MS Bridge Deck Construction For Bridges Rev 5 Eng - Final

Method Statement
Bridge Deck System Construction for Bridges

CHINA ROAD AND BRIDGE CORPORATION Smokovac-Uvac-Matesevo Highway Project
MONTENEGRO BRANCH
CONTENT
1 Introduction.....................................................................................................1
2 Basis for the Works.........................................................................................1
3 Organization Chart..........................................................................................2
4 Construction Methodology.............................................................................5
5 Health and Safety..........................................................................................83
6 Environmental Protection.............................................................................83
7 Quality Assurance and Control.....................................................................84
8 Annexes.........................................................................................................84
Nova Dalmatinska bb, 81000 Podgorica, Montenegro fax: +382 20 512 333 e-mail:mne.letter@crbc.com
CRBC(MNE)-MS-101
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1 Introduction
This document sets out the Method Statement for construction of the Bridge Deck System on the Bar –
Boljare Highway, Smokovac – Uvac – Matesevo Section. Considering the importance of the Works,
the purpose of the document is to specify the materials, activities, technological phases and temporary
facilities necessary for the construction.
Except for the Moracica Bridge in the Method Statement, the bridge deck system is basically the same
and the same construction method is adopted.
2 Basis for the Works

①　Terms of Reference for the Main Design of the 5.8 Bridges, viaducts, overpasses, buildings on
loops, underpasses and in subsection 4.10, subclause 4.10.2 Design of Concrete Works
②　2Employer's Requirements for The Bar-Boljare Highway Construction, Smokovac-Uvac-
Matesevo Section, Section 10 Inspection, sampling, testing
③　Rulebook for concrete and reinforced concrete (PBAB ’87)
④　Technical Specifications for Road works – Volume IV Concrete works, last approved revision
⑤　Steel for reinforcement of concrete (EN 13670:2009)
⑥　Approved Elaborate for construction site arrangement for the Moracica Bridge.
Appropriate abbreviations used in this MS are explained as following:

Abbreviations
CH Chainage
HSE Health, Safety & Environment
CRBC China Road and Bridge Corporation
PPE Personal Protective Equipment
EPP Environmental Protection Program
CWMP Construction Waste Management Plan
HWMP Hazardous Waste Management Plan
TBT Tool Box Talk
MS Method Statement
TS Technical Specifications
3 Organization Chart
Page 1 of 45 CRBC(MNE)-MS-101
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CHINA ROAD AND BRIDGE CORPORATION
MONTENEGRO BRANCH
Smokovac-Uvac-Matesevo Highway Project
The Organization Chart on construction site is as following, and for detailed information on the
personnel on site, we refer to the Annex of this document.
Organization Chart
Part
For the organization chart for the headquarter, we refer to the QAP, Section 5.1.2.1 Contractor’s
General Organization Chart.
3.1 Chief Engineer
i. Explains to the Engineer all technical issues related to the production facilities
ii. Reviews the construction drawings, bills of quantities and topographic measurements
iii. Produces and updates the Programme of Works in accordance with the works progress, as
requested by the General Conditions
iv. Monitors the execution of planned works
v. Approves the documents for construction with the Production Manager
vi. In charge with Works execution, verifies the Subcontractors’ activities, prepares the weekly and
monthly works progress reports
vii. Organizes and verifies the supply of materials on site
Nova Dalmatinska bb, 81000 Podgorica, Montenegro fax: +382 20 512 333
Page 2 of 45
e-mail:mne.letter@crbc.com
CRBC(MNE)-MS-101
MONTENEGRO BRANCH
viii. Responses any question by the Engineer

ix. Takes part in the Meeting requested by the Engineer.
3.2 Site Manager
i. Explains to the Engineer for all technical issues related to the production facilities
ii. Implements this MS
iii. Responsible for the safety of construction workers, including carrying out the safety management
plans and safety management system, the implementation of incident report
iv. Ensures that the works are carried out in accordance with the approved permits and MS
v. Ensures that all personnel are fully aware of their duties and responsibilities
vi. Should communicate with the representative of Employer and Engineer immediately in case any
changes happen during construction
vii. Takes part in the Meeting requested by the Engineer.
3.3 QA&QM Responsible
i. Breakthrough measurement before works, conducts in-depth field investigation, checks the surface,
etc. according to the design
ii. Conducts on-site technical instruction, strictly follow the technical regulation to organize the works.
Strictly control the quality of each procedure
iii. Cooperates with the surveying staff and instruct the tunnel monitoring and measurement
iv. Keeps good record of the works, technical document filling and submitting to Engineer, keep good
track of working diary
v. Responses the ERC on site and submit it to the Engineer
vi. Submit the RI and check together with the Engineer
vii. Participates in the recognition, assessment and environment factor, danger source as prescribed
by relevant law and regulation, provide comments and suggestions
viii. Responsible for all necessary, test and inspections given by design and technical specification
ix. Responsible for training of personnel.
3.4 HSE Responsible
i. Manages safety officers in organization of site health and safety matters

ii. Submits all documentation for HSE to Engineer
iii. Takes action in case of evident risk of H&S of personnel on site
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iv. Regular safety introductions and safety meetings

v. Checks the safety equipment on Site
vi. Helps the HSE Office to organize HSE trainings
vii. On-site inspection, checks on a regular basis
viii. Suggestions for rectification of HSE hazards, and urges the relevant departments to eliminate
potential safety problems.
3.5 Site Engineer
i. Ensures that the construction is in accordance with the approved MS, specifications and design
ii. Takes action according to the design, actual conditions and behavior of ground during construction
iii. Ensures that all data is recorded in accordance with this document
iv. Ensures that all required as built data are recorded
v. Provides any information and instructs that may be required during the work
vi. Organizes geodetic monitoring of structures with surveyors
vii. Provides the Report
viii. Signs the ERC of executed works after each stage of casting.
3.6 Geodetic Surveying Engineer
i. Stakes out the profiles according to the design, ensures that all elements in line with the cross section
in the drawings; maintains the marks until the acceptance of project
ii. Instructs, participates in and inspects the daily surveying works
iii. Participates in the composition of Construction Measurement Techniques Surveying Rules and
Construction Surveying Solution; provides the technical support for the engineers and foremen
iv. Works in charge of the quality, safety and progress of construction surveying, organizes the relevant
data and submits the construction surveying documents for approval
v. Works in charge of the establishment of surveying instrument record and surveying personnel
record, supervises the daily test of the instruments
vi. Other relevant tasks
vii. Ensures that the alignment is in accordance with the improved design
viii. Makes measurements according to the monitoring plan and submits the reports to the engineer.
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3.7 Foreman
i. Reports to the site manager

ii. Manages the work, takes into account that the material is tested in time, approved and built-in in
accordance with the Main Design, under the instructions of Responsible Engineer
iii. Receives and stores the materials
iv. Manages the workers, material and equipment.
3.8 Equipment engineer
i. Evaluates, inspects, maintains, analyzes and improves various types of equipment, including
electronic and mechanical equipment.
ii. Their specific responsibilities may depend on the type of equipment they work on(in the case of
construction of Pier Shafts check of safety of anchors and mechanical parts)
iii. General duties can include testing and overseeing the production of equipment, as well as
performing extensive and complex repairs on existing equipment.
iv. Prepares the Construction log of equipment.
4 Construction Methodology
4.1 General information
General bridges
There are two kinds of superstructure in Main Design, one is slab girder, another is box girder. Basic
information (such as drainage system, waterproof system and Safety Barriers) is shown in follow
figure.
Figure No. 4.1-1 Typical slab cross section of the Bridge Superstructure
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Figure No. 4.1-2 Typical box cross section of the Bridge Superstructure
Moracica Bridge
The bridge is a continuous pre-stressed frame structure of variable cross section. As measured by the
left axis of the highway, the length of the bridge structure is L=960m (95+170+3x190+125). The cross
section of the structure is double-cell box cross section of variable height along the span.
Figure No. 4.1-3 Longitudinal profile of the Moracica Bridge
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Figure No. 4.1-4 Layout of the Moracica Bridge
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Figure No. 4.1-5 Typical cross section of the Moracica Bridge Superstructure with Bridge Deck
System details on Walkway Slab (Edge Beam) and on Central Median Reserve
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4.2 Waterproofing
4.2.1. Equipment and tools
For installation of Methyl Methacrylate (MMA) Waterproofing system – “Eliminator” Bridge Deck
Waterproofing Kit the following equipment is in use:
Name of equipment / Naziv opreme Quantity (pcs) / Količina
(kom)
Portable air compressor /
2
Prenosivi kompresor za vazduh
High pressure spray hoses /
Crijeva za prskanje pod visokim pritiskom
Portable shot blast machine for concrete
substrate treatment /
1
Prenosiva mašina za pjeskarenje za obradu
betonske podloge
MMA waterproofing equipment /
Oprema za MMA hidroizolaciju
Diamond grinding machine for concrete
substrate treatment /
3
Dijamantna brusilica za obradu betonske
površine
Hand tools and other ‘small’ equipment
necessary /
Ručni alat i druga neophodna manja oprema
4.2.2. Materials
Waterproofing Methyl Methacrylate (MMA) – “Eliminator” Bridge Deck Waterproofing Kit produced
by “Stirling Lloyd GCP Applied Technologies”, UK.
4.2.3. Construction Methodology
 Waterproofing
Waterproofing systems “Eliminator”:
1．Two-coats waterproofing system for concrete bridge deck carriageway, based on acrylic resins
MMA – “Eliminator”:
1) Fast curing primer – a two component, 100% reactive, fast curing, MMA primer consisting of resin
base and a powder catalyst (BPO)
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2) Waterproofing – a three-component, 100% reactive, fast curing, MMA based coating consisting of
Part A-pre-accelerated base resin, a Part B-pigmented resin and a powder catalyst (BPO), applied in
two coats, the first one is pigmented yellow and the second one is usually white or grey, of nominal
thickness in dry conditions up to 2.0mm
3) Bond Coat – a hot melt adhesive bond coat based on polymer-modified bitumen.
2．One-coat waterproofing system for concrete bridge deck sidewalk, based on acrylic resins MMA
– “Eliminator”:
2) Waterproofing – a three-component, 100% reactive, fast curing, MMA based coating consisting of
Part A-pre-accelerated base resin, a Part B-pigmented resin yellow or white, and a powder catalyst
(BPO), applied in one coat.
3) Protection coat on sidewalks – anti-slip decorative coating for bridge deck sidewalk protection,
liquid applied, based on acrylic resins MMA:
5) Antislip decorative coating – Safetrack system consisting of two components-MMA resin pigmented
base and a powder catalyst (BPO), applied in two coats, 0.90kg/m2 per coat for thickness of 0.50mm
per coat, of grey colour.
 Application
1) Surface preparation
New concrete bridge deck should be minimum seven days old. The substrate must be clean, dry
and structurally sound. It must be free from laitance, oils, grease, loose and friable matter, dirt,
bituminous products and previous waterproofing material, and all other surface contaminants.
Irregularities in concrete surface are executed by authorized applicator and with materials approved by
Engineer.
Removal of contaminants and surface preparation is performed by grinding machine.
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Figure No. 4.2-1 Concrete Bridge Deck surface preparation by grinding machine
This finish is for bridge decks that are to receive the approved waterproofing systems. The
concrete shall be uniformly leveled and to produce a plain finish. Finally the surface shall be textured
by brushing or otherwise as per the requirements by producer of waterproofing as agreed with
Engineer. After finishing the substrate preparation, prepared part of bridge deck should be closed for
any type of traffic before application of waterproofing layers.
Adequate pull-off test for adhesion to the substrate shall be conducted on the substrate by
applicator at construction site. Adequate surface preparation is indicated by tensile bond strengths of
primer to the substrate.
2) Surface finishing method
When the top surface elevation of concrete is lower than designed, repair material or concrete is
used to make the surface level
When there are some lumps on the top surface, they are burnished by using the polishing machine
When the top surface elevation of concrete is more than 2cm higher than designed, at first the
above parts are cut, then two layers are applied for concrete cover
If there is some oil on the top surface, it is washed.
3) Repair of defects
After application of each coat, only identified pin/blow holes must be over-coated with
“Eliminator” or “Patch Repair Waterproofing membrane” at an additional minimum wet film thickness
of 1.2mm per coat
Any blisters or damage must be made good by cutting back to sound material, the periphery
prepared if necessary as for lapping and a repair coat of “Eliminator” or “Patch Repair Waterproofing
membrane”, ensuring a minimum peripheral lap of 50mm around the repair.
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Where the damage is through to the concrete deck, the exposed concrete at first must be cleaned
and then re-primed.
4) Construction
①　Waterproofing of bridge deck carriageway
“Eliminator” system on bridge deck carriageway is applied on the following areas:
i. all horizontal parts of concrete bridge deck
ii. Primer PAR 1, MMA “Eliminator”, bond coat
iii. all verticals of concrete bridge deck (if any) in height according to design, or by Engineer’s order;
on vertical surfaces one type “Eliminator” is in use as it is thixotropic
iv. Primer PAR 1, MMA “Eliminator”, bond coat
v. parts of steel structures/drainage water outlets, and/or parts of Expansion Joints
vi. Anti-corrosive primer Zed S-94, MMA “Eliminator”.
(1) Primers
Primer for concrete, fast curing PAR 1 – the primer shall be applied in one coat by roller. It should
be noted that particularly porous substrates may require additional primer to give a sealed gloss finish
to the primed deck. PAR 1 is used with a typical coverage rate of 0.20kg/m2 to 0.25kg/m2.
Primer for steel, anti-corrosive primer Zed S-94 – the primer shall be applied in one coat by roller
with a typical coverage rate of 0.20kg/m2. Removal of contaminants and surface preparation shall be
performed by grit blast cleaning
(2) Waterproofing membrane “Eliminator” – two coats
“Eliminator” membrane consists of two resin components (Part A and Part B) supplied in metal
drums, and a bag of BPO, supplied in pre-weighed quantities ready for on-site-mixing. The Part A
resin component is of neutral colour. The Part B resin component is pigmented to yellow and white or
grey.
The membrane shall be applied in two colour-coded coats using an airless-spray machine-pump.
A coverage rate of 1.60kg/m2 per coat may be adopted to achieve a minimum dry film thickness of
1.0mm per coat. The membrane shall be capable of being applied at the specified thickness on all
vertical sections. The first coat is usually pigmented yellow. The colour of the second coat is white or
grey.
These measures take account of localized variations in the substrate profile and help ensure that
the minimum dry film thickness of 1.0mm per coat is achieved over the whole substrate including over
any peaks and irregularities in substrate. The required minimum coverage rate is 1,6kg/m2 per coat.
“Eliminator” can be applied on vertical surfaces too. Procedure is the same as for horizontal
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surfaces.
Where new “Eliminator” membrane is to be jointed to existing cured membrane, the new
application should be lapped on to the existing by 50mm.
If an area is left untreated or the membrane becomes damaged, a patch repair shall be carried out to
restore the integrity of the system. The damaged area shall be cut back to sound material and wiped
with solvent (e.g. acetone) up to a width of at least 50mm on the periphery, removing any
contaminants. The substrate shall be primed as necessary, followed by the application of membrane. A
continuous layer shall be obtained over the substrate with a 50mm overlap onto existing membranes.
(3) Bond coat for bonding with hot-rolled asphalt concrete AC 8/PmB surfacing
The applied bond coat shall be dry and contaminant free prior to the application of the hot-rolled
asphalt.
The finished rolling temperature of the surfacing shall exceed the activation temperature of the
bond coat, which is 90°C for bond coat.
The maximum permissible surfacing temperature for application onto the “Eliminator” system is
230°C when using bond coat.
The mechanical action of the asphalt paver on bond coat should be kept to a minimum. Wherever
possible, pneumatic tyred vehicles are in use. Tracked vehicles can cause pick up and so should only
be used with extra care. Paver wheels should be cleaned and sprayed regularly with a detergent
solution (washing-up liquid: water at a ratio of about 1:100).
Delivery vehicle wheels should be inspected, cleaned and sprayed with detergent solution
(washing-up liquid: water at a ratio of about 1:100) before being driven on the bond coat.
Stationary vehicles on the bond coat should be avoided. If operations are suspended or delayed, all
vehicles should be removed from the bond coat.
②　 Waterproofing of bridge deck sidewalk (This part is only applied on Moracica Bridge)
i. “Eliminator” system on bridge deck sidewalk is applied on the following areas:
ii. all horizontal parts of concrete bridge deck sidewalk Primer PAR, MMA “Eliminator” one-coat
iii. all verticals of concrete bridge deck sidewalk (if any) in height according to design, or by
Engineer’s order; on vertical surfaces one type “Eliminator” is in use as it is thixotropic
iv. Primer PAR 1, MMA “Eliminator” one-coat.
(1) Primers
Primer for concrete, fast curing PAR 1 – the primer shall be applied in one coat by roller. It should
be noted that particularly porous substrates may require additional primer to give a sealed gloss finish
to the primed deck. PAR 1 is used with a typical coverage rate of 0.20kg/m2 to 0.25kg/m2.
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(2) Waterproofing membrane “Eliminator”– one coat

