planning document_bhavnagar chimney (revised)

GAMMON INDIA LIMITED

Planning Document For

R

PLANNING DOCUMENT CONSTRUCTION OF 1 NO. 220m HIGH TWIN FLUE REV.NO. 00

RCC CHIMNEY AT BHAVNAGAR, GUJARAT 20th JAN 2011

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GIL H.O._C.P.E.S. GAMMON INDIA LIMITED 3

PREFACE

The project planning document is prepared with the objective of providing an initial plan

incorporating the changes after the tendering stage till date, based on the inputs received from the

project site. It attempts to provide a base line plan for monitoring progress, turnover and

expenditure at site and corporate office levels. It aims to provide a guide towards optimum

resource utilization at site level and planning resource allocation at corporate office level by

interlinking the resource requirements from all the sites.



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Contents:

Sr.No. Description Page No.

1. Introduction 5

2. Salient Features 6

3. Scope of Work 9

4.

4.1

4.2

4.3

4.4

4.5

Planning basis, overview & detailed schedule

List of Milestones

Assumptions in Planning

Sequence of work

Detailed Schedule

Shell Profile

15

5. Construction methods for major activities 18

6.

6.1

6.2

6.3

Resource requirements

Equipment requirements

Manpower requirements

Productivity Norms

29

7 Site establishment plan 31

8 Preventive Safety Measures for Main Activities 31

9 General Preventive Measures 36

10 Summary 37

11 Annexure - I : Construction Programme 38

12 Annexure - II : Site establishment plan 39



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1) Introduction:

The job consists of design and construction of one(1) no. 220 m high RCC Chimney for

2x250 MW Lignite based Thermal Project at Padva, Bhavnagar district, Gujarat.



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2) Salient Features

2.1) Commercial Features

1. JOB NUMBER 8933

2. CONTRACT PRICE

Rs. 43,00,00,000/- only (Rupees Forty Three

Crores only)

3. TYPE OF CONTRACT

Lump Sum Contract

4. NAME OF CLIENT

Bhavnagar Energy Company Ltd.,

Block No. 8, 3rd

Floor, Udyog Bhavan,

Sector-11, Gandhinagar, Gujarat-382011

5. PROJECT START DATE Date of LOA (9th

December 2010)

6. PERIOD OF COMPLETION 21 Months from the date of LOA

7. PROJECT END DATE 8th

September 2012

8. SECURITY DEPOSIT 5 % of Contract Price

9. LIQUIDATED DAMAGES 0.5 % of Contract Value

10. MOBILISATION ADVANCE 10 % of Contract Value

11. PRICE BREAK UP

1. a) On approval of GA drawings and

design & detailed foundation drawings

b) On approval of design & detailed

shell, shell openings drawings

c) On approval of structural steel

design drawings

d) On approval of fabrication

drawings

0.5 %

0.5 %

0.5 %

0.5 %

2. Foundation Works

a) On completion of excavation

work including disposal

b) On completion of Raft

foundation including pedestals for duct

1 %

10 %



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& stair case earth filling (inside), earth

filling (outside), compaction etc

c) On raising RCC shell to 0.000m

level

1 %

3. RCC Shell

a) On mobilization of slipform

equipment at site

b) On erection of slipform

equipment in position

c) On completion of RCC shell

upto 45.0m level

upto 45.0m level

upto 45.0m level

upto 45.0m level

upto 45.0m level

1 %

1 %

5 %

5 %

5 %

5 %

5 %

4. Steel Beam Platforms

a) On fabrication of steel beams

b) On erection of steel beams

including grouting work

c) On laying of gratings and

handrails

d) On painting of steel beams

5 %

3 %

2 %

1 %

5. Lining & Insulation (Both Flues)

a) On fabrication of steel flues

b) On erection of steel flues

c) On completion of insulation

and cladding works

12 %

6 %

3 %

6. Staircase & Ladder

a) On fabrication & galvanising

b) On completion of erection

work

1 %

1 %

7. Lift

a) On supply of lift at site

1 %



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b) On erection of lift including

completion of all related works

1 %

8. Painting of Chimney

a) External surface of Chimney

b) Internal surface of Chimney

1.5 %

1.5 %

9. Electrical works including

earthing, lighting works, aviation

obstruction lights, lightening

protection works etc

5 %

10. Miscellaneous works 8 %

11. Finishing works, site clearance

etc 2 %

12. Final commissioning &

completion of all other works in all

respects

5 %

Total 100 %



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2.2) Technical Features

Sr. No Data Description

1 No. of Chimney 1

2 Height of Chimney 220 m

3 Outside diameter of Shell (Bottom) 23.000 m

4 Outside diameter of Shell (Top) 17.300 m

5 Flue Type Steel Flue

6 No. of Flue 2 Nos.

7 Flue Diameter 5.4 m

8 C/L Elevation of Flue gas Duct Opening EL(+) 15m

9 Internal Platforms 6 Nos.

10 External Platforms 6 Nos.

11 Taper (El. -1.0 to 120 m) Slope

12 Taper (El. 120 to 215 m) Straight



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3) Scope of Work:

3.1) Chimney

The scope includes Analysis, Design, Preparation of Construction drawings and

Construction of one number 220m high multiflue RCC Chimney with all accessories.

