Method Statement for Sludge Digestion Tank

Content

1 Introduction
2 Construction Flow Chart
3 Quantity
4 Equipment list
5 Work schedule
6 Work Procedure for Interception Facility
7 Work Procedure of rebar work
8 Work Procedure of rebar work
9 Work Procedure of scaffolding
10 Work Procedure of Concrete work
11 Quality Management
12 Safety Management

Attached Documents
Attachment – 1 Construction Schedule
Attachment – 2 Wire mesh catalogue
Attachment – 3 Step concrete work for SDT
Attachment – 4 Expansion joint material
Attachment – 5 Wall form work drawing and calculation
Attachment – 6 Drawings and calculations for temporary scaffolding
Attachment – 7 Inspection and Testing plan (SDT)
Attachment – 8 Risk assessment
Attachment – 9 FDT plan
0
1
1. Introduction
This method describes ground foundations, pile head treatment, lean concrete placement,
rebar and formwork installation, concrete placement and Sludge Digestion Tank

The method statement consists of site preparation, material supply, quality plan and other
related work to contractor’s responsibility for implementation of the construction work in
accordance with the project’s specification.

1
2. Construction Flow Chart

Summary of construction work flow chart for Sludge Digestion Tank is shown below.
3. Quantity
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
2
 (1) Sludge digestion Tank

Reference quantities for SLS are shown in the table below.

No. Description Unit Quantity
1 Concrete　Works
Gravel Bedding t=20cm ㎡ 301
Leveling Concrete, t=100mm (18N/mm2) m3 29
Reinforced Concrete (24N/mm2) m3 397
Rebar works D14～D25 t 40
Form work ㎡ 1360
Pipe Support ㎡ 870
2 Scaffolding
Scaffolding (Installation/Removal)Prefabricated scaffold m2 367
3 Other Parts
Acrylic paint ㎡ 222
Asphalt roofing installation ㎡ 173
Asphalt roofing sheet ㎡ 173
Concrete for roof protection ㎥ 14
Roof drain fixture φ100 pc 4
Downspout m 17
Manhole Cover(Circular) FRP φ600 pc 3
Handrail(H-1.1m) m 57
Water stop 300mm m 79
Non-slip tile work for stairs m 18
Roof fan 50cm 1000CMH pc 1
Ventilation block window W1000*H800 ㎡ 2
Exterior ladder sus304 =400 m 5
SD-1 W=1800*H2000 pc 1

4 Precast Concrete Pile

Precast Concrete pile φ600 pc 38

※Methods statement for steel handrails, steel stairs and painting (anti-corrosion coating) and
Asphalt roofing are to be submitted separately.

Noted: Quantity will be modified based on actual site condition.

4. Equipment list
List of major equipment are listed below.

3
 No. Description Unit Quantity
1 Surveying Equipment set 1
2 Generator　125KVA set 1
3 Submersible Pump set 2
4 Electric Welding Machine set 1
5 4t truck with crane set 1
6 Concrete Cutting Saw / Concrete Cutter set 1
7 Excavator 0.5 or 0.7/ Long Arm Excavator unit 1
8 Bulldozer 3B set 1
9 Plate Compactor/Tamping Rammer/10t roller set 1
10 Pile pressing Machine unit 1
11 Rough Terrain Crane　25t unit 1
12 Dump Truck unit 2
13 Concrete Pump Car　8t/10t/16t unit 1
14 Truck Mixer 5～6㎥ unit 10
15 Concrete Vibrator　( φ60×1　φ50×2　φ32×1) unit 4
16 Par Loader unit 1

5. Work schedule
Schedule of Sludge digestion Tank shown in Attachment – 1

6. Work Procedure for SDT

1. Excavation up to EL.6.50m

4
 Check the height of the bottom of the excavation and excavate to the bottom sand
(EL.6.5). The excavated sand is transported by pay loader to the temporary area.

2.

