KEC INTERNATIONAL LIMITED

Document Name Work Instructions

Document Title Foundation Methodology

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Document No. KEC_PE_0016 VERSION: - 1 Date 15 September 2020

SOP on Foundation Activity in Transmission Line

Gaurav Bhaskar Dhiraj Rajinder

Chugh Sarathy Vashisth Gupta

Name Sign Name Sign Name Sign Name Sign

Prepared By Reviewed By Approved By

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Document Title Foundation Methodology

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Document No. KEC_PE_0016 VERSION: - 1 Date 15 September 2020

Contents
1. Objective ....................................................................................................................................... 3
2. Scope ............................................................................................................................................. 3
3. References ..................................................................................................................................... 3
4. Acronyms ...................................................................................................................................... 4
5. Roles and Responsibility: .............................................................................................................. 4
6. Standard Machines and Tools: ..................................................................................................... 5
7. Tower Foundation –PPE Matrix .................................................................................................... 6
8. Flow Chart: Tower Foundation Activity: ....................................................................................... 7
9. Flow Chart: Selection of Workman and Tools & Tackles .............................................................. 8
10. Pre Operational Checks ................................................................................................................ 9
I. Excavation by blasting method.............................................................................. 10
II. Shoring, Benching and Sloping types.................................................................... 12
III. Well Point Requirement: (Exceptional Case) ..................................................... 12
11. Operational Procedure: .............................................................................................................. 13
A. Pit Marking ............................................................................................................ 13
B. Excavation ............................................................................................................ 14
C. Excavation in Unequal Ground Level................................................................. 15
D. Well Point Requirement: (Exceptional Case) ..................................................... 15
E. PCC (Plain Cement Concrete) .............................................................................. 16
F. Stub setting by Template and Prop Setting ........................................................... 17
G. Reinforcement Rod Binding ............................................................................... 19
H. Formwork and Shuttering .................................................................................. 20
I. Concreting ............................................................................................................ 21
12. Form Box Removal / Curing / Backfilling ................................................................................... 36
13. Post Operational Checks ............................................................................................................. 37
14. Checklist, Records, Permits and Other Requirements ................................................................ 37
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Document Title Foundation Methodology

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Document No. KEC_PE_0016 VERSION: - 1 Date 15 September 2020

1. Objective
To establish the procedures for Foundation and concreting activities for tower locations in
Transmission Line Projects

2. Scope
This SOP is applicable in all KEC projects and shall be followed by all KEC Employees, Sub-
contractors and their employees.

This SOP is applicable to all configurations of A/C & D/C Transmission tower foundations

 Type A – Suspension tower – 0 degrees

 Type B – Angle tower – 0 to 15 degrees

 Type C – Angle tower – 15 to 30 degrees

 Type D –Angle & Dead end tower – 30 to 60 degrees and dead end

3. References
A. QMS Work Procedure

B. HSE Manual

C. Electricity Act 2003 and Electricity Rule 2005

D. IS 3764: 1992 Excavation Works – Code of Safety

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Document No. KEC_PE_0016 VERSION: - 1 Date 15 September 2020

4. Acronyms

Acronyms Full Form

SOP Safe Operating Procedure
QMS Quality Management System
PTW Permit to Work
KV Kilo Volt
EHS Environment, Health & Safety
T&P Tools and Plants
BOCW Act Building and Other Construction Workers Act
HT High Tension
LT Low Tension
S/C Single Circuit
D/C Double Circuit
M/C Multi Circuit
IS International Standard
PPE Personal Protective Equipment
PCC Plain Cement Concrete
RCC Reinforced Cement Concrete
SST Stub Setting Template
FRP Fiberglass Reinforced Plastic

5. Roles and Responsibility:


A. Primary Responsibility : Site Supervisor, Section Incharge and Construction Manager
B. Secondary Responsibility : Project Manager
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6. Standard Machines and Tools:

Mobile Excavator Crawler Self Loader Concrete Mixer

Screwed Jack Stub Setting Template Vibrator with Needle

Spade Shovel Rebar Tying Machine

Water Tanker Metal Ladder Prop Setting Pipes

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Tractor with Trolley Under Ground Utility Detector Chop Saw Cutter

7. Tower Foundation –PPE Matrix

PPE MATRIX
Pit RCC
PCC Stub Bar Chimney
PPE List Survey Marking & Concretin Earthing Curing Backfilling
Concreting Setting Binding concreting
Excavation g
Safety Helmet
Safety Shoes
Gumboot
Nose mask
Thermo Latex Hand Gloves
PVC Hand Gloves
Goggles
Full Body Harness
Ear Muf/ Ear Plug
Shoulder Pad
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8. Flow Chart: Tower Foundation Activity:

PIT MARKING

EXCAVATION TO APPROVED DEPTH

PCC (PLAIN CEMENT CONCRETE)

STUB SETTING USING TEMPLATE / PROPS

REINFORCEMENT STEEL FIXING

EARTH STRIP FIXING

FORM WORK / SHUTTERING

RCC (REINFORCED CEMENT CONCRETE)

