PROCEDURE FOR PILE CAP CASTING
ISSUED TO
CONTROLLED COPY ISSUED BY:
SIGNATURE:
METHOD STATEMENT
FOR
PILECAP CASTING
REV DATE DESCRITION PREP’ BY CHK’ BY REV’ BY APP’ BY
OF REVISION
0 Issued for (Planning) (QA/QC) Project
Approval Manager
PROCEDURE FOR PILE CAP CASTING
TABLE OF CONTENT
1. Purpose
2. Scope
3. Reference
4. Resource Required
4.1 Equipment’s
4.2 Concrete
4.3 Reinforcement
5. Procedure
5.1 Earthwork in Excavation
5.2 Laying of PCC as leveling course
5.3 Chipping/ trimming of Pile Head
5.4 Bending and fixing of Reinforcement Steel
5.5 Fitting, fixing of Shuttering and de-shuttering
5.6 Concreting
5.7 Curing
5.8 Backfilling
6. Quality Assurance
7. Safety
8. Person Responsible
9. List of Formats
1. PURPOSE
The ………………………………… has included the conduction of pile cap as scope of work
with the construction of ……………………………………………..
The broad method statement for construction of pile cap is presented hereinafter.
2. SCOPE
The works comprises mainly of the following steps:
(a) Earthwork in Excavation.
(b) Preparation of Pile Head.
(c) Leveling, Dressing of Excavated Pit bottom.
(d) Laying of PCC as leveling course.
(e) Bending and Fixing of Reinforcement Steel.
(f) Fitting, fixing of Shuttering and de-shuttering.
(g) Concreting & curing.
(h) Extraction of Sheet Pile.
(i) Backfilling.
3. REFERENCE
a) Contract document/ Tender Document.
b) Good for construction Drawings of Pile Cap.
c) IS 456 for reinforced cement Concrete.
d) IS 2502-1963 for reinforcement and Bar Bending Schedule, prepared by Agency and
approved by PMC.
e) IS 1200 Code of practice for measurement of works.
f) MORTH Specifications.
4. RESOURCE REQUIRED
4.1 Equipment’s
Total set of Equipment and Accessories required for the work are detailed below:
(a) Earth Excavator / Backhoe loader.
(b) Dumper / Tipper.
(c) Water Pump/curing pump
(d) Hydra / crane.
(e) Compressor & breaker (if required).
(f) Concrete Pump.
(g) Total station and leveling instrument.
(h) Batching plant of capacity 30 Cum/Hr.
(i) Transit Mixers of capacity of 6/4 Cum.
(j) Water Tank.
(k) Power Generator (DG).
(l) Electrical Vibrator & needles.
(m) Rebar cutting and bending machine.
(n) Welding machine.
4.2 Concrete
Concrete of grade M35 or as per GFC drawing and it will be supplied from centralized batching
plant / approved RMC supplier conforming to MORTH specifications the workability of
concrete placed through boom placer and pump shall be not greater than 120mm.
4.3 Reinforcement
Reinforcing steel shall be of HYSD (Grade FE: 500) conforming to IS:786 & 18-gauge GI
binding, only TMT bars shall be used for the pile cap works. All reinforcement work shall be
executed in conformity with the approved drawings and instructions given by the Engineer and
shall be carried in accordance with relevant Indian Standard specifications IS:2502- Bending
and Fixing of bars concrete reinforcement. For Bars more than 16mm dia mechanical coupler
shall be used instead of providing lap length.
5. PROCEDURE
5.1 Earthwork in Excavation
Survey points will be marked for corners of pile cap as per drawing, before excavation. The size
of excavation shall be so as to suit the site conditions. The excavation shall be done using
excavator / backhoe loader up to a level 100mm above the concrete bottom level & further it
shall be than dressed manually to the final level. Prior to excavation, shoring may be done
around the pile cap location and/or may be in one or two sides (considering the site condition at
close proximity), keeping a clearance of minimum 1m from the pile cap edge for working space,
up to the required depth.
