METHOD STATEMENT

For Bored Pile Work DOC. NO. : MS-CHOSUK-003

REV. NO. : 0
Date : 16 Nov 2020

METHOD STATEMENT
for
Bored Piling Work

PROJECT NAME : JAWA – 9 & 10 COAL FIRED STEAM POWER

PLANT 2 x 1000MW
SITE : CILEGON-WEST JAVA INDONESIA

REVD DATA
REV. DATE DESCRIPTION PREPD CHKD HSE QA/QC APPD

PT CHOSUK Development Indonesia

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 METHOD STATEMENT
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Date : 16 Nov 2020

TABLE OF CONTENTS
------------------------------------

1.0 INTRODUCTION

2.0 DEFINITIONS

3.0 RESPONSIBILITY

4.0 REFERENCE DOCUMENTS

5.0 REFERENCE CODES AND STANDARDS

6.0 PILING WORKS PROCEDURE

6.1 SURVEYING

6.2 SETOUT OF PILING WORKS

6.3 SEQUENCE OF PILING WORKS

7.0 TESTING

8.0 HEALTH, SAFETY AND ENVIRONMENT

9.0 QA/QC CONTROL

10.0 MATERIAL CONTROL AND EQUIPMENT

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 METHOD STATEMENT
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1.0 INTRODUCTION

This method statement describes the plan of piling works including safety and
quality management on the site of JAWA – 9 & 10 COAL FIRED STEAM
POWER PLANT 2 x 1000MW in CILEGON-WEST JAVA, INDONESIA.

2.0 DEFINITIONS

2.1 “AFC Drawing” means Approval for Construction Drawing.

2.2 “ASTM” means American Society for Testing and Material.
2.3 “Contractor” means PT Hutama Karya (HK)
2.4 “PPE” means Personal Protective Equipment such as safety helmets,
safety shoes, safety goggles, etc.

3.0 RESPONSIBILITY

PT CHOSUK Development Indonesia (hereinafter called “CHOSUK”) has

responsibilities for implementation of piling works.

3.1 The Site Manager

 The overall responsibilities for construction activities including quality,

safety.
 Instructions and coordination of the construction execution throughout all
phases of the piling works.
 Review for the Quality Assurance Manual (QAM).
 Review for work procedure for work method and technique.
 Control for the incoming & outgoing documents.

3.2 The Construction Manager

 Establishment and execution of construction schedule

 Preparation of material requisition
 Implementation of work procedure for work method and technique
 Preparation of Construction Technical Queries (CTQ)
 Preparation of Inspection & Test Plan (ITP)
 Report of the construction progress and problems
 Request for inspection and measurement
 Preparation of Field Change Request (FCR)
 Preparation of as-built drawing

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3.3 The QA/QC Engineer

 Preparation and distribution of the Quality Control Procedure (QCP)

 Preparation of work procedures
 Review and approval of Inspection & Test Plan (ITP)
 Review of procurement documents
 Control of Non-Conformance Report (NCR) and Corrective Action
Request (CAR)
 Preparation and control of quality audit

3.4 The Safety Engineer

 Safety control
 Fall prevention control
 Collapse prevention control
 Safety operation control for dismantling the equipment
 Electric shock prevention control
 Fire and explosion control

4.0 REFERENCE DOCUMENTS

4.1 Project Specification.

4.2 General Technical Requirements.

4.3 Geotechnical Evaluation Report.

4.4 Design Data and Calculation Sheets

 Documents for piling works.

 Detailed pile drawing.
 AFC drawing.

5.0 REFERENCE CODES AND STANDARDS

5.1 ASTM D1143/D3966/D3689 for standard load test

5.2 ASTM A615 grade 60 or SNI 07-2052 BjTS 50 as specified for Standard
Specification for Steel cages for Concrete Reinforcement

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6.0 PILING WORKS PROCEDURE

6.1 SURVEYING

 Setting out of the main grid lines shall be carried out by the Contractor.

 The installation of marker pins shall be carried out from main grid lines
by the contractor in accordance with the pile location drawings.

 Prior to boring, the pile position relative to the main grid lines shall be
checked.

6.2 A TABLE OF THE EQUIPMENT

No. Item Capacity Unit Q`ty Remarks

1 Pile Rig. 135TON ea 2 -
2 Auger(upper) 150P ea 3 -
3 Auger(lower) 200P ea 3 -
4 Crane 100ton ea 2 -
5 Generator 500kw ea 2
6 Excavator 0.8m3 ea 2
7 Welding machine - ea 2 For welding
8 Compressor 900cfm ea 6 -
For excavation soil
9 Dump truck 15Ton ea 2 disposal
10 Accessories - ea 1

6.3 SEQUENCE OF PILING WORKS

 Ground preparation

 The platform elevation shall be decided on the basis of the pile cut
off level +1m and ground condition,
 The ground shall be levelled and made firm for balance of the
equipment and support of working weight.

