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Method Statement

FOR
RECONSTRUCTION OF THE AKTOBE-MAKAT ROAD PROJECT,
AKTOBE-KANDYAGASH ROAD SECTION". LOT 1 - SECTION I: KM 11-52.
==============================================================

1.0 Steps:

Excavation
100mm Blinding of abutments & piers
Waterproofing for base
50mm Protection screed
Head beam & wing-wall
Pile-cap of pier
Piers
Bearing installation
Bottom slab of deck
Top slab of deck
Reinforcement work
Grouting &closing anchor
Ballast wall of abutment
Approach slab
Parapet on deck slab and sealing joint

2.0 Construction procedure

2.1 Excavation
Separate method statement will be submitted.

2.2 Blinding construction procedure

BLINDING SHUTTER DETAIL

The blinding shall be constructed in succession as the following procedure:

1. Line out the blinding.

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2. Forming the blinding area by timber and plywood.

3. Give the blinding top surface level. The level will be controlled by the top level of steel bars
inserted into the ground at an interval of 4.0m.

4. Inspecting.

5. Concrete the blinding and smooth the surface as required by the waterproofing supplier.

6. Water curing, with the surface covered by hessian cloth and polythene sheet.
7. Remove the blinding formwork.

2.3 Waterproofing procedure

After the Blinding construction is completed, the Waterproofing works of Abutment will be carried
out according to the following procedure:

1. Cleaning the concrete surfaces, keep dry and free form projecting tying wire, concrete curing
membrane, dust, grease.

2. All shape edge will be removed and all depressions filled with mortar prior to the application
of waterproofing membrane.

3. Paint the adhesives bitumen coat

4. Sticking the Bitumen membrane and make the sheets level up.

The method statement for waterproofing works of Piers under water-Level shall be according to
the property and use of special material protecting from seawater agreed by engineer.
2.4 Cement screed procedure

Line out the screed.

Forming the screed area by timber and plywood.

Give the Screed top surface level. The level will be controlled by the top level of
50mmX50mmx50mm concrete block place on the blinding at an interval of 4.0m.

Inspecting.

Concrete the screed and rough the surface as required.


Water curing, with the surface covered by hessian cloth and polythene sheet.

Remove the screed formwork.

2.5 Foundation construction procedure


2.5.1 Contents
General
Reinforcement
Formwork
Concrete pouring
Construction Joint
Curing
Working conditions.
2.5.2 General

After the protection screed is completed, foundation construction works will be carried out
according to the following procedure:

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1. Setting out the center line & edge line of foundation and kicker.

2. Fix reinforcement bars of the foundation, using Class 20/20 concrete spacer blocks to ensure
accurate cover to the reinforcing steel.

3. Fix the foundation formwork and other pre-buried members (drainage pipe etc.).

4. Give level of foundation top surface.

5. Cleaning.
6. Check the reinforcement, formwork and level by the consultant.

7. Pouring the foundation concrete, with top surface finished as approved by Engineer.

8. Curing elaborately.

9. Remove the formwork.

2.5.3 Reinforcement

All reinforcement shall be stored above the ground on the timbers and covered with tarpaulin
to avoid any damage and dust.

All cutting and bending works for reinforcement bars shall be done according to the
specifications and bar schedule approved by the consultant. Cutting and bending machine
shall be used for this work and epoxy coating shall be painted to cover the new cutting ends
and any damage observed during inspection and placement.

All reinforcement steel shall be accurately placed and, during the placing of concrete, firmly
held in its position, and all tying wire shall be 1.2 mm Stainless steel (SI 304) wire(refer to
GS4-4.3). Ensure PVC pipes and other articles embedded in concrete securely fixed in the
correct position.

Concrete spacers will be used to give the proper reinforcement cover.

The top layer reinforcement mesh will be supported to the bottom layer by use of the chair
bar at an interval of 1.2m each way.

Reinforcement placed in any member shall be inspected and approved by the Engineer before
any concrete is placed.

2.5.4 Formwork

All the formwork shall be fabricated and erected according to the approved formwork design
that shall have considered strength, manufacture, lifting, reinforcing and removal.

