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Chimney Raft Foundation Methodology

This document provides a method statement for constructing the chimney raft foundation at the Udangudi Super Critical Thermal Power Plant project. It outlines the procedures for fabricating and erecting rebar, constructing formwork and supports, pouring concrete, and other quality control measures. The raft will be cast in 8 segments by September 10, 2019. Rebar will be fabricated according to approved drawings and specifications. Formwork will be constructed using 12mm plywood and hardwood battens. Concrete will be poured using 3 batching plants, 2 concrete pumps, and 14 transit mixers to achieve a pour rate of 42 cubic meters per hour.

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Sandip Paul
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161 views10 pages

Chimney Raft Foundation Methodology

This document provides a method statement for constructing the chimney raft foundation at the Udangudi Super Critical Thermal Power Plant project. It outlines the procedures for fabricating and erecting rebar, constructing formwork and supports, pouring concrete, and other quality control measures. The raft will be cast in 8 segments by September 10, 2019. Rebar will be fabricated according to approved drawings and specifications. Formwork will be constructed using 12mm plywood and hardwood battens. Concrete will be poured using 3 batching plants, 2 concrete pumps, and 14 transit mixers to achieve a pour rate of 42 cubic meters per hour.

Uploaded by

Sandip Paul
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

Subject:

METHOD
STATEMENT
FOR THE
CONSTRUCTIO
N OF
CHIMNEY
RAFT

PROJECT: 2X660 MW UDANGUDI SUPER CRITICAL THERMAL


POWER PLANTCHIMNEY RAFT FOUNDATION
METHODOLOGY
Work Order No. Document No. Revision
BHEL/PSSR/SCT/1736/2018/907 BYG/BHEL/USTPP/001 3

Organization Description Name Signature with


Stamp

M/S Prepared by
ByggingIndia Ltd
(Sub-vendor)

M/S BHEL (EPC Scrutinized by


Contractor)

M/S TCE (PMC) Reviewed by

M/S TANGEDCO Approved by


(Customer)

CONTENTS

1|Page
S. No. Description Page No.

1 Drawings & Technical Specification 3


2 Schedule 3
3 Rebar Fabrication 3
4 Rebar Erection/ Reinforcement Work 3
5 Shuttering and Supporting 4
6 Pouring of concrete 5
7 De-Shuttering and Post Concreting Treatment 7
8 Contingency Plan 7
9 Quality 8
10 Pouring Arrangement 8
11 Safety 9
12 Overall Manpower requirement for chimney Raft (Detailed 10
Breakup)

13 Responsibility Matrix 10

1. General
The Project envisages design, engineering and construction of 275 m RCC twin flue chimney
comprising of raft, windshield, internal platforms, flue can liners, painting and protective coating,
elevators and electrical works. This method statement has been prepared to provide an explanation
of the work procedures to be carried out during the entire execution of the chimney foundation. The
entire raft has been divided into 8 segments and the completion of entire raft is planned on 10 th Sep
2019.

1. Drawings& Technical Specification:


The work shall be carried out as per the following drawings and Technical spec:
a. PE-DG-435-620-C003: Reinforcement Details of Chimney Foundation Rev 1
b. PE-DG-435-620-C002: GA of Foundation & details of starter bars Rev 3
c. Technical spec. Vol-II Section 5.

2. Schedule:

2|Page
The raft will be cast in 8 segments. The schedule for casting is given below as per latest schedule
shared by M/S BHEL.

3. Rebar Fabrication:
3.1 Relevant IS CODE: SP 34.
3.2 Equipment –
 Bar Cutting Machine.
 Bar Bending Machine.

3.3 Procedure:

 SAIL CRS FE 500 shall be used for chimney raft.


 Bars will be cut as per approved BBS approved by Customer.
 All fabricated bars shall be properly tagged with BAR MARKS for easy identifications
during lying of bars.

