Integrated Light Rail Transit Project in Jabodetabek

PROGRAM PERCEPATAN
PENYELENGGARAAN KERETA API DOC. NO.

:
RINGAN/LIGHT RAIL TRANSIT TERINTEGRASI
DI WILAYAH JAKARTA, BOGOR, DEPOK DAN DATE REV
BEKASI
CHAPTER I
I. GENERAL
I.1 Project Data
Integrated Light Rail Transit Project Jabodetabek (LRT Project) is a
rapid transportation system using light rail train (LRT) developed in Jakarta,
Indonesia.
LRT will connect Jakarta and the suburb area such as Bekasi and
Bogor. LRT is developed by Local Government of DKI Jakarta that build and
develop LRT around the city and PT Adhi Karya appointed by Government
qq Ministry of Transportation as the Main Contractor which responsible for
planning and developing LRT for connecting the Suburb areas under the
name LRT JABODEBEK.
For this purpose, PT Adhi Karya cooperated with their Sub Contractor
to achieve and optimize the project smoothly i.e. PT. Adhi Persada Gedung
(APG) and PT Smart-modular Building Indonesia (SBI) as one of the the Sub
Contractors of APG.
SBI is appointed as a Sub Contractor for the architectural works
especially for fasade and roof of the LRT stations. Here below is the Project
Chart :
Kemenhub (Owner)
OCG (Consultan)
PT. Adhi Karya (Contractor)
PT. Adhi Persada Gedung (Contractor)
PT. Smart-modular Building Indonesia

(Fabrication)
METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

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PT. Smart-modular Building Indonesia got the assignment at 2 line

services, that is services line 1:
a. Taman Mini
b. Kp. Rambutan
c. Ciracas
d. Harjamukti
Services line 3:
a. Jatibening (Jaticempaka)
b. Cikunir 1
c. Bekasi Barat
d. Jatimulya (Bekasi Timur)
e. Cikunir 2
Picture 1.1 LRT Station

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I.2 Scope of works

1. Pay Item
7.3.2 = Façade
7.3.2.1 = Dinding Façade Panel Ringan (Sandwich Panel)
7.3.2.2 = Dinding Façade Panel Precast Ringan pada station
corner (beton precast)
7.3.2.3 = Terali Louvre Alumunium pada Tangga Darurat
7.3.2.4 = Terali Louvre Alumunium
VO-7.3.2.1 = Dinding Façade Panel Ringan (Sandwich Panel)
75mm
VO-7.3.2.2 = Expansion Solid Joint Sandwich Panel
VO-7.3.2.3 = Insulated Gutter
VO-7.3.2.4 = Alumunium Composite Panel
VO-7.3.2.5 = Manhole
VO-7.3.2.6 = Safety Track
VO-7.3.2.7 = Safety Line
VO-7.3.2.8 = Curtainwall pada sisi atas louvre t:6mm
2. Scope of works
a. Workshop
Scope of work in the workshop:
- Lamination Sandwich Panel
- Instalation of solartuff on to Sandwich Panel (RAL 5007 / Brilliant
blue)
- Gutter production

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Picture 1.2.0 Unloading SWP from Container
Picture 1.2.1 SWP stock at SBI workshop Picture 1.2.2 Moving SWP Using Forklift
on workshop
Picture 1.2.2 SWP stockyard at SBI workshop

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- Fabrication Skylight

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- Fabrication Gutter

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b. Materials Distribution
document provided for materials distribution consist of:
- Delivery Order
Gambar 1.3 Form Delivery Record Material Sandwich
- Delivery materials procedure

SWP are delivered to site using by Truck to the project location. All
materials arrived should be checked against conformity of document
as well as the quantity, dimensions, color, defect, etc.

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Picture 1.4 SWP stacking
Load to
truck
Ready
to
deliver

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c. Instalation of Material
Gambar 1.5 Instalation zone
Picture 1.6 scope of work

1. Panel curve T.75mm Ral 1013, ( bahan PIR (Fire Retertdan), Alm.
Ekstude, Sealent, Self screw).
2. Ekpansion Joint (bahan Alm. Ekstrude curving, Coil 0,5mm
Flashing, Rubber gasket, Bithutane, No more no seal).
3. Fix Joint (bahan Alm. Ekstrude curving, Coil 0,5mm Flashing, Self
screw, Rivet).
4. Capping ending curve (bahan panel, ACP, coil 0,5mm flashing,
Sealent).
5. Panel roof Ral 5007/6018 + Skylight, (bahan panel curve T.75mm,
Polycarbonat T.4mm, Alm. Mullion, Alm. Ekstrude).
6. Safety rail.

