1986.
 The coarse aggregates stack shall be kept physically separated depending upon the sizes of coarse
aggregates as per IS 4082-1986.
 If the coarse aggregate contains any foreign material (mud excess fines, etc.) they shall be washed
prior to use.
 FINE AGGREGATES
 The sand used for the concrete shall be composed of hard siliceous materials.
 It shall be clean and of a sharp angular grit type and free from earthy or organic matter and
deleterious salts.
 Fine aggregates found to contain foreign material shall be rejected.
 The sand shall conform to Zone 1 Grade to IS: 383, which is the coarse variety with maximum size
of 4.75 mm. Zone II Grade of fine aggregates may also be used or as per client’s requirement.
 WATER
 The water used for mixing concrete shall be fresh clean and free from oil, acid and alkali organic
materials or other deleterious substances.
 Brackish water should not be used.
 Potable water is generally satisfactory.
 Litmus paper should be used for checking of water purity.
 The PH value of water shall not be less than 6.
 Sea water shall not be used for mixing purpose.

 SPREAD/PIER FOUNDATION
 LEAN CONCRETE (PCC)
The methods used for the preparation of concrete, and all its properties regarding its strength under
compression, tension, shears, punching and bending etc., as well as workmanship shall conform to IS: 456.

 MEASUREMENT OF CONCRETE PRIOR TO MIX

 For Lean concrete sub-bases or pads, mix cement concrete ought to be as per client mix design.
The properties of concrete and mix proportions to be as given in IS 456- 1978.
 After that a design mix concrete shall be done and client approval to be obtained for use at site.
 Weigh-batching shall be adopted for mixing the ingredients of Concrete by using weigh-batcher
initially and conversion of the weighed materials in equivalent volume shall be done in Batch Box.
For actual execution of work, equivalent volume batching shall be adopted by marked batch
boxes.
 It shall be permissible to proportionate the concrete as follows:
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 Prepare a wooden measuring box of 35 liters capacity (that is, equal to 1 bag or 50 kg of
cement) with inside dimensions not exceeding 30X30X30 cm alternatively 34 cm diameter and
39 cm height.
 Measurement of water may be made with separate water-tight drums of the above size with 1
or 2 liter mugs.
NOTE - For concreting the bored foundations by displacing the drilling mud’s 10% extra cement in the mix is
required.

 BATCHING & MIXING OF CONCRETE:

 All material aggregate, cement and reinforcement will be checked, prior to commencement of
concreting.
 Prior to commencement of concreting activities the following shall be available on site :-
 Mixer in good condition
 Vibrator
 Water (required quantity)
 Fine Aggregate (required quantity)
 Coarse Aggregate (required quantity)
 Cement (required quantity) and protection for the same
 Aggregate measuring boxes
 Concrete chutes / Slides / Elephant Trunks
 De-watering pumps (if necessary for site)
 Sieves for coarse & fine aggregates
 The equipment shall be constantly maintained in first-class workable condition during the working
period.
 The concrete mixing shall be proper and inspected at suitable intervals in the presence of the
Client.
 Each time the work stops, the mixer shall be cleaned out, and while recommencing the first batch
shall have 10% additional cement to allow for sticking in the drum.
 The concrete shall be mixed with an approved concrete mixer. In no case shall hand mixing be
allowed.
 In difficult location, where it is not possible to transport the concrete mixer, hand mixing of
concrete can be done after client’s approval. In such cases 10% additional cement shall be used
over and above that being used for such foundation where mixer is being used.
 When hand mixing is adopted, it shall be carried out on water-tight platforms, such as 1.8 mm
galvanized iron plain sheets properly overlapped and placed upon level ground.
 The concrete mixer shall be placed in a location so that the transport distance of the concrete to
the foundation is minimized.
 No ready mixed concrete shall be used in foundation work, if it has been mixed in the lorry during
its journey to site for more than 45 minutes prior to placing. On the approval of client, ready mixed
concrete may be used in foundation if the journey to site is in excess of 45 minutes.
 The measuring equipment shall be maintained and operated as required to accurately determine
and control the amount of each separate ingredient entering the concrete.
 The boxes shall not be overfilled. After filling the box the contents shall be flush with the top edges
of the box sides to ensure the correct quantity in each box.
 The mix quantities / ratio shall at all times be strictly in accordance with the approved design mix
quantities as per foundation drawing.
 Normally mixing shall be done close to the foundation, but in case it is not possible the concrete
may be mixed at the nearest convenient place, the concrete shall be transported from the place of
mixing to place of final deposit as rapidly as practicable by methods (transit mixers), which shall
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prevent the segregation or loss of any ingredient. The concrete shall be placed and compacted
before setting commences.
 The coarse aggregates shall first be evenly spread out in required quantity over the sheets. The
fine aggregates shall be evenly spread out over coarse aggregates next. The aggregates shall than
be thoroughly mixed together and leveled.
 The required amount of cement shall not be spread evenly over the mixed aggregates and wet
mixing shall start from one end with required amount of water using shovels.
 The aggregate together with the cement shall be first added to the mixer without water and mixed
for a minimum of one minute or as long it is necessary to ensure a homogenous mix.
 The whole lot shall not be wetted. Instead mixing shall proceed progressively. If the aggregates are
neither wet nor washed, cement shall not be spread out, but shall be put in progressively.
 The minimum cement content, the water cement ratio, the slump and all other characteristics of
concrete shall be demonstrated to conform to the relevant Indian Standards & same to be filled in
Slump Test Report.
 Mixing shall be continued until there is uniform distribution of material and the mix is uniform in
colour and consistency but in no case the mixing is done for less than 2 minutes.
 The quantity of water added shall be as per design mix refer foundation volume & construction
material details.
 When a homogeneous mix has been obtained the water then shall be added after which the
mixing shall continue for not less than 1 minute.
 The mixer shall be rotated at the speed recommended by the manufacturer and thereafter mixing
shall be continued for at least 2 minutes and at least forty (40) revolutions after all materials are in
the drum.
 For batches larger than 0.75 cum., mixing time shall be increased by 15 seconds for each additional
0.75 cum. or fraction thereof.
 All concrete shall be discharged within 3 minutes after the introduction of mixing water to the
cement and aggregates.
 The concrete should be mixed as stiff as the requirement of placing the concrete in the forms or
moulds with ease and the degree to which the concrete resists segregation. Hence the quantity of
water used should not be too much.
 TRANSPORTING
 Normally mixing shall be done right at the foundation. In places where it is not possible, concrete
may be mixed at the nearest convenient place.
 The concrete shall be handled from the place of mixing to the place of final deposit as rapidly as
practicable by methods which shall prevent the segregation or loss of any of the ingredients.
 If segregation does occur during transport the concrete shall be remixed before being placed.
 During hot or cold weather, concrete shall be transported in deep containers.
 The deep containers, on account of their lower ratio of-surface area to mass, reduce the rate of
loss of water by evaporation during hot weather and loss of heat during cold weather.
 PLACEMENT & COMPACTION OF LEAN CONCRETE (CASTING)
 The excavated foundation level shall be free from loose material.
 The site engineer will ensure the line level, dimensions and surface to receive the concrete
according to drawings & specifications.
 Grade of concrete shall be checked as per requirement. Concreting can start only after getting
Pour card clearance.
 Site Engineer will inform the client & quality engineer the timing of concrete well in advance.
 Pour the lean concrete on the surface and level it using hand tools to the required finish.
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 Concrete shall be thoroughly compacted during the placing operation, and thoroughly worked
around the reinforcement, around embedded fixtures and into corners of form work by means of
16 mm diameter poking bars pointed at the ends.
 Water curing of finished concrete surface shall be done for 1 day for OPC Cement & 2 days for PPC
(min.) with water wetting, before backfilling. When shuttering and reinforcement is being placed /
tied, then water sprinkling shall be done.