Gravel bedding EL6.7,EL7.7,EL8.7

3. Casting Lean concrete EL6.8,EL7.8,EL8.8
4. PHC pile Treatment
As the pile level (EL6.9, EL7.9, EL8.9) is divided into three stages, excavation, gravel
bedding and learn concrete are also carried out in three stages. At each stage, install
bricks are placed on the slope to prevent sand from collapsing.

Cross section

5
 Lean concrete is casting used hopper with a 25 t crane and a 20 t crane.

Plan

20t Crane
Maximum Operation radius is 17m
Hoper(0.5t)+Concrete(0.3㎥:0.71t)=1.21t

25t Crane
Maximum Operation radius is 20m
Hoper(0.5t)+Concrete(0.5㎥:1.2t)=1.7t

6
 Temporary H100×100-beams are installed when casting of the inside of the PHC pile. The
temporary H100×100-beams are used as the supports for scaffolding and supports. After
the top slab has been casting, the H-beam is cut and removed and casting concrete. The
H100×100-beam is installed by a 25t crane

Cross section

H-Beam detail

Plan

7
 5. Casting concrete Base slab EL10.05(Tank side)
Rebars and formwork for the Base slab are installed and concrete is casting by concrete
pump truck. Also install wire mesh 1 m pitch to prevent concrete sliding above the
slope side.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.
Wire mesh catalogue shown in Attachment – 2.
Step concrete work for SDT shown in Attachment – 3
The steps for casting concrete plan are to be submitted separately

Wire mesh plan

Wire mesh Cross section

Working plan

8
After the casting concrete and the formwork is removed, sand is backfilled into the base slab to
level the base of the scaffolding and Support.

Cross section

6. Casting
concrete Base
slab EL9.55(Pump room side)
Rebars and formwork for the base slab are installed and concrete is casting by concrete
pump truck. Water stop material for expansion joints is installed prior to casting and
after the concrete is casting, joint filler material is installed to form the expansion joint.
After concrete is casting on the other side, remove the top joint filler material for
expansion joint and fill with sealant. (Detailed installation method are provided in the
catalog.)
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan
Cross section

Expansion joint detail

Concrete Expansion joint

1: Joint filler(Hydrocell) (XL) Wide=20mm)

9 2:Water stop(Supercast Hydrofoil)(wide=300)
3:Sealant for expansion joint
(Fosroc Nitoseal MS600)

This material catalogue shown in Attachment – 4

 Concrete

7. Casting concrete wall EL12.0(Pump room side)

After casting base slab EL9.55 (Pump room side), rebar and formwork for the wall
(EL12.0) are installed and concrete is casting by concrete pump truck. Expansion joint
water stop is installed only for Below EL11.3.

20mm
Joint material thickness is proposed at 20 mm.

Drawing sheet No 73

※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan
Cross section

EL11.3

10
 After Casting concrete wall EL12.0 (Pump room side), sand backfill around SDT and
northwest side STP area. FDT should be conducted every 500 m3 based on the FDT.
Compaction should be carried out every 30 cm by watering and 10t -roller, but 1 m near
structures that cannot be compacted with a 10-ton roller should be compacted every 15 cm
with a plate compactor or rammer.
※ FDT plan shown in Attachment – 9
.
Sand backfill area

※Access road after September when

the ASB starts will be from the MPB
side (Sand backfill finished for MPB
and ASB) or access road will be
installed on the north side.

: Access road

※FDT is kept more than 90% on the

pavement subgrade at STP area.(From
EL9.3 to EL10.3)

Cross section

8. Casting concrete wall EL 12.85(Tank side)

After install scaffolding along the walls, rebars and formwork for the wall (EL12.85)
are installed and concrete is casting by concrete pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan
Cross section

Scaffolding image

11
9. Casting concrete wall EL13.7(Pump room side)
After casting wall EL12.85 (Tank side), rebar and formwork for the wall (EL13.7) are
installed and concrete is casting by concrete pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan
Cross section

10. Casting concrete middle slab and wall EL12.6(Pump room side)
After casting wall EL13.7 (Pump room side), rebar and formwork for the middle slab
(EL12.6) are installed and concrete is casting by concrete pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.
Cross section
Plan

