Method

Dompak – Bintan Statement

Bridge Project Date : 11 Mar, 2014
Bridge BCM Works Page : 1 of 23

Table of Contents

Section Description Page

1.0 Purpose 2
2.0 Work Scope 2
3.0 Work Flow 2-7
4.0 Work Procedure for Form Traveler Installation 8-9
5.0 Work Procedure for BCM Segment Construction 10-14
6.0 Work Procedure for Closure Segment 14-15
7.0 Work Procedure for Form Traveler Dismantling 16-17
8.0 Work Procedure Segments on False work 18-21
9.0 Safety 21-23
10.0 Environmental Management 23
 Method
Dompak – Bintan Statement
Bridge Project Date : 11 Mar, 2014
Bridge BCM Works Page : 2 of 23

1. Purpose
This document describes the method and work sequence of the cast in place Bridge BCM Works
(Balance Cantilever Method) for the Dompak - Bintan Bridge Project, Riau islands.

2. Workscope
2.1 Scope
The scope of this method statement includes the construction of the superstructure of the
Dompak - Bintan Bridge Project, Riau Islands. The work starts from the installation of the
form travelers on the pier head until the completion of the closure segments and dismantling
of form travelers.

3. Work Flow Chart

3.1 General
It is assumed that the construction of the pier head is complete before starting the work flow
as follows:

Site Preparation &

Mobilization

Installation of Form
Travellers (P6 & P7)

Segmental Construction by Construction of End

Balanced Cantilever Segments by Falsework
Method (P6 & P7) (P5 & P8)

Construction of Closure
Segments

Dismantling of Form
Travellers
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3.2 Installation of Form Traveller

This work sequence is to be carried out for P6 & P7.

Pre-assemble on the ground/pontoon

Main components Formwork

Install main components on the pier

head

Install formwork
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3.3 Segmental Construction by Balanced Cantilever Method

This work flow shows the cycle of segmental construction which is to be carried out for
P6 & P7.

Form traveler in concreting position

Fixing of formwork

Installation of rebar, inserts and PT

ducts

Survey Check
Installation of end formwork,
anchor block

Repeat this cycle from Pouring of concrete

segment 1 to segment
10 of P6 & P7 both Curing
sides

Installation of tendon

Prestessing
Prestressing

Advance form traveler to the next

Grouting
segment

Grouting
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Bridge Project Date : 11 Mar, 2014
Bridge BCM Works Page : 5 of 23

3.4 Construction of Side Span by Scaffolding

This work sequence for P5 & P8 shall be carried out simultaneously with the segmental
construction of P6 & P7 in such a way that when the segmental construction by form
travelers is finished, the side span is also finished thus ready for the construction of the
closure segment.
Instalation of scaffolding

Installation of bottom & outer web

formwork

Installation of bottom and web

rebar, PT bars, ducting.

Installation of inner web formwork

1st stage

Survey Check
Pouring concrete 1st stage

Install scaffolding for 2nd stage

formwork

Install inner web and top formwork

Installation of top rebar, PT ducts

Pouring concrete 2nd stage

Curing

*Remove web & top slab formwork

only

Note*: Scaffolding shall only be removed after prestressing continuous tendons

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3.5 Construction of Closure Segments

This work flow applies to both center span closure segment (P6 to P7), and side span
closure segments (P6 to P5, P7 to P8).

Last segment of balanced cantilever

completed

Remove inner formwork of form

traveller

Remove hand rails of front working

platform of bottom formwork

Advance form traveler to opposite Advance form traveler to last

last segment of balanced cantilever segment of side span on falsework

Fix front end of bottom and web Front end of bottom and web
formwork to concrete of opposite formwork must still hang from the
segment form traveler but tight against
concrete of opposite segment

Install bottom and web rebar, PT

bars, ducting

Install special inner formwork (web

& top)

Install top rebar, PT ducts

Pouring concrete
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Install continuous tendon

Prestressing

Grouting

Dismantling of form traveler and

falsework

3.6 Dismantling of Form Traveller

Lower cantilever formworks into

the bottom formwork

Launch back form traveler towards

the pier.

Lower bottom formwork to the

ground and disengage from form
traveler. Dismantle.

Dismantle main components from

the bridge deck
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4.0 Work Procedure of Form Traveller Installation

4.1 Pre-assembly on the ground.
With the use hydraulic crane, pre-assemble each component on the ground. Find sufficient
space to store the following components:
- A- frame
- Front & rear trusses
- Drive deck
- Cantilever
- Rails
- Formwork panels

Bottom formwork shall be pre-assembled under the pier head on its lifting position.