• Design of Chimney including all appurtenant civil works.

• Supply at site of all required materials

• Construction of RCC raft foundation supporting the wind shield as well as duct supports,

staircase etc including excavation, dewatering, backfilling, etc complete. The excavation

quantity is about 38650 cum.

• Construction of RCC wind shield using Slip-form equipment including provision of

openings of various sizes in the windshield at various levels.

• Construction of internal RCC corbels at various levels to support structural steel beams.

• Construction of RCC roof slab for wind shield including acid resistant tile protection of the

roof & drainage arrangement of roof.

• Fabrication and erection of structural steel platforms at various levels such as roof

supporting platform, flue support platform, restraint platform, access platforms etc with

openings for flues, flooring of gratings, hand rail etc including their bearing supports on the

wind shields.

• Fabrication and erection of structural steel flues supported from support platform with one

expansion joint. Top portion of flue will be of stainless steel construction.

• Fabrication and erection of bottom portion of structural flues below bottom expansion joint

supported below on structural steel work.

• Fabrication and erection of flue support assembly at support platform, where flues are

suspended and flue support assembly at bottom on which the bottom section of flue is

supported of specialized construction details.

• Providing restraints to the flues at various levels with bracket and buffers of specialized

construction details.

• Structural steel flue gas ducting of rectangular configuration from terminal points of supply

for steam generator vendor of structural steel upto circular steel flue including structural

steel stiffening arrangement for the ducting.

• Fabrication and erection of restraint & support arrangement for ducts on windshield of

specialized construction details.



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• Providing ash hoppers of structural steel connected at the lowest level of duct.

• Providing supporting arrangement for flue duct supports outside windshield of specialized

construction details.

• Providing insulation on the outside of the steel flues & ducts including protective

aluminium sheet.

• Providing structural steel work for supporting bottom supported portion of flue and ducting,

both inside and outside of windshield.

• Fabrication & erection of structural steel staircase inside wind shield from ground floor

level to top support platform for flues with interconnection to various platforms and cage

ladder from top support platform to roof of chimney.

• Painting of RCC windshield and structural steel works.

• Aviation warning lighting, general lighting inside the chimney and obstruction lighting and

all connected electrical works and embedding conduits, junction boxes, pull boxes, cabling

etc.

• Earthing and lighting protection system including all connected works from top of chimney

to terminal point outside chimney at groun level.

• Supply and installation of rack & pinion type lift inside the chimney.

• Provision of inserts/pipe sleeves for mounting instruments for monitoring air quality,

including conduiting junction, pull boxes, cabling etc.

• Construction of plinth protection including surface drains.



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3.2) Schedule of Quantities (As per Tender stage Design)

Sr.

No.

Description of Works Quantity

Item Grade

A. Excavation in all type of soils 27400 m3

B. Excavation & Backfilling

i) Excavate in soil heap on site for suitable

material and backfill around and on chimney

foundation outside chimney shell

- 11250 m3

C. Backfilling with crushed rock - 310 m3

D. Concrete

i) P.C.C. under any structural concrete M 10 230 m3

ii) Raft M 30 17200 m3

iii) Chimney shell M 30 6800 m3

iv) Corbels, beams, roof platform, pedestal and

other internal constructions etc

M 30 52 m

3

v) Floor slab at grade level M 30 60 m3

E. Reinforcement (HYSD)

i) Raft IS:1786/IS:432 1050 MT

ii) Shell IS:1786/IS:432 476 MT

iii) Others IS:1786/IS:432 10 MT

iv) M.S.Steel plain round bars Grade 1 2 MT

F. Form work For R.C. Work

i) Raft - 3100 sqm

ii) Slip forming for windshield: external + internal - 26800 sqm

iii) Roof Platform - 195 sqm

iv) Others - 50 sqm

v) Openings and block-cuts - 110 sqm

G. Structural Steel

i) Corrosion resistant Mild steel COR-TEN-B

liners (8mm thick) for height upto EL 210 m

including stiffeners, restraints, openings,

bottom supports, etc. including fabrication and

erection

- 515 MT



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ii) Stainless steel liners (AISI Type 304L) at top

a) 6 mm thick (EL +210 to EL +220 ) including

flashing and cladding on outside.