12
11. Casting concrete wall EL14.35(Tank side)
After casting middle slab EL12.6 (Pump room side), rebar and formwork for the wall
(EL14.35) are installed and concrete is casting by concrete pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan
Cross section

13
 12. Casting concrete top slab EL16.60(Tank side)
After casting wall EL14.35 (Tank side), rebar and formwork for the top slab (EL16.60)
are installed and concrete is casting by concrete pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan
Cross section

13. Casting concrete top slab EL13.95(Pump room side) and top slab opening(Tank side)
After casting top slab EL16.60 (Tank side), rebars and formwork for the top slab
(EL13.95) (Pump room side) and top slab opening (Tank side)are installed and concrete
is casting by concrete pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan
Cross section

14
14. Casting concrete wall of scum storage EL15.6(Pump room side)
After casting top slab EL13.95(Pump room side) and top slab opening (Tank side),
rebar and formwork for the wall (EL15.6) are installed and concrete is casting by
concrete pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan
Cross section

15
15. Casting concrete top slab of scum storage EL15.85(Pump room side)
After casting concrete wall of scum storage EL15.6 (Pump room side), rebar and
formwork for the top slab (EL15.85) are installed and concrete is casting by concrete
pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

Plan

Cross section

16
16. Casting concrete for stairs and middle slab(inside)(Pump room side)
After casting concrete top slab of scum storage (EL15.85), rebar and formwork for
stairs and middle slab are installed and concrete is casting by concrete pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.
Plan

Cross section

17. Casting concrete for stairs(outside) and Hand hole(outside) (Pump room side)
After casting stairs and middle slab (inside), rebar and formwork for stairs and middle
slab (outside) and Hand hole(out side) are installed and concrete is casting by concrete
pump truck.
※The method of installation the rebar, formwork and concrete is in accordance with the
attached work procedures.

17
18. Leakage test up to EL14.8(Tank side)
After casting concrete top slab EL15.85, remove sand from base slab and fill water to
EL14.8 using well water. Then conduct leak check.
Cross section

18
※Methods statement for steel handrails, steel stairs and painting (anti-corrosion coating) and
Asphalt roofing are to be submitted separately.

7. Work Procedure of rebar work

7.1 Material
1） Reinforcement bar strength is SD390.
2） SLS will be used Dia. 14,16,20,22,25
3） The reinforcement steel bar must be free of rust, paint, oil, grease, mud or any
other substance that may prevent adhesion with the concrete, as well as other
elements that may cause corrosion or erosion.
4） The size and length of the reinforcement steel bar should not be less than the
values shown in the submitted drawings.

7.2 Placement and Fastening

1） The reinforcing steel bar shall be placed and fixed precisely in the positions
shown in the drawings with the method approved by the Consultant. At the
principal crossing point, the steel bars must be tied with annealed wire with
diameter greater than 0.8mm，not to cause any displacement.
2） All accessories such as spacer to keep the thickness of covering concrete and
other complementary elements remaining within the concrete shall be placed in
sufficient quantities in the correct position.

19
 (The strength of the spacer shall be equal to or greater than the strength of the
concrete.)
3） The quantity of spacers that are placed in the concrete shall be more than 2
units per 1㎥on the sides of the structure， and more than 4units per 1㎥ on
the bottom surface.
4） Before placing the concrete shall be rapidly reviewed the accuracy of the
placement and cleanliness of the reinforcing bar, and if necessary those must be
adjusted correctly.
5） Unless specified in the Drawings or required by the Consultant, concrete
covering shall meet the requirement shown in the table below, with tolerance
approximately equal ±3mm.

　　　　　　　　　Table. Requirement of thickness of covering concrete

Location Directly contacted with water or soil General
Covering 7cm 5cm

7.3 Joints
1） Joints shall not be permitted except in the places that are shown on the
Drawings and accepted by the Consultant in writing.
2） Joints shall be done by overlapping the ends in a length not shorter than 35
times of the diameter of the steel bar, fastening them with tie wire.
3） Position of joint adjacent rebar shall be provided by shifting to each other.