All the formwork shall keep a smooth surface. Silicone sealant will be used at the plywood
joints to prevent grout leakage.

A pre-made formwork for the kicker 100mm high and shear key will be accurately erected on
the place of wall stem and this formwork will be supported on the reinforcement by small
concrete blocks (Class 20/20) and be supported from the side formwork as approved by
Engineer.

The formwork will be supported to the ground, excavation slope or temporary concrete
blocks whose size must be indicated and approved in advance. All the supports should
properly keep the formwork in its position without any displacement.

Before fixing, the non-staining agent which is compatible with the waterproofing will coat the
formwork surface to keep the surface free from the concrete when it is removed.

All the formwork shall be inspected and approved by the Engineer before concrete poured.

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2.5.5 Concrete pouring

Before pouring concrete, the related reinforcement bar and formwork shall be inspected and
approved by the consultant.

Concrete:

Grade : as per requirement

Slump : 140~160mm (Site shall according to suppliers data)

Interval time : 2 hours (from batching to setting in place) According to


laboratory
Temperature : less than 20 degree
&Specification
Quantity : various

Pump Rate : 40m3

Manpower, equipment and material:

Manpower : 22~25 persons

Concrete pump : 3 sets 2 sets working and 1 set standby

Pokers - 4 inch : 6Nos. 5 working and 1 standby

Hessian cloth : As required

Polythene sheet: As required

Water tanks : As required (with full water inside)

Generator : As required

Lights : As required

Handy tools : As required

Concrete shall be poured continually by layer and stage, each layer shall be around 40 cm,
and each stage shall be around 2.5 m. Each successive layer shall be placed before initial set
of the deposited layer is hardened.

The 20x20mm plastic triangle chamfer will be fixed on the shutter and &short reinforcement
bar (space 1.2x1.2m) will be fixed with top layer reinforcement bar according to the leveled
by surveying and those will control the head beam top level.

The pile-cap top surface will be smooth by steel trowel, and water curing shall start
immediately after initial set of concrete.

24 hours after the concrete poured, the formwork will be removed and water curing with
hessian and polythene sheet will be carried out immediately.

2.5.6 Construction Joint

Construction is detailed on the drawings and shall be constructed in accordance with


specification and as approved by the consultant.
Horizontal construction joint at the bottom of the Abutment walls the pier shaft (10cm higher
than the top foundation level) shall be constructed.

Shear key shall be used at the joints.

2.5.7 Curing

All new placed concrete shall be cured, and curing will begin immediately after finishing and

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continue for at least 7days, curing will be done so that moisture is always present.

The curing will be initiated immediately following the first rub while the concrete is still moist,
and the moisture retaining material shall then be saturated with water and the entire area
covered with hessian and polythene sheet.

2.5.8 Working condition

Safety precautions shall be taken on side at any time.

Vertical dowel bars shall be safety capped.


Appropriate equipment shall be provided to support work.

When night work is necessary, enough illumination will be provided wherever required
through tower lights and projectors.

The equipment and tools shall be in good operating conditions and mechanical crew will be
stood by to deal with any accidental mechanical breakdown or electrical shutdown.

A small store for handy tools and a lavatory shall be set up on site.

2.6 Abutment & wing-wall procedure


2.6.1 Contents
General
Formwork
Reinforcement
Concrete pouring
Construction Joint
Curing
Working conditions.
2.6.2 General

After the protection screed construction is completed, the abutment and wing-wall construction
works will be carried out according to the following procedure:

1. Setting out the center line & edge line of abutment and wing wall and kicker.

2. Fix reinforcement bars of the abutment and wing wall, using Class 20/20 concrete spacer
blocks to ensure accurate cover to the reinforcing steel.
3. Fix the formwork of abutment & wing-wall and water-stop bar and other pre-buried members
(drainage pipe etc.).

4. Give level of abutment & wing-wall top surface.

5. Cleaning.

6. Check the reinforcement, formwork and level by the consultant.

7. Pouring the abutment & wing-wall concrete, with top surface finished as approved by
Engineer.
8. Curing elaborately.

9. Remove the formwork.

2.6.3 Formwork

All the formwork shall be fabricated and erected according to the approved formwork design

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that shall have considered strength, manufacture, lifting, reinforcing and removal.