“Eliminator” membrane consists of two resin components (Part A and Part B) supplied in metal
drums, and a bag of BPO, supplied in pre-weighed quantities ready for on-site-mixing. The Part A
resin component is of neutral colour. The Part B resin component is pigmented to yellow or white or
grey.
The membrane shall be applied using an airless-spray machine–pump. A coverage rate of
2.80kg/m2 may be adopted. The membrane shall be capable of being applied at the specified thickness
on all vertical sections.
Coverage rate of 2.80kg/m2 shell be achieved. Tolerance up to 8% is acceptable in coverage rate
due to evenness of surface.
“Eliminator” can be applied on vertical surfaces too. Procedure is the same as for horizontal
surfaces. Where new “Eliminator” membrane is to be jointed to existing cured membrane at day joint,
the new application should be lapped on to the existing by 50mm.
If an area is left untreated or the membrane becomes damaged, a patch repair shall be carried out
to restore the integrity of the system. The damaged area shall be cut back to sound material and wiped
with solvent (e.g. acetone) up to a width of at least 50mm on the periphery, removing any
contaminants. The substrate shall be primed as necessary, followed by the application of membrane. A
continuous layer shall be obtained over the substrate with a 50mm overlap onto existing membranes.
③　Anti-slip decorative coating “Safetrack SC”
“Safetrack” system on bridge deck sidewalk is applied on the following areas:
i. all horizontal parts of concrete bridge deck sidewalk
ii. Primer PAR 1, Safetrack.
(1) Primers
Primer for concrete PAR 1 – the primer shall be applied in one coat by roller. It should be noted
that particularly porous substrates may require additional primer to give a sealed gloss finish to the
primed deck. PAR 1 is used with a typical coverage rate of 0.20kg/m2 to 0.25kg/m2.
(2) Anti-slip decorative coating “Safetrack”
Safetrack consists of a liquid pigmented resin containing hardwearing aggregates and a powder
catalyst (BPO), all supplied in pre-weighted quantities ready for on-site mixing. The content of the kit
should be stirred thoroughly by using a mechanical stirrer, such as an air-driven drill (400-800rpm) and
paddle, just prior to use. Some settlement may occur during storage and transportation so stirring
should be continued until the mix is fully homogenized.
Once the BPO is added, this initiates the “working life” of the material during which time it
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should be applied. It is not allowed to add fresh material to partially cured material.
Application may proceed while the air and substrate temperatures are between 0°C and 30°C,
providing the substrate is above the dew point. Pour the content of the bucket, in quantities appropriate
to the pre-marked areas, onto the substrate and using a short pile roller, to ensure the binder is spread
evenly.
Safetrack is applied in two coats, each coat applied to give dry film of 0.50mm per coat. It is
necessary that the first coat is fully cured before the application of the second coat. Each coat shall be
applied in 0.90kg/m2 per coat for thickness of 0.50mm per coat. It is applied by roller in colour by
Employer’s wish. The required coverage rate depends on surface texture and porosity.
The works cannot be performed during the atmospheric precipitation.
Side effects of performing the waterproofing works when applying the MMA “Eliminator”
system and Safetrack system is only a sharp and strong smell that characterizes all components of the
system.
When applying of waterproofing system is fully completed, that surface should not be in use prior
to starting of asphalt works.
For Manufacturer’s Method Statement for waterproofing works, we refer to the Annex of this
document.
4.2.4. Checking
Two types of Requests for Inspection and Approval (RIA) for waterproofing works:
(1) RIA for checking the MMA waterproofing material prior to applying the waterproofing on Bridge
Deck (ref. to the Annex of this document with the approved subject RIA)
(2) RIA for pull-off test after the waterproofing works have been completed.
Construction plan for waterproofing works / Plan izvođenja radova na hidroizolaciji
planned start / planned finish /

bridge element / length / dužina width / area /
planirani planirani
element mosta (m) širina (m) površina (m2)
početak radova završetak radova
1 RIA after
Edge works are
Beams&Central completed / 1
Median Reserve / 86.50 8 692 19/08/2019 24/08/2019 ZOM nakon što
ivične grede i su radovi
razdjelni pojas kompletirani
1 RIA after
Edge works are
Beams&Central completed / 1
Median Reserve / 873.50 8 6988 20/10/2019 10/11/2019 ZOM nakon što
ivične grede i su radovi
razdjelni pojas kompletirani
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1 RIA after
bridge works are
carriageway / completed / 1
960 15.40 14784 10/01/2020 30/01/2020 ZOM nakon što
kolovozna ploča
mosta su radovi
kompletirani
Measuring of thickness of each layer of waterproofing system is conducted by using the so-called
comb gauge test and per each 10m2, in accordance with Technical Specifications in the Bridge Main
Design. Also the material consumption is controlled. The results on performed measuring of thickness
of waterproofing layers will be recorded in check list.
For Manufacturer’s check list, we refer to the Annex of this document.
Pull-off test for MMA waterproofing is performed by Contractor’s laboratory in accordance with
the standard EN 13596:2004. According to Technical Specifications in the Bridge Main Design,
frequency of pull-off testing is at three points per each 500m2. According to ETAG 033 Liquid
Applied Bridge Deck Waterproofing Kits, the required minimum bond strength value between the
waterproofing layer and concrete substrate is 1.0MPa. The adopted average value is around 1.5MPa.
The minimum adhesion value per waterproofing layer is 1.0MPa. After testing for waterproofing is
completed, Test Report is submitted to Engineer.
Overlapping between the old and the new waterproofing is max 10cm.
After the pull-off test is completed, the part of surface where the test was performed is
subsequently processed manually, in accordance with Manufacturer’s instructions and technical data
sheet – manual repair of damaged areas.
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Figure No. 4.2-2 Waterproofing on the parts of surface where the pull-off test has previously been
performed
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4.3 Safety barriers

Main equipment table of cast-in-place superstructure safety barrier
No. Equipment name
1 Cranemobile
2 Special lifting tool
3 Crowbar
4 24 mm wrench
5 Electric hammer (with drill)
6 Generator
7 Lifting belt
8 Forklift
9 Truck crane
10 Torque wrench
4.3.2. Materials
(1) Safety barriers
“New Jersey” RC Safety Barriers H2W1 of containment level, precast concrete barriers, type
RB80A_8_H2/W1,: L=6m and other non-standard
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Figure No. 4.3.1 Cross section of Safety Barrier, type RB80A_8_H2/W1,

(2) Handrail for the Bridge
Handrail positioned on the top surface of “New Jersey” Concrete Safety Barriers is applied on the
. Bridge, and for that the MAR will be submitted to Engineer in the future.
(1) Process flow
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Transportation of safety barriers
Treatment of foundation of safety barrier
Setting out of foundation line
Placement of prefabricated safety barriers
Drilling with electric hammer
Installation of bolts
Overall inspection
Bridge safety barriers installation process flow chart