8. Work Procedure of Form work

8.1 Material for Formwork

1） Plywood (Thickness 12mm)
2） Timber
3） Steel Square pipe
4） Steel Rectangular pipe
5） Steel pipe
6） U-head, jacks base, tie rod, wood plank, and, other accessories

8.2 Structure
1） Forms shall be placed in the shapes, elevations and dimensions designed
adequately for the structure, and shall be so constructed as to prevent
deformation due to load, drying and wetting, vibration and other causes.
2） Forms shall be fitted in accurate alignment to assure surfaces free from
irregularities.
3） Unless otherwise instructed by the Consultant, the Contractor shall use forms
that allow making beveled at the corners of reinforced concrete structure.

20
 4） Forms and joints shall be sufficiently tight to prevent leakage of grout and
cement paste during placing of concrete.
5） The form and brackets shall be installed on a firm ground or reinforced
concrete base, so that they can support the weight and load during the
construction being prohibited untying bundle.
6） Forms shall be structured considering easy installation and dismantling, and
shall be readily removable without impact, shock, or damage to the concrete.
Formwork shall be fixed in correct position according to working drawings.
And dimensions of the form shall be inspected by the Consultant.

8.3 Assembling
1) Studs and walls shall be spaced to prevent distortion of the formed material
2) Forms shall be designed, constructed, and maintained to insure that after their
removal the finished concrete members will have true surface free of offset,
waviness or bulges.
3) In places where the water proof paint is applied on the inside walls, the remover
of formwork shall not be used.

4) Tank side wall form work drawing

Tank side wall form work drawings and calculations shown in Attachment – 5
5) Tank side top slab form work drawing
※Tank side top slab form work drawings and calculations are to be submitted 　
separately.

8.4 Removal
1） When the time of removal of formwork and supports is determined on the basis
of concrete strength tests, removal shall not be started until the concrete has
reached design strength.
2） In principle, the forms are allowed to be removed under the following
compressive strength of concrete;

Part of structure Compressive Strength of

Concrete
Lateral side of base 3.5 N/mm²
Side of pillar, wall ,beam 5.0N/mm²
Bottom of slab, beam 14.0N/mm²
3） After remove formwork, check surface on concrete and repair any problems
with the concrete surface. (Cold Joint, Honey combing, crack, Air void etc.)
※Concrete repair method will be submitted later if necessary.

21
9. Work Procedure of scaffolding

9.1 Assembly
1） Scaffolding is a temporary structure used to support access and working
platform of structure.
2） The component consists of base jack, U-head, load bearing base, scaffold
coupler, and scaffold part.
3） The scaffolding shall be made of safe and appropriate materials maintained in
good condition, with a size and shape sufficient and with endurance necessary
for the works.
4） After the scaffolding is completed, the scaffolding should have a sheet on the
outside.
5） The flooring isn’t using a material deformed, damaged, or corroded
6） The width of the flooring is material more than 40 cm.
7） No damage or corrosion to the taut fittings.
8） No damage or corrosion on joint fittings.
9） The height of the lower is part of the baseboard between 15 cm and 40 cm, or
the baseboard is at least 15 cm high.

22
 10） The handrail properly is attached to the gable end with a
minimum height of 85 cm.
11） Jack-up type bases with fittings and root clamps. And sill
plates are not damaged or corroded.
12） Rootstock must be secured by clamps.
13） Handrails/railing frames should be installed at staircase
openings.

9.2 Temporary scaffolding plan

1） Material for Formwork

① Single pipeφ48.6
② Temporary net
③ Orthogonal clamp
④ Flexible clamp
⑤ Base plate
⑥ Support
⑦ Chain
⑧ Wire
⑨ Frame scaffolding

2） Temporary scaffolding drawing

Drawings and calculations for temporary scaffolding for the wall shown in Attachment
–6

10. Work Procedure of Concrete work

10.1 Concrete Material
Standard Design Strength of Concrete
Class
Item
A B

Minimum compressive strength at 28 days 24 N/mm2 18 N/mm2

Class of Concrete

Item Usage

For all the reinforced concrete structures such as elevated water tank, Reservoir tank,
Class A
valve box etc.

