EPC FOR LAYING OF PIPELINES AND COMPOSITE WORKS FOR SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT Indianoit PARADIP (INDIA) COCRETING RCC AND PCC DOCUMENT NO. : FCIPLIOCLIEIL/AOS6/Civiv07 ReviC - DATE : 12/09/2011 Job Procedure for CONCRETING RCC AND PCC >| PROJECT : | JETTY PIPE LINE PROJECT JOB NO. > A036 FOA NO. ; EIL/CONT/A056/T03/FOA, DATE-16/02/2011 OWNER : | INDIAN OIL CORPORATION LIMITED. | PMC : | ENGINEERS INDIA LIMITED. | EPC : FERNAS CONSTRUCTION INDIA PVT.LTD. | LOCATION : | PARADIP, ODISHA, INDIA * | & | 2207201 | review > o ot GS ie le B | 05072011 | Review BFE Nl aa C© | 12.09.2011 | Ay T At x WS uR ey | 12 pproval KARMAJITSINGH | VINAY aE napa Prepared by | Checked by | Approvedby | Reviewed By | aj y rev} pate | Description |" FeIPL For. | FcIPL | EILIOCL jock | ‘Sign / Name ‘Sign / Name ‘Sign / Name ‘Sign / Name sign’Name Page 01 of 07EPC FOR LAYING OF PIPELINES AND COMPOSITE WORKS FOR SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT PARADIP (INDIA) COCRETING RCC AND PCC ‘CIPLIOCLIEILIAOSSICIviIO7 Rev.C E DATE : 12/09/2011 Contents Sr. No. Description. Page No. 1 Purpose 3 e Reference 3 3. Scope 3 4. Equipment 3 5. Materials 3 6. Methodology 3 2 Documentation 7 ITP: (Enclosed Formats) Inspection Reports: (Enclosed Formats) Page 02 of 07(gug-za) | COMPOSITE WORKS FOR SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT EPC FOR LAYING OF PIPELINES AND | a) 6.1 Indianoit PARADIP (INDIA) ‘COCRETING RCC AND PCC DOCUMENT NO. : FCIPLIIOCLIEIL/AOS6/CivivO7 §—Rev:C ® DATE : 12/09/2011 1. PURPOSE: The purpose of this: procedure is to summaries production of quality concrete. As per specifications REFERENCE: EIL specification No. 6-68-004/005 Rev. Tender Doc no. PDRP-8310-SP-0005 SCOPE: This procedure covers method for the batching, mixing, transporting placing, compacting curing and protecting of all concrete for use in the civil works EQUIPMENT: Batching Plant Measuring Box Vibrator Calibrated Jar Slump Cone |. Calibrated Cylinder '. Thermometer Cube Moulds . Mixture machine/Weigh Batcher. OCONSTAENS MATERIALS: Cement, coarse aggregate, Fine aggregate, Water, admixture, reinforcement, Joint materials. METHODOLOGY: The following sequence will be adopted for producing quality concrete. All sources of constructions materials will be identified. Then Properties of material shall be tested / checked for acceptance criteria Spec / Relevant Codes. net 6.1.1 Cement: 3 ve Page 03 of 07 Ae =) wey, eo asEPC FOR LAYING OF PIPELINES AND (gai¢za)) | COMPOSITE WORKS FOR SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT PARADIP (INDIA) Indianoit COCRETING RCC AND PCC DOCUMENT NO. ; FCIPLIIOCLIEILIA0S6/CiviI07_ Rev.C DATE : 12/09/2017 Cement shall be from EIL approved Manufacturer from ElL Conforming to IS: 8112 OPC Gr 43 MTC of every consignment shall be submitted to ElL tested in lab as per IS: 8112 (if OPC) ! Other types of cement may be used depending upon the requirements of certain job with the approval of Engineer. These shall confirm to the following standards ! | and one lot of cement shall be tested in approved lab during design mix, Cement shall be | Portland Pozzolana Cement IS: 1489 ~ Rapid Hardening Portland cement IS: 8041 53 Grade Ordinary Portland cement Is: 12269 Hydrophobic Portland cement Is: 8043 Sulphate resisting Portland Cement IS: 12330 Field quality