Construction Activity 
Report‐I (May‐2010) 
Submitted to: Dr. D. Sarkar 
 
 
 
 
 Submitted By: Mitul S. Shah (CP1809)
 
 
 
 
 
 
 

           
 
M.Tech, Construction and Project Management Department
  Faculty of Technology, CEPT University, Ahmedabad-9
 
 
 
 
 
 
 Construction Activity‐Report‐I  CP1809 

 
      Construction Activity Report‐I  

Period: 5th May to 1st June

Introduction:

There were several civil construction activities going on at the 5x660 MW Thermal
Power plant project at Mundra which consisted of the following:

 Main Power House Building

 Chimney Construction and Internal Erections
 Cooling Towers
 Cooling Tower Main Control Buildings
 Mechanically accelerated Clarifiers
 Coal and Ash Silos
 Electrostatic Precipitator Erection
 Circulating Water Culvert
 Coal Conveyer Galleries
 Demineralization Plant
 Wastewater Treatment Plant
 Circulating Water Pump House

In addition there were various miscellaneous activities going on at the site which
consisted of installation of pipelines and other buildings as required on the site. The work
for the power plant components of the TPP were awarded to a main contractor i.e.
SEPCOIII and they subcontracted the work to various other sub contractors as mentioned
in the preliminary site report.

Due to the vast nature of the activities which were going on at the site, two activities were
concentrated upon during the first month, which are the main power house construction
and the chimney construction. The details of the construction are as follows.

   
Page 2
   
 Construction Activity‐Report‐I  CP1809 

Main Power House Construction

Introduction

The 4620MW Power plant consisted of 9 units which were divided into the following
phases. Out of which the first and the second phase which consisted of a total of 4 units
which produced 330 MW each and were subcritical were given as a direct contract to a
particular Chinese contractor. But with the problems arising in the operation of the
contract, Phase-III and Phase-IV which consisted of 5 units of 660 MW (Supercritical)
were given as an EPC contract to a Chinese company SEPCOIII which specializes in
power construction. They subcontracted the work to three major subcontractors who
were
 Gannon Dunkerley Ltd. [ Constructing Units 5, 7, 9 ]
 Simplex Infrastructure Ltd [ Constructing Units 6,8 ]
 Larsen and Toubro, ECC Division [ Fabrication and erection of ESP ]

4620MW
Thermal Power
Plant, Adani
Power, Mundra

Phase-I Phase-II Phase-III Phase-IV

Unit-7 Unit-8 Unit-9

   
Page 3
   
 Construction Activity‐Report‐I  CP1809 

There was rapid civil construction work going on in the Unit-8 and Unit-9 and thus
there was observation of the activities going on at both the sites.

Typical Layout of the Main Power House Building

10

6 7
5 8

Legends showing various major components of a Main Power House (MPH)

Legend Description Legend Description

No. No.
1. Electrostatic Precipitators 6. High Power Turbines
2. Boiler House 7. Generator Area
3. Coal Bunkers (6 Nos) 8. Maintenance Access
4. Deaerator Area 9. Low Power Turbines (2 Nos)
5. Control Cabin Room 10. Conveyer Tower

   
Page 4
   
 Construction Activity‐Report‐I  CP1809 

Status of the work when joined at the site:

Unit-8: There are four stages of construction of a particular unit which is consisting of
the raft foundation which is followed by the column construction and then there is the
mid deck construction. After that there is a 3rd lift of the columns from the foundation
which is followed by the final construction of the Turbine and Generator Deck slab.

For the Unit-8, the staging works for the TG Deck slab were completed and the
reinforcement was being fabricated along with the shuttering work for the TG Deck slab.
A very important activity in the TG Deck Slab casting is the arrangement and leveling of
the bolts for the turbines and generator. The bolts along with their sleeves were already
roughly inserted in the slab, but the alignment, precise centre to centre distance and level
were still not done.

Unit:9 At Unit 9 the raft foundation works had been completed and the staging was being
done for the construction of the columns above the foundation. All the steel erection
work for the the Unit-9 was completed when we joined the site and the tower crane for
the same was also erected. Reinforcement fabrication was going on for the columns as
well.

Fig- Construction of TG Deck after Staging and Reinforcement Placed

   
Page 5
   
 
 Construction Activity‐Report‐I  CP1809 

TG Deck Slab Construction

The Turbine and Generator Deck slab is the most important civil construction work in
the main power house. The dimensions and the layout of the slab can be understood as
follows:

Materials of Construction

Sr. No Material Grade Related IS Remarks

Code
1 Reinforcement CTD, Mild IS 1786, IS 20mm, 25mm,
Steel 432 36mm, 16mm
Respectively Reinf. used
2 Concrete M30, M35, IS 456:2000 RMC Used
M40
3 Shuttering 1220x2440x12mm
Plates Plates Used
4 Staging Pipes Mild Steel 40mm NB Pipes
and Clamps Used, 6m length
5 MS Sleeves According to For the Fixing of
and Bolts DongFang Turbines and
Turbine Generator as by
Measurements supplier.
6 Embedded Mild Steel For Welding of
Insert Plates Beams.
200x200x5mm
Plates used
7 Structural Steel ISMB 250 For the
Beam Sections Foundation of
Pulling Block

Manpower Employed at the Site

Sr. No. Type of Labour Quantity Remarks

1 Carpenters 58 For Shuttering
2 Semi Skilled 40 For Various Works
Labourers
3 Helpers 75 Assisting the
Skilled Labour
4 Fabricators 40 Fabrication of
Reinforcement
5 Welders 25 For Welding and
Erection of
Reinforcement