 REINFORCEMENT WORK
 All reinforcement bars shall be strictly as per the sizes in the approved drawing.
 All bent reinforcement shall be fabricated in the store yards and transported to the site.
 On arrival at site the reinforcement shall be stored in a location where it will be kept clean and sorted
for delivery to the excavation point in such a sequence that will permit the correct order of work.
 During placement the following shall be adhered to:
 All reinforcement shall be cleaned of foreign materials (mud etc.) prior to placement.
 The spacing between the bars is as per the foundation drawing.
 Precast concrete cover blocks are to be utilized at all locations to ensure a minimum concrete
cover of 50mm is obtained.
 The reinforcement bars shall, however, be placed clear of stubs and cleats where interfering. For
binding, iron wire of not less than 0.9 mm shall be employed, and the bars may be bound at
alternate crossing points.
 Bars crossing each other, where required, shall be secured by binding wire (annealed) of size not
less than 0.90 mm and conforming to IS: 280-1962 Specification for Mild Steel Wire, in such a
manner that they will not slip over each other at the time of fixing and concreting.
 Every compression bar shall be tied at least in two perpendicular directions.
 For bored footings, stub angle shall be used as reinforcement.
 The mortar or concrete used for the cover blocks or rings shall not be leaner than the mortar or
concrete in which they will be embedded.
 To provide necessary cover for reinforcement at any section, only single cover blocks shall be used.
 In case of the foundation having steel reinforcement in pyramid on base slab, at least 50 mm thick
pad of lean concrete as per client design mix shall be provided to avoid the possibility of
reinforcement rod being exposed due to unevenness of the bottom of the excavated pit.
 The pad reinforcing shall be provided with adequate supports to prevent sagging.
 After placement of the reinforcement the same shall be checked and the appropriate observations to
be entered in the reinforcement work checklist (KEC-Q-TL-SA-CL-0010).
 FORM BOX WORK
 The form work shall conform to the shape, lines and dimensions as shown on the design drawings, and
be so constructed to be rigid during the placing and compacting of concrete, and shall be sufficiently
tight to prevent loss of liquid from concrete.
 It shall be of light design easily removable without distortions and shall be of steel / hardwood or
framed plywood.
 The inner surface coming in contact with concrete shall be smooth and free from projections.
 Window on one face shall be provided for pyramid forms to facilitate concreting in the lower parts
which shall be fixed after concrete in the bottom part is placed.
 In bored footings, form work may be needed only towards the top for the portion above ground level.
 The chimney and pyramid portions are adequately braced to retain proper shape while concreting. To
avoid honeycombs in the concrete, the former boxes shall be sufficiently tightened to prevent cement
slurry from coming out.
 The form work for slabs and pyramids shall be made symmetrical about the base of the chimney to
ensure interchangeable faces as illustrated in below Picture (Fig 1).
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 As soon as the base concrete is laid and after the required initial setting time, the form boxes for the
chimney portion will be fixed in position.
 In the event that concrete has not set adequately, protection over the pad concrete will be provided to
have a suitable working platform.
 Where the chimney form work is longer than 1.5 M they will be installed and concreted in sections.
 Care shall be taken to ensure a clean cover to the reinforcing steel be maintained on all the four sides
along the length of the chimney and the form is centered about the stub leg.
 After placement the form boxes the same shall be checked and the appropriate observations entered
in the checklist (KEC-Q-TL-SA-CL-0011)

 CLEANING AND TREATMENT OF FORMS

 All rubbish, particularly chippings, shavings and sawdust and traces of concrete, if any, shall be
removed from the interior of the forms before the concrete is placed.
 The surface in contact with the concrete shall be wetted and sprayed with fine sand, or treated
with an approved composition before use, every time.

