KOLKATA METRO RAIL RAIL PROJECT

GAMMON INDIA
LTD ANV2- CONSTRUCTION OF 5.27 KM VIADUCT FOR
RAIL VIKAS NIGAM LIMITED REV No: R2
DT: 17.12.2012
METHOD STATEMENT –PIER

A) TITLE: CONSTRUCTION OF PIER.

B) CONSTRUCTION MACHINERY

C)
S. No. DESCRIPTION TYPE CAPACITY NO. STAND BY
1. Batching Plant Stetter 30 cum/hr 1
2. Transit Mixers Stetter 6 / 4 cum 2*
3. Concrete Pump Stetter 35 cum 1 1
4. Welding Generator 400 Amps 1 1
5. Concrete Vibrators Internal 4 2
6. Concrete Needles 60/ 25 mm dia 4/2 4/2
7. Compressor 300 cfm 2*
8. Crane 5 / 8 ton 1
* As per site condition it can be increased.

D) SAFETY
Pier location shall be barricaded 9 m (minimum 9m i.e. 4.5m on either side
from centre of pier) on road location. Working platform shall be provided and one stair
having handrail shall be provided for accessing pier. Suitable reflectors, blinkers and
diversion boards shall be provided at specific locations to provide safe driving at night.
All site personnel will wear helmets, boots and other safety devices as required. For other
activities such as handling of reinforcement, electrically operated equipment etc. safety /
precautions shall be taken as per the approved safety plan. Risk assessment has been done
for these activities and all precautions shall be taken for safely carrying out the activity.
Traffic may be diverted if required as per approved Traffic Diversion plan that will be
controlled by Traffic guards. Pier works shall be done as per the approved Plan. Incident
of accident, if any, shall be reported in enclosed format.

E) PROCEDURE
1) SURVEY :-
Layout of pier will be done with the help of reference points established
around the pile cap T-1, T-2, R-1, R-2 and will be checked from the same.

2) REINFORCEMENT

1
 KOLKATA METRO RAIL RAIL PROJECT
GAMMON INDIA
LTD ANV2- CONSTRUCTION OF 5.27 KM VIADUCT FOR
RAIL VIKAS NIGAM LIMITED REV No: R2
DT: 17.12.2012
METHOD STATEMENT –PIER

a) Fabrication :-
For fabrication of reinforcement, BBS shall be prepared as per the drawings
and got approved from RVNL. The Reinforcement shall be cut using cutting machines or
manually as required and bent at Rebar yard. The rebar shall be transported to location in
dumpers/ trailers to the location or manually depending upon the lead.

b) Fixing of Rebar: -
The rebar shall be manually fixed upto the bottom level of pier cap in
one go. Cover blocks of same grade of concrete in which it is going to be embedded or as per
provision of contract shall be provided as required to ensure uniform cover and tied together
with GI binding wire as mentioned in the drawing. The rebar shall be get checked by GIL
engineers and all the rebars shall be jointly checked by RVNL and GIL. After completion of
rebar placing. After getting the clearance, shuttering work will be taken up. After rebar
fixing, the drainage pipe will be fixed as per the drawing.

3) SHUTTERING
Shuttering fabricated as per approved drawings shall be placed at
locations as per the pier dimensions shown in the drawing. Initially with reference to the
layout, a starter formwork of 150 mm is fixed. This 150 mm portion will be cast first and top
of the starter will be roughened with wire brush. As the height of the pier varies, the
remaining shuttering will be fixed by lapping the shuttering at various level around the starter
cast before to achieve the desired top level of pier. After casting the initial starter of 150 mm,
a starter channel is fixed around at required level, a timber packing is given below the starter
channel for extra support. Before placing the shuttering, shuttering oil shall be applied on
shutter face in contact with the concrete face to ensure easy removal of shuttering and proper
form finish. Pier shuttering in four side pieces are erected by crane and will be bolted
together by the provisions provided. For minor correction / adjustment in top level, jacks will
be used. It will be fixed at the bottom leg of the pier shuttering and the jacks will rest on pile
cap. To maintained the verticality of the Pier Cap, Suitable arrangement will be done with the
help of adjustable turn buckles to be kept at suitable positions. After maintained the
verticality the shutter will be strengthen by Waller frames which is to be connected by means
of tie rod and nuts.

2
 KOLKATA METRO RAIL RAIL PROJECT
GAMMON INDIA
LTD ANV2- CONSTRUCTION OF 5.27 KM VIADUCT FOR
RAIL VIKAS NIGAM LIMITED REV No: R2
DT: 17.12.2012
METHOD STATEMENT –PIER

4) CONCRETING
The concrete required shall be produced as per the approved design mix at
the centralized batching plant at the casting yard and transported by transit mixers to the
pouring location. Before pouring concrete slump of 100mm to 120mm or as per approved
mix design shall be checked at pouring location. Before starting of concrete the pipeline shall
be pumped with cement grout. The concrete shall be placed by concrete pump with flexible
hose / crane and bucket. The drop height of the concrete should not be more than 1.5m. The
concrete shall be vibrated using 75mm /60mm / 40mm diameter vibrators needle or as per
applicable as per arrangement. Concrete cubes shall be taken for testing of compressive
strength as per IS: 456-2000 at pouring location. Few cubes may be kept at site near pier
location. So as to get the actual strength during site curing. Concrete cylinders shall be taken
for testing permeability as per contractual requirement. Concreting should be done
continuously in one pour.

5) CURING
The concrete shall be cured by surrounding the pier with hessian cloth and wetting
it till 14 days or by spraying approved curing compound in two coats. The curing compound
will be sprayed in two coats immediately after removal of shuttering. Necessary MTC and
performance report of curing compound will be checked in advance for confirming test of
curing compound.
6) ENCLOSURE
a) Safety Checklist.
b) Formwork Checklist.
c) Bar bending schedule.
d) Reinforcement inspection.
e) Permission for concreting.
f) Pier pour card.
g) Checklist for curing.
h) Checklist for post concrete inspection.