GUJARAT ENERGY TRANSMISSION CORPORATION LTD. Sardar Patel Vidyut Bhavan, Race Course, Vadodara: FQP PILE CONSTRUCTION

Transcription

1 GUJARAT ENERGY TRANSMISSION CORPORATION LTD. Sardar Patel Vidyut Bhavan, Race Course, Vadodara: FQP PILE CONSTRUCTION /C/FQP PILE/R0 DT. 15/03/2008

2 SECTION : Foundation Materials 1. CHECKING OF FOUNDATION MATERIALS A) CEMENT i) Fitness One sample IS:456, IS:4031, IS:269, Manufacturer/ Review of B ii) Compressive Strength per lot of IS:8112, IS:12269 / manufacturers iii) Initial & final setting time 100 MT or part IS:1489 & approved lab test certificates iv) Soundness thereof from specification. (MTCs) and v) Heat of Hydration for low each source laboratory test heat cement (Not Applicable for MTC's and results by for OPC & PPC) one sample per lot of 200 MT or part thereof from each source for site testing. vi) Chemical Composition of One sample per IS:456, IS:4031, IS:269 Manufacturer Review of B Cement lot of 100 MT IS:8112, IS:12269 manufacturers or part thereof IS:1489 & test certificates from each specification. by source for MTCs. B) COARSE AGGREGATES i) Determination of Particle One sample IS:383, IS:2386 Each source to be B size (Sieve Analysis) per lot of and approved lab. ii) Flakiness Index 200 cubic meter specification. Review and iii) Crushing Value or part thereof acceptance of iv) Specific Gravity* from each test result by v) Bulk Density* source for each vi) Absorption Value* size vii) Moisture Content* viii) ix) Soundness of Aggregate** Presence of deleterious materials * Applicable to design mix concretes only. ** Applicable to concrete work subject to frost action. PAGE-1

3 Section : Foundation Materials C. FINE AGGREGATE i) Gradation : Determination One sample IS:383, IS;4031, IS:2386, Each source to B of Particle size per lot of 200 IS:236, IS:456 and approved lab be approved by (Sieve Analysis) cubic meter or specification. ii) Specificy Gravity and density* part thereof Review and iii) Moisture content* from each acceptance of iv) Absorption Value* source test result by v) Bulking* vi) vii) Silt Content Test Presence of deleterious materials D) WATER i) Cleanliness 100% IS:456, IS:3205 and Contractor Each source C (Visual ) specification. to be approved The water used for mixing by concrete shall be fresh, clean and free from oil, acids and alkalies, organic materials, or other deleterious materials ii) Suitablity of water for One sample per specificaiton Contractor Certification B RCC work source Potable water is generally regarding suitably for concreting. potability of water by contractor and approval by RCC work iii) P.H Value One sample per IS : 456, IS : 3025 and Approval by B source specification approved lab Min. 6 Contactor Max. 8 * Applicable to design mix concretes only. ** Applicable to concrete work subject to frost action. PAGE-2

4 Section : Foundation Materials E. REINFORCEMENT STEEL i) Identication & size Random IS:432, IS:1139, IS:1786 & Contractor Approval by B specification ii) Chemical Analysis Test One sample per IS:432, IS:1139, IS:1786 & Manufacturer Review of B heat specification manufacturers test certifcates by iii) Tensile Test One sample per IS:432, IS:1139, IS:1786 & Manufacturer Review of B iv) Yield Stress/ proof stress lot of 40 MT specification manufacturers v) Percentage Elongation or part thereof test certifcates for each size as well as lab by of steel confirming to IS:1139 and 5 MT or part thereof for HDS wire for each size of steel as per IS:432. For steel as per IS:1786 under 10 mm 1 sample for each 25 MT or part thereof. 10mm - 16 mm 1 sample for each 35 MT or part thereof. Over 16 mm 1 sample for each 45 MT or prt thereof. vi) Bend/ Rebend Test One sample per IS:432, IS:1139, IS:1786 Manufacturers Review of B lot of 20 MT or specification manufacturers part thereof for Approved lab test certificates as well as lab PAGE-3

