METHOD STATEMENT FOR

PORTAL BEAM ERECTION

PROJECT : CMRL C4 ECV-02 Package

Chennai Metro Rail Limited

EMPLOYER:

GENERAL AECOM-OC Global-Nippon Koei (AEON Consortium)

CONSULTANT:

CONTRACTOR: HCC-KEC Consortium

CONTRACT CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass

DETAILS: Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan
Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus,
Poonamallee Bypass & Associated Viaduct from Chainage 17982.240 to Chainage
25928.186 and Approach to Depot at Poonamallee & All Associated works

DOCUMENT TITLE: METHOD STATEMENT FOR PORTAL BEAM ERECTION

DOCUMENT HCC-KEC/CMRL/C4-ECV02/MS/QC/74
NUMBER: Revision: 00
P20C4ECV02PRW-HCKC-QMSWMS-0074(0)
DOC STATUS: P P-Preliminary, D-Definitive, C-Construction Reference, W-Working Drawing,
B-As Built, M-As Manufactured Drawing, E- Employer's Drawing
DATE OF FIRST
21-08-2023 No of sheets: 18
ISSUE:

Prepared by: Mr. Venkatesh (Sr. Engineer Quality) 21-08-2023

Reviewed by: Mr. Afroz Khan (Quality Manager) 21-08-2023

Safety Reviewed by: Mr. Thangaraj (Chief Safety Manager) 21-08-2023

Environmental
Mr. Saurabh pundy 21-08-2023
Reviewed by;

Approved by: Mr. Mohan (Project Manager) 21-08-2023

Document history and status

SI.NO DATE DESCRIPTION PREPARED BY REVIEW BY APPROVED BY

1 21-08-2023 METHOD STATEMENT FOR PORTAL BEAM ERECTION R0 RV AK SM

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TABLE OF CONTENT
PAGE
SL. NO. CONTENTS
NO.
1.0 Introduction 3

2.0 Objective 3

3.0 Purpose & Scope of Work 3

4.0 Abbreviations 3

5.0 References Documents 3

6.0 Materials 4

7.0 Resources & Equipment 4

8.0 Authority & Responsibility 6

9.0 Work Methodology 8

9.1 Site Preparatory work 8

Cutting & bending of reinforcement of pier-portal beam
9.2 8
connection portion
9.3 Lifting of portal beam from stacking yard & loading on trailer 9
Transportation of portal beam from loading point to erection
9.4 9
point
9.5 Erection & aligning of portal beam 9
Tying & fixing of pier- portal beam connection portion
9.6 11
reinforcement
Cast in-situ concreting of pier- portal beam connection
9.7 11
portion
9.8 Curing of Concrete 11
9.9 Threading of strands 11
9.10 Post tensioning of Portal beam 11
9.11 Cutting of strand beyond anchorages & protection of strands 13
9.12 Grouting of post tensioned cables 13
9.13 Concreting of anchorage recess portion 14
10.0 Quality Assurance and Quality Control 14
11.0 Environment, Social, Health & Safety 14

12.0 Annexure 15

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1. INTRODUCTION

In Relation to CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass

Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan Chavadi,
Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass &
Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and Approach to Depot
at Poonamallee & All Associated works. This methodology covers detailed sequence of work
method to be adopted for portal beam Erection.

2. OBJECTIVE

The object of this Method Statement is to lay down a procedure for carrying out the portal
beam erection work for Chennai metro rail CMRL C4-ECV-02 (As per the approved drawings
& relevant technical specifications).

3. PURPOSE & SCOPE OF WORK

This basic activities described under this method statement are transportation of portal
beam, lifting & erection of Portal beam, levelling of portal beam using hydraulic jacks,
preparation & concreting of pier-portal beam connection portion & stressing of portal beam

4. ABBREVATIONS
 CMRL : Chennai Metro Rail Limited
 GC : General Consultant
 GFC : Good For Construction
 IRS : Indian Railway Standard Codes and Specifications
 IRC : Indian Road Congress
 IS : Indian Standard
 ASTM : American Society for Testing and Materials
 MS : Method statement
 PQP : Project Quality Plan
 ITP : Inspection & Test Plan
 QC : Quality Control

5. REFERENCE DOCUMENT:

 Contract / Tender Documents – Technical Specification

 Relevant latest approved GFC drawings
 IS 1786:2008, High strength deformed steel bars and wires for concrete
reinforcement
 IRC 78, Road and bridges
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 IS 2911(part1/2), IS9417:1989,Welding for cold worked rebars

 IS 456:2000, Plain & Reinforced concrete – Code of practice
 Quality assurance plan
 Health, Safety and Environment plan

6. MATERIALS

S No Description Specification Source Remarks

1 Cement OPC 53 Grade Approved source IS 12269

Reinforcement
2 Fe 500D SAIL, RINL, JSW IS 1786
steel
Mechanical
3 Approved source Approved source BS 8110 & ACI 318
Couplers

4 Water Borewell Near batching plant IS:456

Hyper-plasticizers &
5 Admixture Approved brand IS:9103
expanding
15.2mm diameter,
6 HT Strands stress relieved, low Approved source As per IS:14268 Class-2
relaxation

7 Anchorages Approved source Approved source As per BS:4447

As per technical
8 Epoxy mortar Approved source Approved source
specifications & MTC
As per technical
9 Shuttering Oil Approved brand Approved brand
specifications & MTC

10 Binding wire 18 Gauge GI Locally available IS:280 & 4826

7. RESOURCES & EQUIPMENT

S No Description Nos
1 Gantry Girder- 100/150MT 02

2 Hydraulic Crane for Erection As required

3 Heavy duty Multi-axle trailer (Capacity not less than 200MT) As required

4 Lifting Beam (strong back) 01

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5 Lifting devices, other tools & tackles As required

6 Welding Machine As required

7 Diamond wheel Grinding Machine As required

8 Survey Instrument-Total station 01 Nos

9 Survey Instrument-Auto Level 01 Nos

10 Vibratory roller-2.0 T Capacity 01 Nos

11 Excavator-Back Hoe 01 Nos

12 Dumpers As required

13 Power Generator 01

14 Rebar Cutting Machine As required

15 Rebar bending Machine As required

16 Chisel, hammer & Manual tools As required

17 Batching Plant-60 Cum/hr 01 Nos

18 Transit Mixers As required

19 Electrical needle Vibrator-40/60mm diameter As required

20 Calibrated pressure gauge (0-1000Kg/Sqcm) 02 Nos

21 Hydraulic Pumps 02 Nos

22 Hydraulic jacks with wedge seating device- Capacity-400 MT 02 Nos

23 High pressure hose pipe (5.0m) 04 Nos

24 High pressure hose pipe (1.0m) 04 Nos

25 Low pressure hose pipe (5.0m) 04 Nos

26 High pressure hose pipe (1.0m) 04 Nos

27 Grouting machine with agitator 01 Nos

28 Calibrated pressure gauge (0-25Kg/Sqcm) 02 Nos

29 Grouting hose pipe (35.0m) 01 Nos

30 Ball valves 10 Nos

31 Cribs 06 nos

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32 Stool for jacks 06 nos

33 MS plate 06 nos

34 ISMB 200 x 100mm 10m

35 Bracings and packing plate As required

8. AUTHORITY AND RESPONSIBILITY

Position Reporting / Responsibilities

 He shall be responsible to control the overall activities in
Project Manager construction.
 Shall report to the Project Director.
 Reporting to the Project Manager.
 Responsible for implementation of method statement in
totality.
 Liaison with Engineer/ Engineers representatives
 Planning and arrangement of resources.
 Liaison between design department and site execution team.
Erection In-charge  Liaison with specialized agencies, internal departments like
planning department, quality control department, plant &
machinery department, safety department, stores etc. for
effective progress.
 Implementation of Safety & quality system.
 Monitoring the program against Planned vs. achievement as
per the target.
 Reporting to the Erection In-charge.
 Interacting with the shifting in charges about the daily
activities.
 Up keeping the survey instruments including calibration in
consultation with QA/QC section and safe custody.
Surveyor  Documentation /protection of benchmark and survey points.
 Interacting with Engineer’s survey department
representatives.
 Responsible for reduced level of each and every erection
related work.
 Ensuring line leveled as per survey records.
 Reporting to the Erection In charge.
 Ensuring erection activities as per lift plan.
Erection Engineers  Interacting with Engineer’s representatives and internal
departments.
 Daily review of program and progress with the project
manager.

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Position Reporting / Responsibilities

 Safe working condition and safe acts of all workman,
machineries etc.
 Quality at all the stages shall be ensured.
 Responsible for resources allocation.
 Preparation of Daily & Weekly Program.
 Submission of requirement of materials & other resources for
the next week/ month to the Construction Manager.
 Progress to be achieved as per the program.
 Arranging required resource inputs for both shifts according
to the activity planned.
 Co-ordination between the shift engineers.
 RFI submission as per the systems according to the activities
planned.
 Documentation of all process related reports as per ISO
requirements.
 Reporting to the respective in-charge.
 Prepares micro planning schedule for all the activities
 Achieving targets as per the planned.
 Targeting for zero accidents.
 Quality check at all the stages of activities as per ITP
Site Engineer  Material wastages control like rebar, concrete, consumables
etc.
 Inspection of pre-stressing works with Pre-stressing
agency/Engineer/ internal QA/QC section.
 Arrangement of necessary materials required for next shift.
 Updating the shift registers/records.
 Handing over & taking over with the counterparts.
 Checking the proper location of crane and trailers for safe
operation.
 Make ensure the radius, boom length and angle of carne
Lifting Supervisor before and during lifting.
 Responsible for proper placing of portal beam on pier
assembly.
 Ensuring True alignment of portal beam.
 Shall report to Project Manager.
QA/QC Manager  Shall be responsible for overall implementation, monitoring
and control of QC activities as per approved methodology.
 Material source approval
 Finalization of mix designs for concrete
QC Engineer  Reviews Inspection plan & Test plan
 Implementation of QMS at site
 Involves in quality pep talks, periodical demonstrations of
best practices in work.
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Position Reporting / Responsibilities

 Arranges routine testing for concrete, reinforcement, and
other construction material as per inspection and test plan.
 Inspection of all work as per QAP
 Raising Non Conformance for the any deviation from work
method statements, drawings, specifications.
 Raising periodic site Quality observations to precast yard in
charge
 Follow up for the closure of Non-conformance & compliance
of site quality observations
 Inspections of activities after completion of work activity for
product quality.
 Ensure periodic preventive maintenance of all major
machines & equipment’s at site
 Timely breakdown repairs of all machinery & electrical
equipment’s as per their inspection manual
P&M Engineer  Monitoring of efficiency of all major equipment’s for site
activity
 Internal & third party testing of machines & equipment’s
prior to their due date of testing
 Calibration of all machines & equipment’s deployed at site
Chief ESHS Manager  Shall report to Project Manager.
 Shall be responsible for overall control of ESHS Activities.
 Involves in regular safety pep talks, demonstrations of safe
practices in work.
 Helps in providing requisite safety materials as per
requirements.
Safety Supervisor  Implement and supervise ESHS requirements before
commencement and during work.
 Organize training programs on safety awareness.
 Coordinates with site administration, first-aid center, doctors
& hospitals during emergency.

