Method Statement For Plunge Column

CEC - UG1B
CONTRACT: ICB No. :-JP/EW/1B/C1
JAIPUR METRO RAIL

CORPORATION LIMITED
METHOD STATEMENT FOR

CONSTRUCTION OF PLUNGE
COLUMN IN STATION
DOC NO:
PR/JMRC/MS/UG1B/PHOF/14-R0
CONTRACT UG1B
PROJECT: Design and Construction of Tunnel between Chand

Pole and Badi Chouper and reversal line by Shield TBM,
Underground Metro Stations at Choti Chouper & Badi
Chouper by Cut & Cover Method on East-West Corridor
of Jaipur Metro (Phase 1B) at Jaipur, Rajasthan, India.
LOCATION: JAIPUR
METHOD OF STATEMENT FOR

CONSTRUCTION OF PLUNGE COLUMN IN
STATION
Page 1
CEC - UG1B
Project
Manager
RV AKASH
GANGA
INFRASTRU
CTURE
Constructio
n Pvt. Ltd.
JAIPUR METRO RAIL

CORPORATION LIMITED

COLUMN IN STATION
DOC NO:
CONTRACT UG1B
DGMPlanning
Department
,
CEC
DPM
STATION,
CEC
Senior
Manager
QA/QC
Department
,
CEC
Chief
Manager
HSE
Department
,
CEC
Project
Leader
CEC
Table of Contents
Sr. No.
1.0
2.0
3.0
4.0
4.1
4.2
5.0
6.0
7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
Description
Purpose
Scope of Work
Site Establishment & Setting Out
Major Resources to be Deployed
Equipment to be Deployed
Manpower to be deployed
Materials
Responsibility and Authority
Construction Procedure
Traffic Management and Barricading
SHE Measures
Design & Drawings
Site Establishment
Surveying
Pre Trench
Plunge column boring
Muck Disposal
Preparation of Rebar Cage
Page 2
Page No.
03
03
03
04
04
04
04
05
06
06
06
07
07
07
08
08
09
10
CEC - UG1B
7.10
8.0
9.0
10.0
11.0
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Concreting
Quality Control / Control Assurance
Environmental Management
Safety and Emergency Procedure
Attachments
12
12
12
13
13
1.0 PURPOSE
This Method Statement describes the construction process of 1500 mm
diameter Plunge columns in station areas.
2.0
SCOPE OF WORK
The scope of work and the Construction Sequence for installation of permanent
Plunge Column shall be as mentioned below:
a. Traffic Management and Barricading
b. SHE Measures.
c.Design and Drawings
d. Site Establishment
e. Surveying
f. Pre-excavation
g. Boring into soil to the design depth
h. Muck Removal
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CORPORATION LIMITED

COLUMN IN STATION
DOC NO:
CONTRACT UG1B
i. Fabrication of structural steel flange column

j. Cage preparation and cage lowering
k.Tremie Lowering
l. Concreting for Plunge Column
m. Back filling
3.0 SITE ESTABLISHMENT & SETTING OUT
Good firm access shall be provided to allow safe passage of plant and
equipment throughout the Plunge Column construction area.
Adequate, hard, all weather platforms shall be provided and maintained for the
execution of the Plunge Column operations. Platforms shall provide sufficient
bearing capacity for the pilling rig and cranes.
Safety barriers shall be provided at all times to prevent unauthorised access to
the operation area.
The position of the Plunge Column shall be determined by the setting out as Per
Drawing No.OKICPL-JM1B-C-SC-0475.
4.0
4.1
MAJOR RESOURCES TO BE DEPLOYED

Equipment to be Deployed
1. 70 Ton capacity crawler crane
- 1 no
2. Supporting crane(70Ton)
- 1 no
3. Hydraulic self-propelled Kelly Rig
-1 no
4. Polymer setup
-1 unit
5. Tremie pipe (200 mm Dia; with hopper)

