Name of work : CONVEYOR I LEG SLIPFORM WORK

Name of Project : CIMASSO LINE 02

Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

METHOD STATEMENT FOR CONSTRUCTION

OF CONVEYOR I LEG USING SLIPFORM
TECHNOCLOGY

CONTRACTOR : AYOKI FABRICON PVT LTD.

CLIENT : CIMASSO SA.

PROJECT : CIMASSO LINE 02

LOCATION : CIMASSO, BURKINA FASO

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

CONTENTS

Sl No Description Page no
1 Objective 2
2 Scope 2
3 Reference 2
4 Equipment’s 2
5 Tools and Materials 3
6 Manpower 3
7 Safety Health and Environmental Issus 3
8 PPE’s Required 4
9 Abbreviations and Definitions 4
10 Procedure 4,5,6 &7
11 Contingency Plan 6
12 Slipform operation 7
13 Layout of crane, miller & Access tower 10

1. OBJECTIVE
The purpose of this method of statement is to define the procedures to ensure that the
proposed materials and workmanship to be used at the site are complying with the condition /
requirements as stipulated in the specifications.

2. SCOPE
This method statement covers the requirements for Slip form shuttering, steel work fixing and
concreting for Belt Conveyor column. This method statement describes the procedure and specify
controlling elements during the slip form shuttering, steel work and concreting of BC-3.
Estimated quantities of work to be done is follows.
From LVL -1.200m to + 18.500 M
1. Slip-form Shuttering: 260.04 m2
2. Reinforcement Steel: Tons
3. Concrete C-30/37: 68.360 m3
3. REFERENCE
 Latest construction Drawings received from INTERCEM.
 Bar Bending Schedule.
 EN Specification codes.

4. EQUIPMENTS
 Batching Plant – 60 Cum/hr Capacity – 01 No
 Transit Mixers (8 m3 capacity) – 03 Nos.

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

 Concrete transportation by Crane Bucket - 1no’s

 Reinforcement lifting by Crane Capacity 70t.
 Bar Cutting Machine- 1 no’s
 Bar Bending Machine- 1 no’s
 Needle Vibrator with 40/60mm diameter needle - 6 No’s (Electrical and petrol)
 Access tower.
 Hydraulic jacks 3.5T Capacity – for 10 no’s + 24 no’s Standby
 Hydraulic power pack with 10 HP Motor. – 1no’s with Accessories.
 Welding Machine.

5. TOOLS AND MATERIALS

 Wooden Planks 25 mm Thick.
 Wooden Battens 2” x 3”
 Masonry tools (Plumb bob, trowel, spade etc.)
 Binding wire
 Cover blocks by means of 40 mm.
 Reinforcement Steel.
 C-30/37 Concrete.

6. MAN POWER
 Civil Engineer-1 no’s (Day & Night)
 QA/QC Engineer-1 no (Day)
 Asst. QC Lab Supervisor – 01 no’s (Night)
 Slip form Operators – 2 no’s
 Safety officer-1 no’s (Day & Night)
 Surveyor-1 no’s
 Driver-3 no’s
 Skilled Workers- 8 no’s of steel fixers, 4 No’s of masons
 Unskilled Workers-12 no’s
7. SAFETY HEALTH AND ENVIROMENTAL ISSUES
 Conditions and precautions listed in the project specifications shall be followed as minimum.
 All staff involved in the project shall be inducted on the safety, health and environmental
issues associated with the work.
 Only trained personnel with relevant experience shall be allowed to handle machinery.
 All operations shall be carried out in accordance with the safety requirements.
 All field personnel will use PPE safety requirements like safety shoes, helmets, dust mask, etc.
as required.
 Tool box talk and good housekeeping practices shall be done.
 Unauthorised entry to the work area will be strictly prohibited
 Proper illumination should be provided for night work
 Follow the instructions from team leader.
 Avoid unsafe access and egress.

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

8. PPEs REQUIRED
 SAFETY HELMET
 SAFETY GOGGLES
 DUST MASK
 REFLECTING JACKET
 HAND GLOVES
 SAFETY SHOES
 GUM BOOTS

9. ABBREVATION AND DEFINITIONS

1. FFL- Finished Floor Level
2. FGL- Finished Ground Level
3. TOC- Top of Concrete
4. Formation Level: It is the level at which excavation ceases and construction starts.
10. PROCEDURE
As per drawing, the work will be completed in Single Stages.
1. From (-)1.200 m to (+) 18.500 M level
a. Setting-out
1. Micro chipping to be done inside wall portion to receive fresh concrete if required.
2. A surveyor is appointed to set out the dimensions of wall inside & outside including all
details like openings.
3. Inspection for Slip form work setting will be carried out for periphery shutters for walls
inside & Outside.

b. Reinforcement Steel work

1. Reinforcement steel will be fabricated as per BBS provided using cutting and bending
machines.
2. The reinforcement will be transported from yard to site using crane and trailer.
3. As per markings the reinforcement will be placed in layers and proper inspection request
will be raised at regular intervals.
4. Proper binding will be ensured between each reinforcement bars by using Binding wires.
5. Insert Plates will be fabricated at fabrication yard and will be installed as per drawings
after the approval from INTERCEM site engineers In-Charge.
6. 40 mm cover blocks to maintain the cover as per drawing, at required locations.
7. Reinforcement lift will be done continuously during slipping.

c. Access Tower & Concrete transportation.