5 Section : Foundation Materials each size of steel as per IS:432/ IS:1139. For steel as per IS:1786 under 10mm. 1 sample for each 25 MT or part thereof. 10 mm - 16mm. 1sample for each 35 MT or part thereof. Over 16 mm. 1 sample for each 45 MT or part thereof. test result by vii) Reverse Bend Test or HDS wire One sample per IS:432 Manufacturer/ Review of B lot of 5 MT specification manufacturers or part thereof approved lab. test certificates for each size. as well as lab test result by. PAGE-4

6 Section : Foundation ] 2. FOUNDATION A) EARTHWORK (EXCAVATION) i) Initial ground level, depth of Each pipe approved Joint Approval by B xcavation, final bed level. drawings/ specification Inspection by & Contractor ii) Dimension of Excavated PIT Each pile approved Joint Approval by B drawings/specification Inspection by & Contractor iii) Side slopes during excavation Each pile As per Site working Joint Approval by C final bed level condition Inspection by & Contractor iv) Nature of soil/rock Each pile specification -do- -do- B B. STUB & TEMPLATE (Applicable only if it is in the scope of pile foundation contractor) i) Identification & Assembly 100% on approved Joint Approval/ B each location drawings/specifications Inspection by clearance & contractor ii) Template level, width & 100% on approved Joint Approval/ B diagonal each location drawings/specifications Inspection clearance by and contractor iii) Tightening of all bolts & 100% on approved Joint Approval/ C nuts of template, stub & cleats each location drawings/specifications Inspection by clearance by & by contractor PAGE-5

7 Section : FOUNDATION iv) Stub setting 100% on approved Joint Approval/ B each location drawings/specifications Inspection by clearance by b y C) P.C.C. Padding For all locations IS:456 and Joint Approval by B approved foundation Inspection by drawings & specification D) STAGING FOR RAISED CHIMNEY i) durability, strength & 100% Joint Approval by B soundness of staging, joints specification Inspection by adequacy of its joints & specific levels E) SHUTTERING (Formwork) i) for materials, 100% Joint Approval by C breakage or damage specification/approved Inspection by drawings ii) for plumb alignment, 100% before Joint Approval by B parallelism, squareness and casting specification/approved Inspection by equidistance from stub. drawings iii) Dimensional check 100% before Joint Approval by B casting specification/approved Inspection by drawings iv) for level & height 100% before Joint Approval by B casting specification/approved Inspection by drawings v) for rigidity of frame/ 100% Joint Approval by C tightness specification/approved Inspection by drawings PAGE-6

8 Section : Foundation vi) Cleaning and oiling 100% Joint Approval by C approved specification / Inspection by drawings and contractor vii) Diagonal bracing if required 100% Joint Approval by C as per drawings /site approved specification / Inspection by conditions drawings viii) ing of joints to avoid 100% Joint Approval by C undue loss of cement specification/approved Inspection by slurry drawings F. PLACEMENT OF REINFORCEMENT STEEL i) the steel bars for 100% IS:456 and Joint Approval by C rust, cracks, surface flaws, Specification/approved Inspection by laminate etc. (Visual check) drawings ii) as per the bar bending For all IS:456 and Joint Approval by B schedule before placement locations Specification/approved Inspection by of concrete drawings iii) cutting tolerance for For all IS:456 and Joint Approval by B bars as per check list/ locations Specification/approved Inspection by drawings. drawings whether all the bent bars and lap lengths are as per approved bar bending schedule iv) whether all joints 100% IS:456 and Joint Approval by C & crossing of bars are tied Specification/approved Inspection by properly with right guage drawings & annealed wire as per specification PAGE-7

