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Concrete Method Statement
Concrete Method Statement
K. P. S
METHOD STATEMENT CONCRETE WORKS
RAZ AL KHAIR ALUMINUM SMELTER
Table of Contents
1.
2.
3.
4.
5.
6.
7.
8.
Scope
Purpose
References
Responsibilities
Equipments
Material
Shop Drawings
Procedure
8.1 Excavation and Backfilling
8.2 Formwork
8.3 Steel Reinforcement
8.4 Embedded Metals, Anchor bolts
8.5 Concrete Placement ( Stage-1)
8.6 Concrete Placement ( Stage-2)
9. Concrete Compaction
9.1 Curing of Concrete
9.2 Curing of Top Surface
9.3 Curing of Vertical Surface
9.4 Curing Compounds
9.5 Pre- Cast Concrete
9.6 Pre Concrete Placement Activity
9.7 Activities during the Concrete Pouring
9.8 Release of Formworks
9.9 Repairs
9.10 Water Proofing
9.11
Coating and Backfilling
10. Safety
11. Attachment
1.
SCOPE
The scope of this method of statement is to cover concrete works activity which includes
( Formworks installation, rebars supply and installation, concrete supply and placement, water
proofing, etc.) d supply for cast in situ Concrete in the project. In accordance with contract
requirements and approved project specification, project safety procedure and approved issued for
construction drawings.
2.
PURPOSE
The method statement shall address the precedence of physical operations applicable for the
supply and placing Structural / nonstructural Concrete on the project.
This Method Statement is to ensure that concrete works activity will be expedite in an efficient
and safe manner in accordance with all relevant contract documents, (Specification and
Drawing) and international accepted methods, utilizing proven methods and procedures, as
detailed herein and was implemented on previous projects.
3.
This Method Statement is for submittal to Consultant / Employer for their concurrence.
This Method Statement will, if deemed necessary, be revised as and when required to
accommodate circumstantial requirements that cannot be foreseen at this page.
REFERENCES
a) Project Standard Specification for CONCRETE WORK
25457 0000 3PS DB00 0001 Rev. 001 for Concrete Work
25457 - 0000 3PS - DB01 0001 Furnishing and Delivering Ready- Mix Concrete
25457 - 0000 - 3PS DG01 0001 Reinforced steel, Embedded items and
Miscellaneous Concrete Accessories.
b) EN 206-1 Concrete specification, performance, production and conformity.
c) EN 12620 Aggregates for Concrete
4.
RESPONSIBILITIES:
Project Director / Project Manager have the responsibilities for overall the project
activities including safety measures.
Site Engineer / Site General Foreman: Shall be supervising closely that activities
designated to them ensuring that all instruction are followed are strictly adhered to,
(this may involve providing alternative access routes for moving Traffic with Traffic
Signs if necessary are in place prior to commencing the work, safety procedures of the
project are strictly followed.
The SE shall be responsible for the following:
To ensure that the surveyor has completed setting out with reference points complying
with the approved for construction drawings.
Ensure that all parties who are required to make any kind of test / inspection are
suitably informed as to the overall program of the works and daily inspection testing
requirements.
The QC Engineer or his designee (QCI) shall be responsible for the following:
Review all relevant documentation and test reports issued by parties involved (SE, Lab
Tech (ITL Laboratory), Surveyor and QC Inspectors) and submit records to consultant.
Ensure that all discipline activities that require to be inspected in the concreting
operation has been inspected and approved.
Organized and allocate inspection works to the Quality Control Inspectors (Civil).
To issue NCRs / DRs, when and where required and to check that the construction
department provides timely appropriate corrective and preventive action.
Sign off and obtain signatures from the Consultant on the forms and verifying
documents as required.
Keeping a daily log of all the inspection Request submitted by the SE.
5.
Carry out statistical analysis of the inspection and test result to improve quality control
operation on site, to verify testing compliance and to advise the SE of the results.
Filling and compiling controlled copies of all test reports under the supervision and
instructions of the QC Engineer.