1.Detailed drawings/sketch will be submitted to INTERCEM for Approval prior to

installation.
2. Locations of both and fixation details for lateral supports access tower will be marked in the
drawing.
d. Slip form Assembly

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

Check list for slip form assembly:

 Sketch / drawing showing all facilities like location arrangement of access crane, concrete truck, Stair
tower, curing tank etc. to be prepared.
 Whole yoke set, shuttering plates, access tower with hoist tower, concrete hoppers / buckets etc. to be
made ready well in advance.
 Planning of deployment of engineers, staff and manpower in day & night shifts.
 Check availability of following items at site well in advance in requisite quantities.
o Whole hydraulic system with jack rods including mandatory spares
o Reinforcement steel – to be fabricated for full slip form & made ready
o Crane for lifting reinforcement
o Wire ropes, D shackles, U clamps for spider as well as stay guide rope for access tower.
o Light fittings & cables for main platform deck & mason’s platform.
o Light fittings & cables for access towers.
o Curing tank with curing pump including GI / MS pipe for verticals, PVC pipe with perforations
in circular shape on mason’s platform and flexible pipe for connections.
o Electric & petrol operated concrete vibrators & needles.
o Wooden planks & runners.
o Transit mixers in working condition.
o Batching plant in working condition.
o Built up stock of aggregates, sand & cement and regular delivery of the to be ensured.
o Concrete cube moulds, slump cone.

Slip form Assembly Procedure and Slipping Process

 Shutter plates to be placed in line & level. Wooden pieces to be placed & adjusted at the bottom of plates
to ensure perfect line & level of the plates. Shutter plates to be connected with each by means of nuts &
bolts.
 Yoke legs are to be erected & assembles in single uniform level. All yoke legs should be in plumb in
both the directions; i.e. in both the faces.
 All the shuttering plates should have an inside taper of 5 mm.
 Inner & outer diameters of shutter plates and the wall thickness should be as per drawing.
 Walers to be fixed to shutter plates by means double clips.
 The yokes should be connected to the walers as explained during the mock-trail.
 Yoke legs are to be inter-connected with yoke beams at two levels.
 Waler bracket, Yoke foot, platform brackets, waler shoes etc. should fixed as explained during visits &
as sample erected.
 After assembly as mentioned above, line & level of yoke legs & shutter plates to be cross checked once
again and corrections to be made in case of any deviations.
 Hydraulic jacks & hydraulic hoses / pipes are to be checked for any leakage before assembling on the
yoke beams.
 After due checking for leakage, hydraulic jacks are to be placed on yoke beams. It is to be ensured that
all jacks are in perfect plumb.
 Since there are 8 out lets from the hydraulic power pack, jacks are to be connected in 8 circuits and not
in single series. At end of each circuit, the hose pipe is to be blocked. This is being done to have uniform
hydraulic pressure on each jack. And need not shut down whole hydraulic system in case of maintenance
of a jack in a particular circuit.
 There should not be any gap in between jack rods when they are joined. If there is any gap, then the balls
in the bearings of jack will get stuck in the gap and further rise of jack will not be possible.
 Vertical pipe of 1.2 m height shall be placed at outer most end of each platform bracket on inside &
outside. These pipes are for the purpose of hand railings. To complete hand railing, 4 no’s. of 16 or 20
dia. reinforcement shall be welded to such vertical pipes.

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

 Care shall be taken that light / bulbs for illumination during night shall be placed on inner & outer
periphery of the working platform as well as on mason’s platform. On working platform, this can be
done by inserting vertical reinforcement / pipe / wooden runner into each vertical hand railing pipe. The
height of light should be above head level.
 Wooden planks 50mm thick shall be fixed over wooden runners placed over platform brackets. Top of
wooden planks should be 5 to 10 mm above the shutter plate.
 The mason platform height should be about 1.80 m. from the bottom of shuttering plate.
 Zero level as well as every one-meter height should be marked on access tower. Later this reference mark
will have to be transferred on to jack rods; which will help us in fixing inserts, openings, maintaining
deck level etc.
 Curing water pipeline of 40 to 50 mm dia. PVC Pipe will have to be fixed along the access tower which
will have outlets at every 6 m. level. These outlets shall be connected to PVC pipe with flexible pipes.
 Suitable plasticizer will have to be used to get 180 to 200 mm slump. A trial for setting time finalizing
already conducted and report attached for ready reference
 The access tower and the builder’s hoist mast should be raised to at least 22.500 height. This is required
because the discharge chute is about 2.50 M above deck level and at least 4.00 M extra should be
available for crane operation.
 The concrete from the hoist should be received at a hopper mounted on slip form and from there it will
have to be unloaded to wheel barrows.
 Lifting around will be 3.50 to 4.0m per day (24 Hours).
 Daily reports to be submitted, consisting of manpower, lifting per day, and QA QC documents.