CURING

DESHUTTERING

BACKFILLING
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9. Flow Chart: Selection of Workman and Tools & Tackles

SELECTION OF MANPOWER

SUB CONTRACTOR WITH REQUISITE KNOWLEDGE AND EXPERIENCE

SCREENING OF WORKMEN

TL SAFETY INDUCTION TRAINING

VIRTUAL REALITY TRAINING

PREMEDICAL CHECK UP FOR WORKMEN

ISSUE OF SAFETY INDUCTION CARD

ISSUE OF PPE AT STORE

SHIFT THE MATERIAL FROM STORE TO SITE

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10. Pre Operational Checks

A. Ensure screening of all workmen is done by Time office / EHS Officer / Site engineer.
B. Safety Induction should be imparted by the Site Engineer and EHSO before engaging
them on the job.
C. Check adequate PPE / Manpower / Emergency vehicle / First Aid kit / Tools and
plants are available at site.
D. No visitor is allowed near the vicinity of work.
E. Ensure before excavation, that the area of work is checked by UG utility detector for
the presence of any Under Ground utilities and take necessary precautions.





Trial Pit UG Utility Detector

F. In case of working within city limits, excavation clearance permit should be
obtained from the concerned authorities before excavation. (Wherever applicable)
G. Ensure that the machines have valid registration and fitness certificates. (Equipment
fitness report for vehicle & earth moving equipment)
H. Valid driving licenses of the vehicle drivers.
I. Ensure the vehicle speed is low while approaching to site
J. Before excavating, soil classification test shall be conducted to classify the soil type
as per the standard requirement. This will help in deciding the angle of repose
(slope).
K. As per the foundation classification (DRY, WET, DFR, FS, PS, and WBC) and type of
tower, pit marking shall be done.
L. As per the foundation classification (DRY, WET, DFR, FS, PS, and WBC) and type of
tower, pit marking shall be done.
M. Rigid ladder made of FRP / Steel should be used for easy ingress / egress into the
excavated pit. No bamboo ladder is permitted.
N. Ensure excavated pits are properly barricaded and caution boards are displayed in
local language.
O. Adequate line clearance is to be maintained while working near live lines.
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Voltage Clearance above

(kV) ground (m)

Up to 11 4.6
33 5.1
66 5.49
132 6.1
220 7.015
400 8.84
765 12.24
800 12.48

Clearance above Ground level

I. Excavation by blasting method

a) Ensure all blasting operation shall be carried out by Licensed blaster and all
safety precautions have been taken.
b) Be aware of free boulders movement on hilly terrain.
c) Control blasting procedure shall be adopted while working near existing
transmission lines, villages, houses or any structure which can be impacted by
the blast.
d) Ensure contractor possesses all the relevant forms as mentioned in The
Explosives Act and Rules.
e) Ensure a contractor is having Licensed Shot Firer’s (Form no. 30) check its
validity.
f) Ensure blasting shall not be done during thunderstorm / lightning.
g) Ensure Explosives & Detonators are transported separately.
h) Ensure Explosives & blasting caps are stored in separate place.
i) Ensure no metal tools shall be used during blasting process.
j) Ensure not to carry blasting cap in pockets.
k) Ensure not to load any hole other than required.
l) Ensure nose mask, Goggles, ear muff, Gloves are worn by Rock drillers while
drilling the hole.
m) Ensure that control blasting is done to prevent flying of rocks.
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II. Shoring, Benching and Sloping types

a) Sloping, Benching and Shoring shall be provided during excavation where
ever the possibility of soil collapse exists or the water table is high. Where
the water is stagnant dewatering shall be done.
b) Check the water table and surface water level.
c) Ensure the presence of dewatering pumps along with appropriate hose
length.

Shoring Sloping Benching

III. Well Point Requirement: (Exceptional Case)

a) In case of presence of ground water at the level of excavation, dewatering
to be done by well point method to lower the water table to a level below
that to which excavation is to be made. The dewatering technique can be
as shown in the sketch.
b) A typical Well Point system consists of a series of small diameters wells
(known as well points) connected via a header pipe, to the suction side of a
suitable WellPoint pump. The pump creates a vacuum in the header pipe,
drawing water up out of the ground.
c) Well Point are typically installed in lines or rings around the excavation, and
are pumped by diesel pumps, with associated header mains, water
discharge pipes
d) Well Point have the advantage of being able to be installed in most ground
conditions as well as being easy to maintain.
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e) Geo technical investigation data should be collected and position of subsoil

water should be known.
f) Before beginning the dewatering operation, the well point system should
be checked for its leak-proof.
g) Always provide each well point with a stop cock so that the individual well
points can be connected or disconnected from the network.
h) Provide a solid base to the pump.
i) Well point connections to pump shall be decided based on site conditions.
j) Awareness regarding nearby the canals/ river shall help in deciding suitable
dewatering measures.
11. Operational Procedure:
A. Refer the flow chart section for the sequence of sub activities. Below is the description
of individual sub activity.

