7 18 December 2020, To, The Engines National High Spsed Rail Corporation Limited 1001-1006, 0 Floor, Swastik Universal, Opp. Central Shopping Mall, Pipl, Rundh Surat Magdalla Road, Surat ~ 395007, India Kind Attn: Shri Amiyansu Das, Chief Project Manager/NHSRCL/Surat ‘Sub: Designand Construction of Civil and Building Works including Testing and Commissioning ‘on Design B.ild Lump Sum Price Bass for Double Line High Speed Railway involving Viaduct, Bridges, Maintenance Depots, Tunnel, Stations (Vapi, Bilimors, Sura and Bharuch), and Surat Depot between Zaroli Village at Maharashra-Gujarat Border and Vadodara from MAHSR Ki. 156.600 to MAHSR Km. 393.700, excluding Works for 04 No, PSC Bridges and 07 No. Stee! ‘Truss Bridges, inthe State of Gujarat and the Union Teritory of Dadra and Nagar Havel forthe Project for Consruction of Mumbsi-Ahmedabad High Speed Rail (Package No. MAHSR-C-4). Submission of Method Statement for Concrete Mix Design for approval. Ret 41. LOA issued by NHSRCL-COMA/CA/OI/PACKAGE-C4/6/2/0HQ975 dated 28" Oct'20 2, Contract: Package No. MAHSR-C-4 Dear Sir, With reference tothe above captioned subject and Contract Specification Section VI-I, Employer's Requirements (General Specifications), we are submitting herewith the Method Staestent for ‘Concrete Mix Design, Senet oaeeerin eee ee enter a eee de hoa Bhavani) te Segment Heed - Metos, Heavy Civil infastucture IC Copy Shri, Pramod Sharma, ED/Contracts, NHSRCL ego Ofc LB Hous. Mg at te mb 0000, A [oer toon ose coeNATIONAL HIGH SPEED RAIL. CORPORATION LIMITED: NHSRCL Larsen & Tobro Limes CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL MAHSR - C4 METHOD STATEMENT FOR CONCRETE MIX DESIGN Document No: MAHSR/LATPKGICAQAQCIMIG A : \ © | 18.12.2020] SM a NK Wg ov » r taal [sign [init [Sin | nat | fon ae NAVNEET ter] ome [See wes [me [PERE [eo Prepared By Reviewed By ‘Approved By fect — | Ciena | aac)CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL PACKAGE C4 METHOD STATEMENT FOR CONCRETE MIX DESIGN Date of Revision 18.12.2020 | SUBMITTED FOR INFORMATION Status‘CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL. PACKAGE C4 METHOD STATEMENT FOR CONCRETE MIX DESIGN Page 3 of 1 INTRODUCTION 4 SCOPE, REFERENCES DEFINITION OF TERMS [RESOURCES 5 6 AUTHORITY AND RESPONSIBILITY ‘ PROCEDURE 7 a 9 ‘QUALITY ASSURANCE AND QUALITY CONTROL SAFETY ASPECTS, 10 | ANNEXURES B ANNEXURE:1: SAMPLE FORMAT-MIX DESIGN STIPULATION 4 'ANNEXURE-2; SAMPLE FORMAT. CONCRETE TRIAL MIX OBSERVATION RECORD "ANNEXURE-3: EHS RISK IMPACT REGISTER/ASSESSMENT 1”‘CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL PACKAGE C4 Q (METHOD STATEMENT FOR CONCRETE MIX DESIGN Doc. No: HAHSR/LBT/PKG/C4/QAQC/0006 , Rev -O Page 4 of 19 }) INTRODUCTION: “This method statement describes the sequence of designing concrete tral mixes is to determine the most ‘conomical and practical combination of available materials to produce concrete that wil satefy the performance requirements under particular conditions of se 2) score: ‘This method statement is covering fr all concrete grades to be used in Ct package of NHSRCL Project Site such as MSO, M40 Pile, M40, M35, M30, and M20 3) REFERENCES: Contract Technical Specification Seetion VI. Employer's Requirements (Technical Specifications) IRS: CBC: 2014 15 269:2015 Specification for Ordinary Portland Cement 1S 1489: 2015 Specification for Portland Pozzolana Cement 1s 3812: 2013 Specification for Pulverized fuel ash (Par-1) 1s 167142018 Specifcaion-Ground Granulated Blast fumace slag for us in Cement mortar and concrete 1s 10262-2019 Concrete Mix Proportioning Guidelines ‘SP 23 ~ 1982, Handbook on Concrete Mixes, 1S 383: 2016, Coarse and Fine Aggregate for Concrete ~ Specification (Third Revision) 1S 456: 2000 (REAFFIRMED 