All the formwork shall keep a smooth surface. Silicone sealant will be used at the plywood
joints to prevent grout leakage.

A pre-made formwork for the kicker 100mm high and shear key will be accurately erected on
the place of wall stem and this formwork will be supported on the reinforcement by small
concrete blocks (Class 20/20) and be supported from the side formwork as approved by
Engineer.

The formwork will be supported to the ground, excavation slope or temporary concrete
blocks whose size must be indicated and approved in advance. All the supports should
properly keep the formwork in its position without any displacement.
Before fixing, the non-staining agent which is compatible with the waterproofing will coat the
formwork surface to keep the surface free from the concrete when it is removed.

All the formwork shall be inspected and approved by the Engineer before concrete poured.

2.6.4 Reinforcement

All reinforcement shall be stored above the ground on the timbers and covered with tarpaulin
to avoid any damage and dust.

All cutting and bending works for reinforcement bars shall be done according to the
specifications and bar schedule approved by the consultant. Cutting and bending machine
shall be used for this work and epoxy coating shall be painted to cover the new cutting ends
and any damage observed during inspection and placement.

All reinforcement steel shall be accurately placed and, during the placing of concrete, firmly
held in its position, and all tying wire shall be 1.2 mm Stainless steel (SI 304) wire(refer to
GS4-4.3). Ensure PVC pipes and other articles for Electrical, bearing fixing, drainage, etc.
that shall be embedded in concrete securely fixed in the correct position.

Concrete spacers will be used to give the proper reinforcement cover.


The top layer reinforcement mesh will be supported to the bottom layer by use of the chair
bar at an interval of 1.2m each way.

The each face reinforcement of wing-wall will be connected t by use of the space bar at an
interval of 1m each way.
Reinforcement placed in any member shall be inspected and approved by the Engineer before
any concrete is placed.

2.6.5 Concrete pouring

Before pouring concrete, the related reinforcement bar and formwork shall be inspected and
approved by the consultant.

Concrete:

Grade : as per requirement

Slump : 140~160mm (Site shall according to suppliers data )


Interval time : 2 hours (from batching to setting in place) According to
laboratory&
Temperature : less than 35 degree
Specification
Quantity : various

Pump Rate : 40 m3

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Manpower, equipment and material:

Manpower : 28 persons

Concrete pump : 4 sets 3 sets working and 1 set standby

Pokers - 4 inch : 8Nos. 6working and 2 standby

Hessian cloth : As required

Polythene sheet: As required


Water tanks : As required (with full water inside)

Generator : As required

Lights : As required

Handy tools : As required

Concrete shall be poured continually by layer and stage, each layer shall be around 40 cm,
and each stage shall be around 2.5 m. Each successive layer shall be placed before initial set
of the deposited layer is hardened.

The plastic chamfer 20mmX20mm will be fixed on the shutter according to the leveled by
surveying and it will control the head beam top level.

The head beam top surface will be smooth by steel trowel, and water curing shall start
immediately after initial set of concrete, and water curing shall start immediately after initial
set of concrete.

24 hours after the concrete poured, the formwork will be removed and water curing with
hessian and polythene sheet will be carried out immediately.

2.6.6 Construction Joint

Construction is detailed on the drawings and shall be constructed in accordance with


specification and as approved by the consultant.

Horizontal construction joint at the bottom of the ballast wall (10cm higher than the top head
beam level) shall be constructed and fixing water-stop bar (according with specification and
as approved by the consultant)

Vertical construction joint at the Joint with the ballast wall (10cm out form the wing-wall
vertical face) shall be constructed and fixing water-stop bar (according with specification and
as approved by the consultant)
Shear key shall be used at the joints.

2.6.7 Curing

All new placed concrete shall be cured, and curing will begin immediately after finishing and
continue for at least 7days, curing will be done so that moisture is always present.
The curing will be initiated immediately following the first rub while the concrete is still moist,
and the moisture retaining material shall then be saturated with water and the entire area
covered with hessian and polythene sheet.