A. Pit Marking

a) Pit Making is the first and foremost important part of tower foundation. Pit
marking is done only after the soil classification approval for type of casting
done. Pit Marking is calculated using foundation drawings duly approved by
client.
b) A typical pit marking calculation is shown below

PIT MARKING CHART

PIT MARKING CALCULATION
A B C
B = M (B/B of Pit Centre)
C = M+P (Pit Size)
M
A = C/2
D = P*√2+C, Where P = Pit Size
D E = A*√2+C

O,E

PIT SIZE
P
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B. Excavation

a) Ensure that all excavation shall be carried out as per the approved drawing
b) Check for any HT / LT lines if present Line Clearance shut down shall be
obtained
c) Ensure angle of repose or slope is maintained depending on the soil type


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

c) Ensure the stacking of the excavated soil
shall be stored at safe distance from the
pit
d) Ensure the heap of the stacking shall not
exceed 1.8 m. Ensure shoring done on
water logged / soil. Check whether the
shoring components are good enough to
withstand the pressure of the load
e) In sandy area please ensure that all the
workmen are using Dust Hood Mask

C. Excavation in Unequal Ground Level

a) The depth of actual excavation at the pit centre is measured with reference
to the ground level at the centre of the tower location.
b) A typical example of determining the actual depth of excavation of the pits
is shown below.

D. Well Point Requirement: (Exceptional Case)

a) In case of presence of ground water at the level of excavation, dewatering to

be done by well point method to lower the water table to a level below that
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Document No. KEC_PE_0016 VERSION: - 1 Date 15 September 2020

to which excavation is to be made. The dewatering technique can be as

shown in the sketch
b) A typical WellPoint system consists of a series of small diameters wells
(known as well points) connected via a header pipe, to the suction side of
a suitable WellPoint pump. The pump creates a vacuum in the header
pipe, drawing water up out of the ground

c) WellPoint are typically installed in lines or rings around the excavation,

and are pumped by diesel pumps, with associated header mains, water
discharge pipes.
d) WellPoint have the advantage of being able to be installed in most
ground conditions as well as being easy to maintain

e) Geo technical investigation data should be collected and position of

subsoil water should be known.
f) Before beginning the dewatering operation, the well point system should
be checked for its leak-proof.
g) Always provide each well point with a stop cock so that the individual well
points can be connected or disconnected from the network.
h) Provide a solid base to the pump.
i) Well point connections to pump shall be decided based on site
conditions.
j) Awareness regarding nearby the canals/ river shall help in deciding
suitable dewatering measures.


E. PCC (Plain Cement Concrete)

a) Plain cement concrete (PCC) is generally used for providing a non-porous,

firm and level space for laying RCC. Generally M10 grade concrete is used
for PCC in Tower Foundation with a ration of Cement: Fine Aggregate :
Coarse aggregate ([Link])
b) Concrete pouring shall be done as per the prescribed procedure.
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F. Stub setting by Template and Prop Setting

a) In general, Template shall be used in all locations for Stub setting. In Special
cases like Special Towers, RC Towers, Hilly Terrains, Water logged areas,
Sandy Soil where template setting is not feasible, stub setting using props
May be preferred
b) Stub Setting Template Method

i. A stub setting template is a specific tool for a type, design & make of
tower. It is a light rigid steel framework and is used to hold the tower
stubs at the correct alignment and slope during the concreting work. The
template is adjustable type which can suit the standard tower as well as
towers with standard extensions.
ii. The template is lifted and placed on jacks. Eight jacks are used, two for
each corner of the template. The jacks are supported on sleepers which
are placed across the pits so that the load of the template is distributed
away from the excavated pits. The lengths of the sides and diagonals of
the template are measured. These are compared with those given in the
drawing and corrected as required.
iii. The template is centered on the location with the help of the plumb lines.
The template is levelled and the height of the base of the template above
ground level is kept.
iv. The stubs are then fixed on the legs of the template. The distance
between the end of the stub and the base of the pit is checked with
reference to the foundation drawing. If the distance is less, then the pit is
accordingly excavated. In case the distance is more, the extra excavation
is filled with lean concrete of 1 : 3 : 6 mix and allowed to set before
further activities are taken up. Never use sand to fill the extra excavation
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v. Ensure the person shall take precautions from pinch / shear injury while
handling jack
vi. Ensure the workman wears full body harness while working on chimney
box.
vii. During Prop setting, check the condition of ground level for firmness and
rigidity. Anchoring shall be done on ground if required.
viii. Ensure stubs are supported by Pipes / Angles to prevent accidental fall of
stub on workmen inside the pit.
ix. Use ladder wherever the height of fall could be more than 1.5 m

x. A Typical Prop Setting drawing and slope calculation using this drawing is
shown below for reference.
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 Slope (X) = Tanά x SL x √2)

Development
 Where SL = Stub Length and Calculation of development is as:
 Development = √(Tanά² + Tanά² + 1)

