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Jetty Extension

CONSTRUCTION
METHOD
LONTAR EXTENSION COAL FIRED
STEAMPOWER PLANT
(1x315 MW)

PT. CEMERLANG SAMUDRA KONTRINDO


PROJECT
INFORMATION

Proyek Name : LONTAR EXTENSION COAL FIRED


STEAMPOWER PLANT
(1x315 MW)
Location : Lontar Balaraja
Local Main Contractor : PT. SSP
Duration : 240 HK

CONSTRUCTION METHOD
WORK LAYOUT DRAWING

PLTU 3 (1 x 315 MW)


Jetty Extension
ACTIVITY AREA LAYOUT

Work Area
Jetty Extension
Site Structure Organization

6
MANPOWER
Manpower
Core Manpower : Manpower Support :
1. Project Manager 1. Welder
2. Site Manager 2. Operator of Crane
3. Safety Engineer
3. Operator of Pile Hammer
4. Supervisor
4. Mechanic
5. Superintendent
6. Estimator 5. Concrete worker
7. Quality Control 6. Foreman
8. Drafter 7. Skill worker
9. Surveyor
10. Administrasion
11. Logistik
EQUIPMENT EQUIPMENT LIST

FOR LONTAR JETTY PROJECT

No Description QTY Relocated From Contac person Shipping date Unloading date Location

1 Barge Cemerlang (incl. Tug boat) 1 T.Mesjid Tono

2 Barge Camar (incl. tug boat ) 1 T.Mesjid 0813-6551-1710

3 Crane 50T 1 T.Mesjid 0813-6551-1710

4 Crane 35T 1 T.Mesjid 0813-6551-1710

5 Crane 80T (service piling) 1 T.Mesjid 0813-6551-1710

6 Crane 50/45 T 1 T.Mesjid 0813-6551-1710

7 Hammer DD 63/DD65 1 Perawang Setiawan

8 Rig dia 600 1 Perawang 0813-7147-3881

9 mal bekisting Perawang 0813-7147-3881

10 Genset 150 KVA 1 Medan Steven

11 Genset 100 KVA 1 Medan 0812-6066-1716

12 Trafo las 6 T.api2/Amir 0813-9130-6768

13 Flat deck truck 1 Perawang 0813-7147-3881

Barge ; Crane & Piling Rig 14 Colt diesel 1 Perawang 0813-7147-3881

15 Excavator 1 Merak/Jusuf 0853-1917-2137

16 Pickup 1 Jakarta Amin

17 Operasional car 1 Jakarta 0852-1534-7693

18 Container gudang 2 Jakarta 0852-1534-7693

19 Container office 1 Jakarta 0852-1534-7693

20 Plat baja Jakarta 0852-1534-7693

21 Bar bender 2 Jakarta 0852-1534-7693

22 Bar Cutter 2 Jakarta 0852-1534-7693

23 CCTV 6 Jakarta 0852-1534-7693

24 Lampu sorot 6 Jakarta 0852-1534-7693

Welding Machine 25 etc, small tools 2 jakarta 0852-1534-7693


Material And Safety Tools
Material
Main Materials for this project :
Steel Pipe Pile dia 711 mm, t=14mm(161@16mL+322@12 mL)
Readymix concrete C-303900 m3
Steel Rebar 1000 T ,
Bollard 50 T=8 Pcs , Fender Type V dan Type D
Gantry Rail Crane Span 25 m= 125 mL