b) 6 mm thick (cap) (Hood)

c) 4 mm thick kerb plate

-

16 MT

1.1 MT

0.7 MT

iii) HSFG bolts Grade C 1 MT

iv) MS flue duct including stiffeners, supports, etc.

up to terminal points - 25 MT

v) Structural steel in external platforms at all

levels including welding and bolted

connections

a) ISMC 75x40 @ 1200mm c/c and L75x6

b) GI grating for external platforms (weight 52

Kg/sq.m)

c) GI handrailing for platforms

d) GI Posts for platforms

-

13 MT

470 sqm

410 RM

410 RM

vi) a) Structural steel in internal platforms at all

levels

b) GI grating for internal platforms

- 125 MT

1100 sqm

vii) Structural steel hot dip galvanised using a

minimum of 610 grams of

zinc per sq. m for Staircase from Grade slab to

EL 210m (i.e topmost

internal platform)

- 50 MT

H. Insulation

i) Semi-rigid resin bonded fibrous mineral wool

or rockwool 64 Kg/cum

- 510 m

3

ii) Rock wool slabs, 150 mm thick (100 kg/cu.m) - 52 m3

iii) Rock wool slabs, 75 mm thick (200 kg/cu.m) 7.5 m3

iv) 20 mm thick AR tile ( IS:4457) on roof and

inner surface of shell

177 sqm

v) 1.0 mm thick aluminium cladding 9 sqm

vi) Structural steel E250 4.3 MT



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vii) 5mm thick lining of Stainless steel AISI 304L 2.7 MT

I. Painting

i) Acid and heat resistant of acrylic polyurethane

paint

IS:5410 13100 m

2

ii) Acid and heat resistant paint IS:158 12500 m2



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4) Planning basis, overview & detailed schedule

4.1) List of Milestones

Sr No Activity Period of completion from

date of LOI

1 Completion of Analysis & design of all

elements and submitting the same for

approval of Consultant/Owner

4 months

2 Mobilisation and completion of all

foundation works below ground level

including backfilling etc

5 months

3 Completion of windshield 11 months

4 Erection of steel floor framing 14 months

5 Erection of steel flue & completion of all

works for unit 1 17 months

6 Erection of steel flue & completion of all

works for unit 2 19 months

7 Completion of all works for the chimney 21 months

4.2) Assumptions in Planning

• Commencement of the work is considered from date of LOA i.e. 9th

Dec’2010.

• The program is based on tender drawings, tender milestones & estimated

quantities.

• Foundation for chimney is considered as Raft Foundation.

4.3) Sequence of work

Sequences of work for all major activities are as per detailed construction schedule

attached herewith.

Mobilisation and preliminary activities:

Preliminary activities like setting up of site office, fabrication yard, batching plant, labour

quarters, reinforcement cutting and bending yard etc will be completed during first two

months.



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Foundation:

The foundation for the chimney consists of a reinforced concrete raft which will rest upon

PCC bed.

Shell Construction:

The Shell will be constructed using the Slipform technique.

Steel Flue Erection:

The chimney consists of twin flues which will be erected with the help of lifting frames

and Jack assembly.

4.4) Detailed Schedule

•••• Refer Annexure-I for Construction Schedule.

4.5) Shell Profile

Sr.

No.

Elevation

( m )

Outside

Profile

Grade of concrete

1 EL -1.00 to EL

120.00 SLOPE

M 30 2 EL 120.00 to EL

215.00 STRAIGHT



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4.5.1)4.5.1)4.5.1)4.5.1) External Steel Platforms



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5) Construction method of major Activities

5.1) Foundation:

Foundation for chimney mainly involves following activities -

1) Excavation,

2) Reinforcement fixing & Concreting,

3) Backfilling

1) Excavation –

•••• Excavation will be done only after detailed checking of coordinates of the survey

pillar handed over by Client.

•••• Reference pillars at East-West side and North–South of chimney 10 m away from

the outer edge of excavation. Size of pillars should be concrete of size

300x300mm and 600mm deep.

•••• Last layer of about 200 mm will be excavated manually/tractor breaker to avoid

over excavation.

•••• Stock quantity of earth will be use for back filling.

•••• Work will be carried out from 8:00 am to 8:00 pm and 8.00pm to 8.00 am every

day excluding Sundays.



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Layout of Excavation

Note: 1. First excavate the portion in front of ramp in layers and then mucking

and cleaning is carried out and continuing in same way.

2. Keep Ramp till completion of PCC and raft footing

2) Reinforcement fixing & concreting

The foundation for the chimney consists of a reinforced concrete solid raft of

dia.57 m with M30 grade of concrete. Raft is having depth of 6.8 m below the ground

level. The general method for construction is as below:

•••• Lay 75 mm thick PCC of M10 concrete at raft foundation.

•••• Divide entire area for Raft Foundation into 8 equal segments or as per detailed

design for raft foundation. (Do partwise reinforcement fixing & concreting.)