   
Page 6
   
 Construction Activity‐Report‐I  CP1809 

6 Khalasi 20 For various works

7 Unskilled Labour 70 Other Misc Works
Total 328

Equipment Used for Construction

Sr.No Equipment Manufacturer Model No. Capacity Remarks

1 Gantry SEPCO NA 80/20 Tons

Crane Fabricated
2 Tower JINGLU- TW-4563 10T
Crane QTZ
3 Crawler KOBELCO CSK-2500 250 Tons
Based
Lattice
Boom
Crane
4 Telescopic P&H R4ST-15 75 Tons
Boom
Crane
5 Air
Compressor
6 Electric 3600 2.5m Length,
Operated Vibrations/minute 6mm needle
Vibrators
7 Gas Cutters Ramco NA
8 Total Leica, PON1243
Station Germany
9 Boom Sany SY5256THB 6 m3
Placers
10 Concrete Putzmeister NA 45 cum/hr
Pumps
11 Transit Tata, Ashok 6m3
Mixers Leyland
12 Bar - For
Bending Reinforcement
Machine Bending
13 Bar Cutting - For
Machine Reinforcement
Cutting
14 Batching Schwing 30 Cum/Hr
Plant Stetter

   
Page 7
   
 Construction Activity‐Report‐I  CP1809 

Civil Works for the TG Deck Unit-8 were to be commenced on the date 10/03/10 and
were to be completed by the date 28/3/10, but now the projected completion date has now
gone behind to 28/4/10 which results in a delay of one month in the completion of the TG
Deck. We have attempted to find out the reasons for the delays so that they can be
corrected in the future execution of similar magnitude.

Data Collection and Analysis

Data collection was done from the records maintained by the client engineers and the
major activities in the TG Deck Casting program are shown with their scheduled start and
end dates along with the actual start and finish dates. Please note that we have assumed
the date for casting as obtained from the site.
Sr. Activity Sch.Dur Act.Dur Scheduled Actual Scheduled Actual
No. Description Start Start Finish Finish
1 Raft 42 45 20/10/09 26/10/09 1/12/09 9/12/09
Foundation
2 Column 1st 36 38 25/11/09 3/12/09 31/12/09 9/1/10
Lift
3 Column 2nd
Lift
4 Mid Deck 41 46 22/12/09 29/12/09 1/2/10 12/2/10
5 Column 3rd 29 30 1/2/10 9/02/10 1/3/10 10/3/10
Lift
6 TG Deck 57 83 4/3/10 10/3/10 29/04/10 31/5/10

Table-1: Activity Planning for the MPH-Unit:8

Lag Analysis- Unit-8

Cum. Duration (Days)

300
250
200
Planned
150
Actual
100
50
0
TG ft
fts

ck
ft
PH

ck

Li
Ra

De
Li

De
M

d
n

3r
d
um

n
M

m
l
Co

lu
Co

Activity

   
Page 8
   
 Construction Activity‐Report‐I  CP1809 

Lag Analysis
As we can see that there is a total lag of 37 days in the completion of the MPH building
up to the TG Deck Level. The Percentage Lags for each and every major activity for the
MPH building can be shown as follows:
Activity % Lag
Raft 7.14%
Column Const. 5.55%
Mid Deck 12.2%
Column 3rd Lift 3.45%
TG Deck 45.6%
Total Project Lag 18%

Labour Productivity Analysis for TG Deck

Productivity can be defined as, the total time (generally in terms of hours) required to
complete unit work. We have attempted to find out the total productivity analysis for the
TG Deck of Unit-8. The quantities of the materials to be worked upon are as follows:
Description  Qty.  Nos. of  Working  Productivity 
labourers  hrs./day/labour 
Staging  25000 pipes  0.0384hrs/pipe 
80  12 
  85000 clamps  0.0112hrs/clamp 
Reinforcement  260 MT  84  12  3.87 hrs/mt 
Shuttering  1025 sq.mt.  66  12  0.77 hrs/sq.mt 
Concreting  1290       
Table-2: Quantities and Productivity Calculation for the TG Deck Slab (Unit-8)

Now the productivity calculated is as per the actual work done for the slab and the
collected data has been used. Now the scheduled productivity and the actual productivity
can be compared to find the productivity lag which would be very useful for planning in
the future.

Productivity as Per Schedule and Actual

% Reduction in
Item Scheduled Actual Productivity
Staging Pipes 0.0294 0.0384 23.2%
Staging
Clamps 0.0073 0.0112 34.11%
Shuttering 0.462 0.77 40.76%
Reinforcement 2.246 3.87 42.2%
Table-3: Productivity Actual and Scheduled

   
Page 9
   
 Construction Activity‐Report‐I  CP1809 

Staging Productivity Analysis Productivity Analysis

0.045 4.5
0.04 4
0.035 3.5

P roductivity
Productivity

0.03 3
0.025 Scheduled 2.5 Scheduled
0.02 Actual 2 Actual
0.015 1.5
0.01 1
0.005 0.5
0 0
Staging Pipes Staging Clamps Shuttering Reinforcement
Activity Activity

Fig- Graphs showing the difference in the scheduled and actual productivities for
TG Deck Slab-8