 Setup of the pile drilling rig

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 The piling rigs mounted with a crane and shall be set up accurately
on the marked piling position.
 The piles shall be installed by using a specially developed rotary
system which ensures a minimum disturbance of original soil
conditions and negligible influence to piles already casted.

.
Top Sheave

 Drilling for test pile and permanent piles

Leader
Upper Auger
 The marked piling position shall be bored by the pile rigs.
 Due to Method of equipping a full steel casing with the rotary table of
the piling rig, the verticality of the borehole is ensured
 The depth of borehole shall be measured with a band tape.
Back Stay Screw

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Out
Generator
Trigger Lower
CasingAuger
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 A full steel casing diameter 800mm and 600mm based on outside

size will be rotated into the ground by piling rig itself and will extend
to the top unit. The casing length depends on the actual soil
conditions and will be fixed on site to required depth.
 If, for any reason, the power of the rotary drive of the piling rig is not
sufficient to advancing the casing into the rock stratum, a special air
hammer will be available, which can be attached onto the piling rig to
turn in the casing to the required depth easily.

 Preparation and installation of steel cage

 Preparation
Steel cage shall be preassembled in accordance with the detail
drawing of pile reinforcement.
The central location of the steel cage and the minimum cover shall
be ensured by placing the appropriate spacers and stiffeners on the
steel cage.
Damaged portion of steel cage by roller of bending machine which
made by iron shall be applied touch up paint which is certified by
project specification and repainted portion shall desiccate enough.
 Installation
When the designed drilling depth is reached and fully graded at pile
base, the preassembled steel cage shall be installed down into the
hole with the crane.

 Cleaning of the base of the borehole

To ensure total removal of sediments and loose soil particles at the

bottom of each pile, the following steps are taken

 When the drilling depth reaches the bearing layer, the pile base will
be graded and the cuttings, sediments and loose soil particles shall
be removed by the method the high-pressure air from air-
compressor is jetted through bottom of the screw while pulling out of
auger unit.

 Steel casing

 After the pile base is cleaned, the pre-assembled steel cage should
be immediately inserted into the steel casing by using the crane.
 The required concrete cover of the installed steel cage should be
secured by the approved spacers.

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 Pouring Concrete

 After installation of steel cage, the ready mixed concrete shall be

poured after the completion of the required field test.
 The concrete is poured through the tremie pipe under the water
concreting method that the water inside the borehole is displaced by
concrete. The tip of the tremie pipe is always kept submerged in the
fresh concrete surging into the tube.
 The casing and tremie pipe shall be progressively pulled out during
the process of concreting.
 After concreting up to the top of the casing in the first concrete
pouring stage, the casing shall be pulled out about two or three
meters. And then, the concrete shall be refilled into the casing up to
top of the casing.
 The casing shall be pulled out slowly.
 If there is not enough concete, we need to fill it up and overflow it.

 Extraction of casing

 Casings shall be extracted while the concrete within them remains

sufficiently workable to ensure that the concrete is not lifted. During
the extraction, the motion of the casing shall be maintained in an
axial direction relative to the pile.
 When the casing is being extracted, a sufficient quantity of concrete
shall be maintained within it to ensure that the pressure from
external water, drilling fluid or soil is exceeded and that the pile is
neither in section nor contaminated.
 The concrete level within a casing shall be topped up where
necessary during the course of casing extraction in such a way that
the base of the casing is always below the concrete surface until the
casing of the pile has been completed.

 Finishing of concrete work

 After completion of concrete work, overflowed concrete, and others

shall be cleaned by the appropriate equipment prior to hardening of
the concrete.

 Pile Head Treatment

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 Cut off level shall be checked by a surveyor and marked by paint

after excavation by a hydraulic excavator.
 Surroundings of a pile shall be ground in 10 ~ 15mm depth along
with the cut off level.
 The pile shall be broken down to the ground line by breaking
machines without strain or steel bar damage.
 The top of the broken pile shall be chipped by a hand hammer.