FIG 1: FORM WORK FOR SLABS/PYRAMIDS

 CONCRETE (RCC)
 MEASUREMENT OF CONCRETE PRIOR TO MIX : Refer Details as mentioned in LEAN CONCRETE (PCC)
 BATCHING & MIXING OF CONCRETE : Refer Details as mentioned in LEAN CONCRETE (PCC)
 TRANSPORTING : Refer Details as mentioned in LEAN CONCRETE (PCC)
 PLACEMENT OF CONCRETE (CASTING)
 CASTING OF FRUSTUM
 Before placing of concrete the pit shall be cleaned properly.
 Concrete shall not be started unless bolts shall be fixed as per relevant drawing and be
checked with respect to its lines and levels.
 Grade of concrete shall be checked as per requirement. Concreting can be started only after
getting Pour card clearance.
 Field tests on workability of concrete and consistency may be carried out in the form of slump
test in accordance with IS 1199: 1959.
 Concrete shall, in all cases, be placed in the presence of the client. No concrete shall be placed
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until the Client has approved the excavated surface, stub setting, and inspection of formwork
and completion of all preparation work.
 The concrete shall be placed and compacted before setting commences and should not be
subsequently disturbed. The placing should be such that no segregation takes place.
 Concrete shall not be directly poured from a height more than 1.5m to avoid mix segregation.
 Adequate chutes or other approved method shall be employed to place concrete.
 Concrete shall be poured to the pit immediately after its production in the concrete mixture
machine.
 For concreting in depth, chutes shall be used. Chute shall be designed such that concrete, is to
some extent, re-mixed at lower end.
 Concrete shall be thoroughly compacted during the placing operation, and thoroughly worked
around the reinforcement, around embedded fixtures and into corners of form work by means
of 16 mm diameter poking bars pointed at the ends. As a guide for compacting the poking bars
to be worked 100 times in an area of 200 mm square for 300 mm depth.
 Over-compacting causes the liquid to flow out upward causing segregation and should be
avoided.
 All concrete shall be consolidated to the maximum practicable density with a concrete vibrator
and make surface smooth and free from pockets and honeycomb.
 Immediately after pouring of concrete in the form work, it shall be compacted using
mechanical vibrating equipment. Immersion type vibrator shall be inserted in vertical position
and care should be taken so that it does not over or under vibrate.
 At the time of placing of concrete all the precautionary measures are to be taken to avoid any
sort of deterioration in quality.
 In case of placing of concrete in layers, which are advancing horizontally as the work
progresses, great care shall be taken to impart adequate vibration for bonding and molding of
concrete between the succeeding layers.
 Concrete shall be deposited as near as practicable in its final position to avoid re-handling.
 Concreting is to be done continuously so that the subsequent layers are laid before the final
setting of the bottom layer begins.
 In wet locations, the site must be kept completely de-watered both during the placing of the
concrete and for 24 hours after completion. There should be no disturbance to concrete by
water during this period.
 For concreting during hot weather and cold weather, adequate provision shall be made to
maintain the suitable concrete temperature.
 In hot weather, the concrete temperature shall not increase beyond 400C at the time of
placement of fresh concrete.
 In cold weather, the temperature of the concrete shall not be less than 50C in moderate
weather or 100C when the mean daily temperature drops below 50C.
 Immediately after pouring of the base and chimney concrete the setting dimensions will be
checked and adjusted provided concrete setting has not yet taken place.
 Inspection of each point is to be done and must be recorded in checklist
Note: Sample of mix must be taken each & every time while pouring to facilitate for slump and cube test.

 CASTING OF CHIMNEY
 After the frustum part is poured, the earthing connection is fitted on the designated stubs.
 Earthing is provided on Leg 1. Additional earthing, if required, is provided on Leg 3.
Counterpoise earthing is provided on all legs.
 The chimney is centered and fixed so that equal spacing from the stub is available all around.
 The chimney is bolted to the frustum portion and slurry of sand and water is applied at the
joints to prevent leakage of cement slurry.
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 The earthing connection is passed through the joint of the two parts of the chimney.
 If fresh concrete is to be laid on old concrete less than a week old, the surface of the old set
concrete should be chipped and cleaned thoroughly with wire brush and washed with a layer
of thick cement slurry before the new concrete is laid.
 If, however, the concrete is more than 10 days old, the top layer of the set concrete should be
chipped and cleaned thoroughly with wire brush and water and layer of cement mortar (1:2)
12 mm thick shall be laid evenly after giving a coat of cement slurry, as specified above to
ensure proper bonding between old and new concrete.
 The concrete is then poured into the chimney portion. After pouring of every 450 mm of
concrete, poking rod or vibrator is used so that no empty spaces are left inside. The chimney is
filled up to the level shown in the foundation drawing.
 The coping on the chimney, which is generally of a height of 75 mm, is done after the tower
erection has been completed.
 After concreting the chimney portion to the required height, the top surface should be
finished smooth, with slight slope towards the outer edge to drain off the rainwater falling on
the coping.
Note: Sample of mix must be taken each & every time while pouring to facilitate for slump and cube test.
A typical completed chimney and pyramid foundation will look like the one shown in the drawing below.
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 STRIPPING TIME
 Under fair weather conditions (generally where average daily temperature is 20°C or above), and
where ordinary cement is used, forms may be struck after 24 to 48 hours of the placing of concrete.
 In dull weather such as rainy period’s very cold temperature, the forms shall be struck after 48 hours
of the placing of concrete.

 FORM BOX REMOVAL

 The forms or mould shall not be removed before a lapse of about 24 hours after the completion of
concreting if OPC is used & for PPC minimum 48 Hrs. are must.
 All form work shall be removed without such shock or vibration as it would damage the concrete or
the forms.
 The exposed surfaces of the concrete will be checked for any imperfections or weakness (i.e.
honeycombing, etc.)
 If, after the form work has been struck, the concrete surface is found to have defects. All the damaged
surfaces shall be repaired with mortar application composed of cement and sand in the same
proportion as the cement and sand in the concrete mix.
 Local repairs to the concrete surface shall only be permitted with the approval of client.
 Such repairs shall be carried out well before the foundation pits are back filled.

 CURING
 Immediately after the removal of the formworks, all concrete exposed surfaces shall be thoroughly
wetted before back filling commences.
 The concrete, after it is 24 hours old, shall be cured by keeping concrete wet continuously for a period
of 14 days / Client requirements after laying (for OPC Cement).
 The concrete, after it is 24 hours old, shall be cured by keeping concrete wet continuously for a period
of 21 days / Client requirements after laying (for PPC Cement).
 Where back filling of the excavation is not to take place immediately, the concrete is to be covered by
the application of jute covers to avoid rapid drying of concrete.
 In all cases concrete exposed to the sun shall be kept moist and cool for a period of five days after
casting.
 The pit may be backfilled with selected earth sprinkled with necessary amount of water and well
consolidated in layers not exceeding 200 mm of consolidated thickness after a minimum period of 24
hours and thereafter both the back-filled earth and chimney top shall be kept wet for the remainder of
the prescribed period of 14 days / Client requirements.
 The uncovered concrete chimney above the back-filled earth shall be kept wet by providing empty
cloth or hessian bags dipped in water fully covered around the concrete chimney for curing and
ensuring that the bags are kept wet by frequent pouring of water on them.
 Water curing of finished concrete surface shall be done as per IS standard.