G. Reinforcement Rod Binding

a) Sufficient Electrical clearance shall be maintained while handling the rebar

assemblies.
b) Place all bar binding wires gently inside the reinforcement cage. Do not drop the
bar binding wires from the top of the pit.
c) Cover block to be provided below the rebar matrix so that concrete may flow
underneath the rebar. In order to prevent corrosion of the rebar, it needs to be
fully encased in concrete. By code, it usually needs about 2 to 3 inches of
coverage on all sides.
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d) Provide chair rods for reinforcement as per drawing to avoid deflection of the
top reinforcement.
e) Ensure that any workmen is not alone in excavated pit

f) Battery operated Rebar Tying machine shall be used for tying of rebar joints.
Advantages of rebar tying machine is mentioned below.

i. Slab tying time can be reduced up to three

times by which we can speed up our
construction.
ii. Manpower can be optimized as time is
saved.
iii. Musculoskeletal disorder, Ergonomic
risks, hand pain can be reduced.
iv. The cut length binding wires are wasted
due to falling form the bundles.

H. Formwork and Shuttering

a) Form box are made out of M. S. Sheets having adequate thickness so as to be

rigid during the placing of the concrete. The chimney and pyramid portions are
adequately braced to retain proper shape while concreting. To avoid
honeycombs in the concrete, the form box shall be sufficiently tightened to
prevent cement slurry from coming out.
b) Form box of the shape, size and dimensions for the individual type and make of
tower as per approved foundation design and drawing are to be used.
c) Adequate quantity of form box for all types of towers, particularly suspension
towers for the Project shall be fabricated so that work can be carried out
simultaneously at various locations to achieve desired progress.

d) Ensure sufficient manpower is engaged for shifting the formwork and shuttering
materials as per the resource plan.
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e) Check all the shuttering supports for rigidity.

f) Erect scaffold or platform for storing of materials and supporting the workmen
working at height

I. Concreting

a) General Preliminaries:

i. All wet locations must be kept completely dewatered both during the
placing of the concrete and for 24 hours after completion. There should
be no disturbance to concrete by water during this period. All
arrangement for dewatering shall be made before starting the work of
concreting.
ii. The base pad of required depth as per foundation drawing is then placed
using the specified concrete mix and allowed to set.
iii. In case of RCC type foundation, the cover of 50 mm shall be provided all
around between the reinforcement steel and the sides of the frustum /
chimney

b) Step Type RCC Foundation:

iv. The steel reinforcement shall be placed on the pad as per the design and
the bar bending schedule.
v. The shuttering for the first step of the foundation is first placed on the
pad and concrete is poured within the shuttering. After pouring of every
150 mm of concrete, vibrator is used for proper compaction.
vi. The above procedure is repeated for all the steps of the foundations one
by one till the chimney level is reached.

c) Casting of Chimney (Common Procedure):

i. After the frustum part is poured, the earthing connection is fitted on the
designated stub / stubs. Earthing is provided on Leg 1. Additional
earthing, if required, is provided on Leg 3. Counterpoise earthing is
provided on all legs.
ii. The chimney portion of the form box is fitted on the frustum. The
earthing connection is passed through the joint of the two parts of the
chimney. The chimney is centered and fixed so that equal spacing from
the stub is available all around. The chimney is bolted to the frustum
portion and slurry of sand and water is applied at the joints to prevent
leakage of cement slurry.
iii. The concrete is then poured into the chimney portion. After pouring of
every 450 mm of concrete, poking rod or vibrator is used to avoid voids in
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the concrete. The chimney is filled up to the level shown in the

foundation drawing.
iv. Coping to be done as per approved foundation drawing.

v. Procedure for casting of Cubes: It should be filled in 50 mm layers and

compacted, with a steel tamping bar, with a minimum of 35 tamps per
layer for a 100 or 150 mm mould respectively. After tamping each layer,
the mould should be lifted slightly and dropped or the sides tapped, to
close the top surface of each layer.

vi. Testing of the concrete is to be got done as specified in the Standard Field
Quality Plan (SFQP) annexed with the work order. Samples of the
concrete in form of concrete cubes of size 150*150*150 shall be taken as
per the requirements and procedures given therein

d) Precautions to be taken during Concreting Works:

i. All construction materials should be stacked at a safe distance away from

the excavation pit.
ii. The form boxes should be properly cleaned and oiled before using for
concreting
iii. Keep the Self Loader Mixer machine 1.5 m. away from the edge of pit.
iv. Use a stable metal chute for withstanding concrete capacity.
v. Ensure reverse horn is functioning on self-loader and other moving
vehicles.
vi. Self-loader should not travel more than 10 km / hr. while working at site.
vii. Ensure that signal man is engaged to guide truck when it is reversing

e) Concreting through RMC (Ready Mix Concrete)

i. Ready Mix Concrete (RMC) allows speedy construction through

programmed delivery at site, mechanized operation with consequent
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economy and reduces the labor cost.

ii. RMC comes with consistency in quality through accurate & computerized
control of sand aggregates and water as per mix designs