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SWP installation shall start based on zone area. Start from zone 1
to zone 4 or reverse, before installing SWP, installing gutter is
mandatory. This is important as the start point for installing panel under
gutter or above gutter to minimize short length of SWP.
SWP installation shall use supporting equipment such as heavy
equipment, fixing equipment as the followings:
1. Total Station 2. Safety Face
3. Self Baricade 4. Shackle

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5. Welding Tools 6. Webbing Sling
7. Chaing Block 8. Drill Tool
9. Jig Saw 10. Gerinda

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11. Sigmat 12. Portable Winch
13. Scafolding
16. Safety Block

15. Full Body Harness

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17. Safety Net For Tool 18. Safety Line
19. Safety Helm 20. Safety Shoes

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d. Working area
Picture 1.7 Working Area
Working area is on the existing steel structure provided by others.

SWP is the LRT stations roof and the steel structures is the steel
frame where the SWP shall be installed on it. Supporting equipment
such as manlift is located at the platform for installing gutter and
SWP above gutter. White working area for installing SWP under
gutter is in the councorse.

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CHAPTER II
II. STANDARD OF WORK

II.1 Guidlines Standard of work
Picture 2.1.1 Table SOP NC

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Gambar 2.1.2 Table SOP NC

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Gambar 2.1.3 Table SOP NC
Gambar 2.2 Table SOP Corrective Action Report

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II.2 Materials Technical Requirement

a. Spesification of Sandwich Panel
Picture 2.3 Specificaion Sandwich Panel

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- Conclusions
On the table spesification there is sandwich panel burning on temperature

100 c – 118 c, while on test laboratorium sandwich panel burning on
temperature 305 c – 415,8 c. it meant SWP meet the spesification.

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b. Spesification of Gutter
Picture 2.4 Specification Gutter Sandwich

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c. Solid Polycarbonat
Picture 2.5 Specification Polycarbonat For Skylight
d. Acsesoris
- Flashing (0,5mmT), from coil (skin panel)
Gambar 2.6 Specification Skin Sandwich Panel

- Folded, from Galvanis
Gambar 2.7 Material Closing Joint between Sandwic Panel

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Picture 2.8 Mill Certificat For Galvanize Iron Sheet
- Alm. Ekstrusion
Picture 2.9 Material Alumunium Extrution

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Picture 2.10 Mill Certificat For Extrution
e. Fixing
- Self Screw for Despach & Ekstrusion
Picture 2.11 Specification of Self Screw For Joint Sandwich Panel & Steel

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Picture 2.12.1 Specification of Self Screw Performance Data
Gambar 2.12.2 Specification of Self Screw Performance Data

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- Self screw for SWP to Steel
Picture 2.13 Self Screw For SWP To Steel

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- Rivet for Hidden Despatch and Ekstrusion
Picture 2.14 Specification Rivet

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- Sealent
Picture 2.15.1 Sealent

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Picture 2.15.2 Sealent

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Picture 2.5 Specification Sealent

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f. Safety Track
- Specification of Safety Track
Gambar 2.6 Specification of Safety Track

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- Detail Junction
Picture 2.7 Detail Junction

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- Nut for Fixing on Bracket
Picture 2.8 Nut for Fixing on Bracket
- Tilting End Stop
Picture 2.9 Tilting End Stop

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- End Stop
Picture 2.10 End Stop
- Trolley
Picture 2.11 Trolley

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- Methode Install Safety Track
Picture 2.12 install Safety Track
Picture 2.13 Picture Safety Track

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g. Safety Lifeline
Picture 2.13 install Safety Line
- Life line
Picture 2.14 Safety Life Line

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Picture 2.15 Install Safety Life Line