2016), Plain and Reinforced Conerete-Coceof Practice 1S 516; 1959 Method of tet for Strength of Concrete 18 1199: 1959 (REAFFIRMED 2013), Methods of Sampling and Analysis of Concrete 1S 2386: 1963 (REAFFIRMED 2016), Methods of Tes for aggregates fo Concrete: Prt to Vill 18 2430: 1986 (REAFFIRMED 2014), Methods for Sampling of aggregts for Concrete 18 3085: 1965 (REAFFIRMED 2016), Method of Test for Permeability of Conerete 18 7320: 1974 (REAFFIRMED 2013), Specification for Conrete Slump Test Apparatus 18 903: 1999 (REAFFIRMED 2018), Specification for Concrete Admintres 18 9013: 1978 (REAFFIRMED 2013), Method of Making, Curing snd Determining Compressive ‘Strength of Accelerated Cured Concrete Test Specimens Other Relevant Standards & Specifications applicable to the projectCONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL PACKAGE C4 (a METHOD STATEMENT FOR CONCRETE MIX DESIGN oe. Nos MAHSR/LAT/PKG/€4/QKQC/0006 , Rew -0 Pape 5 of 19 4) DEFINITION OF TERMS ‘Admixture~ A material other than Water, aggregates and hydraulic Cement, used as an ingredient of concrete or rortar, and added to the batch immediately before or during its mixing to modify one or more ofthe properies of concrete CConrse Aggregate ~ Crushed stone or crushed boulders, gravel or such othe inert materials, conforming generally to 18: 383, Fine Aggregate ~ Natural sand or sand prepared from crushed stone, gravel or such other inert materials, conforming generally 1015: 383, Batching ~ Weighing or volumetrically measuring and introducing into the mixer the ingredients for a batch oF concrete or mortar Concrete A mixture of Cementitious material, Water, Fine and Coarse Aggregates with or without sdmintres Consicteney The celaiveplaiiy of feshly mixed conerete oe mariar, an 8 measire of its worksily (Cube Strength — The loud per unit rea at which standard cube fs when tested in a specified manner. Curing of Conerete ~ Maintenance of moisture conditions to promote continued hydration of Cement i the consrete Slump — A measure of consistency of ffeshly mixed concrete mortar, or stusco equal to the subsidence ‘measure tothe nearest 6mm ofthe moulded trncated cone immediacy afterremoval ofthe skimp cone. ‘Water-Cement Ratio “The rato of amount of Water, excusive only of tha absorbed by the aggregates, to the amount of Cement in a conereteor mortar mixture; preferably stated asa decimal by weightCONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL PACKAGE C4 © METHOD STATEMENT FOR CONCRETE MIX DESIGN aren & Torn Lied sia ea Page 6 of 19 5) RESOURCES + Materials (© Cement / Cementitious Material (© Mineral Admixture © Coarse Agsregate (© Fine Ageregate © Water (©. Chemical Admixture + Manpower (©. Batching workers siled& tained at Ready Mix Coneret plant laboratory premiset © QC Technicians to measure slump, temperature ete. of fresh concrete & hardened concrete cube crushing © QC Engineer Inspector to record the results of abservationsin specific forms + Equipment? Apparatus (© Batch Mixers setup at Ready Mix Coneree Pant laboratory {© Slump cone set, Thermometer, adequate Cube moulds, Curing Tank, Cube crushing ‘machine, aggregate Sieves, weighing scales ee ©) AUTHORITY AND RESPONSIBILITY 64: FOR COMMERCIAL READY MIX CONCRETE SUPPLIER [Ready Mix Conerete Supplier QC Representative: He shall propose themix design proportion ‘Contractor QC Representatives based on raw material test results, slump retention requirement considering the pouring location during actual use of mit a site All tarts salle conducted a roped independent laboratories and evidence test reports shall be submited long wth the mix propos Ready Mix Concrete Supplier QC Technicians: shall be responsible for observing testing the fresh & hardened concrete