 PILE FOUNDATION
 IN SITU PILES
 Driver casing is to be driven in the soil up to the level as specified in drawing, with use of suitable
equipment.
 Dewatering to be done in case of water ingress.
 In a pile group the sequence of installation of piles shall normally be from the center to the
periphery of the group or from one side to the other.
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 Piles shall be installed as accurately as possible according to the design and drawings either
vertically or to the specified batter.
 Piles are to be marked for different height level.
 As a guide, for vertical piles, an angular deviation of 1.5 percent and for raker piles, a deviation of
4 percent should not be exceeded.
 Piles should not deviate more than 75 mm or D/6 whichever is less (75 mm or D/10 whichever is
more in case of piles having diameter more than 600 mm) from their designed positions at the
working level.
 In the case of single pile under a column the positional deviation should not be more than 50 mm
or D/6 whichever is less (100 mm in case of piles having diameter more than 600 mm).
 Greater tolerance may be prescribed for piles cast over water and for raking piles.
 Whenever condition indicates ingress of water, casing tube shall be examined for any water
accumulation and care shall be taken to place concrete in a reasonably dry condition.
 The top of concrete in a pile shall be brought above the cut-off level to permit removal of all
laitance and weak concrete before capping and to ensure good concrete at cut-off level.
 The reinforcing cages shall be left with adequate protruding length above cut-off level for proper
embedment into the pile cap.
 Where cut-off level is less than 1.50 m below working level, the concrete shall be cast to a
minimum of 600 mm above the cut-off level.
 In case the cut-off is at deeper level, the empty bore shall be filled with lean concrete or suitable
material, wherever the weight of fresh concrete in the casing pipe is found inadequate to
counteract upward hydrostatic pressure at any level below the cut-off level.
 The slump should be 150 to 180 mm at the time of pouring.
 Also before initial withdrawal of the casing tube, adequate quantity of concrete shall be placed
into the casing to counter the hydrostatic pressure at pile tip.
 In case defective piles are formed, they shall be left in place and additional piles as necessary shall
be provided.
 While removing excess concrete or laitance above cut-off level, manual chipping shall be
permitted after three days of pile concreting.
 While removing excess concrete or laitance above cut-off level, manual chipping shall be
permitted after three days of pile concreting.
 Before chipping/breaking the pile top, a groove shall be formed all around the pile diameter at the
required cut-off level.
 A competent inspector shall be maintained at site to record necessary information during
installation of piles and the data to be recorded shall essentially contain the following:
a) Sequence of installation of piles in a group
b) Type and size of driving hammer and its stroke.
c) Dimensions of the pile including the reinforcement details and mark of the pile.
d) Cut-off level and working level.
e) Depth driven.
f) Time taken for driving and for concreting recorded separately.
g) Any other important observations, during driving, concreting and after withdrawal of
casing tube.
 Typical data sheet for recording piling data are shown in Annexure I (page no.25).
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 15 of 43

 BORED CAST IN SITU PILES

 Four reference points (making two lines perpendicular to each other) should be marked for
checking centre of pile bore during boring of pile.
 Initial boring of about 2.0 meters is to be done using cutting tool of desired diameter of pile
 Then boring will be carried out according to the sub-soil investigation report of that location. It will
be done using liner, bentonite or both.
 The temporary guide casing, approximately 2.0 meter length with outside diameter equivalent to
nominal diameter of the pile, may be then lowered in the bore hole. In such a case diameter of
cutting tool will be little less, maximum 75 mm less than outside diameter of casing for free
movement in the casing pipe during operation.
 Position / centerline of the guide casing pipe with reference to pile reference points already fixed
around the pile location shall be checked to shift/adjust the casing pipe to ensure proceeding of
drilling at exact pile location without any deviation.
 Boring has to be done up to the founding strata as per drawings/ pre decided depth using
intermittently bentonite slurry as per requirement. In case of requirement the bore hole is then
supplied with bentonite slurry, from bentonite installation. Bentonite circulation channel to be
made from bore hole to bentonite tank and fresh bentonite slurry to be pumped to bore hole
through hose pipes.
 24 hours prior to start of pile boring, ensure that bentonite is completely dispersed in the water
and attains required density to stabilize the sides of bore hole during drilling. Bentonite slurry of
specified quality should be circulated continuously during boring process.
 Bentonite used to stabilize the sides of bore hole should be conforming to requirements as listed
in inspection and test plan.
 Density of bentonite solution should be checked during boring operation to ensure that it is as per
specifications.
 The concreting operations should not be taken up when the specific gravity of bottom slurry is
more than 1.12.
 The slurry should be maintained at 1.5 m above the ground water level.
 After boring up to required depth under reaming will be done using under reamer of desirable
diameter.
 Completion of desired bulb cutting will be ascertained by
a) Vertical movement of the handle.
b) Using L shaped rod of length enough to reach up to bulb location from approximately 2
feet above ground level and horizontal dimension equal to 0.5 of bulb diameter minus pile
diameter.
 If a borehole is stabilized by drilling mud, the bottom of the hole shall be cleaned of all loose and
undesirable materials before commencement of concreting in the following manner:
a) Boring done with normal bailer and chisel with temporary/permanent liner — First heavier
material to be removed with cleaning tools, such as, bailer and then reinforcement cage
and tremie pipe to be lowered. Flushing then to be continued with water/drilling fluid
under pressure through tremie pipe.
b) Boring done with bentonite slurry — Procedure given in (a) above to be followed However,
flushing shall be done with fresh bentonite slurry.
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Revision. No. 00
FOUNDATION
Sheet No 16 of 43

c) Boring done by rotary drilling rigs — Cleaning bucket attached to the kelly shall be used for
cleaning the bore. Wherever bentonite slurry is used, after using cleaning bucket, the bore
shall be flushed with fresh bentonite slurry.
 Cleaning of bore holes is done as follows
 Bentonite slurry is pumped by high pressure reciprocating pumps/ vertical pump into the bore
hole and the same is allowed to overflow the bore hole.
 The overflow slurry with bored mud/soil etc that comes out along with bentonite slurry is passed
through channels and is collected in sediment tanks where sediments settle and bentonite can be
re used. If necessary, the bentonite may be passed through the de sander tank to remove sand
particles before it is re used.
 The next step is to put reinforcement steel in the bore which is done as follows.
 Prefabricated reinforcement cage prepared as per the drawings and approved depths, is brought
and kept near pile location while boring is in progress.
 After getting the permission from the site engineer, the reinforcement cage to be gently lifted and
lowered by crane/manually into the bored hole.
 Necessary concrete cover to be obtained by using the circular cover blocks already made of the
same strength as of pile.
 If the reinforcement cage is very long i.e. not possible to handle in one lift, the cage to be lifted
one by one and spot welded at the joints and then lowered inside the bored hole.
 It is to be checked whether the reinforcement cage has reached up to bottom of the pile by
measuring from the top of the cage to the ground level.
 The next step is to carry out tremie concreting.
 Concreting for bored piles shall be done by tremie method. The following requirements are
particularly to be followed for tremie concrete work:
a) The concrete should be coherent, rich in cement (not less than 400 kg/m3) and of slump
between 150-180 mm.
b) The tremie should be water-tight throughout its length and have a hopper attached to its
head by a water-tight connection.
c) The tremie pipe should be large enough in relation to the size of the aggregate. For 25 mm
down aggregate, the tremie pipe should have a diameter not less than 200 mm. For 20
mm down aggregate, tremie pipe should be of diameter not less than 150 mm. All piling
above 600 mm diameter piles, should, however preferably be done with 200 mm diameter
tremie pipe.
d) A steel plate or a ball is placed at the bottom of the hopper and the hopper is filled with
concrete. The first charge of concrete is sent down the tremie by removal of this plate or
ball. Additional concrete is then added into the hopper and by surging action is pushed
down the tremie and into the pile bore to the bottom of the pile. Theoretically, a small
part of the first charge which gets contaminated is supposed to be the top of the rising
concrete within the bore.
e) The tremie pipe should always be kept full of concrete and should always remain at least
one meter into the concrete in the bore hole with adequate margin against accidental
withdrawal of tremie pipes.
f) The pile should be concreted wholly by tremie and the method of deposition should not
be changed midway to prevent laitance from being entrapped within the pile.
g) All tremie pipes should be cleaned before and after use.
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Revision. No. 00
FOUNDATION
Sheet No 17 of 43