4. Rebar Erection/ Reinforcement Work-

4.1 Relevant IS Code: IS1786 ,IS456 ,IS2502


4.2 Equipment-
 Hydra/crane will be used for transportation & erection of r/f.
4.3 Procedure-
• SAIL CRS FE 500 bars shall be transported from the fabrication yard to work
area.
• All reinforcement shall be placed and maintained in the positions as shown
in the drawings.
• 16 SWG wire shall be used as binding wire.
• All bars crossing one another shall be tiedas mentioned in Clause no 7.2.3
of IS 2502. Type of Tying shall be either 6A.
• Bars must be cleaned with wire brush, if they are coated lightly with rust or
other impurities and foreign materials.
• Required number of chairs & spacer bars shall be used in order to ensure
accurate positioning of reinforcement. 
• All cover blocks shall be of same grade of concrete.
• The minimum cover will be maintained properly as per drawings.

5. Shuttering and Supporting-


5.1 Relevant IS Code: IS 4990
5.2 Equipment-
• Chap Saw Machine
• Plywood and batten cutting machine
• Welding Rectifier

3|Page
5.3 Procedure –

 Shuttering scheme drawing:

3”x4” vertical runner @


600 c/c
16Dia Tie rods
Inner bar extra
@ 1200 mm c/c
welded with chair
BTD
bars

12 mm Densified
Ply
Inner bar
2”x3” vertical extra runner
wooden Steel Prop jack
@300 c/cwelded with chair strut support @
bars
600 mm c/c BTD
25 dia Steel bars as walers
– Total 9 nos
circumferentially

 Rigid formwork will be ensured using 12mm plyboard with hard wood battens
placed maximum 300mm interval.
 Form work shall be made to the exact dimensions within the permissible tolerance.
 Fabricated shutter boards will be shifted and place properly in position.
 Inter- connected boards will be joined properly.
 Bracings&tie rods at proper places & intervals will be provided to take care of
lateral loads.
 Shutter will be checked properly aligned & fixed firmly with required lateral
supports and ties.
 Construction joint shutter treatment: Retarder of approved make shall be applied
on the shutter (Construction joint) inside surface very carefully. Before
application the steel below the application area, shall be covered properly, so
that the reinforcement bars doesn’t come in contact with retarder. The
application of Retarder as well as deshuttering shall be governed by the
manufacturer’s specification. After de-shuttering, the CJ concrete surface shall be
washed by Water jet so that the slurry inside the aggregates get washed out and
a 100% rough surface (Like green cutting) is developed.
 Shuttering board’s joint gap shall be closed by shuttering tape& foam so that
cement slurry leakage is completely controlled.
 Shear Key shuttering and supporting will be done carefully and properly as per
drawing. Minimum 1/3rd area shall be made with shear key and the remaining
area shall be scrapped to make a complete rough surface for any pedestals or
wall.

4|Page
 Dowels and insert plates shall be fixed properly in position as per specification
and drawing.

6. Pouring of concrete:
6.1 Pouring Plan:-
• Thickness of each layer -400mm
• Qty of each layer 83 cum
• Initial setting time of concrete - 180 min
• Layer should be laid before (T-60 min) = 120 min
• Rate of Pour = (83/120 X60)Cum = 42 cum/hr
• Capacity of Batching plant required 45 cum/hr
• No of Batching plant = (45+ 10/20) NOS = 3nos
• Capacity of concrete pumps = (45+10) CUM= 55 cum.
• No of Concrete pumps = 55/30 = 2 NOS
• Stand by batching plant = 1 nos
• Stand by concrete Pump -1 nos
• Transit Mixture = (55 +10) cum in hr= 65 cum in hr.
• Number of transit mixtures = 65/6 = 11 Nos + 3 nos standby = 14 Nos

