Matara-KataragamaRailwayExtensionProject(Phase1)SriLankaMatara-BeliattaSector

Matara-Kataragama Railway Extension Project

Matara-Beliatta Sector (Phase 1)
(DK0+44 ~ DK26+461)
Method Statement for Culvert Upper portion

MS-08B
Rev. A

Contractor:China National Machinery Imp. & Exp. Corp.

No Date Prepared Checked Approved Remark

REV.A 2013.10.1 LI BO Zhang Qunjian He Peizhi

Ref.Letter No :
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CONTENT
1.0 Purpose of Method Statement
2.0 Relevant documents and Standards
3.0 Responsibilities for activity Describe within this Method Statement
4.0 Detailed method of carrying out&method statement activity
5.0 Quality assurance and quality control measurements
6. 0 HSE measures
APPENDIX 1: SLR-RC Box Section Construction-Wall steel formwork(data)
APPENDIX 2:SLR-RC Box Section Construction-Wall steel formwork(member design)
APPENDIX 3:relevant Chinese material specification
APPENDIX 4:Technical Code for Safety of Forms in Construction
APPENDIX 5:Technical Code for Safety of Steel Tubular Scaffold with Couplers in
Construction
APPENDIX 6: Technical Code of Composite Steel-form
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Method statement for Culvert upper portion

1.0 Purpose of Method Statement
This method statement provides the details of the materials, the equipment, the procedure and
relevant documents related to the construction of reinforced concrete box culverts upper
portion, which refers to the structure above foundation bed concrete level. This method
statement shall refer along with MS 08A- Method statement for construction of culvert lower
portion.

2.0 Relevant documents and Standards

2.1 ICTAD publication SCA/5, section 1000
2.2 BS 8666: 2000 Dimensioning, scheduling, cutting and bending steel reinforcement for
concrete structures
2.3 Working drawings for culverts
2.4 Method Statement for construction of culvert lower portion

3.0 Responsibilities for activity Describe within this Method Statement

Construction manager, structural engineer, site engineer and other relevant personnel within
whose scope of works shall be responsible for referred construction activities in related to
construction of reinforced concrete box culverts shall carry out according to the method
stipulated in this statement unless otherwise changed by the Engineer.

4.0 Detailed method of carrying out&method statement activity

4.1 Initial setting out, preparation, ground bearing capacity check, foundation construction
and concreting are described in MS 08A- Method statement for construction of culvert lower
portion.

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4.2 Material

4.2.1 Steel and wooden formwork

4.2.2 Steel reinforcement
4.2.3 Water stop material for Movement joint (300mm width)
4.2.4 1.5mm thick, Highpolymer modified asphalt water proofing membrane (500mm width)
– for movement joint
4.2.5 1.5mm thick, Polythene waterproof coating (660mm wide) – for movement joint
4.2.6 Asbestos asphalt plate 30mm thick – for movement joint
4.2.7 C40 concrete – 40mm thick cover layer for movement joint
4.2.8 C20 screed concrete
4.3.8 C 30 concrete for retaining wall and culvert foundation at inlet and out let
4.3.9 C40 concrete for culvert, retaining wall and cap block

4.3 Construction
4.3.1 Steel reinforcement work
Reinforcement will be clean and free from loose rust and mill scale, dirt, oil, grease and paint
at the time of fixing in position and subsequent concreting. Reinforcement will be handled and
stored in a manner that they will not be deformed.
Bars will be cut and bent cold by applying a slow, even pressure with equipment and methods
approved by the Engineer to the dimensions given in the Bar Bending Schedules shown in the
relevant construction drawings.
All reinforcing bars will be placed in positions shown in the Drawings and will be firmly held
in position, with the specified spacing, prior to concreting operations using necessary wire ties
at bar intersections, spacer bars, steel chairs of approved type or by other approved means.
Wire ties(binding) will be black annealed M.S or G.I. wire, not less than 1.0mm in diameter
and will be firmly tied and folded so that they do not project into concrete cover region.
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The adequacy of supports and ties to secure the reinforcement properly will be subject to the
approval of the Engineer.Layers of bars will be separated by spacer bars, concrete cover
blocksAll horizontal and vertical reinforcement will be supported on mortar blocks, of
approved shape conforming to cover requirements, with tie wires embedded in them, made out
of 1: 1 ½ or 1:2 cement sand mix. Supports which are in contact with the external face of the
concrete will all be concrete cover blocks. The use of small stones or wood blocks will not be
allowed. As far as possible, bars of full length will be used. In case this is not possible splicing
of bars will be done as specified in the Drawings or as directed by the Engineer. Lap splicing
(as per BS 5400 part -4 and design drawings)will be staggered for different bars and will
generally not be located at points, of maximum tensile stress.
No concreting will commence until the reinforcements have been inspected and approved by
the Engineer.
Reinforcement after being placed in position will be maintained in a clean condition until
completely embedded in concrete. Special care will be exercised to prevent any displacement
of reinforcement in concrete already placed.