During the process of excavation work, the excavated material as required for backfilling shall
be stored at suitable places beyond 1.50m from the edge of excavation and excess earth shall be
disposed off by dumper /tipper to a designated dumping yard.
5.2 Laying of PCC as Leveling Course
Over the leveled ground, M15 grade PCC will be laid in required thickness and dimension as
depicted in the drawing. Concrete for the same will be transported by means of transit mixers
from centralized batching plant/RMC and in unlikely cases 10/7 spot mixer machine shall be
used for mixing with prior approval from the Engineer.
5.3 Chipping/ Trimming of Pile Head
After laying of PCC, the exposed part of the pile concrete will be removed/ chipped off upto the
cut-off level with mechanical or manual means. The pile cut out shall be finished in a manner to
ensure that the top portion of the pile is embedded into the Pile Cap as mentioned in the GFC
drawing. All loose material on top of pile head after chipping to the desired level shall be
removed and disposed off.
The projected reinforcement above COL shall be cleaned, straightened and/ or bent to the
required shape and level as per drawing. The pile will be checked for variation from the
theoretical coordinates with PMC representative & joints measurement shall be recorded.
Deviation of pile in location shall not be more than 75mm.
5.4 Bending and Fixing of Reinforcement Steel
The reinforcement bars shall be cut, bent and fixed to the required shape and size as per
approved Bar Bending Schedule and relevant GFC drawing. The formed bars shall be
transported from bending yard to the location of fixing by suitable means of transportation.
Chairs, spacers shall be used for accurate positioning of the reinforcement bars. Generally, the
reinforcement cage of pile cap shall be prefabricated on level ground near the pile cap location.
Subsequent to cleaning, straightening and/ or bending of projected pile reinforcements the
prefabricated reinforcement cage of pile cap shall be lowered to the desired position using hydra
/ crane having suitable capacity. Clear cover shall be provided to reinforcement by using cover
blocks of same grade of concrete as that to be used for pile cap concreting.
5.5 Fitting, fixing of Shuttering and de-shuttering
After fixing the reinforcement bars, formwork shall be erected in all four sides maintaining the
actual dimension of the Pile caps, as mentioned in the drawing. Steel shuttering boards shall be
used as formwork for this purpose. The shuttering board shall be fixed in such a manner that the
same can withstand the concrete pressure & Standard formwork release oil shall be applied on
formwork material. De-shuttering shall commence after the period specified in the contract
specification or as provided in IS 456.
5.6 Concreting
Concreting shall be done either by chute or by concrete pump. Concrete, required for this
purpose, shall be transported from centralized batching plant or RMC plant by transit mixer.
Slump test will be done to check the workability of concrete after the arrival of transit mixer at
site. In general, concrete shall be placed as nearly as possible to its final position and shall be
compacted during placing, with needle vibrator by inserting the needle vertically at different
points and withdrawn slowly till air bubbles cease to come to the surface, leaving no voids.
Concrete shall be placed in horizontal layers of 500mm and care shall be taken to ensure
adequate vibration, blending of the successive layers. Concrete shall generally be poured at one
go till completion of a particular Pile cap but, in case, stopping is unavoidable then properly
formed Construction Joint shall be made. Before resuming the concrete from any construction
Joint all laitance, loose stones shall be thoroughly removed by wire brush/ hacking and a thin
layer of cement slurry shall be applied on the surface for proper bonding between the hardened
and fresh concrete. Unless otherwise instructed the face of exposed concrete placed against
formwork shall be rubbed down immediately on removal of the formwork to remove
irregularities, if any. The face of concrete for which formwork is not provided shall be
smoothed with a float to give a good finish.
5.7 Curing
Curing of concrete shall be taken up using potable water. Curing will be done by water-ponding,
by moist curing by spraying water or using approved curing compound etc. Period of curing
shall be maintained as per specification, minimum wet curing by ponding shall be for 7 days
and followed by water spray for moist curing for 14 days.