6. Welding set
-1 unit
-4 no
7. Cutting and bending machine
-2 no
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8. Transit Mixer
- 8 no
9. Batching Plant (60 cum/hr)
- 1 no
4.2
Manpower to be deployed
Sr.
No.
Construction Manager
Site Engineer
QC Engineer (Field and Lab)
Mechanical Engineer
Surveyor
Foreman
Supervisor
Electrician
Safety Officer
Mechanic
10
MATERIALS
Concrete as per Approved mix design M35 Grade.
Reinforcement Steel conforming to specification
Polymer (from approved supplier)
6.0
6.1
Number
5.0
Category
RESPONSIBILITY AND AUTHORITY
DPM-Stations
He shall be overall responsible for following

o Safety Rules
o Statutory Compliances
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o Quality Manuals
o Construction Methodology
Overall responsible for the whole operation.
6.2
Station Manager
He shall be overall responsible for the whole procurement of Men, Material and
Machinery at site, including operation planning and adhered with works
program. He shall be liaison with Utility Owning Agency for approval of Utilities
Diversion Plans (if any).
6.3
6.4
Site Engineer
Responsible for site operation.
Material and equipment planning.
Ensure works are carried out in accordance with the method statement.
Ensure works follow approved drawings and specification.
Ensure works are carried out in a safe manner.
Field control and supervise all site activities.
Apply and issue relevant work permits.
Design Engineer
He shall be responsible to issue controlled copies of all drawings to the site
personnel and return back all obsolete copies. He shall provide detailed design
specifications to carry out the work.
6.5
Planning Engineer
He Shall be Responsible for arrangement of all external resources
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6.6
6.7
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Safety Personnel
Ensure works are carried out in a safe manner and in accordance with the
safety requirements stipulated in the SHE plan.
Conduct tool box talks on the safety requirements, construction risks and its
control measures etc.
Surveyor
Carry out setting up works and locate as per submission drawings.
Carry out inspection for location and level of structure.
Keep monitoring the movement of ground and structure.
6.8
7.
QC Engineer
Ensure works are carried out in accordance with specification.
Carry out inspection for all activities in accordance with the Inspection and
Test plan.
He shall be responsible to prepare the method statement in co-ordination
with Design, Safety & Quality and enclose Inspection and Test Plan and risk
assessment. He shall review the method statement as per site requirement.
CONSTRUCTION PROCEDURE
7.1
Traffic Management and Barricading
Traffic management shall be carried out as per the approved Traffic Diversion
Plan. For heavy equipment mobilization, necessary precautions shall be taken to
bring the required items within the work area boundary by carefully managing
the traffic. The work location shall be barricaded as per the site requirement and
all the equipment shall be installed inside barricaded area.
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CEC - UG1B
7.2
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SHE Measures
1) All the workers shall be provided with required PPE (safety jacket, shoes, helmet,
hand gloves etc.) before they are engaged in the work.
2) Safety induction shall be provided to the supervisors, engineers and workers.
3) Tool box meetings shall be organized every day by site supervisor before start of
work in order to keep workers aware of associated risks and safe working in
order to avoid accidents/injuries.
4) Unauthorized/outsiders shall not be allowed to enter inside/stay near the area
barricaded during work in progress.
5) First aid facilities shall be made available at site and male nurse shall be
available at principal work spot to render the first aid services, if so required.
6) Proper Lighting arrangement shall be maintained during night work (or in day
time in case of low visibility).
7) Housekeeping shall be maintained at work spot to avoid any undesirable
incident.
8) Emergency contact number shall be available and displayed at the designated
locations near the work spot to tackle any emergency situation occurring at site.
9) All the machines shall be inspected before deploying to the work and proper
guarding for moving parts
Shall be in place prior to commencement of work. Operators with valid licence
(where applicable) shall be allowed.
10) Silent type DG sets shall be deployed at work location.
11) Drip tray shall be provided underneath the machineries to avoid land
contaminations.
12)
Dust bins shall be available at prominent locations of work site to collect
generated waste out of site activities.
13) Risk assessment shall be discussed among all concerned prior to start of the
activity.
14) After completion of work at a particular stretch required back filling shall be
taken up depending upon site requirement.
15) After completion of work post inspection shall be carried out to ensure that the
tidiness has been maintained and the work location has been restored to
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COLUMN IN STATION
DOC NO:
CONTRACT UG1B
original condition.
7.3 Design & Drawings
A. The work shall be carried out as per the approved design and drawing.
B. Controlled copies of relevant drawings shall be made available at site and shall
remain available with site engineer throughout the work.
7.4
Site Establishment
Before starting any activities, a site utilization plan is drawn showing the various
establishments at site such as location of Panel formation, Putting DGs, Polymer
tanks, Muck bin, office etc. through a detailed survey. The site area shall be then
cleaned properly and made free from any on and over ground obstruction and
necessary barricading shall be installed. All plant and equipment shall be placed
as per this plan.
7.5 Surveying
Upon clearing the site area, the setting outpoints shall be marked for the
subjected Plunge Column panel and with reference to that guide wall, points
shall be marked through requisite survey. Reference pillars shall be always
preserved for checking of constructed guide wall at later stage. All the survey
points/coordinates shall be maintained in survey sheet and checked/approved
by Engineer prior to construction work.
7.6 Pre Trench
During this pre excavation process, investigation and verification of
underground utilities shall be done at the subjected location. Manual excavation
shall be done for finding the underground utilities. In case of any utilities found,
the mapping shall be done through requisite survey and a drawing shall be
drawn. In order to construct the Plunge Column such utilities if required to be
shifted marginally, the same shall be done either through local shifting or
providing the local diversion as agreed upon by the utility owner. The diversion
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CORPORATION LIMITED