Activity Productivity Analysis for TG Deck

Description  Qty.  Scheduled  Actual  Scheduled  Actual 
Duration  Duration  Productivity  Productivity 
Staging  25000  0.00056 0.0008
pipes 
14  20 
  85000  0.00016 0.00023
clamps 
Reinforcement  260 MT  20  31  0.076 0.12
Shuttering  1025 sq.mt.  22  32  0.021 0.031
Concreting  1290  1.5  1.5  0.0011 0.0011
Activity Productivity Analysis-I Activity Productivity Analysis-II

0.0012 0.14
0.001 0.12
Productivity
Productivity

Scheduled 0.1 Scheduled

0.0008
Productivity 0.08 Productivity
0.0006 0.06
Actual Productivity Actual Productivity
0.0004 0.04
0.02
0.0002
0
0
g
t
en

rin
g

em

te
in

tin

ut
ag

rc
re

Sh
fo
St

nc

in
Co

Re

Activity Activity

Fig- Graphs showing the difference between the Actual and Scheduled
Activity Productivity

  Page   
  10   
 Construction Activity‐Report‐I  CP1809 

Reasons for the Lag in Schedule and Productivity

There are various reasons because of which the MPH unit-8 civil works were delayed and
the reasons can be stated as follows:
 Improper Planning of Materials: There was a lack of planning on the part of the
sub-contractor i.e. Simplex Infrastructure wherein the laborers were sitting idle
for a lot of time due to the unavailability of materials. But the Simplex office
stated that there was material available but it had to be deshuttered from a
previous casting activity. This resulted in one gang de-shuttering the forms and
one gang sitting idle which resulted in lag in schedule and productivity.

 Unavailability of Materials: The Steel gangs were often sitting idle during the mid
deck slab construction and TG Deck construction because the steel had not been
provided to them for working by Simplex.

 Unhygienic Labor Colony: There was a lack of cleanliness and other sanitation
facilities in the labor colonies and hence there were frequent instances of many
skilled, unskilled and semi-skilled labourers etc. remaining absent during critical
times. This resulted in frequent delays and hence the lag occurred in completion.

 Temperature: There was an inherent increase of about 10-13 degree Celsius in the
temperature during the initial months of the construction activities for the MPH
unit which was started in the winter season, but as the summer season
approached, due to the high temperature and drastic variations in humidity there
was a delay as well and loss of productivity.

  Page   
  11   
 Construction Activity‐Report‐I  CP1809 

Construction Procedure

Pre-Construction Activities: There are some pre-requisites which need to be

fulfilled before the actual construction can commence on the site. The details for the
same are as follows:
 The Level of the third lift of the columns from the raft foundation level is to
be checked if they have reached the required level as per the design.
 All the columns are to be checked whether they are at the same level or not.
 Dowel bars from the third lift are extended enough for lapping for the final
casting or not.

After the following activities are completed, the actual construction activities of the
TG Deck construction can start and the various activities of construction can be given
as below:

Staging with Completion: First step of the TG Deck construction is to raise the
staging which has been started from the Foundation Level, from the Mid Deck Level
which is at a height of FL+7.2m to a height of FL+14.72m which is the height for the
TG Deck top level.
Normal Staging Material of 40mm NB Pipes and MS clamps are being used for the
staging. The length of the pipes is 6m. The pipe lengths can be adjusted if required
with the help of gas cutting.
The clamp and pipe arrangement can be seen in the following image and staging
material specifications and drawings can be given as follows.

The staging pipes are clamped together horizontally and vertically to form a H-Frame
as shown in the figure. These H-Frames are then provided with Cross Bracings
clamped together to protect them from wind loads as well as to arrest the movement
of the legs of the H-Frame.

Vertical Pipes are placed at a distance of 675m C/C and the horizontal pipes are
clamped together at the spacing of 1200mm C/C. Alternate Cross Bracings are
provided and the frame is positioned.

Similar procedure is followed and the staging is erected for 7m height. The total
height of the staging is kept at 14.72m at the Beam Bottoms and 20m in the cutouts as
shown in the plan of the TG Deck Slab.

  Page   
  12   
 Construction Activity‐Report‐I  CP1809 

Beam Bottom and Insert Plate Fixing: After the staging works are completed, and the
required level of the beam bottom has been achieved, beam bottom fixing and the insert
plate fixing activities are commenced. Steps for the same can be given as follows:
 Prop Heads are attached to the vertical staging pipes.
 ISMC100 Channel sections are then inserted into the prop heads as shown in
the figure bottom facing.
 Now horizontal wooden battens of 25x25x50 which can be called as waler
beams are then supported on the channel sections perpendicular to them as
shown in the figure.
 On the top of the waler beams the wooden shuttering plates of the dimensions
1220x2440x12mm are nailed together to the waler beams and the shuttering
plates are as seen in the sketches for the formwork.
 Care is taken at every point that the level is maintained and it is done either
with the help of a bubble tube or in some cases with the help of a dumpy level.
Centre-lines are also marked. When the entire bottom shuttering is completed,
again the level is checked for being at FL+14.72m as indicated in the plans.
 With that the activity of beam bottom shuttering is completed.
 After that the position of the bottom insert plates is checked and they are fixed
together. The dimensions of the plates vary and they range from
250x250x5mm to 500x500x5mm. They are provided by the Dong Fang
Turbine Plant, China and are generally used for welding the beams which will
support the hanging turbines and generator.

