MASS CONCRETING & TEMPERATURE CONTROL MONITORING METHOD STATEMENT

1.) PURPOSES This method statement has been prepared to provide a general guide, special
considerations to be given in relation to the heat of hydration for concrete pours. This method
statement describes the work procedures to be carried out during an execution stage of mass
foundations /structures of which the character of the concrete is technically specified as a structure with
large dimensions simply figured of greater than 1.50 meters for all dimensions. In this case the cracks &
temporary control is required both during the concrete mix control at concrete batching plant prior to
concreting and its monitoring after the concrete is placed in order that the requirements stated in the
Engineering Standard, Specification for Concrete Works e.g. a temperature differential between the
interior of the concrete and any outside face will not exceed 20 C , can be maintained ( Basically , heat
on the surface of the concrete is easily released toward the ambient whereas the center remains its high
temperatures, this follows that the temperature difference will induce the internal restraint and
subsequently introduce thermal contraction cracks. The method statement also includes details of
temperature difference control procedure and all necessary temporary works such as curing method by
thermal quilts, precaution barricade, temporary access and related activities which are required to
undertake during a certain period. Special care and planning is required as the volume of pour is large in
relation to those normally being place on Site.

2.) SCOPE OF WORK This method statement includes e.g. concrete batching plant control including
supply and delivery to Site, casting sequence , the method to control and prevent the concrete cold joint
being introduced during concrete placing and a proper curing to maintain, control temperature
difference not to exceed the specified tolerance stated in the Engineering Standard , Specification for
Concrete Works of which the method of monitoring will be included , and all incidentals necessary to
complete the entire works.

3.) SAFETY POLICY One of the main aspects of this procedure is Safety and Health Control. This is to
control occurrence of injuries as well as damage to equipment and properties during the entire
execution period. In order to ensure a safe working environment during the entire execution period, the
following safety measures will be implemented as follows:

Machinery and Equipment:

Prior to using any machinery’s/equipment at site, it will be inspected and certified by qualified person.
Periodic Preventive Maintenance will be made on all equipment and machineries. All operators and
drivers are to be equipped with valid driver’s/operator’s license or permit from concerned government
agency. Only authorized drivers or operators will be allowed to operate machineries or equipment. Only
authorized signalman will be assigned together with the operator or driver. All lifting equipment as well
as its accessories such as sling wire, nylon sling, shackles, chain blocks crane hook and latch shall be
inspected periodically.
Personal Protective Equipment:

Personal Protective Equipment (PPE) will be issued to all workers such as safety shoes, hardhat, working
gloves, earplug and safety goggles. Wearing of the basic PPE will be enforced fully. All new recruits will
undergo proper orientation and safety induction before they could be deployed at site for work.

4.) WORK METHOD

4.1 Works Preparation

a.) General: With a large concrete pour of this magnitude it is essential that proper pre-construction
planning methods and safety checks be in place prior to execution of the works. A mass pour is
considered to be demanded a special attention to be given to logistical and technical considerations
such as concrete supply, casting sequence , prevention to cold joint being introduced during concrete
placing and temperature differential control by thermal quilts curing method etc. In addition the method
of temperature difference for the selected points will be discussed, prepared prior to the work begin.
Among these practices are such important measures as a pre-cooling ingredient, consideration of
concrete temperature as placed, transportation time and curing technique. The method of concrete
temperature control will be proposed as using the mix 6: use of ice as part of mixing water is effective in
reducing concrete temperature, because on melting alone, to absorb heat. In this case there is no
change in the design mix but it may encounter a difficulty to control the temperature differential
between such selected points within the concrete mass to be within the specified figure stated in the
Engineering Standard, Specification for Concrete Works.

The sequence is as follows:

(1). Spray cool water for every 30 minutes to the course aggregate stock. This will be done at least 2
hours in advance prior to mixing of concrete.

(2). Add ice into the water for mixing of concrete to reduce the water temperature. The ice will be
added until 8-10 Celsius Degree for water temperature is reached. The amount of ice added to the water
is dependent on the air temperature at the certain mixing day.

(3). Spray cool water to the trucks mixers to reduce the temperature of the trucks mixers.

(4). At the batching, the first batch of the concrete shall be checked its temperature. The water
temperature will be continued to reduce until the concrete temperature is lower than 33 Celsius Degree
prior to the delivering to Site.

