Client: Jabal Omar Dev.

PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC

Corp International Consulting

Title Method Statement for Construction of Tunnel

Retaining Wall

Fixing of reinforcement, Supply and installation of

Work Package formwork, pouring concrete for Tunnel Retaining
Wall at Part 3-5 and 5-5 of S10

Document
Transmittal # 0615 & SBT # 0361 Rev: 00
Number

Eng. Omar Gentilezo

Prepared by 28/09/2014
Construction Manager

Mr. Mohamad Mohsin

28/09/2014
HSE

Eng. Abdul Wasay

Reviewed by 28/09/2014
QA/QC Manager

Eng. Omar Zarour

28/09/2014
RCC/DEP Technical Manager

Eng. Nabil Abdel Samad

Approved by 28/09/2014
Project Manager

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Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

1. SCOPE:
To outline the method statement for fixing of reinforcement, supply and
installation of formwork, pouring concrete for Tunnel Retaining Wall at S10
part 3-5 and 5-5.

2. SPECIFICATION:

1) Contracts Specifications and Approved Shop Drawings as per the

documents received from the Engineer.
2) Reinforcement and concrete shall comply with relevant standards
specifications as per Section 03300.
3) Approved project QA/QC Plan and Procedure
4) Approved Project Workplace Health and Safety Plan and Procedure.

3. MATERIALS:

1. Reinforcement: Grade 460 from approved supplier.

2. Concrete: f’c= 60 Mpa as per approved mix design/supplier

4. PERSONNEL:
The team of trained personnel from subcontractors will be involved in fixing the
reinforcements, assembling and erecting the formwork, concreting the walls and
de-shuttering at the specified days. The workers shall be supervised by
subcontractor’s foreman and engineers.

The main contractor will be responsible for liaising between the subcontractor’s
own engineers first, followed by inspections by the main contractor. The main
contractor will invite the Engineer to inspect the work once it is ready for
inspection.

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Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

Subcontractor Inspection

↓
RCC/QC Inspection

↓
EHAF Inspection

The above procedure is described in detail in the inspection and test plan
enclosed with this document

5. PLANTS AND EQUIPMENT:

1. Tower Cranes/Mobile Cranes

2. Mobile Pump/Static Pump/Placing Boom
3. Transit Mixers
4. Poker Vibrators 2” and 1”
5. Steel pipes/Hose pipes extension concreting
6. Concrete Bucket Chute/Mobile Crane (if necessary)
7. Hilti Mini Jack Hammer for scabbling
8. Power Lights (for night casting/works)
9. Set of mechanical and carpentry tools

6. SEQUENCE AND METHOD:

Survey Works:

1. The surveyor sets out the alignment and level of the Tunnel Wall using the
Total Station in respect with backsite and foresight references from known
Control Points approved and provided by the client.

2. An offset line of at least 0.3-0.5m from the required line of Tunnel Wall
shall be provided by the surveyor on the existing Tunnel slab ramp.
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Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

3. From the control on the slab, the surveyor shall mark the position of the
external face of the wall shutters. This shall ensure that the shutter system
is placed in its correct design position at the commencement of
construction.

4. The control of verticality of the wall will be done using a string attached at
the top edge of the shutter (at both sides) and hanging freely with a plumb
bob tied at the end of the string. Alternatively a straight edge bar with
bubble markers can be used ensuring the bubble is in the middle marker.

5. The casting level shall be determine by the surveyor as per the drawing
requirement and shall mark inside the wall (at the upper portion) by either
providing the choke line or nails at appropriate distance in order to limit the
casting level.

Reinforcement Works:

1. Prior to fixing of new reinforcements, the existing dowels/starter bars shall

be free from loose rust or any concrete laitance and shall be cleaned using
either by wire brushing or sand blasting depending on the degree of rust or
laitance.

2. Zinc rich shall be applied on most dowels that have been cleaned prior to
lapping the extension bars and scabbling works on the existing concrete
joint will be done.

3. Bars received on site from the delivery truck shall be checked by the site
engineers on the correctness of steel fabrication tags in respect to the BBS
attached in the Delivery Notes (size and length) and the corresponding
location and type of structure the reinforcement arrived.

4. All the reinforcement will be stored in a dry and flat area, ideally within the
reach of the Tower crane. Timber or steel spacers will be provided between
the Reinforcement and Ground to avoid direct contact of moisture and
water.

5. Bars shall shifted near the fixation and will be segregated in accordance
with bar codes shown on the approved shop drawings.
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Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

6. Scaffoldings shall be erected beside the wall to provide platform during

reinforcement works and shuttering works. Scaffolds shall be in compliance
with the safety requirements of the project.

