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Gujarat Pipavav Port Limited

Contract IV Construction of Container Berth and Bulk Liquid Jetty

Concrete development and production : Methodology of work

Page 1 of 5

Introduction and work ideology

For Proposed Container Berth & Bulk Liquid Jetty, there will be considerable requirement of
reinforced concrete to be done in a short time period of time. Depending upon design, specification
and working method; there will be requirement of varying grade of concrete upon its workability,
slump retention, pouring method, type of placement, congestion of reinforcement, strength
requirement etc. Workability of different type/grade of concrete is specified in clause 752 & 773 and
in table 7.1 of specification. However, majority of the concrete shall be of insitu pile (workability of
150+/-25mm) and insitu superstructure work done by Concrete pump with higher workability (100+/20mm) with an approval from Engineer.
Temperature restriction of the concrete shall be followed as per specification Section 700, Table 7.1.
Cement for concrete manufacturing shall be procured from reputed cement manufacturer having
cement plant close-by and in the state of Gujarat with a prior approval of Engineer, and a back up
supplier shall also be processed for contingencies. Aggregates and water will be procured from local
sources, subject to their physical and chemical properties are maintained within the acceptable
limits. Approved quality fly ash shall be used for partial replacement of cement and to reduce the
effect of chloride, sulphate and lesser permeability and better performance. Water will be used within
the limit specified in the Indian standards and specification based on the exposure and durability of
the structure. Admixer, from reputed manufacturers will be used in combination to achieve the
workability, and slump retention of the concrete.
Transit mixers will carry the concrete upto the place of pouring. Concrete pouring may be done in
different methods e.g. concrete pump, crane-bucket arrangement, through steel chutes and
manually.
Prior to the productive concrete, a series of mix design will be carried out based on the properties of
cement, fly ash, aggregate and admixer. A concrete development and testing laboratory shall be set
up in the site for proper control on concrete mix.

Infrastructure for concrete production

Coarse and fine aggregates shall be stacked properly at a selected stack yard prior to use; fine
aggregate shall be screened to get required grain size as stipulated in approved mix design.
Screening plant shall be installed nearer to Batching plant.
Concrete for the entire works will be manufactured in a centralized batching plant, having 30 cum
per hour capacity. The plant shall have adequate arrangement of cement and admixer storage,
water storage and distribution system, aggregate bins etc. The area of batching plant will be big
enough to accommodate minimum 15 days stock of sand and aggregates. Cement go-down of
suitable size to accommodate 15 days stock shall be set up and the consumption be strictly
monitored to follow first in first out system.
The plant will be fully automatic in nature with control on weighing of basic constituents, waterpouring, mixing of fly ash and admixer.
R0 : 12-August-2006

Gujarat Pipavav Port Limited

Contract IV Construction of Container Berth and Bulk Liquid Jetty

Concrete development and production : Methodology of work

Page 2 of 5

Cement will be loaded into the silo and from there it will be fed into the mixing drum. Aggregates will
be poured into the skip by operating pneumatic valves attached to bin gates. Water will be poured
into the mixer directly from the storage through a pump connected through a pre-set timer. All
monitored by an electrical/electronic control system. Admixer etc will be poured into the concretemixing drum from top of the mixing drum through a pre-set timer. The ingredients will be mixed
thoroughly in the drum to form a homogeneous mix and discharged into the transit mixers place
underneath the Batching plant.
Site laboratory will be maintaining the in-process quality control of concrete production on a daily
basis. It will be used for conducting necessary tests on incoming materials besides monitoring the
mixing process, accuracy of weighing system, moisture, temperature and quality of final produced
concrete.