36mm-# TMT Bar Tie Rods @

700mm C/C

12mm thick Ply Shuttering Plates

Wooden Walers (15x5mm) W/Jacks

Wooden Battens (50x100) Nailed

@ 300mm C/C

Prop Heads and ISMC 75 Channel

Sections @ 675mm C/C

40mm NB MS Pipes (IS: 1239) @

1200mm C/C Vertically

  Page   
  13   
 Construction Activity‐Report‐I  CP1809 

Fig- Staging and Shuttering arrangement for Beams

Fig- Arrangement of Formwork and Staging for the TG Deck Slab

Reinforcement Work Completion: Reinforcement work for the beams and the columns
which form the decks slab are then fabricated and erected on the top of the bottom
shuttering plates. As shown in the structural drawings, the main reinforcement for the
beams consists of 36mm# reinforcement which are tied together with the help of 20mm#
bars.
40mm cover is used before the reinforcement in placed into position. The reinforcement
cages are either fabricated on the deck or on the ground and then are transported to the
deck with the help of a crawler crane or a tower crane according to the suitability.
The reinforcement are then tied together to complete the erection with the help of 2mm
binding wires.
Reinforcement is then checked if it is according to the structural plans provided. This
steel checking is done by all parties involved in the construction which are Adani Power
Limited, SEPCO III and Simplex Infrastructure. After that the shuttering and bolt-sleeve
fixing activity is commenced.

Fig- Horizontal and Vertical Reinforcement Arrangement for the TG Deck Slab

  Page   
  14   
 Construction Activity‐Report‐I  CP1809 

Fig- Typical Reinforcement Arrangement for the TG Deck Beams and Slab

Fig: Section 1-1 of the Reinforcement Cage for the TG Deck Slab

  Page   
  15   
 Construction Activity‐Report‐I  CP1809 

Side Insert Plate Fixing: After the reinforcement work is almost completed or is nearing
completion, the side insert plate fixing is commenced either besides the reinforcement
activity or after its fabrication. Side Insert Plates are generally of 5mm thickness and are
welded to the reinforcement cage with the help of 4-10mm# reinforcement bars with a
weld length of 35mm on the plate. The side insert plates are used for welding the beam
sections which will support the turbines and generator which are hanging.
Additionally the bolts according to the arrangement provided by M/S Dongfang turbines
which are used which vary from the bore sizes of 56mm to 89mm, which are used to fix
the turbines and generator are to be inserted into the reinforcement cage.
The bolts and sleeves are provided by the turbine supplier and are made available at site.
Their initial position is fixed and stayed with the help of random channel sections with
holes in them as shown in the figure.
This is a high precision activity and the bolts should be aligned and leveled with an
allowance of +1-2mm error only. Thus continuous leveling and alignment with the help
of level instruments and total station goes on with the succeeding activities.

Shuttering: After the rough alignment and level of the bolts has been completed along
with the reinforcement work, the shuttering work commences. Shuttering works can be
divided into two parts:
 Inside Shuttering: Shuttering enclosing the Cutouts
 Outside Shuttering: Shuttering enclosing the entire slab.

Total Shuttering Quantity as mentioned above is 1350 Sq. Ft and the shuttering material
used is the Bonded Plywood which is having the size of 1220x2440x12mm which was
specially manufactured for this project.

Shuttering Procedure can be started by first nailing the shuttering plates with each other
to form the chain of shuttering which is of the size of a particular section. Waler beams
and props are then nailed to the shuttering boards. This may be already done or is done on
site. Now this shuttering is then first nailed to the sides and the bottom, and immediately
stayed with the help of jacks which are made of the same staging 40mm NB Pipes
attacked with the prop heads.

Tie Rods are considered to be most important component of the shuttering and they are
inserted after boring a hole through the shuttering plates at approximately 750mm C/C
and at every 500mm C/C vertically. Tie rods are made out of 36mm# reinforcement.

Additionally sometimes the two back to back angle sections welded together may be used
as props which will act as tie rods and as props for the side shuttering. The line and level
of the shuttering is checked and then final jacking is done to completely fix the
shuttering. Any space in the tie rod holes is filled with gunny bag wastes, so that the
cement slurry does not leak from the particular place during concreting. This is the
shuttering procedure for the TG Deck Slab.

  Page   
  16   
 Construction Activity‐Report‐I  CP1809 

Checking of Bolts, Reinforcement and Shuttering: After the shuttering is fixed, then
the final checking of the bolts, reinforcement and shuttering is commenced. Firstly the
reinforcement needs to be checked,
whether the column and beam
reinforcement is according to the
structural plans provided by the
contractor. If not, the additional
reinforcement required is then welded
to the cage.

Along with the checking of the

reinforcement, the bolts are then
checked for level and alignment along
with their centre to centre distance
which are provided by the contractor
after receiving the details from the
turbine and generator supplier. It was
seen that a lot of time is taken up during
this activity to achieve the required
accuracy in work. Dumpy level and
total station with the regularly
calibrated measure tape is being used
for the particular activity. After checking is completed by Clients Mechanical division
and the contractor’s mechanical division, permission is given to the subcontractor to
commence casting of the TG Slab.

Fig- Arrangement of Sleeves and Bolts and their connection with Reinforcement

  Page   
  17   
 Construction Activity‐Report‐I  CP1809 

Casting: After all the checks have been completed and the protocol has been signed by
the client, contractor and the subcontractors, the casting activity of the TG Deck Slab is
commenced. M40 grade of concrete is used in the casting which is of Ready Mixed
Concrete type and is produced by a Macons Batching plant of 60 cum/hr capacity
operated by Simplex Infrastructure. Mix Design for the same can be given as follows:

Proportions 1 M3 Mix 0.5 M3 Mix

Cement 460.00 230.00

Water 193.20 96.60

Sand 743.93 371.97

10 mm Aggregates 400.35 200.18

20 mm Aggregates 600.53 300.27

Admixture ( Sikament
4.60 2.30
600 HP/2 APL )

The total amount of concreting that needs to be done is 1290m3 and has to be completed
as soon as possible and hence no joints should be allowed to form as it is a very important
structure. Hence the entire concreting is done at a single go in 36 hrs. The concreting is
done by using One Concrete Pump with the capacity of 45 m3/hr and Two Boom Placers
which are having a capacity of 100m3/hr if no operation and movement of boom is
involved. The frontal sides were to be concreted with the help of the boom placers
whereas the inner sides with the help of the concrete pump. Concrete Pipe used was of
100mm diameter. A rubber hose pipe was to be attached for maneuvering the flow of
concrete.