7. Bars to be installed and lapping shall be as per lap requirements. Any

crank bars provided therein shall be arranged as per shown on the
approved drawings.

8. Each intersection of the bars between horizontal and vertical bars shall be
tied using binding wires and knot in a proper sequence.

9. Starter bars for provision of any slab or wall connections to this wall shall
be fixed after the surveyor marked the possible location on the rebar
installed.

10. When one full segment of wall area is complete and ready for inspection,
an IR will be raised at this stage to approve the reinforcement and
embedments/fixing of MEP. Once approved, the shuttering works will
proceed.

Shuttering Works:
1. Shuttering works either by ULMA system or normal ecoflex timber
beam system as adaptable for this wall.

2. Fabrication of shutter system can be carried out at the area near the
wall to be constructed. Some segments of the shutter system can be
installed directly to the wall kicker as it is not in the same height due to
the wall is on the Tunnel ramp.

3. Wall shutter system is supported with threaded jacks diagonally fixed

the end portion to a base plate or bolt/rebar planted on the adjacent
existing concrete and then adjust its verticality.

4. Horizontal steel ribs shall be provided to support the lateral pressure of

the concrete inside the wall and with the addition of tie rods passing
through the thickness of the wall with clamp heads on both ends. This
spaced at appropriate locations for rigidity and stableness of the
shuttering system.
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Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

5. Concrete cover blocks with embedded tie wires shall have the same
strength of the wall concrete or to use any approved pvc covers shall
be fixed between the shuttering system and the reinforcement at an
evenly spaced location.

6. Once the verticality, covers and levels are confirmed by the

subcontractor and contractor site engineer, the wall be offered to
consultant for final inspection and approval for casting.

7. Release or removal of shutter shall follow as per the striking out

requirement in the specification.

8. Care shall done during removal and shall be lifted in sequence to avoid
damage on concrete surfaces and edges and the stack the shutter for
reuse. Proper oiling shall be ensure to maintain the condition of
shutters.

Concreting Works:
1. Compressed air will be blown to remove tying wires, rubbish and other
particles (if any) in the concrete pour area prior to casting.

2. The concrete surface shall be wetted using a normal water minutes

before the concreting begins to allow proper contact between the old
and the new concrete.

3. The concreting can be done on the upper platform provided within the
scaffoldings as a working area.

4. Maximum pour rate shall be determined so as not to be exceed 50kpa

form pressure (approximately 2 meters per hour) or truck delivery at
maximum of 60m3 per hour.

5. Each concrete truck mixer will be inspected for its temperature, slump
and time requirement in accordance with relevant standards and
QA/QC plan and procedure. Concrete not in compliance with the
requirement will be rejected automatically. No water should be added
in the truck on site, otherwise it will be rejected.

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Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

6. Pouring of concrete shall be done by Placing Boom/Concrete

Pump/Static Pump and shall not drop the concrete more than 2m in
height. Extended steel/hose pipes shall be provided for portion that is
not reachable by the pump.

7. Each layer of concrete (max. 1.0m) shall be properly vibrated using

efficient concrete vibrators sufficient to cover the entire layer for
adequate compaction.

8. Avoid over vibration in the forms which tends to create excessive

bleeding in the concrete and vibrators will not be used to convey
concrete within the formwork.

9. After reaching the required level of casting, the top portion will be
covered with wet hessian cloth to avoid exposure to direct sunlight.

10. Adequate lighting will be installed surrounding the concrete area and a
standby Electrician will be made available throughout the pouring
operation when concreting carried out during the night.

11. No release of tie rods or shuttering until the concrete gain enough
strength as per the striking out requirement set out in the specification.

12. After striking the shutter, water curing or approved curing agent will be
applied thoroughly on all over the exposed surfaces of the concrete as
per duration required in the specification.

7. HEALTH & SAFETY:

1. Tradesmen & Helpers should wear suitable protective clothing, safety

shoes and hard hats.

2. The mobile crane that is used will be certified by respective third party
agency. Proper approved lifting methods will be followed for all kinds of
lifting.

3. The lifting gears / tackles will also be certified by the respective third party
agency.

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Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

4. Vibrator and needles are checked under periodical inspection and regular
maintenance would be done with our won technician.

5. The scaffolding erecting will be done under the competent person’s

supervision with the tag systems.