Sampling and conducting field testing according to the instruction of the consultant and
QC Manager and in accordance with the Specifications.
The ITL ( Independent Testing Laboratory ) to ensure that the required numbers of
samples are taken from concrete works for the evaluation of quality and Durability of
Concrete works.
Ensure that all tests required specified for frsh concrete Production is completed.
Issuing, reviewing / interpreting all laboratory test result report in timely manner,
submitting it to QC department keeping records in laboratory for consultant Reference.
Compilation and filling all laboratory Test Forms / RFI for Certification submitting all
records to QC department.
Scaffolding Supervisor: To ensure that all scaffolding system has been erected
accordingly to safety and requirements.
Safety Inspector: To ensure all safety precautions has been taken into consideration
before commencing the concrete works.
All equipment should be inspected by Bechtel inspector and should have entry pass
before working on site.
All heavy equipment operators such as excavators cranes, forklift, etc, should have
third party license.
EQUIPMENTS:
5.1
5.2
5.3
Transport Mixer
5.4
Concrete Pump
5.5
5.6
Concrete buckets
5.7
Air Compressor
5.8
Survey Equipment
5.9
Level
5.10 Total Station ( Surveying instrument for checking the levels & distances )
5.11 Masonry Accessories
5.12 Wheel Barrows
5.13 Concrete Vibrators
6.
MATERIAL:
6.1 Form Plywood
6.2 Timber
6.3 Scaffolding
7. SHOP DRAWINGS.
a.
8.
PROCEDURE
8.1 Excavation and Backfilling\
All the areas where excavation is required, the surveyor will give the information to
the excavation foreman to start the excavation to the levels indicated in the ifc
drawings.
After the excavation is completed, the surveyor will check the final grade of the
excavation and the grade will be adjusted accordingly.
Slight trimming will be carried out when and where required before the placing of
polyethylene plastic sheet.
Cast in situ elements shall be constructed in accordance with IFC drawings and line
with project specification.
Surveyor shall mark the location of structural member ( foundation, wall, Column,
etc.) as per approved drawings.
Excavation shall be carried out up to bottom level of blinding, leveled, sprayed with
water, compacted and tested as per relevant specification and approved drawings.
Allow the concrete blinding to be hardened and cured as per relevant specification.
On specific areas where rate of concrete placement is to be very slow Dry mix
concrete will be delivered to site. Water and Concrete admixture meeting concrete
mix design requirements will be mixed on small batches using small site Mixers, the
same site mixers will be used for Cement plaster.
Where construction joints detailed on the drawing, width of concrete element warrant
establishment of construction / expansion joints, or concrete placement to be
stopped due to an avoidable circumstances on site, Construction joints shall be
made, Concrete surfaces will be roughened cleaned to establish a good joint
between old and new fresh concrete, QC inspection, Consultant approval is required
before concrete placement continue in concrete member.
Cleaning of Starter Bars shall be carried out following concrete placement completed
in preparation for the next concrete pouring.
8.2 Formwork
Concrete placement will not commence before Engineer Approval of Formwork and
Rebar Installation.
The design and construction of formwork shall take account of safety and of the
surface finish required. The formwork will be sufficiently rigid and tight to prevent loss
of grout or mortar from the fresh concrete and stand concrete Vibration (Excreted
Hydrostatic Pressure) without Movements. Form work and its supports to maintain
the correct position and to maintain correct shape and profile.
The formwork for foundation, beam connection, column neck and manholes etc. will
be made of either traditional formwork (plywood and timber and supported by tie rod
and steel support ) or DOKA system which a combination of DOKA wooden beams,
plywood and DOKA steel supports system with tie rod.
Formwork will be placed and aligned fixed to the required dimensions as detailed in
issued for construction drawings by the carpentry crew.
Formwork shall be rigid / sturdy and fixed in such a way to retain the structure
members dimensions.
QC Inspector will check the formwork installation and safety officer to ensure safety
of the work.