Concrete mix design and establishment

Concrete mix design shall be carried out in accordance with Indian Standards and handbook SP23
at the site laboratory under the supervision of Engineer & Contractors representatives. Laboratory
test results for cement, aggregates, water and admixer will be taken care of for development of mixdesign. Trial mixes shall be carried out prior to concrete production to establish the mix ratio for
different grade of concrete.
Following operations and tests shall be carried out before preparation of concrete.
Testing of coarse and fine aggregate as per IS:2386 and conforming to IS:383
Testing of cement as per IS:4031. The cement for the work shall be ordinary portland cement
of blended cement conforming to IS:12269.
Testing of water as per IS:456.
Admixtures shall be used conforming to IS:9103 for all types of concrete with varying doses.
Recording of all pre-concrete works, like determination of surface moisture etc.
Recording of post-concrete works, like compressive strength.
Based on the grade of concrete and quality of component materials, design mix, of concrete shall be
developed conforming to I.S:10262. Various trial mixes will be taken and tested for all required
parameters as strengths, workability, density and selecting the final mix.
Proportioning of aggregates and cement, as determined by the concrete mix design, will be done by
weight. The weigh batcher & other equipment will be calibrated time to time to ensure proper
batching. Measured quantities of water will be added to produce concrete of required consistency,
specified strength and satisfactory workability.
The concrete mix, thus produced will be inspected visually for its consistency and cohesion. The
workability will also be checked by slump-cone test method. If the mix passes these initial tests,
required number of concrete cubes will be taken following the method prescribed in Indian
Standards. Cubes shall be taken at pouring point, shall be removed from cube-moulds next day,
cured in water and tested for its crushing strength using an electrical cube testing machine.
R0 : 12-August-2006

Gujarat Pipavav Port Limited

Contract IV Construction of Container Berth and Bulk Liquid Jetty

Concrete development and production : Methodology of work

Page 3 of 5

Concrete in different ratio with different dosage and combination of cement and admixer will be done
to ascertain their compatibility and most suitable permutation.
All the above inspection & tests will be conducted as per inspection & test plan. Based on the initial
inspection, behavior of concrete after production and crushing value, the mix ratio will be proposed
to the engineer for approval.

Concrete batching operation

Ingredients of the concrete will be tested during incoming and stored properly at their designated
place. Laboratory situated close to Batching Plant will do all necessary testing required regularly to
find out moisture content of sand and coarse aggregate by rapid moisture-meter for correction of
water adjustments, if any.
On receipt of requisition from respective site engineer, laboratory in-charge will hand over the mix
proportion data to batching plant operator who will input the data to the system and start production
of concrete. The weighing scales are all calibrated once in three months. Coarse and fine
aggregates will be weighed cumulatively and discharge into the pan. Similarly cement and fly ash
will be weighed cumulatively in another scale and water and admixture will be weighed and
discharged into the pan. Mixing will be done for 60 seconds and then discharge into the transit
mixture batch by batch.
Once the transmit mixer is full loaded, the same is directed towards pouring point for final discharge.
Each transit mixer will carry a delivery record containing all relevant information regarding mix
proportion, vehicle no., quantity, time, and also remarks for re-dosing of admixture, addition of water,
if any at site etc to be noted. If for any reason there is a delay in discharge of concrete from transit
mixer and slump of concrete falls below workable range, then re-dosing of appropriate admixture will
be done as per standard practice @ 0.1 to 0.3 % to regain the slump . For precast concrete, transit
mixers will directly unload the concrete into the formwork or into a concrete skip (bottom discharge
hopper) which in turn pour the concrete into the formwork. For in-situ work the concrete will be
discharged into the concrete pump hopper.
The mixer will be cleaned every time the work stops and prior to start of fresh batch of concreting.
Workability will be checked at random at the pouring point and sampling of cubes done at the point
of discharge as per the specified frequency indicated in inspection and test plan.

