RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
METHOD STATEMENT FOR
REINFORCED CEMENT CONCRETE
WORK
Prepared by Reviewed & Approved by
Name
Date
Signature
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
OBJECTIVE
To provide general instructions for RCC work at site.
1.0 SCOPE
This document covers instructions for site development for Reinforcement
cement concrete (RCC).
2.0 Reference Documents
i) Contract Documents
ii) Spec
3.0 Reinforcement concrete (RCC)
3.1 Concreting in Foundations
Based on the AFC drawing, the layout of structure shall
be established in the excavated area.
PCC / Lean / Blinding concrete shall be placed to the
required thickness as per AFC and recorded in the Pour
card
The lean concrete shall be compacted using vibrators /
hand rammers & cure the same for a minimum of 3
days.
Centre line & Grid line of the structure shall be marked
on PCC surface to establish structure position & dimension. The
reinforcement / Embedded parts shall be shifted from yard &fixed in position
(if any) as per Approved For Construction Drawings. Sub Contractor
Supervision shall check the laying of reinforcement & give clearance to fix
the forms. Inspection call shall be raised to CS / CSR as required per FQP /
QAP for clearance to next activity.
Formwork shall be fixed as per AFC & SCS to check the same & offer for
Contractor Supervision/Client Site Representative inspection.
CS/CSR shall check the forms and clears the structure for concreting.
Pour scheme for mass concrete operations shall be prepared (e.g. Tower /
Transformer Foundations). Concrete shall be placed in layers not exceeding
300 mm to avoid unnecessary pressure on forms, cold joints & high heat of
hydration due to Thickness & Size.
SCS shall check the Delivery Order (Challan) of the concrete received from
RMC at site for ensuring the mix is as per approved mix design & grade.
The concrete shall be placed in position using chutes, buckets or Pump. The
concrete shall not be heaped at one place; the concrete shall be spread
across the foundation by using spades.
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
The concrete shall be vibrated (refer Vibration of concrete sec-5.7) using 60
mm / 40 mm needle vibrators. The concrete shall be placed in forms to the
required level & finished.
SCS shall check the forms during concreting for any deformations or
disturbances in sizes / lines / levels & rectify the same by adjusting the forms
when the concrete is green.
Concrete shall not be dropped from height more than 1.5m.
The top of the foundation shall be finished twice. First, finish the concrete to
bring line, level & Second finish after bleeding water disappears.
The curing shall start immediately after concrete starts hardening (final set)
approximately in 3-4 Hours after placement.
Use wet hessian cloth for initial curing with water spray. Latter build the
bunds with 1:3 cement mortar on the periphery for retaining water for
curing. (Refer curing of concrete section).
Start de shuttering the sides of
the foundations only after 24 Hours.
3.2. Concreting in wall / Columns
The column or wall construction joint area in raft / foundation shall be
cleaned from loose concrete / cement laitance by hand chiselling or hand
operated concrete hammers. The Construction joint shall be cleaned with
water jet to remove loose particles.
Column kicker or starter shall be cast for a Minimum height of 150mm
from the foundation top level for fixing column form shutters. Care shall be
taken to vibrate the starter.
In case of shifting of bars in foundation from original location, bars shall
not be bent either using heat or mechanical force. New rebar’s shall be
implanted using chemical or mechanical positioners. Any deviation from
drawing shall be carried only after approval from Designer.
Shutters / form shall be erected only after checking the reinforcement’s
position & conformance to BBS requirements. Mould releasing agent shall be
applied on the form shutters & any excess application shall be wiped.
Cover blocks shall be placed to main reinforcement bars at different
elevations to maintain uniform concrete cover at all locations. Cover blocks
shall be made of the same grade of concrete that is used for main member.
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
Column shutters shall be placed along with secondary & primary supports
& aligned using push pull props. The position of the supports shall be as per
Formwork Scheme.
Hang at least 2 numbers of plumbs in one face in each direction to check
the plumb at top and bottom - both directions.
Pour shall be cleared for concreting by CSR after verification of structure
for dimensions, reinforcement, cover, plumb Etc as per FQP. Sub Contractor
Supervision to fix rate of rise of concrete & control the layer thickness &
ensure proper vibration. (Follow section 5.7 for vibration).