9. WORKING METHODOLOGY

9.1 Site Preparatory Work

 Existing ground surface shall be firm & compacted before positioning of crane & trailer for
erection.
 Area shall be levelled using excavator & shall be compacted with vibratory baby roller.
 Entire area in the domain of crane boom movement shall be made free from any
obstructions/utilities etc.,
 The access and egress to work zone shall be checked to ensure the safe entry and exit of the
crane.
 Necessary check for overhead clearances, wind speed shall be made & the erection will be
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allowed only after overhead clearance is made and wind speed is normal.
 Any unauthorized entry will be strictly prohibited by clearly demarcating work zone.
9.2 Cutting & bending of reinforcement for Pier – Portal beam connection portion
 Fe 500D grade reinforcement of approved source shall be used.
 Reinforcement cutting and bending shall be done at pre-cast yard and shall be shifted to
desired location as per the construction program.
 Bar bending schedule (BBS) shall be prepared & get approved as per approved drawing.
 For each bar type total length of the bar (calculated) shall be cut with the help of mechanical
reinforcement cutting machine.
 All the cut pieces of steel shall be stacked diameter wise at designated platform free from
moisture. Scrap pieces of steel shall be shifted to scrap yard.
 The cut pieces of steel shall be suitable marked & bend to suitable dimension & angle as per
approved BBS.
 The bending of steel reinforcement steel shall be done with the help of bending machine
consisting of mandrel & number of holes for the adjustment of bending angle of steel as per
approved Bar Bending Schedule.
 The bent-pieces of steel shall be stacked at different locations free from moisture.
9.3 Lifting of Portal beam from stacking yard & loading on trailer
 Survey axis of both faces of portal beam shall be suitably marked before lifting.
 Lifting frame for portal beam shall be fabricated as per approved drawing.
 Lifting of portal beam from the stacking yard shall be done with gantry girder attached with
portal lifting frame as per approved lifting arrangement drawing.
 All necessary safety checks for the trailer shall be done before lifting of portal beam as per
attached checklist.
 Portal beam shall be loaded on multi-axle trailer of capacity not less than 70MT & is secured
in position properly with necessary tools & tackles.
9.4 Transportation of Portal from loading point to erection point
 The route of transportation shall be pre-decided and all approvals from the concerned
authorities, field erection team shall be taken prior to the transportation of portal beam from
precast yard up to the erection point. Safety checklist for the lashing & other arrangements
has been attached.
 The transportation of the portal beam will commence only after getting confirmation from
erection location that the site is ready for erection.
 During transportation on public roads, each trailer shall be accompanied by escort vehicle.
 Portal beam transportation Permit shall be taken before transportation from casting yard.
 Trailer inspection checklist should be verified by P&M and ESHS staff before its use.
9.5 Erection and aligning of Portal Beam
 The erection crane & trailer shall be moved to the pre-marked location for erection of portal
beam.
 Aligning of crane shall be done with steel plates will be put at the out-riggers location to

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ensure uniform distribution of load.

 The erection of portal beam shall be done with two hydraulic cranes capable of lifting a portal
beam of weight 200MT.
 The poral beam shall be erect directly to the corbel portion of the pier.
 Portal beam shall be lowered on the lifting frame & both portal beam along with lifting frame
shall be lowered and placed in the corbel
 Portal beam shall be aligned to true line & level within ± 5-10 mm accuracy.
 The survey engineer will check the line, level and final positioning of the portal beam and will
suggest for adjustment required if any. Survey record shall be maintained in attached
checklist.
 For lifting & lowering operation only one authorized signal man will be made responsible to
ensure seem less erection operation.
9.6 Tying & fixing of Pier-Portal beam connection portion reinforcements
 All Reinforcements of Pier-Portal beam connection portion shall be tied as per approved
drawing.
 Reinforcements shall be tied with 18Guage GI Binding wire in double turn so that each joint
point will not loosen due to improper fixing.
 Couplers shall be used at required locations as per drawing, source & locking arrangement &
position of couplers in the rebar cage shall be as per drawing & technical data guidelines of
the material.
 Uniform spacing & cover to the reinforcements shall be provided at all locations as per
drawing.
 Cover block of required dimension & shape shall be placed at adequate intervals so that the
uniform cover shall be maintained at all locations of rebar cage
 Cover block shall be same or more than structure grade of concrete
 Lap length as per drawings shall be provided as required in staggered pattern & not more
than 50% bars shall be staggered at any section.
 Minimum anchorage length as per drawing shall be used at required locations.
9.7 Cast-in-situ concreting of Pier-portal beam connection portion
 Concrete surface at the pier-portal beam connection portion shall be roughened for effective
bonding with new concrete.
 Roughening of concrete shall be done by chisel or other hand tools.
 Availability of necessary equipment’s, tools & tackles (slump cone, cube moulds, Hand tools,
needle vibrator) in required Nos. & working condition shall be ensured prior to start of
concrete pour.
 Concrete of M55 Grade or as per GFC drawing shall be prepared & mixed as per the approved
mix design at batching plant using materials from approved sources.
 Workability & temperature shall be checked & maintained as established as per approved mix
design.
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 Concrete shall be transported to casting location in transit mixer & conveyed to the pouring
location with the boom placer/static pump as per site condition with uniform rate of pour.
 Concrete shall be poured in individual layers of maximum 300mm thick & shall be compacted
uniformly with high frequency electrical needle vibrator of 60mm/40mm size vibrator.
 Concrete shall be placed into the form gently and shall not drop from a height of 1.5m
 Special care shall be taken to fill the concrete at corner & joint locations.
 Concrete shall be poured in one stage & no construction joint is allowed.
 The concrete at top surface shall be finished to required level.
9.8 Curing of Concrete
 Immediately after completion of concreting, concrete shall be cured by covering it with wet
hessian cloth till concrete attains its final setting.
 After final setting of concrete, curing of exposed concrete surface shall be done by
continuously wetting the surface with water soaked hessian cloth for a period of 14 days
9.9 Threading of Strands
 HT Strands selected for use shall be from approved source
 Strands shall be accurately located & maintained inside the duct as per approved drawing.
 Tendons shall be so arranged that they have a smooth profile without sudden bends or kinks.
 Extra length of Tendon shall be kept beyond the anchorages as per drawing to facilitate
stressing.
 All necessary site precautions shall be adopted to avoid any wear & tear, physical damage in
tendons while threading.
9.10 Post tensioning of Portal Beam
 After erection the prefabricated steel working platform shall be used for post tensioning
activities such as threading of strands, wedge plate fixing stressing, grouting and recess filling
as per site conditions.
 Post tensioning of portal beam shall be done after Cast-In-Situ concreting of Pier-Portal beam
connection portion as per the sequence.
 Second stage stressing the Cable T7 & T10, T5 & T6, simultaneously after 28 days of stitch
concreting.
 After erection of all U-Girders on Portal beam third stage stressing the Cable T8 & T9. The
stressing sequence may be adjusted after finalization of launching scheme.
 Post tensioning shall be done with Multi-strand pull calibrated pressure jacks with concentric
scale type pressure gauges accurate to within 2% of their full capacity
 Pressure gauge shall be so selected that when the tendon is stressed to 75% of its breaking
load, the gauge is reading between 50-80% of its full capacity
 Stressing of the tendons are carried out simultaneously from both ends after concrete
achieves the required strength.
 Before stressing, following are to be checked and recorded in the stressing format:
 Stressing force required at jacking end & stages of stresses at 50Kg/cm2 interval till we reach
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to the final pressure.

 Calculate the maximum pressure required as per the jack details ( depending upon the area
of the jack)
 Apply calibration factors depending upon the calibration certificate of the pressure gauge &
jack
 The wedges are cleaned with petrol to remove dust or oil traces
 The grip length of strands shall be cleaned with kerosene/petrol & wiped with soft cloth to
remove dust & other unwanted materials
 The wedges are inserted on to the strands & are assembled by wedge-seating tool to seat
properly on to the tapered holes of the anchor head
 HT strands are inserted one by one in to the anchor head & they are secured firmly by wedges
 After insertion of strands in to the anchor head, it will be shaken well to ensure no
intermingling of strands near the anchor head
 Master wedges are seated properly by wedge seating tool & secured in place by stressing
plate
 The hydraulic jack & wedge seating device are connected to hydraulic pump by high & low
pressure hose
 The stressing begins as per the stressing sequence given in approved drawing, by aligning the
hydraulic jack on both ends & initial force of 50Kg/cm2 is given to remove any slackness in
the tendon. Ram movement is noted from now on. The pressure is increased slowly in stages
of 50Kg/cm up to maximum pressure. Ram movement is noted for each increment of
pressure. Maximum ram movement is 200mm. The wedges are locked by wedge seating
device & the load is slowly transferred to the anchor head by operating slowly the shut off
valve & DC Valve in the pump.
 Any discrepancy for the actual & calculated value of elongation shall be resolved as follows:
 If the calculated elongation is reached before the specified gauge pressure is obtained,
continue tensioning till attaining the specified gauge pressure, provided the elongation does
not exceed 1.05 times the calculated elongation. If 1.05 times the calculated elongation is
reached before the specified gauge pressure is obtained, stressing shall be stopped.
 If the calculated elongation has not been reached at the specified gauge pressure, continue
tensioning by intervals of 5Kg/Sqcm until calculated elongation is reached provided the gauge
pressure does not exceed 1.05 times the specified gauge pressure.
 If the elongation at 1.05 times the specified gauge pressure is less than 0.95 times the
calculated elongation, the following measures must be taken in succession, to determine the
cause of this lack of discrepancy:
 Check the correct functioning of the jack, pump & leads
 De-tension the cable. Slide it in its duct to check that it is not blocked by mortar which has
entered through holes in the sheath. Re-tension the cable if free
 Re-establish the modulus of elasticity of steel for the particular lot from an approved
laboratory.
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 While stressing from one end only, the slip at the end remote from the jack shall be measured
& an appropriate allowance shall be made in the measured extension at the jacking end.

