10. " 12. 13. 14, 15, 16. Table of Contents Scope / Objectives Reference Definitions Health and Safety Hazards Responsibilities Procedures/ Method to be Employed Manpower Requirement Material Requirement Equipment Requirement Health and Safety Provisions Site Safety Requirements QC. Approval and other Documents ‘Supporting Documents Cases might be faced during the site activities Distribution Site Safety Engineer's Approval1.0 20 3.0 SCOPE AND OBJECTIVES This method of Statement details the method of Post-tensioning work for the ‘HaHHtd#H at AL H####H Floors on Plot #, Sharjah. This includes preparatory works, P/T material supply sequence, installation, casting, tendon stressing, grouting, material and manpower allocations. REFERENCE 4), Project Technical Specification '.) Codes and Standards referred to in the specification ) Contract drawings 4) Shop drawings e) Project Quality and Safety Plans £) Applicable ITPs g.) Method Statement h) Quality Control Manual i) Safety Manual HEALTH AND SAFETY HAZARDS Specific safety measures have to follow as applicable and all the safety measures are covered separately in the Project Safety Manual ‘The following applies to site general safety All lifting appliances and lifting gear must carry appropriate test certificates and be thoroughly examined prior to use and must be adequate for the job. Cranes and other machinery must be selected and used in accordance with the appropriate statutory regulations. A firm level base of adequate bearing capacity must be provided for heavy plant Al personnel must wear the appropriate safety equipment (e.g. Hats, vests, boots, etc.) as per project site induction. Eye and ear protection must be worn ‘when necessary Job Safety Analysis are to be performed for all construction activities prior to ‘commencement of work3.1 Risk Assessment - Post- fensioned Works | Running and ‘Activity | Hazard Precautionary Measures Moving Cage | Crane tipping, | Ensure adequate plant, ensure design chains failing, | by appropriately qualified person, lifting frame failing | ticketed operator. Area clear of obstacles Loading, Gashes and | Strapping on coil not to be cut ooil is bruising from | set up. Coils to be lvaded according to release of coiled strand Cuts from burns on. manufacturer's instructions (direction of coil) Gloves are provided and are to be cutting strand | strand ends wom at all times where practical Safety glasses and face shields are provided - either must be wom Whenever cutting. Stand must not be cut with flame or heated Cutting-out the | Eye injury, | Face shields dust masks and gloves side shutters respiratory provided. ALL must be worn at all | difficulties times where practical Pushing Strand | Cuts from burns on | Gloves are provided through cages | strand ends ‘worn at all times where practical. ‘Checking strand | Components ‘Cage and associated components crossovers, falling, cage falling | supported on resting frame at_both placing poly on ends while still attached to lifting raised caze frame. Personnel are not permitted beneath the cage unless absolutely | necessary. Hard hats are provided and are to be worn at all times on site. Placing of ducts | Bending of Chairs, | Do not lay heavy materials on duets. crushing, and puncturing of ducts leading, to concrete ingress Do not stand on Ducts or weld close to duets. Take care not to puncture with rebar, etc.40 | Activity Hazard Precautionary Measures Pushing strands | Cuts from strand into anchorages Employee guiding strand to direct the pusher when to push and what strand Guide shall also. stand as far from subject strands as practical Stressing Failure of barrel | All wedges, barrels. o-rings, springs and wedge system | and nipples to be stripped, checked for causing strand | defects, cleaned und properly 1e- (under load) to exit, | assembled. Only stressing crew line blown out, | permitted within three (5) meters overstressing of | during stressing. Safety fence of strands caution tape to be checked and in perfect working order. Only those stalT experienced or trained in stressing procedure to participate in this task. Calibration certificates kept current, Where multiple jacks are used, ram extension is to be constantly checked and kept constant among all jacks. DEFINITIONS = Contracting Co. (Main Contractor) = Consultant PIT = Post-tension MS Method Statement QCP = Quality Control Procedure TTP - Inspection & Test Plan ITA - Independent Testing Agency5.0 RESPONSIBILITIES 5.1 ‘The Construction Manager is over all responsible for the implementation of Method Statement and ensures that his team of Engineers and foreman are aware of this method statement and all the resource-human, material and equipments are available to carry out the work as planed and without any delay 5.2 The Project Engineer is responsible to carry out the work as per the approved shop drawings, method statement, contract specifications and documents. He is also responsible to ensure quality workmanship in the course of the project 5.3 QAVAC Engineer is responsible to ensure work has been done as per the specification and drawings; inspections are done as per Quality Control Procedure and the Inspection and Test Plan and offer works for consultant inspection. 5.4. The Safety Engineer is responsible to ensure that all safety precautions are in place, and that all personnel on site are using the required Personal Protective Equipments like Helmet, Hand Gloves, Shoes, and Over-alls. He will also ensure all relevant permissions are available for the works as per U.A.E legal authority's requirements, 5.5. The following organization chart shows the line of responsibilities for contractor and FASTECH. Contractor FASTECH Project Manager I Projet Manso Agro of Design x + 2 hop denier Prt Engine Inspection fr PT ] Tendon Pre x Sie Enger & SurPoR sumror SUPPORT SUPPORT STAFF STM for STAFF fr STAFF fr Stand Mating Ieekng Grating tine Testalation Ste Note: Contractor has to provide skilled labors (steel fixers, carpenters, helpers) & one Experience Foreman to be supervised by FASTECH site stafT to do the above mentioned P/T activities. ‘This team of labors should be fixed up to the end of the project with out changes6.0 PROCEDURES/METHOD TO BE EMPLOYED 6 a) » ° 4) ° dD wy TENDON AND ANCHORAGE INSTALLATION Upon erection of the edge shutters by Contractor carpenters FASTECH Pre- Stressing Foreman shall mark out and supervise the cutting of the anchorage locations ( holes ) to the positions shown on the structural shop drawings, Anchorage’s and recess formers are held bolted into position, Where top pockets are being used instead of edge stressing the pans and anchors are to be tied and positioned at the correct height. ‘Afler the bottom reinforcement has been placed the ducting is laid out from the anchorages and the joints securely taped to prevent ingress of mortar. “The required number of strands as indicated on the working drawings is to be fed into each duct ensuring sufficient length left for stressing (minimum of 0.3 meter for stressing) Al tendons are then located and fixed to the profiles as shown on the engineering and working drawings ‘Top reinforcements are then placed in its position. Once tendons are in position, onion dead ends are formed, Duct joints are checked and live and dead end anchors are sealed, and grout hoses installed on completion. ‘On completion all strands and tendons are to be checked for alignment, no. of strand, fixing and sealing in coordination with Contractor and FASTECH QC. All tendons are to be numbered for report purposes and marked on the plywood by white color paint provided and done by the main contractor under M/s FASTECH supervision Ducts shall rest on epoxy coated chairs to maintain profile as per approved shop drawings. Chairs have to prepared and provided by Main Contractor Inspection carried out and signed by Contractor Project Manager & FASTECH Project Manager prior to forwarding for Consultant Approval. Refer to ITP forms Pre-pour inspection report FASTECHY/No.04/Rev.1/2007 and the Inspection Report FASTECH/No.05/Rev1/2007 All materials especially tendons shall be stored properly and strictly in accordance with specification as per manufacturer's instructions as mentioned below= PC strand should be moved as few times as possible and always lifted with a round pole’ boom through the eye of the coil = Preferably the PC strand is pulled out from the center of the coil, ‘The coil should be placed in a suitable dispenser = PC strand must be stored in dry, well-ventilated conditions. In addition, each coil must be placed on wooden laths or similar support. = In temporary outdoor storage, the strand must be placed on drained ground and covered with plastic. In this case the coils must be placed on a support of steel or concrete, since wood absorbs water. The plastic must be raised well above the steel to improve circulation and minimize condensation. If plastic is kept off the ground, ventilation will be improved and condensation considerably reduced m) A suitable storage area for materials shall be provided by the Main Contractor. 