60 mm needle for thick sections or 40 mm needle for thin sections shall be
used for vibrating the concrete. The vibrator shall not be kept near to forms
& shall not be vibrated more than 20 seconds at a place.
SCS to check the plumb & position of the column immediately after
concreting &any deviations noted shall be adjusted when concrete is still
green.
Remove the form work as per formwork striking time as mentioned in
section 5.11. Care shall be taken not to damage the edges while opening.
3.3.1Concreting of Wall / Columns above 2.0 m
3.3.1.2Form work:
The form work shall be adequately supported and securely braced so as to
be able to withstand, without deflection or movement of any kind. Forms
shall be erected as per formwork scheme.
Necessary lifting tools / equipment’s shall be used for lifting the forms.
Removal of form work shall be done (as per formwork striking time
mentioned in sec.5.11) in safe manner and without damage to the concrete.
3.3.2.1Placement of concrete:
SCS shall verify the rebar / Inserts / Bolts positioning, and plumb & obtain
Pour clearance from Customer.
Insert a chute (Made of 150 mm dia pipe with conical top) for placing the
concrete just 1500mm above construction joint top to avoid segregation.
Concrete joint shall be made rough by hacking the surface. To ensure
proper bonding & moisture loss from the joint, the joint area shall be kept
moistened 2 hours before concreting.
If the concrete is older than 28 days, epoxy adhesive like Nito Bond /
Sikadur -32 or equivalent shall be applied over old concrete. Concrete shall
be placed within the pot life time (around 25 Minutes) as mentioned in data
sheet of the manufacturer.
Concrete shall be placed always in layers. The thickness of layer shall be
determined based on time taken to pour the layer & start the new layer on
top of it at the starting point within the initial setting time of concrete
(Around 30 minutes if no admixtures are used & temperature is ambient at
27± 2oC, if super plasticizers are used it may be extended to 90 Minutes).
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
While placing the concrete in second layer, the vibrator shall be inserted
till it reaches the previous layer by at least 1/3 rd of its depth to avoid cold
joint marks & achieve good bond.
SCS to check the position & plumb, rectify if any deviation from specified
allowances as given in section 5.3 & 5.10 when concrete is green (within
initial setting time of concrete).
Form work shall be removed only after form striking time is lapsed as per
IS 456 section 11.3.1 without causing damage to edges.
3.4. Placement of concrete in Beams and Roof slab:
Forms shall be placed with reference to grids & checked for level, camber
(if required), openings Etc.
SCS shall check & clear the application of Mould releasing agent for placing
the reinforcement bars.
No Mould release agent shall be applied after placing the rebar’s in
position.
Reinforcement shall be placed first in beams & then in slab. The
reinforcement shall be secured in position by tying with binding wire of
gauge 16 or 0.9mm dia or as per specification & maintain cover using
spacer blocks. Sub Contractor Supervision shall check the reinforcement for
the size, shape, spacing &cover. SCS shall raise the inspection note & submit
to CS / Client Site Representative for verification & clearance for next
activity.
SCS shall prepare pour sequence & in case of part concreting, construction
joint shall be made by using stoppers or ribs in position.
SCS shall ensure that the joint shall always be given within first 1/3 rd from
column support as shown in sketch below.
SCS to obtain clearance from CSR & start concrete only after Pour card is
cleared. Concrete shall start using pump / crane bucket for fast placement.
Alternatively manual placement with winch (where available) shall be used.
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
Top level of slab shall be marked on periphery beam edges & on rebar’s of
the columns for easy identification of Slab top level.
SCS shall place the concrete first in beams then in slab. Care shall be taken
to avoid cold joints during lengthy beam pours. The distance to which the
concrete can be poured in beam is determined by the initial setting time of
concrete. The next layer of concrete shall be placed before the first layer
achieves initial set.
Concrete shall be spread from the point of placing to all sides by using
spades and shall not be stacked at one place & shall not be spread by using
vibrator.