control Testing of Samples: . The contractor shall supply a copy of the manufacturer's test certificate for each consignment ‘of cement supplied by Him and consignments shall be used on work in the order of delivery. The contractor shall supply samples of cement to the Engineer as frequently as he may require for testing. The sampling of cement for testing shall be according to IS : 3636. Alll tests shall be in accordance with relevant clauses of |S: 403184032 a 6.1.2 Aggregates 1. Coarse aggregates will be procured from quarries and approved sources only and shall be tested in lab approved by EIL. The grading of aggregate shall be tested atleast at weekly or at 40m’ interval whichever is the earlier. 2. Fine Aggregate will be procured from any Suitable quarries approved by EIL and shall be tested in lab approved by EIL. Amount of material passing a 75 micron sieve test shall not exceeded by 2% by wt. for river & 3% for quarry sand. 3. Course Aggregate Amount of material passing 75 micron sieve test shall no exceeded by 1% by weight re oe vie” Page 04 of 07Indianoit EPC FOR LAYING OF PIPELINES AND. COMPOSITE WORKS FOR SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT Reanas) PARADIP (INDIA) COCRETING RCC AND PCC DOCUMENT NO. : FCIPLIOCL/EILIADS6/CivII07_Revic~ DATE : 12/09/2011 4. Testing of Aggregates shall be as perTable-3 below TABLE -~3 MANDATORY TESTS ON SAND & STONE AGGREGATES NC ary OF | MATERIAL . FIELD LAB FREQUENCY OF No | MATERIAL | TEST Test | WORKFOR | FRET oot ine Teer 1. [Sand (a) Bulking of Field 20m ‘Every 20 m® or part aa” fartat rene (Sit canton | Fok 2m Sea a Engineerin-Charye (c) Particle size Field or Lab as| 40 m* 1) Every 40 m’ of Sianoason* | Secs ty we the apuroat! send Engineer reous RCS cage ooo 2) Every 80 m’ of ie apgrepealoond toculee te one tons % [Stone |a)Pavaniape of | General veual [As required” by | Fort aaron sopreoat | soRoraactonove |iepecion | Eagnaasie’ mmatarate | borate est | Grae “| where required by trotenginoer i Charge or as | specifies 3) Paice za] Fld or abs aa [5 nF For wren nor Steouien’ | tequecd by signers Enon Seca by Eranaor. cae imaneroe Ton porant Fe] cabo Bar Tal est and vane ae Subsequent fst as & & when required by Erginoetin Shogo 6.1.3 Water Water used for concreting & Curing shall be clean & free (shall conform to clause 5.4 of IS 456) from injurious amount of acid, alkalis, organic matters or the harmful substance that may be deleterious to concrete or steel. Portable water shall be used. Water from Bore well or near any Source can be used for mixing in concrete and curing. This water shall be tested in lab approved by EILMOCL. Test report of water shall be submitied to owner/consultant for source approval. (The acceptance criteria is as per clause 5.4 IS 456) ‘The PH value of water shall not be less than 6. or Page 05 of 07EPC FOR LAYING OF PIPELINES AND f (es) COMPOSITE WORKS FOR SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT anes PARADIP (INDIA) COCRETING RCC AND PCC DOCUMENT NO. : FCIPLIIOCLIEILIADS8/Civil07 Rev. DATE : 12/09/2011 6.1.4 Reinforcement Steel reinforcement shall comply with IS 13920 and IS 1786. High Strength deformed steel bars produced by Thermo Mechanical Treatment (TMT) process of grade Fe 500, having elongation more than 14.5 % shall be used for reinforcement Welded wire fabric shall be either square or oblong meshes, structural fabrics or wrapping fabrics, as shown on the drawings, or elsewhere, and shall comply with IS 1568.The reinforcing steel shall have been tested in every respect in accordance with the above mentioned Standards. Contractor shall supply IOCL with copies of test certificates to verify compliance. Bis admixture When required admixtures may be used if full details are supplied to IOCL and approval granted. 