2.6.8 Working condition

Safety precautions shall be taken on side at any time.


Vertical dowel bars shall be safety capped.

Appropriate equipment shall be provided to support work.

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When night work is necessary, enough illumination will be provided wherever required
through tower lights and projectors.

The equipment and tools shall be in good operating conditions and mechanical crew will be
stood by to deal with any accidental mechanical breakdown or electrical shutdown.

2.7 Piers construction procedure


2.7.1 Contents

General

Reinforcement

Formwork

Concrete pouring

Construction Joint

Curing

Working conditions

2.7.2 General

a Pier shaft construction work will be carried out after pile cap completed.

b The construction procedure is as below:

c Chipping the construction joint and cleaning.

d Adjusting start bars and fixing reinforcement bars of pier shaft according to the approved
construction drawings.

e Checking the reinforcement.

f Fixing and fastening formwork of the pier shaft. To prevent the mortar leakage, foam tape
will be used between the wall formwork and kicker concrete

g Marking top level with chamfer.

h Fixing curve part reinforcement bars of pier shaft according to the approved construction
drawings.

i Placing concrete (Class AA 45/20) with vibrating using poker and vibrator.

j Curing with water, Hessian cloth and polythene sheet.

k The form removal shall be as the following:

Ordinary Portland cement concrete


Removal of Formwork
Cold Weather (below Normal Weather (over
from
15C) 15C)
Side of beams, slabs, walls
48 hours 24 hours
and columns.
Slab soffit forms (props
10 days 4 days
left under)

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Beam soffit forms (prop
14 days 9 days
left under)

Props to slabs 21 days 11 days

Props to beams 28 days 15 days

Table 1#

l Reinforcing steel shall be protected at all times from damage by storing on blocking, racks, or
platforms. Prior to placing concrete, reinforcing steel which is to be embedded shall be free
from heavy rust, dirt, mud, loose scale, paint, oil, or any other foreign substance.

m All embedded item must be in their correct position and solidly fastened and to be check by
engineer

2.7.3 Reinforcement

a All reinforcement shall be stored above the ground on the timbers and covered with tarpaulin
to protect any damage.

b All cutting and bending works for reinforcement bars shall be done according to bar schedule
approved by the engineer. Cutting and bending machine shall be used for this work and touch
up with approved epoxy coating shall be applied to cover the new cutting ends.

c All reinforcement steel shall be accurately placed and, during the placing of concrete, firmly
held in position in the formwork by use of approved concrete spacers Pile cap cover 100mm
and pier shaft cover 80mm.

d Reinforcement placed in any member shall be inspected and approved by the Engineer before
closing the formwork.

2.7.4 Formwork

a Formwork of structures to be checked for conformance to line and grate and all exposed
sharp edge to be chamfered with plastic triangular fillets not less 2cm by 2cm.

b All the formwork shall be inspected and approved by the Engineer before they are erected
and concrete is casting

c All the formwork shall keep a smooth surface. Silicone sealant will be used at the plywood
joints to prevent grout leakage.

d Before fixing, the oil released agent which is compatible with the waterproofing will coated
the formwork surface to keep the surface free from the concrete when it is removed.

e Before casting concrete care should be taken to cleaning the concrete areas by using air
compressor to collecting any dust small piece of timber and binding wire.

2.7.5 Concrete pouring

Before pouring concrete, the related reinforcement bar and formwork shall be inspected and
approved by the consultant.

Concrete:

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Grade : Class 35/20

Slump : 140~160mm (Site shall according to suppliers data )


According to
Interval time : 2 hours (from batching to setting in place) laboratory&
Temperature : less than 35 degree Specification

Quantity : various

Pump Rate : 30m3


Manpower, equipment and material:

Manpower : 15~20persons

Concrete pump : 3 sets 2 sets working and 1 set standby

Pokers - 4 inch : 6Nos. 4working and 2standby

Hessian cloth : As required

Polythene sheet: As required

Water tanks : As required (with full water inside)

Generator : As required

Lights : As required

Handy tools : As required

Concrete shall be poured continually by layer and stage, each layer shall be around 40 cm,
and each successive layer shall be placed before initial set of the deposited layer is hardened.