Safety Tools
Safety tools required :
o Safety helmed
o Safety Shoes
o Hand Glove
o Life Jacket
o Masker
o Welding Safety Equipment
GENERAL FACILITY LAYOUT PLAN
PILING PLAN
BEAM & SLAB LAYOUT PLAN
CROSS SECTION
PILLING & PILE CAP DETAIL
PILLING &PILE CAP DETAIL
BEAM & SLAP PRECAST DETAIL
GENERAL ACTIVITY
Preliminary Work
A. Preliminary Work
Preliminary work should be done in fourteen (14) days after commencement
date (SPMK) released as mentioned in Keppres No. 80 Tahun 2000 or
amendment. For preliminary it would be done :
1. Making action plan detailed include schedule of equipment and manpower
mobilization.
2. Proceed project administration for guarantee letter, permit of project area
included weather data, soil data, and community development to support the
activity of project as the schedule.
3. Propose the shop drawing to get approval by the engineer regarding to layout
of working area for site office, shelter, warehouse, workshop and boundary.
1. Project Information Board
After commencement date this project information board shoud be
installed soonest and boundary area installed as project direction
approval.
The information improve and explain of :
Project Name :
Ownwer :
Contractor :
Supervision Consultant :
Duration activity :
2. Boundary Fence
The Boundary of fence should be priored before the activity started. Therfore the
activity done in safety condition and monitorable and to separate with other activity of
the contract.
Fence Construction by corugated steel wall supported by strength column posted
around the boundary quoted as activity area functioned as security fence of activity
area , constructed in 7 days.
a. step of construction
1. Staking out should be done for marking of the area boundary.
2. installing the fence column and steel corrugated wall as the main matrials.
3. to strengthen the column could be supported by other column by the inside
area
b. tools:
1. using saw for wooden material.
2. steel scissor for corrugated steel wall .
3. And other tools using for other as the fence construction tools to be builded.
Security fence for the project
1 2

Installing wall and column Back View of the Fence

3 4

Side View Front View


3. Cleaning Area

Cleaning area aiming to make all activity easier to do especially for staking out.
a. Step of activity :
- Logging the trees
- Trimming the grass
- Moving the rock and garbage .

b. Implementation :
1) logging the trees could be done by heavy or light equipment (depend of difficulty).
2) Trimming the grass have no high difficulty could be done by handyman tools
3) Moving the rock could be done by 1 10 personals and for the big size handled by
heavy equipment, and all hard materials should be discarded by the area.
Cleaning Area
1 2

Using Excavator Cleaning by exavator

3 4

Being Cleaned Finish for Cleaning


4. Lighting Area, Security, and Safety
Electricity needed to expedite the work especially for night activity even on the
site of dark area. Electricity resourced by the Generator machine depending of capacity
outputted for the lighting.
a. Equipment :
- Generator
- Pliers
- Screwdriver (test pen)
- Scissors, dll
b. Materials :
- Cable
- Isolation tape
- Lamp
- Switch
- Socked
5. Staking Out
All activity outlining by the staking out and positioning.
Kind of staking out equipment :
Theodolite ( 2 Unit )
Long Tape 50 100 m
Small tape 5 m
Water Pass

Method :
The staking out team should state the starting point by the ocean tide level for
construction level and top of piles and all points accurately.
Controlling the point by the bench mark or local coordinate to state direction of piles
and the distance for the base of construction as the planning .
Staking Out Equipment

Waterpass

Waterpass & board

Measuring by Theodolite
6. Water and First Aid
Explanation :
a. Water
Clean Water or Water of work supplied by the boreholes water resource or other
resources in accordance with the technical specification .

Clean water needs for :


Concrete mixing, plastering, and mortar.
Curing time of concrete
Toilet (MCK)
Mechanical equipment test
Others.

Equipment to procure :
- Bore machine
- Hose
- Bore Pipe
- Jet Pump
- Others for support
7. Mobilization and Demobilization :
For mobilization and demobilization need equipment to be functioned by the
time, number and also for the manpower. For the unspecified worker can supplied from
local area, and for specified worker mobilized from out of local .

Mobilization and Demobilization Process :


- Counted of material and equipment to be mobilized
- Count the transportation charge
- Measuring the materials size for loading and unloading
- Measuring the tools and equipment, and
- Personal to be mobilized to site

Mobilization and Demobilization equipment :


- Using Barges and Tug boat.
b. First Aid (P3K)
First aid is the support activity should be necessary posted at site for accident
case for the worker.

First Aid materials :


Cure wounds
Wound cover
Medicine
Others support firs aid.

First Aid Box


Mobilization and Demobilization
1 2

Crane Service 50 T Pile Crane 100 T and Hammer


3 4

Service Barge Piles Mobilization


8. Documentation, Administration report and As Built Drawing
The activity needed for documentation of the activity from the beginning until 100%
progress achievement , include all data to support the document. .