6. All the above sited activities are carried out under the supervision of
competent person supervision.

7. Sharp edges of the cut ends of reinforcement should be suitably rounded

off to prevent injury to personnel.

8. Only carpenters are allowed in the erection or stripping area other trades
mans are not to be allowed while decking in progress.

9. All material lifting with cranes should be properly supervised by the Banks
man assigned this duty at all times. Cranes should be taken during
securing all chairs & hooks by the responsible Banks man assigned for the
crane.

10. Tool box meeting will be conducted and risk forecast will be
communicated before the commencement of the works.

11. Personnel working above 2m height will be required to wear safety

harness.

12. All the engineers, supervisors are instructed to follow the method
statements that are agreed and periodical verification will be done to
check the same in the site.

13. A full time safety Engineer will be available at site during the entire
duration to monitor all safety aspects and will ensure that all safety
guidelines and procedures as enlisted in the safety plan and are as
followed.

14. Necessary Guard Rails and Toe boards will be erected as directed.

15. All material lifting with cranes should be properly supervised by the Banks
man assigned this duty at all times. Cares should be taken during securing
all chairs & hooks by the responsible banks man assigned for the crane.

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Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

16. While pouring the concreting for placing the mobile pump/concrete boom
more care will be taken.

17. All waste materials will be removed from the site, transported and dumped
at approved dumping areas.

18. Disposal will be carried out as per the local legislation and practices in
force.

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 Client: Jabal Omar Dev. PMC: Hill Main Consultant: Ehaf Contractor: Saudi RCC
Corp International Consulting

JABAL OMAR DEVELOPMENT

PROJECT- PHASE IV INSPECTION AND TEST PLAN
(CONSTRUCTION OF TUNNEL RETAINING WALL)
ZONE S09, S10 AND S11
Fixing of reinforcement, Supply and installation of formwork, pouring
WORK SCOPE concrete for Tunnel Retaining Wall at S10 part 3-5 and 5-5

PART 1- APPROVALS REQUIRED PRIOR TO COMMENCEMENT OF THE WORKS

Item Description of Operation/Inspection, Test and Frequency of Inspection & Hold, or Witness Point
Records Generated
No. Approval Test Plan Subcon RCC EHAF
1 Tunnel Retaining Wall Drawings and Details Once Approved Drawings Sub* R R&A
Mix Design, Data
Materials Submittals- 45 Mpa Concrete Mix,
2 Once Sheets, Product Sub R R&A
Grade 460 Reinforcement
Certificates
Method Statement, Inspection & Test Plan
3 Once MS & ITP Sub R R&A
(this documents)
Survey reference and Bench Marks Approved Drawings,
4 Once Sub** R R&A
(drawings) Control Point
Work Notification to Start New Activity,
5 Permits/Licenses/NOC’s and Authority Once Approval of work Sub** R R&A
Approvals (if required)
Note*- All deviation from the approved drawings/documents to be recorded and discussed with the Main Consultant prior to
proceeding. * Other subcontractor/sub consultant engaged by RCC. ** By RCC
PART 2- INSPECTION AND TEST DURING CONSTRUCTION WORKS
Item Description of Operation/Inspection, Test and Frequency of Hold, or Witness Point
Records Generated
No. Approval Inspection & Test Plan Subcon RCC EHAF
1 Survey Setting Out –alignment and level of wall By Area/Stages/Layout Survey Report H H R&A
Rebar Installation –size, length, shapes as per Checklist, IR, As
2 By Area/Stages/Layout H H I
code and shop drawings built
MEP Embedment/Insert –size, location as per MEP Checklist, IR, AS
3 By Area/Stages/Layout H H I
shop drawings and layout built
Wall Shuttering –thickness, location of joint,
Checklist, IR, As
4 verticality, alignment, casting limit, box out (for MEP By Area/Stages/Layout H H I
built
or opening) as per shop drawings.
Consultant Inspection and Approval for
5 reinforcement, survey, MEP embed/insert, shuttering, By Area/Stages/Layout IRs H H I&A
concrete pouring
Concrete Casting- Concrete grade, qty required,
Pouring Request,
cleaning inside forms, poker vibrators, supervision,
6 By Area/Stages/Layout Delivery notes, Pour H H I
Sampling on site: Slump/Flow, Temperature,
Record
Batching time and pouring
Abbreviations: Sub- SUBMIT, H- HOLD, R&A- REVIEW & APPROVE, RC- RANDOM CHECK, I&A- INSPECT & APPROVE, S-
SURVEILANCE, CL= CHECKLIST, IR- INSPECTION REQUEST, I- INSPECT

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