(5) The above process (4) will be regularly done during the entire period of supply to ensure that the
same degree of temperature always be maintained.

(6) At the Site, upon a delivery of the concrete the fresh concrete will be re-measured whether the
temperature is still within the specified tolerance.
Concrete Delivering: since the temperature rise can be increased with a passage of time thus the period
between mixing and delivery will be kept to an absolute minimum. Attention will be given to
coordinating and dispatching of the mixing trucks with the rate of placement to avoid delays in delivery.
At Site, all existing facilities which are within the construction site radius considered to obstruct any
work activities, will be removed or be provided with protection against damage, dust and dirt. Enclose
the site construction area to control material equipment as well as to avoid any incident/ accident
from/to others. Works should start confirmation of the permission and the handing over area of the
work. Prepare, check and submit verified construction drawings of excavation areas to be attached as
addition to this method statement distribute & details to all concerned parties as required.

Planning: A pre-concreting meeting will be held internally and with concrete supplier to finalize
agreement of the proposed concreting procedure.

Access: Designated site access routes for concrete supply will be prepared and traffic control measures
implemented. The proper access must be organized to enable a continuous transportation of the
concrete during the entire period of pouring so that the required temperature of concrete pour will be
maintained.

Supply: Concrete batching plant capacity and numbers of delivery trucks will be planned to maintain a
continuous supply of concrete so that an introducing to cold joint can be prevented. In addition to
minimize temperature differentials occurred within the concrete mass during pour.

Pouring: Concrete will be placed in a predetermined layering sequence of 600 mm to avoid any
possibility of cold joint formation within the foundation. It is approximately the time spent in each
poured layer will be not exceeded 60 minutes.

Quality Control: Sufficient quality control measures will be set up in place for checking concrete supply
and deliveries throughout the duration of the pour.

Contingency Measures:

a) Large pours cannot readily be stopped due to failure in concrete supply or plant breakdown. For this
reason, adequate back-up and standby facilities in all aspects will be provided.

b.) Formwork: Alghanim will provide sufficient forms and suitable access platforms to execute the work
for the entire pouring stage. Forms will be made of timber studs with 18 mm plywood with lining
surface, and include all necessary support bracings and fixings, etc. The scaffolding access erected will be
in compliance with BS Standard.

c.) Rebar: Rebar will be supplied and fixed in accordance with the latest Rebar will be cut and bent at the
designated yard close to the work site in accordance with the latest bar bending schedules. Prior to
calling off reinforcement, scheduled bars will be checked for discrepancies. To facilitate crane handling
and avoid confusion during installation the specified cut and bent bars will be clearly grouped, bundled
and tagged for identification before transporting to the workface. Rebar will be placed at a designated
lay-down space and each tagged bundle will be properly segregated for easy retrieval and handling once
installation of rebar starts. Following identification, rebar will be distributed either manually and/or by
mobile crane directly to their final fixing location in line with the bar installation sequence. concrete
pouring will only be executed during dry weather to avoid the possibility of stoppage due to rain. In
addition in case of high temperature during the pouring day is encountered the pouring is preferred to
be carried out during the night time. In case of sudden rain, plastic sheeting or canvas will be used to
cover the concrete slab surface yet to set during concrete pouring. The plastic sheets will be provided
sufficiently both for emergency case of sudden rain and for fully cover the whole concrete surface
immediately once the concrete is reached its initial set. Pre-pour inspection of the rebar, form panels,
embedded items and construction joints will be carried out before concrete pouring. Three (3) concrete
pumps will be engaged for concrete pouring (See appendix 1). The concrete pump arrangement will be
prior arrangement for their highest efficiency when the concrete placement is to be carried. Internal-
type concrete vibrators will be used for concrete compaction during concrete placing to ensure
adequate vibration during the entire pouring stage.

d.) Concrete: Due to one-go casting of each raft foundations. The plastic sheet, burlap and fiberglass
insulation will be used for curing purposes. This will be done immediately once the concrete is reached
its stiffening time by fully cover the whole concrete surface onto the whole area and sides to prevent
concrete temperature loss too quick and result high temperature differential between the surface and
at the middle. Care must be taken during the entire curing for 10 days to ensure by reading its
temperature by a thermocouple that the temperature at the middle of the concrete is low enough to
result the difference of temperature in comparison with the surface not exceed 20 C.