For thrust block, lean-mixed concrete foundation, leveling concrete, pipe supporting base
Class B
etc.

Mix Design
23
 Cement water Sand Rock W/B S/A Admixture Slump Remark
Class
(Kg) (L) (Kg) (Kg) (cc) (cm)

Lean
B 285 180 890 1100 0.63 0.45 1800 10±2.5 Concrete

RC
Structure
A 330 175 870 1090 0.53 0.44 2400 12.5±2.5 Air
Content<4%
10.2 Concrete Casting
1） Position and level of each structures shall be measured from reference point.
2） Before concrete casting, dust or other foreign materials shall be removed from
inside of forms by spreading water, so that it shall be cleaned and keep wet.
3） In order to prevent segregation of concrete, the total time, ranging from the
start of mixing until the completion of the placement, shall not exceed the
standards listed below.

Table. Requirement of total time for placing

Ambient Temperature (Degrees Celsius)
Item
Less than 25 More than 25

Total time ranging from the start of Max. 2.0 hours Max. 1.5 hours
mixing until the completion of the
placement

Actual assume time from the plant to site

①CPAC Plant 7 Chamka Dong (30min)

CPAC Plant 7 Chamka Dong

STP site

②CPAC Plant 12 Boeng Snor (30min)

③CPAC Plant 5 Boeng Snor (30min)

24
 CPAC Plant 12 Boeng Snor
4
STP site

STP site CPAC Plant 10 Prek Ho

）
4） Don’t use concrete that exceeds the above limits.
5） The Contractor shall confirm proper disposition of the forms and reinforcing
bar before casting concrete. In addition, the Contractor shall make a firm
fixing of all the elements, especially not to cause displacement there and the
expansion of the formwork panels at the time of placing concrete.
6） The Contractor shall indicate the height of the concrete to be placed at a time in
the construction plan and present it to the Consultant, except in the case of
small structures that need only one time placing concrete.
※Layers of concrete placement should be 500 mm or less to prevent cold joints.
7） The Contractor must never place the concrete that has started hardening
process. Not allowed to remix the concrete that has started hardening process
adding water.
8） The placed concrete shall not be allowed to move horizontally inside the forms.
9） The Contractor shall place the concrete continuously until placing of the first
layer in the designated area completely finishes.
10） Before placing the concrete, transport equipment and placement and inside the
formwork area should be clean, free off foreign material. The surface of
formwork panels that may absorb water in touch with the concrete shall be
moisturized previously.
11） When the concrete slab is placed on the bottom of water tank, and the placing
of concrete is done dividing several layer for water tank, the water stop bar
made of PVC (Polyvinyl Chloride) shall be placed to avoid water leakage from
these parts.
12） In case that the concrete is placed in more than two layers separately the
concrete for upper layer shall be placed before the concrete of lower layer
begins to harden, so that both layers remain completely incorporated.
13） Before placing concrete, the pump trucks are pumped with a mortar to attach
the mortar to the inner surface of the hose.
14） Concrete placement height from concrete truck hoses and concrete buckets
should be less than1.5 m

25
10.3 Compaction
1） Immediately after placing, each layer shall be compacted with a mechanical
vibrator. The form shall be beaten with hammer for uniform placing.
(Prepare four vibrators φ60 :1nos φ50:2nos φ35:1nos on the site, 　　
including spares.)
2） The number of units and power of the vibrating equipment shall at all times be
adequate to properly consolidate all the concrete. And vibrators are inserted
less than every 50 cm of one layer.
3） If placing concrete in more than two layers separately， concrete in the upper
layer shall be placed carefully installing the vibrator 0.10m below from the top
of existing layer, in principle, before the bottom layer begins to harden, so that
both layers remain incorporated later.
4） After concrete placement, re-vibration is performed after the bleeding is
confirmed
10.4 Construction Joint
1） If the new concrete layer is placed on the concrete already placed, the
Contractor shall completely remove the layer of grout, poor-quality concrete
and loose aggregate grains from the surface of old concrete by chipping an
electric drill also laitance is removed by wire brush, and moisture the surface
sufficiently
2） The area where the new concrete is placed must to be filed down with a wire
brush or by sand blasting, removing surface water. Before placing of new
concrete, the form must be firmly rested.
3） The Contractor shall, present to the Consultant the plan of construction joint
prior to the concrete work for his approval. The location of the construction
joint shall not affect structural characteristics, durability, impermeability and
appearance of the structure.