Wire nail will be fixed on the shutter according to the leveled by surveying and it will control
the pire top level.

The piers top surface will be smooth by steel trowel, and water curing shall start immediately
after initial set of concrete, and water curing shall start immediately after initial set of
concrete.

24 hours after the concrete poured, the formwork will be removed and water curing with
hessian and polythene sheet will be carried out immediately.

2.7.6 Construction Joint

For pier of fixed Connection with deck horizontal construction joint at the top of pier shaft
bottom of deck slab shall be constructed.

Shear key shall be used at the joints.

2.7.7 Working condition

Safety precautions shall be taken on side at any time.

Vertical dowel bars shall be safety capped.

Appropriate equipment shall be provided to support work.

When night work is necessary, enough illumination will be provided wherever required
through tower lights and projectors.

The equipment and tools shall be in good operating conditions and mechanical crew will be
stood by to deal with any accidental mechanical breakdown or electrical shutdown.

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A small store for handy tools and a lavatory shall be set up on site.

2.8 Bearing installation


2.8.1 General
The removable Reinforced Elastomeric Bearings should be used and replaced by design,
when the Elastomeric bearing reach to using and design deadline.
2.8.2 equipment and material
1. The dry mortar with small aggregates and liquid component from construction
chemical supplier.
2. Reinforced Elastomeric Bearings
3. Grinder machine 4 with concrete cutting and grinding disc
4. Light chipping-hammer
5. Air-compression
6. The slow speed(400/500) heavy duty drill
7. Measuring container
8. The mixing paddle
9. The bucket for grouting
10. Protection glasses
2.8.3 Sequence:
Rough surface of concrete step
Drill the anchorage hole
Grout the block for controlling levels
Fix the shutter
Mix and grout the leveling layer
Place the Elastomeric Bearings
2.8.3.1 Rough surface of concrete steps
a) Before fixing the elastomeric bearings, should be made rough surface for the
leveling layer grouting as follows:
b) The minimum 50mm concrete thick steps for placing bearings should be ready
after previously constructing of abutment.
c) Oil and grease deposit should be removed by detergent scrubbing or the use of a
proprietary degreaser.
d) Use the light chipping-hammer roughing the surface of concrete steps
e) Clean the roughed face by oilfree compressed air.
2.8.3.2 Drill the anchorage hole
Drill the anchorage hole of 20mm Diameter at four corners, and clean them.
2.8.3.3 Grout the block for controlling levels
Before grouting the leveling layer, it should be given the exact the levels, the little
block is made for controlling the levels and easily for leveling.
a Putting box shutters around 50x50mm on the top of anchoring block, and use
little mortar and liquid component mixing and grouting into the box shutters.
b After the block harden, use the 4 grinder machine grinding according to the
given the levels of top of leveling face till the levels is exact
2.8.3.4 Mix and grout the leveling layer

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The mixing of dry mortar with small aggregates and liquid should be strictly done
as follows:
a Clean the mix vessel and the mixing paddle
b Measure out some liquid component into the mix vessel and add the relevant
ratio of dry mortar (refer to products instruction) slowly, the dry mortar
should be loose-filled to rating value.
c Mixed the dry mortar and liquid component by used slow speed (400/500)
heavy duty drill and paddle around 3 minutes. Pay closer attention to bottom
and sides of the mixing vessel until a fully homogenous paste is achieved.
Use the mixed homogenous mortar grouting into the boxing shutter up to the
given levels by the block height.
2.8.3.5 Place the Elastomeric Bearings
Before fixing the elastomeric bearings, it should be done as follows:
a The levels should be checked again, and the point for orientation should be
given and made the cross liners for easily fixing.
b If the level is little high, should be grinded down to exact levels
c Make sure the top face is one level face, otherwise it should be grinded and
leveling
d After the above things have be sure, the elastomeric bearings should be the
gently lifted and placed on the leveling layer according to the given
orientation and location by manual.
2.9 Bridge deck(box girder)
2.9.1 Bottom slab of deck
2.9.1.1 Contents
Construction joint treatment
Scaffolding
Formwork for bottom slab
Formwork for out web outside and cantilever bottom
Reinforcement of bottom slab, webs and diaphragm
Post-tensioning duct
Post-tensioning anchorage and end formwork
Tendons
Formwork of inter-webs and diaphragm
Pouring concrete of bottom slab and webs(1st stage)
Curing
Working conditions
2.9.1.2 General
a) The preparatory work for deck construction will be carried out during
sub-structure construction, it includes backfilling and temping, pre-casting base
blocks for scaffold, making reinforcement bar, fabricating formwork etc.
b) The construction work shall be carried out according to the program. The general
procedure for each deck is as below:
1. Construction joint treatment
2. Erecting scaffolds