(2) Construction of safety barriers
①　Preparation before works
Before installation, check whether the prefabricated safety barrier has a missing corner and
whether the site is ready.
Integration and positioning of the elements
The elements are positioned and adjusted according to the previously marked road alignment. The
element, which is to be connected to the already placed barriers, is positioned so that the lower face of
the coupling is directly above the upper face of the coupling of the pre-positioned element. It is
important to avoid collision of neighbouring elements during installation and manipulation, in order to
reduce any concrete damage. In a further step the element is lowered and the adjoining couplings are
slowly and evenly interconnected.
Following positioning and inspection, the anchoring bore holes are drilled in the substrate to a
depth of 120mm using a concrete drill hammer with Ø22mm concrete hammer-drill bit. The bore hole
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should be cleaned and prepared according to the injection adhesive manufacturer’s directions.
Attention should be taken that the bore hole is free from all dust, dirt particles and water.
The injection adhesive paste is injected into the prepared bore hole following the manufacturer’s
directions. The M20 threaded steel bar with rectangular (RW50_65) and round washers and nut is
inserted as group into the adhesive-filled bore hole.
②　Transportation
The prefabricated safety barrier is transported to the construction site by transportation vehicle.
On-site storage must be done in a flat surface to prevent cracks from uneven distribution of force.
Crane is usually used for unloading of prefabricated safety barriers. Safety barrier prefabricated block
is used together with a special lifting tool to prevent bumping during transportation and lifting.
③　Technical requirements
The requirements for the installation of the prefabricated safety barriers are as follows:
i. Expansion screw drilling depth is 12cm.
ii. During installation gap between prefabricated blocks is14mm.
iii. Before the installation, setting out of the line shall be done.
iv. Nut torque needs to reach 100NM.
v. The electric hammer drilling tool has a diameter of 22mm.
vi. Drilling requires a blower to clean the drill residue inside.
vii. At the position of expansion joint the length of the non-standard block is accurately measured for
the prefabrication of the later non-standard block.
Only after expiration of the required curing time, the nut is tightened to a torque of 100Nm using
a
FigureNo. 4.3. Installation detail for Safety Barrier, type RB80A_8_H2/W1
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④　 Installation process
1）Site storage and transportation (on site):
- DB 80 AS-A is storage three units elements in high.
- Two wooden slats ( approx. 10x10 cm) must be placed between each layer.
- It is recommended to place the bottom layer of elements onto larger wooden blocks.
a) Requirements for storage area:
- Stable surface with adequate carrying capacity is required both for the storage of the elements and for
the use of fork-lift trucks
- The load to be placed on the floor corresponds to the weight of the elements and the weight of a
loaded fork-lift truck.
- Weight: DB 80 AS-A: 3040 kg per unit
- Space required: 9 units (3x3) of DB 80 AS-A elements require a storage area of 13 m2.
b) Handling of the elements:
- Handling with concrete barrier grab,
- Handling with looped straps and steel bolts（√）,
- Handling with straps looped around the element,
2）Installation process DB 80 AS-A:
a) Smoothing and Marking:
- Concrete surface should be smoothed with approved material and elevation of the concrete surface
should be checked. And then waterproofing material should be applied on the concrete surface in
accordance with the main design.
- Site must clearly mark the exact start and end point on the concrete surface before installation begins.
b) Moving and Installation
- The elements must only be moved by means of a suitable lifting device.
- The elements should be places exactly along the marked places.
- Finally the concrete barrier should be installed on the exact position where was marked on the
concrete surface before installation.
c) Drilling:
- Required Ø22 mm borings should be drilled through the reserved hole on the bottom of concrete
barrier.
- The depth of boreholes should not be less than 125mm.
- Boreholes must be cleaned (the all dust and concrete parts must be cleaned from holes and surfaces)
- The cleaning must be with wire round brush and air-cleaning with compressed air or alternately with
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pressure water.
- The cleaning sequence should be performed as follows: compressed air cleaning →wire round brush
cleaning → compressed air cleaning →wire round brush cleaning → compressed air cleaning.
d) Conglutination
- To ensure the operation of the anchoring system and thus fir the entire restraint system, it is if utmost
importance to ensure clean and professional conglutination of the anchoring posts M20x285 8.8 FVZ.
- The installation instructions for the cartridge adhesive HIT-HY 200A must be observed, especially in
regard to temperature and waiting time.
- The sub-plate of bolts should be utilized when perform the installation of bolts to ensure the
anchorage length of bolts meeting the relating requirement.
e) Fixing
- The anchoring must be screwed on by means of a torque spanner and the fastening torque should be
50 Nm.
- Attention must be paid that the coupling is introduced completely. All residual concrete in the
couplings Y profile must be removed prior to application.
f) Inspection of bolts installation
- Proposed inspection method for the bolts installation: Randomly choose any installed bolts (total
quantity should not be less than 3%), 60 ~ 70 Nm (20% ~ 40% higher than required) torque should be
applied on the bolts, which can confirm its conformity if this is successful.
Detection method
The installation of the crash barrier must be smooth, with little fluctuation.
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4.4 Drainage system

The movable scaffold、auto crane、power drills erection、transport truck and some necessary
hand tools will be used during installation of drainage system with hanging system on the bridge, it is
applied both in bridge Morarica and other bridges within this project.
4.4.2. Materials
 Moracica bridge
Drainage system – gullies produced by “ACO” (gully type “HSD-5 Multitop Bruckenablauf
Klasse D 400, mit Wendeauflagerin, DN 150”), approved within MAR No. 388, are applied on the
Moracica Bridge.
Hanger system for drainage of bridge superstructure, constructed and installed by “ERGAS”,
Sarajevo, BiH, approved within MAR No. 535, is applied on the Moracica Bridge.
Material Specification / Specifikacija materijala
Main material /
Glavni materijal
polyester sewer pipes GRP / DN 150, DN 250, DN 300,

poliesterske kanalizacione cijevi GRP DN 400, DN 500mm
pipe supports – hanger consisting of hinge at receiving DN 250, DN 300,

point, threaded rod M16, 50x5 clips (for pipes Ø250- DN 400, DN 500mm
Ø500), ribbed rubber profiled to be hung onto clip, all
metallic parts are hot-galvanized /
nosači cijevi – vješaljke koje se sastoje od zgloba na
prijemnom mjestu, zavojne šipke M16, obujmica 50x5
(za cijevi Ø250-Ø500), rebraste gumene profilisane da se
okače na obujmicu, svi metalni dijelovi su toplo-
pocinkovani
Additional material required for quality and correct installation /

Dodatni materijal potreban za kvalitetnu i preciznu ugradnju
polyester pipe fittings WYES DN 150 / DN 250/150/45, DN 300/150/45,

poliesterski fitinzi za cijevi WYES DN 150 DN 400/150/45, DN 500/150/45
polyester pipe fittings ELBOW 45 / DN 250, DN 300, DN 400, DN

poliesterski fitinzi za cijevi ELBOW 45 500mm
polyester pipe fittings – transition reducing pieces / DN 300/250, DN 400/300, DN

poliesterski fitinzi za cijevi – prelazni redukcioni komadi 500/400
fixed hangers, longitudinal and lateral / DN 250, DN 300, DN 400, DN

fiksirane vješaljke, podužne i poprečne 500mm
polyester pipe fittings – additional poliester coupling / DN 250, DN 300, DN 400, DN

poliesterski fitinzi za cijevi – dodatna poliesterska 500mm
spojnica
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CE coupling / DN150/168, DN150

CE spojnica
polyester pipe fittings – end cover / DN250

poliesterski fitinzi za cijevi – krajnji poklopac
polyester pipe fittings – compensator DN/L=MN / DN 250/500, DN 300/500, DN

poliesterski fitinzi za cijevi – kompenzator DN/L=MN 400/600, DN 500/600, DN 300/500
Table No. 4.4.1-1 Material Specification for Drainage System on the Bridge
 General bridge
Gullies produced by “ACO”or“PURATOR”approved within MAR No. 388, are applied on Bridge
structures.
Also pipes for water filtering Ø50mm of diameter, set per each 6m, approved within Supplement
1 to MAR No. 062, are applied on bridges.
 Moracica bridge
All the water collects into the gullies by crossfall and grade and it is discharged out of the bridge
by longitudinal drainage pipes which are set under the cantilever of main girder at lower side. The
gullies are set on the lowest part of the carriageway in the line that is 20cm far from the curb. The
water interflows towards the gullies by carriageway crossfall and grade. The water from the bridge
carriageway is collected into longitudinal drainage pipes in two ways: the first water collecting is
carried out on the part of the bridge which is in straight line and the other one is carried out on the part
of the bridge which is in curve. There are 2 longitudinal drainage pipes on the part of the bridge in
straight line in cross section. These pipes are set under the cantilevers of girder on both sides. The
longitudinal grade of pipe follows the longitudinal grade of bridge. The crossfall at the part of the
bridge in the curve is turned towards one side, so there is a drainage pipe added in the middle of the
girder. Considering the longitudinal grade of vertical alignment is turned towards the beginning of the
bridge, the pipe under left cantilever of the bridge continues to the beginning of the bridge. There are 3
drainage pipes in the cross section of the bridge on this part.
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Figure No. 4.4-1 Gully type “HSD-5 Multitop Bruckenablauf Klasse D 400, mit Wendeauflagerin, DN
150”, Moracica Bridge
Installation:
i. Prior to concreting of Top Slab of Box Girder the lower part of gully is set, and then connected to the
reinforcement. The connection-coupling is set and the concrete works are performed.
ii. The waterproofing is set under the Pedestrian Walkway and glued on the circular connecting flange.
iii. The concrete works for Walkway are performed.
iv. The waterproofing for the carriageway is set and glued on the circular connecting flange.
v. The upper part is set on the designed height and slope (1cm under the upper edge of wearing
surface) by using the clamp ring. The screws are set and tightened up, the catch basin is set, the
openings in cast iron frame are closed by protective sheets.
vi. Dewatering layer is performed by using the single-grain concrete (8-16mm) with addition of
artificial resin, all around up to the upper edge of protective layer of asphalt, by filling the upper part so
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it is bearing.
vii. The protective layer is performed. If necessary, the protective sheets of drainage are removed so
the drainage is enabled.
viii. The covering layer is performed.
ix. The couplings are filled.
Detail of solution for the vertical opening in Top Slab of Box Girder of the Moracica Bridge for
the gully:
Figure No. 4.4-2 Detail of gully before cutting the rebars, Moracica Bridge
Figure No. 4.4-3 Detail of gully after cutting the rebars, Moracica Bridge
Detail of solution for the vertical opening in Top Slab of Box Girder of the Moracica Bridge for
the gully:
i. Additional rebars in the zone of gully (acc. to PBAB '87)
ii. Designed rebars of the Top Slab and Bottom Slab in the zone of gully will be cut
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iii. Weld the additional rebar of Г shape on each cut rebar for anchoring the cut rebar
iv. When installing the gully, perform the spot welding in the zone of cut rebars of the Top Slab to the
gully body in both directions - on all 4 sides
v. Top surface of gully is in the same level with the Box Girder Top Slab top surface
vi. Marked area is filled with permeable drainage concrete.
Figure No. 4.4-4 Reinforcement detail around the opening in Top Slab of Box Girder, Moracica Bridge
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Figure No. 4.4-5 Cross and longitudinal section of connection of gully and drainage pipe, Moracica
Bridge
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Installation of Drainage System :