5.8 Backfilling
After de-shuttering of pile cap and extraction of shoring (if any), the excavated area shall be
filled in layers, with good earth obtained from excavation. Each layer shall be watered, rammed
and properly consolidated before the succeeding layer is laid.
6. Quality Assurance.
Workability test shall be carried out on the concrete on arrival of transit mixer from batching
plant and records shall be maintained. Test cubes shall be cast as specified and the 07 days as
well as 28 days strength results shall be submitted to the Engineer. Cube identifications shall be
embossed on cubes with date of casting, structure identification, concrete grade and reference
number. The reinforcement as per approved Bar Bending Schedule, shall be inspected with
respect to GFC drawing.
All the tests will be done as per ITP & will be recorded as per prescribed formats & checklists.
7. SAFETY
While casting the pile Caps, following steps shall be taken for maintaining safety at work site,
a. All activities shall abide by approved HS&E manual
b. Underground utilities shall be detected before commencement of work.
c. Movement of crane, Excavator, transit mixers etc. shall be monitored, so that, no fatality
gets happened.
d. Working area shall be properly Barricaded & sign boards & signals shall be used.
e. No loose clothing shall be worn while working.
f. PPEs shall be provided to all the workmen and no one shall be allowed inside the working
area without proper PPE.
g. Housekeeping shall be done regularly and if contaminated waste is found it will be dis-
posed off in environment friendly manner.
h. Adequate traffic marshals & safety personnel shall be deployed during the course of work.
8. PERSON RESPONSIBLE
Below mentioned person are responsible for following activities.
I. Project Manager: Overall management of activity.
II. Deputy project manager: responsible for control, supervision and direction for
implementation and execution of construction plan also for develop schedule & preparation
of construction record.
III. Site In-charge: Day to day planning at site, Various works at site and preparation of
construction record.
IV. QA/QC Engineer: responsible for overall QC activities include subcontractor and carryout
inspections.
V. Site Supervisor: Report to site engineer and responsible for supervision of all work guided
by site engineer.
9. LIST OF FORMATS
A. Safety Check List
B. Bar Bending Schedule.
C. Form-work inspection checklist.
D. Concrete inspection format.
E. Reinforcement inspection checklist.
F. Concrete Pour Card.
G. Accident Occurrence report
A. SAFETY CHECKLIST
S. No. Items Yes No.
(j) All workers wearing Personal Protective Equipment’s
(k) Emergency medical kit and other emergency facilities are provided at site
(l) All lights are properly covered using insulated wires, Halogen lamp and
Hand lamps with wire mesh covering
(m) All hot cutting scraps are quenched and removed properly
(n) Safety officer/supervisors are on constant duty at site
(o) Proper warning sign boards/instructions boards in Hindi and English
provided at site
CHECKED BY APPROVED BY
SIGN: SIGN:
NAME: NAME:
DATE: DATE:
B. BAR BENDING SCHEDULE
Location :
Schedule No. : Pier No. : Pile No. :
Ref Drg. No. :
BAR BENDING SCHEDULE
Dia Total Length in Meter/feet for Dia of
Sr. Bar Total Cutting Bending
Item in
No. Mark Nos. Length Details
mm 8mm 10mm 12mm 16mm 20mm 25mm 32mm
Total
Length
Unit
Weight
Weight
(Kg.)
