Report On

Method of Statement for Floor Construction by

Vacum Dewatering System.

Project: CONSTRUCTION OF ELECTRIC LOCOMOTIVE

FACTORY, DANKUNI
Client:

Contractor:

Simplex Infrastructures Limited

Report Issue Status

Issue Date Description Prepared by

<01> November18,2013 Method of Statement for Floor Construction P.K.PARIDA
by Vacum Dewatering System.

SIMPLEX. QA/QC

Certified that Report is in Conformity to Contractual and Codal Provisions.

Somnath Guchhait
Project Manager
SIMPLEX INFRASTRUCTURES LIMITED.

Checked by Reviewed by Approved Accepted

by by

QA/QC RESIDENT.ENGG. PM/PMC AM/ RVNL JGM(P) RVNL

EXPORT/PMC CIVIL./PMC
PURPOSE

The purpose of this procedure is to ensure that Floor Construction by Vacum dewatering system
and related activities are executed in accordance with the contract requirements, safety procedures,
implemented with all quality assurance / control activities are conducted in a systematic manner,
works inspected and documented.
Scope:-
The Scope of this Segmental Methodology shall covers the Concrete mixdesign,
workmanship,equipments,accessories, cement,admixture,water, in accordance with the requirement
of contract document,RVNL Specifications and in conformity with the control of alignment as
shown in approved drawings.
The Procedure is applicable only for Work Shop , Sub-Station Howrah end,Sub-
Station Delhi end,Store Building and as per approved drawings.
It covers the following activities:

>Selection, Testing and Acceptance of all incorporated Materials.

>Design Mixes for Pile Acceptance etc.

>Details of Plant, Equipment / Machinery as required in execution of pile

>Batching, Mixing, Transporting, and Placing Concrete for pile

> Control of alignment,use of drilling mud and cleaning of bore hole.

>Quality Assurance and Control Checks during exucation of work.

> Materials like cement,coarse & fine aggregate,water,reinforcement with aunty corrosive
treatment,cover block,,lapping,welding,spacing,supporting,
bending
The following abbreviation shall have the meaning as set forth below:
> ACI 302.1R and its Ref no:36 and 37
>BIS: Bureau of Indian standards
>QA: Quality Assurance Manufactures Test Certificate >Contract
Document ,Approved Drawings,Technical Specifications of RVNL & its References .

Responsibility:-
Sl.No. Activity Description Performing Checking/ Approving
Verifying
1 Preparation of Quality Section In- Works Manager Project
Plan charge & QC & QA/QC
Engineer. In charge manager

2 Selection and Testing of Section In- Works Manager Project

Various materials for charge & QC & QA/QC
VDF and Mix Design Engineer. In charge manager
prior to start activity

3 Survey,Setting out of Surveyor Section-in- Engineer

point prior to start work charge / Site
Engineer
4 All Machinery Section In- Works Project
deployment at various charge/Site In Manager
locations and other charge manager
logistics managements
etc.
5 Batching & Mixing of QA/QC QC Engineer / -
concrete as per approved In charge Lab
Design mix
technician
6 Control of movement of Site engineer/ Section-in- Works Manager
all equipments during Supervisor charge / Site
Operation.
Engineer
7 Transportation and Section In- QC Engineer / Engineer
Placing of Concrete. charge/Site In Lab
charge
technician
8 Sampling and QA/QC In QC Manager / Project
workability check of charge/ Lab. QC Engineer manager
Concrete Technician
9 Inspection & Testing of QA/QC In QC Manager / Engineer
all materials as per charge/ Lab. QC Engineer
approved QAP and Technician
maintaining all formats

Benefit

Physical properties of the slab produced should be superior to those of untreated ones in
that
.Compressive and flexural strengths are higher by about 20 to 50 percent .
.Shrinkage is lower ,permitting use of fewer joints
.Wear resistance is greater.
.Concrete is dense and water tight .
. Resistance to damage by freezing is higher
EQUIPMENTS:

The Equipments involved in the works in details are listed below:

1)Vacum Pump unit:- The vacum unit consists of a pump,a water collecting tank for the
extracted water,a filter and control unity with capable of (reaching a vacum of at least 0.8
atmosphere/80 percent of maximum possible vacum)8000-10000 kg force per square meter,which
is equivalent to 588.447 to 735.559 mm/hg. All this is generally assembled on a common frame
with pneumatic wheels.