62 CASTING TIME 4) A supervisor is to be present during concrete pours to ensure no damage occurs {o post-tensioning components or that tendons are displaced. b) Extra care should be taken by all parties concerned with construction at all times to avoid dents and bending in ducts especially during installation and concrete- pouring. In cases when ducts are damaged, that portion shall be replaced and where necessary/as required the entire length shall be replaced, ©) The scaffolding inspection is the main contractor responsibility and has to keep this slab and one level down with fully main scaffolding and not allowed to de shutter any part of the slab only when getting M/s FASTECH permission by filling the form of de shuttering shows the slab which required to be de shuttered as per ‘The ITP forms De-shuttering form FATECH/NO.11/Rev1/2007 ‘The same care has to be taken against the pour strip area if available which should be fully supported by the main scaffolding and not allowed strictly to remove the scaffolding only by getting M/s FASTECH officially permission together with the consultant approval 6.3. SPECIAL SAFETY PROCEDURES 63.1 Stressing The following procedures are to be complied with all times and in ‘general the guidelines adopted in the code of practice: “Safe Post ~ Tensioning of Concrete Buildings” shall be followed.64 6.3.2 Safety Precautions Prior to Stressing 1a) All required personnel are to be informed that stressing will be ‘commenced by contracting the site engineer and where applicable the site Safety Committee b) Warning signs “CAI s ING I SS” are to be erected at access points to deck ©) All stressing staff shall wear hard hats, safety boots and will comply with all requirements of the site Safety procedures. d) Working Platform of 1.0 meter width at the edge slabs shall be provided for the stressing staff ©) Anchor blocks are to be located on the live ends of the cables ensuring no strands are twisted or interlocking, STRESSING PROCEDURE Pre-Stressing of cables shall be generally carried out in two stages or as specified on the Engineers drawings. These two stages are commonly referred to.as The Initial Stress and Final Stress. 64.1 Stress ‘At foi = 10 Mpa or as per the general notes and details, or 24 hours after the completion of the concrete pour an Initial Stress equivalent to 25% of the final jacking load shall be applied to each strand to minimize the risk of shrinkage cracks developing Note: ‘© Jack force is as per the General notes and details drawing no. Siti ‘© Cube Test Report shall be submitted for approval prior to commencing, initial stressing, Procedures to be adopted for the initial stress shall be as follows: i. Edge boards are stripped immediately after initial concrete set by contractor and recess formers are removed and stressing blocks and wedges are installed by contractor. ji All strands are spray painted at zero load as a reference mark for ‘measuring final extensions. iii, Stress all strands in each tendon to 25% of the design force.6.4.2 Final Stress When the concrete has reached minimum transfer strength of 25 Mpa (Cube) ‘or as per the general notes and details the final jacking force equivalent to 75% of the minimum breaking load shall be applied to each strand, The following procedures shall be adopted for the application of the final stress. a Obtain confirmation in writing from the builder's representatives that the concrete has reached the required minimum strength (Cube). Cube Test Report shall be submitted for approval prior to ‘commencing final stressing, b. Refer to the shop drawings and to the specification for any special stressing sequences that may be specified. Wherever applicable, the final stressing should first be applied to beam/band tendons, followed then by the slab tendons. © Stressing warning signs shall be erected at access point to the deck. ‘and areas immediately adjacent to live and tendons shall be flagzed off with admittance limited to those people only directly involved with the stressing procedure. All strands in each cable shall be stressed to the final jacking load ‘as per the design