LEARNINGS ON AGL &

SPECIAL AGENCY
ENGAGEMENT
 Material & mix
• HDPE Pipe, spacer & coupler. • Cementitious content – 360 to 380 kg/cum
• L-868 mounting base (Deep can) for rigid (grade M25 to M35)
• L-850 A/L-823 Shallow light base for flexible • % replacement of cement with GGBS – 50%
• • 100% crushed stone sand
Runway/taxiway center-line light
• • OPC-53 grade cement
Runway/taxiway edge lighting system with
elevated or in-pavement light fixture • W/C ratio – Max 0.45
• PAPI-Approach light • (0.5 to 0.6)% Admixture – Third generation, low
• Touch down zone light range PCE, super plasticizer & water reducer
• Retention time – 90 min
• Threshold/runway end light
• Workability – 50 to 80 mm
• Runway guard light
• Characteristic compressive strength – 25 to 35
• Runway stop bar light
Mpa
• Signages, High Mast light & VDGS with pole • Aggregate properties – AIV: Max 45% & FIEI:
Reference - ICAO Manual & FAA Circular Max 35%
How to formulate method statement & checklist
• A method statement is a brief description about the activities necessary to complete tasks with safety in
accordance with the specified requirements.
• Engage the external agency by their competency & experience in the AGL field.
• Purpose of the method statement shall be described.
• Categorize the different activities involved in the process and state the preventive measure for special
requirements.
• Identify the resources (man & machinery) required to finish the activities
• Declare the reference based on which the method statement established
• Describe the detailed work procedure sequentially to complete the activities
• Describe the responsibilities of site engineer, qc engineer, qa engineer, construction manager & project
manager.
• Prepare the control measures for each activities
• Identify the risk involved in the activities & take necessary precaution to mitigate the risk.
• Declare the safety & environmental hazards if any
• A checklist is a list of items needs to be verified, checked or inspected.
• It is a guide of items need to be ready for a construction or a list of process/procedures to be performed to
finish the construction
• Constraints involved in the process or procedure shall be reflected in the checklist.
What we look into the method statement
• Understand the purpose & importance of the work.
• Check the activities involved.
• Refer the standards & drawing for specification & dimension.
• Check whether the required resources are available to finish the activities.
• Go through the detailed work procedure.
• Find out the responsibility classified designations.
• Check the control measure – ITP & checklist.
• Check the risk involved & how to mitigate the same.
• A methodology for rectification of blockage in AGL ducts.
Constraints – Material & mix
• Storage- Improper storage can lead to damage of material.
• Exposure of HDPE pipe to direct sunlight cause color fading.
• Unavailability of different colors of HDPE pipe
• Mis-handling and improper shifting of material to site.
• No protection from weather (rain water & dust) while stored at warehouse.
• Negligence of conducting inspection prior to usage.
• Alteration of mix at plant or during transportation – addition of extra water results more than
required free water leads to bleeding & less compressive strength
• During transportation TM drum is forcibly stopped by operator affects homogeneity of
concrete mix
• Negligence in providing trip sheet leads to degradation of fresh concrete properties & difficult
to identify the grade of concrete, malfunction of concrete grade based on requirement
How to overcome constraints - Material & Mix
• Storing need to be done in a proper way with identification for easy traceability.
• Cover the HDPE pipe with tarpaulin in order to protect from sunlight
• Availability of color pipes to meet specification shall be ensured before starting the activity.
• Proper method of shifting and loading/unloading to be followed to avoid any damage while
transportation.
• All material has to be covered and stored above to ground level in the warehouse.
• As soon as material reaches site inspection to be carried out and if any defects found to be
rejected.
• Conduct checking by reverse rotation of TM to ensure there is no water in drum
• Control over the transit mixer/plant operator for adding external water for getting required
workability & ensure rotation of TM drum through out the haulage. Check slump at plant
frequently, fine tune the mix proportion accordingly to get desired workability
• Provide trip sheet with each TM providing the required details like loading time, slump at
plant, grade, structure & location to prevent malfunction
Constraints - Execution
• Deployment of unskilled work force in sensitive work like HDPE pipe laying.
• Absence of detailing of circuits and light fixing point in GFC drawing.
• Lack of coordination between laying and AGL team.
• Lack of supervision while excavation which leads to damage in nylon rope by JCB teeth of laid conduits.
• Improper cutting of GSB or WMM layer for placing & laying of HDPE pipe.
• Negligence in providing spacer/cover blocks & supports to HDPE pipe.
• Fixing of coupler inappropriately.
• Laying of conduits on bumping surface.
• Mismatch in color code of conduits joined with pits.
• Lack of identification of interdependent activities.
• Negligence in sealing gaps & proper backfilling
• Negligence in maintaining earthing & damage of drainage pipe in deep can.
• Insufficient arrangement to ensure height of fall of concrete.
• Unfinished concreting for duct encasing.
• Mismatch in FRL of PQC and deep can top.
How to overcome constraints - Execution
• Special agency should deploy proper work force prioritizing the importance of work which will not lead
to any re-work or delay.
• Circuit detailing, pit position and light fixing points should be incorporated with pavement GFC.
• A single point contact by building a proper channel should be developed in between laying and AGL
team.
• Proper supervision to be done if any excavation work to be carried near encased duct location for
protection of the same.
• Cutting of trench on GSB or WMM layer to be done maintaining proper line and level.
• Spacer/cover block and cut-piece re-bars should be provided at regular interval to avoid undulation and
misalignment in pipe line.
• Coupler should be provided maintaining proper lap and by cutting HDPE pipe sharply.
• Over watered or surface having bumping should be rectified before laying conduits.
• Color code of conduits joined with pits has to be maintained so as to meet its purpose as mentioned in
drawing.
• Interdependency plan to be made before starting of work.
How to overcome constraints - Execution
• Gaps after laying conduits to be sealed using masking/duct tape to prevent ingress of slurry
which leads to blockage.
• Backfilling shall be done & compacted to prevent the duct from getting damage.
• Concrete pouring should be done through chute of required length to limit the height of fall.
• Concreting done for encasing should be finished properly to its required level and to be
compacted while pouring.
• Haphazardness while concreting which blocks drainage pipe and disturbs earthing wire while
fixing deep can to be supervised.
• Top level of deep can to be cross checked with FRL of PQC.
What we have to take care during process
• Material inspection to be carried out of all the materials.
• Control points to be protected with utmost care.
• Co-ordinate marking to be done of all lights & pits with tolerance within range.
• All excavated area to be marked properly by using lime powder and excavation to be done
up-to required width and depth followed by dressing.
• HDPE pipe to be measured and cut to length as required at site to avoid wastage.
• L shaped HDPE pipe to be firmly fixed in light fixing points with end cap and proper care to
be taken from any damage and blockage subsequently.
• All the material should be protected carefully so as to avoid any damage due to negligence.
• Pre-checking to be done with respect to drawing before proceeding to each associated
work subsequently.
• Movement of convenience and construction vehicle should be strictly restricted in order to
avoid damage of untreated core pit.
• Duct concrete to be cured as specified.
What needs to addressed for a defect free product