4.2 Installation on the pier head.

With the use hydraulic crane, install the components in the following order:
- Rails
- A-frame
- Rear truss
- Bracings
- Front truss
- Hydraulic systems
- Cantilevers
- Drive deck
- Bottom formwork
- Web formwork panels (outer)
- Web formwork panels (inner)
- Safety provisions
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Bridge BCM Works Page : 9 of 23

Set the form traveler to its concreting position.

Form Traveler Assembly (Front View)

Form Traveler Assembly (Side View)

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5.0 Work Procedure for BCM Segment Construction:

5.1 Survey
After form traveler installation, survey the Bottom Form, Cantilever Form, Drive Deck
Form and make necessary adjustments according to design camber specified in
construction engineering.

5.2 Rebar Works

Install bottom slab and web reinforcing bars according to working drawings providing
adequate space for sheathing ducts insertion. Provide spacer blocks where in contact
with forms at proper intervals to maintain required concrete covering and prevent rebar
exposure. Top slab rebar shall be installed taking into account the installation of the
longitudinal and transversal tendon.

5.3 Longitudinal Tendon and Hole Location

5.3.1 Install longitudinal ducting after rebar is finished. Provide support bars
in every 0.5m – 0.8m of the duct to attain the desired profile of the
tendon. Additional bar supports shall be put to keep the ducts in place.
Install anchorage system temporarily. Fixing of the anchorage and
grouting tubes shall be done later simultaneously with the end formwork.
5.3.2 Install holes location for form traveler anchors and miscellaneous
embeds on location.

5.4 Inner Web Forms

Close inner web formwork. Install tie rods. Install Special Formwork

5.5 End and Side Forms

Install end formwork starting from the bottom slab, the web, then to the top slab. The
fixing of anchorage system of longitudinal tendon shall also be done simultaneously.
The connection between the ducting and the anchorage shall be made watertight by
putting duct tape and cover the opening of the anchorage to prevent concrete from
going in.
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5.6 Final Survey

Check formwork levels and alignment and make necessary adjustments prior to
pouring concrete.

5.7 Pouring Concrete

Set up a 32m pump car from the ground wherein the discharge end can reach the
bottom formwork through the inside of web. Concrete must not be dropped higher than
1.5m from end of pipe to the formwork to avoid segregation. Using concrete of class
K500, pour bottom slab first one side at a time pouring 0.5m high of concrete each
time. Pour concrete from the side towards the center until the whole bottom slab is full.
While pouring, consolidate concrete using high frequency vibrators of not less than
7,000 impulses per minute in a uniform pattern of about 450mm distance for about
5~15 second not farther apart where vibrator is visibly effective. Proceed to the web
pouring the center one then from one side to the other at a time with 0.5m high of
concrete each time in layers and cover each layer of fresh concrete within 45minutes.
While pouring consolidate concrete using high frequency vibrators. Work vibrator well
around rebars, ducts and embeds to create a good concrete compaction. Proceed to the
top slab by pouring from one side to the other working towards the center until the top
slab is full. Again, while pouring, consolidate concrete using high frequency vibrators
and work well around rebars, ducts and embeds. Keep an eye on the grouting tubes,
making sure that nothing is damaged/broken. Finish concrete to desired level and slope

2 2 2

Stage Pouring Concrete

(bottom slab web top slab/flange)
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5.8 Curing
Burlap sheets and water shall be used for curing the deck; and curing compound for
soffit and web walls.

5.9 Remove End and Side Formwork, Form Ties

Remove end and side formworks in a careful manner as not to damage the end of the
ducting. Clear all the cover from the anchorage. Chipping of concrete shall be done
after then. Form ties shall be removed before prestressing.

5.10 Insert Strand

Remove anchorage covers. Check ducts for any obstruction, remove and clean. Install
tendons in individual sheathing ducts either by pushing or pulling each strands inside
the duct. Place the required number of strands to be provided inside and cut to required
length.

5.11 Stressing
5.11.1 Installation of wedge plates and wedges
Place the wedge plate both on the anchorage end and on the stressing end. Rotate
the plates to align strands. Install the wedges over the strands. Use a 1-inch G.I.
pipe to push the wedges into the wedge plate.

5.11.2 Cutting of Strand at stressing end

Check required strands protrusion and cut to equal lengths adequate for the jack.
The strand might also be cut in ascending length to ease insertion of the jack
starting from the inner core group going to the outside.

5.11.3 Jack mounting

Mount jack using hoisting gear pushing towards the strands. Make adjustments, the
axis of the jack must coincide with the tendon axis.