COLUMN IN STATION
DOC NO:
CONTRACT UG1B
process if necessary shall be done in consultation with utility owner. Utility

diversion shall be done as per Approved Method Statement. The utility diversion
method statement shall provide detailed information about the underlying
utilities and the process to be followed for the diversion process.
7.7
Plunge Column Boring

(a)Boring of Soil
1.5 meter dia; Boring of soil shall be carried out using a rotary Hydraulic
pilling rig in normal soil strata to the required depth as Per Drawing
No.OKICPL-JM1B-C-SC-C-0411.Soil stabilization will be ensure by polymer
final depth of concrete shall be confirmed by sounding method. The
verticality of the Bore shall be monitor during installation and letter check
before lowering of cage. The eccentricity shall be jointly done with
verticality.
(b)Setting out of guide frame

Minimum 200mm trench shall be excavated, a levelling PCC (M15/M20) will
laid for placing the guide frame as per the Drawing attached.
(c)Placing of Guide frame
After placing of PCC guide frame shall be placed carefully in line and level
layout as per the surveyor.
(d)Instillation of temporary casing
To stabilize the upper bore, temporary steel casing of length 2.5 m shall be
installed at the bored pile locations as follows:
A 1500mm Dia bore shall be drilled using a Hydraulic Boring machine to a
required depth.
A 2.5m long steel casing shall be installed in the 3-4m deep bore holed by
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COLUMN IN STATION
DOC NO:
CONTRACT UG1B
lowering the Casing with crane. Vertically shall be checked and ensured
during installation.
The casing shall then be driven into the ground with rotary machine until
about 300 mm is left protruding above the ground.
Drilling rig is then used to progress the excavation to the bottom of the
casing pipe and then polymer shall be added before any further excavation
is made.
During excavation polymer shall be added continually from the storage tank
such that level is maintained with in 1000mm below top of casing pipe.
Excavation depth shall be found by sounding tape.
(e)Polymer Slurry Preparation, Storage and circulation
Dry polymer powder shall be tested and approved prior to the use. The
batching plant shall be erected on adequate impermeable slab. Dry
polymer powder shall be mixed in the mixing tank with the water. The
mixing shall be achieved by dedicating a pump and compressed air system.
The mixing tank capacity may be 1.5 times the excavation's volume. The
mixing tank shall be connected to the slurry storage tank with appropriate
routing valves. Thus polymer slurry is made ready for use with required
properties.
In the second phase the polymer slurry shall be pumped to the trench and
circulated continuously till excavation is over. While the panel excavation is
going on the polymer slurry continuously flows to the trench and thus
stabilizes the trench throughout its depth. While excavation, the polymer
slurry get mixed with soil and loses its properties. Continuous circulation of
fresh polymer shall help to keep the properties of the polymer slurry even
then it is mixed with the soil. The return slurry shall be pumped into the
sedimentation tank. The sedimentation tank shall be kept open to the top
to allow an easy cleaning and removal of sediments. As sedimentation tank
is included with three deflector vertical plates, continuous flow of slurry
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DOC NO:
CONTRACT UG1B
shall occur in "cascade" like mode and increase the speed of the
sedimentation occurring between different compartments. The final de
sanded slurry shall be connected to the storage tank with after being
treated properly to achieved required property and sent to storage tank
with proper pumping arrangement.
(Details of Polymer Batching Plant mix is shown in Annexure - B)The polymer