Movable scaffold works on electricity (using a generator), electric motor is set on movable
scaffold. This scaffold has mounted movable steel ‘arm’, and it lifts the material to the working
platform. Three to four skilled workers are needed for assembly. Scaffold is positioned on the bridge
and is moving on wheels. The access to the working platform by the staircase has a backbone
protection.
At first the hole is drilled in concrete. Steel anchor is set into the hole. After that, the thread rods
and hangers are fixed, followed by the installation of drainage pipes. For connecting the pipes the
connectors are in use, as well as the EPDM rubber. Connecting is finished when two pipes are joined
on seat of rubber step and the connectors are screwed on.
Gully is vertically connected to the drainage pipe fitting by stainless CE connection rings, in
which the EPDM rubber is embedded. The connection is achieved when both connecting parts of the
pipe fit into the clamp to the EPDM rubber and after the stainless CE connection rings are fixed.
There are two hangers installed per 6m of length of pipes DN 250, DN 300, and three hangers
installed per 6m of length of pipes DN 400, DN 500.
At the position of Expansion Joint, the compensator is set. When drainage pipe extends to the
Abutment, it crosses the performed hole for Expansion Joint and it is connected to the manhole in the
Open Route part.
Figure No. 4.4-6 Installation of drainage system by using a movable scaffold, Moracica
Bridge
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Figure No. 4.4-7 Sketch for drainage system in the area of Expansion Joint
 General bridge
This chapter presents general method statement for installation of drainage pipes under bridges, it
is described below:
i. Mounting of the movable bridge scaffolding
ii. After the detailed project overview, the pipe hangers have been installed.
The pipe hangers are put on every 1.50 till 2.00m, for pipe, and right between polyester couplings
on both ends, for T pieces.
The threaded roadФ16mm has been installed in the bridge plate with anchors M16.
The threaded rod length depends of projected bridge slope, i.e. of projected pipes drop to the
outlets.
iii. After hangers are installed, the next is installation of the demounting – mounting couplings (or
EPDM according to the request) DN150 on the outlet of bridge gully with the pipe part DN 150 from T
piece. We fix it by screwing the existing screws on EPDM DN150, or on demounting – mounting
couplings.
iv. The next step is installing of the GRP pipes. We are giving it to the workers who are on the bridge
scaffolding by straps.
When installing the pipe in the clamp, it is mandatory that the EPDM tire is installed in the clamp,
which is mounted to protect the pipe from damage during dilatation. When the installers have taken the
pipe, then the distance from the T-pieces to the next T-slide is approaching, the pipe is machined cut to
a certain extent, and then the ends of the pipes are lubricated with the standard product supplied with
the pipes.
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The pipe which is prepared moves backward, so we can install T piece. We fix it on already
installed drainage pipe DN150. We install pipe in lubricated polyester coupling on the end of the T
piece, so that one worker is fixing a T piece on one side, and other worker push the pipe in the
polyester coupling by the pressure. After a preparing T piece, the other pipe DN 150 end is fixed to
bridge coupling or EPDM by screwing of existing screws.
After we have finished pipe and T piece fixing, we are starting with the tightening of the clamps
with 6 nuts fi 16mm, which has been put on two threaded rod ends, which wear the clamp.
Note: We mount 4 nuts on the pipe hangers, for pipes DN200, and 6 nuts fi 16mm for pipes
DN250 and bigger diameters.
4.4.4. Testing method
 Moracica bridge
Construction and testing of pipelines is performed according to EN 1610:1997.
All pipelines have to be secured from separation. For standard pipelines, the testing pressure is
min 0.1bar and max 0.5bar. At first, the filling of pipeline with water is performed, starting from the
deepest point of pipeline system. The pipeline is being filled with water till the whole pipeline is fully
filled, and the existing air should go out at the highest point. Recommended preparation time is about
one hour, which includes the period in which the porous materials absorb the water in natural way, and
until the required temperature equation between the water temperature and the temperature of the pipe
walls is achieved. Later the ends of pipe are closed, and the required pressure for testing is applied.
The water amount which is spilled is compensated by adding the water. Duration of testing has to be
unique – 30min.
The complete system and all the connections are tested, and the criteria is that the water level
does not fall down for 24h, and that there is no leakage.
Maintenance of Drainage System
Drainage system made of polyester does not require a special kind of maintenance. Visual
inspection has to be conducted twice a year – prior to winter period and at the end of winter. Pipes and
hangers should be controlled.
If there is a snow in pipes, it should be cleaned by lukewarm water, so there is no damage to
connections.
 General bridge
Construction and testing of pipelines is performed according to EN 1610:1997.
During this procedure, all pipelines must be secured against the separation. The testing pressure is
min 0.1 bar, and max 0.5 bar for standard pipelines. Then we start with the filling. We are fill first at
the deepest point of the pipeline system. We are filling the pipelines with the water until the whole
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pipeline is completely filled with the water, and the existing air should go out at the highest point.
Recommended preparation time is about one hour. Here, it is meant at what time, in which the porous
materials in the natural way absorb water until saturation of the limited amount, and until the desired
temperature equation between the water temperature and the temperature of the pipe walls is achieved.
The pipe ends are closed later, and we bring in desired pressure for the testing. The water amount that
is spilled has been compensated by water adding. It has to ensure that the aqueous subsequently
refilled quantity does not exceed the discharge height of 10cm of water column (1 psi).
The duration of pipes testing must be unique for 30 minutes.
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4.5 Water supply

 Moracica
Detailed specification of equipment refers to annex .
 General bridge
Equipment for installation of Water supply of bridge
specifi
Total remark
catio ns for
No. Items Capacity Unit Quant
ity other
1 Generator 150KW Pcs
2 Crane 25T Pcs
Tools (hammer set,
3 - Set
wrench)
movable bridge
4 - Set
scaffolding
5 Truck - Pcs
equipment refer to book of equipment
4.5.2. Materials
 Moracica
The materials will be certified and approved by the Engineer and only approved materials will be
used in works.
 \General bridge
The materials will be certified and approved by the Engineer and only approved materials will be
used in works.
The materials which will be used are: Walraven Suspension system for the Pipeline:Chemical
Anchor and Hanging set And Saint Gobain Preinsulated pipe DN300 ISOPAM(approved by the
Engineer in MAR-WS-45 And MAR-WS-03),. Materials with MAR number used refer to annex
Engaged material for bridge
No. Items Total Quantity Remark
Walraven Suspension system for the Material quantity will be

1 -
Pipeline:Chemical Anchor and Hanging as designed.
Material quantity will be
2 Saint Gobain Preinsulated pipe DN300 ISOPAM
as designed.
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 4.6.3.1．Moracica
(1) General information
This part defines the methodology of execution of works, which are an important part of the
works on the Bar - Boljare highway, of the Smokovac – Mateševo section. This Construction Method
Statement will describe works on the construction of regional Water Supply System – installation of a
300mm diameter pipeline of ductile material on the Moracica Bridge.
The water supply pipe is set in the right cell of Box Girder of the bridge along the top slab. There
are two different type of support for fixing the pipe. One is from the hanger which is located in the top
slab, the other one is located in the bottom slab.
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Figure 4.5-1 The type for fixing the pipe

The construction of water supply system for Moracica Bridge includes the following main steps:
i. drilling of holes in Abutment wall and diaphragm wall in the segment 0# on the Piers P1-P5.
ii. installation of pipes.
During the installation of water supply pipe, there should be a location control report, the scaffold
and pipe location control is based on the distance from the middle web and top slab. The location will
be checked per each 18m on average.
(2) Preparatory works
Since the object is of a linear nature and that it passes already prepared route, the preparatory
works will be reduced to the cleaning of the workspace.
Prior to construction, warning signs and protective measures such as fences should be placed
around the working zone in order to prevent unauthorized and uncontrolled entry into the construction
zone.
The supplier has delivered pipes, fittings and armatures to the Contractor's warehouse. Contractor
daily distributes the required anticipated amount of material for the construction site and deposits it
there in the described manner. Unloading will be done in accordance with the recommendation of the
Manufacturer. These are rules:
i. Use textile sling.
ii. Pass the sling under the bundle.
iii. Newer lift the bundle with hooks or suction pads, the strap is not designed to withstand the
bundle load.
Storage will be done with avoiding the swampy areas, polluted land and laying pipes directly on
the ground. The rules are:
i. Stack the bundles in perfect squares, following the maximum heights shown in the table below.
ii. Always make sure that the bundle strap is tight. Never lift a bundle with hooks or suction pads.
Always use slings that pass under the bundle. (The strap is not designed to withstand the bundle load).
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Dimensions and weight of the bundles:

Bundle composition and dimensions
No of
DN No of layers x
bundles L I H Bundle mass
No of pipes
m m m kg
100 6 3x5 6.3 0.67 0.5 1398
150 5 3x3 6.3 0.59 0.66 1272
200 5 2x3 6.3 0.75 0.56 1190
300 4 2x2 6.3 0.74 0.77 1319
Storage of armature and fittings, on wooden palette

The equipment and pipes and scaffold and other material can be transported to inside box girder
from the opening hole which is located in the top slab.
Figure 4.5-2 The opening hole for transport material and equipment
(3) Drilling holes on abutment wall and diaphragm wall on 0# segment of P1-P5
There is one hole in the wall of both Abutments and four holes in diaphragm wall of each segment
0#, P1-P5. Totally there are 24 holes need to be drilled. The holes are drilled with special saws on two
occasions, 350 mm in the first and 600 mm in the second. The thickness of the concrete canvas is 80
cm. At the point of drilling on the surface of the bridge hull there is an electrical connection and a pool
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with water for drilling cooling.

The holes for the Water Supply pipes passing through the parapet wall of Abutment and
transverse girder above the Piers are reinforced by galvanized steel profile. The outer diameter of the
steel pipe is 57cm, and the space between the steel pipe and concrete surface is grouted with SikaGrout
212 HP.
Figure 4.5-3 Location of the hole of abutment A0
Figure 4.5-4 Location of the hole of abutment A1
Figure 4.5-5 Location of the hole in diaphragm wall on 0# segment of P1
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Figure 4.5-6 Location of the hole in diaphragm wall on 0# segment of P2- P5
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Figure 4.5-7 The construction of drilling holes
(4) Installation of pipes

First assembly scaffold as a construction platform for installation pipes and hanging elements.
Second installation of the hanging elements according the location shown in the main design. third
installation of pipes.
Figure 4.5-8 Construction platform for installing hanger and pipes
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In the initial part of the fuselage, on both sides of the columns, the pipes are mounted on a
structure that is fixed to the upper edge of the fuselage (as in the first figure), and around the middle of
the rape the pipeline is fixed on the supports fixed to the base of the fuselage (as in the second figure).
The pipeline is suspended at a distance of 300 cm. An inspection path is installed in the pipe support
structure.
Figure 4.5-9 Tools for connection of the joints