9.11 Cutting of strand beyond anchorages & protection of strands

 Projected length of strands in the recess area for the stressed cables shall be cut immediately
after stressing.
 Cutting of strands shall be done by suitable mechanical of flame cutters. When a flame cutter
is used care shall be taken to ensure that the flame does not come in contact with other
stressed steel.
 Location of flame cutting of strand shall be kept beyond 75mm of where the tendon will be
gripped by the anchorage or jacks
 Cutting of strand beyond anchorages & protection of strands shall be ensured as per GFC
drawing.
 Whole surface of the anchorages shall be painted with two coats of approved epoxy having a
dry film thickness of 80 microns per coat immediately after cutting of strand.
9.12 Grouting of post tensioned cables
 Grouting shall be done 24 hours after stressing the strands and after thoroughly flushing the
sheathing with water.
 Grouting shall be done in the same sequence as stressing.
 Before grouting, grouting vents shall be checked & cleared off any blockage by thoroughly
flushing the sheathing with water.
 Grout shall be prepared with Ordinary Portland cement (53 Grade) with maximum water
cement ratio of 0.4 & with the addition of expanding admixture, Cebex 100 or equivalent to
avoid the any shrinkage effect due to ordinary Portland cement. Design mix of grout has been
given in table below:
Design of grout Cement (Kg) Water (Kg) Cebex100 or equivalent (Kg)

Unit Cum of Grout 1300 520 5.85

Per bag of cement 50 20 225 gms

 All grout components shall be mixed in grout mixer & to keep the grout in homogeneous state
& of uniform consistency, the mixer should have an additional storage device with agitator to
keep the grout moving continuously before it is pumped into the duct.
 Grouting shall be done with mechanical operated calibrated grout pump fitted with a pressure
gauge to enable pressure of injection to be controlled.
 At the time of grouting density of grout shall be checked with hydrometer to ascertain that it
should be in line with the design density. Temperature shall not be exceed 25 degree Celsius
 Injection of grout must be continuous & shall not be interrupted till the completion of
grouting.
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 Grouting shall be done initially with a low pressure of 0.3 Mpa increasing it until the grout
comes out at the other end. The grout shall be made to free flow from the outer end until the
consistency of grout at the outer end is the same as that of injection end. When consistency
of grout becomes same at both ends, the outer end shall be closed off & building up of
pressure shall be commenced.
 Samples of grout shall be collected in cubes of 100x100x100mm size from the outer end
during the grouting.
 Minimum 02 sample (6 Number of cubes) shall be collected.
 Full injection pressure of 0.5 Mpa shall be maintained for at least one minutes before closing
the injection pipe.
 If in any case, there is a buildup pressure much in excess of 1.0 Mpa without flowing of grout
at the outer end, the grouting shall be discontinued & the entire duct shall be flushed with
high pressure water.
 Grout shall be used within 30 minutes of its mixing.
 After the completion of grouting, the projecting portion of the vents shall be cut off.
9.13 Concreting of anchorage recess portion
 The entire recess area shall be cleaned with wire brush to remove all surface laitance,
unevenness or irregularities.
 Reinforcements shall be fixed in the recess portion as per drawing.
 Bonding agent should be applied on the old concrete surface to new concrete.
 Shutters shall be installed at required anchorage location leaving a suitable gap in the
formwork for the pouring of required material
 Entire recess area shall be filled with concrete as mentioned in the drawing.
 All shutters of recess filling shall be removed after 24 hours of concreting.
 Curing of recess filling shall be done by continuously wetting the surface with water soaked
hessian cloth for a period of minimum 14 days or curing compound shall be applied after de-
shuttering
10.QUALITY ASSURANCE AND QUALITY CONTROL
Quality Assurance and Quality Control shall be strictly followed as per approved ITP and
Method Statement and attached formats.

11. ENVIRONMENT, SOCIAL, HEALTH & SAFETY

 Occupational Health & Safety control measures shall be strictly followed during
transportation & erection of Precast Elements as per Project Safety, Health & Environment
Plan. Hazard Identification, Risk assessment and Risk control measures associated with the
operation have been identified and necessary action plan has been initiated as per procedure
before start of the work. Safety Checklists has also been developed for monitoring the
implementation of control measures before and during execution of work. The general safety
operational control measures to be ensured are as below.
 All staff and workmen shall wear safety gear such as Helmet, Safety Shoes and Fluorescent
Page | 14
HCC-KEC/CMRL/C4-ECV02/MS/QC/74
 METHOD STATEMENT FOR
PORTAL BEAM ERECTION

Vest etc.
 Work Permit System shall be followed for the medium and high risk activities as per laid down
procedure.
 Safety Harness while working at height and Face Shield with suitable dark glass for welding
work shall be used.
 The work area shall be properly barricaded as laid down in the lift/construction depot plan.
 Working platform of adequate strength with handrail shall be provided for work at height as
per IS 3696: 1991
 Access Control shall be exercised to check the un-authorized person within construction area.
 First aid box & fire extinguishers shall be kept at site.
 Operator, Workmen and Foreman shall have adequate knowledge and experience.
 Traffic marshals shall be deployed to assist the movement of trailers for smooth traffic flow.
 Trailers and Lifting Devices (Cranes & Tackles etc.) shall be inspected before operations to
ensure safe working condition.
 Safe transportation shall be ensured by deploying suitable capacity trailer with safe and easy
maneuverability during radial turnings in curved roads.
 Trailers shall be fitted with side lamps, tail lamps, audible alarms for safe transportation and
warning to general public using the roads.
 Lifting Equipment’s, Gantries, Tools and tackles shall have third party load test certificates
from Competent Person.
 Approach roads must be cleared and traffic diversion plans shall be strictly adhered to, while
transportation of Precast Elements.
 Persons shall not be allowed under the suspended load while lifting load.
 Environmental aspects/impact shall be identified and appropriate mitigation measures shall
be taken during execution of work as per Project Safety, Health & Environment Plan.
 Utilization of water and non-renewable sources like materials, fuel and energy shall be
optimized during work.
 Spillage of oil & other shall be controlled from all pertinent operations.
 Hazardous waste generated during work shall be managed, stored, and disposed as per rule
& condition of authorization.
12.ANNEXURES
 Inspection Test Plan
 Site Preparation
 Tool Box Talk on Pre Cast Element Lifting
 Pre-Lift Checklist
 Checklist for Trailor Erection
 Lift Evaluation Form
 EIC Pre-Lift
 Transport Permit
 Post Concrete Checklist
 Trailor erection
Page | 15
HCC-KEC/CMRL/C4-ECV02/MS/QC/74
 METHOD STATEMENT FOR
PORTAL BEAM ERECTION

 Dispatch Checklist
 Safety Checklist
 Reinforcement Checklist
 Grouting Record
 Post pour inspection
 Recess Checklist
 Stressing Record
 HIRA

Page | 16
HCC-KEC/CMRL/C4-ECV02/MS/QC/74
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot,
Katupakkam, Kumanan Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass & Associated Viaduct from
Chainage 17982.240 to Chainage 25928.186 and Approach to Depot at Poonamallee & All Associated works

INSPECTION AND TEST PLAN FOR PORTAL BEAM ERECTION

Doc no: HCC-KEC/CMRL/C4-ECV02/MS/ITP/74 Revision:R-00
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSITP-0074(1)
INSPECTION BY
TESTING

Engineer

Engineer
Incharge
REFERENCE DOCUMENTS /

QA/QC
Section

CMRL
Sl No ACTIVITY DESCRIPTION ACCEPTANCE CRITERIA FREQUENCY VERIFYING DOCUMENTS EVALUATIO Remarks

Site
STANDARDS
N SOURCE

1.0 PRIOR TO WORK COMMENCEMENT

Before commencement of
Notice of no objection certificate from Notice of no objection
1.1 Design and Data development Contract specifications work or with design HCC-KEC NA H R R
CMRL / GC / Approved status certificate from CMRL / GC
alteration
Method statement /Work Adequacy to meet scope,
GFC drawings and technical Prior to commencement Notice of no objection
1.2 methodology/ ITP/ Checklist/ Performance and Technical HCC-KEC R P H R
specifications / Relevant IS Codes of work certificate from CMRL / GC
Working drawings specification requirement

Notice of no objection certificate from Prior to commencement HCC-KEC lab

1.3 Testing facilities Contract Specifications Approved Letter NA H H R
CMRL / GC / Approved status of work / External lab

Prior to commencement
Contract Specifications / or any Notice of no objection certificate from Notice of no objection
1.4 Source of materials of work / Change of HCC-KEC NA H H R
additional approved vendor CMRL / GC / Approved status certificate from CMRL / GC
source
Once for each grade and
type of
Notice of no objection
1.5 Concrete mix design Technical specifications / IS Code Approved concrete mix design concrete and Prior to HCC-KEC R H P R
certificate from CMRL / GC
production
commencement
Approved method statement / Prior arrangements to be made Prior to commencement
1.6 Plant and equipment Visual inspection HCC-KEC R P H R
Contract specifications berfore start of production of work
Calibration of batching plant / Notice of Approval from CMRL/GC for RMC plants /
Approval of batching plant / RMC Prior to commencement
1.7 IS:4925 no objection certificate from CMRL / Trial run of the CMRL plant with clearance HCC-KEC R R P/H R
plant of work
GC certificate
Once prior to start and
Calibration certificates for
subsequent periodical Site laboratory plan / External laboratory HCC-KEC /
1.8 Measuring equipment / Load test Contract specifications To be made available R P H R
calibration as per calibration / Manufacturer laboratory External lab
certificate
calibration plan
2.0 MATERIAL RECEIPT, STORAGE, HANDLING AND DELIVERY

2.1 Reinforcement works

Invoice / MTC from manufacturer to be

2.1.1 Receiving inspection Technical specifications For each lot MTC / Delivery challan / Inspection report HCC-KEC R H P R
available

2.1.2 Sampling and testing Refer to ITP of reinforcement bars Sampling record / Test report HCC-KEC R R H W/R

Segregated size wise and stockage above Prior to commencement

2.1.3 Storage and segregation Technical specifications Visual HCC-KEC P H R R
ground with clear space from ground of works and regular

Page 1 of 4
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot,
Katupakkam, Kumanan Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass & Associated Viaduct from
Chainage 17982.240 to Chainage 25928.186 and Approach to Depot at Poonamallee & All Associated works

INSPECTION AND TEST PLAN FOR PORTAL BEAM ERECTION

Doc no: HCC-KEC/CMRL/C4-ECV02/MS/ITP/74 Revision:R-00
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSITP-0074(1)
INSPECTION BY
TESTING

Engineer

Engineer
Incharge
REFERENCE DOCUMENTS /

QA/QC
Section

CMRL
Sl No ACTIVITY DESCRIPTION ACCEPTANCE CRITERIA FREQUENCY VERIFYING DOCUMENTS EVALUATIO Remarks

Site
STANDARDS
N SOURCE

3.0 ERECTION OF PORTAL BEAM

Compaction and levelling of ground Method Statement / Technical Ground shall be firmly compacted before Before commencement of
3.1.1 Visual inspection HCC-KEC P R R W
surface Specification positioning of crane work

Approved method statement /

Alignment should be as marked by
3.1.2 Erection of Portal Beam Approved drawings / Technical P R R W/R
surveyor.
Specification
Approved method statement /
Jointing of reinforcement (Binding Should be tied properly with binding wire
3.1.3 Contract specifications / Before Stitch concrete P R R W/R
/ Welding) of required thickness
Construction drawings
3.2 Concreting

Approved method statement / Item 3.1 to 3.3 is properly implemented, Pre-Pour Checklist
3.2.1 Final inspection prior to concrete Each Portal Beam HCC-KEC P R P H/W
Construction drawings recorded and accepted