properties as required such as slump, temperature of concrete, air content, and ‘compressive strength at Accelerated Curing Testing, 7 & 28 days and reco! them inappropriate forms Contractor QC Representatives: He shall review the test reports of raw material and mix proposal based on contractual requirements and coordinate with Client QC Representatives to witness the til process from fresh concrete materials mixing stage to hardened concrete crushing strength testing stage and ensure to acknowledge the results by signing off inthe joint trial forms as in attached sample‘CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL PACKAGE C4 QO METHOD STATEMENT FOR CONCRETE MIX DESIGN Doc. Not MAHSR/LAT/PKG/C4/QAQC/0006 , Rev -O 7 0f 19 herewith. He will be submitting the Mix Design submittals to Client approval after the hardened ‘concrete taining the satisfactory results ‘Client QC Representatives: He shall randomly review the mix proposal and witness the trial mix process at any stage and sign off the record based on availabilty. Inthe absence of Client Representative, Contractor QC Representative shall witness slong with Ready Mix Conerete plant QC Representatives to ensure the continuity of tral process ‘6B: FOR DEDICATED READY MIX CONCRETE PLANT AT SITE Contractor QC Representatives: He shall propose the mix design proportion 10 Client QC Representatives based on raw material test esl, sump retention requirement considering the pouring location during acl use of mix a site ‘He shall review the test reports of raw material based on contractual requirements and coordinate with Client QC Representatives to witness the trial proces. He willbe submitting the Mix Design submitals to Client approval afer the hardened concrete attaining the satisfactory results ‘Contractor QC Technicians: shall be responsible fr observing / testing the fresh & harden concrete properties as required suchas slump, empersture of concrete, sir content, and compressive strength st ‘Accelerated Curing Testing stages, 7 & 28 days and record them in formats, (Client QC Representatives: He shal jndomly review the mix proposal and witness the trial mix process at any stage and sign off the record based on his availability. In the absence of Client Representative, Contactor QC shall continue to witnes the tra 1) PROCEDURE 7.1 General: Following inputs data required initlly to start the Concrete Mix Design Tras, > Grade designation ‘Type of Cement / Cementitious Material Minimum Cement / Cementitious content cess to ensue its continuity Maximum Cement / Cementitious content Maximum Water-Cement ratio “Maximum nominal sie of ageregate ‘Type of aggregate aw Material Test Reports Exposure conditions Worksbility vvvvvvvvvy “Method of conerete pouringCONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL PACKAGE C4 © METHOD STATEMENT FOR CONCRETE MIX DESIGN /qaqcj0006 , Rev yage B of 12 > Degree of site cont 12 Cement / Cementitions Materiat ‘Cement tobe used shall be any ofthe following types and Furth mentioned in IRS : CBC clause 4.1 4,53 Grade Ordinary Portland Cement conforming to 1S 269 b. Portland Pozzolana Cement ~ Specification conforming tolS:1489 ‘© Cement as mentioned in IRS : CBC 44. Cementitious Material like Fly ash, GGBS &Silice fume ec can be used as per IRC-CBC Clause 4 ©. For selection of Minimum Cement / Cementitious Contit & Maximum Water-Cement Ratio, the Contract Specification Section VI. Employer's Requirements (Technical Specifications) & IRS ‘CAC Shall be refered forthe relevant Grades of mix design for concrete 73° Water ‘Water wed for Mixing shall be clean and fee trom ols, acids, alkalis, salts, sugar, organic materials or other substances. Water shall meet the specified requirements as specified