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3. Bearings installation
4. Laying formwork for bottom slab
5. Installing outside formwork for outer webs and cantilever
6. Fixing reinforcement of bottom slab, webs and diaphragm
7. Installing post-tensioning duct
8. Installing post-tensioning anchorage and end formwork
9. Fixing formwork of webs and diaphragm
10. Pouring concrete of bottom and webs (1st stage)
11. Curing

2.9.1.3 Construction joint treatment


For each out web: One horizontal construction joint will be set at top level of top
fillet.
For each inner web: One horizontal construction joint will be set at top level of top
fillet.
For each diaphragm: One horizontal construction joint will be set at top level of
top fillet.
Before fixing reinforcement, the related construction joints (above mentioned)
should be chipped and cleaned.
2.9.1.4 Scaffolding at land area
Sub-base
Before the deck construction work started, the ground should be backfilled,
tamped and leveled as required by the formwork design.
Concrete base block
a) According to the base condition, the concrete block will be used as plinth for
the vertical supports of the scaffoldings on ground.
b) The dimension of the blocks will be determined by calculation according to
the intensity of the base.
c) To ensure that the blocks are horizontal and uniformly touch the ground, a
layer of 2cm thick sand will be spread under the blocks.
d) Before placing the blocks, the position of each scaffoldings will be set out
according to the scaffoldings distributing design, the blocks will be placed in
its position accurately.

e) Erecting scaffolds
f) Line out scaffolds position according to the formwork design.
g) Building the scaffolds according to the formwork design.
h) Reinforcing the scaffolds according to the formwork design, the completed
scaffolds should be integrated at longitudinal and lateral direction.

2.9.1.5 Formwork for bottom slab


The bottom formwork will be laid according to the formwork design.

1) Adjust jack head top level.

2) Setting out the deck centerline on the top surface of abutments and pier.

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3) Lifting and locating primary beams (I Beam).

4) The wood wedge will be used between the beam and fork head to ensure the
beam position.

5) Lifting and locating secondary beams.

6) The secondary beams will be connected to the primary beams with universal
clamps.

7) Laying plywood of the bottom formwork.

8) Two edges of the bottom formwork will be formed in its exactly position as the
formwork design shown.

9) Checking and adjusting top level of the bottom formwork.

10) Seam treatment.

11) All gaps between plywood or between plywood and concrete should be filled and
smoothed with silicon.

2.9.1.6 Formwork for out web outside and cantilever bottom


1) Formwork processing

a) The Formwork for out web outside and cantilever bottom should be
prepared in advance.

b) The Formwork for out web outside and cantilever bottom will be fabricated
as a monolithic piece according to the formwork design.

c) A 200mm width gap will be set between each piece formwork so that the
formwork can be installed and adjust easily. The gaps will be filled up by
plywood after the formwork be installed and located exactly.

2) Adjust jack head top level

3) Lifting and locating the prefabricated unblock formwork.

4) Adjust the position and level of formworks.

5) Fastening the formworks with steel tubes and clips as the formwork design.

6) Filling up the gaps between each piece formwork with plywood.

7) Seam treatment.

8) All gaps between plywood or between plywood and concrete should be filled and
smoothed with silicon.

2.9.1.7 Reinforcement of bottom slab, webs and diaphragm


1) Setting out the diaphragms and webs.

2) Fixing steel bars for diaphragms and bottom slab according to the approved shop
drawings.

