Page No: 1 of 9

METHOD STATEMENT Revision: 1

Issued : May 2002

UE Construction Sdn Bhd

ELECTRIFIED DOUBLE TRACK BETWEEN RAWANG & IPOH

1.0 Objectives:
This document is prepared to state the construction method for the precast post –
tensioned I Beams.

2.0 Scope
The scope of this method statement comprises the casting and curing of 72 numbers
of precast post – tensioned I beams. These beams are to be cast and Prestressed at a
casting yard situated at site.

A total of minimum 8 numbers of timber casting beds will be prepared. One set each
of steel side mould will be used for the casting of 33.35m and 29.0m I beams. The
clearing and preparation of the casting area with the topping of crusher run are not
within our scope of works.

Reinforcement bars and tendons will be fixed or installed at site. Grade 50/20
concrete will be supplied by Ready-mixed concrete supplier that to be established

Launching and loading for delivery shall not be our responsibility and is out of our
scope of work

3.0 Reference

i) Approved Construction Drawings

a) Road Bridges At Jalan Tapah To Jalan Teluk Intan (WD/R1/B1/B-RDB/2535

& WD/R1/B1/B-RDB/2536).
b) Road Bridge At Jalan Kuning – Banir (CH229424.917) (WD/R1/B1/B-
RDB/2495)
 Page No: 2 of 9
METHOD STATEMENT Revision: 1
Issued : May 2002

UE Construction Sdn Bhd

ELECTRIFIED DOUBLE TRACK BETWEEN RAWANG & IPOH

4.0 Equipment & Resources

4.1.a Materials List:

(i) Concrete Suppliers

Nearby ready-mixed concrete supplier with the dry-mix concrete batching
plant at 60 m3/hr capacity or Supermix Sdn Bhd.

The information of the sources of raw materials shall be provide by the

concrete suppliers

(ii) Rebar – Malayawata Steel Berhad & Perwaja Steel Sdn Bhd will supply
rebar or Southern Steel Sdn Bhd.

(iii) Post Tensioning System

The post – tensioning system used will be VSL Engineers (M) Sdn Bhd
bonded system.

(iv) Mould oil – Compounded Mould oil will be used. Supply from Ssang
Yong.

(v) Curing Compound – Horncure curing compound will be used.

4.1.b Machinery List

Plant & Equipments

Item Plant Quantity Usage
a. 20 tons Crane 1 Fixed Mould, Concreting
b. Poker Vibrator and Engine 4 Concreting
c. Bripad 1 Uncoil Prestressing Strands
d. Disc Cutter 2 Cutting Prestressing Strands
e. Stressing Jack 2 Stressing Cables
f. Hydraulic Stressing Pump “CTC” 2 Operating Jack
g. Grout Mixer Cum Pump 1 Mixing Cement Grout And
Grouting
100 mm Test Cube Moulds 6 Making Grouting Test Cubes
i. Cutting Machine 1 Cutting of Reinforcement
j. Bending Machine 1 Bending of Reinforcement
 Page No: 3 of 9
METHOD STATEMENT Revision: 1
Issued : May 2002

UE Construction Sdn Bhd

ELECTRIFIED DOUBLE TRACK BETWEEN RAWANG & IPOH

4.1.c Manpower List

(i) Site Engineer
(ii) Casting Supervisor
(iii) Minimum 7 labourers

5.0 Handling And Storage

The beams shall be lifted with 2 units of 50mt crane and stock at the casting yard as
per Attachment 1

6.0 Work Methodology

Construction Processes – Refer to Attachment 2

Fabrication of Rebars And Tendons.

(i) Reinforcement Bars

A cutting list will be prepared based on the construction drawing in accordance with
the cover and lapping requirement. Rebars for the beams will be cut and bent at the
factory yard.

(ii) Tendons
A cutting list for tendons will similarly be prepared taking into consideration extra
lengths for stressing and dead anchorage. The required quantities of sheathing,
couplers, casting and other accessories will also be prepared at the same time.

(iii) Installation Of Rebars

Once the prefabricated rebar is ready, installation onto the casting bed can now be
commenced. At the same time, cable support in the form of short bars will also be
tied to the stirrups at the appropriate position following the required cable profile .
Spacer blocks at the soffit will be installed and securely tied to the stirrups.
 Page No: 4 of 9
METHOD STATEMENT Revision: 1
Issued : May 2002

UE Construction Sdn Bhd

ELECTRIFIED DOUBLE TRACK BETWEEN RAWANG & IPOH

(iv) Installation of Tendons

After stirrup cage is ready, sheating of appropriate size will be installed and tied to
the cable supports using wires. After screwing tight the coupler, the gap will be
taped up to prevent any grout leakage during concreting.

Prefabricated strands are now ready to be installed. The strands will be pushed in
through the dead end of cables. After all the strands for a cable has been pushed into
the sheathing, the anchor bars at the dead and will now be installed. At the same it
stance, grout pipes are also installed.

After all tendons have been installed, the profile of the cables are once again
checked. The cables’ support should be adjusted if necessary to maintain the profile
within + / - 5mm tolerance.

(v) Fixing of Steel Mould

Before the installation of side mould, live end prestressing casting will be installed at
the box out at the beam end mould. The castings will be installed with the grouting
hole on top. Following these, the side moulds shall be properly cleaned and with
mould oil applied are installed and bolted together. The alignment of the mould will
be controlled by adjusting the turn buckles.

(vi) Concreting
Concrete grade 50/20 will be obtained from Supermix Sdn Bhd or other ready mixed
concrete suppliers.

