CONCRETE WORKS 1.

OBJECTIVE
The main objective of this document is to provide guidelines for inspection of concrete works at Construction of Canal Intake Structure: Project.

2.

SCOPE
This method statement covers concrete works under the scope of project specifications and Quality Management System (QMS) Companywide.

3.

RESPONSIBILITIES
The Construction Manager will organize resources to perform concrete works activities as per project specification, in compliance with quality, and planning schedule requirements. QCE will assure that all the relevant work is carried out in conformance with project specification, PQP and QIP. In case of any non-conformance, it will be controlled by corrective action request (CAR).

4.

PROCEDURE
4.1 Concrete Materials
4.1.1 Cement

The cement used for concrete, reinforced concrete, mortar, grout & plaster works shall be Portland cement conforming to project specs.

The supplier/ manufacturer shall provide certificates of conformance. Use cement in sequence of receipt of shipments unless otherwise directed by Client.

4.1.2 -

Aggregate (coarse & fine)

Natural sand conforming to project specifications/codes shall be used.

The aggregates to be used in the concrete shall be procured from a source known to produce aggregate that is chemically inert, strong, hard, durable and of limited porosity and free from any adhering impurities that may impair the strength, durability or quality of concrete.

Sampling and testing of coarse aggregate. Each size of the aggregate shall be stored separately and in a manner that will prevent contamination and intermixing. The equipment & method of handling the aggregates shall ensure that the stockpiles do not suffer deterioration and contamination.

4.1.3 -

Water

The water used in the preparation of concrete & mortar shall be clean & free from injurious amounts of impurities (Potable water meets this requirement).

4.1.4

Storage and Handling of Materials All materials shall be stored and handled in such a manner that will prevent damage or deterioration.

4.1.5

Concrete Additives/Admixtures Concrete additives/admixtures shall only be used after approval from the Client.

4.1.6

Mix Design/Trial Mixes Trial mixes shall be prepared to determine the mix proportions necessary to produce the strength of concrete as per project specifications. Each mix shall be prepared to meet the workability requirements for transporting, placing & compacting of the concrete relative to the particular situation it is to be used. The details of the design/proposed mixes shall be submitted to the client/consultant for his approval and no concreting shall be commenced until formal approval has been received.

4.2

Batching Plant
The batching plant shall produce the concrete in accordance with the specific design mix applicable as per project specifications. The Material Engineer/ Lab In-charge shall be responsible for determining the correct amount of water to be added keeping in view the moisture content of coarse and fine aggregates and workability requirements as per project specification. The batch plant controller shall be responsible for checking that all wash water has been removed from the delivery truck drum before adding new ingredients of concrete. After loading fresh ingredients of concrete, the drum revolutions required to produce uniform concrete shall be set. The batch plant technician shall perform the slump test and keep a complete record of each truck of concrete. Calibration and inspection of the equipment of batching plant shall be carried out periodically. Use of horn during movement of concrete trucks (if required).

4.3

Hot weather concreting

During hot weather the batching plant supervisor shall take all necessary instructions to ensure that the temperature of the mixed concrete does not exceed specified temperature. These measures shall include, but not be limited to, shading of aggregates, spraying water on aggregates, linking the mixing water to a chilled unit, chilling the mix ingredients with ice and when ice is used in the mix, maintain the correct amount of water required. Re-tempering of concrete or mortar, which has partially hardened, shall not be permitted.

4.4

Concrete Tests
The characteristic strength of the concrete placed in the formwork shall be determined for 7 days and 28 days by the compressive strength testing of test cylinders as per project specifications. Frequency for testing will be as per specs. Keep a complete record of specimen of test concrete with location and date of placement, proportion of mix blend and type of cement etc.