6.2 Relevant IS Code:-IS 456

6.3 Equipment-

a) Batching Plant-3 Nos Batching Plant + 1 Standby


b) Transit Mixtures – 11 Nos + 3 standby
c) Concrete Pumps/ Boom Placer- 2 nos Boom Placer (30 Cum cap.) + 1 Pump standby
d) Vibrator and Needles – 6 nos (Electrical )+ 6 nos (Fuel operated) +10 nos spare
needle.
6.4 Procedure –
• Bottom of raft (PCC surface) will be cleaned properly by water jet or Air jet as per
site condition for removal of algae, ground water and other foreign/unwanted
particles.
• Pour card to be duly filled and signed by client in approved format before
concreting.
• The production of concrete shall be done with Concrete Batching and Mixing
plant
• Concrete shall be transported through transit mixers, which rotating mixing
drum will be covered by wet Hessian cloth..
• Concrete will be placed by high capacity pump or boom placer. Each 1 nos .

5|Page
• Concrete shall not be freely dropped into place from a height exceeding
1.5m to avoid segregation, EXCEPT THE BOTTOM 5 LAYERS SHAL BE FILLED
WITH HEIGHT OF FALL NOT MORE THAN 500 MM.
• Concreting shall be done with tremie method. All tramie pipes shall be fixed
prior to start the pour. The bottom level of Tramie pipe shall be 500 mm
above the bottom mat primarily, to avoid segregation. Then onwards, 1.5 m
HOF can be followed.
• Compaction of concrete will be done by needle vibrator. The vibrator needle
should penetrate the layer of concrete vertically &into the underlying layer
previously placed at green condition.
• Layer thickness shall not be more than 400 mm.
• Top layer of concrete will be ensured and finished suitably.
• To prevent loss of heat due to hydration, curing shall be done by using moist
hessian cloth duly soaked with water applied on concrete surface after final
setting.
• Availability of concrete ingredient in required qty shall be ensured before
starting the work.
6.5 Curing-

•
To prevent loss of heat due to hydration, curing shall be done by using moist
hessian cloth duly soaked with water applied on concrete surface after final
setting.
• Continuous curing will be continued for at least 14 days by ponding, water
spraying or saturated wet coverings.
• Only Potable/Construction water will be used for curing.
• For formed surfaces curing will start as soon as formwork removed.
7. De-Shuttering and Post Concreting Treatment –

i. Procedure –
• All supporting pipes, jacks, ties will be removed carefully as per stripping
time mentioned in IS 456 or depending upon the temperature variation
inside the cements
• Tie rod Treatment:After cutting the ties, the exposed bars will be
protected by thick cement slurry. Then, the surrounding concrete of Tie
rods shall be chipped by 50 mm depth. Then the tie rods shall be cut from
inside the chipping surface. After then, the holes shall be filled by epoxy
mortar of approved manufacture as per the relevant method statement.
• All formwork shall be removed very carefully.
• Formwork components shall not be dropped but shall be lowered without
damage to the components & structures.
• All the removed formworks material shall be thoroughly scraped, cleaned
immediately & stacked properly for reuse.
• Approved shuttering oil as per TS will be used on plywood surface before
reuse the same.

6|Page
• Damaged shutter should not be used as per direction given by engineer
in-charge.
8. Contingency Plan
• Concrete pour shall be cleared only after producing evidence of stocking of all
ingredients as follows:

Sl. No Materials Qty (Kg / Cum of concrete) Total Qty (MT)


1 CEMENT 400 414
2 CA 20 MM 669 755
3 CA 12.5 MM 479 540
4 FA M -SAND 767 865
5 WATER 156 367
6 MASTER 3.4 3.36
RHEOBUILD 112
7 CI 1.14 1.13
8 Masterpel 777 0.4 0.39
9 Epoxy for filling the As per requirement
tie rod holes