6.1.6 Joint material 1. All water bars shall be proprietary PVC or hydrophilic, swellable, elastomeric strip material, subject to |OCL approval 2. Joint sealants shall comply with the requirements of IS 1834 3. Joint filler shall be proprietary cork or fibre board material approved by IOCL. 6.2.0 HANDLING AND STORAGE OF MATERIALS 6.2.1 CEMENT: a Cement in sacks or bags shall be stored in waterproof, ventilated sheds, andthe floors of the sheds shalll be kept clear of the ground or otherwiseprotected from dampness. The cement shall be stored in such a way that the oldest deliveries are used first Bagged cement shall not be stored higher than 10 bags. Re-bagged cement shall not be used. If bulk cement is used it shall be stored in a type of container approved by !OCL, Cement bags containing lumps that cannot be broken by a light touch of thefingers shall not be used. Cement shall not be kept on site longer than 3months. 6.2.2 AGGREGATES: FCIPL shall ensure that adequate supplies of the approved aggregates are available prior to commencing work and shall at all times maintain on site quantities of each type of aggregate as are considered by IOCL to be Sufficient to, ensure continuity of work ek oe dds ee 06 of 07EPC FOR LAYING OF PIPELINES AND COMPOSITE WORKS FOR SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT 6.2.3 6.2.4 6.3.0 6.3.1 Ingianoit PARADIP (INDIA) ‘COCRETING RCC AND PCC DOCUMENT NO. : FCIPLIIOCLIEILIAOS6/CiviV07 Rev:c ? DATE : 12/09/2011 Each type of aggregate shall be separately transported and stored, and shall not be contaminated with any other type of aggregate or any other material Where two types of aggregate are stored next to each other, they shall be separated by a wall or plate. The floor of storage areas shall be of concrete or other approved material having sufficient slope to ensure drainage of surplus water. Regular cleaning of aggregate bins shall be carried out to remove accumulated dust. Wet aggregate shall be kept on site for at least 24 hours to ensure adequate drainage before being used Other Materials ‘All other materials shall be stored to the approval of IOCL in such a manner as to protect them from deterioration and contamination from whatever source. Rejected Materials All materials which are unidentified, or do not comply with this Specification shall be removed from the site immediately. PLAIN CEMENT CONCRETE (PCC) WORKS The major requirements for PCC is that the surface on which it has to be laid should not be waterlogged as water in the soil may affect the water-cement ratio that in turn affects the strength of concrete The surface of the soil shall be free from any loose debris. The forms also shall be checked to ensure that their intergrity remains intact during concreting. The top level up to which concreting is done shall be marked on the form at various locations ‘Approximately half an hour to starting of concrete, the