load available in the general notes and details of the project e. When all strands are full stressed the distance between the wedges and the paint marks are measured and entered on the stressing, record sheet. Extension shall be measured to an accuracy of +3 mm. [Average extension for all strands in one tendon should not less than 94% of Theoretical or as per the followed design code g All stressing records are to be submitted to the Project Consulting Engineer and the Post-Tension Sub-Consultant for approval before tendons can be cut and sealed, h. All the above should be in accordance with the ITP forms refer to stressing inspection record FASTECH/No.06/Rev.1/2007 and Stressing Results Record FASTECH/No.07/Rev.1/2007 Stressing Results Report Fastech/No.08/Rev.1/2007 GROUTING ‘On the completion of stressing the tendons, ducts are required 10 be grouted with approved materials so that the tendons are permanently bonded into the slab system.The grouting is a two-part operation involving the cutting and sealing of the tendons and then the mixing of the grout and its injection into the duets. These procedures are detailed in the following paragraphs, 65.1 a 652 a) Note: Cutting of Strands and Sealing of Pockets Before cutting of strands check that all strands have been fully stressed to the design load and that the extension records have been submitted to the consulting engineer and approved in writing from the same. Excess strand is then cut back with a high-speed abrasive dise cutter to give a minimum cover of 40 mm to the extemal concrete face. Flame cutting is not permitted. Stressing pockets at the slab edges are then filled with 1:1 sand cement ‘mortar flush with the concrete face. If any special finish is required, then the pockets are to be left recessed 10 mm so that the builder can ‘obtain the finish that is required ‘The pan boxes to be cleaned and bonding agent to be painted at the surface then the pocket has to be poured by the same grade of the slab concrete. ‘Tendons can be grouted when the mortar pack has gained strength for 24 hours. Grouting should not be delayed for any reason unless agreed with Consultant Chemical additives to be provided by contractor and to be used in the grout mix as per the product technical data Grouting of Slabs Tendons Grout Mix Detail ‘Water Cement Ratio 0.34 ‘Cement Quantity 100 kg. Chemical Water Volume 34 liters ‘The above values subject to change as per the General Notes of the project. b) Grout Mix and Injection i Trial tests will be carried out as per the specification requirements and follow the same at siteviii xi xii wii. Ensure that all excess strands have been cut and that recess pockets have been sealed and the pan boxes poured, Al grout tubes and ducts are to be checked for blockage and where necessary these are to be cleared ‘Checked that the grout pump/mixer is in working order and that the grout supply lines are clear. Only fresh ordinary Portland cement free from any lumps is to be used ‘The correct quantity of water is to be added to the mixing bowl, i.e. 17 liters of water for every 50 kg bag of cement ‘Add the cement slowly 1 bag at a time until grout of an even consistency without lumps is obtained Connect the grout supply lines to either the live end or dead end grout inlets and commence pumping. At the same time, a bucket is to be held at the far end bleeder tube to catch any excess grout When grout of the same consistency as that being pumped emerges from the bleed tube the bleed will be locked off and tied with wire. Pressurize the grout in the ducts as per Specifications. As the last grout vent is closed off, the grout pressure is maintained as approx. 0.70 Mpa for about % to | minute. When this pressure is achieved, seal off the inlet tube and immediately stop pumping, The above steps are to be followed for all tendons until the deck is fully grouted Grout tubes are to be left undisturbed for a minimum of 12 hours afler grouting. The grout vents are then cut, flush to the conerete surface and removed not earlier than 24 hours after grouting, Care must be taken that the grouting pressure is not so excessive as to cause the ducts to bugle in tendons where cover is little (ie. slab tendons passing over to beams) and the ‘concrete over the tendon to spall or “pop”7.0 8.0 65.3 Grouting Records Complete records shall be kept on all grouting of cable ducts and a ‘copy shall be submitted