4.5

Concrete operations
4.5.1 Transportation Use of horn for starting a movement. The concrete shall be transported to site in transit mixers immediately after mixing and shall be placed within stipulated time period after adding water. The concrete delivery note shall be endorsed with the time of dispatch of the truck. This information will also be summarized for each pour on prescribed form. No concreting operations shall be performed without the written approval of client. 4.5.2 Placing of Concrete Prior to placing concrete, air & concrete temperatures shall be recorded. Placing of rebar and formwork shall be as per drawing and its get its approval from client. All equipment that are necessary for placing concrete i.e. pumps, vibrators, compressors and concrete test equipment etc. shall be checked for availability, operational capacity, reliability and calibration. For all large pours, prior to pouring, standby vibrators, concrete pumps, batching plants etc. shall be provided for replacement in the event of breakdown.

4.5.3

Compaction of Concrete During compaction, vibration checks shall be made to ensure that rebar spacer blocks are not displaced or dislodged. Rebar that shall be exposed after concreting are protected during the pouring and subject to cleaning during & immediately after the completion of the pouring. After placing, compaction shall be done thoroughly around all reinforcement, embedded fixtures and internal corners and forms with internal vibrators according to the procedure conforming to project specifications or standards. Use gumboots for entering into concrete.

4.5.4

Concrete Curing Immediately after the concrete work has been accomplished, take measures to protect the concrete by spraying the exposed surfaces with a curing compound and by placing burlap or blankets. Cover the exposed surface by hessian, these covers shall be maintained and where possible the burlap or blankets shall be covered by polythene. Curing compound if used shall be approved by client and as per project specifications.

4.6

Concrete Finishing
The concrete face shall be checked for compliance as indicated in the project specifications or construction drawings. The concrete face shall be clean and free from all foreign matters etc.

4.7

Repairs to Damaged or Defective Concrete

Follow the correct instructions so that concrete is not damaged or is not defective. If some damage or defect exists, conduct inspection of the location jointly with client/consultant and submit the proposed method statement for performance of repairs and get it approved in writing before commencing such repairs.

4.8

Construction Joints
Construction joints shall be constructed exactly in accordance with the detail shown in the plans and the specifications with the best of workmanship.

Get approval of client/consultant before introducing such joints if not shown on the drawings. Time as per specs shall be elapsed before casting adjoining concrete. Construction joints shall be perpendicular to the plane of the member. Continue all specified reinforcement through joints. Joints should be roughened. Construction joints shall be cleaned and grouted with cement mortar before placing new concrete.

4.9

Expansion Joints/Water stops

Expansion joints shall be constructed as per drawings/specifications. PVC/SS Water stops as required shall be fabricated and located as shown on the drawings. Water stops shall be accurately cut, fit and integrally jointed at sectional joints and angular junctions to provide a continuous watertight diaphragm at all points. Make adequate provision for the support of water stops during the progress of work.

4.10 Concrete Embedment

Anchor bolts, edging angles and other miscellaneous metal embodiments in concrete shall accurately be located and secured in position within approved tolerance to resist loads incidental to placing of concrete. Verify all anchor bolts and embedded items locations are as per construction drawings.

4.11 Equipment Installation

Equipment shall not be installed till assurance of concrete strength.

4.12 Hand finishing

In the event of breakdown of mechanical equipment, hand-finishing method may be used to finish the concrete already deposited when the breakdown occurs and no additional concrete shall be placed until such equipment is repaired to the satisfaction of Client.

5.

TOOLS & EQUIPMENTS

Batching plant, Concrete Mixers, Transit mixers, Loader (front end), Vibrators Concrete pumps, Wheel-barrows etc.

6.

Related documents
Corrective Action Request (CAR) form Quality of Coarse/Fine aggregate. Survey Report Weather record Flat and elongated particles Calculation Sheet Aggregate Combination For Concrete Design Mix. Specific gravity test Cement Soundness test Unit weight (Loose / Rodded) Summary of Daily Concrete Concrete compression test Monthly / Weekly summary of compression strength of concrete Request/Report for Inspection/Test (RIT)