(wth hammer)
(until C.L +1m)

7.0 TESTING

7.1 Pile load test work shall be conformed to ASTM D1143/D3966/D3689.

7.1.1 Compressive Load Test

 Loading Arrangement

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 To provide the required reaction load on the pile, long rigid steel
kentledge frame made up of I-beams and sufficient number of
concrete block will used.
 The frame can be safely loaded for more than 750tons dead load.
 Crane will be used for setting frame in place, loading of concrete
blocks and shifting them from one test location to the other.

 Site Preparation
 This includes trimming of test piles to the desired level if required,
including pouring of non-shrink grout to level the top of the test pile
and preparation of concrete / compacted marl pad to support the
concrete pedestal.
 The clear distance between the pile and support concrete pedestal
will be minimum 2.5m or five times diameter of the pile whichever is
greater.

 Equipment
 Equipment to be used for testing are as follows:
a. Hydraulic jack system attached with hydraulic pump and
calibrated pressure gauge.
b. Load Cell
c. Rigid steel Kent Ledge Frame
d. Calibrated Dial Gauges with magnetic holders & reference beams
e. Concrete Blocks

 Loading Procedure
 Load on pile will be applied up to maximum of 200% of the pile
design load.
 Each load increment will be maintained until the rate of settlement is
not greater than 50mm.

 Procedure for measuring pile movements

 Readings of time, load, and movement of test pile will be recorded
before and after application of each load increment or decrement.
 Additional readings at intervals of 5, 10, 20 & 30 minutes, then every
30minutes up to 2 hours, then every 1 hour up to 6 hours and then 2
hours interval thereafter where applicable will be recorded.

 Report
 Field test results recorded on Load test format and Load versus
Deflection Graph along with the test reports & conclusion will be
submitted.

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Compressive Load Test

7.1.2 Lateral load test

 Reaction load
 To obtain the required reaction loads concrete blocks will be placed
on compacted ground.
 For transferring reaction load on the concrete blocks, steel I sections
will be used as spacer if required between hydraulic jack and
concrete blocks.

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 Equipment
 Equipment to be used for testing are as follows:
a. Hydraulic Jack attached with pump and calibrated digital pressure
gauge
b. Load Cell
c. Concrete Blocks for reaction load
d. Calibrated Dial Gauges of 0.01mm accuracy per division with
magnetic holder and reference beams

 Test procedure
 Pile shall be tested after attaining a required strength.
 The test shall be performed, in general, according to ASTM D-3966
“Standard Test Method for Piles under Lateral Loads”.
 Prior to the test, a pad will be installed adjacent to the test pile on the
excavated ground, which will serve as the base for reaction load
capable of providing the required lateral thrust without yielding.
 The reaction load is in the form of concrete blocks each of 1.0m x
1.m x 2m size arranged in layers will be used.
 The bearing plate will be fixed to the pile at the test level with high
strength non shrink grout.
 The load cell and hydraulic jack will be placed horizontally in
between the test pile and the reaction load so that the ram of the
jack will move freely.
 Lateral movement of the pile will be monitored using calibrated two
(3) dial gauges of 0.01mm accuracy supported on reference steel
beam and its needle resting on the pile in opposite side of the
location of the reaction loads.
 The reference beam will be supported independently on firm/non-
movable ground away from the test pile.

 Record
 Field test results will be recorded on test record format enclosed.
 Load versus Deflection Graph will be submitted along with the test
reports and conclusions.

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Lateral Load Test

7.1.3 Tension Load Test

 Loading arrangement
 To apply the required tension load on the pile, rigid steel reaction
frame will be placed over the concrete support blocks placed
sufficiently away the pile on the in-situ cast concrete pad /
compacted marl base.
 Hydraulic jack system placed over the reaction frame will be used for
application of load on the pile by reaction through thick 100mm thick
anchor steel plate which is above the load cell and properly welded
to the extended pile reinforcement steel.
 Load cell will be placed over one of the hydraulic jack.
 Crane will be used for setting up the equipment.

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 Equipment
 Equipment to be used for testing are as follows:
a. Hydraulic Jack system
b. Load Cell
c. Reaction Frame
d. Calibrated Dial Gauges with reference beams
e. Support Concrete Blocks

 Test procedure
 Pile shall be tested after a minimum period has elapsed since
installation to ensure that the fresh concrete of the pile has attained
the required strength.
 The test shall be performed, in general, according to ASTM D-3689
“Quick test”.
 Load on pile will be applied up to maximum of 200% of the pile
design load in increment of 10% of the pile design load thereafter in
increment of 5% of the pile design load.
 Each load increment will be maintained for 10 minutes.
 Maximum applied test load will be removed in four equal decrement
holding 10 minutes between each decrement.