 General bridge
Bridge Water Pipe Installation procedure
i. Mounting of the movable bridge scaffolding
①Mobile scaffolding certificate refer to annex
②For static calculation-Model refer to annex
③Hidrualika ERGAS refer to annex
④Access platform - Report final refer to annex
ii. Use mobile scaffolding
iii. Install pipe supports and hangers,Product technical description and installation method refer to
annex .
iv. Install Preinsulated pipe DN300 ISOPAM
(1) Preparation for installation
The pipes will be arranged along the edge of the bridge, as shown at the Figure below one day before
the
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installation. Pipes will be placed on wooden pads, in order to be protected from damage and for easier
manipulation of pipes.
(2) Pipeline lifting
According to the use process of the above mobile scaffolding, lift the pipe and hang it above the
work platform, the worker accepts it and slowly puts it on the support fixed on the mobile platform,
and then installs it on the already in place support Hanger.
4.5.4. Detection method
 Moracica bridge
Pipeline Pressure Test shall be performed in accordance with the testing procedure defined in the
European standard EN 805 (Water supply, Requirements for systems and components outside
buildings) – preliminary test, pressure drop test, main pressure test.
The test device will be set in the manhole which node is 11 and 12, the test will performed when
all the pipes are installed. There will be no personnel in Box Girder during testing.
Rise the pressure steadily until the System Test Pressure (STP) is reached.
The duration of the pressure loss test shall be 1 hour. During the Main Pressure Test, the pressure
loss ∆p shall display a regressive tendency and shall not exceed the 20 kPa (value for the ductile iron
pipes with cement mortar lining) at the end of the test.
Test evaluation: If the loss exceeds that specified, or faults are identified, the system shall be
examinated and rectified where.
Testing of pipelines on the bridge will be conducted after placing the whole installation through
the bridge and all elements of the water supply in the moves before and after the bridges.
1 2 3
After that, on the pipeline being examined, starting from the lower side, install elements and testing
devices, as it's shown at the picture, and then from the upper side.
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Drawing legend
1 Test pump; 2 Pressure gauge; 3 Pump connection; 4 Air vent; 5 Low end part; 6 High end part;
7 Anchor system; 8 Pile of soil
①　Preferably rise the pressure in the pipes leaving joints uncovered in order to check that they are
watertight, depending of the type of the site.
②　Block the ends of the relevant section with blank flanges fitted with valves, for water filling and
air venting.
③　Evaluate the hydraulic loads exerted on the ends of the pipe, and set up a properly sized system
of anchors.
④　Water shall be released with Engineers permission. After the uninstallation of the pressure test
kit, plastic taps should be placed.
Engineer will be informed in advance that pressure test is to be performed. Starting point for
pipe testing (where inflow, flow gauge, valve, pressure gauge, pump and valve and high-pressure
pump shall be installed) can be socket or tube with the flange.
Example of the end with the spigot and socket with the flange.
Example with the spigot with the flange:
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Upper end is closed with the spigot with the flange or only with the flange:
Gray colored parts ar to be installed and uninstalled
Water tank trucks carry the water and fulfilling the pipe line with the water thru the pump
connection. Flow meter measuring the quantity of the water that passed in the pipe line.
Tank trucks have to deliver water continuously, without the breaks. Capacity of the tanks are
approximately 20 m³. Chart below present necessary quantity of water, or number of tank trucks for
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testing the pipe line. Capacity of the tank truck pump is about 8 lit/sec, so the fulfilling the pipe line
section to be tested lasts as it is shown ate the table below:
Lenght of pipeline m 350 400 450 500 550 600 650 700 750 800 850 900 950 1000 1050 1100 1150 1200
Volume of pipeline m³ 24.73 28.26 31.79 35.33 38.86 42.39 45.92 49.46 52.99 56.52 60.05 63.59 67.12 70.65 74.18 77.72 81.25 84.78
Number of trucks pieces 2 2 2 2 2 3 3 3 3 3 4 4 4 4 4 4 5 5
Needed Time h ' '' 52' 59' 1 h 6' 1 h 13' 1 h 20' 1 h 30' 1 h 36' 1 h 45' 1 h 50' 2 h 2h 5' 2 h 12' 2 h 20' 2 h 30' 2 h 35' 2 h 42' 2 h 50' 3 h
Electronic pressure gauge is connected with the computer, or has it’s own USB drive, on which
pressure changes are recorded and can be printed and added to the site documentation.
After the test is performed, the water has to be released. The way in which used water be released
shall be confirmed by the Engineer.
All rubber parts of the testing tools used in a testing has to be checked and, in a case of need,
replaced, especially rubber flange gascets.
After test is finished, lower part of tested section is connected with the previous section, and
upper end of pipe line is closed with the plastic tap.
Pipeline Disinfection Procedure
i. The pipe will be fulfilled directly from the tank trucks, or from the ‘’Podovi” tank. The valves are
close. About 20 tank trucks of water are needed. Check the quality of the water after it has been
disinfected. If it is of good quality, open the valve towards the BPC ‘’LIJEVA RIJEKA’’.
ii. Fulfilling the pipe line Podovi-Lijeva Rijeka and BPC ‘’LIJEVA RIJEKA’’. The valve towards the
BPC ‘’DUŠKE’’ is closed. After checking the quality of the water, and if used water is in good
condition, the valve towards the BPC ‘’DUŠKE’’ will be opened.
iii. This procedure will be repeated till the last BPC ‘’VEŽEŠNIK’’ and pipe line from BPC
‘’VEŽEŠNIK’’ to the stationary 0+000 will be disinfected.
iv. At the other part of the Pipe Line, from tank ‘’PODOVI’’ towards Mateševo, the pipe line will be
fulfilled throw the temporary connection added in the manhole 55, at the stationary 29+950, with the air
valve, at the highest point of the pipe line. The section of the pipe line which will be fulfilled with water
start from tank ‘’PODOVI’’ and end at the manhole with the sectional valve, NODE 58, at the stationary
31+580. The volume of the needed water is 116 m³. There is a sledge outlet in a manhole 58 for release
the water in a case if it is in a bad condition or containing particles.
v. After the disinfection and test of the quality of the water, if water is in good conditions, the sectional
valve at manhole 58 will be opened and the water will flood the pipe line to the NODE 65, at the
stationary 35+350, which will be closed. There has to be added 100 m³ of water in order to fulfill that
pipe.
vi. After the proval of the quality of the water, the valve 65 will be opened in order to fulfill pipe line
amongst the NODE 65 and NODE 69. In NODE 69 is located the sectional valve which will be closed.
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After the disinfection and test of the quality of the water, if water is in good conditions, the sectional
valve at NODE 69 will be opened and the water will flood the pipe line to the NODE 76, which is at the
end of the pipe line. At NODE 76 there is sludge outlet and there will be final outflow for the water, after
its quality will be confirmed.
 General bridge
1.Pipeline Pressure Test
Pipeline Pressure Test shall be performed in accordance with the testing procedure defined in the
European standard EN 805 (Water supply, Requirements for systems and components outside
buildings) – preliminary test, pressure drop test, main pressure test.
The test device will be set in the manhole which node is 11 and 12, the test will performed when all the
pipes are installed. There will be no personnel in during testing. Rise the pressure steadily until the
System Test Pressure (STP) is reached.
The duration of the pressure loss test shall be 1 hour. During the Main Pressure Test, the pressure loss
∆p shall display a regressive tendency and shall not exceed the 20 kPa (value for the ductil iron pipes
with cement mortar lining) at the end of the test.
Test evaluation: If the loss exceeds that specified, or faulis are identified, the system shall be
examinated and rectified where.
Testing of pipelines on the bridge will be conducted after placing the whole installation through the
bridge and all elements of the water supply in the moves before and after the bridges.
2. pull-out test
There is no need to carry out pull-out on site, because the manufacturer has carried out pull-out te
st under all kinds of concrete label.
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4.6 FRP pipe box under bridge

Besides the equipment listed in the MS of ‘General form of Methodology for construction works
for telecommunication cable ducts within the communication system’, suspension access platform
(scaffold) will be used for this installation. The suspension access platform manufactured by ‘Lisina
d.o.o Nikšić’, which have been approved by the Engineer (confirmed by Engineer’s email on May. 5,
2019)
Picture of Equipment：
No. Equipment Type Picture
suspension
access
1
platfor
m
Hand - held
electric
2 TBH260
drill
Hand - held
3 drill TBS1300
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Kit tool
4 —
Movable
genera
5 —
tor
4.6.2. Materials
The materials used for this part of installations are:
i. FRP pipe box, approved by MAR 793
ii. Drop-in anchor type Fischer EAII M12x50, approved by MAR 880
iii. Threaded rod G12 (M12 x 1000), approved by MAR 880
iv. L profile bracket 50 x 5 x 800 approved by MAR 880
v. Expansion anchor type Fisher FBZ 12/10 (M12 x 110mm), approved by MAR 524 supplement 1
Stainless steel anchor bolts, produced by Fisher.
vi. L profile lateral and longitudinal reinforcement 50x50x5 approved by MAR 785
(1) Basis for the works
1) Basic document of this project, such as Terms of Reference, Employer’s Requirements.
2) Main design (BBC000KU001MD04) - Highway control and Management; and Main Design
(BBC000KU001IP04) – Highway Control and Management – Appendix (FRP box Installation Under
Bridge) submitted with Contractor’s letter RB-BBH/1162/EI-P5 dated May 5, 2020.
3) Plain view drawing and Intersection drawing of each bridge signed by the responsible designer and
main designer showing position of all the installations under the bridge, which will be provided before
the installation of each bridge starts
4) In order to give a brief prior instruction for the process of communication system, we prepare the
sketch of work steps as below.
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Preparation Site investigation Equipment inspection Route inspection
Manhole construction Excavation of the trench and manholes and pipe laying
Pipe laying Visual inspection

Testing
4.6-1 Sketch for work steps of communication system

Annotation: The sketches in this document are only examples which based on the approved
design or working experience, details of each bridge refer to per approved design.
5）Abbreviations
CH Chainage
HSE Health Safety & Environment
ITP Inspection and Test Plan
CRBC China Road and Bridge Corporation
PPE Personal Protective Equipment
EPP Environmental Protection Program
CWMP Construction Waste Management Plan
HWMP Hazardous Waste Management Plan
TBT Tool Box Talk
MS Method Statement
(2) References
Main design (BBC000KU001MD04) - Highway control and Management; and Main Design
(BBC000KU001IP04) – Highway Control and Management – Appendix (FRP box Installation Under
Bridge).
Other references in the MS of ‘General form of Methodology for construction works for
telecommunication cable ducts within the communication system’,
(3) Work methodology
The construction of the FRP pipe box will be executed in accordance with the Statement as
followed. If necessary the method will be adjusted based on the condition on site during construction.
The main working steps as below:
①　Preparation works
②　Installing FRP pipe box under bridge
③　Installing communication pipes in the FRP pipe box
④　Closing the boxes
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(4) Preparation Works

①　It must be in place the intersection drawing of the bridge signed by the responsible designer and
main designer showing position of all the installations under the bridge.
②　Before installing the pipe box, it has to be coordinated with other installation constructors that
the installed FRP box will not block the subsequent installation of other elements under the bridge
(drainage pipe, water supply, 20KV cable pipes,).
③　To make sure that the entire installation is in conformance and in accordance with the design of
the project for the Electrical and Low Voltage System in addition to the specification and as per approved
drawings and comply with Local and International Standards.
④　Before beginning installation in any area, examine all parts of the adjoining work onto which
applicable work is to be placed. Should any condition be found which will prevent the proper execution
of the work, installation shall not proceed in that area until such conditions are corrected by the
contractor.
⑤　FRP boxes, Pipes and Accessories shall be stored on site, protected from damaging.
(5) Installing FRP pipe box under bridge (not including the transition area between the bridge and the
open route)
The installation of FRP pipe box will follow the drawing in above ‘reference 1’, which is briefly
shown in the following Figure 4.6-2 and 4.63. The installation steps are briefly described as follow:
Figure 4.6-2 Pipe Box Installation front view
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Figure 4.6-3 Pipe Box Installation side view

①　Set out, locating the position of the drop-in anchor and install the anchors. The type of the
anchors are Fischer EAII M12x50, the installation method of this anchor is described in page 11 of
attachment 1,which is part of the document in approved MAR 880.
②　Install the threaded rods and L bracket , Suspension sets comprise M12 zinc coated threaded
rods together with nuts and locking washers, and L-profile horizontal bracket that holds the FRP box. All
of the above components shall have a galvanized finish. Any cut ends supports, rods, etc., must be
corrosion protected by use of galvanizing or equal.
③　Adjust the leveling of the L-profile bracket and its distance to the bridge deck to be in line with
the design, namely, The thread rods will be installed with distance of 60cm between each other, with L-
profile bracket which connecting them (also supporting the FRP box) installed at distance of 80cm from
under bridge deck. Same setup will be repeated each 1m along the bridge.
④　At every 6 meters, install L-profile lateral reinforcement , at every 12 meters, install L-profile
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longitudinal reinforcement . The anchor bolt used is Fischer FBZ 12/10, and the method of installing
this anchor is shown in page 2 of attachment 2, which is part of the document in approved MAR 524.
⑤　Fix the FRP pipe box on to the L-profile bracket that have been previously installed at each 1m,
on each bracket, 1 or 2 bolts (remark 1) will be used to connect the FRP box.
(6) Installing communication pipes in the FRP box
①　The method of installing the PVC communication pipes is the same as is described in the MS of
‘General method of works in Communication system’.
②　FRP boxes will have reserved manhole 80cm long every 100m to allow ease of access to all
pipes and cables when installed, this ‘manhole’ is formed by disconnecting the PVC communication
pipes in the pipe box with a space of 80cm. For preventing pipes separation due to mechanical and
temperature oscillations, the 6 PVC pipes will be installed in stagger way in the longitudinal direction,
namely the joints of the 6 pipes will not be at the same cross section. At every 100m manhole pipes will
be secured/attached to FRP box construction using polypropylene or steel strap (remark 2) and strapping
at the beginning and the end of manhole in following way (see Picture 4.6-4)
Picture 4.6-4
③　Make appropriate markings on the positions of the inspection opening (manhole) to accurately
show their positions. The letter M-manhole to the entire width and the entire height of the inspection
opening will be applied. Also, on the bridge concrete guardrail above the manhole, viewed from the side
of the road, an appropriate sign/mark (M-manhole) will be placed to indicate the position of the
inspection opening. (See picture 4.6-5)
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Picture 4.6-5
④　Small diameter tubes (32mm black pipes) for optic cable installation will be installed in one
piece with maximum length of 500m (length of one black pipes coil), without breaking, all the way
where it is possible due to site conditions. On bridge which is longer than 500m connectors will be used
to join 2 tubes to extend the length. For their installation it will be used standard push-through technique,
with one worker at every manhole helping and forwarding small pipes in right big 110mm pipe. (See
Picture 4.6-6)
Picture 4.6-6
(7) Closing the boxes
The closure of the box is done in parallel with the installation of 110mm communication tubes in
such a way that each cover is attached to a FRP box with 3 screws. In the places provided for the
manhole revision, the lid is cut in following way - 80cm manhole - 1m lid, see Figure 7.2.2, in order to
dismantle only part of the lid above it when accessing the manhole. The cut-out parts of the lid will be
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fastened with 2 screws for the FRP box.