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- Specification Stainless Steel Cable
Picture 2.13 Specification Stainless Steel Cable
- Horizontal Lifeline on Ground
Picture 2.14 Horizontal Lifeline on Ground

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- Components of Akrobat Lifeline
Picture 2.15 Components of Akrobat Lifeline

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- Configurasi Components of Akrobat Lifeline
Picture 2.16 Configurasi Components of Akrobat Lifeline
- The Energy Absorber LVD032
Picture 2.17 The Energy Absorber LVD032

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- Crimping ring on end anchor
Picture 2.18 Crimping ring on end anchor
- Crimping ring with threaded tip M10.
Picture 2.19 Crimping ring with threaded tip M10.

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- Crimping ring – turnbuckle ligne
Picture 2.20 Crimping ring – turnbuckle ligne

- Crimping ring junction
Picture 2.21 Crimping ring junction

- Crimping rings for curve section
Picture 2.22 crimping rings for curve section

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- Checking the crimping
Picture 2.23 checking the crimping

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- Warning Plate
Picture 2.24 Warning Plate

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- Tensionning toll
Picture 2.25 tensionning toll

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- Schematic plan of installation
Picture 2.26 Schematic plan of installation

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- Indentification of Akrobat Lifeline
Picture 2.27 Indentification of Akrobat Lifeline

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- Recommendations relating of periodic review procedure
Picture 2.28 Recommendations relating of periodic review procedure

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CHAPTER III
III.1 Implementation Flow
Picture 3.1.1 Flow Chart Deliver Material

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Picture 3.1.2 Flow Chart Deliver Material

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Picture 3.2.1 Flow Chart Inspection

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Picture 3.2.2 Flow Chart Inspection

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III.2 Work Preparation

1. Work Preparation Step
a. Individu Handling Sandwich Panel
Man power should use safety K3. When moving sandwich panel sheet
by sheet, moving sandwich panel should not with flat position because can
over stretch on the sandwich panel. Exposure from the sun to the sandwich
panel can make arch on SWP, then placed of sandwich panel on shade
area.
Picture 3.3 Individu Handling SWP

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b. Handling SWP using Forklift
Picture 3.4 Handling SWP busing Forklift
Loading and unloading SWP using forklift shall be the following:

- SWP with length < 9,14 meter use single forklift with wide distance
fork. Fork placement shall realy in the center of stacking as show in
picture 3.4 above.
- SWP with length > 9,14 meter, shall use two forklift with the same
distance points. As show in picture 3.4 bottom.
Picture 3.4 Handling SWP using Double Forklift

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c. Delivery Sandwich Panel
Picture 3.5 Delivery SWP
Delivery SWP by truck with protector sheet.
d. Storage
Picture 3.6 Storage Panels
Storage sandwich panel are placed in shade area and supported by

sterofoam, and given protector sheet.

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e. Bolt Calculation
Picture 3.15 Bolt Calculation Picture 3.16 Gutter

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Picture 3.17 Design Dimensions of Screw Threards, bolt, and according

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f. Screw Calculation
Picture 3.18.1 Bolt Calculation Picture 3.18.2 Calculation Bolt
Quality Tapping Screw :

Tapping Screw Ø 5.5 mm
Tension Strength = 2.71 kN
Shear Strength = 1.2 kN ( See Attachment spesification )
Quality for design :

Tension Strength = 2.71 kN x 0.75 = 2.03 kN
= 207.19 kg
Shear Strength = 1.2 kN x 0.75 = 0.90 kN
= 91.74 kg
Due to loading, force that occurs on the top and bottom of the pedestal.
Force recive every support = 1/2 Fy dan 1/2 Fz
Fy = 609.7 kg 1/2 Fy = 304.85 kg
Fz = 75 kg 1/2 Fz = 37.5 kg
1m
Panel @ 1m
Loading area tapping screw

Picture 3.18.3 Bolt Calculation
Instalation Tapping screw every 500mm

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Receive force every tapping screw :

(1/2) x (1/2 Fy) = 152.4 kg
= 153 kg
= 1.50 kN Tension < 2.03 kN (OK)
(1/2) x (1/2 Fz) = 18.75 kg