9 Section : Foundation v) for proper cover 100% IS:456 and Joint Approval by C distance, spacing of bars, Specification/approved Inspection by spacers & chairs after the drawings reinforcement cage has been put inside the formwork. vi) whether lapping of 100% IS:456 and Joint Approval by B bars are tied properly with Specification/approved Inspection by right guage and annealed drawings wire as per specification. G. PILE FOUNDATION (additional Tests) i) ing of centre line of Each pile group IS:2911 & Joint list to be B pile group approved pile foundation Inspection by prepared and drawings/specification. signed jointly ii) pile location Each pile IS:2911 & Joint list to be B approved pile foundation Inspection by prepared and drawings/specification. signed jointly iii) Temporary casing tube & Each pile IS:2911 & Joint Verticality of the B permanent liner also check approved pile foundation Inspection by tube to be thickness of liner material drawings/specification. checked (if applicable) iv) Bentonite slurry Each pile IS:2911 & Joint Records to be B (if applicable) approved pile foundation Inspection by kept by drawings/specification. for specific gravity of slurry v) Pile depth, level, size and Each pile IS:2911 & Joint Approval by A alignment approved pile foundation Inspection by drawings/specification. PAGE-8

10 Section : Foundation vi) Chipping of pile head Each pile IS:2911 & Joint Before concreting B approved pile foundation Inspection by pile cap, pile head drawings/specification. to be chipped off for concreting vii) Standard Penetration Test As per IS:2911 & Joint Records to be B approved pile foundation Inspection by kept by BOQ/ drawings/specification.. specification Approval by viii) Pile load testing As per IS:2911 & Joint Records to be B approved pile foundation Inspection by kept by BOQ/ drawings/specification.. specification Approval by ix) Anchor bolts if applicable a) Level,, centre to centre 100% on each Joint list to be B distance of bolts location approved pile foundation Inspection by prepared and drawings/specification. signed jointly b) Visual check for galvanising 100% on each Joint list to be B location approved pile foundation Inspection by prepared and drawings/specification. signed jointly 3) CONCRETING A) BATCHING, MIXING & 100% IS:456 and Joint Approval by B PLACING OF CONRETE approved drawings and Inspection by AND COMPACTING specifications. B) FIXING OF CHIMNEY 100% IS:456 and Joint Approval by C COLUMN approved drawings and Inspection by for Width/length, specifications. squareness, parallelism & equidistance from stub PAGE-9

11 Section : Foundation C) PLACING CONCRETE, 100% IS:456 and Joint Min. gap between C POKING AND approved drawings and Inspection by boxes and reinfor- COMPACTING specification. cement bars should be maintained. Approval by D) CONCRETE TESTING i) Slump Test One sample per IS:456, IS:516, IS:1199 Contractor Approval by B location and specification. ii) for quantities for 100% on all IS:456, IS:516, IS:1199 Contractor list to be B cement, fine aggregate, locations and prepared and coarse aggregate and water specification. signed jointly while batching E) CHECK FINISHING, 100% IS:456, IS:516, IS:1199 Contractor Approval by B DIMENSIONAL and CONFORMITY AND specification WORKMANSHIP BEFORE & AFTER BOX REMOVAL F) BACKFILLING 100% Contractor Approval by C i) for thickness of specification layer & watering ii) for compaction/ ramming G) COPING 100% on all Contractor Approval by B location Specification H) CURING 100% on all Contractor Approval by C location Specification I) EARTHING 100% IS:5613 and Contractor Approval by B (Pipe or counter poise type) Specification PAGE-10

12 Section : Foundation J) CONCRETE CUBE TESTING i) Compressive Strength a) One sample IS:1199, IS:456, IS:516 Approval by A for each and approved lab locations (One Specification Cubes must be sample consists tested within a of min. 3 test week after 28 cubes for 28 days curing days strength) period and test b) For pile results should be foundation one approved before sample for tower erection. each pile. ii) Compressive Strength for One sample for IS:1199, IS:456, IS:516 - DO - A concrete of pile cap, beams, every 20 Cum and approved lab chimney etc. of concrete or Specification part thereof for each days of concreting PAGE-11