4.6.4. Detection method
To prove the security of the drop-in anchor and the threaded rod, a proof pull-of test to the
anchor-rod of 9kN force will be performed by 3rd party laboratory on 5 anchors at each bridge
according to ETAG 001 part 6 (2010 edition), the test report will be attached with the RIA.
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4.7 Expansion joint

Crane or forklift、hanging bracket、electric welding machine、chain block and some necessary
hand tools will be used during installation of expansion joint.
4.7.2. Materials
Before the expansion joint is put into use within this project, this material shall get approved by
engineer with specific MAR No, e.g. Expansion joint with approved Mar.NO 387 produced by Mageba
Company.
This work shall be performed in accordance with the valid Producer’s detailed drawings signed by
Designer of the bridge.
Installation of Expansion Joints must be planned and carried out by competent personnel.
Transport and handling
Fixing points for lifting belts are generally marked (e.g. with yellow paint). Modular Expansion
Joints generally have lifting points for crane slings marked.
If a single crane only is used for lifting and lowering into position, then the angles between the
two straps must not exceed a safe value (typically max. 45°) – otherwise a suitable lifting beam/frame
should be used.
Figure No.4.7-1Lifting of Expansion Joint

(1) Check on delivery
Expansion Joints must be checked as follows immediately following delivery:
i. Check that joints are free of external visible damage
ii. Check that joints are clean
iii. Check that corrosion protection has not been damaged
iv. Check that temporary transportation fixings are tight and in order
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v. Check that type plate is as expected

vi. Check that dimensions and geometry of joints are according to drawings
vii. Check the value of pre-setting against bridge drawings.
(2) Storage
The Expansion Joint must be stored in a safe place on wooden beams (approx. 12x12cm) if
installation does not take place immediately after unloading. The wooden beams must create a flat,
level surface to avoid tensions and torsion within the Expansion Joint.
Figure No.7.3-2 Storage of Expansion Joint
When storing over a longer period, the whole Expansion Joint should be covered with suitable
canvas covers to protect the joint from the environment and damage. However, attention should be
paid to ensuring sufficient ventilation, in order to avoid condensation from air humidity and corrosion
of exposed surfaces.
(3) Installation
TENSA®MODULAR (types LR among the rest) Expansion Joints provide a safe driving surface
for traffic while offering exceptional flexibility by dividing the structure’s movement gap into a
number of smaller gaps, separated by steel centre beams (also known as lamella beams). These
individual gaps are spanned by rubber seals which make the joint 100% watertight. The centre beams
are supported by cross beams (also known as support bars), which span the bridge gap.
The installation of TENSA®MODULAR modular Expansion Joints is described below on the
basis of joints which are connected to the main structure by concreting.
Reinforcement that interferes with the installation of the Expansion Joint must be bent away
sufficiently to make space.
Reinforcement may only be removed or modified in consultation with the responsible bridge
engineer.
It should be ensured that adequate space will remain after the joint has been positioned to allow
concrete to be placed, filling the space between the joint and the concrete deck.
The recess must be thoroughly cleaned. All loose material must be removed, e.g. using
compressed air.
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(4) Checking of pre-setting

The pre-setting is the fixing of the sides of the joint relative to each other before leaving the
factory, based on the bridge engineer’s estimate of the width the superstructure’s movement gap will
have at the time of installation (depending on temperature etc.). These values are indicated on the
Expansion Joint drawings.
(5) Placing in the recess
After preparation of the recess, and confirmation or adjustment of pre-setting as appropriate, the
Expansion Joint can be lifted into position in the superstructure.
Thereafter, the joint is precisely levelled and adjusted in the longitudinal, transverse and vertical
planes. It is noted that the Expansion Joint must have the same inclines, in longitudinal and transverse
directions, as the final road surfacing at each side of the joint, to ensure a smooth ride for traffic.
(6) Preparation of shuttering / formwork to retain fresh concrete
Shuttering plates and/or formwork panels will be needed to seal any spaces between the underside
of the joint and the vertical face of the recess at each side of the bridge movement gap.
Shuttering projecting at least mm over the edge / Zatvaranje/Poklapanje najmanje 100mm preko ivice
(7) Concreting
Prior to concreting, the position of the joint must be checked once again, and the pouring of
concrete must be approved by the responsible engineer. The recess must be thoroughly saturated with
water in advance of concreting to prevent too much water being lost from the fresh concrete.
When all is prepared and confirmed, concrete can be poured. Sufficient vibration of the concrete
must be ensured (filling all voids, without disturbing the shuttering).
The fixing devices can be removed after concrete pouring is finished.
The space beneath the cross beam (support bar) must be completely filled with concrete. This
ensures that traffic loads are safely transmitted into the structure.
Fresh concrete should be protected and kept damp until it has fully cured in order to avoid
cracking at this critical stage.
(8) Installation of cover plates
In general, the fixed side of the cover plate should be located at the superstructure side and the
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sliding side at the abutment side.

Final check and cleaning of fully installed joint
Before a newly installed Expansion Joint is permitted to be exposed to traffic, its suitability and
readiness for this must be declared by the responsible engineer. In particular:
Its corrosion protection (if any) should be in good condition, with any damage caused during
transport or installation repaired.
It must be clean, and free of any obstructions or debris that could inhibit free movements.
Its complete and proper installation, and readiness to be exposed to traffic, must be confirmed.
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4.8 Construction of asphalt AB

For the construction of the AB 16sA asphalt layers, the following equipment will be used on the
construction site:
MARK TIP/MODEL
1 ROLLER HAMM HD-12VT
2 ROLLER /HAMM HD-12
9 FINISHER /VOEGELE 1900-2
ASPHALT ADDITIONAL /
10 MT-3000-2
VOEGELE
11 FINISHER /VOEGELE 2100-3
12 FINISHER /SUPER VOEGELE 1603-2
SPRAYERS BITUMEN
13 TM804SH
EMULSION /WEIRO
14 ROLLER/HAMM HD-75
15 KOMPRESOR/ATLAS COPCO XAS137
16 MOTORIZED BROOM
The efficiency of the machine is demonstrated by the construction of the Trial Sections. In case of
brake down of equipment, “reserve” equipment such as additional asphalt paver(s) and rollers will be
available on the construction site.
4.8.2. Materials
(1) Bitumen Emulsion
Bitumen emulsion (polymer cationic unstable bitumen emulsion PmB KN 60) is used to adhere
asphalt layers to each other, that is, it will be used on the leveling layer. It is applied by spraying on a
dry surface in an even layer. Amount of emulsion depends on the state of the base surface with respect
to the type of the base.
Before laying the asphalt mix made on the basis of the modified bitumen polymer, it is obligatory
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to spray the unbound road base with a polymeric bitumen cationic emulsion (0,15-0,35 kg/m2) at least
three hours before asphalt laying.
For all constituent materials for the preparation of asphalt mixtures, the Contractor will obtain
usability proofs, will carry out our own supervision of the mixing process, calibration and maintenance
of the instruments, all in accordance with the requirements of MEST EN 13108-10.
Materials that are stored on an asphalt plant area must meet the requirements of the Technical
Requirements.
(2) Crushed aggregate
Stone materials shall be stored in such manner to avoid mixing or contamination (materials are
stored in separated boxes which are covered and material are protected from rain and dust). The
surface on which stone materials are stored will be concrete or asphalt, and the compartments
separated (Aggregates to be used: 0-4 mm, 4-8 mm, 8-16 mm)
Each compartment shall have the nominal marking of the stored fraction.
(3) Filler (natural)
Filler is stored in silos.
(4) Bitumen
At the asphalt production plant, bitumen shall be properly stored in silos with installed
thermometers for temperature control.
The silos shall be marked and set for only one type of bitumen.
(1) Introduction
This Method Statement describes the Technology of performing works for the construction of
upper bearing layer on bridges.
All necessary activities for the execution of works are described in accordance with the Main
Road Construction Project and the Technical Conditions for the Works of the BBC000TR000GL03.
For the pavement structure on bridge applies:
i. For upper bearing layer - 50mm AB16sA
ii. For wearing layer - 40mm SMA 11E.
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Figure 4.8-1 Cross section of pavement structure on the bridge

(2) Description AB 16sA
Upper bearing layer (AB 16sA) is an integral layer of pavement structure on bridges
(waterproofing protection) made of a mixture of filler (natural filler), stone material largest nominal
grain size 16 mm and polymer modified bitumen as binder, produced and placed according to the hot
mixed procedure.
It is used to perform a protective layer of waterproofing on bridges.
AB 16sA layer will be executed in thickness of 5 cm. It will be executed in one layer.
The AB 16sA hot mix asphalt mixture will be composed from 3 gradation of aggregate (0-4 mm,
4-8 mm and 8-16 mm).
Filler for mixture will be natural filler from limestone.
Binder will be polymer modified bitumen class 45/80-65.
Aggregates will be crushed aggregate.
AB 16sA will be produced and constructed according to the requirements given in the Technical
Specifications for Construction Works chapter 13040, which is enclosed this Method Statement as
Attachment .
(3) Asphalt mixture production plant
Asphalt mixture plant shall be technically equipped in a manner the enables production of asphalt
mixture of the quality set in these specification and maintain the constancy of mixture within the
allowed deviations.
Specification asphalt plants “BENNINGHOVEN ECO 3000 U” owned by the Contractor, is
given in Attachment no. 3.
Calibration of measuring devices must be done annually at least once. The Contractor shall
submit documents on calibration to the supervising engineer.
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The batching plant ensures a unified and controlled inflow on stone material from a sufficient
number of feeders.
The drying drum performs efficient and uniform drying and heating of stone material.
Stone material dusting and screening system effectively screening of stone mass at the full asphalt
mixture production capacity.
Material obtained by the dedusting process (filler removing from 0-4 mm aggregate before
mixing) shall be stored in separate silos. Uncontrolled return of the dusted material into the production
process is not allowed.
The screened stone material is stored in such a way that there is no interconnection.
Silos for bitumen binder shall be daily checked (for stoppage, level, …) and maintained (visual
and machinery check by operator)
The asphalt mixture production plant is equipped with the correct thermometers for measuring the
temperature of the constituent materials and the produced asphalt mixture.
(4) Methodology
①　Technology
i. Before starting to produce AB 16sA with polymer modified bitumen the following will be prepared:
Execution of initial job mix of asphalt mixture with belonging initial and control tests of component
materials (aggregate, filler, PmB) in accordance with Quality control plan for laboratory tests,
Execution of confirmed job mix of asphalt mixture in accordance with Quality control plan for
laboratory tests and
ii. Execution of trial section with proving production and adopting build technology.
iii. Execution of program of quality assurance of material and works.
All of the above mentioned activities are the responsibility of the Contractor.
The Contractor will keep written record on the test results performed during the control testing.
(See attachment 4). Copies of the initial tests results will be submitted to the Engineer’s Supervisor and
one copy will be kept for Contractor.
②　 Initial job mix of asphalt mixture
Contractor need to have all appropriate documentation according to approved Quality Control
Plan (Certificates, test results, …) about usability of all materials which will be used in asphalt
mixture, in accordance with chapter 13040-10 and tables 13040-5 and 13040-6 of technical conditions.
The documents will be forwarded to Engineer for review and approval.
Initial job mix of asphalt mixture it is made in laboratory, according to Marshal procedure, and
with asphalt mixture of optimal binder content there are tested two more asphalt mixtures with less or
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more binder part with increment near 0.3% in relation to the presumed optimal part of binder.
When all conditions are satisfied, the Contractor will prepare a report on the confirmed job mix
formula as asphalt mixture, which contains:
i. General part with data on the manufacturer and the asphalt production plant,
ii. Data on the testing of materials stored at the asphalt production plant,
iii. Basic data on the initial job mix formula of asphalt mixture,
iv. Individual laboratory test results of asphalt mixtures samples taken during production tests,
v. Evaluation of the mean value discrepancy of asphalt mixture composition from the preliminary
composition value set on the basis of samples tested during production tests,
vi. Data on the asphalt mixture production plant and the production elements obtained at the production
plant during production tests (opening and the working regime of the batching plant and feeders,
separators, individual feeding of screened stone material fractions, proportioning of stone flour and
bitumen, time of mixing, production capacity, temperatures of asphalt mixture, stone material an
bitumen binder).
Report of initial job mix of asphalt mixture contents:
i. general data (producer, properties of material) about used material,
ii. percent parts of individual types or fractions and of crushed stone materials in hot mix asphalt
mixture,
iii. percent part of binder in asphalt mixture, including corresponding tolerances, according to
Technical Specifications
iv. density of all materials,
v. granulometric composition of optimal stone mixture, including corresponding tolerances, according
to Technical Specifications
③　 Job mix of asphalt mixture (trial run on asphalt plant)
Job mix of asphalt mixture includes following pre-orders:
i. Checking the composition and properties of materials on an asphalt base that will be used in asphalt
mixture
ii. An appropriate check of corrections and accuracy of devices for dosing and another parts of asphalt
factory.
Production of asphalt mixture is considered proven when is middle value of three samples of
asphalt mixture taken from asphalt factory during continuous work (at least 50 tons), matches with
initial job mix within tolerances which are allowed for every asphalt mixture.
So obtained middle value of asphalt mixture is job mix of asphalt mixture. Physical and
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mechanical properties of all samples must match to the technical conditions.