Thoroughly mixing of the ingredients to Concrete Pour Card

3.2.2 Mixing time …. Each batch HCC-KEC R R P R
be ensured

Pre-numbered and to be issued

3.2.3 Delivery docket Issued with each transit mixer sequentially. Must record time of Each transit load R R R R
batching completion

Random vehicle. Agitator

PCE based admixture-150 mm (min)
deliveries to be checked at
3.2.4 Workability testing Technical specifications (Non confirming first slump can be Concrete Pour Card R R P W/R
the HCC-KEC
retested from the same sample
point of discharge at site

3.3 Sampling of hardened concrete

As per IS:456, clause 16 and table
Concrete cube moulds
3.3.1 Technical specifications 11. Should achieve minimum Each Portal Beam R R P W/R
(150x150x150 mm)
characteristic compressive strength
3.4 Post-Tensioning

3.4.1 HT Strands Technical specifications / IS Code Approved HT Strands / MTC Every Lot MTC / Delivery challan / Inspection report HCC-KEC P R R W/R

3.3.2 Physical Check Technical specifications / IS Code Packed properly free from rust Every Lot MTC / Delivery challan / Inspection report HCC-KEC P R R W

Page 2 of 4
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot,
Katupakkam, Kumanan Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass & Associated Viaduct from
Chainage 17982.240 to Chainage 25928.186 and Approach to Depot at Poonamallee & All Associated works

INSPECTION AND TEST PLAN FOR PORTAL BEAM ERECTION

Doc no: HCC-KEC/CMRL/C4-ECV02/MS/ITP/74 Revision:R-00
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSITP-0074(1)
INSPECTION BY
TESTING

Engineer

Engineer
Incharge
REFERENCE DOCUMENTS /

QA/QC
Section

CMRL
Sl No ACTIVITY DESCRIPTION ACCEPTANCE CRITERIA FREQUENCY VERIFYING DOCUMENTS EVALUATIO Remarks

Site
STANDARDS
N SOURCE

3.3.3 Sampling and testing Refer to ITP of HT Strands HCC-KEC/CMRL/ECV02/ITP/11 Revision:R-00 HCC-KEC R R H W/R

Approved method statement /

No damages shall be observed while
3.3.4 Threading & Fixing Construction drawings / Bar bending Every strand Visual HCC-KEC P H H H/R
threading and fixing
schedule

Approved method statement /

3.3.5 Fixing of Bearing Plate Bearing plate should be fixed in position Every Bearing Plate Visual HCC-KEC P H H W/R
Construction drawings

Assembled by wedge-seating tool to seat

Approved method statement /
3.3.6 Fixing of Wedges properly on to the tapered holes of the Every Wedges Visual HCC-KEC P H H W/R
Construction drawings
anchor head

Approved method statement / Check the pressure gauge reading and

3.3.6 Per-Tensioning Every Stressing Stressing Record Checklist HCC-KEC P H H W/R
Construction drawings elongation as per calculation / drawing

3.4 Grouting

3.4.1 Grout Material Technical specifications / IS Code Approved Material / MTC Every Lot P R R W/R

Approved method statement / Mix should be homogeneous and uniform Grot record checklist HCC-KEC
3.4.2 Grout Mix Every new mix P R R H
Construction drawings / IS Code consistency

Approved method statement / Min. 01 sample (3 nos) in cube 100 x 100

3.4.3 Sampling Every Grout P R R W/R
Construction drawings / IS Code x 100mm

3.5 Anchorage Reccess Filling

Approved method statement / Each Pier - Portal beam Pre-Pour Checklist
3.5.1 Final inspection prior to concrete Items 1.0 to 3.4 should be complete HCC-KEC P R P H/W
Construction drawings Stitch concrete

Thoroughly mixing of the ingredients to Concrete Pour Card

3.4.2 Mixing time …. Each batch HCC-KEC R R P R
be ensured

Pre-numbered and to be issued

3.4.3 Delivery docket Issued with each transit mixer sequentially. Must record time of Each transit load R R R R
batching completion

Random vehicle. Agitator

PCE based admixture-150 mm (min)
deliveries to be checked at
3.4.4 Workability testing Technical specifications (Non confirming first slump can be Concrete Pour Card R R P W/R
the HCC-KEC
retested from the same sample
point of discharge at site

Page 3 of 4
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot,
Katupakkam, Kumanan Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass & Associated Viaduct from
Chainage 17982.240 to Chainage 25928.186 and Approach to Depot at Poonamallee & All Associated works

INSPECTION AND TEST PLAN FOR PORTAL BEAM ERECTION

Doc no: HCC-KEC/CMRL/C4-ECV02/MS/ITP/74 Revision:R-00
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSITP-0074(1)
INSPECTION BY
TESTING

Engineer

Engineer
Incharge
REFERENCE DOCUMENTS /

QA/QC
Section

CMRL
Sl No ACTIVITY DESCRIPTION ACCEPTANCE CRITERIA FREQUENCY VERIFYING DOCUMENTS EVALUATIO Remarks

Site
STANDARDS
N SOURCE

3.5 Sampling of hardened concrete

As per IS:456, clause 16 and table
Concrete cube moulds
3.5.1 Technical specifications 11. Should achieve minimum Each Portal Beam R R P W/R
(150x150x150 mm)
characteristic compressive strength
Prepared by : QA/QC ENGINEER REVIEWED BY : AM - QA/QC APPROVED BY : PROJECT MANAGER

NAME : R. Venkatesh NAME : Afroz Khan NAME : S. Mohan

DATE : 26-08-2023 DATE : 26-08-2023 DATE : 26-08-2023

Legend: H= Hold, R = Review, W= Witness, P = Perform, S= Submit, RW= Random Witness, HCC-KEC CONSORTIUM = CONSORTIUM of HCC & KEC, CMRL = Chennai Metro Rail Ltd.

Critical Category is Hold Point This activity requires inspection / verification and acceptance by CMRL Responsible for the stage before further processing is permitted.

This activity requires inspection / verification, and acceptance by the CMRL responsible for this stage before any further processing is permitted.
Major Category is Wittness Point
HCC-KEC CONSORTIUM / Sub-Contractor shall not process activity beyond a witness point without written approval by CMRL. The related quality records shall be submitted to CMRL for their review.

Page 4 of 4
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan
Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee
Bypass & Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and
Approach to Depot at Poonamallee & All Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 01
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(1)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC Consortium
Project : CMRL C4 ECV02
Portal beam Date of checking:
identification: Date of casting:
CHECKLIST FOR SITE PREPARATION
Observation
S No Description Remarks
Yes No

1 Crane placing area properly levelled and compacted

Is area of operation is free from high tension overhead

2
cable lines?
Working Platform, Edge Protection and life line Provisions
3
available?

4 Is the area free from unwanted Materials?

5 Is the area free from all the utilities?

6 Crane Operator day time inspection Completed?

7 Collar arragements fixed and checked

8 Axle placed as per transportation plan

9 Traffic diversion Plan approved?

10 Lifting Plan approved

11 Cranes are placed at pre-determined position

12 Temporary Road blocking arrangemens done

13 Entire area is free for crane boom movement

14 Sufficient illumination provided

Contractor Representative CMRL / GC Representative

Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC Consortium
Project : CMRL C4 ECV02
Portal beam Date of checking:
identification: Date of casting:
CHECKLIST FOR SITE PREPARATION
Observation
S No Description Remarks
Yes No

1 Crane placing area properly levelled and compacted

Is area of operation is free from high tension overhead

2
cable lines?
Working Platform, Edge Protection and life line Provisions
3
available?

4 Is the area free from unwanted Materials?

5 Is the area free from all the utilities?

6 Crane Operator day time inspection Completed?

7 Collar arragements fixed and checked

8 Axle placed as per transportation plan

9 Traffic diversion Plan approved?

10 Lifting Plan approved

11 Cranes are placed at pre-determined position

Sign

Name

Designation

Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass Crossing,
Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan Chavadi, Karayan
Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass & Associated Viaduct
from Chainage 17982.240 to Chainage 25928.186 and Approach to Depot at Poonamallee & All
Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 02
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(2)
Project: CMRL C4 ECV03
Client: Chennai Metro Rail Limited (CMRL)
Contractor: HCC-KEC Consortium
Tool Box Talk on Pre Cast Element Lifting & Erection
Location Details Name & Chainage S.No.
Activity Date:
AA.Useful General Topics (Please tick " " the topic covered in tool box or write it)
Overhead Power
1 House keeping 8 15Illumination
transmission
2 Hand tools 9 Crane Operation 16.Personnel
Transit Mixture/Concrete
3 Power tools 10 17.Working at Height
Pump
4 Excavation 11 Trailer Operation 18.Diversions
5 Loading/Unloading 12 Mobile Equipments 19.Traffic
6 Lifting & Shifting 13 Permit to work 20. Others (Pl specify)
7 Life Line 14 Working Platform 21) Edge Protection

BB.Equipments used at Site

Name of Equipments No. Name of Equipments Nos Name of Equipment Nos

1 Vehicle 5. Grader 09. Paver (Bitumen)

2 Roller 6.Crane 10.Others (pl specify)

3 Dumper 7.Front End Loader

4 Trailor 8.JCB

CC:Critical Hazard & its control (To be written by concerned exexcution supervisor/Engineer)

DD.Attendance of persons participating on tool box (includes all staffs,workmen & subcontractor employee)

Name Designation Sign Organisation Name Designation Sign Organisation

Tool Box conducted by: Tool box witnessed by;

Name Name
Sign. Sign.
Date Date:
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass Crossing,
Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan Chavadi, Karayan Chavadi,
Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass & Associated Viaduct from Chainage
17982.240 to Chainage 25928.186 and Approach to Depot at Poonamallee & All Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 03
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(3)
CRANE LIFTING OPERATIONS - PRE-LIFT CHECKLISTS
Date lift study completed: Lift location:
Lift permit number:
Lift Description : SHE Manager: / /
Lift study authorised by:

S.No. Description of Check Acceptance

1 Name of crane driver (s) /operator
Test Certificates and Liscence to be produced by the Crane certification Number & attach photo copy:
2
crane operator
a) Crane test certificate number to correspond with
a.1 Last crane inspection date : Date:
a.2 Next crane inspection date: Date:
a.3 Boom Stamp Number: B-Number:
a.4 Hook Stamp Number: H-Number:
a.5 Inspection disc/sticker number in crane cabin D-Number:
Check Operators name against ROC ID card & crane
b) Photo Copy: Yes/No ID Check : Yes /No
Liscence
c) Inspections Crane certification Number & attach photo copy:
c.1 Crane Weekly & Daily Inspection record c.1) Weekly Yes /No Daily: Yes/No
Crane Pre mobilisation Inspection must be c.2) Attached : Yes / No (if No "DO NOT USE CRANE"
c.2
completed & crane inspection passed to be used for
3 Other test required Other test certificates
a) Chains & Shackles Register: Yes/No Pre Lift Inspection : Yes/No
b) Wire ropes inspected Register: Yes/No Pre Lift Inspection : Yes/No
c) Sling inspected Register: Yes/No Pre Lift Inspection : Yes/No
4 Provide Rigger Banksman RIGGER/BANKSMAN
a) Suitable method of communication a) Radio / Whistle / Uniform Hand Signals
Ensure Banksman clearly distinguishable if hand b) Distinguished How ?
b)
signals used
5 Provide Warning Provide Warning
a) Notices,Bollards,barriers,Lookout a) Notices b) Bollards c)barriers d) Lookout
6 Provide temporary lighting LIGHTING Yes / No- Day / Night /Low Light
Check outriggers "FULLY'' extended & Load Load Distribution
Extended Fully:
7 distribution plates /blocks are adequate for the Outriggers Plates:
weight & correctly position. Yes / No Yes/No
8 Check Crane Level Crane Level Yes /No. / Relevel Compacted
Check Safe Load Indicator is working and any Auto Safe Load Indicator :
9
computer input set up is correct Computer Input :
Check Lift Study method statement being complied
10 Lift Study Method Statement Yes/No
fully
11 Ensure load correctly sling as per lift study MS Load correctly slung Yes/No
12 Check tag lines fitted to control load Tag Lines Yes/No /Gantry no requirement
13 Check load after lifting 150 mm Load Checked: Yes / No
14 Check no one is or can walk under load being lifted Safety Zone Demarcated Yes / No
Check load is landed on battans to prevent damage Yes / No
15 Batterns in place
to slings and to allow their removal

Engineer In Charge SHE Manager CMRL / GC

 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan
Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee
Bypass & Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and
Approach to Depot at Poonamallee & All Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 04
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(4)
CHECKLIST FOR TRAILOR
Date of inspection: Location:
Observation
S.No. Description of Check Recheck at Site Remarks
Yes/No
A Trailer Requirements
1 Valid Registration Certificate
2 Pollution Placard

Brakes,Horn,Front,rear,brake lights,back mirrors

3
/wind screen wiper,reflector & indicator

4 Portable fire extinguisher

5 First Aid kit Fire Extinguisher
Emergency information panel & emergency
6
contact no.
7 Tyre condition and pressure
8 Condition of Trailer Bed
9 Side gaurd ,under-run gaurds,bumpers

10 Spare Jacks & Tools

11 Electrical equipment ,wiring

12 Engine Oil,Fuel tank,Exhaust

13 Brake system and components

14 Spare tyres

B Driver Requirements

1 Valid Drving Liscence

2 Trained for defensive driving
Expererienced and technical knowledge about
3
vehicle handled
C Operational Requirements
Escort available with red flags for movement
1
alongwith trailor
Traffic Management mechanism available the
2
route
Driver Name & Contact No:- Registration No:-

Liscence No & validity Date:- Model & Manufacturing Date:

Medical Examination of driver: Eyesight Audiometry General
Is driver approved by P&M and SHE :-

Engineer In Charge SHE Manager CMRL / GC

 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass Crossing, Ramachandra
Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan Chavadi, Karayan Chavadi, Mullai Thottam,
Poonamallee Bus Terminus, Poonamallee Bypass & Associated Viaduct from Chainage 17982.240 to Chainage
25928.186 and Approach to Depot at Poonamallee & All Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 05
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(5)
LIFT EVALUATION FORM
1. Activity
Location of Lift: Pier No. to Pier No. (L/C/R) Date & Time :
Load Weight :
Block Weight:
2. Description of Load Spreader Weight :
Rigger Weight:
Hoist Line Weight:
3. Crane Manufacturer
Model No. Crane 1 Crane 2 Serial No.
Maximum Load radius: On:
Corresponding Boom Angle: On Tyres:
Corresponding Boom Length: On Crawlers: Extended Retracted
Lift will be On boom Over side Over End
Rated Capacity
Capacity Margin =(Total Load/Rated Capacity)x100
4. Are there underground hazards ?
Soil Condition Yes No
Are Fire or Explosive Hazards within reach ? Yes No
Are there Electrical hazards within reach ? Yes No
Has permit been obtained? Yes No
HCC-KEC CONSORTIUM GC / CMRL
Erection Safety Erection Safety
Sign
Name
Designation
Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at
Chennai Bypass Crossing, Ramachandra Hospital, Iyyapanthangal Bus
Depot, Katupakkam, Kumanan Chavadi, Karayan Chavadi, Mullai Thottam,
Poonamallee Bus Terminus, Poonamallee Bypass & Associated Viaduct
from Chainage 17982.240 to Chainage 25928.186 and Approach to Depot at
Poonamallee & All Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 06
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(6)
Crane Lifting Operations: Engineer In-Charge Pre-Lift Checklist
S.No. Lift Description Comments
1 Name of crane drlver(s) / operator 1. Name:
2 Test certificates and licence to be produced by the crane driver 2. CRANE & DRIVERS CERTIFICATES & LICENCE
a.) Crane test certificate number to correspond with a) Crane Certification Number & Attach Photocopy:
a.1) Last crane inspection date a.1) Date:
a.2) Next crane inspection date a.2) Date:
a.3) Boom stampnumber a.3) B-Number :
a.4) Hook stamp number a.4) H-Number:
a.5) Inspection disc/sticker number in crane cabin a.5) D-Number:
b.) Check Operators name against ROC ID card & crane licence b.) Photo Copy: Yes/No ID Check: Yes/No
c.) Inspections c.) Inspections
c.1) Crane Weekly & Daily inspection record c.1) Weekly: Yes/No Daily: Yes/No
c.2) Crane Pre mobilisation Inspection must be completed & crane
c.2) Attached: Yes/No ( IF NO " DO NOT USE CRANE" )
inspection passed to be used for lift.
3 Other test certificates required 3. OTHER TEST CERTIFICATES
Pre Lift Inspection:
a) Chains & shackles a.) Register: Yes/No
Yes/No
Pre Lift Inspection:
b) Wire ropes Inspected b.) Register: Yes/No
Yes/No
Pre Lift Inspection:
c) Sling inspection c.) Register: Yes/No
Yes/No
4 Provide Rigger Banksman 4. RIGGER/ BANKSMAN
a) Suitable method of communication a.) Radio / Whistle / Uniform Hand Signals
b) Ensure Banksman clearly distinguishable if hand signals used b.) Distinguished How?
5 Provide warning 5. PROVIDE WARNINGS
a) Notices, Bollards, Barriers. Lookout a.)Notices / Bollards / Barriers / Lookout
6 Provide temporary lighting. 6. LIGHTING Yes / No - Day / Night / Low light
Check outriggers "FULLY" extended & Load distribution plates 7. OUTRIGGERS Extended Fully: Load Distribution Plates:
7
/ blocks are adequate for the weight & correctly position Yes/No Yes/No
8 Check crane level 8. CRANE LEVEL Yes / No / Re-level Completed
Check safe load indicator Is working and any computer input set 9. AUTO- SAFE LOAD INDICATOR ASLI
9 up is Serviceable: Yes / No
correct Computer Input: Yes / No / N/A
10 Check Lift Study Method Statement being complied with fully 10.LIFT STUDY METHOD STATEMENT Y es/No
11 Ensure load correctly slung as per Lift Study MS 11.LOAD CORRECTLY SLUNG Yes/No
12.TAG LINES Yes/No/Gantry no
12 Check tag lines fitted to control load
requirement
13.LOAD CHECKED: Adjustment Required:
13 Check load after lifting150mm.
Yes/No
14 Check no-one is or can walk under load being lifted. 14.SAFETY ZONE DEMARCATED & ENFORCED: Yes
Check load Is landed on battens to prevent damage to slings and to
15 15.BATTENS IN PLACE: Yes / Not required
allow their removal
HCC-KEC CONSORTIUM CMRL / GC
Sign

Name

Designation

Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan Chavadi,
Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass & Associated
Viaduct from Chainage 17982.240 to Chainage 25928.186 and Approach to Depot at Poonamallee &
All Associated works
PORTAL BEAM TRANSPORT PERMIT FROM PCY
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 07
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(7)
Date: Vehicle type and Reg. No:

Destination Point: Driver Name:

Structure No: Id no of driver:

Max Load of Structure(MT): Contact No of driver:

Time of dispatch:

Sl No. CHECK POINTS YES NO REMARKS

All safety measures taken while placing of Pier cap on trailer by
1
Gantry

2 Whether vehicle has green tag? If Yes then mention Tag No

Whether Brakes, Main horn, Back horn, all lights and wipers are
3
working?

4 Whether Fire extinguisher and first aid kit available?

5 Whether condition of tyre and trailer bed is OK?

Whether trailer design as per the approved drwg. to carry the U-

6
Girder?

7 Whether Driver competency available and its display on vehicle?

8 Whether 02nos Escort & Trailing vehicles are available?

Whether sufficient no of belts / straps provided for lashing

9
arrangement?
Are chocks (blocks or wedges) Secured to the transport vehicle and
10
removal of loose material?

11 Whether the route is identified and approved?

12 Whether signages available on trailer back side?

Whether adequate no. of traffic marshals, cones, batten lights to

13
control traffic available?
Whether fog light (for winter season) and wipers (for rainy season)
14 are
installed in vehicle?
Trailer driver and helper are medically fit and not under influence of
15
alcohol?
Contractor Safey Contractor Representative CMRL / GC Representative
Sign

Name

Designation

Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan
Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee
Bypass & Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and
Approach to Depot at Poonamallee & All Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 08
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(8)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC Consortium
Project : CMRL C4 ECV02

Location: Drawing No: Structure:

RFI No: Date of Deshuttering: Date of Inspection:

POST CONCRETE INSPECTION CHECKLIST

S. No Description Yes No Remarks

1* Surface finish OK

2* Alignment, levels, dimensions are OK

Levels (as per drg):
2A
Levels (Actual):
3 Curing Method

4* Curing is proper as per approved methodology

5** Any surface defects

If yes, type of defects, Honey comb, Blow Holes, Bulging, Cracks,
6**
Surface Voids, Edge & Surface damage
7* Any repair required

8* Repair done as per approved methodology

9 Match key, Construction joint provision are OK

All inserts Bearing Pedestal, shear key, Safety sleeves, earthing rod,
10
drainage pipe & drain sprout, and lifting hole etc, are in position

11 Coupler provision of stitch concrete

Reinforcement provisions for U-Girder bearing pedestal, shear key,
12
Jacking R/f, PPB Pedestal, recess dowels are in position

13 Inhibitor solution to be coated for the dowles left out

NOTE: DEVIATION DETAILS ("NO" IN CASE OF 1,2,4,7 & 8 AND "YES" FOR 5,6)

Contractor Representative CMRL/GC Representative

Sign

Name

Designation

Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan Chavadi,
Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee Bypass &
Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and Approach to Depot at
Poonamallee & All Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 09
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(09)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC Consortium
Project : CMRL C4 ECV02
Portal Beam Type: Date of checking:
Portal Beam identification: Date of casting:
CHECKLIST FOR PRECAST ELEMENT DISPATCH FROM PC YARD TO SITE
Observation
S No Description Remarks
Yes No
1 Any NCR / SOR's closing Pending?
2 All dimensions checked ( L*B*D) and found ok
Precast Element Nomenclature along with
3
direction is mentioned as per standard
Shear key, Bearing pedestal, Stitch concrete
4 dowels / coupler and stitch concrete ducts are
provided as per drawing
5 Curing period completed
6 Inhibitor Solution is applied in all the dowels
Surface Finishing has been done and there are no
7
Honeycombs over the surface of the Pier cap
Post Concrete Inspection Check list has been
8
approved?