As Built Drawing :
As built drawing is the final drawing as the actual site implementation for the basic
responsibilities of the activity to be approved.

Tools using :
- 1 set camera
- 1 set computer and other support
- A3 paper.
- Printer size A3 and A4.
Duration of this activity proceed as the project duration
Preliminary Work Chart
FLOW CHART
FLOW CHART OF SHOP DRAWING
MATERIAL SUPPLY

FIRST
PREPARATION
PROPOSAL OF MEETING
MATERIAL

NO
CORRECTION MUTUAL CHECK
SURVEY
OF CALULATION (MC -0 )

CHECK

SHOP DRAWING
YES
NO
APPROVED
MATERIAL CHECK

YES
SUPPLY OF
MATERIAL APPROVED
DRAWING

NO

PERMIT
OF
CHECK
ACTIVITY

NO

YES
CHECK

MATERIAL
USED IN YES
ACTIVITY
WORK
EXECUTION
FLOW CHART
QUALITY CONTROL

PROPOSAL OF
ACTIVITY

NO

CHECK

YES

WORK
EXECUTION

NO

CHECK

NO YES

MAINTENANCE

CHECK

YES

CERTIFIED
CIVIL WORK JETTY EXTENSION 130 x 25 M
1 . Steel Pipe Supply
The Steel Pipe of Piles will use diameter 711.2 mm, 12 & 14 mm thickness and the length per segmen
24+24 m as the drawing and bill of Quantity and : class A 252 Grade 3 ASTM.

The Piles transported from Bojonegara by the sea to location and directly using from the service
barge by the secure barge from the damages
1 . Transportation Illustration

1 2 3

4 5 6

1. Production by fabrication
2. Transportation in fabrication area
3. Loading on factory
7
4. Transportation to site
5. Unloading on site
6. On site Project area
Piling Specification
Piling of Jetty Extension (130 x 25 M2)
Pile SPP dia 711.2 mm
Thickness of pile 12 mm and 14 mm
Lenght Per point 48 m (24+24)m
Vertical piling = 63 points
Tilt piling = 105 points

168 points of Pile


Piles Supply Chart
Phase of the procurement of steel Pipe :

Start

Factory Observation

No

Test Spec

Yes

Ordering

Transport Order

Unloading Finish
4. Piling Activity
Once Piling work starts, it has to be continued without interrupted, except for conection
until the pile is finished to be piled in appropriate with the presistent criteria/characteristic
. The characteristic of piling will be evaluated and necessary will be revised based on the
initial piling data and load test data. The Criteria will be used as a control to the following
piling . If the piling has got a refusal , so the piling has to be done carefully so that it will be
not deprave the piling caused of piling excessive.

On this case , the contractor will report it to the supervision consultant or engineer to decide
the next action to be taken. :
- If pile cant be piled further more, where the elevation of the lower and upper pile is less than
determinate.
- If the piling is not comply with the criteria that has been persistented .
- If theres an obstacle or pile damage during the piling process.
[Vertical Piling Illustration]

Leader/Rig 33 M

Pile Hammer K 45-60


1. SURVEYING
2. PILING
Piles SPP dia 711.2 mm
Tichkness of pile 12 mm & 14 mm
Lenght Per point =48m
2
Crawler Crane 100 T Number of Piles = 63 Point
Jointing = 63 Point
PRESSURE BOOM
1
[Tilt Piling Illustration]

Leader/Rig 33 M

Pile Hammer K 45-60


1. SURVEYING
2. PILING
Piles SPP dia 711.2 mm
Thickness 12 mm & 14 mm
2 Lenght Per Point 48 m
Number of Piles = 105 Point
CRAWLER CRANE
Jointing = 105 Point

1
FLAT BARGE

Cross Section
Piling Prosedure
Responsibility Flow Chart Description Document Support

Start

Surveyor Determine the coordinates and Construction Drawing


Surveying elevation for the foundation and
site clearance
Project Manager Piling equipment mobilization As the Specification
Equipment Mobilization