characteristics shall be checked with respect to the following prescribed
values:
Permissible Value
Sr.
Test
Prior to
No.
Fresh mix
Reused Slurry
concrete pour
Density
1.00 to
1
1.06
1.05
(kg/m3)
1.04
2
pH Value
11 to 12
11 to 12
9-12
Marsh
Cone
3
55-140
55-140
50-140
Viscosity API (s)
Sand
Content
4
<2%
2%
(%)
Properties as per annexure G
7.8
Muck Disposal
The Bore Muck generated from excavation process shall be shifted to space
available near by the work area using JCB. The shifting shall be continued till the
completion of grabbing operation. After Completion of grabbing the working
area shall be cleaned for stacking of Stop End and Reinforcement Cage. The
Bore muck initially dumped at available space near working area then shifted to
designated dumping yard by covered and leak proof tipper/truck having the
fitness certificate checked by Engineer. The tyres of the truck shall be cleaned
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COLUMN IN STATION
DOC NO:
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thoroughly and be made free from muck before the truck exits the site. After
removing all the muck the area shall be cleaned using water through the water
pipe line arrangement at site.
7.9
Preparation of
Rebar Cage
7.9.1 Reinforcement Steel Cage Cutting, Bending
The reinforcement cage shall be in single piece or two pieces depending upon
the site condition and equipment availability, the cage may be fabricated and
lowered into Bore Pile. The reinforcement should be cut and bend at the steel
yard or at site as per bar bending schedule and the cages shall be prepared at
site over a level ground. Necessary spacer bars, fixtures, inserts and cover
blocks shall be provided along with the reinforcement cage. Care shall be taken
to fabricate the cage in true line and level with cover blocks fixed with proper
supports and brought to the panel by crane. Cover blocks shall be provided at
close spacing of 1.5m to 2.0m. While cage fabrication, roller cover block shall be
introduced to the outer rebars before fixing.
7.9.2 Fabrication of Rebar Cage

Based on the approved reinforcement drawing, the Bar Bending schedule shall
be prepared and shall be submitted for approval. The reinforcement shall be cut
and bent as per approved Bar Bending Schedule in reinforcement yard situated
at the casting yard. The cut and bent steel shall be shifted to the site with the
help of Trailer for making the cage.
The reinforcement cage shall be fabricated at the site. If there is insufficient
space on site, the same shall be fabricated at the casting yard or other offsite
location and the prefab cage shall be shifted to site through trailer. The
reinforcement cage shall be fabricated using the Binding wire and wherever
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COLUMN IN STATION
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required welding shall be done. (Details of Plunge Column Reinforcement are

shown in Drawing No. OKICPL-JM1B-C-SC-D-072A).
The cage shall be fabricated over the fabrication bed consisting either of steel
chairs, channels or wooden sleepers. The clear cover shall be maintained as per
design which is 75 mm. Concrete spacers (same grade as Plunge Column
concrete , circular or trapezoidal skid shape) shall be fixed to the cage typically
at intervals of 1500mm horizontally and 4000mm vertically.
1
Cutting / Shearing of Rebars : The bars with improper ends like bent, too much heated, improper
manufactured ends etc., are cut with Bandsaw machine or sheared with shearing machine. This is
done in order to achieve a flat surface for further forging of the rebar. Also the face of the rebar
becomes perpendicular to the axis of the bar. This flat face also helps in abutment of two rebar when
in contact with each other.
7.9.3 Cage Lowering and fabricated plunge Column