 Procedure for measuring pile movements

 Readings of time, load, and movement, of test pile will be recorded
after application of each load increment or decrement and at 2.5, 5 &
10 minutes after application of each load increment or decrement.

 Report
 Field test results, recorded on load test format, summary of test
results and Load versus Deflection Graph will be submitted along
with the test reports and conclusions.

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Tension Load Test

7.2 All testing records and analysis reports shall be submitted to Contractor
after inspection by the engineer appointed by Contractor or Client.

7.3 All pile tests shall be carried out in accordance with the project
specification and standard by skilled technicians from authorized
laboratory.

8.0 HEALTH, SAFETY AND ENVIRONMENT

The safety supervisor shall carry out the safety site inspections to ensure that
safety requirements laid out in safety work plan are followed during all phase of
the piling works. CHOSUK`s safety manager shall review Safety Work Plan and
Safety Action Plan and secure work permit if necessary, prior to start of the work.
Personal Protection Equipment (PPE) shall be provided to all personnel involved
in the job. Barricades shall be set up around the sites. Warning signs shall be
posted to caution other personnel on site of ongoing work. The material Safety

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Data Sheet of the hazardous materials shall be available on site whenever in use
at site. Only trained and skilled personnel shall be allowed to handle and work
with any hazardous material.

8.1 Material Safety Data Sheet

Material Safety Data Sheet shall be provided on site where material

classified as hazardous is being used. It shall be submitted to the
Contractor along with the Material Approval Request for review and
approval to use it in the project.

8.2 Elevated Works

Works at the unreachable or elevated areas shall be provided with enough

working platforms rigid and firm for completing the activity. If the elevation
more than 1.8m above the ground level, proper scaffolding to be introduced
shall be governed by designated scaffolding supervisor and foreman. Both
emergency and common access shall be provided and the working men
are strictly allowed under necessary PPE.

8.3 Testing & Qualification

The operator qualification, testing and certification requirements shall be as

per specification requirements and will be provided to Contractor / Client
before commencing the work. Heavy equipment’s and vehicles shall be
operated or driven by operators / Drivers only with a related license.

8.4 Extended Working Hours

Extended working schedule shall be intimated in advance to Contractor /

Client. Proper lighting arrangements, PPE, tools shall be arranged with
necessary safety personnel engaged in the working area.

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HAZARD IDENTIFICATION PLAN

Detailed Specific Preventive Responsible
Activity Hazards Measure/s Person/s
Empty spray paint cans shall
Housekeeping Surveyor
be removed from the site

Surveying Surveying area shall be

  Slips and Trips cleared from scattered Safety Officer
  materials
Steel use for marking shall be
  safely capped with warning Surveyor
tapes
Only licensed driver can drive
Material Delivery Road Traffic a vehicle Equipment
  supervisor
   Safe access route shall be
  provided to the driver
Safety briefing shall be
Hitting personnel and conducted prior to start the Site Supervisor
Ground work
damage to property as
Preparation
activity in progress Trained flagman, spotter shall
  
  be assigned to assist the Site Engineer
equipment operator.
Safety Officer with assisting
flagman shall control and
  Road Traffic Safety Officer
make sure that the traffic will
move smoothly and safely
Loading / Equipment inspection before
Equipment breakdown Site Engineer
Unloading of the work start

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Engine in full stop when

Fire occurrence during Supervisor
refuelling is being done
refuelling of the
equipment
  Leak-check shall be
Supervisor
conducted

Licensed and certified

Foreman
operator

Hitting personnel Certified rigger Site Safety Officer

during equipment Well-trained flagman/spotter
operation shall be available in the area
 
carpentry Equipment
  On the spot equipment
materials by Supervisor
  inspection shall be conducted
mobile crane  
  on a daily basis
   
  Lifting area shall be isolated
  by Safety tape
  Environmental (fuel
  Leak-check shall be
leakage on the engine Equipment
  conducted / immediate repair
that could spoil the Operator
  to be done immediately
ground)
 
Daily inspection for all lifting
  paraphernalia shall be Spotter/Flagman
  conducted
  Breakage of lifting
paraphernalia Documentation of all
   
  inspection result
 
 
Unsafe lifting gears shall
immediately be removed from  
the site
Lifting perimeter shall be
Fall of suspended
isolated and barricaded to  
materials during lifting
avoid unwanted personnel
Crane positioning shall be
visually inspected before the  
Crane tip off during lifting start
operation
  Crane checklist and Lifting
risk assessment shall be filled  
up for every activity
Fall of concrete Concrete pouring shall be at
Concrete Pouring materials during low pressure at regular rpm Site Engineer
pouring speed