11. Contingency Plan

 In case of crane breakdown, we can use for another for concrete pouring for slip form works.
 In case of batching plant breakdown, we have another standby another batching plant its just 500 m
away from our working area by to expedite the concrete pouring without any interruption.
 In case of power failure, for emergency power we can use Cimasso Plant DG Set.

12. Slipforming Operations

Requirements of the Process

Slipforming is a continuous process which requires openings and embedment’s to be installed within time limits
determined by the rate of slide, as sliding cannot be stopped for lengthy periods due to the high risk of concrete
bonding to the forms. Stopping is possible, but the slipform rig must continue to climb a further 600‐700mm
to allow the last mix placed to set to minimize the risk of bonding, during which time the forms must also be
washed down. Detailed schedule of events shall be prepared to avoid undue stoppages; which should be
adhered to throughout the whole slipform operation, with a log kept to record all activities and relevant data
and information.

Concrete Trials & Delivery: Concrete trials should be carried out in good time prior to Slip-forming
operations to allow for modifications to a mix design, if found necessary.

24Hr Continuous Sliding: Slip-forming is a continuous process and care shall be taken to ensure that all
materials such as reinforcement for full height, embedded parts, insert plates, frames for openings etc., which

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

are to be incorporated into the slide; are made ready & kept on site prior to commencement of the Slip-forming
activity, to avoid interruption in slip-forming activity.

Assembling Hanging Platforms: Bottom frames shall be attached; when the slipform has climbed
approximately 1.0m and they are attached to the top frames via 4 No M10 bolts (Grade 8.8 in double shear).
Initially 2 bolts are inserted to enable the frames to be attached at an angle and as the slipform rises they will
eventually hang vertically. Decking boards, toe boards and handrails shall be installed on the platform without
interrupting the continuation of the slide.

Climbing tubes: Are set in a sleeve with an external diameter 60mm which is carried by the jack anchor which
forms a vertical void in the concrete wall in which the climbing tube passes through to the base slab, on completion
of the slide the climbing tubes are extracted and recycled for reuse on following slides.

First fix of Steel:

Prior to commencing concreting operations, first lift of vertical reinforcement steel, spacers and the horizontal
bars up to the underside of the yoke crossbars shall be placed & fixed. The lengths of first lift of vertical bars
shall be staggered to make fixing subsequent lifts easier by not all coming at once.

Openings and Inserts

Openings: As with the first fix of steel, any openings or embedded items that can be installed before concreting
starts shall be done.

Embedment Plates: Where large and heavy embedment plates shall be fixed to and held in place solely by
tag welding to the reinforcement, requiring no lateral restraint from the slipform rig and positioned with
sufficient clearance to enter the forms without levering.

Initial Filling of Forms

The slipform supervisor will monitor setting and will only take the first lift of the rig when satisfied the first
layer placed has reached its initial set. If it is in the right condition, pouring the top layer can then proceed
whilst the rig will be lifted at a relatively reduced rate to cause the initial setting layer to rise up the form to
eventually occur midway down the shutter.

Lifting the Slipform Rig

Every lift initiated by the technician takes around 1 minute depending on the number of jacks on the rig. On
completion of each lifting cycle the pump is switched off and the oil pressure released which causes the load
to transfer automatically to the bottom grip. The jacks are manually levelled at each datum position, every
1/3m rise, to ensure that the slipform rig is level throughout and that the jacks are functioning normally. At this
stage, the readings for the verticality and position are also taken.

The concrete level shall be kept as even as possible throughout the whole process so that slip-forming can
cease under adverse conditions, such as a major plant breakdown or heavy raining. Sufficient time should
then be allowed to climb the rig to its safe stopping level 600 ‐700mm above the last layer of concrete; which
will, typically take 2‐3 hours after the concrete has finished allowing the last layers to harden sufficiently to
minimize the risk of bonding.

be done to place the capping reinforcement bars and revised vertical reinforcement to the correct levels
including concrete cover and to pour the concrete up to that level as per construction drawings.

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

Positional Reference

Height
A measuring tape shall be provided and mounted on the slipform with the free end anchored and calibrated to
a known datum at or near the base. The tape will then unwind as the slipform climbs to provide continuous
height measurement.