5.11.4 Stressing
Stressing shall commence only upon required concrete strength of 28 Mpa has been
reached.
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5.11.4.1 Stressing operations

 The stressing should be done in the steps agreed to and indicated on the
stressing report. Stressing forces and calculated elongation are supplied
by the engineer.
 All stressing results have to be recorded on a project specific stressing
report. The net elongation should be within -7% / +7 % of calculated
elongation. Reasons for eventual discrepancies should be investigated
and relevant measure be taken if necessary.
 When the stressing operation is complete, the engineer or supervisor
responsible for the stressing should collect the stressing report from each
cable end and combine them in a single report, which should be signed
and then proposed to the client's representative engineer for approval.

5.11.4.2 Main procedure:

- Start the pump and increase the oil pressure to the value indicated in the
stressing report.
- Measure the elongation from the jack to the stop fixed to two strands of
the projecting tendons using a measuring tool.
- Record the value in the stressing report.
- Increase the oil pressure in steps indicated in the stressing report and
record the corresponding elongation values in the stressing report.
- When stressing a tendon with an elongation with more than one stroke
of the piston of the jack, the load must be released to the wedge plate
head about 10 mm before the end of the stroke of the piston.
- Transfer the load to the wedge plate
- Retract piston completely
- Re-adjust self gripping assembly
- Re-start stressing.
- After removing the jack, check that all wedges have set correctly.
- Compare the net elongation with the calculated elongation given in the
report.
If elongations are within tolerances, stressing can be approved.
If elongation exceeds the specified tolerances, cause of deviations must
be investigated.
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- When the stressing report has been approved, the strands can be cut
approximately 30 - 50 mm from the wedge plate by using a grinding
disc.

5.12 Grouting
Grout consists of:
- Portland cement in 50 kg bags
- Water
- Sika Intraplast Z additive, or similar
- Water / cement ratio: 0.4 ~ 0.45

The DSI mixers are specially designed for the purpose of mixing and agitating the
grout and carrying out the grouting operation in a single unit of equipment.

They enable the grout constituents to be metered accurately and an absolutely

homogeneous mixture passes through a standard sieve to the pump. The pump
fitted to the mixer is capable of exerting a constant working pressure of approx. 5 -
7 bars.

5.13 Advance Form Traveller to Next Segment (repeat sequence up to last segment)
Upon completion of each segment, release forms, anchors and advance form traveller
to next segment.

6.0 Work Procedure for Construction of Closure Segment

6.1 Remove form traveler inner formwork from inside of deck..

6.2 Remove hand rails of front working platform of form traveller and advance to fit into closure segment.
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Dompak – Bintan Statement
Bridge Project Date : 11 Mar, 2014
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FT

CLOSURE

BCM Segments

Closure Segment Construction (Center Closure)

6.3 Fix front side of formwork

6.3.1 For center closure, fix front side of formwork to the concrete of opposite segment.
6.3.2 For side span closure, the formwork still hang from the form traveler but must be
tight to the opposite concrete at the front.

6.4 Rebar Work 1st stage

Install bottom and web rebar (Refer to Section 5.2)

6.5 Special inner formwork

Install special inner form work for inner web and top slab

6.6 Rebar Work 2nd Stage

Install top slab rebar (Refer to Section 5.2)

6.7 Install Tendon and Hole location (Refer to Section 5.3)

6.8 Inner Web Forms (Refer to Section 5.4)
6.9 Side Forms (Refer to Section 5.5)
6.10 Final Survey (Refer to Section 5.6)
6.11 Pouring Concrete (Refer to Section 5.7)
6.12 Curing (Refer to Section 5.8)
6.13 Remove side forms, form ties (Refer to Section 5.9)
6.14 Insert strand (Refer to Section 5.10)
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6.15 Stressing (Refer to Section 5.11)

6.16 Grouting (Refer to Section 5.12)

7.0 Work Procedure for Form Traveller Dismantling

When last cantilever segments on both sides are completed, one of the two form travelers shall
be removed while the other one shall stay to construct the closure segment. After constructing
the closure segment, the 2nd form traveler shall be removed as well using the same procedure as
follows:
7.1 Dis-engage cantilever & bottom formwork from the concrete by removing the hanging
bars.
7.2 remove outer web formwork panels.
7.3 Using lever blocks, lower the cantilever formwork into the bottom formwork and secure.
7.4 Using either 2 hydraulic cranes lower the bottom formwork to the ground and dis-engage
from form traveler.
7.5 Remove hanging bars and chain blocks.
7.6 Remove front truss.
7.7 Install temporary support for main frames (i.e. wire slings on both sides)
7.8 Remove rear truss and rear suspension at chassis.
7.9 Remove anchor stars.
7.10 Dis-engage main frame from rear carriage and remove.
7.11 Remove rails and rear carriages.
7.12 For the inner formwork removal, there are 2 cases in which different procedure is applied
to wit:

7.13.1 Case 1: After constructing the last cantilever segment:

7.13.1.1 Advance form traveler at least 3.5m. Temporary holes for rear anchorage shall
already be provided for this purpose.
7.13.1.2 Dis-engage web inner formwork from drive deck and put on top of bottom
formwork.
7.13.1.3 Remove top inner formwork.
7.13.1.4 Remove drive deck beam assembly.
8.13.1.5 Remove web inner formwork.
8.13.1.6 Proceed to Section 7.1.
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7.13.2 Case 2: After constructing closure segment:

As discussed in Section 6.5, special inner formwork shall be used for closure segment,
which is not connected to the form traveler. Therefore, the removal of such formwork
after the prestressing of the continuous tendon can be done at anytime depending on
the convenience at the site. Manholes on top of the deck shall be provided for this
purpose.

8.0 Segment on Falsework:

8.1 Falsework
Spread timber or sheet pile base beam on the prepared ground proportionate to shoring
intervals. Install heavy shoring falsework and position in such way to cater the imposed
load by girder segment construction. Provide adequate bracings to properly secure
assembly. Set the top u-head jacks to required elevation.

Closure Segment

Abutment
BCM
Segment on Falsework

Segment on Falsework Construction

8.2 1st Stage Construction

8.2.1 Bottom and Web Forms
Install beams and bottom forms on the completed shoring assembly, align and fix to
required level. Cut to fit bottom form at bearing area. Install prefab outer web/flange
form on both sides. Ensure alignment and connections by providing adequate bracings
and supports. Apply release agent evenly on all form surface exposed to concrete.
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8.2.2 Survey
Establish survey points on top of forms, marking layout and elevation from which all
other measurements shall be reckoned.

8.2.3 Rebar Works

Install bottom slab and web reinforcing bars according to working drawings providing
adequate space for sheathing duct insertion. Provide spacer blocks where in contact with
forms at proper intervals to maintain required concrete covering and prevent rebar
exposure.

8.2.4 Install Tendon and Hole Location (Refer to Section 5.3.1-5.3.2)

8.2.5 Pouring Concrete

1st Stage Pouring Concrete (bottom slab & web)
Set up a 32m pump car from the ground wherein discharge end can reach the bottom
formwork through inside of web. Concrete must not be dropped higher than 1.5m
from end of pipe to the formwork to avoid segregation. Using concrete of class K500,
pour in layers not exceeding 500mm and cover each layer of fresh concrete within
45minutes. Pour bottom slab with concrete until whole slab fully covered gradually.
Consolidate concrete using high frequency vibrators of not less than 7,000 impulses
per minute in a uniform pattern of about 450mm distance for about 5~15 second not
farther apart where vibrator is visibly effective. Work vibrator well around rebars,
ducts and embeds to create a good concrete compaction. Finish concrete to desired
level.

1st Stage Pouring Concrete (bottom slab)

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8.3 2nd Stage Construction (Web)

8.3.1 Rebar
Install web rebar.

8.3.2 Install Tendon (Refer to Section 5.3.1-5.3.2)

8.3.3 Web Formwork

Install inner web formwork. Support the formwork from the 1st stage concrete by
shoring .
8.3.4 End Formwork
Install end formwork for web.

8.3.5 Pouring Concrete ( web )

Set up a 32m pump car from the ground. Concrete must not be dropped higher than
1.5m from end of pipe to the formwork to avoid segregation. Using concrete of class
K500, pour in layers not exceeding 450mm. and cover each layer of fresh concrete
within 45minutes. Consolidate concrete using high frequency vibrators of not less than
7,000 impulses per minute in a uniform pattern of about 450mm distance for about
5~15 second not farther apart where vibrator is visibly effective. Work vibrator well
around rebars, ducts and embeds to create a good concrete compaction.

2 2 2

2nd Stage Pouring Concrete ( web & diaphragm )

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8.4 3rd Stage Construction (Top Slab)

8.4.1 Scaffolding
Install scaffolding on top of the 1st stage concrete.

8.4.2 Formwork
Install top formwork on the scaffolding.

8.4.3 Survey
Establish survey points on top of forms, marking layout and elevation from which all
other measurements shall be reckoned.

8.4.4 Rebar Works

Install top slab and reinforcing bars according to working drawings providing
adequate space for sheathing duct insertion. Provide spacer blocks where in contact
with forms at proper intervals to maintain required concrete covering & rebar
exposure.