④　 Report of job mix of asphalt mixture contents:
i. general part of datas about manufacturer and asphalt mixture production plant,
ii. datas about tasting materials stored on the asphalt mixture production plant,
iii. general datas about initial job mix of asphalt job mixture,
iv. separate laboratory reports about testing samples of asphalt mixture taken during production
proving,
v. estimate retreat of middle value of asphalt mixtures from initial job mix, determined on the basis of
tasted samples in proving production.
⑤　Trial section with proving production and adopting build technology on site
Trial section serves as a prove that with asphalt mixture produced according job mixture with
appropriate build technology, can build asphalt layer with technical condition quality.
During trial section, Contractor will test (trial section minimum length of 300 meters, and width
of complete one side of the bridge) the following on the trial section:
i. Temperature of asphalt mixture asphalt plant, after transport at delivery on site, for every delivery
vehicle,
ii. Structure and physical and mechanical properties of asphalt mixture according to control plan given
in attachment 5 of this document,
iii. Compaction level, air voids percentage, thickness of asphalt layer, on least three samples,
iv. flatness of each traffic lane along full length of trial section.
v. Determine the number of passing for each roller used in compaction process.
vi. The quality of the asphalt production will also be controlled by testing 3 samples from the asphalt
plant.
Laying of asphalt layer will be done by paving machine and level control will be performed using
sensors to monitor height. All stops of paver during laying of asphalt shall be avoided. Every delivery
will be followed by delivery label with details of delivery (quantity, type of material, transport
duration, asphalt mixture temperature) see attachment .
On the basis of own laboratory and field tests, Contractor will make report about trial section,
which consists three parts.
I. part - general data:
i. construction, Contractor and Investor,
ii. description of trial section,
iii. lists of certificates and other datas about material usability.
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II. part - Prove about asphalt mixture produce (initial job mix):
i. capacity production of asphalt factory, description of transporting asphalt mixture,
ii. description of the means of transport of the asphalt mixture;
iii. temperature of mixing and laying of asphalt mixture, and minimum compaction temperature
iv. laboratory analysis about testing mixture and properties for installation asphalt mixture,
v. tests review about asphalt mixture relative to initial job mix, in accordance with subtitle 1.1.4 of
technical conditions.
III. part - prove about asphalt mixture installing:
i. description of paving process,
ii. description of rolling and compaction process,
iii. results for compaction ratio, air voids and thickness of layer.
⑥　The process of installing layer AB 16sA
1). Introduction
After finishing and approval of waterproofing layer, approval of initial job mix and confirmed job
mix as confirmed method of production and installation technology, Contractor can begin to produce
AB 16sA.
2) The protective layer of waterproofing
The protective layer of waterproofing is applied on a completely dry and completely hardened
Bond Coat 3 layer (serves as a bond between the waterproofing and the asphalt). Installation of AB 16
sA asphalt concrete layer will be carried out with a wheeled paver. The tires of the pavers and asphalt
delivery vehicles must be cleaned regularly before driving on Bond Coat 3. The stationary vehicles on
the bonding layer should be avoided.
For transporting are used appropriate vehicles, with back tipping and with tarpaulin protection for
bituminous mixture from rain, cooling and dust. Before loading, internal surface (sides and bottom)
from steel caissons must be sprayed with appropriate agent (potassium soap) against gluing which does
not work harmful on bituminous mixture.
Depending of designed quantities for daily installation, sufficient number of driving units, in
order to secure continuous work of paver and other mechanization, will be operating.
Asphalt temperature is measured on every delivery truck of delivered asphalt and laid asphalt
right behind the paver. The asphalt temperature which is being installed on Bond Coat 3 drops rapidly
because it is installed on a cooler substrate, and therefore it will be ensured that the asphalt temperature
does not fall below the technological installation temperature for the mixture.
Every delivered truck has its delivery note with all necessary information about mixture (time of
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mixing and arrival to the site, temperature of mixing, type of mixture, quantity)
If it happens any kind of stoppage in mixture transport, or in production so that the temperature
falls under minimum (130°C), installation will be stopped. On the parts where it comes to hitch, it is
necessary to install suitable working joint, but the joint in general should be minimized.
In order to meet projected height of protective layer, on waterproofing shall be on each 10 m
marked thickness of protective layer next to Concrete safety Barrier, and at the junction ofthe
trainandthe emergency lane.
If there are irregularities on the concrete slab of the bridge and on the waterproofing layer, the
protective layer of waterproofing will have a variable height.
3) Leveling layer
Before any other works, detailed geodetic surveys of the finished waterproofing layer must be
performed in order to record potential recesses in relation to the designed elevation.
If it is determined that there are recesses where the thickness of the protective layer of
waterproofing would exceed the allowed 6 cm (technological thickness of the layer AB 16sA allowed),
a leveling layer needs to be done.
The quality and characteristics of the leveling layer shall be defined in relation to the required
thickness of the leveling layer, in accordance with the applicable standards and in agreement with the
Supervisory Engineer.
Marking of fixed points is done, from which the asphalt layer can be safely carried out as
leveling. The asphalt for leveling is performed by a wheeled paver. The surfaces of the leveling layer
will be sprayed with 0.5 kg / m² polymer cationic emulsion for a minimum of 12 hours before the
protective layer is installed.
4) Over width
Over width of the various asphalt layers according to main design are given in Main Design of
Pavement structure, Book BBC000TR000GL04.
Before continuing to install it is necessary to coat surface of work joint with bituminous emulsion
(polymer cationic unstable bitumen emulsion PmB KN 60) (minimum quantity 0,5kg/m2), and area of
work joint indirectly heat up with heaters. The coating is performed in 15cm width on the joint area
and on slope of external layer. Coating is also performed before starting of works on longitudinal
joints.
Over width in horizontal curves will be done according to drawings from Main design. It shall be
marked on previous layer, before installing asphalt layer.
On the parts that are not available to the rollers (on the extensions, manhole covers, etc.),
compaction will be done using manual tools.
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Note:
The following conclusions from the meeting held on 23.07.2020 are:
i. On bridges were survey report shows that surface of span structure is larger than +1cm we wil
perform cutting of surface in order to achieve maximum +1cm deviation;
ii. Thickness of levelling layer of asphalt AB16sA doesn't have to be in accordance with previously
agreed tolerances for asphalt (5%). Minimal thickness of levelling layer of asphalt AB16sA should be 4
cm.
iii. If shows that on some parts we can't have appropriate compaction of first levelling layer of
asphalt AB16sA in accordance with standard, on those places we would first install levelling layer of
asphalt AB8SA and above it designed levelling layer of asphalt AB16sA which will be confirmed by
trial section.
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4.9 Central Median Reserve

Unit / Total quantity /

Ser. No / Capacity / Remark /
Items / Stavke Mjerna Ukupna
Redni br. Kapacitet Napomena
jed. količina
1 Generator / Generator 200kW pcs 1
2 Loader / Utovarivač 5t pcs 1
Concrete mixer truck /
3 2x8m3 Pcs 2
Mikser za beton
Cutting machine /
4 pcs 4
Mašina za sječenje
Steel bar bender /
5 Mašina za savijanje armarurnih pcs 1
šipki
PERI Variokit VGW Cantilevered
Parapet Formwork Carriage /
6 set 4
“PERI Variokit VGW” pokretna
konzolna parapetna oplata
Table No. 4.9-1 Engaged equipment
Design of PERI Cantilevered Parapet Formwork Carriage for construction of Edge Beam of the
Moracica Bridge and the Review Report, we refer to the Contractor’s letter No. RB-BBH/3147/EM-P1
(17/08/2019), and the Engineer’s letter No. IG/12587/EP,MKa (26/09/2019). Prior to starting the
construction at the subject formwork, the test load for scaffold will be performed.
For more details on equipment, we also refer to the Book of Equipment (submitted to the
Engineer in the letter No. RB-BBH/2143/EM-P1, 13/10/2016).
4.9.2. Materials
All materials which are in use for construction should be certified and approved by the Engineer,
and only approved materials are used for execution of works. For material control, we refer to the
QAP, Chapter No. 8.1. Material Control.
(1) For Edge Beams:
Reinforcement bars B500B of quality are in use.
Concrete with concrete grade MB 40 V-8 M-200 MS (0) is in use, and total concrete quantity for
both Edge Beams amounts 956.48m3. For detailed information regarding the Concrete Mix Design, we
refer to CDB for Edge Beam of the Moracica Bridge (document No. CRBC(MNE)-CDB-P1-10.
PVC pipes Ø110mm of diameter are in use in Edge Beam (6 pipes in total per Edge Beam cross
section), therefore we refer to the approved MAR No. 142.
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(2) For Central Median Reserve:

Reinforcement bars B500B of quality are in use.
Concrete with concrete grade MB 40 V-8 M-200 MS(0) is in use, and total concrete quantity for
Central Median Reserve amounts 634.66m3. For detailed information regarding the Concrete Mix
Design, we refer to CDB for Edge Beam of the Moracica Bridge (document No. CRBC(MNE)-CDB-
P1-11).
Pipes Ø63mm of diameter are in use in Central Median Reserve (3 pipes in total per Central
Median Reserve cross section), for lighting cable, power supply cable and signal cable. Power supply
cable and signal cable end up at the weather station (ref. to the Working Drawings for Central Median
Reserve of the Moracica Bridge).
(1) General information
Details of cross section of Edge Beam and Central Median Reserve of the Moracica Bridge are
following.
Figure No. 4.9-1 Typical cross section of Edge Beam of the Moracica Bridge
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Figure No. 4.9-2 Cross section of Edge Beam on Wing Walls of Abutment
Besides the position between the Expansion Joints at the beginning and at the end of the bridge
structure, Edge Beam also extends on Wing Walls on Bridge Abutments. Total length of Edge Beam on
upstream side of the bridge amounts 982m, and on downstream side it is also 982m. Protective
concrete layer for Edge Beam is 2.50cm, except for its top surface where it is 4.50cm.
Figure No. 4.9-3 Cross section of Central Median Reserve of the Moracica Bridge
Central Median Reserve is all along the bridge length between the Expansion Joints at the
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beginning and end of the bridge. Total length of Central Median Reserve amounts 982m. Viewed in
cross section of Central Median reserve, protective concrete layer for Central Median Reserve is
4.50cm at the top surface, and at the lateral sides towards the curbs, and 2.50cm at the bottom of
Central Median Reserve.
Waterproofing for Bridge Deck is performed all over the top surface of Top Slab of Box Girder,
therefore also under the Edge Beams and Central Median Reserve.
There are also six manholes for installations in Central Median Reserve longitudinally.
(2) Construction method
The flatness tolerance for top surface of Edge Beam and Central Median Reserve is 1cm.
Construction tolerance for protective concrete layer is ±5mm.
 For edge beam:
Edge Beam are performed in segments with 21m of length. For construction of Edge Beams,
Cantilevered Parapet Formwork Carriage is in use, 22m of length, two sets per each side of the bridge.
Figure No. 4.9-4 Cantilevered Parapet Formwork Carriage for Edge Beam construction for the
Moracica Bridge – cross section
 For central median reserve:
At first, curbs are installed in the Central Median Reserve zone, thereafter the reinforcement
works for Central Median Reserve are following, installation of pipes for installation cables, and then
the concrete works can be performed. One concreting segment is planned to be around 20m of length.
For executing the Central Median Reserve, the curbs are in use as a formwork at the lateral sides
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of Central Median Reserve.