surface to be concreted must be made moist, so that the water in concrete is not absorbed into the soil and shrinkages in concrete are prevented. Mixing concrete: Suitable concrete mixers of approved type will be used for mixing concrete materials including water Batching of each size of aggregates and cement shall be carried out in tum. The aggregates and cement will be batched by means of suitable weigh batching machines and materials will be handled in steel boxes of specified size, Convenient system of measuring water to the concrete mixture will be installed. Calibration / verification of weigh batcher is must when shifted room one to another location. awe Page 07 of 079 EPC FOR LAYING OF PIPELINES AND | | & COMPOSITE WORKS FOR SOUTH JETTY. GREANAS, PIPELINE PROJECT OF M/S IOCL AT Indianoin | PARADIP (INDIA) COCRETING RCC AND PCC DOCUMENT NO. : FCIPLIIOCLIEILIAOS6/Civil07 Revic DATE : 12/09/2017 6.3.2 Compacting of concrete: Concrete will be compacted within 30 minutes of water being added to the mix with the help of vibrator only, no manual compaction allowed. Vibrator shall not be used to make concrete flow in the formwork 1, Slabs beams and similar members shall be poured in one operation. 2. All fixtures shall be embedded in concrete as shown o0n the drawings. 3. Concrete will be compacted with internal vibrators of size varying diameter, © 4. Vibrators should not be used to move concrete laterally. They should be inserted and withdrawn vertically, so that they quickly penetrate the layer and are withdrawn slowly to remove entrapped air. | 5, Vibrators needle shall be kept clear of forms at least by 100 mm. 6.3.3 Curing and protection: Concrete will be cured by wet Hessian cloth. Hessian will be kept always wet. Curing will be done for min 7 days For Horizontal Surfaces the following procedure will be followed 1. Immediately after compacting and finishing, polythene sheeting will be placed 2. After final set, Polythene will be replaced by wet Hessian, which will be immediately covered with polythene; Hessian will be kept always wet. Curing shall be done for 7 day after compaction & finishing 3. After an initial curing period of 7 days approved curing compound shall be sprayed or Hussein kept in place wet for another 15 days. 7.0 CONCRETE WORKMANSHIP Conerete workmanship shall comply with IS 456, IS 3370, IS 10262. Identity Testing of Fresh Concrete Identity Testing shall be carried out to Provide independent assurance that the fresh concrete conforms to the specification. Identity Tests shall be carried out on each sample for compressive strength (test cubes), slump, air content and temperature. All Identity Test results shall be sent to |OCL on a regular basis.EIL/IOCL specification shall be followed for Rate of ‘Sampling. ov axe ” Page 08 of 07 gy ca we asa veEPC FOR LAYING OF PIPELINES AND COMPOSITE WORKS FOR SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT. inotench) PARADIP (INDIA) COCRETING RCC AND PCC 7 | SREANAS) DOCUMENT NO. : FCIPLIIOCLIEILIAOS6/CivIVOT Rev.C DATE : 12/09/2011 Transporting Concrete shall be transported in accordance with IS 4926 which ensures that at the point of deposition itis of the correct quality and consistency. Concrete delivery trucks used for transporting concrete Shall incorporate means of agitating the concrete during transport to site. 