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3) Fixing steel bar for webs according to the approved shop drawings.

4) Fixing steel bar for anchorage reinforcing according to the approved shop
drawings.

2.9.1.8 Formwork of inter-webs and diaphragm


1) Formwork processing according to the formwork design, the web and diaphragm
formwork shall be prepared in advance.

2) Closing the web formworks.

3) Close the diaphragm formworks.

4) Adjusting the formworks position and bottom level.

5) Fastening the formworks as the formwork design. The web formwork will be
supported to the bottom formwork by support block. The web formwork should
be tight to the bottom by tie rod to avoid the formwork move up when the
concrete pouring.

6) Making top level of 1st stage concrete.

2.9.1.9 Pouring concrete of bottom slab and webs


Before pouring concrete, the related reinforcement bar and formwork, post-tensioning
anchorage shall be inspected and approved by the consultant.

15 10cm

10 14 35cm

6 9 13 40cm

3 5 8 12 40cm

1 2 4 7 11 40cm

5m 5m 5m 5m 5m 5m

Web Pouring Sequence

Concrete:

Grade : As required

Slump : 130~150mm (Site shall according to suppliers data )


Interval time : 2 hours (from batching to setting in place) According to
laboratory&
Temperature : less than 35 degree
Specification
Quantity : various
Pump Rate : 70m3/hour to 80m3/hour

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Manpower, equipment and material:

Manpower : 60persons

Concrete pump : 8sets 6sets working and 2 set standby

Pokers - 4 inch : 14Nos. 12 Nos. working and 2 standby

Hessian cloth : As required

Polythene sheet: As required

Water tanks : As required (with full water inside)


Generator : As required

Lights : As required

Handy tools : As required

2.9.1.10 Curing
Two water pumps will be provided for supplying curing water to the top surface at each
end of the deck. The top surface of concrete shall be protected from sunshine by wet
hessian covered with polythene sheet after final set.
2.9.1.11 Working condition
Safety precautions shall be taken on side at any time.
Vertical dowel bars shall be safety capped.
Appropriate equipment shall be provided to support work.
When night work is necessary, enough illumination will be provided wherever
required through tower lights and projectors.
The equipment and tools shall be in good operating conditions and mechanical crew
will be stood by to deal with any accidental mechanical breakdown or electrical
shutdown.
A small store for handy tools and a lavatory shall be set up on site.
2.9.2 Top slab of deck
2.9.2.1 Contents
Removing inner web formwork, inside formwork of out web and diaphragm
formwork
Formwork of top slab
Fixing reinforcement of top slab
Edge formwork of top slab
Marking top level of top slab
Pouring concrete of top slab (2nd stage)
Curing
Removing outside formwork for outer webs and cantilever

Removing formwork for top slab

Grouting
Removing bottom formwork and scaffolds

Superstructure waterproofing

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Finishing work
Working conditions
2.9.2.2 Removing inner web formwork, inside formwork of out web and diaphragm
formwork
24 hours after pouring concrete of bottom slab, all inside formworks will be removed.
After the formworks removed, all concrete surfaces will be cured by water immediately,
and will be covered with wet hessian cloth and plastic sheet timely. All removed
formwork should be orderly stacked in a suitable place.
2.9.2.3 Formwork of top slab
Chipping and cleaning the construction joint.
Fixing and fastening the special bracket and support pipe that used as top slab
formwork support according to the formwork design.
Checking and adjusting the jack head top level.
Lifting and locating primary beams.
The wood wedge will be used between the beam and fork-head to ensure the beam
position.

Lifting and locating secondary beams.


The secondary beams will be connected to the primary beams with universal clamps.

Laying plywood on the secondary beams.


Checking and adjusting the formwork top level.
Seam treatment.
All gaps between plywood or between plywood and concrete should be filled and
smoothed with silicon.

2.9.2.4 Fixing reinforcement of top slab


Setting out edge line of top slab.
Fixing reinforcement of top slab according to approval shop drawings.
Fixing parapet start bar according to the approved shop drawings.
The start bars should be fixed exactly in its position, so that the precast parapets can
be installed propitiously.

