Matara- Kataragama Railway Extension Project (Phase 1) Sri Lanka Matara-Beliatta Sector

Matara-Kataragama Railway Extension Project

Matara-Beliatta Sector (Phase 1)

(DK0+44 ~ DK26+461)

Method Statement for Culvert

MS-08
Rev. B

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

No Date Prepared Checked Approved Remark

REV.A 2013.9.3 LI BO Zhang Qunjian He Peizhi

REV.B 2013.9.23 LI BO Zhang Qunjian He Peizhi

Ref.Letter No :
 Matara- Kataragama Railway Extension Project (Phase 1) Sri Lanka Matara-Beliatta Sector

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
 Matara- Kataragama Railway Extension Project (Phase 1) Sri Lanka Matara-Beliatta Sector

Method statement for Culvert

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.

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

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 and excavation

Initially, the boundary of box culvert will be set out considering culvert width, working space

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required and allowance to maintain slope during excavation to foundation depth.

The existing canals, drainage will be temporary diverted appropriately so there will be no

disturbances to the users. Temporary drains, ditches, earth berms will be constructed to

avoid the Box culvert area inundate by rainwater.

In the areas where soft soil exist other than preloading areas, the exaction will be carried up

to the design invert level of the proposed box culvert. After reaching the designed level, DCP

will be carried out to test the founding level.

The calculation of bearing capacity will be as follows

1. The DCP testing will be carried out to competent level where Penetration Index is less
than 10mm/blow.

2. Using penetration index, the SPT N will be obtained using the chart published by
Minnesota Department of Transportation. (refer annexure 3, figure 7a- relationship
between SPT N and PI)

3. After obtained SPT N value for sound bearing level, calculation for bearing capacity
will be calculated using conventional geotechnical equations and submit for
Engineer’s approval.

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If it is inadequate, it will be excavated up to the sufficient bearing strata. The additional

excavation will be backfilled with compacted granular material.

If the fill height is greater than 0.5m, the filling will be done using 125 – 500 mm rock

material, blinded with 40mm graded aggregate at the top of the layer, to form dense

interlocking foundation. It will be compacted thoroughly to obtain firm surface. If the fill

height is less than 0.5m, the filling will be done using 40mm graded material and compact

thoroughly to obtain firm layer. The number of layers will be decided based on the height of

the fill and agreed with Engineer.

In areas other than soft ground areas, boulders, logs and other objectionable material

encounters during excavation will be removed. After complete the excavation the engineer

will be notified. No further construction activity will be carried out until the Engineer

approved depth of excavation and character of the founding materials.

Rock and other hard materials will be cleared off all loose materials and cut to a firm surface

either leveled, stepped or serrated as specified and shown in the drawings or as directed by

the Engineer.

All loose disintegrated rock and thin strata will be removed. When the foundation is to rest

other than rock, special care will be taken not to disturb the bottom of the excavation,
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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 Rubble mound and foundation concrete

After completing the excavation up to design invert level, the bearing capacity verification

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will be done. If the bearing capacity is sufficient, a layer of rubble will be spread with

thickness not less than 100mm, under the foundation. The foundation concreting can be

categorized in to three parts.

a). Retaining wall foundation – 200mm thick C30 concrete layer

b). Culvert inlet and outlet section foundation – C30 concrete layer, (2000mm x 2800mm x

1000mm) or dimensions as specified in the approved construction drawings.

c). Culvert foundation bed – C20 concrete, 200mm thick

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Before placing foundation concrete, the formwork will be setup using timber planks as

sideboards and steel rods as anchors, so that the sideboards will hold tightly.

The sequence of concreting will be as follows;

The foundation bed of culvert will be concreted in one-step.

The Retaining wall and culvert inlet - outlet foundation will be concreted together. The

internal vibrators will be used in culvert inlet-outlet foundation which thickness is 1m.

The freshly laid concrete will be kept undisturbed and protected from the effects of sun and

rain and from drying out /loss of moisture until it hardens. Once hardened, the concrete will

continuously be cured in moist atmosphere for minimum period of seven days.

4.3.2 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.

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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. 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 blocks All 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.

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4.3.3 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

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

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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. Each batch of the concrete delivered at the job site will be

accompanied by a batch ticket bearing complete batching information. The temperature of

fresh concrete will not allow exceeding 32°C unless otherwise specified. The addition of
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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.

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 exceeded further 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.

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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 be well 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

until the surfaces of the larger aggregate are exposed. The aggregate stones will not be loose.

4.3.5 Concreting sequence

1.the concreting carry out four steps given below;

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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.

100mm

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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.

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
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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.

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
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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 10m3 and for each new pouring .

5.8 Temperature of the fresh concrete will be kept less than 32oC at the pouring time.

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.

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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
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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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