• Effective planning & ensure the availability of all required resources

• Quality inspection to be conducted for all the incoming material prior to use.
• Carrying out activities as per the method statement.
• Conducting checks as per inspection test plan.
• Frequent training among the concerned team.
• Ensuring activity wise check as per checklist by site engineer & QA engineer.
• A clearance shall be taken from the AGL team before proceeding the next layer.
• Evaluate the performance of the agency deployed for AGL work on monthly basis
Snags
• Absence of circuit details on pit.
• Discontinuity of earthing cable till earth bar.
• Secondary cable laid through opening of primary cable or vice versa.
• Excess cable messed around earth bar and other electrical fitting.
• Negligence in cable dressing in pits.
• Secondary/primary connectors connected loosely and no insulation.
• Excess conduit opening left open.
 WHAT NEED TO BE ADDRESSED SO THAT SNAGS SHALL NOT BE THERE
• Tag to be provided depicting the details of circuit for easy traceability.
• Earthing cable to be continued till earth bar rerouted through cable tray.
• Ensure the placing of primary & secondary cable in the designated opening of the AGL pit.
• Excess cable should not be messed around the earth bar or any other electrical fitting.
• Cable inside pits should always be dressed.
• Secondary/primary connectors in pits to be connected firmly and proper insulation to be
provided.
• Excess conduit opening to be grouted to avoid entrance of mud/water into pits which may
damage wires and other electrical fittings.