10.5 Hot weather concrete

1） The concrete temperature at the time of the placement of concrete should not
exceed 35 degrees Celsius. When the concrete temperature exceeds 35 degrees
Celsius at the time of mixing concrete at site, this mixed concrete shall be
rejected and not be used in any permanent structure. We will be plan to cast the
concrete in the evening or morning time to lower the concrete temperature. And
take measures to cool the mixing water with ice to lower the concrete
temperature before mixing. Also water will also be sprayed on the coarse
aggregate and sand to take measures to reduce the temperature of the material.

10.6 Curing
1） After placing the concrete, curing must be performed so that the concrete
maintains the temperature and moisture necessary for the generation of effects
and is not affected by adverse reactions.
2） When a level of tightening becomes enough for working without risk of
damaging the surface the exposed portion shall be covered with a curing tarp or
wet cloth, keeping the wet condition more than 5 days or longer after surface of
concrete become cold.

26
 10.7 Quality Test
1） Parameter for testing
 Concrete Temperature
 Slump
 Air Content
 Unit Volume Weight of water (Only Class A)
 Chloride Content
 Compressive Strength of Test Piece

Location of testing compressive at site Subcontractor office (Northwest side of STP)

WC

No Description
1 Concrete compressive
machine
2 Concrete mold size
3 Pool for curing mold
Specification
Max Capacity: 1000KN
Ram diameter: 180mm
1 Diameter 100mm Height 200mm
2 Diameter 150mm Height 300mm
Size：2950mm×700㎜×700㎜
Pool temperature：27℃~33℃

2） Sampling Test
 The slump test and air content, unless　otherwise directed by the Consultant,
shall be made in principle in each 20m3 of concrete or each structure under
continuous placing.
 The standard value of slump shall be in 5 to 12 cm. The standard value of air
content shall be less than 4.0%.
 The period and the frequency of sampling for testing the compressive strength
test of concrete and controlling the ratio of water and cement, in principle,
and unless otherwise instructed by the Consultant, at least once on the volume
27
 of concrete placed in one day at each site, or once every 20㎥ of concrete
placed continuously, de pending on the importance of the structures and the
magnitude of the work.
 The number of samples shall be six (6) in each sampling. The three (3) of
those shall be tested for 7 days strength and others for 28 days strength.

10.8 Leakage Test for Concrete Structure

1） Preparation and Cleaning
 All water retaining structures shall be carefully cleaned.
2） Execution Test
 Concrete tanks, conduits and channels shall be tested for leakage. Tests
shall be done before the structure is backfilled and before any water
proofing material, if required, is applied.
 Concrete tanks, conduits and channels shall be tested individually. These
shall be kept filled with water for at least three (3) days for the concrete to
absorb water thoroughly. Then, will be tested for leakage.
 No leakage from the concrete tanks, conduits and channels will be allowed.
 Concrete tanks conduits and channels shall be tested individually. After the
water level drops due to concrete water absorption, check for leaks 24
hours.conduct a water surface lowering test for 24 hours, The leakage shall
then be assessed based on any diminution of water level，accounting for
any evaporation losses. The water surface lowering after 24 hours should
be within about 5 mm.
 If any test shows that there is a leakage of any tank, conduit or channel, the
structure shall be emptied and examined and all defects shall be repaired
by grouting, cutting out or remaking joints, as directed, or by any other
approved method. Such tests shall be repeated until there is no leakage any
more.
 Non-potable water (approval water before use from consultant) may be
used for testing, provided that discharge of water after the testing should
not cause any environmental problem.