h) A sliding plug of polystyrene or similar material lighter than water and approved by the
Engineer-in-charge or his representative shall be placed in the tremie pipe to prevent
direct contact between the first charge of concrete in the tremie and the bentonite slurry.
 Normally concreting of the piles should be uninterrupted. In exceptional cases of interruption of
concreting, it shall be resumed within 1 or 2 hours, but the tremie shall not be taken out of the
concrete.
 Instead it shall be raised and lowered from time to time to prevent the concrete around the tremie
from setting.
 In case of withdrawal of tremie out of the concrete, either accidentally or to remove a choke in the
tremie, the tremie may be introduced 60 cm to 100 cm in the old concrete and concreting
resumed as mentioned in above point.
 The fresh concrete will emerge out of the tremie displacing the laitance and scum and prevent
impregnation or laitance of scum in the fresh concrete.
 The top of concrete in a pile shall be brought above the cut-off level to permit removal of all
laitance and weak concrete before capping and to ensure good concrete at the cut-off level.
 The reinforcing cages shall be left with adequate protruding length above cut-off level for proper
embedment into the pile cap.
 Where cut-off level is less than 2.5 m below the ground level, concrete shall be cast to a minimum
of 600 mm above cut-off level.
 For each additional 0.3 m increase in cut-off level below the working level, additional coverage of
minimum 50 mm shall be allowed.
 Higher allowance may be necessary depending on the length of the pile. When concrete is placed
by tremie method, concrete shall be cast up to the ground level to permit overflow of concrete for
visual inspection or to a minimum of one meter above cut-off level.
 In the circumstances where cut-off level is below ground water level, the need to maintain a
pressure on the unset concrete equal to or greater than water pressure should be observed and
accordingly length of extra concrete above cut-off level shall be determined.
 While removing excess concrete or laitance above the cut-off level chipping by manual or
pneumatic tools shall be permitted seven days after pile casting. Before, chipping/breaking the pile
top, a 40 mm deep groove shall be made manually all round the pile at the required cut-off level.
 Typical data sheet for recording piling data are shown in Annexure II (page no. 27).
Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 18 of 43

Figures above show the Bore Cast Piling process’s pictorial view
Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 19 of 43

Figures above show the Bore Cast Piling process’s pictorial view
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 20 of 43

 DRIVEN PRE-CAST CONCRETE PILES

 Casting & Tolerance
 The casting yard for all concrete piles should preferably be so arranged that the piles can be lifted
directly from their beds and transported to the piling frame with a minimum of handling.
 The casting yard should have a well-drained surface to prevent excessive or uneven settlement
due to softening during manufacture and curing.
 All shuttering shall be placed on firm supports capable of withstanding the loads of shuttering, wet
concrete and incidental load of workmen, so that cast piles are straight and free from
deformations.
 The shuttering shall be lubricated with oil on the inside face.
 As far as practicable the longitudinal reinforcement shall be in one length. In cases where joints in
reinforcing bars cannot be avoided, the joints in bars shall be staggered.
 The hoops and links for reinforcement shall fit tightly against longitudinal bars and be bound to
them by welding or by tying with mild steel wire, the free ends of which should be turned into the
interior of the pile.
 The longitudinal bars may be held apart by temporary or permanent spreader forks not more than
2.5 m apart.
 The reinforcement shall be checked for tightness and position immediately before concreting.
 The piles should be cast in a continuous operation from end-to-end of each pile.
 The concrete should be thoroughly compacted against the forms and around the reinforcement by
means of immersion and/or shutter vibrators.
 Immediately on completion of the casting, the top surface should be finished level without
excessive trowel.
 Care should be taken to ensure that vibration from adjoining works does not affect the previously
placed concrete for piles during the setting period.
 In-situ extension of piles already pitched shall be avoided. If necessary, piles may be extended at
the top and cured before pitching.
 Lifting positions shall be adjusted to suit the increased length of piles.
 The reinforcement at the top of the pile will need to be exposed for a distance of 40 times the bar
diameter and the new bars overlapped for the distance.
 The central duct will also have to be carefully extended.
 Where facilities at site are available, welding of reinforcement shall be as per the relevant Indian
Standard referred for welding in the product specification standard for steel reinforcing bars.
 Extension of piles length 150 mm or lesser should be avoided and instead pile cap depths
increased suitably 150 mm all around the pile.
 For precast piles, the following tolerances should be adhered:

a) Cross-section (Each direction) Tolerance

1 Up to 500 mm ± 6 mm
2 500 to 750 mm ± 10 mm
3 Additional for every subsequent 250 mm ± 3 mm

Straightness or bow Tolerance

b)
(Deviation from intended line) (maximum)
1 Up to 3 m 6 mm
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 21 of 43

2 3 to 6 m 10 mm
3 6 to 12 m 12 mm
4 Additional for every subsequent 6 m 6 mm
 All precast piles shall be inspected for any defects/honeycombing, etc, and approved for
installation as per structural requirements.
 Piles shall be identified by marking in paint the number of the pile, length of the pile and its date of
casting.
 The piles have to be cured well after casting.

Figures above show the In Situ Piling process’s pictorial view

 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 22 of 43

 Before the handling of the piles, the minimum periods counted from the time of casting shall be as
given in Table below.

 Typical data sheet for recording piling data are shown in Annexure I (page no. 25.).

 Storage & Handling

 Piles shall be stored on firm ground free from chances of unequal subsidence or settlement under
the weight of the piles.
 Care shall be taken at all stages of transporting, lifting and pitching of the piles so that they are not
damaged or do not crack.
 During transportation, the piles shall be properly secured and shall be lifted at the appropriate
lifting holes provided for the purposes.
 If the piles are put down temporarily after being lifted, they shall be placed on trestles of blocks
located at the lifting points or on firm level ground.