• All plants and machinery shall be checked thoroughly well end before and spare
parts will be stacked at site for avoiding any breakdown.
• Adequate tarpaulin shall be arranged for preventing the rainwater into the
concreting area.
• Alternative back up for power supply will be arranged.
• Sufficient light fixtures shall be available at site for smooth work progress at
night.
• Continuous shuttering and supporting will be checked and monitoring by a
separate carpenter team.
• All workers shall in present with proper PPE.
9. Quality:-
• Design Mix to observe workability, strength & permeability. Satisfactory trail mix
shall be adopted at site.
• Concrete workability will be checked by slump test before concrete pouring.
• Concrete temperature will be checked at site to ensure that it should not be more
than 40 deg C.
• Cubes will be casted by fresh concrete at site in presence of QC Engineer as per
standards for checking the strength
• Post concreting checks to be conducted after deshuttering as per the checklist.
• Batching plant readiness, aggregates platform, dust protection, partition for
aggregates etc.

10. Pouring Arrangement :

2 7

7|Page
5 4
W
E
1 8

6 3

List of Protocols

The attachedchecklists formats shall be followed:

1)Form Work

2) R/F Checklist

3) Pre concreting Checklist.

4) During concreting checklist.

5) Post concreting checklist.

6) Pouring Plan sketch.

11. Safety-
 JSA number…………………………..to be followed for this work.
 All workers shall be in proper [Link] face shield will be used during plywood cutting,
welding.
 Electrical connections will be in proper manner.
 Machine conditions shall be checked by Technician before use.
 Only trained worker will be operating the machines.
 Regular Toolbox Talk will be conducted before starting the work.
 Earthling for welding rectifier will be fixed properly.
 In case of leakages, bulging & sagging immediate actions shall be taken by tightening
wedges or adjusting by jack which must be done before the concrete ask takes its initial
set.
 Walkway shall be in proper manner so that workers can move smoothly.
 Emergency exit (secondary access) will be available from deep excavated area.
 Bar placing area will be illuminated by enough flood lights for smooth work progress during
night.

12. Overall Manpower requirement for chimney Raft (Detailed Breakup)

8|Page
Manpower Required

Bar.+Help. Car. +Help. Unskilled

DAY Night DAY Night DAY Night

33 33 4 4 5 5

33 33 5 5 5 5

35 35 6 6 5 5

25 25 6 6 5 5

20 20 5 5 5 5

27 27 7 7 5 5

27 27 7 7 5 5

40 40 10 10 5 5

13. Responsibility Matrix:

Sl No Sub-activities Day Shift Night Shift


1 R/F works Manik Jana Sandip Jana
2 Shuttering works Behara Rehan
3 Quality Nilanjan Ajay Singh
4 Safety Karthick Manikandan
5 Electricals Mukesh Sanju
6 Batching Plant Operator 1 Operator 2

9|Page

Common questions

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The use of a specific design mix for concrete is crucial as it determines the structural strength, workability, and density required for the chimney raft foundation. The selected mix is tested for properties like slump for workability and casting strength to meet quality standards, ensuring durability and integrity under the design loads. Appropriate use of additives, like Master Rheobuild, is also significant as it enhances the concrete's performance characteristics, ultimately impacting the project's overall quality and long-term reliability .

Maintaining the proper temperature and curing process is critical in ensuring the structural integrity of the concrete used in the raft foundation. The concrete temperature is measured at the site to ensure it doesn't exceed 40°C to prevent rapid hydration that can lead to cracks. Continuous curing for at least 14 days using methods such as ponding, water spraying, or using soaked hessian cloths prevents heat loss and ensures the concrete sets correctly. Such practices help achieve desired workability, strength, and permeability of the concrete .

The management of batching plants and concrete mixers is crucial to achieve the designated pour rate of 42 cum/hr for the chimney raft. Calculated requirements led to the setup of three batching plants with an additional one on standby and the deployment of 11 transit mixers with three on standby to ensure a consistent concrete supply. This strategic allocation prevents delays and accommodates any equipment failures, thus maintaining continuous operation to meet project timelines efficiently .

Reinforcement placement in alignment with IS codes, such as IS1786 and IS456, ensures structural integrity and compliance with design specifications in the chimney raft. Proper positioning and secure tying of reinforcement, as dictated by IS 2502, prevent displacements during concrete pouring. The use of chair spacers and tying techniques ensures the designed load-bearing requirements are met, achieving the structural goals of strength and stability .