①　Detail of anchoring the Steel Safety Barrier pole in Edge Beam and Central Median Reserve
concrete
There is a bolt connection between the steel plate for Steel Safety Barrier pole and Edge Beam or
Central Median Reserve concrete, bolts M20x220 – 4 pieces per barrier pole. The holes for bolts are
drilled subsequently in Edge Beam concrete.
Figure No. 4.9-5 Detail of anchoring the Steel Safety Barrier

Detail of anchoring the Wind Protection Barrier pole in Edge Beam concrete
Prior to concrete works for Edge Beam, per single pole of Wind Protection Barrier, for its
anchoring, three U-bolts and one embedded steel plate are installed. Wind protection strips are
installed after installation of all poles is completed.
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Figure No. 4.9-6 Detail of anchoring the Wind Protection Barrier pole in Edge Beam concrete
②　Detail of anchoring the Pedestrian Guardrail pole in Edge Beam concrete
Prior to concrete works for Edge Beam, there are the holes 18x18cm of dimensions, around 7cm
of depth left in formwork, in which the Pedestrian Guardrail poles will be anchored subsequently. The
position of those holes longitudinally is per each 2m, and it is 22cm transversely measuring from the
external edge of Edge Beam, which is determined by the formwork position.
Three rebars of longitudinal reinforcement Ø10mm in the upper zone of Edge Beam concrete are
'lowered' for around 2.10-2.60cm along the Edge Beam, in order to avoid the cutting of rebars at that
location. Also one more transverse rebar is added for positioning of those three lowered rebars.
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Figure No. 4.9-7 Detail of anchoring the Pedestrian Guardrail pole in Edge Beam concrete.
On Edge Beams on Abutments only Steel Safety Barriers and Pedestrian Guardrail are set.
③　Detail of anchoring the Lighting pole in Central Median Reserve concrete
Lighting poles for the Moracica Bridge are anchored in Central Median Reserve concrete by
anchors Ø32mm of diameter (4 pieces per pole in total) and steel plates and steel profiles L80*80*10,
as given in the following figures. These elements are installed prior to concreting works for Central
Median Reserve.
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Figure No. 4.9-8 Typical cross section of Central Median Reserve of the Moracica Bridge with the
Lighting pole
Figure No. 4.9-9 Detail of anchoring the Lighting pole in Central Median Reserve concrete
④　Detail of anchoring the weather station in Central Median Reserve concrete
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Figure No. 4.9-10 Detail of anchoring the weather station in Central Median Reserve concrete at the
bridge chainage RK 6+840
(3) Reinforcement installation
Reinforcement is prepared in reinforcement workshop and it is transported to the place of
installation, where it is installed in structural element. The connection of longitudinal reinforcement at
the place of installation is performed by overlapping of rebars.
There is also the reinforcement in the zone of steel safety barriers for connection of Top Slab of
Box Girder with Edge Beam and Central Median Reserve, which was previously installed in the
subject areas in Top Slab, as given in the following picture.
Figure No. 4.9-11 Cross section of reinforcement plan of Edge Beam

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For executing the Edge Beams, a common wooden formwork is in use, and also the curbs are in
use as formwork at the inner side of Edge Beams.
Figure No. 4.9-12 Typical cross section of Central Median Reserve of the Moracica Bridge with
reinforcement plan
For all the details regarding the Reinforcement plan for Edge Beams and Central Median Reserve
of the Moracica Bridge, we refer to the subject Working Drawings, which are submitted to Engineer
for review and approval.
(4) Pouring and curing of concrete
Concrete is delivered to the place of delivery in a concrete mixer, concrete pump or a chute is
used for pouring the concrete in formwork. Concreting is performed in layers.
When pouring of concrete is finished, curing of concrete is performed, top surface of element is
sprinkled with water for seven days in order to lower the temperature effect.
For detailed information regarding the concrete quality requirements, concrete composition
requirements, production, transport of concrete and proof on concrete quality, pouring, vibrating and
curing of concrete, we refer to Concrete Design Book for the Moracica batching plant (doc. No.
CRBC(MNE)-CDB-P1-2), to Method Statement Production and delivery of concrete. Moracica
batching plant (doc. No. CRBC(MNE)-MS-P (1-4)-6-7), and to MS Concrete Pouring and Curing (doc.
No. CRBC(MNE)-MS-P (1-4)-6-4). Also, for detailed information on Concrete Mix Design, precise
quantities per each segment and concrete sampling for Edge Beams and Central Median Reserve, we
refer to CDB Edg Beam and Central median Reserve of the Moracica Bridge (doc. No. CRBC(MNE)-
CDB-P1-9).
After completing the construction of all segments of the subject bridge elements, and after all the
conditions are met, all Cantilevered Parapet Formwork Carriages and formwork can be dismantled and
removed.
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4.10 Wind Protection Barriers for the Moracica Bridge

4.10.1. Materials
All materials which will be in use for construction will be certified and approved by Engineer,
only approved materials will be used for execution of works. For Material Control we refer to the QAP,
Chapter No. 8.1. Materials Control.
Wind Protection Barriers by producer “Dunex” Belgrade, Serbia, approved within Supplement 2
to MAR No. 742, are applied on the Moracica Bridge.
Wind Protection Barriers construction steps are following:
Step 1: Prior to concrete works for Edge Beam, U-bolts and one embedded steel plate are installed
for anchoring a pole of Wind Barrier.
Figure No. 4.10-1 Installation of embedded steel plate

Step 2: per single pole of Wind Protection Barrier is installed by bolts with the steel plate.
Figure No. 4.10-2 Longitudinal and cross section of the pole of Wind Protection Barrier
Step 3: Wind protection strips are installed after finishing all poles.
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Figure No. 4.10-3 Typical longitudinal and cross section of Wind Protection Barrier, Moracica Bridge
4.11 Pedestrian Guardrail for the Moracica Bridge
4.11.1. Materials
All materials which will be in use for construction will be certified and approved by Engineer,
only approved materials will be used for execution of works. For Material Control we refer to the QAP,
Chapter No. 8.1. Materials Control.
Pedestrian Guardrail produced by “Utva Silosi” a.d. Kovin, Serbia, approved within MAR No.
493, is applied on the Moracica Brigde.
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Figure No. 4.11-1 Typical cross section of Pedestrian Guardrail, Moracica Bridge
Figure No. 4.11-2 Detail of anchoring the Pedestrian Guardrail pole, Moracica Bridge
For Pedestrian Guardrail, Expansion Joint is set per each 6m. Besides the typical piece of
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Pedestrian Guardrail with 6m of length, there are also several special types considering the existing
bridge Expansion Joint at the beginning and the end of the bridge, and considering the total length on
which the guardrail is installed, all in accordance with Working Drawings.
There is no welding works on site. On site only drilling of holes for anchors is performed, and
anchors and nuts are installed.
The steel plate already has holes for anchors made in factory. All the elements must be welded in
factory, and all the elements must be galvanized before being delivered to construction site.
Specification of all galvanized elements must meet the standard EN ISO 1461.
Prior to concrete works for Edge Beam, there are the holes left in formwork, in which the
Pedestrian Guardrail poles will be anchored subsequently.
The steel plate is 'lowered' for 2cm comparing to the designed position, and for that purpose three
rebars of longitudinal reinforcement Ø10mm in the upper zone of Edge Beam concrete are 'lowered'
for 4cm along the Edge Beam, in order to avoid the cutting of rebars at that location.
For grouting of anchor holes “MULTIFIX USF” is in use. The holes for guardrail poles are later
on filled with epoxy-mortar.
Concrete cover layer at the top edge of Edge Beam is 4.0cm. The anchoring details are given in
the relevant Working Drawings.
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5 Health and Safety

Its complete and proper installation, and readiness to be exposed to traffic, must be confirmed.
Construction of the Bridge Superstructure shall be undertaken in accordance with this document,
the contract requirements, Health and Safety Plan (last approved revision) and approved elaborate for
construction site arrangement for the Moracica Bridge prior to commencement of works.
For HS Checklist, we refer to the Annex No. 4. For HS Risk Assessment, we refer to the Annex
of this document.
6 Environmental Protection
(1) The MS is established in accordance with the environmental management documentation:
i. EPP – latest approved revision
ii. WMP – latest approved revision
iii. HWMP – latest approved revision.
(2) Analysis of risks of impacts with the operations concerning the environment is following:
Environmental
issue / Pitanje Object/Activity / Risk of impact /
Measures / Mjere
vezano za životnu Objekat/Aktivnost Rizik za uticaj
sredinu
- Drainage ditch and settling basin /
Drenažni kanal i taložni bazen
Water
- Water soluble waste well treated /
catchment/River / Concrete, machine Water pollution /
Ispravno tretirati otpadne vode
Oticanje / Beton, mašina Zagađenje vode
- Clean-up the contaminated soil
vode/Rijeka
immediately / Odmah očistiti
zagađeno tlo
- Monitoring of noise / Praćenje buke
- Equipped with personal protective
equipment / Opremljenost ličnom
Human health /
Noise / Buka Machine / Mašina zaštitnom opremom
Ljudsko zdravlje
- Limit the working time in
residential area / Ograničenje radnog
vremena u naseljenoj oblasti
(3) According to the recommendations of the Environmental Protection Program and in order to ensure
the protection of Environment, the following specific additional measures/procedures will be
implemented/established:
i. preparation of warnings boards
ii. installation of a sprinkler system in order that the emissions of dust in the air at the plant are
decreased
iii. waste on construction site will be classified in storage and get professional treatment
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iv. check of equipment on construction site every day before starting the works, making sure that no
leak situation exists (if it exists, cleaning-up of contaminated soil immediately).
(4) All workers will be warned about preservation of Environment at all and specific procedures which
should be implemented.
(5) Reports regarding the periodic checks will be included in Weekly Environmental Report and
Monthly Environmental Report for specific activity. The Report and the Check form will be done by
the Contractor’s Environmental Representative.
(6) For Environmental Check Form with the check list concerning the operations which are the subject
of this MS, we refer to the Annex of this document.
7 Quality Assurance and Control

Quality assurance and control will be according to:
1) Main Design
2) Quality Assurance – latest approved revision
3) Technical Specifications
4) Internal checklist.
8 Annexes
Annex No. 1References
Annex No. 2Environmental Check List
Annex No. 3 HS Checklist
Annex No. 4 HS Risk Assessment Form
Annex No. 5 Standards and Regulations
Annex No. 6ERC_for Bridge drainage.xlsx
Annex No. 7ITP bridge drainage.xls
Annex No. 8 edge beam
Annex No. 9water supply
Annex No. 10 waterproof
Annex No. 11 asphalt concrete of type AB 16sA
Annex No. 10 FRP pipe box under bridge

MS Bridge Deck Construction For Bridges Rev 5 Eng - Final

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Method Statement

Bridge Deck System Construction for Bridges

2 Basis for the Works.........................................................................................1

5 Health and Safety..........................................................................................83

7 Quality Assurance and Control.....................................................................84

2 Basis for the Works

Appropriate abbreviations used in this MS are explained as following:

viii. Responses any question by the Engineer

3.3 QA&QM Responsible

3.4 HSE Responsible

i. Manages safety officers in organization of site health and safety matters

iv. Regular safety introductions and safety meetings

3.5 Site Engineer

3.6 Geodetic Surveying Engineer

i. Reports to the site manager

3.8 Equipment engineer

Figure No. 4.1-3 Longitudinal profile of the Moracica Bridge

Figure No. 4.1-4 Layout of the Moracica Bridge

(2) Waterproofing membrane “Eliminator”– one coat

Construction plan for waterproofing works / Plan izvođenja radova na hidroizolaciji

planned start / planned finish /

4.3 Safety barriers

2 Special lifting tool

5 Electric hammer (with drill)

Figure No. 4.3.1 Cross section of Safety Barrier, type RB80A_8_H2/W1,

Transportation of safety barriers

Treatment of foundation of safety barrier

Setting out of foundation line

Placement of prefabricated safety barriers

Drilling with electric hammer

Bridge safety barriers installation process flow chart

FigureNo. 4.3. Installation detail for Safety Barrier, type RB80A_8_H2/W1

4.4 Drainage system

polyester sewer pipes GRP / DN 150, DN 250, DN 300,

pipe supports – hanger consisting of hinge at receiving DN 250, DN 300,

Additional material required for quality and correct installation /

polyester pipe fittings WYES DN 150 / DN 250/150/45, DN 300/150/45,

polyester pipe fittings ELBOW 45 / DN 250, DN 300, DN 400, DN

polyester pipe fittings – transition reducing pieces / DN 300/250, DN 400/300, DN

fixed hangers, longitudinal and lateral / DN 250, DN 300, DN 400, DN

polyester pipe fittings – additional poliester coupling / DN 250, DN 300, DN 400, DN

CE coupling / DN150/168, DN150

polyester pipe fittings – end cover / DN250

polyester pipe fittings – compensator DN/L=MN / DN 250/500, DN 300/500, DN

Installation of Drainage System :

4.5 Water supply

No. Items Total Quantity Remark

Walraven Suspension system for the Material quantity will be

4.5.3. Construction Methodology

Figure 4.5-1 The type for fixing the pipe

Dimensions and weight of the bundles:

Storage of armature and fittings, on wooden palette

with water for drilling cooling.

Figure 4.5-3 Location of the hole of abutment A0

Figure 4.5-4 Location of the hole of abutment A1

Figure 4.5-5 Location of the hole in diaphragm wall on 0# segment of P1

Figure 4.5-6 Location of the hole in diaphragm wall on 0# segment of P2- P5

Figure 4.5-7 The construction of drilling holes

(4) Installation of pipes

Figure 4.5-8 Construction platform for installing hanger and pipes

Figure 4.5-9 Tools for connection of the joints

Example with the spigot with the flange:

Gray colored parts ar to be installed and uninstalled