•••• Cut the reinforcement as per bar bending schedule & fix it manually.

•••• Provide timber shuttering/formwork.

•••• Provide construction joint with vertical joint.

•••• Concrete the raft segment by truck mounted concrete placer boom. Concrete M-30

Grade shall be supplied through batching Plant through Transit Mixers. Concrete



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shall be poured into the foundation Segments using direct chutes or concrete pump

as per accessibility Chutes shall be made using M.S. Sheets/G.I. Sheets Chutes

shall be placed with appropriate slope for concrete free flow.

•••• 40 mm Needle Vibrators will be used for proper compaction of concrete.

•••• Cure the foundation by applying curing compound making arrangement of Wet

Hassein Cloth.

•••• Strip of formwork after minimum of 24 hrs.

•••• Cast remaining segments in the same manner

Foundation for Chimney Raft:

3) Backfilling

•••• Trenches shall be backfilled with the suitable material as per specification in

layers not exceeding 300 mm loose depth.

•••• Each layer of fill shall be adequately consolidated throughout its full depth

immediately after placement and prior to placement of additional layer.

SURVEY PILLAR

CHIMNEY CENTER

CHIMNEY

FOUNDATION AREA

POUR No. 8

POUR No. 5

POUR No. 9

POUR No. 2 POUR No. 6

POUR No. 3

POUR No. 7

POUR No. 4

POUR No. 1



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•••• Source: Approved borrow pit and Excavated soil shall be checked up for the

suitability for reuse. If it is suitable then use in back filling.

•••• Laboratory test: Before starting of fill work in Laboratory to determine of

Maximum Dry Density/Optimum Moisture Content relationship as per IS: 2720.

•••• Field test: Field density test shall be carried out as per IS: 2720 till the minimum

90% compaction achieved.

Note: Backfilling should be done after minimum of 7 days after concreting.

5.2) Shell Construction:

Slip-form equipment consists of shuttering attached to walers that stiffens the

Shuttering panels and transfers the load to the yokes. Hanging scaffolds and working

deck are also connected to the walers. The waler yoke connection is designed to transfer

all loads of the decks to the yokes. The yokes transfer the loads to the hydraulic jacks that

further transfer the load to the jack rods on which they move up and down. To prevent the

jack rods from getting embedded in concrete, sleeve pipes are used which along with the

jack rods, transfer the load to the base or the foundations.

The following are the major components of slip form equipment:-

Shuttering/form panels, Walers, Yokes, Working decks, hanging scaffolds, Truss system

Hydraulic jacks, Jack rods, Pumping units for jacks, Bracings, Operation screws

Extraction jacks, sleeves etc.

Main truss type = Octagonal

No. of yoke legs = 48 Nos

Hydraulic jacks = 6 t capacity 80 nos.

= 12 t capacity 16 nos

Note: The slip-form truss design may vary during actual execution



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Typical Schematic Arrangement of Slip form

Elevation

Plan

Main Beam/Wing Beam

Spider Beam

Ring Beam

Center Frame



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5.3) Platform Girder (PG) Erection:

A) Shifting of Girders -

•••• Road making

The road will be well leveled to avoid any kind of undulations, so that movement of

crane or hydra or trailer will be safe.

•••• Bringing the Girder

For bringing the top most girders inside the chimney, 75MT capacity crane (suitable

capacity crane) will be used. Lifting hooks will be attached to the girder at specified

distances by means of sling fixed to D’ Shackle.

•••• Keeping in to position

Bring the girder near to the shell opening; one end of girder will be fixed to the steel wire

rope passing through the two sheave pulley (Winch no.1). Then pull the girder inside the

chimney & fix another steel wire rope (Winch no.2) to the girder inside the chimney &

keep the girder in position.

B) Lifting of Girders -

STAGE I (At 215.00 M EL.)

2) Bring the top most plate Girder (EL+215.00 m) inside the chimney by hydra.

3) Anchor HT 5/8”Wire rope to PG1 Girder at both ends where rope is connected to the

double gear hand winch.

4) Lift the PG1 girder by using 2Nos of double gear hand winch.

5) Rest the Girder on Neoprene pad in the opening provided at shell, align it properly as per

approved Drawing.

6) Remove Anchoring device from Girder.

7) Repeat the same steps PG2 Girder erection.

8) Lift the rolled section I Beam by material bucket.

9) Fix the entire rolled section I Beam by Bolting as per approved drawing & Specification.



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STAGE II (At 210.00 M EL.)

• Repeat the step for EL. 210.00 M Plate Girder. Fix & align it properly the entire unit

as per approved drawing & specification.

STAGE III

Repeat the step for EL. 170.00 M Plate Girder Fix & align it properly the entire unit as per

approved drawing & specification.