8.0 DOCUMENTATION: ITP PCC sense FCIPLIOCLIEILAQS6/CIVILIO7/ ITP-01 | ® RCC (Sub structural)... FCIPL/IOCL/EIL/AOS6/CIVIL/O7/ ITP-02 RCC (Super- structural)... FCIPLIOCLIEIL/AOS6/CIVIL/O7/ ITP-03 RCC (Critical Structural)... FCIPLIOCL/EIL/AOS6/CIVIL/O7/ ITP-04 Formats Pour Card-1 FCIPL/IOCL/EIL/AOS6/CIVIL/O7/ IR-01 Pour Card-2 FCIPL/IOCLEIV/AOS6/CIVILIO7/ IR-02 Cube Test FCIPLIOCLIEILIAOS6/CIVIL/O7/ IR-03 Sieve Analysis (Fine aggregate) FCIPL/IOCL/EIL/AOS6/CIVILIO7/ IR-04 Sieve Analysis (Course aggregate) FCIPLIIOCL/EIL/AOS6/CIVILIO7/ IR-05 a paws payed© EPC FOR LAYING OF PIPELINES AND COMPOSITE WORKS FOR ‘SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT PARADIP ennai paet te on IndianOit {INDIA} INSPECTION TEST PLAN FOR PLAIN CEMENT CONCRETE (RCC)-Sub Structure own TROT OH CORPORATION UMTTED uc ENGINEERS HOA LTD revision. ere Fe Fomat No IPLAOCLELANSSCIMLATITPION fee fatty raven Fore | EE Ventcaten 0 a Revi fairer crates a nama es EQNS w ca ma Fed cabaton any WE WE w w ru 7 [emeting fino and rate compan Tad ade WES w 5 ru 3 poporion WES w 5 ru 4 [omeok rst dovaeina ay WES w s Ran 5 [conan win proper canpacton W'S we s aun 6 [Checking of top level of PCC WC S- IC we s RM 7 eg w 5 rt a Soe Legend ~ Be Acceptance Approval HP ad port yy at Random iepecton RRevewof Record We Wines At Sen NAME Se ote O Prepared FOP Tene proved oy FPL arrears "ee woEPC FOR LAYING OF PIPELINES AND COMPOSITE WORKS FOR ‘SOUTH JETTY PIPELINE PROJECT OF MIS IOCL AT PARADIP (eS © (INDIA) Gannaay INSPECTION TEST PLAN FOR REIGNFORCED CEMENT CONCRETE (RCC)-Sub Structure lorie T ROAR CORPSRATON TED {ENGINEERS NOIALTD meion fore Femat hr RUIOCVEIURosScrunrMTPAe SNe = Iepectin 8 Fam. | Von Vernon by OGL 7 eae Wo m7 2 _[enrevewt catvaten centres oT navaraa ing SR we | w ra [eyed cairn any we ¢ eu 3 [onstrate conto a PCC ORE we $ ra 4 [orectntesng et mater we 5 ra . 3 [Own ofmac we 3 ra Ea lee = a = [thot or eo wae dao oreo Toy we = ra ae We w i 0 wer ancora are dees poi SOROS BE wo 3 ra 10 [Pow cara wo we ra 11 | wc abies sacred (Enea Ges ppC TNT BE] we 5 ra 12 [onset sg, competion sig we w ra [33 [Casting of cubes We Ww RM 1a fora We 5 rt 15 [resrg abe we w ra 1 [Ronovle shag we 5 ra 17 [omc water tines ein, any we 3 ra 18 [Prerain os: Ba reg we re ma Legend ‘Wines by Contactor Fandom inspection Review of Record ness AR Reviewed/Approved by EIMIOCL " Beri‘SOUTH JETTY PIPELINE PROJECT OF M/S IOCL AT PARADIP eS EPC FOR LAYING OF PIPELINES AND COMPOSITE WORKS FOR (INDIA) INSPECTION TEST PLAN FOR REIGNFORCED CEMENT CONCRETE (RCC)-Critical Structure lowner TINIAN OIL CORPORATION RATED ENGINEERS INDIA LTD For. lrewsion Fommat NoFCIPLIOCUEIUADSS/CIVILOTATPAO4 ‘city Inspection By FCIPL Vesifeation by EL Veriton by IOC aot wea oO ) even o eaationcentieatos of nsronenta testing eQpmEnTe [Ftd carton any [checking of ayo [Chockngiesing of matera [Sci erata below PCC [Design of mi [check or ne & ave of ahaa & Sat anger BRS |neixang nosing arangaments, [Rentorcemen' & aver to rentorooment [nsers, anchor bots, pipe sleeves, Me rugs, concealed lecrical [conduits tan nooks, twas, etching wold any [Pockets opening [Seperation anc apse consructopn nis Fany [Expansion Jon. fay [check or water sops, slopes, loppers Fanp [Poor cara [Gcncreatng tesing compacton & fishing 2/2/2)2|2|2/2| 8 |2| 2 |2/2)2|2|2/2/2 [easing of cabes Jeune RM. 