Doc No.

:
Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 1 / 13

Cirebon 2, 1x1000 MW Coal Fired Power Plant Project

Document No. AI-CB2-C-CT-0004
Rev. 0

Casting Plan For Cooling Tower 4nd

Segmen

PT. Acset Indonusa Tbk

 Doc No. :
Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 2 / 13

TABLE OF CONTENTS

1. MANPOWER & EQUIPMENT MOBILIZED

2. GENERAL DESCRIPTION

3. WORK METHOD

4. FORM REMOVAL AND INSPECTION

5. SAFETY CONTROL AT SITE

6. QUALITY PLAN

7. EMERGENCY CONTACT PERSON

 Doc No. :
Method Statement AI-CB2-C-CT-0003
For
Cooling Tower (Mass Concrete)
Rev. 0 Page 3 / 13

1. MANPOWER & EQUIPMENT

1.1 Manpower

CRAFT OF NIGHT
No. DAY SHIFT Remarks
EMPLOYER SHIFT
1 Super visor 1 1
Dewa+Vibrator+Lighting
2 Electrician 2 2

3 Pump car operator 4 4 (1 Spare)

4 Concrete pouring team 27 27 1 team = 9 man
5 Formworker 3 3

CRAFT OF NIGHT
No. DAY SHIFT Remarks
EMPLOYER SHIFT
6 Rebar worker 3 3
7 HSE staff 2 2
8 QC 1 1
9 Traffic control 3 3
10 Road cleaning 3 3
11 Dewatering team 1 1
Total 50 50

1.2 Equipment

No. Equipment Spec. Work Spare Remarks

1 Pump car 43,35 & 25m 3 1 (25 m)
2 Generator 80 KVA 1
3 Lighting system CT Z1 area 12
4 Spare lighting system Emergency 2
5 Submersible pump Rain 4
Pipe, claim, Rotari &
6 Casting 1 set
Fleksibel
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Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
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7 Panel Casting 3 set

8 Vibrator machine 3 unit 1 unit
9 Stick Vibrator 9 unit 3 unit
10 Blue Sheet 10x30 m 8 unit
11 Stick Lamp 2 unit
12 Trowel 2 unit
13 Water tank 1000 L 2 unit

2. GENERAL

2.1 ESIMATED QUANTITY & PLACING TIME

A. TOTAL VOLUME
1) V= 1107 ㎥
2) V/ 3 Pump cars ≒ 1170 ㎥ / 7 ㎥ ≒ 159 Mixer Trucks / Pump Car

B. ESTIMATED PLACING TIME

1) 1107 ㎥/ 84 ㎥ / HR = 14 HRS (28 m3/CP)
2) 0.5 m (Height) / 14 Hrs ≒ 0.08 m / hr (Estimated Placing Speed)
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Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 5 / 13

C. CONCRETE MIXED TRUCK ACCESS ROAD MAP

Pump car location, slump house, way of truck mixer in/out

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Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 6 / 13

Note : Red radius 25 m + blue radius 43 m & black radius 33 m

PUMPCAR DEPLOY PLAN

ELECTRICAL PLAN
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Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 7 / 13

3.0 WORK METHOD

3.1 Concrete to be used

3.1.1 Concrete Mix Design

A. Concrete Mixing rate

Compressive Total Fly
W/C S/A Water Cement Sand Coarse Ad
Strength Binder ash

MPa % kg/㎥
35 37 40.1 160 432 302 130 670 1000 5.62

3.1.2 Concrete Slump & Fresh Concrete Temperature

All delivered mixer truck from batch plant shall be checked his slump and fresh
concrete temperature via dedicated slump house.
The designed and approved slump is 15cm ± 2.5cm and fresh Concrete
Temperature is below 32℃.

3.2 Concrete Mix Control

Use of ice, chiller water as part of mixing water is effective in reducing concrete
temperature, because on melting alone, to absorb heat. In this case there is no
change in the previous approved design mix.

3.3 Concrete Delivery

Since the temperature rise can be increased with a passage of time thus the
period between mixing and delivery will be kept to an absolute minimum.
Attention will be given to coordinating and dispatching of the mixing trucks with
the rate of placement to avoid delays in delivery.
At Site all existing facilities, which are within the construction site radius
considered to obstruct any work activities, will be removed or be provided with
protection against damage, dust and dirt in mixed truck delivering.
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Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 8 / 13

3.3.1 Planning
A pre-concreting meeting will be held internally and with concrete supplier to
finalize all of the proposed concreting procedure in advance.

3.3.2 Delivery Route

Assigned site access routes for concrete supply will be prepared and traffic
control measures implemented. The proper access must be organized to enable
a continuous transportation of the concrete during the entire period of pouring so
that the required temperature of concrete pour will be maintained.

3.3.3 Concrete Supply

Concrete batching plant capacity and numbers of delivery trucks will be planned
earlier to maintain a continuous supply of concrete so as to prevent cold joint. In
addition to minimize temperature differentials occurred within the concrete mass
during pour.
The Batch plant will have capacity to produce averagely 100 m3 per hours and
will be fully examined earlier with a good manner.

3.3.4 Casting
The Concrete will be placed in a predetermined layering sequence;
approximately 50 cm, to avoid any possibility of cold joint we must pouring 1
segmen on 1 times. It is approximately the time spent in each poured layer will
be not exceeded 60 minutes.