STAGE IV



STAGE V



STAGE VI



STAGE VII



Note: The Platform Girder levels may change during actual execution depending on

the detailed design.

5.4) Shifting of Flue Cans:

• For bringing the steel flue can near to chimney, rails of certain LB will be laid first with a

trolley over which cans are shifted towards the chimney. 50 T capacity crane will be used

for lifting the cans from GL over the side shifting trolleys. Lifting hooks at specified

distances are used, inside the steel flue can, to which sling is fixed by D’ Shackle.



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• The flue w i l l b e insulated externally. The insulation w i l l be tightly secured to

the exterior surface of the liner by impaling them on studs welded to the surface at 450

mm c/c both horizontally and vertically. The studs will extend a minimum of 25 mm

beyond the thickness of insulation and 63 mm circular or square metal plate speed

washers of standard thickness will be placed on the extended portion of the studs to hold

the impaled insulation material well in place.

• Insulation for the exposed portion of flue at the top will consist of 6 layers of

insulation material each of a minimum thickness of 25 mm and all joints will be

staggered.

5.5) Erection of Steel Flue Cans:

The steel flues will be fabricated separately in parts of specific height called CANS.

The Methodology for erection of Steel Flue for chimney with Twin flues is given below:-

STAGE-I (For Flue-I)

6. The Flue cans are divided in certain units and erection of cans takes place unit wise.

7. Bring the top most Can which is properly insulated, inside the chimney & align it

properly.

8. Anchor the HT Strands coming from lifting jack to the lifting bracket of Top most steel

flue can.

9. Lift the top most can to a height just sufficient to accommodate next can under it.

10. Bring the next Can inside the chimney which is properly insulated & align it properly.

Connect these two cans by Bolting/ welding as per approved drawing & specification.

11. Lift the assembly of cans to accommodate next can under it.

12. Continue the process for remaining cans.

13. Lift the entire Unit # I of Flue # I to its final position & fix with the support platform at

an elevation of say EL+ 210.00 M ( as per approved design).

14. Remove the lifting tackles from Unit # I of Flue # I.

15. Assemble the cans for Unit # II in the similar manner as described for Unit# I.

16. Lift the entire Unit # II one by one to its final position and fix with unit # I and access

restraint platform at EL+ 170.00 M.

17. Remove the lifting tackles from unit # II of both flues.



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18. Assemble the cans for Unit # III in the similar manner as described for Unit# I.

19. Lift the entire Unit # III one by one to its final position and fix with Unit # II & access

restraint platform at EL+ 130.00 M.

20. Remove the lifting tackles from Unit # III of both flues.

For the remaining III Units, Apply the similar procedure for lifting the cans as mentioned for the

other units and fix them on access restraint platform at ELs (+) 90.00 M, 50.00 M, 20.00 M

respectively.

STAGE-II (For Flue-II)

21. Apply the above same procedure for erection of cans for all VI units of Flue # II.

5.5) Ladder:

• The chimney shall be provided with GI ladder with safety cage.

• Cage ladder shall be provided from E.L.210.00 m to E.L.215.00 m.

5.6) Staircases: -

The staircase is supported by structural steel formwork; clear width of stairs treads inside

stringers is 750mm. Tread will be 25mm thk. MS Grating with anti-skid nosing, and 250mm

wide. Handrails used will be MS Pipes of 32NB with toe protection of 65x8 mm flats. The

staircase will be provided from Grade slab to EL 210.00 m

5.7) Roof Slab:-

The roof of the chimney is at E.L.215.00 m which is protected against acid-corrosion by

providing thick layer of acid proof tiles. The arrangement of the roof consists of a reinforced

concrete slab with an opening called hatch for access from staircase which stops at last flue

support platform. The hatch has a single leaf door of 6mm thk to cover a clear opening of

750mm x 1000mm. For roof Drainage system 200 mm Galvanised MS drain pipe including

necessary jointing, fixing to windshield with packing, clamps/brackets, etc will be provided.

5.7) Painting

• Painting of top 15 m external surface of chimney shall be done with alternate bands of

Red and White. Total DFT not less than 150 microns. Painting of external surface shall be

done with acid & heat resistant 2 coats of acrylic polyurethane paint confirming to IS:5410



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over 2 coat of clear epoxy primer. Painting of complete internal surface of chimney shall be

with two coats of acid and heat resistant paint confirming to IS:158 (2 coats over a primer).

One coat of zinc phosphate primer paint of 35 microns thickness shall be done on inner and

outer surface of flues & ducts. The total surface area of painting will be about 33010 sqm.

Rope suspender platform will be used for Chimney Painting. The general assembly

of Rope suspender platform will be as below:

•••• The platform is made to climb on the stationary wire rope by means of hoisters.