Fig- Concrete Pump and Boom Placers in Operation

  Page   
  18   
 Construction Activity‐Report‐I  CP1809 

Precautions and other Procedures followed during Casting:

 The temperature of the concrete had to be maintained at 23 degree Celsius

because of the mass concreting and if not then micro-cracks could develop during
the casting itself. This was achieved by adding ice into the water which was used
for producing concrete.
 The Boom placer operator had to be positioned at the slab rather than at Ground
level and this was achieved with the help of a remote control which the operators
of the Boom placers had. It is for the efficient movement of the boom during
concreting and quick co-ordination.
 No particular area of the concreting was allowed to be filled in layers larger than
300mm at a time. The layers were not allowed to become dry and new concrete
was immediately placed above it as soon as the signs of dryness occurred.
 Vibrators were immersed in the concrete at full depths of 3m as the vibrator
needle had a depth of 2.5m and the vibrator was kept immersed in the concrete for
about 7-8 seconds. The vibrators were immersed only in the centre and where
concrete stack had formed and not at the edges because then it can harm the
shuttering and affect the tie rods as well.
 Any concrete on the reinforcement top was cleaned with the help of Khurpi or
Vibrators.
 If by any chance there was a dry area formed in the concrete then it was treated
with Nito-bond compound from Fosroc mixed with cement slurry and then the
new concrete was poured above it.
 Level bolts known as Topping Bolts were also welded to the reinforcement to
maintain the level of the concreting of the slab.
 Additionally all the equipment foundation bolts were covered by gunny and
plastic bags so that concrete does not enter the sleeves of the bolts.
 Constant checking was done so as to avoid any failure of shuttering or tie rods.

Fig- Level Bolt for Concrete (Welded) Fig- Boom Placer in Operation

  Page   
  19   
 Construction Activity‐Report‐I  CP1809 

Pour Card

Pour Records TG DECK SLAB Unit No. 8

BP2/ Cumulative
Date Time BP1/ Macons Total Cum.Hours Average
SEPCO Pour
31-May- 17:00 25.00 20.00 45.00 45.00 1.00 45.00
10
18:00 15.00 18.50 33.50 78.50 2.00 39.25
19:00 10.00 20.00 30.00 108.50 3.00 36.17
20:00 15.00 20.00 35.00 143.50 4.00 35.88
21:00 20.00 30.00 50.00 193.50 5.00 38.70
22:00 20.00 45.00 65.00 258.50 6.00 43.08
23:00 15.00 29.80 44.80 303.30 7.00 43.33
01-Jun-10 0:00 15.00 16.80 31.80 335.10 8.00 41.89
1:00 10.00 24.50 34.50 369.60 9.00 41.07
2:00 20.00 30.00 50.00 419.60 10.00 41.96
3:00 30.00 40.00 70.00 489.60 11.00 44.51
4:00 30.00 30.00 60.00 549.60 12.00 45.80
5:00 20.00 12.50 32.50 582.10 13.00 44.78
6:00 15.00 12.50 27.50 609.60 14.00 43.54
7:00 20.00 32.50 52.50 662.10 15.00 44.14
8:00 10.00 15.75 25.75 687.85 16.00 42.99
9:00 10.00 20.00 30.00 717.85 17.00 42.23
10:00 20.00 25.00 45.00 762.85 18.00 42.38
11:00 15.00 25.00 40.00 802.85 19.00 42.26
12:00 17.50 35.00 52.50 855.35 20.00 42.77
13:00 23.00 30.00 53.00 908.35 21.00 43.25
14:00 10.00 35.00 45.00 953.35 22.00 43.33
15:00 20.00 20.00 40.00 993.35 23.00 43.19
16:00 15.00 47.00 62.00 1055.35 24.00 43.97
17:00 20.00 25.00 45.00 1100.35 25.00 44.01
18:00 15.00 40.00 55.00 1155.35 26.00 44.44
19:00 10.00 45.00 55.00 1210.35 27.00 44.83
20:00 20.00 15.00 35.00 1245.35 28.00 44.48
21:00 10.00 15.00 25.00 1270.35 29.00 43.81
22:00 5.00 20.00 25.00 1295.35 30.00 43.18
23:00 5.00 10.00 15.00 1310.35 31.00 42.27

Table: Pour Card Details for the TG Deck Slab Unit-

  Page   
  20   
 Construction Activity‐Report‐I  CP1809 

Chimney Construction

The Chimney System will discharge combustion gases to the atmosphere.