3.3.5 Equipment and Manpower

A detailed equipment and manpower resources schedule will be prepared to
ensure sufficient workforce in each pour. In case of workers, considering
estimated placing time, 2 shift work is expected.
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Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
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3.4 Form work

Sufficient forms and suitable access platforms to execute the work for the entire
pouring will be provided. At least 2 nos access way to evacuate in emergency will be
installed around the top table slab.
Forms will be made of certified materials and include all necessary support bracings
and fixings, steel props etc. The scaffolding access erected will be in compliance
with local regulation. The form components are to be enough strong to support and
resist to concrete lateral pressure.
Basically, the foundation base mat is installed and set by ULMA system which fully
supported in technology with shop drawings.

3.5 Reinforcement Work

Rebar will be supplied and fixed in accordance with the approved construction
drawings. Unless otherwise specified, the rebar passing required test in the
specification shall be only used. Rebar will be cut and bent at the designated yard
close to the work site in accordance with the approved drawing. Bars shall be free
from cracks or splits on bends.
No reinforcement shall be bent down into position in the Works without approval
whether or not it is partially embedded in the hardened concrete.
Unless otherwise specified in the drawings, minimum cover to reinforcement shall
be in accordance with Clause 5.2 concrete cover in the design criteria approved or
specified in the approved drawing.
Reinforcement shall be furnished in full splice length as shown on the approved
drawings.
Field welding of reinforcement shall not be permitted without the prior written
consent or approval.

3.6 Concrete Work

In addition, in case of high temperature during the pouring day is encountered the
pouring is considered to be carried out at the night time.
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Casting Plan AI-CB2-C-CT-0003
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In case of sudden rain, plastic sheeting or canvas will be used to cover the concrete
top surface. The plastic sheets will be provided sufficiently both for emergency case
of sudden rain and for fully cover the whole concrete surface immediately.

- Canvas w/proper slope (Rain cover if necessary)

when rain uses a blue sheet to cover

it on concrete

Pre-pour inspection of the rebar, form panels, embedded items and construction
joints will be carried out before concrete pouring.
Three (3) concrete pumps and One (1) back-up pump car will be engaged for
concrete pouring e.g. 3 pumps is organized for concrete pouring; 1 pump will be at
the workface for standby and will be on duty when the pouring pump is trouble or
breakdown. The concrete pump arrangement will be prior arrangement for their
highest efficiency when the concrete placement is to be carried.
Electric-type concrete vibrators will be used for concrete compaction during
concrete placing to ensure adequate vibration keeping each 50 cm distance during
the entire pouring stage with sufficient quantity (Refer to clause 4.2 Equipment) and
continue finish with trowel so concrete can levelling, for safety worker required for
use rubber shoes. Provide water tank for do curing and finish concrete trowel
machine.

3.7 Protection & Curing after Pacing

Mechanical disturbance of concrete during the specified curing period and damaged
to finished concrete shall be prevented. After completing placing and finishing
operations, efforts must continue to protect the concrete from high temperature,
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Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 11 / 13

direct sunlight, low humidity and drying winds. If possible, the work should be kept in
a uniformly moderate temperature condition to allow the concrete to develop its full-
strength potential.
The concrete should also be protected against thermal-shrinkage cracking from
rapid temperature drops, particularly during the first 24 hours.

Air Bubble Sheet

Non Woven pabric

0.5 m

The combined protection material as below will be used for curing purposes. This
will be done immediately once the concrete is reached its stiffening time by fully
cover the whole concrete surface onto the whole to prevent concrete temperature
loss too quick and result high temperature differential between the surface and at
the middle. Care must be taken during the entire curing (for 7 days) to ensure.

4. FORM REMOVAL AND INSPECTION

The forms shall not be removed until the concrete is sufficiently set to bear both
dead load and live load which may be on it.
Removal of forms is only carried out when concrete meets the required strength and
avoid causing sudden stress or crack to affect to the concrete structure. After 14
days from placing, the forms can be removed with shoring. After form removal,
concrete surface shall be investigated and notify the employer to inspect. In
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Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 12 / 13

addition, form tie holes can be filled and any necessary repairs made by uncovering
a small portion of the concrete at a time to carry on this work with approved
materials. These repairs should be completed in the first few days after stripping so
the repairs and tie-hole fillings can cure with the surrounding concrete.

5. SAFETY CONTROL AT SITE

One of the main aspects of this procedure is Safety and Health Control. This is to
control occurrence of injuries as well as damage to equipment and properties during
the entire execution period. In order to ensure a safe working environment during
the entire execution period, the following safety measures will be implemented as
follows:

6. Quality Assurance and Control

1) Works shall be carried out strictly in accordance with relevant

technical specifications and construction drawings.
2) Survey accuracy shall be improved by repeat survey and regular calibration
of instruments.
3) Support of formwork not leak, fixing alignment of formwork
4) Checking rebar free from dust and any other mill scale
5) Check Slump test, temperature of concrete & ambeint
6) Delivery T ime , height limit of placing, compaction (space, depth,
time of penetration) and segregation of concrete
7) Protected by approved means from rain, sun and wind, keep free any vibration
disturbance
7. Emergency Contact Person

1) Deputy Project manager : +62 821-6685-1967 (Ikhsan)

2) Project Eengineer Manager : 081310868645 (Nurcahyanto)
3) Construction manager : +62 821-1075-8887 (Baidhowi)
4) Safety Officer : 085717009309 (Edi)
 Doc No. :
Casting Plan AI-CB2-C-CT-0003
For
Cooling Tower 4nd Segmen
Rev. 0 Page 13 / 13