2) Double Beam Screed vibrator.

3) Cover mat/Suction mat.: Easier to seal /water tight against the concrete than plates.
4) Filter Pad
5)Power trowel.
6)Batching Plant
7) Transits Mixer

APPROACH ,WORKING PLATFORM & FORM WORK:The Contractor shall arrange all
approaches, scaffolding, working platforms etc. for carrying out the entire operation safely and in a
work-man-like manner. The working area shall be nearly maintained and all the facilities required
by the Engineer-in-Charge for proper supervision of the work shall be provided.

Setting of Forms.(Steel or Wooden)

The forms shall be jointed neatly and shall be set with exactness to be required grade and alignment
.Both before and after the forms are placed and set, it shall be throughly fixed/tamped in an
approved manner. Sufficient rigidity shall be obtained to support the forms in such a position that
during the entire operation of compacting and finishing of concrete they shall not at any time
deviate more than specified. The length and number of stakes shall be such as to maintain the forms
at the correct line and grade. All forms shall be cleaned and oiled each time before they are used.
Forms shall be sent ahead of the actual placing of concrete for the entire day of work.

SPECIAL REQUIREMENT:
All works covered by this specification shall be carried out by an experienced agency having
sufficient expertise in vacuum dewatering concrete system. Only skilled and experienced operators
shall be employed for the purpose. All the equipment shall be of approved and proven types and
suitable for the work involved.The work shall be planned and exucated so that there is no delay
between the placement,screeding,dewatering and floating of the concrete .
 Fig:Concrete is placed and Vibrated

PROCEDURE:
The concrete is placed (Grade of Concrete M25,having workability of 75-100mm) on the clean
surface and it is vibrated with immersion vibrators .It is then leveled ,and vibrated with a double
beam vibrating screed which works with the form edges above the concrete. The evenness of the
concrete surface is entirely dependent on the proper level of the form edges.

Fig:Suction / Filter mat is covered and concrete is dewatered

The concrete surface is immediately covered with the suction mat and vacum dewatering is begun.
The duration of the treatment should be about 10 to 12 minutes(1min.per centimeter).
A filter pad is being placed with the top cover in position. The pump unit ,with its water
collecting tank on top,has been connected to this top cover.

After the dewatering has been finished the mat is moved to a fresh surface. It is already possible to
walk on the concrete if necessary and the dewatered surface is immediately floated with a power
trowel fitted with a planing disc. Workers do not walk on the concrete unnecessarily.
After another period of time -30 to 90 minutes – final troweling can be done using a power trowel
with blades. The time required from the placing of the concrete till the finishing of the surface is
thus 60 to 150 minutes depending on the surface finish required and the weather.
Finishing :
The surface of the vacum -treated concrete is finished in two stages by machine for smoother
surface .For the first the planning disc easily moves concrete from higher to lower sutface areas
and leaves a flat surface.After another period of time -30 to 90 minutes (before the concrete is hard
enough to support a machine with troweling blades)final troweling can be done using a power
trowel fitted with blades .

Curing.
After completion of the finishing operations,the surface of the pavement shall be entirely covered
with wet Hessian cloth ,burlap,or jute mats. The coverings used shall be of such length (or width)
that when laid will extend at least 500 mm beyond the edges of the floor slab,shall be so placed that
the entire surface and placed as soon as the concrete has set sufficiently to prevent marring of the
surface. Prior to their being placed ,the covering shall be throughly wetted with water and placed
with the wettest side down. They shall be sufficiently heavy so as to cause them to remain in
intimate contact with the surface covered. To maintain the coverings wet,water shall be gently
sprayed so as to avoid damage to the fresh concrete. Water curing shall be done for a minimum
period of 14 days.

Removal of Forms :
Forms shall be removed only after the concrete has set for at least 12 hours. They shall be carefully
removed without causing damage to edge of the slab.
General Safety
The Site Manager, will have overall responsibility for safety.
As the construction area will be isolated and fenced. All site visitors within the
construction areas will be accompanied by a member of the Site Team. Suitable barricades and sign
boards shall be erected and maintained and watchmen employed to exclude traffic from the newly
constructed pavement and these barriers shall be so arranged as not in any way to interfere with or
impede traffic on any lane intended to be kept open and necessary signs and light shall be
maintained clearly indicating any lines open to the Traffic/local bodies.