 Pile Driving Controls

 The hammer, helmet, dolly and pile shall be coaxial and shall sit squarely one upon the other.
 It is always preferable to employ the heaviest hammer practicable and to limit the stroke/drop so
as not to damage the pile.
 The stroke/drop of a single acting or drop hammer shall preferably be limited to 1.2 m.
 A shorter stroke/drop with particular care shall be used when there is a danger of damaging the
pile.
 A satisfactory set with an appropriate hammer and drop for the last 10 blows shall be achieved.
 Repeat tests shall be carried out if necessary, with caution.
 Long-continued driving, after the pile has almost ceased to penetrate, shall be avoided.
 Any sudden change in the rate of penetration which cannot be ascribed to normal changes in the
nature of the ground shall be noted and the cause ascertained, if possible, before driving is
continued.
 The head of precast concrete pile shall be protected with packing of resilient material, care being
taken to ensure that it is evenly spread and held securely in place.
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Revision. No. 00
FOUNDATION
Sheet No 23 of 43

 A helmet shall be placed over the packing and provided with a dolly of hardwood or other material
not thicker than the width of the pile.
 Jetting may be used as a means of minimizing or eliminating the resistance at the tip; frictional
resistance along the surface of the pile shaft may also be reduced.
 Jetting of piles shall be carried out only when it is desired and in such a manner as not to impair
the bearing capacity of the piles already in place, the stability of the ground or the safety of any
adjoining buildings.
 The jetting pressure shall be from 0.5 to 1.0 N/mm2 or more.
 The arrangement of the jets shall be balanced to ensure that the pile penetrates vertically.
 Jetting shall be stopped before completing the driving, which shall always be finished by ordinary
methods.
 In ground where there is a possibility of piles rising due to ground heave, levels of the tops of the
piles should be measured at interval while nearby piles are being installed.
 Piles which have risen as a result of driving adjacent piles should be re-driven to the original depth
or resistance, unless re-driving tests on neighbouring piles have shown this to be unnecessary.

10 ACCEPTANCE CRITERIA:
 Conformity of All dimensions as per design & drawing
 Conformity of Mix Design
 Conformity of Slump
 Conformity of Cube Strength.

11 PRECAUTIONS:
 Necessary safety measures shall be taken as per the project safety plans.
 Shifting of the material to the foundation area to be performed by using truck, tractor or any other means.
 While loading the material it should be ensured the engaged transportation is having all the valid
document and valid license.
 For going inside the pit a ladder is to be installed.
 At the time of tying the reinforcement, the reinforcement to be lowered in a phased manner. It shall not
be thrown inside. Reinforcements to be kept properly to avoid slipping and tripping of the personnel.
 The excavated areas shall be properly barricaded.
 Once the reinforcement is tied then the shuttering work will be started. While doing the shuttering work a
working space of 600 mm each side is available is needed to be ensured. At the time of excavation the
working space is to be considered.
 While lifting of pre cast piles proper care should be taken, that it is supported properly & no sudden
movements of the lifting machine occur.
 Ensure that piles are stacked properly.
 Ensure that pile gaps are properly welded with no gaps.
 Ensure correct use of hammer weight and drop height.
 Ensure that proper types of pile shoe are used.
 Ensure that piles are driven to the required length.
 The concrete mixer machine to be placed 1.5 m away from the excavated pit’s edge. The connecting chute
to be tied and supported properly to avoid its fall at the time of concreting which can cause injury to the
worker inside the pit.
 While pouring the cement, sand and chips inside the concrete mixer machine drum a smooth access to the
concrete drum to be prepared. The access to be free from the slip and trip hazard.
 The rotating parts of the concrete mixer machine shall be covered & fenced.
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 24 of 43

 Specially for doing the stub column (chimney) shuttering a platform is to be prepared. For climbing at the
top of the stub column always a small ladder is to be used. The ladder shall be secured from top and
bottom
 For pouring the concrete in stub column a small concrete platform shall be prepared.
 Once the concreting is completed, minimum after a day the de-shuttering to be done. The removal time of
shuttering will be depending upon the grade of concrete and ambient temperature of the surroundings.
 Lighting shall be provided around the pits as required.

12 RECORDS :
 Drive In Situ Foundation Record (KEC-Q-TL-SA-F-0018) Annexure II.
 Bored Cast In Situ Foundation Record (KEC-Q-TL-SA-F-0019) Annexure II.
 Pour Card (KEC-Q-TL-SA-F-0020) Annexure II.
 Checklist for PCC (KEC-Q-TL-SA-CL-0008) Annexure III.
 Foundation Material Checklist (KEC-Q-TL-SA-CL-0009) Annexure III.
 Reinforcement Work Checklist (KEC-Q-TL-SA-CL-0010) Annexure III.
 Formwork Checklist (KEC-Q-TL-SA-CL-0011) Annexure III.
 Foundation Work Checklist (KEC-Q-TL-SA-CL-0012) Annexure III.
 Joint Measurement Certificate – Foundation (As per Client’s format).

Note: - Any addition and deduction of data can be done in the formats as per the requirement.
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 25 of 43

ANNEXURE I
Special Precautions in Extreme Weather Conditions

1 COLD WEATHER:
 Keep the material in a place free from moisture and snow.
 Ensure that the cement stored doesn’t freezes due to cold weather by providing proper
insulation.
Precautionary Measures

Condition Precaution
1 Keep formwork in position for longer or use rapid
hardening cement
2 Cover the top of concrete with insulating material
a At low temperature
3 Insulate the steel framework
Make sure that the concrete is delivered to the point
4
of placement at not less than 5°C
Take all precautions mentioned in point a and the
following
1 Insulate all formwork
When there is frost at
b Ensure that the concrete is not placed against a frozen
night
2 sub-grade or against reinforcement steel or formwork
covered in snow or ice
3 Place concrete quickly and insulate
Take all precautions mentioned in point a & b and the
following
1 Heat the water & if necessary the aggregates
Make sure that the concrete is delivered to the point
When there is sever
c 2 of placement at not less than 10°C, place quickly &
frost day & night
insulate
Or make sure that the concrete is delivered to the
3 point of placement at not less than 5°C, place quickly
& provide continuous heating to the concrete
For more details refer IS: 7861 Part2-1981 (Code of practice for extreme weather concreting)
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 26 of 43