One common chimney with 2 brick flues (insulated outside the flue) will be
provided and will consist of the following major components:-

a) Shell：
The shell will physically enclose and protect each flue from forces induced by
wind as well as provide support to access components of the chimney. The
chimney shell will be of reinforced concrete. The shell will be of 275 metres.

b) Flues：
The flue dedicated to each unit, will convey combustion gases to the
atmosphere and protect the shell and equipment in the annulus from high
temperatures and corrosive gases. The flues will be made of refractory brick.
The flues will be insulated to achieve desired working temperatures around
internal platforms. The inside of the steel flue will be provided with corrosion
resistant lining/coating, SS metal cladding as per requirement.

c) Aviation Obstruction Lighting ;

The aviation obstruction lighting will warn aircraft of the chimney obstruction to
air navigation during daylight, twilight, and night hours. The aviation obstruction
lighting will be flashing high intensity lights during daytime with reduced
intensity for twilight and night time operation. Intensity step changing will be
controlled by a photoelectric light detector. The lighting will conform to the
standards of the Civil Aviation Department of the Government of India. The
supplier will furnish the detail design and technical data sheet of the Aviation
lighting system and along with the electrical cabling for the approval of client.

d) Lightning Arrestor;
Lightning protection system complete with air terminal rods, circumferential
conductor, down conductors duly earthed or connected to the general
grounding system for the plant will be provided.

e) Platforms and Access;

Internal Platforms: Adequately sized access platforms will be provided for
access and space for service and maintenance of equipment (insulation, lining,
etc) installed in the Chimney System. Platforms will have a minimum width of 1
meter. External Platforms will be provided at various levels as per operation & maintenance
requirements. Access to the external platform will be from the
internal staircase/lift.

f) Stack Elevator;
One elevator of adequate capacity & size for landing on platforms of the
chimney to be provided.

  Page   
  21   
 Construction Activity‐Report‐I  CP1809 

General Description of Chimney-4:

 Height of Chimney : 275 m
 Type of chimney : RCC, triple flue
 Slip form method is used for Shell construction.
 Outer bottom diameter : 30 m
 Outer top diameter : 21.2 m
 Shell thickness at top : 400 mm
 Shell thickness at bottom : 800 mm
 No. of flue openings : 3
 Size of flue opening : 6.5 m (width) x 12.5 m (height)
 Level of flue duct opening : Bottom level- CD (+) 19.750 m
Top level – CD (+) 32.250 m
 Cover to concrete : 50 mm
 Erection opening : 7.5 m (width) x 7 m (height) at G.L.
 Level of erection opening : Bottom level- CD (+) 10.00 m
Top level – CD (+) 16.30 m
 EPC contract is given to Simplex infrastructures by SEPCO III.
 Reinforcement is provided by SEPCO III & design, execution, concrete, labour, slip form
is of Simplex infrastructures.

Fig- Fully Chimney Shell casted at a height of 275m (+GL)

  Page   
  22   
 
 Construction Activity‐Report‐I  CP1809 

Slipform Main Components:

The Form:
 The form consists of height 1.2 m of 8mm thick mild steel plate.
 Both the sides of the form are supported and held together by yokes.

Yokes:
 Yokes represent an inflexible steel construction, which consist of vertical legs &
horizontal beams.
 They are placed at distance of about 1.2 to 2.4m along periphery.
 The walings of the form & the hanging scaffold frames & steel brackets are bolted
to the yoke leg.
 Yokes give the following functions:
 To support the walers & the form.
 To transmit the lifting forces from the jacks to the walers.
 To support the working platforms & hanging scaffolds.

Jack holder:
 A jack holder acts as lifter of the head beam (Yoke beam).
 The jack is enclosed in these two jack holders which are resting on the yoke
system.
 It also has a base plate.
 When the jack moves up on the jack rod, it lifts the jack holder which in turn lifts
the yoke beam.
 Yoke beams which are interconnected with the yoke legs lift the yoke leg.

Jack rods:
 The hydraulic Slipform jacks are designed to climb up plain steel rods with solid
or tubular circular section.
 The outside dia. of these jack rods is nominally fixed for the various types of
jacks.
 In normal Slipform casting the jack rods are placed inside the slide-cast concrete
& thus carry a compressive load.
 At their lower end they rest on the foundation and are then successively extended
by the addition of further lengths during distance covered by the Slipform
structure.
 Total nos. of hydraulic jacks – 64
 2 nos. of jacks are fit on the lower yoke beam where main truss comes on spider
beam & in surrounding two spider beams.
 1 no. of jack is fit in the rest of the yoke assembly of Slipform.
 Length of jack rod varies from 3m (at the yoke legs) to 2m (at the main truss
support).
 The nominal external dia. is 32mm & internal dia. is 16mm.
 6.2 MT capacity of each jack rod.

  Page   
  23   
 Construction Activity‐Report‐I  CP1809 

Hydraulic pump:
 Hydraulic pumps are provided to circulate required quantity of hydraulic oil at
desired pressure for energizing jacks to lift the assembly and facilitate its uniform
lifting.
 The pump bottom is submerged in the oil tank.
 When the pump is running, oil is sucked directly form the oil tank up through the
pump & pressed out to the automatic return valve & the gauge and from there into
the oil piping to the hydraulic jacks.
 Hydraulic oil 68 is used in pump.
 Operation Capacity-64 Jacks.
 Pressure on the Pump-80 T/m².