= 19 kg
= 0.19 kN Shear < 0.90 kN (OK)
2. Clearing Area
a. Ilustration area of Halim station
TO JAKARTA
TO CIKAMPEK
ST. HALIM
Picture 3.19.1 Ilustration Location of Halim station

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b. Traffic Temporary Plans
Picture 3.20.1 Traffic Temporary Plans
III.3 Work Implementation

1. Implementation Instalation

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a. Marking Position
Marking position should adjusted with cutting list panel from engineer.
Picture 3.22 Marking Position
Picture 3.23 Marking Position Bottom gutter
Marking Elevation Gutter

Verticality, Horizontal Length and Gutter Support Position check by surveyor
(Joint Survey) AK, APG, Steel Subcont, and SBI ( Measure With Total
Stations ).

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- Steel structure checking (Joint Survey)

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b. Zone Grouping
Picture 3.23 Zone Division
Picture 3.24 Zone Plan for Installation

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Function of zone grouping for installing sandwich panel, if start installing

SWP from zone 1 then finished at zone 4.
c. Installing SWP
Before installing Sandwich Panel, need to be survey level plat jengger
using total station. After survey and got it level data, the highest plat jengger
become a refrence, while plat jengger shorter need propped up using
tefflon.
Slope conditioning gutter with do survey using total station, after got it
data and fix, then when will installing gutter need pulled thread for ensure
the same level gutter.
Installing SWP begining with installing gutter use U-Boxs, like under the
picture:
Picture 3.24.1 Installing gutter & SWP

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Picture 3.24.3 Handling SWP & Gutter
Picture 3.25 Position Gutter
Picture 3.26 Gutter

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46
5.111
5.119
6. 0
60
°
75 mm
1/5 L 2/3 L 1/5 L
1.000
10.000
Picture 3.28 Lifting Panel
Safety for Erection Panel

Type = GRAY 4 T
Quantity = 2 Unit
Actual Height = 8 m
Rated Capacity = 3200 KG
Weight Panel = 120 kg
Safety Factor = Cap/ W = 6400/ 120
= 53.3 SAFE

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Picture 3.29 Support Manpower install under gutter
- Safety equipment temporary
TECHNICAL DATA
(CARMANTEL ROPE SEMI
STATIC ROPE)
•Length:50 meters
•Diameter:12.5 mm
•Static Strength:2500 kgs
•Weight per meter:68 gr
•Shrinkage:4%
•Dry Treatment:none

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Picture 3.29 Installing Gutter
Picture 3.30 Position Gutter After Installed

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Picture 3.30 Position Gutter After Installed

- Install SWP
A7Z1
A6Z1

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Picture 3.31 SWP Above Gutter
ZONA 1A
ZONA 1B
Picture 3.32.1 Zone Grouping
ZONA 1A
ZONA 1B
ZONA 1C
Picture 3.32.2 Zone Grouping

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- Install Endwall
End Wall Panel Installation

1. Marking Position
2. Cutting Panel
3. Lifting Panel (Hoist 5 Ton)
4. Lifting the second panel
5. Screw to Steel Frame
6. Finish
- Steel Structure & SWP
Picture 3.37 Steel Stucture & Panel

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2. Moving mobilisation U-boxs

Mobilisation scafolding following installing SWP based on zone. Example
from zone 1 to zone 4.
Picture 3.38.1 Movement Scafolding
3. Fixing Material
Fixing material use U-boxs, for support fixing team, placed on U shape.
Picture 3.40 Boddy Harnes
Picture 3.41 Ninja Shoes
Picture 3.39 Suport Tim Fixing with U-boxs

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Fixing screw male female to steel
Picture 3.42 Fixing Srew Male Female
Fixing screw male female with Alm. Area 45-90
Alm. Male-female
Picture 3.4.3 Alumunium

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Picture 3.4.4 keyplan Alm. Male female

Installing alm. Male female from panel number 5 above gutter. For sealent
installing at alm. Male female.
- Install Acesoris

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- Install Safety Track
- Install Safety Line
Safety Track and Safety Line Installation

1. Installation Man power Using scafolding
2. Safety life line bracket installation

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4. Install ACP
End Cape Installation scafolding Method