The concrete shall be finished to the required level & final trowel touch up
shall be given to slab after bleeding water disappears (to avoid cracks
formation due to shrinkage). Steel trowel shall not be used for final finish to
avoid very smooth finish of concrete by surfacing cement & leading to early
shrinkage.
Concrete shall be stopped at predetermined construction joint location&
the stopper used shall be removed as soon as the concrete attains final
setting. The Joint shall be cleaned from loose concrete & debris before
starting next concrete.
Always “DELAYED FINISH & EARLY CURING“ principle shall be followed.
Soffits (sides) of the beams can be removed as per formwork stripping time
mentioned in Section 5.9 in consultation with Contractor / Sub Contractors
QC Inspection.
Close all the slab openings & barricade them using safety ribbons.
Any defects found in concrete like segregation / Honey combing or cold
joint shall be rectified as per Section 6.0 in consultation with customer.
3.5. Placement of concrete in Beams and Roof slab:
Concreting in vertical structures shall be planned well in advance. The
method of placing & resources shall be arranged & workers be briefed on the
method of pouring.
Concreting shall start only after moistening of the construction joint.
For larger pours, concreting shall be carried only with concrete pump.
Manual placement shall not be adopted as it delays the concreting &
promotes cold joints formation.
Concrete shall be placed in layers not exceeding 300 mm & the width or
length of pour shall be decided based on
o Concrete pour rate
o Resources positioning & availability
Concrete advancement is decided to avoid formation of cold joint.
Cold joints are formed after placing concrete exceeding the initial
setting time.
3.6. Activities During & After Concreting
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
Concreting shall commence only after obtaining pour card clearance from
authorized inspectors / Customer.
Direct dropping of concrete more than 1.5 m shall be avoided as it
segregates the concrete & reduces the strength.
Extra supports shall be placed under the concrete carrying pipes (for Pump
Concrete) to avoid sudden jerks & loads on formwork.
Workers shall wear adequate PPE, like Gum Boots, Gloves, Ear Muffs,
Helmets Etc. at all times during working.
Concrete shall be spread to sides immediately after placing to avoid higher
loads accumulation & formwork failure.
Forms shall be checked for any leakages & bulging during concreting. Any
such signs shall be rectified immediately by proving plugs & excess
supports.
All holes shall be plugged & gaps shall be sealed.
A gang of carpenters, fitters, masons shall be available at all the times
during concreting.
Any disturbance in reinforcement during movement of labor or placing
concrete shall be rectified.
Constant vigil shall be kept during the concreting.
SCI shall check the slump & verify the same to the required placement.
Cube specimens shall be cast as per IS 456 – 2000 &as mentioned in Section
5.15.
3.7. Vibration of Concrete:
Concrete shall be vibrated to attain maximum density by expelling air
entrapped.
Mechanical needle type vibrators
of 60mm /40 mm shall be used for
vibrating concrete.
The needle vibrators shall be
placed vertical at all times in a
grid pattern of 300 mm interval for
maximum vibration action.
Vibration shall be carried swiftly
for insertion & removal time not
more than 20 seconds at a place.
Concrete shall not be vibrated
excessively as this leads to
segregation.
Vibrator needle shall not touch the reinforcement bars, as this transfers
vibration to the already concrete laid area leading to disbonding of bars with
concrete.
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
Cold joints shall be avoided by continuous supply of concrete & planning
the overlay time.
3.8. Finishing & protection:
Fresh concrete shall be protected from rapid dryness due to high wind &
temperatures. The concrete surface shall be covered with wet hessian cloth
or plastic sheet.
In case of slabs or floors, the finishing shall be carried with a long
aluminium box section to obtain even level.
For power troweling, care shall be taken not to trowel more time at one
place to avoid soft spots.
3.9. After concreting:
Formwork stability, dimensions, warping, dislocation, Plumb Etc. shall be
checked& the same shall be rectified when concrete is still wet.
Position & level of embedment's like insert plates, Bolts, Channels,
Conduits Etc shall be verified &any minor re alignment be carried if
necessary when the concrete is still green.
Second &final finish of concrete at final setting time shall be ensured to
avoid shrinkage cracks.
The Water stopper or water bar shall be verified for correctness of position.
If disturbed, the same shall be realigned when concrete is still green.