After cage preparation, lifting and placing of the cage shall be done with the
help of service crane and the cage lifter. The cage lifter shall be fixed directly to
the lifting hooks of the cage with shackles and slings of the crane. The cage
shall be lowered up to the desired level and shall be rested with the help of
resting hooks and supports from guide frames. Front and rear sides of cages
shall be marked on site to identify the soil face and excavated face during
placement. Lifting points and lifting lugs are designed (to be approved by our
designer) in such a manner which shall not cause distortion of the cage.
the plunge column shall be lifted with service crane and inserted in eccentric
part of cage to the required depth as per the drawing, holding and jointing of
both reinforcement cage with fabricated plunge column shall be done.
After removal of all the hanging supports, both reinforcement and plunge
column shall be lowered with service crane, maintain the eccentricity and
verticality of plunge column by fixing the survey coordinates on guide frame.
The lowering of cage and plunge column shall be done to the required depth of
pile as per the drawing N0. OKICPL-JM1B-C-SC-0411.
7.9.4 Tremie and Lowering
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After lowering of reinforcement cage, tremie of minimum 200mm dia and length
of 1.2 to 2m shall be lowered in pieces and connected while lowering for full
depth of trench with the help of service crane and hopper of approximately 1.5
cum capacity shall be attached to the top of tremie pipes.
7.10 Concreting
Concrete of required grade M35 shall be batched in the batching plant and same
shall be transported through the transit mixer and poured to the hopper/tremie
pipe. Initial setting and final setting time of concrete shall be 5-6 hrs and 1314hr respectively. The concrete shall be directly discharged into the
hopper/tremie. Before initial discharge there shall be at least 2 nos. delivery
trucks on site. Uniform rising shall be ensured by periodically measuring the rise
of concrete adjacent to the tremie location not less than once per concrete truck
per tremie. There must be a minimum 1.0m immersion of the tremie pipes in
the concrete. This is necessary to avoid polymer inclusions in the concrete.
Tremie pipes shall be shortening depending on the rise of level of concrete. The
tremie lengths and concrete rise shall also be monitored / recorded.
Concrete shall continue to a minimum cut-off level at Bottom of base slab as per
the Drawing No. OKICPL-JM1B-C-SC-72A (typical elevation of pile with plunge
column) as required to ensure sound homogenous concrete at cut-off level. Any
significant remaining portion of Plunge Column from bottom of base slab to top
of concourse slab shall be filled with M5 /M10 Grade slurry Mortar Design
Mentioned Below:Cemen Fly ash Sand
Water
Admixt
t
ure
90 KG
100 KG 1625
310 KG 1 KG
KG
The next remain level of plunge column from concourse slab to the top slab
shall be filled with backfill soil and sand as required.
8 Quality Control / Control Assurance
Quality Control and Quality Assurance of Plunge Column operations at different
stages shall be done using the following ITP & Formats.
Particular care must be shown with respect to control of polymer slurry. Drip
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trays to be used underneath compressors and generators. Site is to be kept free

of dust. Noise levels shall be kept well within the allowable limits.
9. Environmental Management
Safety, Health and Environment (SHE) plan shall be followed throughout the
construction program. The Construction of Plunge Column involves the use of
heavy machineries such as crane, excavators and trucks etc. and these
machines inevitably create noise. However, in order to minimize the noise and
discomfort to the people living in the neighborhood or the shopkeepers and
people coming to the nearby markets, all the machines shall be provided with
suitable silencers and with acoustic enclosures, Noise barriers shall be erected
to minimize the noise pollution.
The construction shall also involve the removal of earth from site to dumping
areas by dumpers that shall use the public roads. During transportation the
dumpers shall be covered by tarpaulins. The muck shall be disposed during the
night hours only and one supervisory level staff shall be engaged permanently
at dumping yard with JCB for leveling the upcoming soil leveling, while dumping
the soil.
Simultaneously the area leveling and shall create a proper way for soil dumping.
The used polymer slurry shall be transported in dumpers.
The washing bay shall be installed near each exit gate. These washing bays are
of improved design using a heavy-duty pump having high head and large
discharge. The tires and the undercarriage of the vehicles shall be washed
before the vehicle leaves the working area for dumping site. In case water is not
available due to water scarcity, tire shall be cleaned manually with wire brush.
Required persons shall be engaged to clean the sides of the vehicles manually.
The working area shall be kept clean and tidy.
10.
Safety and Emergency Procedures
During excavation all necessary precautions to ensure stability to the
excavations and guide walls shall be taken. If excavation be suspended for any
reason, polymer in the trench shall be agitated, periodically with the grab or by
circulation for a maximum period of 24 hrs. This shall be followed by backfilling
of trench with excavated materials.
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In the event of a sudden loss of polymer slurry or trench collapse, the

excavation shall be immediately stopped and the trench backfilled with
excavated materials.
11. Attachments
I) INSPECTION AND TEST PLAN
Inspection and Test Plans attached as annexure D
II) FORMAT/ CHECKLIST
1. Inspection Checklist for Plunge Column - Annexure El
2. Reinforcement Inspection Checklist - Annexure E2
3. Plunge Column concrete pour card - Annexure E3
4. Concrete Pre Pour Card - Annexure E4
5. Plunge Column Boring Excavation Record - Annexure E6
6. Plunge Column Boring Construction Record - Annexure E7
7. Inspection Checklist for Poly Mud Slurry - Annexure E8
8. Concrete Pouring Records Annexure E10
9. Properties of Polymer slurry - Annexure E11
10. Welding Inspection check list-Annexure E12
11. Risk Assessment Annexure K
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Method Statement For Plunge Column

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CEC - UG1B

CONTRACT: ICB No. :-JP/EW/1B/C1

JAIPUR METRO RAIL