9 All the ducts are provided as per approved drawing

10 All the ducts are cleaned/checked

The threaded bars provided for the coupling
11 arrangement has been cleaned and exposed
properly
Lifting Points provided for the lifting of Precast
12 Station Beam/ I Girder is as per the approved
drawing
Transportation Arrangement over the Trailer is
13
found to be in order as per the approved drawing
Contractor Representative CMRL / GC Representative
Sign

Name

Designation

Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan
Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee
Bypass & Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and
Approach to Depot at Poonamallee & All Associated works
Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 10
CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(10)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC Consortium
Project : CMRL C4 ECV02

Location: Date of Inspection:

Structure: Drawing No:

SAFETY CHECKLIST

S. No Description Yes No Remarks

1 Are all workers ESHS inducted?

Have all operators, supervisors & workmen undergone job-specific

2
training?

3 All construction machinery obtained/having valid TPI certificate?

4 All workers are wearing PPE?

5 Housekeeping is up to the satisfactory level at the workplace?

6 All necessary work permits obtained?

7 Work activity is carried out as per the approved method statement?

8 Proper illumination at site ensured?

9 Are proper traffic precautions taken?

10 The workplace is barricaded properly?

11 Safe working platforms and access provided?

12 Is scaffolding and ladder provided with "safe to use" tag?

13 All lifting tools and tackles are Third party certified?

14 Safety green net provided wherever required?

15 Edge Protection Provided & ensured for work at Height?

16 Life Line support Provided or not for work at Height?

17 Fall arrestor provided wherever required?

Remarks:

Contractor Representative CMRL / GC Representative

Sign
Name
Designation
Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan
Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee
Bypass & Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and
Approach to Depot at Poonamallee & All Associated works

Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 11

CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(11)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC CONSORTIUM
Project : CMRL C4-ECV02
Portal Beam Type: Date of checking:
Location: Portal Beam identification:
Ref RFI No:
Reinforcement Inspection Checklist for Pier-Portal Beam Connection portion
Observation
S No Description Remarks
Yes No
Whether Reinforcement is from approved source &
1
Grade Fe 500D:
Whether the reinforcement steel has been cut &
2
bended as per approved Bar bending schedule:
Whether Reinforcement Steel is free from
3
corrosion/Laminations:
Whether all the Reinforcement are tied with approved
4
drawing:
Whether reinforcements are tied with 18 Gauge
5
binding wire in Cross direction:
Check for cover blocks of proper size & fixed at
6
proper spacing:

Whether cover block of same grade has been

7
provided as the grade of concrete:

Whether cover to reinforcement has been provided as

8
per drawing:
Whether lap length & anchorage length to the
9
reinforcements are as per drawing:
Whether coupler to the reinforcements has been
10
provided at required location as per drawing:
Remarks

HCC-KEC CONSORTIUM CMRL / GC

Sign

Name

Designation

Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai
Bypass Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam,
Kumanan Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus,
Poonamallee Bypass & Associated Viaduct from Chainage 17982.240 to Chainage
25928.186 and Approach to Depot at Poonamallee & All Associated works

Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 12

CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(12)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC CONSORTIUM
Project : CMRL C4-ECV02
Portal Beam Type: Date of Casting:
Location: Portal Beam identification:
Ref RFI No:
GROUTING RECORD OF PRESTRESSING TENDONS FOR PORTAL BEAM
Pre-Grouting Checks:
S No Description Observation (Yes/No) Remarks
1 Free of blockage at Inlet
2 Free of blockage at Outlet
3 Free of blockage at Vents
4 Free of blockage at Cable ducts
5 Leakage observed
6 Leakage sealed
7 Whether cable duct blocked

Date of post tensioning: Cable No:

Date of grouting: Brand & type of cement:
W/C Ratio: Week & year of manufacture:
Name & amount of admixture used:
Mixing time of grout:________________________
Density of grout:___________________________ Temp___________________
Time of grouting: Start______________________ End___________________
Equipment: Grout Mixer_____________________ Grout Pump:_________________
Cable duct: Diameter_______________________ Length:_______________
Volume of Grout:____________________________ Regrouting:__________________
Grout pressure:__________________________
Cement consumption: Theoretical___________________ Actual:______________________
Number of cube specimen taken at outlet:______________
Remarks

HCC-KEC CONSORTIUM CMRL / GC

Sign

Name

Designation

Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan
Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee
Bypass & Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and
Approach to Depot at Poonamallee & All Associated works

Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/ 13

CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(13)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC CONSORTIUM
Project : CMRL C4-ECV02
Portal Beam Type: Date of checking:
Location: Portal Beam identification:
Ref RFI No:
Concrete Pour & Post Pour Inspection Checklist of Pier-Portal Beam Connection Portion
Observation
S No Description Remarks
Yes No
Whether M55/M60 Grade concrete mix is prepared
1
as per approved concrete mix design:
Whether workability & temperature has been
2 checked and maintained as per approved mix
design:
Whether pouring is being done with methods as
3
specified in the methodology:
Whether concrete has been poured in layers of
4
maximum 300mm thick:
Whether concrete is compacted properly with high
5 frequency electrical needle vibrator of size 40/60mm
or mould vibrator:
Whether concreting has been done in single stage
6
without formation of construction joint:
Whether heigth of free fall of concrete is less than
7
1.5 metre:
Whether top level of concrete is finished properly to
8
required line & level:
Whether any leakage of slurry observed during
9
concreting:
Whether both Initial & final curing arrangements has
10
been adopted as per method statement:
Whether any defects in the concrete has been
11
observed after final setting:
Whether both stressing & levelling frame has been
12 removed after achieving required strength of
concrete:
Whether elastomeric packing has been removed
13
after removal of stressing frame:
Remarks

HCC-KEC CONSORTIUM CMRL / GC

Sign
Name
Designation
Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai
Bypass Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam,
Kumanan Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus,
Poonamallee Bypass & Associated Viaduct from Chainage 17982.240 to Chainage
25928.186 and Approach to Depot at Poonamallee & All Associated works

Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/14

CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(14)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC CONSORTIUM
Project : CMRL C4-ECV02
Portal Beam Type: Date of checking:
Location: Portal Beam identification:
Ref RFI No:
Inspection checklist for Anchorage recess concrete of Portal Beam
Observation
S No Description Remarks
Yes No
Whether entire recess area has been cleaned to
1 remove all surface laitance, unevenness or
irregularities:
Whether reinforcement in the recess area has
2
been fixed as per drawing:
Whether required formwork has been installed at
3
recess area to true line& level:
Whether all joints in the formwork has been
4
sealed:
Whether safe & adeqauet provision has been
5
made in the form for pouring recess concrete:
Whether recess concrete Grade has been
6 prepared as per approved design mix with
materials from approved source:
Whether pouring of concrete in recess area has
7 been done to ensure adeqaute compaction of
recess concrete:
Whether all shutters of recess concete has been
8
removed after 24 hours of its casting:
Whether curing of recess concrete has been done
9
as per method statement:
Remarks

HCC-KEC CONSORTIUM CMRL / GC

Sign
Name
Designation
Date
 Project: CMRL C4-ECV-02: Construction of Elevated Metro Stations at Chennai Bypass
Crossing, Ramachandra Hospital, Iyyapanthangal Bus Depot, Katupakkam, Kumanan
Chavadi, Karayan Chavadi, Mullai Thottam, Poonamallee Bus Terminus, Poonamallee
Bypass & Associated Viaduct from Chainage 17982.240 to Chainage 25928.186 and
Approach to Depot at Poonamallee & All Associated works

Doc no: HCC-KEC/CMRL/C4-ECV02/MS74/CL/15

CMRL Doc No. P20C4ECV02PRW-HCKC-QMSCHS-0074(15)
Employer : Chennai Metro Rail Limited
Contractor : HCC-KEC CONSORTIUM
Project : CMRL C4-ECV02
STRESSING RECORD
Component: RFI No:
Location: Structure Id & Length
Date of Stressing: Date of casting:
Jack Type: Coil Number
Jack Ram Area: Cable No:
Jack Serial No: Cable Type:
Pressure Gauge Serial No: Theoretical elongation:
Actual Area 'A' Value: Theoretical Area 'A' Value:
Actual MOE 'E' Value: Theoretical MOE 'E' Value:
Modified elongation: Theoritical Elongation* Theoritical Area* Theoritical MOE 5% Elongation:
Actual Area * Actual MOE 5% Elongation:

Pressure applied: (Jacking Force/Ram Area*Efficiency) 5% Maximum pressure:

5% Minimum pressure:

Cable No Cable No
Ram Ram
Pressure Difference Cumulative Dead End Pressure Difference Cumulative Dead End
reading Reading
(Kg/cm2) (mm) (mm) Reading (Kg/cm2) (mm) (mm) Reading
(mm) (mm)

Cumulative Elongation A= A=
Live End slip B= B=
Grip elongation C= C=
Dead End Slip D= D=
Total elongation E=A-B-C-D= E=A-B-C-D=
Pressure(%) Elongation(%) Pressure(%) Elongation(%)
Stressing Agency HCC-KEC Consortium CMRL / GC
Sign
Name
Designation
Date
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
CONTRACTOR HCC KEC Consortium LOADING, TRANSPORTATION AND ERECTION OF Portal Beam
Activity
NAME:
Contract: CMRL /Phase II/ C4 ECV02 Date of Preparation 23/08/2023

KEY: L = Likelihood S = Severity R = Risk (Likelihood x Severity)

L = Low priority to be implemented when resources allow. M = Medium priority to be H = High priority to be acted on immediately.
RISK RANKING:
scheduled as soon as practicable.
Mr. Md. Naziruddin (Manager), Mr. Prem Kumar (Sr. Engineer), Mr. Irfan B (Sr. Manager ESHS), Mr.Mubarak (Sr. Manager ESHS)
TEAM:

Legal Revised Acceptable Rema

Risk Rating
Potential Concern Populatio Rating (A)/ Non rks
Task/Element Risk Involved Control Measures
Hazards (Y/N) n at Risk Acceptable
L S R L S R
(NA)
Removal of Availability of Electrocution, Y Workmen/ 5 5 25  All overhead power lines shall be identified and diverted 1 5 5 A
barricade boards Overhead damage of Staff/  Underground utilities mapping shall be done and diverted
and Area underground underground Public wherever required.
preparation for utilities (Power utilities, Gas  Gas pipes shall be marked at site and MGL contact
placing of crane line, Gas line, leakages, numbers shall be displayed.
Communication Water  Adequate number of pumps shall be ensured if in case of
Line, Water Line, flooding, water flooding.
Storm water damage of  Sufficient Traffic marshals with blinkers shall be ensured to
drain, sewer line trees, traffic control traffic jam.
etc.,) and Trees jam due to  All live trees shall be protected and prior permission shall be
and its water/sewers obtained if any tree needs to be cut.
branches) stagnation  Permit system shall be followed.
Improper Toppling of Y Workmen/ 5 5 25  Crane shall be positioned on firm ground surfaces only. 1 5 5 A
compaction of crane and Staff/  If the area identified as backfilled, MS plate shall be
surface other vehicle Public provided.
 Crane outriggers shall be fully extended while placing the
crane.
Unprotected Vehicle hit to Y Workmen/ 5 5 25  Working area shall be cordoned off. 1 5 5 A
work area from public/ Staff/  Traffic barriers, cones and traffic marshals shall be ensured
public vehicle pedestrians Public  If required traffic diversion shall be done, alternative routes
movement and vehicle shall be identified.
collision  Unauthorized entry sign boards shall be displayed.
Material Obstruction Y Workmen/ 4 4 16  Clear and safe access should be ensured all the times. 1 4 4 A
stacked on for crane and Staff  Working area shall be maintained without any obstructions.
access trailer position  If materials exists, all materials shall be shifted prior to
placing the crane
Inadequate Not able to Y Workmen/ 4 4 16  Minimum 55 lux shall be maintained at the working area. 1 4 4 A
area identify the Staff  Backup DG shall be ensured to overcome power failures.
illumination Work area  Dedicated electrician shall be deployed at the working
hazards area.
Protruding Slip, Trip and N Workmen/ 4 4 16  All protruding rebars shall be removed. 1 4 4 A
rebar’s of board Fall, Bursting Staff  If removing nails is not possible, nails to be cut with minimum
anchoring of Vehicle tolerance to avoid trip hazards, bursting of vehicle tyres.
tyres
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
Portal Beam Improper Fall of person Y Workmen/ 5 5 25  Aluminium ladder shall be used to climb over the Portal 1 5 5 A
loading on trailer access to reach Staff Beam and trailer.
from stacking the Portal Beam  Portal Beam loading area shall be maintained obstruction
yard top for slinging free.
Improper Detachment Y Workmen/ 5 5 25  Competent riggers, signal man and lifting supervisor shall 1 5 5 A
slinging and of load, fall of Staff/ be deployed.
rigging lifting frame Public  Safe rigging procedures shall be followed.
and Portal  Load shall be secured firmly to avoid free falling.
Beam,  Capacity of the crane shall be always considered.
toppling of  Lifting frame should be tested by approved third party
crane once in 03 months.
 Defective tools & tackles should not be used.
 Walkie-talkie shall be used for signalling if required.
Using of Fall of load Y Workmen/ 5 5 25  All lifting tools & tackles shall be inspected by approved 1 5 5 A
Defective and due to Staff third party once in 06 months and TPI certificates shall be
substandard Failure/ available.
lifting tools damage of  Visual inspection shall be carried out for tools & tackles for
tools and each lifting work by lifting supervisor/Riggers.
tackles  Colour coding shall be ensured.
 Defected tools and tackles shall be cut and removed from
site.
 Make shift arrangements shall not be entertained.
 Condition of lifting tools and tackles shall be ensured
before issuing the Permit and ensured free from damage.
Using of unfit Collapse of Y Workmen/ 5 5 25  Gantry crane capacity shall be considered and third party 1 5 5 A
gantry crane gantry crane, Staff inspection shall be carried out.
struck with  Maintenance shall be carried for the gantry crane as per
load schedule.
 Daily operator inspection checklist shall be followed.
 Green tag shall be ensured for the gantry crane.
 Gantry crane track shall be maintained obstruction free.
 Permit system shall be followed.
Person working/ Load can fall Y Workmen/ 5 5 25  Lifting area shall be cordoned off. 1 5 5 A
standing under on to the Staff  No unauthorized entry sign boards shall be displayed.
the suspended person  All workmen shall be educated on tool box talks not to
load stand under suspended loads.
Inadequate Obstruct the Y Workmen/ 4 4 16  Minimum 55 lux shall be maintained at the working area. 1 4 4 A
illumination operator and Staff  Backup DG shall be ensured to overcome power failures.
during night others visibility  Dedicated electrician shall be deployed at the working
time in the work area.
area  No work shall be allowed during power cut.
Engaging of Fall of load, Y Workmen/ 5 5 25  Only authorized gantry operators, riggers, signal man, lifting 1 5 5 A
Unauthorized gantry run Staff/ supervisors shall be engaged in the activity.
gantry operator, over or hit, Public  Authorization card, identity card shall be used to the gantry
rigger, signal toppling of operators, riggers, signal man, lifting supervisors.
man and lifting gantry, struck  Gantry crane key should be available with operators during
supervisor shift change / do not leave the key in the cabin.
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
onto other  End stopper shall be fixed on both sides of track to avoid
object de-railing.

Unauthorized Gantry rail hit Y Workmen/ 5 5 25  Proximity sensors shall be fixed on gantry crane all the four 1 5 5 A
person entry or run over Staff sides.
into the gantry the person  Lifting area shall be cordoned off.
movement  No unauthorized entry sign boards shall be displayed.
area/  All workmen shall be educated on tool box talks not to
unprotected stand under suspended loads.
lifting zone
No visibility of Load and Y Workmen/ 5 5 25  Minimum 55 Lux shall be ensured in the working area. 1 5 5 A
lifting zone to gantry struck Staff  During adverse weather condition, gantry crane shall be
the operator with other stopped.
object and  Lifting zone shall be maintained obstruction free without
person any hindrance to the activity.
Over speed and Derailing of Y Workmen/ 5 5 25  Maximum 5Km/hr speed allowed for gantry crane 1 5 5 A
defective railing gantry crane Staff operation.
arrangements  Gantry crane shall be inspected in proper intervals and
of gantry recorded.
 Synchronization shall be done for both the gantries in case
of tandem lifting.
 Alcohol test shall be carried out for operators specially on
night shifts, weekends.
Transportation of Portal Beam Puller / Axle Y Workmen/ 5 5 25  Puller / Axle capacity shall be ensured with respect to the 1 5 5 A
Portal Beam loaded on structure may Staff/ weight of Portal Beam.
inadequate failure Public  Portal Beam loading shall be done on the fabricated frame
capacity of fixed with Axle Bed
Puller / Axle  Vehicle age criteria shall be considered while engaging
the trailer. i.e Own vehicles- 10 years, hired-5 years.
 The route of transportation shall be pre-decided and all
approvals from the concerned authorities shall be taken
prior to the transportation of U-Girder from precast yard up
to the erection locations.
 The transportation of Portal Beams shall commence only
after getting the confirmation from erection location that
the site is ready for erection.
 Squad team with red flags shall be deployed while
transporting the Portal Beam throughout the length of
travel.
 Trial run will be carried out with skeleton frame/structural
steel frame (max length of Portal Beam) once before the
commissioning of work
Inadequate or Toppling of Y Workmen/ 5 5 25  Portal Beam shall be secured on the Axle by using Chains 1 5 5 A
sub-standard Puller / Axle Staff/ /ratchet belts.
securing along with the Public  Suitable fabricated frames shall be provided on the Axle
arrangements load bed
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
 Defective Chain latching & ratchet belts should not be
used.
 Rash driving should not be allowed.
 Road transport lashing checklist shall be followed.
Using of Vehicle Y Workmen/ 5 5 25  All Puller/Axle documents shall be submitted to P&M dept. 1 5 5 A
Defective Puller collision/ Staff/ & verified.
/ Axle person hit by Public  Inspection tag shall be displayed on Puller/Axle
Puller/Axle  Operator should check the vehicle condition on daily basis
due to brake and daily operator inspection checklist shall be followed.
failure,  Tyre condition, tyre pressure should be ensured during daily
bursting of inspection.
tyres etc.,
Unauthorized Vehicle Y Workmen/ 5 5 25  Driver should possess valid driving license and competency 1 5 5 A
driver collision/ Staff/ certificate.
person hit by Public  Do not leave the key during shift change.
Axle/Puller
Unmanned Vehicle Y Workmen/ 5 5 25  Reverse horn shall be ensured in the trailer. 1 5 5 A
reversing collision/ Staff/  Banksman/marshal shall be deployed to monitor the
person hit by Public reversing vehicle.
trailer
Positioning of Placing the Collapse of Y Workmen/ 5 5 25  Crane shall be positioned on firm ground and level surfaces 1 5 5 A
crane crane un- crane while Staff/ only.
compacted lifting the load Public  If the area identified as backfilled, Steel/MS plate shall be
surface/ provided.
SWD/Drainage/  Crane outriggers shall be fully extended while placing the
Uneven surface crane.
 Padding shall be provided where the ground level differs.
 Drainages shall be marked and crane should not be
placed above drainages.
Outriggers Collapse of Y Workmen/ 5 5 25  Area shall be levelled to place the outriggers. 1 5 5 A
placed on crane due to Staff/  Padding shall be provided to place the outriggers.
ground without settling of Public  Crane outriggers shall be fully extended while placing the
padding crane crane.
arrangements  MS plate shall be used wherever required.