13 Section : GENERAL GUIDELINES FOR IMPLEMENTATION 1. Details of categories of check codes A, B & C including accepting and deviation dispositioning authorities are indicated at Annexure-I. 2. specification shall mean technical specification, approved drawings/data sheets and A/T provisions applicable for the specific contract. 3. Acceptance criteria and permissible limits for certain tests are indicated at Annexure-II. For balance tests, site to verify the same with respect to specification, relevant Indian Standards and/or prevalent code of practice. 4. It is clarified that the tests indicated at column 2 of this FQP i.e. against column "Component operation & Description of Test," are only generally required to be conducted. However, reserves the right to carry-out any additional tests at any stage if the situation so warrants. 5. site representative shall witness all the tests conducted by the contractor as mentioned in this FQP. However, in case of tests conducted in the approved lab, it is preferred to witness the tests in the lab itself, if possible. 6. Head of Construction Division shall approve testing laboratory before accepting the test results from the lab. 7. Head of Construction Division shall approve the sources for cement, coarse aggregate, fine aggregate & water before actual utilisation. 8. All the testing & measuring equipments used by the contractor for testing are required to be calibrated. A copy of valid calibration report shall be retained by as records. 9. Classification of foundations shall be approved by based on the Joint Inspection Report & soil investigation reports. 10. Curing of concrete work should be continued for a minimum period of 10 days. 11. Zone-IV fine aggregate shall not be used for concreting work. PAGE-12

14 Section : GENERAL GUIDELINES FOR IMPLEMENTATION 12. CEMENT 12.1 In case supply of cement is in the scope of the contractor, the same shall be procured from sources approved by site and got tested at site on sample basis for specified acceptance tests as specified in this FQP at a reputed Third Party Lab approved by site The samples of cement for site testing shall be taken within three weeks of the delivery and all the tests shall be commenced within one week of sampling. 13. REINFORCEMENT STEEL 13.1 In case supply of reinforcement steel is in the scope of the contractor, the same shall be procured from the main producers i.e. SAIL, TISCO, IISCO or Rashtriya Ispat Nigam or the rerollers approved by main producers. The reinforcement steel shall be got tested at site on sample basis for specified acceptance tests as specified in this FQP at a reputed Third Party Lab approved by site The results of the testing of cement and reinforcement steel referred to in 13.1 and 14.1 above shall be got approved from site before cement and reinforcement steel are put to use. However, in exceptional cases due to exigencies of work., site may authorise the contractor to use Cement and Reinforcement Steel even before the test results are received. However, in all such cases, if the test results subsequently received are found to be not complying with the specified acceptance criteria, the contractor shall have to dismantle and recast all such foundations cast with such non-conforming materials at his own cost. Confirmation to this effect shall be obtained from the contractor by the Project authorities beforehand in all such cases. PAGE-13

15 ANNEXURE - I ACCEPTING AND DEVIATION DISPOSITIONG AUTHORITIES FOR DIFFERENT CATEGORIES OF CHECKS AS ENVISAGED IN FIELD QUALITY PLAN C ATEGORY TYPE OF 100% COUNTER CHECK/ ACCEPTING AUTHORITY, DEVIATION C H E C K CHECKING/ S U RVEILLANCE IF TEST RESULTS DISPOSITIONING WITNESSING BY CHECK BY ARE WITHIN AUTHORITY PERMISSIBLE LIMITS À' CRITICAL CONSTRUCTION CONSTRUCTION EE CONST. DN. SE(CIVIL) S/DN. DN. B' MAJOR CONSTRUCTION CONSTRUCTION EE CONST. DN. SE(CIVIL) S/DN. DN. `C' MINOR CONTRACTO R S CONSTRUCTION CONSTRUCTION DN. EE CONST. DN. RESENTATIVE S/DN. PAGE-14