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[Reference Document [ripe of structure Location [From re: 2 3 [levels 4 Grade of concrete/ Approved Design mix Icement rand Name, Grade and Consignment no of 6 [Estimated Volume of Concrete 7_ [auantiy of cement required 8 [Reinforcement Checking details em] Length 2} taps b) Separators le) Chairs la) Any other Renarks 3 Pre pour inspection details DI Checked NA a) survey / Layout [o) Sub sou compaction [c) Completion of undergound work cL a) Cleanliness le) Cover to reinforcement A Anehor Boks e} Sleeves / pockets Ih) water stops a I) formwork [nstopes lk) Consteuetion / Expansion joints [yAdmintures im) Any other Remarks 10] Clearance for Elecrical/Mechanical Electrical [Mechanical Satisfactory for concreting, Remarks, any Tal The above structure is finally inspected on @___AR/PN and found not found a be oF FOR FCIPL FOREN /IOC. Name : Name ae signature Signature xt [bate = ate 5 a oot geJOCL PARADIP-SOUTH JETTY PIPELINE PROJECT & INSPECTION REPORT FOR POUR CARD I CPEAnag Indianowt POUR CARD-II (OBSERVATIONS DURING CONCRETING) FORMAT NOx FCIPLIOCLIENTAOSOCIVILOTHROZREV-A = FPC Contractor: [owners Name of the Work 1 Ja) Quality of coarse aggregates satisfactory [ ‘Non Satisfactory Jo) cual of find agaregates = satwtetoy [7] Hon sation c) Bulkage of sand taken into account er ves No a) Quay of water ¢ satisfactory wonsaritactoy [_] 3 [Machinery mobilization Nos. Length a) Mixture machine lb) Ready mixed concrete dumpers lc) Vibrators fa) Pumps: id) Hoists Pour Start time [AM/PM Date: [Type of weather \ | i mm EI 8 [Details of abnormality [Precautions taken for <$°C apd 40s J 9 [Number of cubes taken 40 [Quantity of Concrete poured 11 [Pour completion time AM /PM Date: 12 [euring method. Traditional L| Curring compound. Blankets/folls/gunny bags others (specify) 13. [Period removal of from work 14 [Any defect (6) observed during concreting: ost Concreting Check: ) [surtace ‘i)_ [Dimensional check FOR FEIPL FOR F/IOCL Name Name Signature Signature pate. L Date. oeEFC FORLANING OF PPELNES AND COMPOSITE WORKS FOR SQUTH JETT PELE PROJECT "WS. 1OCL AT PARAD! (NDIA) INSPECTION TEST REPORT OF CUBE TESTING for ae ea ener a oe Q we ~— LAB NCHA =» Revenearigoroved wy FCP.1OCL PARADIP-SOUTH JETTY PIPELINE. PROJECT (:1-zn) FORMAT a ‘SIEVE ANALYSIS REPORT indianoit ame FINE AGGREGATE FCIPLIOCLEILIADSSICIILOTIR-OUREV-E Repor No Project Name of Work: Client: Contractor Wt. of Sample taken: Date: FINE AGGREGATE Sieve i * % Weight | Cumulative % Tes No. * Fineness Modi : Re So. | etm) |WeightRetained| "Weight ee ‘% Passing | Fineness Modulus | Limits (As per 15:383) ‘emarks 1 475 | 2 | 236 3 118 we = | 0600 s | 0300 6 | 0150 7 | oo = 8 Pan 7 9 Total REMARKS... FOR FCIPL FOR EIL/IOCL Signature: Signature: BIZ, 56 Name: Fe Get Date: Date:EES: IOCL PARADIP-SOUTH JETTY PIPELINE PROJECT a FORMAT SREANAS Indianoi SIEVE ANALYSIS REPORT = COARSE AGGREGATE FCIPLIOCLEILIAOSSICIVILIOTIR-OSTREV-A Report No, Project Name of Work Glient: Contractor: Wt. of Sample taken: Date: COARSE AGGREGATE Sieve ; i % Weight] Cumulative % = Fineness] ; So. | simtmny [WeishtRetained] | Weigh Retained | ‘Passing | Fineness | Limits (as per :383) | Remarks a 40 2 25 3 20 : 4 Rs Cc 5 10 6 475 a 7 236 8 Pan 9 Total 7 wi FOR FCIPL FOR EIL/IOCL ‘else Signature sear Sal Name: = [Names er Dat Date: Vv x é &