3.10. Curing:
Surface curing by water
ponding curing compound Hessian cloth curing
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
blanket wrapping in winter
The concrete surface shall be cured immediately after the final setting of
concrete (within 4 to 5 hours of concrete placement).
Curing shall be carried out by wet gunny bags or by ponding on flat
positions for the first 10 days. Continuous curing of concrete members shall
be ensured to avoid plastic or shrinkage cracks.
Larger exposed areas like slabs or pavements shall be cured by Ponding
with water or by spraying Curing compound.
Vertical surfaces like walls & columns shall be cured by water spraying on
wet Gunny / Hessian Cloth or by Spraying curing compound.
Water shall not be used for curing in Cold weather or snow fall areas.
Instead curing compound shall be sprayed & a blanket shall be wrapped
4.0. Post concrete preparations:
The faces of construction joint shall be roughened and concrete laitance,
loose materials shall be removed.
Formwork & supports shall be removed as per project specification or as
per guidelines of Section 5.9.
SCS/Contractor Quality Assurance Surveillance/ CSR shall inspect concrete
surface for any defects and rectify the same as per specification or as per
approved procedure.
The elevation & grid Number of the members shall be transferred on the
structure for all above ground structures for further reference.
4.1. Time for Removal of formwork
The form work surface shall be striked only
after it achieves Minimum of 50 % of
strength or as per IS 456-2000 clause 10.3.1
requirements as mentioned in the below
table.
A striking plan shall be prepared, which
anticipates the climatic conditions, heat of
hydration, strength development, load
conditions and relevant curing methods.
The design concept shall be submitted with
detailed drawings for each main structure as
per the formwork manufacturers’ system
specification such as M/s. L&T formworks or
equivalent.
In general the following parameters shall be
taken into consideration while reviewing the formwork removal
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
1. Unit weight of concrete.
2. Rate of pouring of concrete.
3. Type of structure.
4. Tolerance of deflection.
5. Pouring sequence of concrete.
6. Strength of concrete at the time of removal
7. Span of members
8. Construction joint location Etc.
4.1.2. Defects / deformities & Rectification of concrete.
Concrete shall be inspected as soon as the formwork is removed for any
possible discontinuities or deformations or cold joints.
After de-shuttering, concrete member shall be verified for the dimensions,
line, level, position & shall be verified with specification tolerances. If found
out of tolerance the same shall be rectified.
Curing shall continue even when defects were noticed.
The following table gives the information on kinds of defects & remedial &
preventive measures to be adopted.
5.0. REFERENCE PROCEDURES & WORK INSTRUCTIONS
1. Work procedures for Architectural Works
2. Field Quality Plan
3. Technical specifications
4. IS standards
Standard Number Standard Title
IS 456 : 2000 Plain and Reinforced Concrete - Code of Practice
IS 516 : 1959 Method of test for strength of concrete
IS 1199 : 1959 Methods of sampling and analysis of concrete
IS 10262 : 1982 Recommended guidelines for concrete mix design
IS 269 : 1989 Specification for 33 grade ordinary portland cement
IS 455 : 1989 Specification for Portland slag cement
IS 1489 : Part 1 :
Specification for Portland pozzolana cement Part 1 Flyash based
1991
IS 8112 : 1989 Specification for 43 grade ordinary Portland cement
IS 12269 : 1987 Specification for 53 grade ordinary Portland cement
Specification for coarse and fine aggregates from natural sources for
IS 383 : 1970
concrete
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RADHEY CONSTRUCTIONS INDIA [Link].
DOC. NO.: RCIPL-016-RCC
Project SANCIA RAAGA
IS 2386 :1963 Methods of Test for Aggregates for Concrete
Specification for high strength deformed steel bars and wires for concrete
IS 1786 : 1985
reinforcement
Code of Practice for Bending and Fixing of Bars for Concrete
IS 2502 : 1963
Reinforcement
IS 9103 : 1999 Concrete Admixtures - Specification
SP 23 : 1982 Handbook on Concrete Mixes
6.0. FORMS / RECORDS
Concrete pour card
Concrete cube test report
Bar bending schedule
Delivery slips of RMC batching plant
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