•••• The platforms are to be hanged from the upper area of the chimney which will be

operated within the platform by using the pendant switch.

•••• The workmen will use these platforms for painting of chimney



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The General Layout of External Platform for Painting



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6) Resource requirements

6.1)6.1)6.1)6.1) Equipment requirements

Sr Description Capacity /

Type

Nos Remarks

1 Concrete Mixer Reversible Drum

type 750 Ltr 1 no -

2 Concrete Batching Plant 30 Cum/Hr 1 no -

3 Cement Silo 100 MT Cap 1 no -

4

Transit Mixer 6 Cum/Hr 6 Cum 2 nos

2 nos additionally

required for Raft

Concreting

5 Concrete Pump 35 Cum/ Hr 1 no -

6 Concrete Placer Boom (truck

Mounted)

32 Mtr Long

Boom 1 no

Required only for

Raft concreting

7 Loader Wheeled JCB 3DX 1 no -

8 Compression Testing Machine 200 Ton cap 1 no -

9 Theodolite / Total Station - 1 no -

10 Laser Plummet - 1 no -

11 Hand Winch 5 T Cap 3 Nos -

12 Hand WInch 10 T Cap 2 Nos -

13 Positive Drive Winch Speed 45

Mtr / Min / 600 mtr wire rope drum 5 T Cap 2 Nos -

14 Positive Drive Winch Speed 35

Mtr / Min / 600 mtr wire rope drum 3 T Cap 2 Nos

-

15 Curved Hoist Rack & Pinion Type

1 ton Cap for 220 mtr Height 1 no -

16 Slip Form jacks with power pack

complete set -

1 set -

17 Mobile Crane Hydra 14 ton cap 1 no -

18

Mobile Crane 50 Ton Cap 1 no

On Hire for

Chimney

Girder/Flue Can

shifting

19 Welding Generator / Transformer /

Rectifier 400 Amps 4 Nos -

20 Water Pump High Lift UT 220 C 3 Nos -

21 Plate Bending Machine 2 Nos

22 Bar Cutting Machine 42 mm 2 Nos -

23 Bar Bending Machine 42 mm 2 Nos -



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24 Diesel Generator 110 Kva 1 no For back up power

25 Strand Jack Complete Set with

Strands - 3 Set

For Flue Can lifting

Capacity will be

confirmed based on

Weight of Flue can

modules

Note: 1. Slipform Truss may be allocated from Barh site.

6.2)6.2)6.2)6.2) Manpower requirements

Sr. No. Designation Nos.

1 Project Manager 01

2 Project Engineer 2

3 Safety Supervisor 4

4 Engineers 8

5 Other Technical Staff (Foremen & Supervisors) 08

6 Non-Technical Staff (Accts, Stores, Purchase, Admin) 05

7 Equipment Operators 16

8 Skilled/Semi-skilled Labours 150

9 Unskilled Labours 200

6.3)6.3)6.3)6.3) Productivity Norms

Sr. No. Activity Time

(Days)

Pouring Rate/Excavation

Rate

Raft Foundation

1 Excavation 30 60 m3/hr

2 Casting of Central Pour (1st) 20 24 m3/hr.

3 Casting of 2nd

Pour & 3rd

pour 18 24 m3/hr.

4 Casting of 4th

Pour & 5th

Pour 18 24 m3/hr.

5 Casting of 6th

Pour & 7th

Pour 18 24 m3/hr.

6 Casting of 8th

Pour & 9th

Pour 18 24 m3/hr.

7 Inside & Outside Backfilling 10 30 m3/hr.

Slipform Erection



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8 Slipform Fabrication 30 -

9 Slipform Erection 30 -

10 Slipform Checking 2 -

Casting of RCC Shell

11 Casting of RCC Shell 100 70 M3/Day

12 Slipform Maintenance & stoppages

(During Concreting)

50

Fabrication & Erection of Flue Cans

13 Steel can fabrication (1st Flue) 185 5 days/can

14 Steel can erection (1st Flue) 70 1 day/can

7) Site establishment plan

Refer Annexure-II for site plan

8) Preventive Safety Measures for Main activity

8.1 Excavation

� Preventive Measures:

• Finalize excavation layout considering soil characteristics and nearby structures.

• Prevent sides from collapsing by battering them to a safe angle.

• Provide suitable ramps for movement of Excavators & dumpers.

• Mark safe parking distance for dumpers, transit mixers etc from the edge of excavated pit.

Restrict speed limit of vehicles passing near excavated pit to 20 km/hr.

• Mark safe distance for dumping excavated material from the edge of excavated pit.

• Provide proper barricading or guard rails all around the excavated pit.

8.2 Slip form Assembly

� Preventive measures:

• Ensure that all components of slip form system are available and checked before starting

erection.