Ordering and Negotiation


Project Manager Construction Drawing
Pile material supply
Piles Transportation Elevation Data
Design
Project Manager Unloading by Crane Service Construction Drawing
Transportation Elevation Data
Design
Project Manager Construction
Unloading Piling Process Guideline
Construction Drawing
Elevation Data
Project Manager
Piling Process Final Check Design
Construction
Guideline
Technical manager Construction Drawing
Final Check Elevation Data
Repair if not Agree Design
Owner Repair
Agree to Finish Investigation Report
Agree
No
yes Punch List
Owner
TOC and FAC
Finish
[ FLOWCHART of. PILING WORK (SPP) ]

Start Diesel hammer working

Not Ok
Move the pile from the stock pile by crawler Check alignment and
condition
Repair
crane by the sea using service barge

Ok

Transportation of the piles

Unloading process and install to the rig and


hammer Yet
Check Elevation and Final Set

Positioning of piling equipment with survey


equipment theodolite from 2 direction yes

Stop piling
No
Position check by theodolite No
CEK Elevation
Cut of Pile
TOP of Pile
Yes
Ok
Anchoring the barge
FINISH
Piling Illustration

Theodolite

Total Station
1
SEVICE BARGE
LIFTING PILES ILLUSTRATION

STOCK OF
PILES
Theodolite PLACED

Total Station
1
SEVICE BARGE
6. Connection of Steel Pile

Splicing of piles implemented by way of welded. All welding work


should be in accordance with AWS D1.1 standards. Concrete pipe
piles before spliced clan during welding must be held tightly with
a sling and a Clamp fairly rigid construction to ensure that the
axis of the pile of concrete pipe / segments that are connected
in a straight line.

To help straightness created stopper 4 bush each connection


from 12 mm thick plate, connecting plate welding connection
integrity test can be done with penetrant test spread on the
surface of the weld. After a lapse of 5 minutes, if the resurfacing
penetrant seen the black line (groove hair) indicates that in the
welding area there are cracks that need to be re-welding.

The equipment used is the electric welding machine that


adequate capacity (500A) to produce a specified welding quality.
Electrode welding wire used is of the type that has been
stipulated in the technical specifications
JOINTING PROCESS OF PILE
1 2 3

Welding process Pile jointing


POSITIONING

Dubbing and Strengthen for pile


jointing
Cutting piles made after the pole level measured in accordance with the high trestle or pier, and the rest
of the poles that do not fit anymore cutting with cutting torch uses Oxygen and Acetilen / Elpigi.

8 Cuts Stake
Theodolite

Total Station
1
SEVICE BARGE
NOTE PAPER AND
PILE CALENDRING
Theodolite

Total Station
1
SEVICE BARGE
PAPER OF PDA TEST
9. Stop Steel Plate for concrete pouring of pile, t = 10 Installation of steel
plates cast piles stop after cutting stake finish. Plat cast steel stop plate
in pairs using t = 10 mm, to hold the formwork in the manufacture of
concrete floors. Steel plate mounted on poles encircled by way of piling
pipe inserted into each pile with a certain height in accordance with the
working drawings
.

Used Stop Plate


FLOWCHART OF CONCRETE WORK
FLOW CHART FLOW CHART
Start FLOW CHART Start
STEEL WORK CONCRETE WORK
Formwork

Preparation PROPOSAL
of
MATERIAL
Steel Work
START
Job mix
Pengajuan design and
Proposal
Sample /Contoh Trial mix
Shop Drawing besi yang akan
Of Steel Work PROPOSE No
dipakai
No FORMWORK
No
MATERIAL
Check
Drawing Material
Approval Approval
Yes
Yes
MATERIAL PREPARATION
Preparation Of
bending Chart SUPPLIED Main Material
and Bar Bending Yes Of Concrete
Schedule

Ordering Of FORMWORK Preparation


Steel FABRICATION Of
material Eqipments
IN WORKSHOP

Temporary Preparation Area for


Storage
INSTALLING Pouring Concrete
Steel CONCRETE PRECAST
Fabrication in NO
Workshop FORMWORK
Check
NO
Installing
Rebar Yes
CHECK
Pouring
No
Concrete
Check
YES