4.3.2 Formwork
The formwork will be timber, steel approved by the Engineer. Timber forms will be of
approved quality, well seasoned and of uniform thickness, sound, free from warps, loose knots,
twists, wavy edges, saps and shakes or other defects affecting the strength of the form work
and appearance of the finished surface of the retaining wall. Metal sheets use for formwork
will be kept free from rust and dents with no surface blemishes that will impair the concrete
surface finish.
The supports and scaffoldings will be of metal, sawn timber, round timber or of any other
material approved by the Engineer.
The temporary staging will be provided to enable the constructional operations to be
performed in the required sequence and in a safe manner. The false work will be properly
constructed to provide the necessary rigidity and to carry out loads, which will be required to
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support. Where necessary it will include safe walkways to enable Engineer to inspect the form
work, reinforcement and concreting.
All formwork will be constructed that there will be no loss of materials from the fresh
concrete. Forms will be mortar tight, will be made sufficiently rigid by the use of ties and
bracing to prevent any displacement or sagging, and will be capable of withstanding all
incidentals loading during concreting.
Where internal ties, they will be extracted without damage to the concrete to a depth of at least
25mm from the finished concrete surface and the resulting holes filled with.non shrinkage
mortar. No permanently embedded nuts will have less than 25mm concrete cover from
finished concrete surface.
Immediately before concreting, the forms will be thoroughly cleaned either by water jetting or
by any other suitable method, temporary openings being provided for the purpose. Inside
surfaces will, coated with an approved material such as mould oil to prevent adhesion of the
concrete. This material will not be allowed to come in to contact with the reinforcement.
No concrete pouring will be carried out unless the Engineer has inspected and approved the
formwork, false work and reinforcement.
The engineer will be informed in advance, as to when the formwork removed. The minimum
period between concreting and formwork removal for culvert wall will be 01 day. For the slab
shall exceed to 7 days.

4.3.4 Concreting
When a truck mixer or agitator is used for transporting concrete, the concrete will be delivered
to the site of the work and discharged within one and half hours after the addition of the
cement to the aggregates. A batch ticket bearing complete batching information will
accompany each batch of the concrete delivered at the job site. The temperature of fresh
concrete will not allow exceeding 32°C unless otherwise specified.The addition of water after
completion of initial mixing will not be allowed. Concrete that is not within the agreed
consistency limits at the time of placement will not be used.
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Prior to placing of concrete all formwork and reinforcements therein will be cleaned of all
extraneous material, dust and made free of any standing water. It will be ensured that all
formwork is made leak proof and that there is no loss of mixing water or grout from the
concrete. No concreting will be started without the prior approval of the Engineer.
All mixed concrete will be placed and compacted in the formwork, using approved vibrators
of the internal, external or combinations thereof depending on the type of job. In all cases of
continuous concreting, fresh concrete will be placed before the already laid concrete is less
than 30 minutes old and where this time gap is exceededfurther placing will be subject to
testing the already placed concrete surface to be live. In the event that the surface is not live, it
will be treated as a construction joint and to be allowed to set.
All concrete generally will be placed and compacted in horizontal layers normally not
exceeding 300mm in depth except where adequately sized internal vibrators are used when the
depth may be increased up to a maximum of about 400mm.
No concrete will be dropped from a height greater than about 1.5 meters except with the prior
approval of the Engineer.Where chutes are used for placing of concrete they will be kept clean
and used in a manner to prevent segregation. When concrete is conveyed by chute, the pouring
will be carried out in a way that to ensure practically continuous flow. Slope of the chute will
be so adjusted that the concrete flows without the use of excessive quantity of water and
without any segregation of its ingredients. The delivery end of the chute will be as close as
possible to the point of deposit. The chute will be thoroughly flushed with water before and
after each working period and the water used for this purpose will be discharged outside the
formwork.
When concreting has to be resumed on a surface which has hardened, the surface will be
roughened, swept clean thoroughly wetted and covered with a thin layer of cement grout or
cement mortar as approved. Semi-hardened surfaces will bewell brushed to remove all
laitance, cleaned and covered with a thin layer of cement grout prior to overlaying with fresh
concrete. A concrete surface, which has hardened, will be treated as a construction joint for
further casting after not less than 24 hours. The surface will be free of laitance and leaned
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until the surfaces of the larger aggregate are exposed. The aggregate stones will not be loose.