DATE:……………… DATE:………………
C. FORMWORK-INSPECTION CHECKLIST
LOCATION :
CONTRACTOR’S INSPECTION REQ NO :
1. BARRICATING PLACING YES NO NA
WORKING DRAWING CHECKED & APPROVED
2. YES NO NA
3. BBS APPROVED YES NO NA
4. REINFORCEMENT CHECKED YES NO NA
5. SCHEME FOR EXECUTING THE WORKS APPROVED YES NO NA
6. FORM WORK DRG APPROVED YES NO NA
7. FORMWORK DIAMENSIONS & ALLIGNMENT CORRECT YES NO NA
8. REMARKS IF ANY YES NO NA
DATE:……………… DATE:………………
D. CONCRETE INSPECTION CHECKLIST
LOCATION:
CONTRACTOR’S INSPECTION REQ NO:
1. METHOD STATEMENT APPROVED YES NO NA
2. FORMWORK APPROVED YES NO NA
3. REINFORCEMENT APPROVED YES NO NA
4. CONCRETING EQUIPMENT IN WORKING ORDER YES NO NA
5. ACCESS PROVIDED YES NO NA
6. SAFETY ARRANGEMENTS / DEQUATE YES NO NA
7. ADEQUATE LIGHTING PROVIDED / STAND BY PROVIDED YES NO NA
COMMUNICATION BETWEEN VARIOUS POINTS
8. YES NO NA
PROVIDED
9. REMARKS IF ANY YES NO NA
DATE:……………… DATE:………………
E. REINFORCEMENT INSPECTION CHECKLIST
Ref Drawing No : Date:
Location : Structure identity :
Sr. No. Description YES NO N.A
1. Working drawing checked and approved
2. Latest revision being used
3. Bar schedules approved
4. Reinforcement steel material approved
5. Bar- bending and cutting satisfactory
6. Bar size correct
7. Bar spacing correct
8. Bar lap lengths correct
9. Bar lap at correct locations
10. Bar tied as specified
11. Bar assembly rigid and adequately supported (incld. spacers/ chair supports)
12. Cover to bottom bars correct
13. Cover to side bars correct
14. Cover to top bars correct
15. Cover blocks fixed properly
16. Formwork checklist completed.
Date: Date:
F. CONCRETE POUR CARD
1. TYPE
2. LOCATION PILE CAP
3. LAYOUT OF FOUNDATION CHECKED
4. DEPTH OF PCC IN CUM
5. QUANTITY OF PCC IN CUM
6. CONCRETING MIX
7. THEORITICAL QTY OF CONCRETE IN CUM
8. ACTUAL QTY OF CONCRETE IN CUM
SL Qty of Conc. Transit Pouring Record Redose of Slump in mm Temperature in Cubes
NO Mixer admixture centigrade
No at site , if
Each Cumula Start Finish any At At After Ambient Concrete Nos ID
Pour tive Batching Pouring redosing Temp Temp Mark
Plant Point
TOTAL NOS OF CUBES CAST
TOTAL NOS OF CYLENDERS CAST
DATE: DATE:
I. ACCIDENTAL OCCURENCE RECORD
ACCIDENT OCCURRENCE REPORT FORM ACCIDENT NO :
NAME OF CONTRACTOR : PJB ENGINEERS PVT LTD CONTRACT NO :
INSTRUCTION :
1. A copy of this form shall be completed for every Accident and Dangerous occurrence.
2. It must be signed by a senior site management representative.
3. A copy shall be sent to the employer’s representative within 24 hours of the accident.
Part A: Details of Injured person
Name ___________________Date of Birth ___ Male/Female
Address _______________________________________________________________
_______________________________________________________________
Job Title :________________________ Name of Employer_______________________
Part B: Details of Accident
Date :_______________Time : ______________Location :___________________________
1 Describe the task the injured person was doing at the time of the accident.
2 Description in details how the accident happened (Attach, sketch, plan,
photograph etc.)
3 Was any or machinery involved yes / no : if yes give details :
4 Name of witness :
Part C : Details of Injury
What part of body injured?
Fatal Injury [ ] Major Injury [ ] Minor Injury [ ]
Was the injured person sent to first aid [ ] Doctor [ ] Hospital [ ]
Part D : Certification
I have checked the above information and confirmation that is a true record of the accident.
Signed_______________ Officer________________Date__________________
Signed___________ Project Manager_____________Date__________________