Before placing the steel reinforcement, an approved form release agent will be
applied to the internal face of the formwork.
For columns, walls shutter will not be closed before QC and consultant releases.
Based on the issued bar bending schedule, steel cutting and bending will be carried
out either in site fabrication shop / supplier fabrication work shop delivered to site
and assembled on site as per approved IFC drawings.
Reinforcement will be placed above ground not in touch of soil, either using wooden
blanks or concrete base to comply with project specification and international
accepted procedures.
Upon the arrival of steel rebar to site fabrication shop, the rebar fabrication crew will
cut and bend rebar in accordance with project specification and IFC drawings.
Before placing the fabricated rebar inside the formwork or mold, the formwork shall
be clean, blown out by air with air compressorvand coated with approved releasing
agent.
Rebar will be placed according to the project specifications and IFC drawings.
Rebar will be assembled either inside or outside the concrete member, outside
assembly steel will be placed by a crane to avoid any disturbance to the water
proofing materials / or polyethylene plastic sheet. Additionally, when leveling
concrete is provided, rebar mats can be assembled in the place.
All embedded materials items for civil. Mechanical or electrical activities shall be
placed / inspected by QC inspectors ensuring materials comply with
specifications.
All embedded items shall be unpainted unless noted otherwise, and free of
deleterious materials, such as dirt, grease, and heavy scale.
Anchor bolts and other embedded items shall be positioned and secured within
the tolerances shown on the drawings, in accordance with ENV 13670 and as
required by this specification.
All embedded elements to comply with the project specification and fabricated in
accordance with IFC drawings.
The embedded metals and anchor bolts will be installed in accordance with IFC
drawings.
The QC inspector shall check formwork, rebar steel, embedded metal and
anchor bolts prior to concrete placement.
Section / Site Engineer will submit Request for inspection to QC inspector prior to
start site delivery of concrete.
After the concrete has hardened sufficiently, the exposed portion of anchor bolt
shall be cleaned of all concrete and the threads chased. Threads shall then be
carefully coated with grease and the washers and nuts installed.
The QC inspector ensures that mix Design Proportions / Batch weight available
in batching plant.
Ready mix concrete supplier is aware of project specification requirements for
concrete temperature and slump.
Embedded elements, inserts, box outs chases, chamfers, water bars etc. as per
approved drawings.
Surveyor marks the concrete top level on the shutter as per approved drawings.
Formworks is clean from inside using compressor and magnetic bars used to
remove pieces of binding wires.
Sub- Contractors QC (civil) and company / contractor QCI ( civil) shall inspect
each member prior to pouring of concrete.
Direct discharge
Crane and skip
Concrete pump
Chute
The exact method / procedure for placing concrete shall be decided depending
accessibility of structural member on site.
All necessary laboratory tools for fresh concrete quality testing shall be available
on site prior to pouring of concrete ( cube moulds / cylinder mould, slump cone,
thermometer etc.) And third party laboratory technician is available at site or
Concrete site station ( checking temperature, slump air content and fresh
concrete density and samples taken as per specifications ). Then transit mixer
Mixer released to specified Concrete location.
Place the approved mix concrete into layers 450 mm per layer maximum using
one of the above methods.
If the air temperature is less than 30 deg C concrete shall be placed within 90
minutes of the introduction of the mixing water to the cement and aggregates, or
cement to aggregates. If the air temperature is greater than 30 deg C mixing time
shall be reduced and concrete placed within 60 minutes except when a suitable
set retarding mixture is used and slump requirements can be met. The maximum
time between batching and placing shall not be exceed 120 minutes in all cases.
Specific measures taken for minimum dimension of any casting is .80 merters or
more.
Concrete in high temperature (ACI standard 305.1 for hot weather concrete shall
be complied with.
9. Concrete Compaction:
Stage 3:
Full compaction of the concrete shall be achieved throughout the entire depth of
the layer using mechanical vibrators.
Care shall be taken to avoid over vibration which could cause segregation,
surface laitance or leakage through formwork.