Fig- Yoke Leg and Yoke Beam Assembly Fig- Yoke Legs Positioning

Fig- Various Components and total erection of Slip Form System

  Page   
  24   
 Construction Activity‐Report‐I  CP1809 

Slipform Operation:

 Slipform construction is an extrusion process in which the form of 1 to 1.8m high

& is constantly being raised.
 Fresh concrete is placed into the pumps.
 The concreting of chimney is to carried out in layers. The form panels are filled
with fresh concrete layers of 300-400mm.
 Freeboard i.e. the distance between the form top level & layer of fresh concrete
top level is 150-200mm.
 When the concrete reaches to that level, reinforcement is to carried out. That
means r/f also carried out simultaneously while concreting.
 After two to three hours, the concrete reaches the initial set & loses its plasticity
and starts supporting the newly fresh concrete above that.
 The rate of movement of the forms is controlled & matches the initial setting of
concrete so that the forms leave the concrete after it is strong enough to retain its
shape while supporting its own weight.
 The forms move upward by mean of jacks climbing on smooth steel rods
embedded in the hardened concrete & anchored at the concrete foundation base.
 These jacks may be hydraulic, electric or pneumatic & operate at speeds up to 600
mm/hr.
 Yokes are frame that are used to support the lateral loads & transfer the vertical
loads to the jack rods.
 Laboures continually vibrate the concrete so as to prevent any honeycombing.
 A top working platform is attached to the slip form assembly and slides up with it
to provide a place form where laboures can place concrete.
 A middle working platform is attached to the inner form from where laboures can
vibrate the concrete & fabricate steel reinforcement.
 A lower working platform is suspended from the outer form (in both the sides of
shell (inner-outer)) to allow workers to apply a curing compound & to repair any
honeycombing that may occur.

Radius Screw Operation

 As the diameter of chimney shell decreases, the radius of the slip form assembly
has to be reduced as per the requirement at that elevation.
 The numbers of rotation are as per the requirement, till the inner face of the inner
yoke leg reads as per marking on spider beams.
 The pitch of the radius screw is 2 mm/revolution.
 Every 12 Hour record is maintained and is compared with the required radius.

Wall Thickness Reduction

 The wall thickness screws are also operated continuously to reduce the thickness
of shell at the height of chimney increases.

  Page   
  25   
 Construction Activity‐Report‐I  CP1809 

 There is one wall thickness screw between the channels of upper yoke beam on
the inner yoke leg & another wall thickness screw on the lower yoke beam of the
outer yoke leg.
 The pitch of wall thickness screw is 2mm/revolution.
 These wall thickness screws are operated as per the slip form program from which
number of revolution can be calculated as per the reduction in the Chimney shell
at that level.

How to Know the Working Height of Chimney?

 To know the working height of chimney, the jack rods of some yoke legs have
marking of paint at interval of 50 cm in height.
 From those marking of paint we can have idea about the working height of
chimney.

Spindles for Periphery Reduction

 For the periphery reduction of chimney during its construction, spindles are
connected to the console assembly.
 The form panels being free from one end the slide over each other as per the
reduction in periphery.
 This sliding is controlled by the rotation of spindles which are rotated by console
assembly mechanism.
 It has a piston for its operation which is controlled by hydraulic pump connected
by the high pressure hose pipe. A circuit connection is made to all the pistons of
all the yoke legs.
 The pitch of the spindle is 5 mm/ revolution. The amount of slipping of the form
panels depends upon the reduction in the chimney shell periphery slip form
programme. Turn buckles are located in to the console assembly of the yoke legs
which are used to rotate the spindle for periphery reduction as thee chimney
height increases. (for turn buckle arrangement see attached diagram 9)
 The turn buckles are piston operated which operates the console assembly.
 The amount of slipping of the form panels depends upon the rotation of spindles
which are rotated by the turn buckles & the amount of rotation & there by sliding
operation of the pistons which is carried out as per slipform programme.

Chimney Concreting Procedure:

 Concrete will fill up in the bucket of 0.6 m³ capacity from Transit mixer through
chute.
 Lifting of that bucket to the working level.
 Dump the concrete from the bucket to hopper.
 Fill the trolley with concrete form hopper.
 Dump the concrete from trolley to M.S.Funnel.
 Concrete will pass through 200 mm dia. PVC pipe attached with M.S.Funnel.

  Page   
  26   
 Construction Activity‐Report‐I  CP1809 

Precautions while Concreting of Chimney

 Concrete layer thickness shall not exceed 250mm during each pour.
 Sliding of Slipform panels shall not excee 25mm per lift
 Sliding of slipform panels shall after be 3 to 4 hours subsequent to completion
of placement of earliest layer
 The lifting frequency of form panels shall be restricted to 10 minutes
 Freeboar in slipform panels shall be maintained minimum 250mm while top
layer is poured
 Care shall be exercise that concrete manufactured is consume within 2 hours
and 30 minutes; this includes the time consumed towards the manufacture of
concrete, transportation of concrete an final placement into the forms.
 At two discrete locations diametrically opposite to each other, tilt an or twist
an or complex phenomenon involving tilt and twist shall be checked at 6 hour
intervals during the course of the pour. This verticality check shall be
exercised with Self-Leveling Auto Shut-off Laser Instrument. The locations at
ground where the instruments are proposed to be placed shall be protected
from spilled off concrete from atop, e.g. by covering with plastic sheet or
empty cement bag.
 Site record indicating Tilts/Twists and both shall be maintained for hour to
hour monitoring of verticality.
 The preventive maintenance of Slipform structure shall be planned will in
advance (minimum of two occasions during the course of pour). The period of
such maintenance shall not exceed 12 hours.
 The jack rod retrieval extraction period shall not exceed 4 hours hence all the
requisite arrangements and activities be pre-organized and made well in
advance.
 Requisite PPE shall be enforced and made mandatory for all working
platforms atop the slipform and below the chimney during the course of work.
 Recommendations enumerated at Points 1,2,3 and 4 shall vary as per climatic
conditions which would include temperature and humidity mainly.