8.4.5 Install Tendon and Hole Location (Refer to Section 5.3)

8.4.6 End Formwork

Install end formwork for top slab concrete. Anchorage system for tendon shall also be
done simultaneously.

8.4.7 3rd Stage Pouring Concrete ( Top Slab )

Set up 32m pump car on the ground where discharge pipe can reach and move freely
within pouring area. Using concrete of class K500, pour top slab/flange with concrete until
whole slab fully covered. Consolidate concrete using high frequency vibrators of not less
than 7,000 impulses per minute in a uniformed pattern of about 450mm distance for about
5~15 second not farther apart where vibrator is visibly effective. Work vibrator around
rebars, ducts and embeds to create a good concrete compaction. Concrete shall be leveled,
and screeded manually to produce a uniform sloping surface.
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3rd Stage Pouring Concrete ( top slab )

8.4.8 Curing
Burlap sheets and water shall be used for curing deck; and curing compound for soffit
and web walls.

8.4.9 Remove end forms, side forms, & form ties (Refer to Section 5.9)
8.4.10 Insert Strand (Refer to Section 5.10)
8.4.11 Stressing (Refer to Section 5.11)
8.4.12 Grouting (Refer to Section 5.12)
8.4.13 Removal of Formwork
Important : Formwork shall not be removed until the closure segment has been
constructed and prestressed. However, a space of 1.2m shall be provided to
accommodate the front end of the form traveler formwork after launching for the
closure segment. This shall be done by arranging the scaffolding in such a way that
the end row can be removed independently without removing the rest of the scaffolding.

9.0 Safety

9.1 Conduct safety orientation to equip personnel with the knowledge, skill and attitude that will
enable them to perform their duties in a safe manner and to prevent accidents, and the findings of
the risk and method statements.

9.2 Personal Protective Equipment (PPE)

Provide necessary PPE and safety harness equipment for each type of work such as; Head
protection, Foot protection, Fall protection, eye and face protection, hand protection, noise
protection, respiratory protection
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9.3 Temporary Electrical Installation

Equipment use in temporary electrical installations for BCM works shall be of an approved
type and maintained in good condition. Welding machines, hacking machines, lightings, etc.
should be properly connected and wired.

9.4 Construction Material Storage

Rebars and formworks should be properly stock, arranged in designated area where it shall
not create any obstruction to other works. Provide wedge underneath to facilitate lifting.

9.5 Ingress and Egress

Maintain a passable ingress and egress to all work areas through frequent maintenance
(cleaning, repair and restructuring). Obstruction and hazard should be removed at once.
Safety warning and traffic signs should be posted at visible locations.

9.6 Form Traveller Assembly

Install pre-assembled form traveller components into the pier table by crane. Installation
should be rigged properly. Secure assembly before releasing on crane.

9.7 Safety Platform, Railing and Overhead Net Enclosure

Equip Form Traveller assembly properly with safety platform, railing and kickboards of good
material. Bottom and sides shall be fully enclosed with a heavy duty net (mesh size: 1/8 inch
square) to contain construction debris and to prevent fall directly to the highway. Maintain
enclosure and catchment platform to be free from damage by conducting frequent inspection
and removal of accumulated debris that may cause collapse and damage to the net. All
necessary precaution shall be taken during the entire work period.

9.8 Safety Stairs

Install a pre-assembled safety stair of durable material beside the pier which can be crane-
handled. Anchor /clamped stair assembly properly into the pier to keep in place. Provide
safety net enclosure and proper signage.

9.9 Construction Equipment

9.9.1 Crane – Use type and capacity sufficient enough to lift rebars, forms and form
traveller components into its specific location.
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9.9.2 Concrete Pump – Use pump car fitted with elephant trunk pipes with
sufficient capacity to suit construction condition. It should be positioned on stable
ground during operation.

9.9.3 Jack – Use jack suitable for the required tendon type and stressing load. All
accessories shall be maintained in good condition prior to every operation.
Mount jack with proper hoisting gear. Maximum pressures shall never be exceeded.

10.0Environmental Management

10.1 Engineering waste and waste material from construction

Prepare a sedimentation pond to collect oil and other machinery lubricants used for
maintenance during construction period and disposed properly.

10.2 Living waste water from construction personnel

Movable toilets and combined type septic tank will be provided in construction site during
construction period to handle the waste water and soil discharge, to reduce the amount of
living waste water generated by construction personnel.

10.3 Cleanliness
All vehicles and transport trucks are to be cleaned before they are used on the road.