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Chute shall be handled by

Chute Slip in direct
  sufficient persons holding Supervisor
pouring
firmly to avoid slippage
Concrete spill during Avoid overloading of concrete
   
transiting in moving buckets
Proper PPE shall be required.
Goggles prevent concrete by
  Splashing of concrete admitting into eyes. Coverall Site Safety Officer
protect from hazard chemical
reactions by concrete.
Concrete waste shall
  Housekeeping immediately be removed from Foreman
the site
Working at Competency of
Licensed and certified Site Engineer
Heights operator
Equipment
  Competency of rigger Certified rigger only
Supervisor
Crane shall be inspected prior Equipment
  Crane inspection
to start lifting Operator

Full body harness shall be

  strictly required when working  
at heights
Fall of personnel at
heights Safety training in working at
   
  heights shall be conducted
 
Personnel working at heights
  shall be closely monitored by  
safety personnel

No storing of materials in
   
scaffolding structure

Fall of materials from No direct dumping of

  heights materials from heights down  
  into ground
  Hard barricades shall be
provided around the
   
scaffolding structure to avoid
unwanted personnel
Fall of personnel from Full body harness shall
  Site Engineer
heights strictly be required

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Proper housekeeping for

scattered materials, waste, Area safety
  Housekeeping
scraps, arrangement of Officer
materials, cleared walkways

9.0 QA/QC CONTROL

9.1 Work Flow Chart

Survey for pile point

Inspection

Pile Rig Positioning

Excavation by screw
Auger with Casing
ccccccasing

Inspection
nn

Insert steel cages

Installing tremie pipe

- Slump test
- Concrete mould C
- Pump car o
n
c
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Removal Casing - By pile rig

Site cleaning

9.2 Pile Construction

 Checking the fixing of the pile point,

 Checking the pile type as per the approved shop drawing and the
specified pile diameter, depth, reinforcement and concrete level, −
checking the fabrication of pile reinforcement cage to conform as per
design and placement,
 Checking the installation of tremie, concrete operation,
 Checking the quantity of concrete consumed and casting levels

9.3 Drilling

 Drilling of a pile located at a distance smaller than 3 diameters of another

pile shall not be executed before the final set of the concrete of the last
pile,
 Depth of drilling from working level to be measured,
 Time of beginning and the end of boring to be recorded.

9.4 Reinforcement

 Quality of steel,
 Length above the cut-off level not less than specified,
 Thickness of concrete cover,
 No direct contact with the ground, keep covered when not being used,

9.5 Concreting

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 Concrete to be supplied in sufficient quantity to allow concreting without

interruption,
 Depth of boring to be measured,
 On site, slump test (according to approved concrete mix design);
samples of concrete are to be taken for compression test(as per project
requirement).
 Checking and recording of concrete temperature
 Time of beginning and end of concreting to be recorded; interruption of
concreting
 Outside diameter of tremie pipe not to exceed half the diameter of the
pile,
 Before starting concreting, toe of tremie pipe to be, first in contact with
the bottom of the boring, then lifted 30 cm.

9.6 Pile Load Testing

 Checking the correct installation of the pile testing equipment,

 Checking the test and loading sequence,
 Monitoring and checking the recording of the test results

9.7 Integrity Testing

 Checking the preparation of the pile prior to integrity testing

 After pile head cut off, checking condition of concrete surface where
required to test
 verify correct pile serial numbers communicated to the pile testing
agency

10.0 MATERIAL CONTROL AND EQUIPMENT

10.1 Material

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10.1.1 Water

The water used for the concrete will be clean water, free from quantities
of soil and organic matter and will comply with the Technical
Specification.

10.1.2 Concrete

The concrete will be supplied and shall be in accordance with Technical

Specifications.

10.1.3 Steel reinforcement

The steel reinforcement will be supplied and shall be in accordance with

Technical Specifications. The quality and dimension of steel bars to be
used for the construction of reinforcement cage will comply with the
requirements of Technical Specifications.

10.1.4 Spacers

Circular spacers with a hole in the centre will be used as centralizers.

This will be inserted in the spiral reinforcement of the cage during
fabrication.

10.2 Equipment

To perform the bored piles excavation, the following main equipment will
be available at the site:
 Concrete truck mixers, Concrete pump truck, Pay loader
 Pile Drilling Rig, Cranes, Generators, Air Compressors
 Back Hoe, Unic Crane
 Steel’s hand tools

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