Crane placed Collision with Y Workmen/ 5 5 25  Live road shall be diverted with warning sign boards. 1 5 5 A
on live road outside Staff/  Water barriers, traffic cones shall be used for traffic
without vehicle, public Public diversion.
precautions  Marshal shall be deployed with blinkers.
 Adequate illumination shall be ensured.
 Unauthorized person shall not be allowed in the working
area.
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
Non availability Crane hit by Y Workmen/ 4 5 20  Crane swing area shall be barricaded minimum 6m from 1 5 5 A
of swing area person and Staff/ the crane.
barricade vehicle Public  Barricades shall be readily available in the work area prior
to start the activity
 No one should be allowed to work/move on crane swing
area.
 Other vehicles shall not be allowed in the crane working
area.
Work at height Unsafe access falling of Y Workmen/ 4 4 16  Access shall be provided by Cherry picker/Man lift. 1 4 4 A
person from Staff  maximum two persons allowed to use the cherry
height picker/man lift in the same time.
 Users shall be provided with full body harness and lanyard
shall be anchored with the handrails.
 Cherry picker/man lift statutory documents shall be
submitted to P&M, EHS dept.
 Third party inspection shall be done for Cherry picker/man
lift.
 Operator should possess valid driving license with Identity
card, competency and training certificate.
 Outriggers/Jacks shall be fully extended if applicable.
 Inspection tag shall be provided to the vehicle.
 User should be familiar with the hand signalling.
Inadequate falling of Y Workmen/ 5 5 25  Adequate width of the platform shall be ensured. 1 5 5 A
width of person, Staff  Handrails, mid rails shall be provided firmly.
platform, edge materials from  Gaps shall be checked to avoid man, material falling.
protection and height  Toe guards shall be ensured in the platform.
fall protection

Inadequate Falling of Y Workmen/ 5 5 25  PPE rope will be tied end to end of girder flanges in 2 or 3 1 5 5 A
anchoring person from Staff layers for edge protection.
arrangements height  Anchoring of safety harness will be done in the exposed
for fall protection steel of the shear key.
during Portal
Beam erection
Using of Vehicle Y Workmen/ 5 5 25  Crane shall be inspected by third party and certificate shall 1 5 5 A
defective crane collision/ Staff be obtained.
person hit by  All crane documents shall be submitted to P&M dept. &
crane due to verified.
brake failure,  Inspection tag shall be displayed on the crane.
bursting of tyres  Operator should check the vehicle condition on daily basis
etc., and daily operator inspection checklist shall be followed.
 Tyre condition, tyre pressure should be ensured during daily
inspection.
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
Improper rigging Detachment Y Workmen/ 5 5 25  Competent riggers, signal man and lifting supervisor shall 1 5 5 A
arrangements of load, Staff be deployed.
while lifting the toppling of  Safe rigging procedures shall be followed.
bearing & steel crane  Load shall be secured firmly to avoid free falling.
plate.  Crane working radius and SWL shall be ensured.
 Capacity of the crane shall be always considered.
 Lifting frame should be tested by approved third party.
 Defective tools & tackles should not be used.
Walkie-talkie shall be used for signalling if required.
Using of Fall of load due Y Workmen/ 5 5 25  All lifting tools & tackles shall be inspected by approved 1 5 5 A
defective lifting to Failure/ Staff third party and TPI certificates shall be available.
tools damage of  Visual inspection shall be carried out for tools & tackles for
tools and each lifting work by lifting supervisor/Riggers.
tackles  Colour coding shall be ensured.
 Defected tools and tackles shall be cut and removed from
site.
 Make shift arrangements shall not be entertained.
 Permit system shall be followed.
Lifting the Load hit with N Workmen/ 4 4 16  Guide rope shall be used with minimum 20mm dia. 1 4 4 A
bearing, steel other objects, Staff  Sufficient length of guide rope shall be used.
plate without man and  Guide rope shall be ensured prior to start the lifting activity.
using the tag line machinery  Damaged guide rope shall not be used.

Improper Falling of Y Workmen/ 5 5 25  Bearing, steel plate shall be secured firmly before de- 1 5 5 A
installation bearing, steel Staff slinging.
method/ de- plate from  Spanners and other tools shall be secured from falling.
slinging without height  Only trained workforce shall be deployed.
securing against  Illumination level shall be ensured.
fall of bearing,  Toolbox talk shall ensure the same.
steel plate.
Fingers Caught Cut and N Workmen/ 5 5 25  Activity sequence shall be followed. 1 5 5 A
in between abrasion injury, Staff  All workers shall be provided with cut resistance hand
bearing and Permanent gloves.
pedestal disability  Only trained workforce shall be engaged in the activity.

Portal Beam Parking on live Vehicle hit to Y Workmen/ 5 5 25  Working area shall be cordoned off. 1 5 5 A
loaded Axle road without public/ Staff/  Traffic barriers, cones and traffic marshals shall be ensured
parking on barricade the pedestrians Public  If required traffic diversion shall be done, alternative routes
erection spot to area and vehicle shall be identified.
unload collision  Unauthorized entry sign boards shall be displayed.
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
Inadequate Obstruct the Y Workmen/ 4 4 16  Minimum 55 lux shall be maintained at the working area. 1 4 4 A
visibility to the operator and Staff/  Backup DG shall be ensured to overcome power failures.
operator due to others visibility Public  Dedicated electrician shall be deployed at the working
poor illumination in the work area.
area  Activity shall not be carried out during power cut.

Axle parked on Axle run over N Workmen/ 4 4 16  Axle shall not be parked on steep road. 1 4 4 A
steep road, the public, Staff/  Wedge stoppers shall be provided on trailer tyres.
failure to provide workers, Axle Public  Axle driver shall be instructed about the risk involved.
stoppers on tyres hit with the
equipment.

Person taking Trailer run over Y Workmen/ 4 4 16  No one shall allowed to take rest at site, access and under 1 4 4 A
rest under the the workers Staff any vehicle.
trailer/ persons  Workmen rest room shall be provided at site.
sleeping on  All workers shall be instructed to take rest at workmen rest
vehicle access room only.

Lifting and Unauthorized Falling of Portal Y Workmen/ 4 4 16  Lifting area shall be cordoned off. 1 4 4 A
erection of Portal entry into the Beam on Staff/  No one shall be allowed to stand/work under the
Beam lifting zone public, Public suspended load.
workmen  No unauthorized entry sign boards shall be displayed.
 All workmen shall be instructed on tool box talks.
 Traffic diversion plan shall be provided for each erection
work separately section wise and obtain approval before
commencement of activity
Inexperienced Fall of load, Y Workmen/ 5 5 25  Only authorized crane operators, riggers, signal man, lifting 1 5 5 A
lifting supervisor, toppling of Staff/ supervisors shall be engaged in the activity.
riggers and crane, struck Public  Authorization card, identity card shall be used to the crane
signal man and onto other operators, riggers, signal man, lifting supervisors.
operator object  Only signal man will give signal to the crane operator.
 Permit system shall be followed.
Using of Fall of load due Y Workmen/ 5 5 25  All lifting tools & tackles shall be inspected by approved 1 5 5 A
defective lifting to Failure/ Staff third party and TPI certificates shall be available.
beam, tools and damage of  Visual inspection shall be carried out for tools & tackles for
tackles tools and each lifting work by lifting supervisor/Riggers.
tackles  Colour coding shall be ensured.
 Defected tools and tackles shall be cut and removed from
site.
 Make shift arrangements shall not be entertained.
 Permit system shall be followed.
Failure of lifting Fall of load due Y Workmen/ 5 5 25  Lifting tools and tackles capacity shall be considered with 1 5 5 A
tools & Tackles to lifting tools & Staff respect to the lifting load.
tackles failure  All lifting tools & tackles shall be inspected by third party.
 Visual inspection shall be done for tools and tackles before
every lift.
 Visual inspection shall be carried out for each lifting work
by lifting supervisor/Riggers.
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
 Colour coding shall be ensured.
 Defected lifting tools and tackles shall be cut and removed
from site.
 Make shift arrangements shall not be entertained.
 Permit system shall be followed.
 Erection area shall be barricaded and no unauthorized
entry sign boards shall be displayed.
Using of unfit Crane Y Workmen/ 5 5 25  Minimum each 400T / 450T capacity crane shall be 1 5 5 A
cranes collapse, Staff engaged in the Portal Beam erection work.
Toppling of  All crane documents shall be submitted to P&M, EHS dept.
crane, Falling  Crane inspection tag shall be ensured.
of loads.  TPL Vehicle aging norms shall be considered.
 Crane capacity shall be considered with respect to the
load and third party inspection shall be carried out.
 Maintenance shall be carried for the crane as per
maintenance schedule.
 Daily operator inspection checklist shall be followed.
 Permit system shall be followed.
Overload the Crane Y Workmen/ 5 5 25  Tandem lifting shall be adopted for the Portal Beam 1 5 5 A
cranes collapse, Staff erection work.
Toppling of  SWL shall be reduced at least 25% while load calculations
crane, Falling for tandem lifting.
of loads.  Crane capacity shall be considered with respect to the
load and third party inspection shall be carried out.
 Minimum each 400T capacity crane shall be engaged in
the Portal Beam erection work.
 SWL and working radius shall be ensured as per the load
chart.
 Pre lift checklist shall be prepared and Permit system shall
be followed.
 Crane inspection tag shall be ensured.
 Competent lifting team shall be engaged.
Extend the Crane boom Y Workmen/ 5 5 25  Boom limit switch & hoist limit switch shall be checked. 1 5 5 A
boom while collapse Staff  Safe working load shall be checked as per the load chart
lifting for the particular boom length before extending the crane
boom.
 Crane operator should aware of the load calculation and
load chart.
Unauthorized Vehicle Y Workmen/ 5 5 25  Crane operator should possess valid driving license, 1 5 5 A
person operate collision/ Staff/ operator competency certificate.
the crane person hit by Public  Do not leave the key in cabin during shift change.
crane  Unauthorized person should not be operate the crane
under any circumstance.
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02
Inadequate Obstruct the Y Workmen/ 4 4 16  Minimum 55 lux shall be maintained at the working area. 1 4 4 A
illumination on operator and Staff  Backup DG shall be ensured to overcome power failures.
lifting zone others visibility  Dedicated electrician shall be deployed at the working
in the lifting area.
zone  Activity shall not be carried out during power cut.

Poor Fire, Y Workmen/ 4 4 16  Maintenance of crane shall be ensured as per the 1 4 4 A

maintenance of Mechanical Staff maintenance schedule.
crane, hydraulic failures, short  All hydraulic hoses shall be connected firmly.
system, electrical circuits.  Oil leakages shall be cleaned immediately inside the
system crane.
 Bare electrical cable connections not allowed in the
crane.
 Fire extinguishers, first aid box shall be ensured in operator
cabin.
Excessive wind Crane boom Y Workmen/ 5 5 25  Anemometer shall be fixed in the crane to monitor the wind 1 5 5 A
while lifting collapse, Staff/ speed.
activity toppling of Public  Crane booms shall be kept in down position during
crane excessive wind.
 No lifting activity permitted during excessive wind
situations.
 Gluing of wedge plates shall be done with extra support of
wooden packing provided near the pedestal area for
additional safety precautions.
Restoration of Oil leakage/ Skidding of Y Workmen/ 5 5 25  If any oil leakage and mud spillage observed on road, it 1 4 4 A
erection area spillage of muds, bike riders, Staff/ should be cleaned before allowing the traffic.
unsecured falling of Public  Barricade boards shall be restored and ensured with
barricade barricade on adequate securing arrangements.
boards, failure to road, public  Before allowing the traffic, all materials shall be stacked
restore the vehicle may within the barricade in proper manner.
barricade, enter into the  Before allowing the traffic, our construction vehicle shall be
unwanted construction parked within barricade or else barricade around the
materials lying area, impaling vehicle to avoid endangering to the public road users.
on the road, hazards,  Adequate illumination shall be ensured after work
unprotected or vehicle collision completion too for traffic users.
unauthorized  Vehicle shall be parked at adjacent side of the road with
parking of adequate precautions (Barriers, warning signs, retro
construction reflective warning signs of parking etc.,).
equipment

Prepared By Reviewed By Approved By

SIGNATURE

NAME B.Irfan Thangaraj S.Mohan

DATE 24/08/2023 25/08/2023 25/08/2023
 HCC-KEC JV HAZARD IDENTIFICATION AND RISK
ASSESSMENT
Doc. No: CMRL/ECV02/ESHS/HIRAF/07
Chennai Metro -C4 Rev: 00
Package No.: ECV02