  Page   
  28   
 Construction Activity‐Report‐I  CP1809 

Productivity Analysis of Chimney-4

Civil work for chimney 4 were commenced on the date 11/10/08 and were to be
completed by the date 07/09/10, but due to various delay in construction the schedule
on date had gone behind to 2/5/11 which resulted due to a delay of 8 months in the
final completion of chimney work. We have attempted to find out the reasons for the
delays so that they can be corrected in the future execution of similar magnitude.

Data Collection and Analysis:

Data collection was done from the records maintained by the contractor and owner
engineer. The schedule and actual starting and completion of major activity are listed
in table below.
N Item Schedule Sched Actual Act
o. start ule start ual
Finish Fini
sh
1 Drawings for 11/10/20 18/10/ 15/10/20 12/
excavation received 08 2008 08 11/
and approved by 200
employer 8
2 Drawing for raft of 20/10/20 18/11/ 17/11/20 11/
chimney received and 08 2008 08 1/2
approved by 009
employer
3 Drawing for shell of 14/1/200 11/2/2 20/1/200 16/
chimney received and 9 009 9 2/2
approved by 009
employer
4 All other construction 4/4/2009 2/5/20 6/4/2009 18/
drawings received 09 5/2
and approved by 009
employer
5 Excavation and PCC 10/11/20 18/2/2 24/11/20 30/
08 009 08 1/2
008
6 Foundation 23/2/200 2/5/20 5/2/2009 26/
9 09 8/2
009
7 RCC shell up to 25 m 4/5/2009 14/8/2 12/9/200 17/
009 9 11/
200
9
8 RCC shell up to 100 17/8/200 23/8/2 7/12/200 5/2/
m 9 009 9 201
0

  Page   
  29   
 Construction Activity‐Report‐I  CP1809 

9 RCC shell up to 180 24/8/200 15/9/2 11/2/201 8/4/

m 9 009 0 201
0
10 RCC shell up to 272 16/9/200 14/10/ 16/4/201 14/
m 9 2009 0 6/2
010
11 Dismantling of 16/10/20 14/11/ 17/6/201 2/7/
Slipform construction 09 2009 0 201
equipment 0
12 Fabrication of first 16/11/20 7/1/20 21/7/201 30/
steel flue and all 09 09 0 8/2
necessary steel 010
structures
13 Erection of first steel 9/1/2010 18/1/2 6/9/2010 19/
flues, insulation, 009 9/2
elevator etc 010

14 Fabrication of second 19/1/201 2/4/20 20/9/201 27/

steel flue and balance 0 10 0 11/
steel work 201
0
15 Erection of second 5/4/2010 25/6/2 10/12/20 31/
flues, insulation, 010 10 1/2
elevator erection 011
16 Fabrication of third 25/3/201 22/5/2 4/11/201 3/1/
flue and balance steel 0 010 0 201
work 1
17 Erection of third 28/6/201 2/9/20 16/2/201 28/
flues, insulation, 0 10 1 4/2
elevator erection 011
18 All other work 7/9/2010 17/11/ 2/5/2011
2010

Labour Availability at Site:

There were 6 gang of labour available at site, which was working 24 hours at site in
two shifts. Average no of worker in each gang is mention in table below.
No. PARTICULARS SHIFT No. of heads
1 Reinforcement gang Day 30
Night 30
2 Slipform gang Day 25
Night 25
3 Concreting gang Day 25
Night 25
4 Finishing gang Day 15
Night 15
5 Curing gang Day 5

  Page   
  30   
 Construction Activity‐Report‐I  CP1809 

Night 5
6 Khalasi Day 7
Night 7

Monthly Concreting Report of Chimney:

Monthly reports are available from feb-09 to April-10. Table contains monthly
concreting and monthly labour report for chimney.
From the table we can say that with increase in height, production rate is decreasing..
Month Cmt/month labours/m Productivity
onth (Hrs/cmt.)
Feb-09 5454 3106 13.66776678

Mar-09 1817 3000 39.62575674

Apr-09 38 100 63.15789474
May-09 0 0 0
Jun-09 0 0 0
Jul-09 887.5 2206 59.65521127
Aug.09 482 1962 97.69294606
Sept.09 1287 3105 57.9020979
Oct. 09 1188.5 3213 64.88178376
Nov.09 1829.5 3300 43.29051653
Dec.09 1756.75 3845 52.52881742
Jan-10 1443 4761 79.18503119
Feb-10 1344 3781 67.51785714

Mar-10 1185.5 3619 73.26528891

Apr-10 309 1071 83.18446602

  Page   
  31   
 Construction Activity‐Report‐I  CP1809 

The chart represents monthly fluctuation in productivity.

Reasons for the lag in schedule and Productivity:

 Major delay occurred due to unavailability of slipform assembly for more than 2
months.
 Reinforcement was behind schedule.
 There was Labour shortage in summer.
 A laser instrument which was used for height and alignment measurement of
chimney was not working properly.
 There was a lack of cleanliness and other sanitation facilities in the labor colonies
and hence there were frequent instances of many skilled, unskilled and semi-
skilled labourers etc. remaining absent during critical times. This resulted in
frequent delays and hence the lag occurred in completion.

Recommendations:

 Proper equipment management should have been done for important equipments
so that, they would have been available as and when required.
 For proper availability of labour during summer some innovative steps should
have been implemented, such as increase in wages, & other facilities to maintain
productivity of work.

  Page   
  32