10.9 Concrete crack prevention and deterrence measures

1） Settling cracks
Cracks due to settlement of concrete under the separator after concrete
placement, cracks caused by buried reinforcement, separator and surface
formwork restraint displacement due to bleeding, and penetrating cracks
around the separator. 60 mm and 40 mm vibrators are available, and the
follow-up vibrators are placed immediately after the concrete is placed and
well vibrated. Inserted into the old concrete and pulled up slowly with
sufficient vibration to allow sufficient air to escape without pulling up too fast
and to prevent penetration cracks from occurring.

2） Separators

28
 Use 9 mm separators and prevent cracking at the separator position, as
bleeding water is a major cause of settlement cracking, taking into account the
speed, height and placing sequence.

3） Surface cracks.
Reticulated cracks that form on the surface due to rapid evaporation of water
from the top surface after the concrete has been placed. If the evaporation of
water from the surface is higher than the rise in bleeding, the surface tends to
dry out and stiffen easily, so start watering immediately after pressing is
completed. Tapping should be carried out immediately after placing as concrete
cracks can occur due to settlement caused by consolidation and bleeding
phenomena. Check the weather and avoid direct sunlight. Prepare sheets, etc.
Prevent the temperature of concrete from rising at the time of placing by
cooling materials such as mixing water and aggregate, and spraying water to
control temperature rise.
If this should occur, the concrete should be re-shaken and recovered by
tamping or other treatment.

4） Cold Joint
The two main causes of cold joints are 'overlaying after the prescribed time'
and 'improper casting', and it is important to control the time interval between
overlaying of the upper and lower layers. Control of placing time and jointing
time as quality control. The planned placing sequence of the placing layers
should be controlled.

5） Honeycomb
Honeycomb occurs due to 'separation of materials' and 'insufficient compaction'
when placing concrete, etc. As countermeasures, the falling height of the
placing should be kept below 1.5 m to prevent separation of materials, the
compaction layer should be kept below 50 cm, and vibrators 60 mm and 40 mm
should be prepared and used for the following. Vibrator placement drawing
blow.

6） Poor joint
Planning times for layers and controlling the implementation time as a
countermeasure against poor joints. Control the joint height (marking on the
vibrator) and use a hose or similar to ensure that the vibrator can be inserted at
the bottom of the joint surface. Insert the vibrator vertically 30 cm spacing. Be
careful not to touch the rebar, steel frame, wiring, and formwork into which the
vibrator is poured.
29
 At this time, if the vibration time is too long, the aggregate will sink to the
bottom and the paste will rise too. Much. Insert the vibrator vertically30cm
spacing. Be careful not to touch the rebar, steel frame, wiring, and formwork
into which the vibrator is poured.
The vibration is applied for 5 to 15 seconds. At this time, if the vibration time is
too long, the aggregate will sink to the bottom and the paste will rise too much.

7） No segregation during concrete

This separation occurs the longer the distance to be moved horizontally, so
concrete casting should not be moved horizontally in the formwork. And
concrete casting height should be less than 1.5m

8） Thermal crack
Concrete is exothermic due to the hydration reaction between cement and
water, and the resulting rise and fall in temperature causes deformation
(expansion and contraction) of the concrete, which, when internally or
externally constrained, causes tensile stress in the concrete and cracking, to
prevent concrete temperatures from rising, check the weather and avoid direct
sunlight. Prepare sheets, etc. Prevent the temperature of concrete from rising at
the time of placing by cooling materials such as mixing water and aggregate
cooled with ice, and spraying water to control temperature rise. Since a
thickness of 50 cm or more is considered mass concrete, more attention should
be paid to temperature control during casting concrete.

11. Quality Management

Inspection and Testing plan(SDT)－see Attachment -7

12. Safety Management

Risk assessment (SDT)　– see Attachment – 8

30