in IRS = CBC Clause 43, (Ctause 4.3) “Organi oo met nore Soon met Soiphat= @=S0) | some Chiorides Ge C1) | 2000 mat for pnw concrete ‘Works, 1000 mgr for veinforced ‘concrete works snd $00 mp for Spended nan 74 Coarse & Fine Aggregate: i. Coarse Agaregate (20mm &10mi) shall meet the gradation requirements as specified in IS 383. ii, Fine Aggregate shall meet the gradation requirements as specified in IS 383, Zone Classification for sand tobe done and Fineness modulus to be worked out fom the Gradation report for Sand 20mm & 10mm Grading requirement is given in IS 382 ~ Table? For Fine Aggregate, Grading requirement i given in [S 383 ~Table 9CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL. PACKAGE C4 @ METHOD STATEMENT FOR CONCRETE MIX DESIGN | Dec. No: MAHSR/LET/PKG/C4/QAQC/0006 , Rev -0 Page 9 of 19 '¥. For Grading confirmation & acceptance of Coarse & Fine Agaregat, it shall meet the All in aggregate grading requirement of 1S 383. (Table 1) (Clowes 61 and 62) ‘Regret fons Tas Daw Bem Tem ESR oo) 8 Oo oa Table > Fine Agarenatee (crawse 63)CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL. PACKAGE C$ © METHOD STATEMENT FOR CONCRETE MIX DESIGN MAHSR/LAT/PKG/c4/0R0C/000 rage 10 of 19 18 Chemical Admixtures Admixtures shall conform to the requirements of Contact epecifiation, Section V3. Employer's Requirements (Technical Specifications & IRS : CBC clause 4.6) 7.6 Target mean strength for Mix Proportioning as per 1S 10262 clause 42 “Target mean strength of concrete tobe calla as pr IS 10262 Target mean strength = f+ 1.65 « Sor fa 1.65 * X whichever is higher ‘Where, fk ~ Characteristic strength 'S~ Standard deviation, Refer clause 42.1. I$ 10262 ‘X>factor based on grade of concrete asper Table I of IS 10262 “Table 1 Value of X (Clause 4.2) St Grade of Concrete Value of X No. ay @ e a M10) ans} 0 35 wo M420) M25, M30" M35) 40 Mas M50 M55 M60. M65 and aboveCONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL. PACKAGE C4 © METHOD STATEMENT FOR CONCRETE MIX DESIGN 1 &Tosbro Lined Doc. No: MAHSR/LBT/PKG/C4/QAQC/0006 , Rev -0 | Page a1 of 19 47 Selection of Air Content: Please refer below table 3 of I 10262 ‘52 Estimation of Air Content Approximate amount of entrapped air o be expected ‘im normal (aon-sir-entrained) concrete is given in Table 3 ‘Table 3 Approximate Air Content (Clause 5.2) 3] Nomina Nisin See Ne" of Anarene 78 Selection of Mic Proportion 7B. Selection of Watr-Cement Ratio: ‘© Selection of Witer content shall be dane as per IS 10262 Table 4 based on maximum aggregate used in Concrete with compliances of maximum Water Cement ratio given In Contret Teeical Specification Division 02000 clause 48.3 & IRS : CBC. ‘Table 4 15 10262 2019‘CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL. PACKAGE C4 @ METHOD STATEMENT FOR CONCRETE MIX DESIGN Doc. No: MAHSR/LET/PKG/C4/QAQC/0006 , Rev az of19 182 183 184 18s 136 187 188 Cement / Cementitious content shall be calelatedfixed by conelating Water-Cement ratio and ‘Water content as pet above table 4 of IS 10262, Selected / considered Cement / Cementitious content shall be camplied 10 minimum Cement / Cementitious content as given in Contact ‘echncel Specification Division 02000 clause 4.8.381RS : CBC Absolute Volume of Cement pase (Cement + Water+ Admintue), Coarse Aggregate and Fine ‘Ageregate tbe calculated, ‘Weight of al the ingredients for 1 cubic meter of concrete ta be calculated Ingredients weight pr batch tobe calculated 3 numberof batches of concrete tobe produced and 6 cubes shall be casted in each atch ‘Slump to be checked for inital, 30min, 60min 90min a pr ste conditions CCoverete mix shal le checked visually for cohesiveness also check segregation and bleeding if any Total number of cutes tobe cated per wal