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• Finalize location of passenger hoist, material hoist, and temporary openings in shell for

wire ropes and align the orientation of slip form truss accordingly.

• Selection of crane for erection of Slip form truss shall be based on weight of individual

component to be lifted and operating radius.

• Avoid necessity of providing secondary or deviation pulleys.

• Ensure staging for erection of slip form is as per relevant drawing. Ensure that all

components of slip form are completely assembled when it is at ground level only.

Inspect all welded joints of structural members prior to use.

• Ensure number of bolts at joints and its grade is as per drawing. Inspect bolts for any

visual defects or damage prior to use.

• D-shackle and slings shall be tested and free from any defects.

• Use seasoned timber for the decking of main deck and other working platforms for

avoiding gaps in future.

• Ensure that the hydraulic jacks and its hoses are in safe working condition.

8.3 Shell Concreting


Specifications for Concrete winch:-

• Capacity: 3T.

• Way of mounting: Stationery

• No. of drum: Single drum with capacity to accommodate 600 m wire rope of 16mm

diameter.

• Speed 65-70 rpm

• 30 HP, 1440 RPM, 3 Phase Induction motor

• Wire rope: 16mm

• Guide rope: 19mm

• Ensure that the power winches are tested for safe working load.

• Ensure periodic inspection of wire ropes & alignment pulleys.

• Ensure that working platform at top is free of gaps and provided with railing and toe

boards to avoid fall of material.



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• Concrete bucket, unloading chute etc shall be as per relevant drawings.

• Provide canopy at ground level to protect personnel working below from concrete /

material falling from top.

• Regular inspection of welded / bolts joints shall be carried out at joint locations of ring

beam, wing beam, centre tower passenger cage balancing arm, welded portion taking

loads of concrete and material buckets, shuttering supports and shutter fixing studs.

Winches used for Concrete buckets shall have following safety features:-

• Foot Brake: for gradual stoppage of the winch.

• Limit switch: In case the material bucket goes above the required upper level, the limit

switch cuts the limit and results in the application of both the EHT brakes.

• Marking on wire rope on every elevation

• Bell & Signal Bulb arrangement for upward and downward motion.

8.4 Slipping Operations


• Check alignment and level of slip form platform at every lifting operation.

• Check setting time of concrete regularly and adjust mix design to suit slipping speed.

• Avoid any adjustments in slip form system at higher altitudes.

• Ensure periodic inspection of jacks / components.

• Replace the hydraulic hoses as per the manufacturer’s specifications.

• To prevent overloading ensure that the concrete accumulated on the truss members is

cleaned on daily basis and no unwanted material is stored on main deck and working

platforms.

• Ensure that the jack rod materials, diameters are of given specifications.

8.1 Fabrication of Steel flue cans and Platform Beams

� Preventive Measures :

• Ensure that the lifting machine & lifting tackles used for handling MS plate are of rated

capacity.



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• Provide well planned fabrication yard with sufficient space for plate cutting, rolling, and

assembly and welding of flue cans and also for stacking the same.

• Provide a goliath gantry running over the entire length of fabrication yard for handling of

cans. Capacity and height of gantry shall be decided based on weight and dimensions of

flue cans.

• Provide well compacted and leveled ground within the fabrication yard.

• Use of Hydra or crane shall be restricted only for handling of plates or small beams and

the selection of the same shall be done considering weight of element to be handled and

working radius.

• During fabrication the cans shall be placed on raised platform / pedestals which will

provide safe and easy access to workers and also will not allow the can to sink in the

loose ground below.

• Provide guards / barriers close to the moving parts of plate rolling machine.

8.2 Platform Girder Erection


• Follow erection scheme as per relevant drawing.

• Ensure that the slings and ‘D’ shackles used for lifting are of rated capacity and tested.

• The wire rope shall be inspected daily for any defects or damage.

• Ensure safe functioning of winch prior to start of lifting of girders, shafts, gears and other

safety devices.

• Inspect the pulleys on daily basis prior to start of lifting for condition of sheaves, main

shaft, wear and tear and anchorage arrangement.

• Ensure that beams are fabricated of the required length and actual length required is

checked when the beam is at ground level only.

• Ensure that adjustment in length or repair works of beam are carried out at ground level.

No repair or rectification work shall be carried out at higher levels.

• Ensure temporary platforms with railing are provided for workers at appropriate level for

erection of platform beams.



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• Parallel working at two levels is to be controlled properly so that people working at lower

level are safe against falling objects from top.

• The activity shall be carried under supervision of experienced person.

• Ensure proper inspection, checking and maintenance of Heavy Equipments like cranes,

hydra etc. at specified intervals.

8.3 Flue Can Erection


• Daily Inspection of lifting strands

• Daily Inspection of wire ropes, Jacks used for lifting

• Daily Inspection of brakes

• Ensure transportation, loading and unloading arrangement is done by trained and

competent person.