The following points are checked for Concreting through RMC:

f) Material Storage and Handling

i. All the materials required for RMC should be stored in such a way as to
prevent the risk of contamination. Different materials shall be stored
separately by taking due precautions and care, to avoid intermixing.
ii. For storage of cement and aggregates the instructions given in IS 4082
should be followed.
iii. Stock piles should be arranged in such a way so as to prevent
intermingling of adjacent materials. Different size fractions of aggregate
(say 10-20 mm, below 10 mm) should be stored separately. Coarse and
fine aggregate may be of different types and from different sources, and
accordingly these should be separately stored. (Picture below for
reference)

iv. For better performance & quality, storage bins must be used to store
materials. Open stock-piles are prone to contamination & there is no
control over moisture content during wet season. Moisture probe can
effectively measure water content of the aggregates.
v. The handling procedures of loading and unloading aggregate should be
such as to reduce the segregation to minimum. This can be done by using
rock ladders below the conveyor belts
vi. The RMC manufacturer shall ensure suitable transfer & feed systems.
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vii. Various aspects to be looked into for material storage and handling are
listed in the check list for this item.

g) Batching and Mixing Control Equipments

i. The Batching and Mixing control equipment’s consists of Scales; weigh

Batchers/ Dispensers; batcher controls; recorders and the Central Mixer.
ii. Batching control should be such that process identification at every stage
and back traceability (later on) can be ensured. It is always desirable to
have automation in batching process and its control. Preferably a SCADA
system shall be installed. SCADA is Supervisory control and data
acquisition, is a type of industrial control system for monitoring and
control industrial processes that exist in physical world. Similarly it should
be ensured that the computer printouts are taken for every batch and
proper record shall be kept.

Computer controlled system Batch mixer control

iii. Additionally, for concrete of Road and Bridge work the guidelines given in
section 1707, 1708.1 and 1708.2 of MORT &H specifications published by
IRC (Fifth revision) 2013 as given in references in Annexure I shall be
referred to.
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iv. A well-documented inspection and calibration/recalibration systems and

procedure for the plant and all other requirement shall be prevalent. The
record should maintain regularly and be available during inspection and
submitted to the concerned authorities.

h) Batching Controls

i. Batching controls are the part of the batching equipment that provides
means for operating batching device for an individual material. They may
be mechanical, hydraulic, pneumatic, electrical, etc. or a combination of
these means. A batching system is a combination of batching devices and
batching controls necessary for the accurate and consistent batching of
concrete ingredients in the desired proportions.
ii. Normally, a batching system would include batching devices and controls
for cementitious materials, aggregates, water, and admixtures. Adequate
dosing outlets must be available for different admixtures & fibers. High
strength concrete with silica fume will need at least four outlets.

Paddles of Twin shaft mixer Turbo Pan Mixer

i) System Requirements

i. Automatic System: A combination of the necessary individual weigh-

batchers and volumetric batching devices (for water & admixture), the
controls of which are all automatic
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ii. Various items to be checked during inspection of Batching and Mixing

control equipment’s are listed in the Check list for this item

Tilting mixer’s in batching plant Batching weighments control

and weights

j) Mixing

i. The mixer capacity and performance must be commensurate with the

plant design. Type of mixer does not matter as long as it can deliver
properly mixed concrete. There are basically three types of mixers.

1. Drum Mixers- Which can be further classified as

a) Tilting Type. 0.25 to 4.5 cum capacity
b) Non-Tilting Type. 0.5 to 3.0 cum capacity
c) Reversible Type. 1.0 to 6.0 cum capacity.

2. Pan Mixers- These are further classified as

a) Planetary Counter Current Mixers. 0.25 to 4.5 cum capacity
b) Turbine Pan Mixers. 0.25 to 6.0 cum capacity

3. Twin Shaft Mixers 1.5 to 4.5 Cum capacity

k) Transport of Concrete
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i. Ready Mixed Concrete shall be transported from the mixer to the point of
placing as rapidly as possible and practicable by methods that will
maintain the workability and will prevent segregation loss of any
constituents or ingress of water or foreign matter. The concrete then
shall be placed as soon as possible after delivery.

Transit mixer for transport of concrete

ii. It shall always be emphasized that concrete should be laid in the position
without any loss of time to avoid reduction in workability, setting and
stiffening of concrete. This aspect becomes very critical in case of Ready
Mixed Concrete where the time interval in between mixing and placing of
concrete is considerable. As concrete stiffens with passage of time, delay
in placement of concrete reduces workability of concrete. In addition,
after some time setting of concretes may also take place.
iii. Reduction in workability may lead to difficulty in placement of concrete.
Thus, while planning for use of Ready Mixed Concrete, the aspect of loss
of workability in the likely transit time involved should be taken into
account. By measuring slump/ compacting factor immediately after
mixing at RMC plant and after a lapse of predetermined time (i.e.
anticipated average transit time), loss of workability may be estimated.
Desired workability at the time of delivery should be clearly specified in
the specification or tender conditions.
iv. The ticketing system is given in Annexure ‘G’ of IS 4926 shall be referred.
The producer shall ensure that a proper delivery ticket is issued which
should contain quantity of concrete loaded, the raw material content of
the concrete mix, time of delivery from mixer, truck/lorry number,
signature of Plant operator etc. The standard proforma as given in
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Annexure B shall be filled and given to driver of truck/lorry who will hand
over the same to the supervisor in charge of site. The delivery ticket will
form the basis of invoicing.
v. The transport of RMC to site shall be by transit mixer and agitators. They
shall confirm to IS 5892
vi. Before the delivery of concrete produced in Ready Mixed Plant/ captive
Batching Plant it is the responsibility of the producer to ensure that each
truck mixer is inspected to confirm its compliance with the requirements
given in check list of this section.