1. Marking Position and install the Structural frame
2. Install Alumunium Composite Panel
3. Removing The Protected Lamination
5. Repair Gap SWP & Jengger

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Accesories Installation
1. GAP Between Sandwich panel and Steel Plate (Jengger)
2. Marking Position for the Flashing, Make Hole for csk Rivet attachment ,
Fixing the csk Rivet
3. Sealent the Flasing
4. Mockup Sample
6. Install eksterior Acsesoris with Jaring Methode

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Picture 3.4.5 support jaring
CHAPTER IV
IV.1 Inspection
Picture 4.1.1 Form Inspection Instalation

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Picture 4.1.2 Form Inspection Instalation
2. Check Curve on the Sandwich Panel

Check curve (radius) on the Sandwich Panel using mold from stainless
stell, like the picture.
Picture 4.2.1 Mold SWP R 11

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LAMPIRAN
FORM CEKLIST

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CHAPTER V
V.1 Job Safety Analisys
Picture 5.1 Flowchart Job Safety Analisys

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1. EMERGENCY PREVENTION
PT. SBI will coordination with the customer in case of emergency condition.
In case of emergency situation, Stop the works immediately and do the
related prevention.
In case of accident, immediately report to HSE and do emergency
prevention if the victims become worsth, go to the nearest hospital.
In case of fire, try to extingwish using fire extingwisher. Otherwise, call fire
brigade.
In case of disaster (flooding, earth quake), immediately find a safe place
and contact management for next action.
Base of chaos or striking happened, immediately report to the authority.
2. LIST OF MOBILE PHONE NUMBER FOR EMERGENCY SITUATION

No Name Position No. Telpon
1 I Putu Kusuma S. Project Manager 081347427700

2 Amar Site Manager 081347380484
3 Dewa Supervisor 082220112821
4 Bian Surveyor 081387810008
5 Anang HSE 082134407571
Picture 5.2 Table of Emergency Call Number
3. SAFETY EQUIPMENT
During erection, PT. SBI will provide first and box (P3K) for first and purpose
in case of accident in accordance with Permenaker No. 15/ 2018.

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Integrated Light Rail Transit Project in Jabodetabek

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PROGRAM PERCEPATAN

PENYELENGGARAAN KERETA API DOC. NO.

PT. Adhi Karya (Contractor)

PT. Adhi Persada Gedung (Contractor)

PT. Smart-modular Building Indonesia

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

PT. Smart-modular Building Indonesia got the assignment at 2 line

Picture 1.1 LRT Station

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

I.2 Scope of works

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Picture 1.2.0 Unloading SWP from Container

Picture 1.2.2 SWP stockyard at SBI workshop

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Gambar 1.3 Form Delivery Record Material Sandwich

- Delivery materials procedure

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Picture 1.4 SWP stacking

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Gambar 1.5 Instalation zone

Picture 1.6 scope of work

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

1. Total Station 2. Safety Face

3. Self Baricade 4. Shackle

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

5. Welding Tools 6. Webbing Sling

7. Chaing Block 8. Drill Tool

9. Jig Saw 10. Gerinda

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

11. Sigmat 12. Portable Winch

16. Safety Block

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

17. Safety Net For Tool 18. Safety Line

19. Safety Helm 20. Safety Shoes

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Picture 1.7 Working Area

Working area is on the existing steel structure provided by others.

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

II. STANDARD OF WORK

Picture 2.1.1 Table SOP NC

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Gambar 2.1.2 Table SOP NC

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Gambar 2.1.3 Table SOP NC

Gambar 2.2 Table SOP Corrective Action Report

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

II.2 Materials Technical Requirement

Picture 2.3 Specificaion Sandwich Panel

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

On the table spesification there is sandwich panel burning on temperature

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Picture 2.4 Specification Gutter Sandwich

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Picture 2.5 Specification Polycarbonat For Skylight

Gambar 2.6 Specification Skin Sandwich Panel

Gambar 2.7 Material Closing Joint between Sandwic Panel

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Picture 2.8 Mill Certificat For Galvanize Iron Sheet

Picture 2.9 Material Alumunium Extrution

METHODE STATEMEN SANDWICH PANEL STATION JATIMULYA

Picture 2.10 Mill Certificat For Extrution