Level
At a regular time on every shift, a datum level will be marked on to the climbing tube above each jack. These
marks are used to calibrate a scale on each climbing tube as the work proceeds. These marks are used to
keep the slipform rig level, and can be positioned by optical instrument or a rotating laser.

Position & Plumb

Plumb and height readings are normally taken three times per metre rise manually using heavy plumb bob.
Corrections will be applied to the slipform assembly to maintain tolerances. The type of corrective action
implemented will be considered by slipform technicians in his skill and judgment to be the most appropriate
to the situation.

These include:

• Using secondary jacks

• Tilting the Slipform rig
• Redistributing stored materials
• Controlling the hydraulic jacking circuit
• Rigging tensioning devices from the Slipform rig to fixed anchorage points

Tolerance

Working tolerances of concrete formed by Slipform:

Vertically

For the full height (+/-) 25 mm

Size and shape of elements

Thickness (+/-) 10 mm
Abrupt changes in continuous surface (+/-) 7 mm

Checks of vertical alignment shall be made against control points and shall take no account of structural
members which vary due to other tolerances.

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

Dismantling

Scope, Synopsis & Sequence of Operations

Scope

Dismantling Plans provide a sequence for removing the slipform rig in sections. Sequences however, are only
assigned a ‘proposed’ status with a view to have flexibility to make any changes in the safe execution of the
dismantling process. Any changes will not affect the contents of this Method Statement and therefore can be
changed at site level without necessitating further revisions of this document.

Sequence of Dismantling Operations

The slipform assembly will be completely dismantled from Level +22.500.

Dismantling requires resting the rig on top of the slipformed structure to be able to release it from the jacks.
This is done by raising the slipform rig so that 300 mm remains in the forms. Timbers are then placed vertically
from the top of the finished concrete wall to underside of the crossbars. This means that, at dismantling the top
of the shutter will sit a minimum 800 m above the finished or top‐out level of the slipformed structure.

The raising of the slipform rig to its dismantling position is a two-part operation. After concreting finishes to
the top out level, it is first climbed a further 800mm and parked overnight. This is to avoid any risk of the
concrete bonding to the forms whilst giving time for the concrete to harden sufficiently before raising the
slipform rig by a further 100mm to its dismantling position, usually the next day.

Removing the slipform rig involves breaking it down into manageable sections that are both safe to remove and
leave the remainder of the rig in safe condition depending up on the lifting capacity of the crane and the
sequence in which they are lifted down.

Dismantling the main structure of the rig falls into three

categories:

Extracting the climbing, removal of jacks and hydraulics

Removal of sections of top deck
Removal of complete wall sections

Sections are removed complete with the lower and hanging decks and land them in the designated drop‐down
area.
When lifting sections of the slipform rig down to ground commences, complete removal of the slipform rig in
a short a time as possible will be the objective. Therefore, sufficient manpower and resources shall be made
available on the ground to disassemble landed sections.
The dismantling of a slipform rig shall be carried out under the guidance & supervision competent rigger
and Slinger/Signaller.
All safety measures with respect to dismantling operation shall be taken in to consideration and other safety aspects
like safe access, guard rails on the slipform rig, hazard warning, barricading, temporary barriers, pathways, entry
restriction to unauthorized person, illumination, safe working area, providing mandatory & work specific personal
protective equipment to workers etc. shall also be taken in to account while dismantling of slipform rig.

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 Name of work : CONVEYOR I LEG SLIPFORM WORK
Name of Project : CIMASSO LINE 02
Name of Client : CIMASSO, BURKINA FASO
Name of Consultant : INTERCEM.
Contractor : AYOKI FABRICON PRIVATE LIMITED

A) Concreting and curing

1. Concreting of column shall be done by using ready mix concrete and / or using local digital mixer
machine; lifted & poured through bucket (0.25 cu.m. capacity) mounted on tower hoist fixed
adjacent to the access tower.
2. On main working deck, concrete shall be carried & poured inside the wall forms using concrete
trolleys/wheel Barrows.
3. Concrete bucket along with Crane and sufficient workers shall be engaged round the clock for
concreting of column.
4. For thorough compaction of concrete, sufficient no’s. of immersion needle vibrators shall be used at
main working deck level along with adequate skilled operator throughout the concreting operations.
5. For Jack rod gap filling will be carryout by using cement grouting.
6. Curing of exposed concrete surface shall be ensured by using perforated circular pipes fixed on
lower deck level on both the sides of the column. These perforated pipes shall be connected to high
pressure water pump placed on a water tank at ground level.
7. Sufficient skilled & unskilled manpower shall be deployed round the clock on hanging decks inside
& outside for concrete finishing and exposing of insert plate and other necessary activities.

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