l) Transit Time and Placement Time of Concrete

i. The concrete shall be delivered at the site of work and discharge shall be
completed with-in Two hours of adding mixing water to the dry mix of
cement and aggregate
ii. Concrete received after the transit time, as specified above, shall not be
accepted. (Specify the transit time limit by deducting anticipated time
required for placement of concrete from initial setting time specified in
approved Mix proportion (Design mix)).
iii. Concrete, thereafter, shall be placed in position with-in the designed
initial setting time. At the end of initial setting time, the left-over portion
of concrete, if any, shall be rejected

Delivery of concrete from transit mixer Discharge of concrete from

transit mixer

m) Re-tempering with Water

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i. Under any circumstances addition of any water shall not be allowed after
the initial mixing of concrete, as re-tempering will reduce the
compressive strength of concrete.

n) Re-tempering with Chemical Admixture

i. Re-tempering of mix is permitted only by adding plasticizer in two

installments. The first application is at the plant & second application
after the transit mixer reaches the site & before the concrete is unloaded.
The two applications and their respective quantities is part of the mix
design and must be done while designing the mix along with field trials to
confirm the dosages

o) Pumping of RMC

i. The RMC can be placed into position by using pump, in such case it is a
pump able concrete. Similarly, the RMC can be placed by using other
methods such as buckets, cradles, conveyor belts; chutes etc. in such case
the RMC will be non- pumpable. However most of the RMC nowadays is a
pumpable concrete. Hence detail information about mix proportioning,
types of pumps, pumping pressures, formwork and its stability,
compaction methods is necessary for the quality concrete.

TRANSPORT OF CONCRETE
TICKETING SYSTEM

(A) The delivery ticket should contain the following information

1 Name of Work
2 Location of Plant
3 Serial No. of ticket
4 Delivery date
5 Truck No.
6 Name and location of the site
7 Grade of concrete or mix description of concrete
8 Cement content (if specified)
9 Type of cement and Grade (if specified)
10 Nominal maximum size of aggregate
11 Type or name of chemical admixtures included
12 Type or name of mineral admixtures included
13 Quantity of concrete in m3
14 Time when loading was stored
15 Signature of authorized person

(B) On Site Information

1 Time of Arrival at site
2 Time when discharge was completed
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CHECKLIST - 1
MATERIAL STORAGE AND HANDLING

Description Observations
4.1 CEMENTITIOUS MATERIALS
4.1.1 CEMENT
[Link]. Condition of silos /bins and the cement feeding area, are they
weather-proof ?
Pl. specify:- Good/Bad
Yes/No
[Link]. How is cement supplied – Bags/ Bulk
a) If supplied in bags – Describe how it is stored.
(In weather-proof, damp-proof, well ventilated and reasonably free from
dust, check for test reports; identification tags indicating date of receipt of
lot and type. Quarantine area for damaged bags )
b) If supplied in bulk – Describe how it is fed to silo and from silo to mixer;
whether the loading and handling system permits free flow & easy
discharge of cement.

4.1.2 SUPPLLEMENTARY CEMENTITIOUS MATERIALS (SCMs).

[Link] How is storage system for SCM’s .Is it separate for each type of
SCM’s . – Describe how it is stored (In weather-proof, damp-proof, well
ventilated and reasonably free from dust )
[Link]. If supplied in bulk, describe how it is fed to silo and from silo to
mixer; whether the loading and handling system permits free flow & easy
discharge of cement/ SCM’s.

[Link]
[Link] Describe the provisions for storage for each size and type for
aggregates. ( Does the system prevents mixing of different sizes and
types; are there proper signboards etc )
[Link]. What adequate precautions taken to prevent intermixing of
aggregates with dust ,mud, soil and other deleterious materials. Are they
adequate ?
[Link] What provision regarding water sprinklers or other system made
to bring down the temperature of aggregates in hot weather ?

4.1.4. WATER
[Link] What is the source of water ?
Is sufficient quality and required quantity available? Are test reports
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Description Observations
4.1.5. CHEMICAL ADMIXTURES

[Link] – What chemical admixtures are being used ? what is the shelf life
? what specifications are supplied by manufacturer; Test reports
availability; Are they OK? Are the admixtures supplied with proper marking
and information as per clause 10.1 & 10.2 of IS9103.