4.2 Work Procedure

4.2.1 Survey Setting Out: The setting out will be made at the beginning stage of the work by referring to
the construction drawings. All reference points will be made as necessary for the entire work, develop
method and cross-checking all setting-out will be operations. When principal lines and levels have been
set out, it would be advised to the relevant persons.

4.2.2 Temporary Work Dewatering: As the bottom of the foundation is probably lower than water table
level, therefore dewatering is considered as an important part of the entire execution. To draw off water
the sump pit will be made below the working level. The water contained in the sump pit can be pumped
out by means operation of the suction Pumps connected to the header pipe which connected to the well
points strategically drilled deeper than the bottom of the excavation pit. The outlet of the pumps will
toward the ditch within the vicinity. Slope Protection: It is required that the excavation side slope will be
maintained stabilized for the entire construction period of foundation. In case of deep excavation the
slope will be made to steps to achieve the highest stability. go up/down the working area for
transportation construction resources, temporary removal of excavated soil to stockyard area and
backfilling after concreting works has been finished. Accessible Ramp: The accessible ramp is provided
for machine/equipment Accessible Ladders/Stairs: Ladders/Stairs are to be provided and maintained
sufficiently for workers go up/down the working area during the execution stage of foundation.
Barricade/Sign: Barricade/Sign shall be provided and maintained, as precautionary measures during the
entire stage of construction, to protect the work and workmen. In case of precaution against failure of
lights, barricade will be equipped with suitable reflecting material. Barricade shall be made surrounding
the construction boundary.

4.2.3 Excavation boundary. This area is provided to stabilize of the side slope excavation during the
entire execution stage. Start excavating to reach the required bottom elevation of the foundation in
accordance with the latest construction drawings from one end towards the other end until the entire
excavation is complete. The excavated soil will be relocated to the approved dumping area for
backfilling purpose in the future. From the starting end, continue excavation between the piles rows
until reach the require elevation in accordance with the construction drawing.

4.2.4 Concreting Works:

(a) Setting out: Upon a completion of a compaction of the soil beneath the lean concrete will be carried
out throughout the whole area. A compaction will be conducted properly to reach the requirements
mentioned in the Engineering standard e.g. 95% of the optimum dry density. A surveyor will then
establish the reference lines and mark for the lean concrete boundary by rebar markings. The carpenters
will set the forms using a set of 25x50 mm cross-sectional area steel nails alongside the both edge to the
earth. A set of pegs will be located throughout the placing area to show the placing level thereafter.
After confirming for its conformity e.g. the correctness of level and alignment, the lean concrete will be
poured. After QC inspection of the lean concrete base layer then construction of the foundation will
follow.: • Before work starts Alghanim surveyors will establish baselines and TBM (Temporary Bench
Mark) positions from which co-ordinates and elevations will be taken to set out the foundation works. •
After survey check, set out the perimeter of the raft as specified in the construction drawings.

(b). Formwork: • Formwork installation will commence as soon as the blinding concrete has hardened
sufficiently for trafficking and setting-out points have been surveyed and checked. • Place the formwork
kicker plates made of timber around the foundation outline marked on the blinding and fix down with
concrete nails. • Erect the side forms onto the kicker plates. This can be done using 1.2x2.40 m timber
panel connected together panel by panel at the both side by mean of nails. • Brace the form to the
excavation profile and plumb to true line and level using a plumb bob. • Continue to install the panels
together, one by one onto the timber kicker plate for the complete foundation perimeter. • As work
proceeds ensure forms are connected tightly together and braced against displacement to prevent
leakage of mortar at the joints during placement of the concrete. • Leave open some part of the forms
to provide access for the workmen during rebar and concrete placement. • Mark the concreting surface
level onto the forms.