Yes POURING Finish


CONCRETE
Finish
10. Preparation of cuttings pile reinforcement and pile head
Implementation of concrete casting is done after the installation of formwork and
reinforcement is completed, in this case the implementation of the casting is done
simultaneously for all foundations and columns at a certain height so that it will speed
up the time, which starts from the foundation of the foundry and continued the next.
Pouring fresh concrete into formwork using a cast or use gutters concrete pump /
Excavator / bucket and in the implementation of this we use ready-mixed concrete (Ready
Mix), the concrete used K-350 (fc 30)
Reinforced Concrete Work using concrete steel screw (SNI) around the pile and iron as
iron stirrups in fabricating advance as much as 22 sets and adapted to the head diameter in
concrete, then steel reinforcement will be welded in each stake.

Rebar and Formwork Finish Concreting


11. Concrete Contents of Pile
Concrete pouring of pile :
a. Concrete piles stuffing using ready mix concrete quality K 350 (fc 30)
b. Implementation according the existing measures in the plan drawing.
c. Reinforcement assembled outside according to the image, with the lower end of
reinforcing steel plate welded at t = 10 mm (steel plate stop concrete) so that it can
serve as a basis formwork.
d. Concrete casting is done by using vibrator to prevent segregation of concrete.
e. Charging piles with concrete begins with the closing of the pole with a steel plate (Stop
cast) hung / welded at the lower end of reinforcing stuffing, stuffing inserted steel
reinforcement after the next to do casting the concrete.

Equipment used:
Concrete Pole Contents :
Reinforcement Concreting
1. Blender 1. Concrete Mixer
2. Rebar bender 2. Service Crane
3. Pliers 3. Bucket
4. Tweezers 4. Vibrator
1 2 3

Slump Test Sample of Cube K-400


Ready Mix Concrete

4 5

Fill Concrete to pile by bucket


13. Concrete Beam Precast
Concrete block making do with using quality concrete K-350 (fc 30), The phase of his work as follows:

a. Replace the plate thickness t = 10 mm for precast floor beam.


b. Attach the wall plate beam thickness t = 10 mm in accordance with the necessary requirements and
welded beams.
c. Replace rebar and concrete idea to concrete blankets and tied wire.
d. Replace door and reinforcement beams wall with wooden scaffolding reinforcement, to avoid the
time shift casted.
e. Make checks / check again the formwork connection density and number and position of
reinforcement bars installed and installation of lifting
f. Clean the inside of the formwork by using compressors
g. Once inside the formwork clean casting to do
h. Casting is done by using a mixer and flattened with a vibrator.
i. In casting the beam by over cuttings for grafting purposes to the plate.

Equipment used :
Concrete Pole Contents:
Reinforcement Concreting
1. The cutter 1. Concrete Mixer Blender
2. bending steel reinforcement 2. Carriage Arco
3. Tang 3. Spoon Cement
4. Cockatoo (tweezers) 4. Vibrator

.
1 2 3

Ready Mix K-400 Slump Test


CubeK-400

4 5 6

Rebar of Precast beam PouringReadymix K-400 Precast beam Pouring


14. Concrete Slab Precast
For the manufacture of precast concrete floor through work process stages as follows:
a. Replace the plate thickness t = 10 mm or multiplex thickness t = 9 mm for precast floors.
b. Replace both sides of the multiplex wall thickness t = 9 mm.
c. Replace rebar and concrete idea to concrete blankets and tied wire.
d. Make checks / check again the connection density of formwork and reinforcement position
number and mounted and mounted rebar for lifting.
e. Clean the inside of the formwork using a compressor.
f. Once inside the formwork clean casting to do.
g. Casting is done by using auto mixer and compacted with vibrator.
h. In casting the beam by over-cutting and lifting slab / beam for the purpose of connecting
with slab precast and precast slab appointment.