shall be 18 No's. I required additional eubes shall be cased for Accelerated Curing Testo determine the early strength forecasting as per IS 9013 3 cubes fom each butch shall be tested for 28 days. i.e 9 cubes Remaining cubes shall be ested for 3 days and 7 days "eatiticaton mark 9) be done on the top surface of casted cubes CCulbes shall be cure in the curing tank and temperature of Water in the curing tank hall maintain at PC + 2°C as perlS 516 Similarly, more wast be done forthe Same gre of concrete with the following, Increase the Cement Cementitious content Decrease the Water Cement io as per workability ‘Change the proportin of Coarse and Fine Aggregates Different brands of Cement Different brands of admixtures Different source of aggregates 7.8.11 Cubes to be tested for 7 days and 28 days Correlate the 28 days strength with Target mean strength ‘The 28 days suength shall be more than the Target mean stength otherwise check the other trial results in following days 118.10 Demonstration of Sample mix design calculation snd Trials shall be given,CONSTRUCTION OF MUMBAI-AHMEDABAD HIGH SPEED RAIL PACKAGE C4 @ METHOD STATEMENT FOR CONCRETE MIX DESIGN aren & Toubro Lite MAHSR/L&T/PKG/C4/QAQC/0006 , Rev -0 rage 13 of 19 78.11 Trials t0 be done by lowering of Cement / Cementitious material and maistainng the required srength 18.12 Based on eld results for desired stength compliances and Standard deviation of field cubes ‘compressive stength, the Concrete mix shall be optimized / revised, which is sated in codes 8) QUALITY ASSURANCE AND QUALITY CONTROL All the ingredients batching data source details, and test results during the fresh conerete tial batching, mixing, and hardening stage ae to be recorded as inthe attached form and it shall be submitted 10 further review and approval of Client upon achieving the required stength. Based on the Accelerated ‘Curing Test (1S 9013) oF 7 Day's age Cube Compressive strength, the Conerete mix design submission shall be done for review & necessary approval from Client to start the supply J work tse 9) SAFETY ASPECTS All the erow working inthe mix batching activities are ro observe the flowing safety requirements: ‘All shall wear nse masks to avoid inhaling ofthe fines from Cement and Fine Aggregates ‘+ Admisture Handling shall be appropriately done to avoid spilling on ground ‘© ACT cubes handling shall be done with utmost ear tobe free from injuries fom hot objects Personnel Protective Equipment (PPE) such as hand gloves, Safety helmets and Safety shoes ae to ‘be ensured during the process of handling the test spesimens Safety Norms a8 per Safety Maal shal ‘© Refer attached EHS RISK. / IMPACT REGISTER/ASSESSMENT implemented 10) ANNEXURES ANNEXURE-I: SAMPLE FORMAT: MIX DESIGN STIPULATION (4 PAGES) ANNEXURE-2: SAMPLE FORMAT:-CONCRETE TRIAL MIX OBSERVATION RECORD (1 PAGE) ANNEXURE-5: EHS RISK /IMPACT REGISTER/ASSESSMENT (I PAGE)Mof 19 @ — 2== ape tic [21ST OATAFOR MATERIAL sesso cams ome ase 8B) FacAgpen Suc fn Sete py alceno. ZERERE ERE EEE i PREEE nner Tenn a Sheet ae15 0f19 ® won anc Nisreu| sear a RTS RSE ROR festa 2) pete mone ee so hueateanson ‘nea pete incon a [vt mcansephrcncad tn) woe [a4 appnoxmars an CONTENT we [as SELECTION OF WATER.CEMENT-RETIO [Renextore Tcontnoed to Sheet Sot16 0f19 TAS PTET iastuccrion ce waren cone fm tnn mre gn 2 sox (6 tr oe 9 slate es a = a) = fmt oe ncee nn a us a a176119 | ——— — = t80 -eraneareneni Aggie! Cones Cate te [sto qulyCIT OF NGREDIEITS REQUIRED FOR). OF CONCRETE SSD a === ee a al = [setae = ier A ‘Chana Admire a amt Pats[SEILE FOR CONCRETE TRA OSSERNATON EC iRof19 ONCRETE TRIAL MIX OBSERVATION RECORD fe ae a co = =z te a ehee ec = =——S = = = as = =——s fase seg eee ee et ———————— ae ee Se ee ERATOR = inavian es