Concreting will be commenced from one end of the beam. The Concrete will be
hoisted via a mobile crane, in a concrete bucket, and to be discharge into the mould.
Internal and external poker vibrator powered by petrol engines or air-compressor
will be used to vibrate and compact the concrete.

The top surface of the beam will be trowel level and the surface shall be kept rough.

A minimum of ten (10) numbers 150mm test cubes will be cast for each concreting.
The cube will be tested in batches of three at 7 days and 28 days. The remaining test
cube shall be tested to check the transfer age.
 Page No: 5 of 9
METHOD STATEMENT Revision: 1
Issued : May 2002

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(vii) Demoulding

The externmal formwork will be demoulded after the cube strength has achieved
10N/mm² or 16 hours after casting.

(viii) Curing
After the completion of the demoulding the side form, curing of the beam will be by
spraying curing compound to the concrete surfaces. The curing compound will be
Horncure.

(ix) Stressing
Refer to Attachment 3A & 3B (To be submmit later)

(x) Patching up
After the completion of stressing process, the extra length of tendon will be cut,
leaving approximate 20mm protruding from the anchorage block. A grout pipe will
be fixed into the grout inlet at the live end anchorage. The box out will then be
patched up properly using the same grade of concrete as the beam.

(xi) Grouting Cables

Grout mixture with the correct proportion (see Attachment 4-To be Submit later)
will be pumped into the tendon in one continuous operation. The outlet will be
closed using clamp when the grout coming out from it has the same consistency as
from the inlet. After that the inlet valve will be closed.

Six numbers of 100mm test cubes will be cast for each grouting operating. The
strength will be obtained at 7 days and 28 days by crushing test.

Twenty four hours after the grouting operation the beam will be given final touching
up, extra of grout hose out and it is now ready for launching.
 Page No: 6 of 9
METHOD STATEMENT Revision: 1
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ELECTRIFIED DOUBLE TRACK BETWEEN RAWANG & IPOH

7.0 Quality Control Procedure ( Inspection and Testing )

(a) Concrete Mix

(i) The concrete mix used for the casting I 15 & I20 Beam is G50/20.
(ii) The pre-approved concrete supplier and mix design for G50/20 shall be used.
In the event the mix design has not been approved a trial mix shall be carried
out.
(iii) Slump test are carried regulary before concrete is discharge into the mould
and cube samples taken.
(iv) A minimum of ten (10) numbers 150mm test cubes will be cast for each
concreting. The cube will be tested in batches of three at 7 days and 28 days.
The remaining test cube shall be tested to check the transfer age.
(v) The testing of test cube shall be at the concrete supplier laboratory.

(b) Tendons
After all tendons have been installed, the profile of the cables are once again
inspected. The cables’ support should be adjusted if necessary to maintain the profile
within + / - 5mm tolerance.

(c) Stressing
(i) The cables will be stressed as per the notes as stated in the drawings. At each
stage, the extension against force applied will be properly recorded in steps of
10 Mpa.
(ii) The actual extension obtained will be checked against the calculated
extension. The difference will be within ± 6% tolerance. All stressing length
of cables will be cut after approval of stressing records.
 Page No: 7 of 9
METHOD STATEMENT Revision: 1
Issued : May 2002

UE Construction Sdn Bhd

ELECTRIFIED DOUBLE TRACK BETWEEN RAWANG & IPOH

8.0 Health, Safety and Environment (HSE)

a) First aid Kit

First aid equipment and material should be readily available for treating industrial
injuries or sickness at our workplaces. In the event of an accident the action
should be taken in the following way:

(i) Prevent more people from being injured.

(ii) Call the instructor or Project Engineer for first aid treatment. Call an
ambulance if necessary.
(iii) Aid the injured person.

b) Head Protection

Wear safety helmet at all time whenever necessary.

c) Footwear

Wear safety shoes with nail proof at all time during work. Slippers, sandals or
open toe shoes are prohibited at our workplace.

d) Lifting Equipment

Lifting equipment should be inspected and checked at regular intervals and be

well matained before lfting operation (lifting beam for launching, stockage of
beams). Before engaged in the operation of lifting, workers have to checked on
the beam are firmly hooked or anchored to the crane.Workers engaged in lifting
beams will be supplied with appropriate protective equipment such as helmets,
footwaer and gloves. During operation of lifting, no work is done under loads
travelling overhead.
 Page No: 8 of 9
METHOD STATEMENT Revision: 1
Issued : May 2002

UE Construction Sdn Bhd

ELECTRIFIED DOUBLE TRACK BETWEEN RAWANG & IPOH

Below is the signal chart during the crane operation of lifting.

e) Safety At Workplace

Clear warning signs and notices are put up during the prestressing of beam is
operating. Only authorised personnel are allow in the workplace. All worker
carried out the prestressing work have to stand beside of the beam bed to proceed
their work. During prestressing work, behind area of the beam bed is strickly no
entrance.

9.0 Verification Documents – Refer to Appendix 1 - 5

(i) Prestressing Record

(ii) Beam Preconcreting Checklist
(iii) Concrete Test Cube Result Analysis
(iv) Honcure Concrete Curing Compounds
(v) Mould Oil Compounds
 Page No: 9 of 9
METHOD STATEMENT Revision: 1
Issued : May 2002

UE Construction Sdn Bhd

ELECTRIFIED DOUBLE TRACK BETWEEN RAWANG & IPOH

Organisation Chart

Senior Project Engineer

Project Engineer

Site Supervisor

General Workers Sub-Con Crane Operators