Concrete transportation

Transit mixer of capacities 4 cu.m to 6 cu.m will be used for transportation of ready mix concrete at
site from Batching plant to pouring point. Concrete production and pouring unit will have continuous
communication to reduce the waiting time of the concrete before placement. In general, one-hour
slump-retention will be targeted.
During transportation of concrete, proper checking will be done to maintain the required workability,
to prevent segregation, loss of any ingredients or ingress of foreign matter or water.
R0 : 12-August-2006

Gujarat Pipavav Port Limited

Contract IV Construction of Container Berth and Bulk Liquid Jetty

Concrete development and production : Methodology of work

Page 4 of 5

Special care shall be taken for Concreting in day-time during hot summer when the temperature is
around 35C. The rotating drum of transit mixer will be jacked with jute carpet which shall be always
kept wet and thus the concrete temperature inside the drum be maintained.
Temperature of the mix will also be checked at random at the discharge point. Further to reduce the
temperature of the mix cold water will be sprayed to aggregates to control the temp which in turn
reduces the temperature of the concrete mix. In extreme hot condition, ice flakes will be added to the
water before mixing with the concrete to lower the temperature below 30C at pouring point.
Concreting in day-time during hot days is also will be avoided if concrete temperature continues to
exceed 30C.

Cement concrete placement and compaction

In general 30cum/hr concrete pumps will be used for cement concrete placement in all in-situ works.
The concrete pump will be so positioned that the pumping distance remains within 200 m. In
precasting and small pour with less lead, concrete will be placed by manual means or by cranebucket, skip etc. arrangement.
Concrete will be deposited as nearly as practicable directly in its final position. For locations where
direct placement of concrete is not possible, "Elephant Trunks", Chute etc. will be used with suitable
drops. To avoid segregation, the drop will never be allowed more than 2.0 meter. Concrete will not
be re-handled after its placement.
Concrete will not be placed under water, without using treemies or pipelines from the mixer and will
never be allowed to fall freely through the water.
Concrete will normally be compacted in its final position within 30 minutes of leaving the mixer.
Concrete will be compacted during placing with needle vibrating equipment, inserted into the
concrete vertically from top at a distance mtrs approximately and withdrawn slowly till air bubbles
cease to come to the surface, leaving no voids. Concrete will not be vibrated for more than 1 minute
at a stretch at a point. Proper care shall be taken not to make over-vibration and vibrators nozzle
shall not come in contact with reinforcement, form work. It will be ensured that the concrete does not
segregate till it forms a solid mass, free from voids, is thoroughly worked around reinforcement and
embedded fixtures and flows into all corners of the form work.
When placing concrete in layers advancing horizontally, care shall be taken to ensure adequate
vibration, blending and moulding of the concrete between successive layers. Concrete after
placement shall not be disturbed at finished surface after starting of initial setting of concrete. In
case the excessive evaporation is anticipated during sun, water will be sprinkled at regular interval
on top surface of the concrete, so that water from concrete does not evaporate quickly. After setting
of concrete, it will be covered with wet jute-cloth or ponding with water.

R0 : 12-August-2006

Gujarat Pipavav Port Limited

Contract IV Construction of Container Berth and Bulk Liquid Jetty

Concrete development and production : Methodology of work

Sl
No
1

Page 5 of 5

Risk analysis
Activity

Hazard/Risk

Control/Precautionary measures

Action by
whom

Handling and

storage of

Cement dust

during handling

Cement and

Worker handling cement shall use


proper nose mask, goggles etc.

Fly ash

Proper

ventilation

Batching plant
supervisor

arrangement

shall be made

Falling of bags

during handling

Shifting of bags by head carry


should

be

properly

monitored;

access & egress shall be properly


made.
2

Handling of

Admixers

Damage to skin

and eye

Proper safety PPE; hand gloves,


goggles shall be used by the user.

Batching plant
supervisor

Manufacturers MSDS should be


strictly followed.

Contamination

All admixers container shall be

with subsoil

placed with a secondary container

water

during filling / emptying to avoid


spillage.

Transporting

Reversing of

Proper signaling should be used.

Construction
Manager /

by Transit

vehicle during

Cleaner shall be trained to give

Mixers

filling and

reversing instruction.

discharging

Mechanical In-

Reverse horn compulsory to all

charge

concrete trucks.
Damage to

structure and
human being

Speed limit shall restrict to 20


KMPH in working area.

Regular periodic maintenance of


the vehicle.

Batching plant
operation

Movement of
scrapper

Scrapper

movement

should

controlled and man movement near


aggregate bin shall be restricted.

R0 : 12-August-2006

be

Batching plant
supervisor

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