• Follow the erection scheme as per approved construction methodology and relevant

drawing.

8.5 Outside Painting

� Preventive measures

• Daily inspection of all lifting appliances

• Equipments manufactured by competent manufacturers shall only be used for shifting of

people who are doing the painting works or Use of Boatswain chair.

• The equipments shall have proper controlling and signaling devices located within the

hanging platform so that the workers using the same can control its movement.

• Selection and fabrication of lifting arrangement as per approved drawing and

methodology.

• Inspection and certification of painting arrangement by the competent person.



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9) General Preventive Safety Measures.

9.1 Falls from height

• Provide safe working platforms at regular elevation intervals.

• Provide Hand railing for safe working.

• Provide use fully equipped body safety harness of approved make for every person

working at a height of 275m.

9.2 Mechanical Failure

• Before starting of lifting, third party inspection should be held.

• Once the third party inspection is done, then periodically after 6 months or 12 months

another inspection should be held, as per the acceptance norms of the third party.

• Power packs, SL-80 Hydraulic jacks, HT Strands, Lifting bracket, D’ shackles, chain

pulley block etc should be checked daily and periodic maintenance to be done.

9.3 Electrical Circuitry

• ELCB, MCCB’s should be provided

• Armature cables should be used.

• Periodical inspection of Electrical tools should be carried out.

9.4 Fire

• Fire Extinguishers should be provided where cutting & welding work is going.

9.5 Additional Precautions

• Safety precautions for Gas cutter- LPG or Acetylene fuel supply will be safe guarded

against blast back.

• All the cylinders shall be fitted with pressure gauge cap.

• Good quality rubber hose pipe should be used.

• Cylinder should be stored at cool & dry place.

• Cylinders shall be transported by keeping it at upright position on a trolley, standard

grinding wheels should be used.



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• Gas cutter & grinder men should be well trained, they should always use face shield

(Helmet) during work.

• No men without PPE’S shall be allowed in the vicinity of chimney.

• Tool-box talk should be conducted regularly.

• Highly skilled labour should be hired for Slip form activity.

Summary

• This document would form a baseline providing sequence of work, construction

methodology to be adopted for execution of work, estimation of plant and machinery

and its requirement over the project duration, requirement of enabling works, material

estimation and its monthly requirement, etc. This document would form the bases for

Project Cost estimation required to complete the Project within the stipulated time.

• This document is prepared taking into account the pre-tender & post-tender stage

documents & data available. Also various complexities in the sequence of

construction are considered and the most suitable technique of construction is adopted

to overcome the same.

ID Task Name Duration

0 BHAVNAGAR 2 FLUE CHIMNEY 638 days1 LOI 1 day

2 Mobilisation 90 days

3 Engineering 90 days

4 Completion of Analysis & Design ofall elements and submitting thesame for approval ofConsultant/Owner

0 days

5 Earthwork in excavation 30 days

6 Raft Foundation 90 days

7 Backfilling 10 days

8 Mobilisation & Completion of allfoundation works below groundlevel including backfilling etc

0 days

9 Starter 10 days

10 Erection of Slipform Truss 30 days

11 RCC Shell including Corbels 153 days

12 Completion of Windshields 0 days

13 Fabrication of Platform Girders 72 days

14 Fabrication of Steel flue 1 180 days

15 Fabrication of Steel flue 2 180 days

16 Erection of Platform Girders 30 days

17 Erection of Steel Floor Framing 0 days

18 Erection of Roof Beams 20 days

19 Casting of Roof Slab 15 days

20 Dismantling of Slipform truss 27 days

21 Erection of Steel Flue 1 70 days

22 Erection of steel flue & completionof all works for unit 1

0 days

23 Erection of Steel Flue 2 62 days

24 Erection of steel flue & completionof all works for unit 2

0 days

25 Painting 100 days

26 Erection of Staircase 40 days

27 Misc. activities/Finishing Works 150 days

28 Completion of all works for theChimney

0 days

Completion of Analysis & Design of all elements and submitting the same for approval of Consultant/Owner

Mobilisation & Completion of all foundation works below ground level including backfilling etc

Completion of Windshields

Erection of Steel Floor Framing

Erection of steel flue & completion of all works for unit 1

Erection of steel flue & completion of all works for unit 2

Completion of all works for the Chimney

-1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 302011 2012 2013

Task

Progress

Milestone

Summary

Rolled Up Task

Rolled Up Milestone

Rolled Up Progress

Split

External Tasks

Project Summary

Group By Summary

Bhavnagar 2 Flue Chimney

Page 1

Project: BHAVNAGAR 2 FLUE CHIMNDate: Jan 14 '11

SSK1405464

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ANNEXURE-II

SSK1405464

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planning document_bhavnagar chimney (revised)

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