[Link] Is there proper arrangement to store the chemical admixtures so

as to avoid contamination and degradation on exposure to direct sunlight?
[Link] Are liquid admixtures properly agitated before use & used before
expiry date. Pl. specify the mode of agitation (Manual / Mechanical)

CHECKLIST - 2
BATCHING AND MIXING CONTROL EQUIPMENT

Description Observations
5.1 SCALES
5.1.1 What type of Scale is there? Are they readable by the by batch operator from
his position? Is SCADA system installed?
5.1.2 Have the preset controls been calibrated in increments not exceeding 5kg or
less each for cement and mineral admixtures, 10 kg or less for aggregates and 2
kg or less for water ? (Clause E-1 (c) of Annex E of IS 4926 ) Pl. specify.
5.1.3 For continuous mixer plants has the calibration been done in increments not
exceeding 10 kg/m 3 each for cement and mineral admixtures, 25 kg/m 3 for
aggregates and 10 lit/m 3 for water ? (Clause E-1 (d) of Annex E of IS 4926 ) Pl.
specify.
5.1.4 Do the digital read-outs have a scale increment not exceeding 2 kg each for
cement and mineral admixtures, 10 kg for aggregate and 1 liter of water ? (Clause
E-1 (e) of Annex E of IS 4926 ) Pl. specify.
5.1.5 What is the frequency of recheck of scales carried out ( at least every 3
months for electrical/ load cell system ) ? (Clause E-1 (j) of Annex E of IS 4926 ) Pl.
specify.
5.1.6 Is the recalibration done promptly and correction carried out if the plant is
moved or non compliance is indicated in the 3-month rechecking ? Pl. specify.
5.1.7 What is the record of calibration of weighing and measuring system ? Is it
maintained properly.
5.1.8 Are adequate permanent facilities provided for the application of test weights
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Description Observations
5.2. WEIGH BATCHERS (Clause 9.1.2 and 9.1.3 of IS 4926 )
5.2.1 Are the hoppers for weighing cement, aggregates, and also water and
admixtures ( if measured by weight ) consist of suitable containers freely
suspended from a scale, and are they equipped with necessary charging and
discharging mechanisms ?
5.2.2 Are the hoppers capable of receiving maximum rated load without contact of
the weighted material with charging mechanism ?
5.2.3 Are hoppers self-cleaning and fitted with means to facilitate complete
discharge ? What is the observation?
5.2.4 Are vibrator or other equipment installed in such a way as not to affect
accuracy of weighing ?

5.3 BATCHING DEVICES FOR WATER

5.3.1 How water is measured – (Volume / weight )
5.3.2 Are water meters/ weigh batchers equipped with a cut-off device capable of
stopping flow within the tolerances. Is it without leakages ?

5.4 DISPENSERS FOR LIQUID ADMIXTURES (Clause 9.1.2 and 9.1.3 of IS 4926 )
Chemical admixtures shall be added to the concrete mixture with the help of a
dispenser – a device for batching of liquid admixtures ; preferably with an agitator..
Admixtures shall not be administered manually.
5.4.1 How are liquid admixtures measured (Volume/ Weight)
5.4.2 Whether each dispenser of liquid admixture has been provided with an
accurately calibrated container (if measured by volume) in which the admixture can
be collected when it is desired to check the accuracy of measurement & within
tolerances .

5.5. ACCURACY OF PLANT BATCHING (Clause E-1 of

Annex E of IS 4926)
5.5.1 The accuracy, sensitivity and arrangement of weighing devices shall be such
as to enable the materials to be batched within the following tolerances :
A) Cement and mineral admixtures: Within + 2 percent of the quantity of
constituents being measured .
Pl. specify the accuracy-
B) Aggregate, chemical admixture and water: Within + 3
percent of the quantity of constituents being measured
Pl. specify the accuracy-
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Description Observations
5.6. BATCHING SYSTEMS
5.6.1 Batcher Controls
[Link] Weigh Batcher Controls:- Cementitious materials and aggregates must be
batched by weight; water and admixtures may be batched in a weigh batcher or by
volume . Check and specify about this.
Automatic Control – When actuated by a single starting signal, an automatic weigh-
batcher control shall start the weighing operation of cementitious materials,
aggregate, water, or admixture, and stop the flow automatically when the
designated weight has been reached. Pl. check and write details.

5.7 RECORDERS :
5.7.1 Are the devices (Digital only) that provide a permanent record of the quantity
of cementitious materials, aggregate, water or admixture measured into a particular
batch of concrete. Whether Digital recorders are installed for each of the aforesaid
material.
5.7.2 Pl. check and specify about the following points ;Are recorders :-
1) Properly protected, that is, provided with effective security to prevent tampering
with records.
2) Provide traceability of the particular batch with the corresponding delivery ticket.
3) Register the quantity of ingredients batched; such as cementitious, aggregates,
water, admixture etc.