The use of the tremie method in concrete pouring is significant for preventing segregation, especially when placing concrete under challenging conditions such as in a deep form or underwater. By fixing the tremie pipes and controlling the height of fall, the method ensures uniform distribution and compaction of concrete layers, thereby minimizing segregation and maintaining structural integrity of the raft foundation .

A detailed responsibility matrix is crucial in complex construction projects to clarify roles, ensure accountability, and facilitate coordinated efforts among different teams. By clearly assigning tasks such as reinforcement or shuttering works to specific personnel like Manik Jana and Behara Rehan, the matrix helps prevent overlapping duties and reduces miscommunication, thereby supporting seamless execution and effective project management .

The manpower deployment for the chimney raft construction is strategically organized to ensure efficiency across day and night shifts. Specific tasks such as reinforcement works are handled by designated personnel, like Manik Jana and Sandip Jana for R/F works, ensuring continuity. Each sub-task has assigned personnel for both shifts, indicating a planned transition of responsibilities that reduces downtime and maintains productivity around the clock .

Contingency plans in the construction of the chimney raft foundation include the pre-arranged storage of all necessary materials such as cement, aggregates, and water, ensuring that they are on-site before commencing with pours to prevent delays. Furthermore, backup power supplies and additional spare parts for machinery are prepared to avoid any downtimes due to equipment failure. Tarpaulins are on hand to protect the concreting area from rain, and sufficient lighting is installed for night work .

The method of de-shuttering involves careful removal of supporting structures without damaging the concrete, which maintains surface integrity and prevents structural issues. Post-concreting treatment includes cutting and sealing of tie rods with epoxy mortar after exposing them to prevent corrosion and ensuring a clean finish. These practices contribute to structural stability by ensuring all joints and exposed metal are protected, hence preserving the raft foundation's durability and appearance .

Safety protocols and checks are pivotal in ensuring workforce security during construction. Emphasis is laid on proper use of Personal Protective Equipment (PPE), regular safety briefings (Toolbox Talks), and the secure handling of machinery. Specific measures, such as providing face shields during certain operations and ensuring electrical connections are safe, are critical. Contingency plans for emergencies, including well-marked exits and adequate onsite lighting, ensure the workforce's safety while maintaining efficient workflow .

PROJECT: 2X660 MW UDANGUDI SUPER CRITICAL THERMAL POWER PLANTCHIMNEY RAFT FOUNDATION METHODOLOGY Subject: METHOD STATEMENT
Work Order No. Document No. Revision BHEL/PSSR/SCT/1736/2018/907 BYG/BHEL/USTPP/001 3 Organization Description Name Signature
S. No. Description Page No. 1 Drawings & Technical Specification 3 2 Schedule 3 3 Rebar Fabrication 3 4 Rebar Erection/ Reinf
The raft will be cast in 8 segments. The schedule for casting is given below as per latest schedule shared by M/S BHEL. 3. Re
5.3 Procedure –  Shuttering scheme drawing: Rigid formwork will be ensured using 12mm plyboard with hard wood battens pla
 Dowels and insert plates shall be fixed properly in position as per specification and drawing. 6. Pouring of concrete: 6.1
• Concrete shall not be freely dropped into place from a height exceeding 1.5m to avoid segregation, EXCEPT THE BOTTOM 5 LAYE
• Damaged shutter should not be used as per direction given by engineer in-charge. 8. Contingency Plan • Concrete pour shall
List of Protocols The attachedchecklists formats shall be followed: 1)Form Work 2) R/F Checklist 3) Pre concreting Checklist.
Manpower Required Bar.+Help. Car. +Help. Unskilled DAY Night DAY Night DAY Night 33 33 4 4 5 5 33 33 5 5 5 5 35 35 6 6 5 5 25

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