Special Precautions in Extreme Weather Conditions

2 HOT WEATHER:
 Keep the material in shade away from direct sunlight.
 Sprinkling water on aggregates to keep it at the required temperature.
 If cold water is available, heavy spraying of coarse aggregate immediately before use may also be
done to have a direct cooling action.
 Water shall be kept cool by preserving it in pipes, tanks & storages with insulation.
 Water while transporting shall be done in insulated tanks.
 Ice shall be incorporated directly into the concrete as part of the mixing water.
 Conditions shall be such that the ice is completely melted by the time mixing it completed.
 Cement shall preferably not be used at temperatures in excess of about 77°C.
 Use of admixture for retarding the hydration rate shall be done, but with such a condition that it
doesn’t have adverse effect on the mix’s strength or workability.
 Temperatures of aggregates, water and cement shall be maintained at the lowest practical levels
so that the temperature of the concrete is below 40°C at the time of placement.
 Mixing time shall be held to the minimum which will ensure adequate quality and uniformity,
because the concrete is warmed from the work of mixing, from the air and from the Sun. The
effect of mixer surface exposed to the hut sun should be minimized by painting the drum with
yellow or white & spraying it with cool water.
 Forms, reinforcement, and sub-grade shall be sprinkled with cool water just prior to placement of
concrete.
 The area around the work shall be kept wet to the extent possible to cool the surrounding air and
increase its humidity, thereby reducing temperature rise and evaporation rate from the concrete.
 When temperature conditions are critical. Concrete placement may be restricted to the evening
or night when temperature is lower and evaporation is less.
 Ample personnel shall be employed to handle and place concrete immediately on delivery.
 Immediately after consolidation and surface finish, concrete shall be protected from evaporation
of moisture, without getting ingress or external water, by means of wet (not dripping) gunny
bags, hessian cloth, etc.
For more details refer IS: 7861 Part1-1975 (Code of practice for extreme weather concreting)
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 27 of 43

ANNEXURE II
Formats:
Document No. KEC-Q-TL-SA-F-0018
RECORD Rev. No 00
KEC / Client Name / Project /
DRIVEN IN SITU FOUNDATION Report No.
Location No. / 001
PROJECT :
CLIENT NAME :
Date:
1 LOCATION NO.
2 TYPE OF TOWER
3 Date of Enquiry
4 Date of Piling Commenced
5 Actual or Anticipated date for Piling work Completion
6 Number of Pile

Page 1 of 3
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Revision. No. 00
FOUNDATION
Sheet No 28 of 43

Page 2 of 3
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 29 of 43

Remarks (if Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT(if Required) FOR CLIENT(If Required)

Page 3 of 3
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 30 of 43

Formats:
Document No. KEC-Q-TL-SA-F-0019
RECORD Rev. No 00
BORED CAST IN SITU KEC / Client Name / Project /
Report No. Location No. / 001
FOUNDATION
PROJECT :
CLIENT NAME :
Date:
1 LOCATION NO.
2 TYPE OF TOWER
3 Date of Enquiry
4 Date of Piling Commenced
5 Actual or Anticipated date for Piling work Completion
6 Number of Pile

Page 1 of 3
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Revision. No. 00
FOUNDATION
Sheet No 31 of 43

Page 2 of 3
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Revision. No. 00
FOUNDATION
Sheet No 32 of 43

Remarks (if Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT(if Required) FOR CLIENT(If Required)

Page3 of 3
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 33 of 43

Formats:

Document No. KEC-Q-TL-SA-F-0020

RECORD Rev. No 00
KEC / Client Name / Project /
POUR CARD Report No.
Location No. / 001
PROJECT :
CLIENT NAME :
Date:
1 LOCATION NO.
2 TYPE OF TOWER
3 TYPE OF WORK
4 APPROVED DRAWING NOS.
5 Mix Proportion
6 Quantity of Concrete
7 Top Level of Concrete
8 Check for Shuttering YES / NO
9 Reinforcement OK / NOT OK
10 Cement Brand & Week No
Theoretical Actual
11 Quantity of Cement Gags

12 Water Cement Ratio

Remarks (if Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT FOR CLIENT

Page1 of 1
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 34 of 43

ANNEXURE III
Checklists:

Document No. KEC-Q-TL-SA-CL-0008

CHECKLIST Rev. No 00
KEC / Client Name / Project /
PCC Report No.
Location No. / 001
PROJECT :
CLIENT NAME :
Date:
1 Location No.
2 Type of Tower
3 Type of Foundation
4 Approved Drawing Nos.
5 Date of PCC
6 Mix Proportion Ratio
7 Quantity of Concrete
8 Surface dressing & preparation OK / NOT OK
9 Cleanliness of formation level YES / NO
10 Stability of excavated side slopes ensured YES / NO
Pits are free from Standing Water (Dewatering continued in advance by
11 YES / NO
Pumps / Buckets)
12 Mixing done by HAND MIXING / MIXER
13 Homogenous Mixture YES / NO
14 Thickness of Concrete Bed
15 Compaction of concrete DONE / NOT DONE
16 Vibrator Used during Pouring YES / NO
In case of excess excavation, filling is done by Lean Concrete i.e. Blinding
17 YES / NO
Concrete
18 PCC dimensions as per the approved drawing
19 Curing Done / Not Done
20 Remarks (if Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT FOR CLIENT

Page 1 of 1
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 35 of 43

Checklists:

Document No. KEC-Q-TL-SA-CL-0009

CHECKLIST Rev. No 00
KEC / Client Name / Project /
FOUNDATION MATERIAL Report No.
Location No. / 001
PROJECT :
CLIENT NAME :
Date:
1 LOCATION NO.
2 TYPE OF TOWER
3 TYPE OF FOUNDATION
4 APPROVED DRAWING NO.
A CEMENT
5 Make of Cement, Type of Cement & Week No.
6 Whether Cement Testing done as per FQP YES / NO
7 Stacking of Cement Bags OK / NOT OK
8 Protective covering found OK / NOT OK
9 Condition of Cement Bags Damaged / Un-Damaged
10 No. of Cement Bags Damaged
11 Quantity of Cement
S.N. Quantity Required as per Design Quantity Availed Quantity(OK / NOT OK)
1
B FINE AGGREGATES
12 Source of Material
13 Whether Source Approved YES / NO
14 Storage Condition of Material (Mixing to other Aggregates) OK / NOT OK
15 Condition of Material GOOD / NOT GOOD
16 Use of Sieve YES / NO
17 Quantity of Fine Aggregates
S.N. Quantity Required as per Design Quantity Availed Quantity (OK / NOT OK)
1
18 Sample Collection of Fine Aggregates for Testing as per FQP Done / Not Done
19 Quantity of Sample
C COARSE AGGREGATES
20 Source of Material
21 Whether Source Approved YES / NO
22 Sizes of Aggregates
23 Storage Condition of Material (Mixing to other Aggregates) OK / NOT OK

Page 1 of 2
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 36 of 43

24 Condition of Material GOOD / NOT GOOD

25 Use of Sieve YES / NO
26 Quantity of Aggregates

Quantity Required as per Quantity

Size of Aggregate Quantity Availed
Design (OK / NOT OK)

27 Sample Collection of Coarse Aggregates for Testing as per FQP Done / Not Done
28 Size & Quantity of Sample
D WATER
Cleanliness of Water (Should be free from oil, acid, & organic
29 YES / NO
material)
30 Water Purity Checked with Litmus Paper YES / NO
31 REMARKS (IF ANY)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT FOR CLIENT

Page2 of 2
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 37 of 43

Checklists:

Document No. KEC-Q-TL-SA-CL-0010

CHECKLIST Rev. No 00
KEC / Client Name / Project /
REINFORCEMENT WORK Report No.
Location No. / 001
PROJECT :
CLIENT NAME :
Date:
1 LOCATION NO.
2 TYPE OF TOWER
3 TYPE OF FOUNDATION
4 APPROVED DRAWING NOS.

