This document provides a 36-step checklist for grouting mast foundations for overhead electric lines. It outlines procedures for inspecting site conditions and materials, placing the mast in proper position, mixing and pouring concrete, compacting it, protecting the concrete, record keeping, and submitting reports. Concrete specifications and calculations for a typical M15 mix are also included.

1. CHECK LIST FOR OHE MAST GROUTING REV-00
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1. Check the copy of approved CSD, LOP and the DPR of foundation and JVR for
mast
2. Check the span on both sides, Implantation, step distance, type of foundation,
type of mast, gradient and super elevation.
3. Check type of foundation casted, type of mast / upright erected are as per
approved CSD, LOP and DPR for foundation. If any change observed the same
shall be brought to the notice of in-charge before proceeding further.
4. Check confirmation of changes are recorded the proceed further activity
5. Check for proper tools such as crow bars, shovel, trowel, iron sheet, mortar
hoe, mud pan, water bucket, measuring cup, measurement box, wooden
wedges, measuring tapes, plumb bob/plummet, nylon string and safety items
including nylon/manila ropes of 25 mm diameter.
6. Check use of suitable shutters with proper dimensions as per type of foundation
used while casting the muffs for proper shape and finish.
7. Check for availability of main contractor engineer and safety engineer during
execution
8. Check Permission is obtained in advance from division officers/Staff of TrD,
Engineering and Operating department as applicable.
9. Check Information is given Local Permanent way , TrD, RPF and both side
SM/SS before starting work and all staff , supervisor, engineer are aware of
G&S Rules, safety procedures, applicable instructions and JP issued by
division
10.Check all persons engaged are wearing Personal Protective Equipment.
11.Check for whistle / Flag man on either side to alert the gang for movement of
train
12.Check visually for mast type, make/marking, band ,galvanisation coating, holes,
injury of galvanisation due to transportation / handling, defects, damages,
deformity including bend, twist and inspection mark/seal etc.
13.Check and ensure adequate protection is provided to avoid the mast lean
towards trackside/alongside of track, while adjusting.
14.Check the mast /upright is placed in proper position (implantation, embedded
length, orientation and height of opposite upright in case of portal) by verifying
the web side and bottom portion is in the core hole.
15.Check the embedded length of mast in the core hole is 1.35 metre for individual
mast and 1.45 metre for TTU and Portal up-rights from top of the foundation.
(Cutting length in HLPF and High bank in cutting area should be ensured )

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16.Check the step distance, if it is more than 50cm, Mast should be lifted and
grouted to get adequate height and Super block should be casted on the top of
the foundation. Ex. If step distance is found 60 cm, then mast should be lifted
by10 cm and super block of 10 cm to be casted on the top of foundation to get
required embedded length.
17.Check and adjust the deflection as specified in CSD (particularly at curves),
implantation at platform, yard, obligatory location and verify span and
implantation near signal mast and span near bridges, culverts and OLS
18.Check the wooden wedges are placed firmly after adjusting the mast ensure
the dimensional tolerance on span is +/- 50 mm and the implantation is +/- 20
mm
19.Check following material for grouting at site are approved for M 15 mix:
a. Cement for Make/ brand, Grade, ISI no, batch no & Manufacturing date.
b. Size and quality and quantity of coarse aggregates (20 mm), fine
aggregates (4.75 mm) & Cement shall be of OPC as per IS 12269 Gr 43
or 53.
20.Check and ensure mixing of the dry concrete uniformly i.e. Cement, coarse
aggregates, fine aggregates
21.Check and ensure the required quantity is added with measuring container in
concrete.
22.Check the mixing is done thoroughly for around two minutes to get the
homogenous concrete.
23.Check and ensure Concrete is placed within 15 to 20 minutes of pouring water.
24.Check the concrete is poured uniformly in the core hole.
25.Check proper compaction of the concrete is done to remove air from the
concrete. If compaction is not well, it creates voids/honeycomb in concrete
resulting in reduction of the strength.
26.Check and ensure the compaction is done for every 30 Cm layer of concrete.
27.Check all anchor blocks and foundations of structures carrying overhead
equipment shall be provided with concrete muffs. The top of these muffs shall
be above the level of ground the track formation and of adequate height of not
less than 15 cm for protection during rainy weather

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28.Check for protection done to avoid anyone to disturb muff surface till the
concrete gets hardened (Initial setting)
29.Check and ensure muffs are casted at the same day. The top of such
foundations shall be given a slope of 1 in 50 towards the edge to ensure that
water does not collect at the base of the structure.
30.Check the exposed surfaces of concrete shall be kept continuously in damp or
wet condition by ponding or by covering with a layer of sacking, canvas,
31.hessian or similar material and kept constantly wet for at least seven days from
the date of placing concrete.
32.Check the area is cleaned by removing items such as : balance concrete, pit
cover, empty cement bags, trash items (used for food packaging, preparation,
consuming), plastic items and balance aggregates if any
33.Check the samples of aggregates (fine & coarse), and water from the site
periodically (once in a month) and send it to govt. approved lab for testing as
per approved FQP/Specification and record in sample test register
34.Check and record the, Location Number, date, type of mast, actual implantation
and deflection
35.Check and ensure the DPR is submitted in office within next two days and
update site diary with relevant information which will be subjected to audit
36.Sample Concrete calculation is attached in Annexure 1

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Note : If M15 concrete is used for foundation in locations like HRB , M20 mix to be done for grouting
Annexure :1
Calculation for M15 Concrete (1:2:4)
During concreting when we place wet concrete, it gets harden after certain standard
time. Initial Setting Time : 30 minutes ,Final Setting Time : 10 Hours
Volume of dry Concrete = 1.54 to 1.57 times Volume of wet concrete.
For One cubic metre Concrete work of ratio 1:2:4 ; Sum = 1+2+4=7
Total volume of wet concrete required is: 1.57 Cubic metre
1. Volume of cement = (1/7) x 1.57 = 0.224 Cubic metre; 0.224 x1440 = 323kg
(6.46 bag of 50 kg cement is required for I cubic metre)
2. Volume of fine aggregate or M. Sand required (>.07 to 4.7 mm) = (2/7) x 1.57 =
0.448 Cubic metre
3. Volume of coarse aggregate required (20mm) = (4/7) x 1.57 = 0.896 Cubic
metre.
4. Water cement ratio is maximum 0.6, for one cubic metre concrete quantity of
water required is = 323x0.6 = 193.8 kg or litre.
Use measurement box for correct mixing.
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Relevant Indian Standard Specifications for reference
1. IS 383-1970 Specification for coarse and fine aggregate from Natural Source for
Concrete.
2. IS 456-1978 Code of practice for plain and reinforced concrete.
3. IS 516-1959 Method of test for strength of concrete
4. IS 1199-1959 Method of sampling and analysis of concrete
5. IS 2386-1963 Method of test for aggregate for concrete work. a) Pt. I Particle size
and shape b) Pt. II Estimation of deleterious materials ii organic impurities c) Pt. IIi
Specific gravity, density, (km and bulking. d) Pt. IV Mechanical properties.
IS 12269 Specification for ordinary Portland Cement
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