to Consultant Representative for approval See ITP form Grouting Record Fastech/No.09/Rev.1/2007 MANPOWER REQUIREMENTS 7.1 Engineering Staff: ‘There will be one group shifts allocated for the Engineering and Supervisory Personnel. It shall be as follows See the ITP form Daily Report Fastech/No.01/rev.1/2007 7.2 Staff & Labour Allocation: Labour distribution per shift will be as follows: See ITP form Request for manpower Fastech/No.03/Rev.1/2007 73 Shift Changeovers ‘The shifts shall be arranged as per the main contractor's work programme. MATERIAL REQUIREMENT P.C. Strand (Coils) Anchor Blocks Stressing Blocks Barrels Wedges Flat Ducts (Sheathing) Chairs (should provided by Main Contractor as per the list will be submitted by FASTECH) Flexible Grout vent pipes Grease Polystyrene Recess Formers Stapler pins Spray paints Bolts & Nuts Approved Chemical or equivalent (if required or specified in the site) for tendons grouting Hydraulic oil ‘© Jack repair materials9.0 10.0 11.0 EQUIPMENT REQUIREMENT Hydraulic Onion Machine Hydraulic P/T Jack Hydraulic Stressing Pumps Grouting Machine Stapler Gun Power tools (Grinder, Drill, Hacksaw, & Jigsaw) (must be provided by Main Contractor) HEALTH AND SAFETY PROVISIONS All the safe practices mentioned in the Post-tension Safety Manual will be adopted during the P/T works All working platform will be inspected by Site safety Engineer. All necessary personal protective equipments to be used. Full body harness will be provided for the labours working with pumps, grinders and power tools Proper access for the labours and equipments will be provided to the place of P/T works All the machinery will be checked for its maintenance records. Site will be cleaned from all the debris, rubbish, etc. which are related with P/T works SITE SAFETY REQUIREMENTS * All FASTECH Technicians and supervisors have to wear the visible suit, safety helmet, the gloves, safety shoes, * All workers have to use the pedestrian’s road in the site between the buildings. We have to use the safety entrance of each building. © We have to avoid the P/T activities [strand cutting, unloading materials and other] near the buildings edges to avoid any solid tools might be fall down from upper levels. © Stressing groups has to use the safety belt for the stressing jack and the safety belt for the supervisor working on the stressing platform.120 © During stressing time and before the stressing FASTECH Site Engineer and Foreman have to ensure that there is signboard (warming board available beside ach stressing pump) and the other Labors should be far away of the stressing pump and jack to avoid any accidents if the pressure of Hydraulic oil fail down suddenly ‘© The site store should be always clean and no smoking in the store or atthe site, © The supervisor who working on the safety platform has to stand away of the stressing jack during cable jacking, ‘* The Hydraulic stressing pump must be located at the left or right side of the anchor, but not behind the anchor. ‘© During the cables pushing FASTECH supervisor has to ensure that required cable in out connected with other one to avoid any accidents if the cable falls down. © The site Engineer has to check if the width of safety platforms is enough and as per the approved method statement otherwise he has to inform the project manager to inform Contractor engineer officially to provide the required width and itis not allowed to start stressing if the platforms not safe. * NOT ALLOWED TO ANY ONE OF FASTECH STAFF TO STAY IN THE YARD [NEAR THE BUILDING BECAUSE OF MORE DANGEROUS ACTIVITIES LIKE PRECAST PANELS FIXING, LOADING AND UNLOADING BUILDING MATERIALS BY HEAVY VEHICLE] © All staff available in contractor site should respect and follow the Safety Instructions. ‘© After completing the Strands cutting for each slab the Foreman has to instruct the contractor Labours who are working with him to make the strands as a Rolls then afler that we can shift it to the slab by crane. Q.C. APPROVAL & OTHER DOCUMENTARY REQUIREMENTS All the quality control documentation related to the P/T works should be approved before commencing the work stated as follows ITP for Post-Tension Works. All relevant shop drawings. Allrelevant material approval Safety Manual Note: Respecting this method statement by the Main Contractor and Sub-contractor for all P/T activities will give the required quality for the P/T work in the site.