4.3.4Concreting sequence
1. The concreting carries out four steps given below;

100mm thick kicker will be casted by pouring additional concrete height above from the
chamfer top level after Step 2 to support formwork erection at step 3.
The lateral brace supports will be setup on formwork founded on culvert base to avoid
swaying of the frame during concreting of step 3. The brace supports will be independent for
each wall. The spacing will be same as vertical studs in longitudinal direction of the culvert.

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3. Construction sequence along the longitudinal direction

The foundation bed concrete, which named as part one in above will be placed together
(sequence A).
Then the part 2,3and 4 will be concreted in different segments separated by the movement
joints.

E E
settlement joint
B C B C
D D

A
The sequence of concrete is A B C D E

Figure 2. Longitudinal sectional view

The concrete pouring will be carried out using pouring buckets handled by a crane. Whenever
the concrete falling height will be more than 1.5m, especially in cases of concreting sidewall
of the box culvert, concrete will allowed to pour through a chute arranged in a way that the
free falling of concrete is less than 1m. The internal vibrators used during concreting work
sufficiently, so the concrete will spread, compact in even along the entire layer.

4.4 Back filling

After completion of the structure tie holes will be filled with non-shrinkage cement
mortar.Prior to the backfill, the excavated area will be dewatered until existing bed exposes,
and the slope prepared 1: 0.5 gradient from the bottom of the excavation. The debris and other
unsuitable materials within the excavation area will be removed using excavators during the
time of bed and slope preparation.

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0.5m

H 1:0.5

Typical Section of structure back filling

The back filling of two sides of culvert will be carried out using graded granular material or

permeable soil. The permeability requirement of back filling material will be 10-4 m/s.。 The

light compaction equipment will be used to compact the back fill adjacent to structure. The
compacted layer thickness will not be more than 150mm. The compaction will be not less than
93% of the maximum dry density. The backfilling work will be carried out both sides
simultaneously.The difference of the two sides filling height will not allowed to exceed
300mm.

5.0 Quality assurance and quality control measurements.

5.1 Bearing capacity testing will be carried out at proposed foundation level after excavation.
5.2 Site layout strictly according to the design drawing.
5.3 Material for concrete will be from approved sources, compliance with requirements.
5.4 Reinforcement fabrication is strictly in accordance with design drawing.
5.5 Reinforcements only from approved suppliers, brands, and in a acceptable conditions, free
from dirt, corrosion, grease and oil.
5.6 Binding wires shall be minimum thickness 0f 1mm, free from corrosion.
5.7 Cube samples will be collected 3 per each 10m3and for each new pouring.
5.8 Temperature of the fresh concrete will be kept less than 32oC at the pouring time.

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5.9 Slump of the concrete before pouring shall comply with the mix design requirements
5.10 After reinforcement fabrication completed, Engineer’s inspection will be called upon to
check the reinforcement fabrication in accordance with the design drawing.
5.11 During the concrete pouring, internal vibrators are used adequately.
5.12 The pouring work will be carried out in approved manner, the layer thickness and time
duration between two pouring will be strictly controlled.
5.13 The structure back billing will be strictly according to the drawings

6.0 HSE measures

6.1. Site staffs are allowed to enter the construction site only with the safety helmets on their
heads.
6.2. Mechanization of the sub base construction is applied in this trial section. All the
equipment shall be maintained regularly.
6.3. Safety measures must be taken during the excavation close to buildings, facilities’
foundations, electricity posts and scaffolds.
6.4. To control the speed and keep the distance from other vehicles during the tipper is
running; Lighter vehicles should give way to heavier vehicles when passing each other;
6.5. It is forbidden to stand within the operating area of a running machine. All the operations
of machines shall strictly conform to the regulated process of safety operation.
6.6. When the soil structure is unstable, when the collapse happens and when the water level
rises suddenly or any other dangers occur, all the site staffs should immediately stop the work
and be evacuated to safe places. They can go back and resume the construction only after the
site is confirmed to be safe.

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