5.8 CENTRAL MIXER

(i) Check whether the mixer is capable of producing uniform concrete within the
time specified in the operational manual of manufacturer of the plant (Clause
[Link] of IS 4926 )and specify.
(ii) In automated plants ,is the mixer equipped with a timing device that will not
permit the batch to be discharged before the pre-determined mixing time has
elapsed ?
5.8.1 Condition of blades and paddles – Pl. specify whether
i) The central mixer maintained in an efficient and clean
condition ?
ii) There is any accumulation of hardened concrete in the
mixer drum and on the mixer blades ?
5.8.2 Mixer blade wears
The wear of mixer blade shall be checked at the point of maximum drum diameter
nearest to the drum head. [ The blade is considered excessively worn if height of
the blade at this point measured from the drum shell , is less than 2/3 rd of the
original radial height ( Clause [Link] of IS 4926) ]Pl. Check whether the blades of
central mixer free of excessive wear & tear ?
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CHECKLIST - 3
TRANSPORT OF CONCRETE

Description Observations
6.2 DELIVERY FLEET INSPECTION
6.2.1 Hardened concrete built up in mixer drum and on blades
[Link] Are the truck mixers maintained in an efficient and clean
condition ?
[Link] Is there an appreciable accumulation of hardened concrete in
the mixer drum and on the mixer blades ?

6.2.2 Charging hopper

[Link] Is the surface of charging hopper clean and smooth?

6.2.3. Discharging opening, hopper and chute

[Link] Is the surface of discharging opening, hopper and chute clean
and smooth?
[Link] Are the discharging opening, hopper and chute free from
appreciable accumulation of concrete ?

6.2.4 Speed of agitation

The recommended operating speed for agitation (in rpm) shall as per
the recommendation of the manufacturer. The mixing speed generally
be in the range of 4 rpm to 14 rpm. Minimum and maximum operating
speed shall be visually verified . Is the agitating mixer capable of
operating at mixing speed in the range as specified by manufacturer of
truck mixer/agitator .

6.2.5 Water tank, meter and pump system

[Link] Is the gauge /meter on water tank fitted to the truck mixer clean
and legibly graduated?
[Link] Is the water pump/injection system in good working condition?
[Link] Is there any leakage of water from the nozzle into the mixer?
[Link] Check on calibration of water meter( should not show variation
beyond 2%)
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p) The Major upsides of ready mix concrete are:

i. Production by weigh batching in a Mechanized Batch mixing plant with

computer/Numerical controls.
ii. Quality of concrete – The concrete is produced in controlled condition with
excellent control on w/c ratio and consistent quality of raw materials
begets quality control.
iii. Speedy construction – Due to mechanization the production of concrete is
fast with minimum wastage.
iv. Eliminates the problems and inconvenience associated with stacking of
construction material on construction sites, public pathways etc. Also, the
pilferage of material gets eliminated.
v. Lowers the labor and supervisory cost also lowers inventory and
overheads.
vi. Reduced pollution – creates a clean environment with reduced noise and
air/dust pollution.
vii. RMC is not only a “Material” but also a “Service”.

12. Form Box Removal / Curing / Backfilling

A. Form box are normally removed 24 hours after concreting. Concrete surfaces
should be set right, where required, with rich cement and mortar
immediately after removal of the former boxes.
B. After removal of the form box, the pits shall be back filled up to top of
chimney concrete level with earth, (which shall be free from foreign materials
& boulders) in layers not exceeding 150mm, sprinkled with sufficient amount
of water and well compacted with rammer or mechanical compactor. The soil
which was excavated last should be filled in first.
C. In case backfilling is not done immediately after removal of form box, then
curing of the concrete should be done by providing wet gunny bags till the
back filling is done.
D. The stub setting template shall be removed after all the pits have been back
filled to full depth
E. The concrete should be cured by keeping the backfilling continuously wet for
14 days for OPC and 21 days for PPC. A 150-mm high earthen embankment
(bandh) for filling water shall be made along the sides of the excavated pits at
the end of the back filling. Water shall be filled in this embankment to keep
the back filled earth wet for the remainder of the prescribed curing time.
F. All surplus soil, if any, including residual sand, stone and concrete waste, lying
around shall be stacked within the tower base.
G. The date of back – filling shall be recorded in the stub setting register and
signed by the Site Engineer in token of its verification.
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13. Post Operational Checks

A. Ensure that all waste is properly removed and disposed of in a safe manner
B. Ensure curing to be done as recommended for type of cement used during concreting.

14. Checklist, Records, Permits and Other Requirements

A. Tower Foundation Safety Checklist

B. Project (Specific) EHS Plan
C. Checklist for Tractor / Concrete mixer / Self-loader / Vibrator
D. Pep Talk format
E. Excavation clearance permit
F. Permit for blasting operation
G. PTW Plant & Machinery
H. Shut down clearance (HT / LT) cum work permit for TL
I. Equipment fitness report for Vehicle & Earth moving Equipment
J. Weather report shall be updated on a daily basis.
K. Do’s & Don’ts poster display
L. Safety Induction card
M. Licensed blaster copy (wherever applicable)
N. Fully equipped first aid box