(c) Rebar • Rebar installation will commence once the formwork is complete. • A mobile crane and
manual workers will be used for rebar installation. • Rebar placement will follow the installation
sequence detailed in the construction shop drawings and bar bending schedules. • Throughout the fixing
procedure Alghanim surveyor will provide all necessary control setting-out points to ensure correct
location, spacing, verticality and cover is maintained during bar placement. • The cover and location of
rebar will be accurately controlled by using sufficient concrete spacers, special support chairs and tying
wire to secure reinforcement in the correct position during succeeding operations. • Cover will comply
with the design requirements indicated on the reinforcement drawings. • Concrete spacers will be
produced to the desired cover with the same strength of concrete foundation. • Bars will be tied with
tire-wire. • All the rebar will be accurately located and securely fixed in the correct position. •
Reinforcement will be inspected prior to, and after erection of formwork, to check quantity, cleanliness,
fixing and cover. • Set the remaining forms and make an opening at the bottom of the selected area to
allow removal of unwanted debris. • Clean the area at the final stage using air compressor and wet
forms with water immediately prior to placing concrete. •

(d) Concrete • Final inspection with FDH JV. • Concrete will be moved from the batcher to the point of
deposition via concrete truck mixers. Adequate back-up supply shall be available prior to calling for
concrete. • It will be placed from the truck mixer via concrete pumps • In the event of a batcher or
pump delay or breakdown, supply of concrete will be maintained by the nominated back-up source and
back-up pump. • Alghanim site Engineer shall ensure that safe access, back-up pump, adequate
vibrators and compressors are available prior to the commencement of concreting. • Concrete delivery
shall be in a closed interval. A minimum of 3 numbers of vibrators shall be used for compaction. •

(e) Concrete Supply Concrete will be as approved trial pumping mix. • Three (3) pumps will be mobilized
for the foundation pour. • Concrete pump will be used for pouring concrete at any one time in a
predetermined rotating sequence around the perimeter of the raft. • Suitable pump truck standing area
and concrete truck delivery area will be constructed at designated locations around the foundation.

(f) Pouring. The following measures will be adopted • A continuous supply and placement of concrete
will be maintained throughout the pouring sequence to avoid any possibility of cold joint formation. •
Concrete lifetime between succeeding layers shall not exceed 120 minutes therefore not taking mixing
time + transportation time + parking time into the account the pouring time should not be exceeded 60
minutes , to prevent a formation of cold joint. • Thickness of pouring layers is 600 mm approximately
e.g. 3 layers in total for thickness of 1650 mm. • Pouring concrete will begin with three (3) pumps
working simultaneously together from the deepest area of 1650 mm and the three (3) pumps will be
simultaneously pumping going towards the 1250mm and 600mm • Successive batches of concrete will
be placed on the edge of previous batches to maintain progressive filling of each layer without
segregation. • The two pumps are set up in designated pouring locations around the perimeter of the
foundation and rotated in a predetermined sequence as the pour progresses. • The rotating pump
sequence is repeated until the foundation pour is complete. • The leading edge of each layer should not
be vibrated until being covered with fresh concrete to avoid ‘segregation and bleeding out’ at the face. •
The elevation of the concrete pouring will be controlled with string among the center surround the
interior circumference

4.3 Test and Monitoring of the Concrete Mass after Poured As soon as the concrete has reached its
stiffening time approximately 1 hour after pre-molded contraction joint forms shall be laid as per
approved drawings. Power trowel finishing shall commence immediately. A set of plastic sheet and
burlap will be covered fully the concrete surface. Fiberglass insulation with 4” thickness is filled fully
onto the whole area where the plastics sheet and burlap cover sits. The plastics cover and the side forms
will be maintained for a couple weeks until the temperature differential at any selected points in the
mass concrete are not exceeded 20 C. To ensure that the temperature differential will be controlled a
set of measuring apparatus will be set (Refer to appendix 2). The measurement purposes are to finding
the temperature development within the concrete mass. The results will show peak temperature and
the temperature differential for such measuring points. As previously explained, sets of thermocouples
will be installed and embedded to the concrete at the bottom, middle and top e.g. top and bottom sets
will be approximately 50 cm of measuring from the edges. The heat generated will be converted to the
circuit and sent to the data logger which will record and show information of temperature measure. In
general case the temperature differential at any selected points should not exceed 33 C. The maximum
temperature of mass concrete will peak at 48 hours after pour and will be constant for 7 days and will
decrease to the air temperature after 14 days

Equipment Installation: Temperatures will be measured at 4 levels e.g. ambient, top, middle and
bottom. The end of each thermocouple wire(s) were fixed to the designated position to the concrete
mass prior to pouring. The others ends were linked to the rear panel of the data logger which is set to
read the temperature at every 30 minutes for at least 3 days.