16 ANNEXURE - II ACCEPTANCE CRITERIA AND PERMISSIBLE LIMITS FOR FOUNDATION MATERIALS & CONCRETE A) CEMENT : Description of the 33 Grade OPC 43 Grade PPC as per Low Heat tests as per IS:269 cement as IS:1489 Cement per IS:8112 (i) Fineness (Min.) 225 m 2 /kg 225 m 2 /kg 300 m 2 /kg 225 m 2 /kg (i) (ii) (iv) Compressive Strength (Min.) hours 160 kgf/cm 2 23 MPa 16 MPa 100 kgf/cm hours 220 kgf/cm 2 33 MPa 22 MPa 160 kgf/cm hours - 43 MPa 33 MPa 350 kgf/cm 2 Initial Setting Time (Minimum) 30 Minutes 30 Minutes 30 Minutes 30 Minutes Final Setting Time (Maximum) 600 Minutes 600 Minutes 600 Minutes 600 Minutes (v) Soundness Maximu m Maximu m Maximu m Maximu m (Le chatelier Method) 10mm 10mm 10mm 10mm expansion expansion expansion expansion (vi) Heat of hydration -- - Max. 65 cal/ (Max.) gm for 7 days & max. 75 cal/gm for 28 days (vi) Chemical Composition As per IS As per IS As per IS As per IS B) C OARSE AG G R E G ATE : (i) Sieve Analysis IS SIEVE DESIGNATION PERCENTAGE PASSING FOR GRADED AG G R E G ATE OF NOMINAL SIZE 40 mm 20 mm 40 mm 95 to mm 30 to to mm 10 to to mm 0 to 5 0 to 10 PAGE 1 OF 3 PAGE-15

17 ANNEXURE - II (i) Flakiness Index Not to exceed 25%. (ii) Crushing Value Not to exceed 45%. (iv) Soundness of aggregate Loss of weight after 5 cycle not to exceed 12% when tested with applicable for concrete works Sodium sulphate and 18% when tested with magnesium sulphate. subject to froast action (v) Deleterious material Not to exceed 5% of the weight of aggregate. (C) FINE AGGREGATE (i) Sieve Analysis Shall confirm to Zone I, Zone II or Zone III. IS Sieve designation Percentage Passing for Grading Grading Grading Grading Zone-I Zone-II Zone-III Zone-IV 10 mm mm mm mm Micron Micron Micron (i) For guidance of adjusting the quantity in mix of concrete, the following table may be used. Moisture Content % Bulking % by volume (ii) Silt content Test : Shall not exceed 8%. (iv) Deleterious Materials : Total deleterious material shall not be more than 5% by weight. (D) REINFORCEMENT STEEL : As per relevant Indian Standards PAGE-16 PAGE 2 OF 3

18 ANNEXURE - II (E) CONCRETE CUBE TEST For nominal (volumetric) concrete mixes, compressive strength for 1:1½:3 (cement : sand : Coarse aggregate) concrete shall be 265 kg/cm 2 for 28 days and for 1:2:4 nominal mix, it shall be 210kg/cm 2. (F) ACCEPTANCE CRITERIA BASED ON 28 DAYS COMPRESSIVE STRENGTH FOR NOMINAL MIX CONCRETE a) The average of the strength of three specimen be accepted as the compressive strength of the concrete, provided the strength of any individual cube shall neither be less than 70% nor higher than 130% of the specified strength. b) If the actual average strength of accepted sample exceeds specified strength by more than 30%, the Engineer-in-charge, if he so desires, may further investigate the matter. However, if the strength of any individual cube exceeds more than 30% of specified strength, it will be restricted to 30% only for computation of strength. c) If the actual average strength of accepted sample is equal to or higher than specified strength upto 30%, then strength of the concrete shall be considered in order and the concrete shall be accepted at ful rates. d) If the actual average strength of accepted sample is less than specified strength but not less than 70% of the specified strength, the concrete may be accepted at reduced rate at the discretion of Engineer-in-Charge. e) If the actual average strength of accepted sample is less than 70% of specified strength, the Engineerin-Charge shall reject the defective portion of work represented by sample and nothing shall be paid for the rejected work. Remedial measures necessary to retain the structure shall be taken at the risk and cost of contractor. If, however, the Engineer-in-Charge so desires, he may order additional tests to be carried out to ascertain if the structure can be retained. All the charges in connection with these additional tests shall be borne by the Contractor. (G) ACCEPTANCE CRITERIA FOR DESIGN MIX CONCRETE SHALL BE AS PER IS:456 PAGE 3 OF 3 PAGE-17