Equipment used:
Concrete Pole Contents:
Reinforcement Concreting
1. The cutter 1. Concrete Mixer Blender
2. bending steel reinforcement 2. Carriage Arco
3. Tang 3. Spoon Cement
4. Cockatoo (tweezers) 4. Vibrator
.
Fabrication& Erection Preacast Beam
1 2

Pouring Concrete of Precast


Precast Beam Erection
Beam

3 4

Erection Beam Precast Beam Precast Installed


Gantri Crane Rail
1 2

Crane Rail Reiforcement Installing Gantry Crane Rail

Finishing of Gantry Crane Rail


15 Densotip Corrosion Protection
DensotipCorrosion protection is a process of piling protection against rust. Corrosion of steel in seawater is very
complicated. Many factors, such as temperature, salinity, dissolved oxygen, pH, Gyablow waves and currents, as well
as biological pollution. Sea water conditions are also influenced by factors related to the metal. Environmental coastal
structures can be divided into five types based on their position on the surface of the sea, namely: local atmosphere,
blood splashes / pounding (splash zone), the surface area of tidal (tidal zone), the area between LWS with the seabed
(submerged zone), and the area mud (mud zone). Splash zone is part of the experience very severe corrosion, while
relatively mild tidal zone to a vertical rod structure without a protective layer, such as the stake.

Equipment used for the installation:


1. Lock Pas
2. Times for retaining temporary densotip
3. Hammer little bolt hole to hole punch
4. The canoe and pontoon iron drum
5. Diving equipment
Corrosion protection for the stake splash zone areas can be done in several ways, among others:

1. System concrete jacket / blanket concrete. This system did not survive too long. The quality of this system is
determined at the time of casting, and in case of damage will be difficult to repair

2. System jacket HDPE (high density petrolatum). In this system, the first pole is coated with a paste (eqDenso paste)
and then wrapped with tape and marine piling outer material is protected by the HDPE

Pile located at the submerged zone can be effectively protected by wearing a cathode current (cathodic
protection) for metal receiving direct current from the environment such as the cathode electric cells. Corrosion in
wet environments are usually accompanied by cessation of direct current generated by the electric potential
difference on certain corrosion cell. The use of current from an outside source is quite capable of stopping the flow of
corrosion and restore the flow of current to the metal. Technological aspects to consider is how to provide smooth
flow to every part of the stake in the submerged inner zone long time and easily. The portions were not quite accept the
current begins to corrode, while the part that receives too much current will be damaged by the cover of organic
material.
Installing Process of Densotip Protection for corosion
1 2 3

Clamp of densotip Plate strip for densotip bolt


Densotip and bolt plate

4 5 6

Corosion Cover Corrosion Covering Finishing


16. . Installation of Rubber Fender Type V (2000Lx600H)
Works using a type V Installation Fender 2000L x 600H size (23 units) Fender
functions as a buffer when the ship docked to the jetty. To be able to do curbs, fenders
usually have high energy absorption and low reaction force.

Equipment used for the installation:


1. Lock Pas
2. Sling steel
3. Hammer
4. Crane Service / Corkscrew

Fender Type V
9. Installation Bit 50 Ton Bollard
Installation Work Bit Bit Bollard using a type of a capacity of 50 Tons
of 8 units. Bit function as a tether strap Bollard vessel is currently docked
to the boat dock fender.

Equipment used for the installation:


1. Lock Pas
2. Sling steel
3. Hammer
4. A corkscrew

Bit Bollard 50 Ton


MAINTENANCE PERIOD
A. Period of Maintenance for 6 months (180 calendar days) commencing from the period of execution has been
completed with the publication of fiber received first (PHO), the contractor will carry out repairs and
maintenance required during this period at no additional charge so that upon completion of the maintenance
can be handed over both (FHO) which is the same condition at the time of the handover of the first,

B. The criteria used in the maintenance period, include:


1. Fast Action / AC (Immediate Response), should be implemented immediately by a matter of hours if
the damage can lead to a real nuisance to the construction,
2. Immediate action / AS (intermediate Response). Implemented immediately in a matter of days or
weeks, when there is severe damage that can lead to lower physical quality of construction,
3. Action Pause / AT (Delayed Response), implemented within months, remedial action taken to
components that do not directly influence the physical construction,
4. Preventive maintenance, operations need to be planned, programmed and implemented consistently
every year

C. The activities would be likely to have an impact on the maintenance aspect in this regard include:
1. Work HDPE
2. Jobs Fender & Bollard
3. concrete Floor
4. curb
JAKARTA, 24 September 2016
PT. CEMERLANG SAMUDRA KONTRINDO