5 Material Quantity & Quality as per Approved. Drg. / specs

Diameter Qty. Reqd Qty. Avail Apprd. Source Quality
S.N.
(mm) (kg) (kg) Yes/No (Ok / Not Ok)
1 6 mm
2 8 mm
3 12 mm
4 16 mm
5 20 mm
6 25 mm
7 32 mm
6 Bending/Placing as per approved Drg. YES/NO
7 Binding done as per specifications YES/NO
8 Any undue stress or bending of steel bars YES/NO
Steel is clean and free from loose rust or any other foreign
9 YES/NO
materials
10 Position of bars w.r.t. stub as per drawing YES/NO
11 Clear cover of 50 mm from reinforcement structure. YES/NO
12 Remarks (If Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT FOR CLIENT
Page1 of 1
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 38 of 43

Checklists:

Document No. KEC-Q-TL-SA-CL-0011

CHECKLIST Rev. No 00
KEC / Client Name / Project /
FORMWORK Report No.
Location No. / 001
PROJECT :
CLIENT NAME :
Date:
1 LOCATION NO.
2 TYPE OF TOWER
3 TYPE OF FOUNDATION
4 APPROVED DRAWING NOS.
5 All dimension of form box is accurate and placing as per drawing YES/NO
6 All bolts and nuts are water tight YES/NO
7 Oiling of form boxes properly done YES/NO
8 Clear cover of 50 mm from reinforcement structure. YES/NO
9 No holes/crevices or damage from where leakage is possible YES/NO
10 Remarks (If Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT(If Required) FOR CLIENT(If Required)

Page1 of 1
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 39 of 43

Checklists:

Document No. KEC-Q-TL-SA-CL-0012

CHECKLIST Rev. No 00
KEC / Client Name / Project /
FOUNDATION WORK Report No.
Location No. / 001
PROJECT :
CLIENT NAME :
Date:
1 LOCATION NO.
2 TYPE OF TOWER
3 TYPE OF FOUNDATION
4 APPROVED DRAWING NOS.
5 Concrete Mix proportion as per design
6 Dimensions of Measuring Boxes as per approved specs. YES/No
7 Pits are free from all Foreign Materials Yes/ No
Pits are free from standing water (Dewatering continued in advance
8 Yes/ No
by Pumps/Buckets)
9 In case of excess excavation filling is done by lean concrete Yes/ No
10 Concrete mixing by mixer Yes/ No
11 Homogenous mixture Yes/ No
12 In process de-watering done (if required) Yes/ No
13 Lean concreting done up to specified level and in all the four pits Yes/ No
As per design Actual
14 No. of cement bags consumed

15 Use of poking rod for compacting Yes/ No

16 Use of vibrator for compacting Yes/ No
17 Use of Chutes for pouring concrete over 1.5m height Yes/ No
18 Checking of templates levels & its diagonals at regular intervals Yes/ No
19 Casting of legs done in continuity Yes/ No
20 Concrete taken for slump test Yes/ No
21 Concrete taken for Cube testing Yes/ No
22 Concreting done up to the specified level above ground Yes/ No
Removal of Template, Shoring, Shuttering & Stripping of form work
23 Yes/ No
after minimum of 24 hours or as per client's requirement done
24 Damages observed in concreting after removal of form boxes Yes/ No
25 Rectification of damages done before back filling Yes/ No

Page1 of 2
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 40 of 43

26 Curing
a Availability of water pump for curing Yes/ No
b Date of commencement of Curing
c Date of completion of Curing
d Curing of chimney done as per specified procedure Yes/ No
e Cubes cured for specified time & sent for testing Yes/ No
27 All surplus material is removed from site Yes/ No
28 Remarks (If Any)

(Site Supervisor / Engineer) (QA / Q C Engineer) (Site Supervisor / Engineer) (QA / QC Engineer)
for KECIL for KECIL For CLIENT FOR CLIENT

Page2 of 2
 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 41 of 43

ANNEXURE IV
Dos & Don’ts:
Right Wrong

Proper Binding of Reinforcement Loose Binding of Reinforcement

Use of Measurement Box No Measurement Box Used & Unsafe Act

Concrete Poured after Water Removal Concrete Poured in Water

 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 42 of 43

Dos & Don’ts:

Right Wrong

Use of Vibrator No Vibrator Used

Proper Chute Position Improper Chute Position

Proper Slump Improper Slump

 Standard Operating (Work) Procedure Document No. KEC-Q-SOP-0012

Revision. No. 00
FOUNDATION
Sheet No 43 of 43

Dos & Don’ts:

DOs DON’Ts
Reinforcement steel tied as per the procedure Loose tying of reinforcement steel
PCC as done per drawing PCC done without considering drawing
Full Dewatering done before pouring concrete Concrete poured in water
Pit cleaned from any soil or foreign material before
Concrete poured without cleaning the pit
pouring concrete
Chute used to pour concrete above 1.5m No chute used or chute end above 1.5m height
Formwork properly tautened Formwork not properly tightened
Giving 50mm cover for concrete from all sides Uneven cover or no cover for concrete
Foundation casting done in continuation Foundation casting done in intervals
Homogeneous concrete mixture used Inhomogeneous concrete mixture used
Material mixed in concrete using measurement Material mixed in concrete using nonstandard
boxes receptacles.
Concrete taken out for slump test & Cube test from Separately concrete mixed for cube test & slump
the mix that is poured test
Use of vibrator while concreting No vibrator use while concreting
Form boxes taken out after a minimum of 24 hours
Form boxes taken out before 24 hours
or as per site condition
Curing is done for the minimum said period Curing done for less time
Chimney & exposed portion cured by keeping wet Chimney & exposed portion cured by just watering
bags for some time