2.9.2.5 Edge formwork of top slab


Processing formworks.
a) The edge formworks will be prepared in advance.

b) Fixing and fastening the edge formworks according to the formwork design.
2.9.2.6 Marking top level of top slab
Marking top level on the edge formwork.
Increasing level control point by steel pipes.
a) The pipes will be tight to the top slab reinforcement by banding wire.

b) Top level of the pipes will be adjusted to the same level with top surface of top
slab.

c) The pipes will be laid on each web.

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d) The pipes will be removed as the concrete pouring progressing.

2.9.2.7 Pouring concrete of top slab (2nd stage)


Before pouring concrete, the related reinforcement bar and formwork shall be
inspected and approved by the consultant.

Concrete:

Grade : As required

Slump : 130~150mm (Site shall according to suppliers data )


According to
Interval time : 2 hours (from batching to setting in place) laboratory&
Temperature : less than 35 degree Specification

Quantity : Various

Pump Rate : 70m3/hour to 80m3/hour

Manpower, equipment and material:

Manpower : 40~60persons

Concrete pump : 8sets 6sets working and 2 set standby

Pokers - 4 inch : 14Nos. 12 Nos. working and 2 standby

Hessian cloth : As required


Polythene sheet: As required

Water tanks : As required (with full water inside)

Generator : As required

Lights : As required

Handy tools : As required

2.9.2.8 Curing
Two water pumps will be provided for supplying curing water to the top surface at each
end of the deck. The top surface of concrete shall be protected from sunshine by wet
hessian covered with polythene sheet after final set.
2.9.2.9 Removing outside formwork for outer webs and cantilever
The outside formwork for outer webs and cantilever will be removed after the 7days
by the top slab pouring.
a) The formwork will be lifted down as unblock piece by crane.
b) All the formwork should be orderly stacked in a suitable place.
2.9.2.10 Removing formwork for top slab
The top slab formwork should be removed before post-tensioning.
The materials of top slab will be taken out from the hole opened in the top slab.
A big fan will be installed near each hole to exchange the air when the workers
working in the deck box.
All the removed materials should be orderly stacked in a suitable place.
2.9.2.11 Post-tensioning

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The post-tensioning work will be carried out after the concrete reached the specified
strength.
A special method statement will be submitted to expound the post-tensioning works
according to approved pre-stressing design.
2.9.2.12 Grouting
After 24 hours by post-tensioning, the ducts will be grouted one by one.
A special method statement will be submitted to expound the grouting works
according to approved pre-stressing design.
2.9.2.13 Removing bottom formwork and scaffolds
The bottom formwork and scaffolds will be removed after post-tensioning.

1) Releasing and reducing height of top and bottom jack head.

2) Removing and putting down the plywood.

3) Removing and putting down the beams.

4) Unfixing the scaffolds.

All the removed materials should be orderly stacked in a suitable place.

2.10 Ballast wall of abutment


Method statement is same as wall.
2.11 Approach slab
Method statement is same as Foundation (pile cap).

3.0 Responsibilities

Project Manager shall liaise with QA/QC Engineer & Safety officer to ensure work is done in
accordance with quality and safety requirements; and liaise with Chief Engineer and Site Manager
to ensure work is done in planned schedules in conformance with applicable specifications and
quality plan.

Chief Engineer shall liaise with QA/QC Engineer & Safety Engineer to ensure work is done in
accordance with quality and safety requirements and liaise with design engineers & supervise the
shop drawings and As-built drawing in conformance with applicable specifications.

The Site Manager liaises with site engineers and subordinate staff & executes the work planned
schedules in conformance with applicable specifications and quality plan.

The QA/QC Engineer liaises with consultant site representative for conducting inspections on day
to day basis.

The Design Engineer executes the shop drawings and As-built drawing in conformance with
applicable specifications, and adjusts the shop drawing according to situation in process of
construction.

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The site engineer co-ordinate with subordinate staff & execute the work as per planned schedules
in conformance with applicable specifications and quality plan.

Responsibility of the Chief Survey is to perform all the required surveying activities required
achieve target dates.

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