METHOD STATEMENT FOR

CONCRETE WORK

COLOMBO CITY CENTRE MIXED USE

DEVELOPMENT PROJECT

AT

NO: -137,

SIR TAMES PEIRIS MAWATHA, COLOMBO -02

Sanken Construction (Pvt) Ltd.

No. 295, Madampitiya Road
Colombo -14
CONTENTS

1.0 OBJECTIVE ..................................................................................................................................... 3

2.0 INTRODUCTION .......................................................................................................................... 3
3.0 MATERIAL, MACHINERY AND EQUIPMENT ...................................................................... 3
3.1. Material ....................................................................................................................................... 3
3.2. Machinery and Equipment ...................................................................................................... 3
4.0 RESPONSIBILITIES ....................................................................................................................... 4
5.0 WORK DESCRIPTION FLOW CHART ...................................................................................... 5
6.0 WORK PROCEDURE .................................................................................................................... 6
6.1 Pile Cap Concreting ................................................................................................................... 6
6.2 Slab and Beam Concreting ........................................................................................................ 6
6.3 Column and Wall Concreting .................................................................................................. 7
7.0 FURTHER CONSIDERATION .................................................................................................... 8
8.0 PROCEDURE OF P CONE REPAIR WORK .............................................................................. 9
9.0 QUALITY ASSURANCE AND QUALITY CHECK.................................................................. 9
9.1 Concrete Sampling & Testing Plan .......................................................................................... 9
9.2. Inspection for Construction ................................................................................................... 10
10.0 SAFETY PLAN ........................................................................................................................... 10
11.0 REFERENCES ............................................................................................................................. 10
12.0 ANNEXURES ............................................................................................................................. 10
12.1 Annexure A – Mixed designsreports............͘͘͘͘͘͘͘͘͘͘͘͘͘͘....................................................... 10
12.2 Annexure B – Quality check forms ...................................................................................... 10

TABLE OF FIGURES

Figure 4.1 Organizational chart…………………………….....…………………………..…………4

Figure 5.1 Work flow chart……………………………………..………………………....…………5
Figure 6.1 Thermo control arrangement for Large Scale Concrete Elements …..……………....6
Figure 6.2 Sketch of concrete pouring using mobile crane …..……………………..….………...7
Figure 6.3 Sketch for vertical element concreting..……………..…………………….……….…...8
Figure 6.4 Poker vibrating sequence for slab …………………………..…………………..…...……9

Method statement for concrete work 2

 METHOD STATEMENT FOR CONCRETE WORK

1.0 OBJECTIVE
The objective of this method statement is to inform the consultants and the client the
relevant methods and procedures that Sanken Construction (Pvt.) Ltd. shall follow for the
concrete casting and to ensure all engineers and workers at the site are following the well-
defined and safe methods and procedures

2.0 INTRODUCTION
Colombo city center Mixed use development project consists of 48 levels as well as an
additional MEP & LMR level, which includes: basement , retails, Car park, Hotels, View
deck, Residents & other facilities. This Method statement describes the procedure of
concrete work for columns, walls, slabs/beams & stairs.

3.0 MATERIAL, MACHINERY AND EQUIPMENT

3.1. Material

1. Ordinary Portland Cement / Pozzolanic Portland cement

2. Aggregates – should be free from clay
3. Water – should be free from minerals
4. Admixtures (The amount is designed by doing Trial mix and trial workability tests)

3.2. Machinery and Equipment

1. Truck Mixers
2. Concrete placing boom / Stationary Pump / Pump Cars
3. Shovel / Mamoty
4. Porker / Shutter Vibrator
5. Level Bar
6. Level Machine and staff
7. Concrete Chute
8. Tower Crane with Bucket
9. Mason Trowel / Power Trowel

Method statement for concrete work 3

4.0 RESPONSIBILITIES
The following figure (figure-4.1) shows the organizational chart.

Figure 4 1- Organizational Chart

Method statement for concrete work 4

 5.0 WORK DESCRIPTION FLOW CHART
The following figure (figure-5.1) shows the work procedure of basement slab.

•Check chipping and cleaning

.

•Close all the opening left for cleaning

.
Prior to concrete pouring
•Inspection and approval for concrete

•Arrangement for concrete

•Testing & sampling

During concrete pouring •Quality of compaction

•Check stability of the f/w (if necessary)

•Surface finish

After concrete pouring •Curing method

•Cube test

Figure 5.1- Work flow Chart

Method statement for concrete work 5

6.0 WORK PROCEDURE

6.1 Pile Cap Concreting

Concreting of pile caps shall be done with self-leveling concrete. The concrete grade of 40
N/mm2 will be used for the PC4, PC5 and PC6 and rest of the pile caps will be concreted
with 50 N/mm2. The relevant mixed designs and test reports are attached with this report
(Please refer Annexure-A). The concreting process will be done with pump car. It shall be
concreted layer wise, and the thickness of concrete layers shall not be exceeded 500mm

6.2 Slab and Beam Concreting

Slab and Beam shall be concreted by using the mobile crane (for below levels) or stationary
pump. The concrete grade of 40 N/mm2 will be used. Concrete shall be poured in to the
Beams and column heads first and then to rest of the slab.

Proper compaction shall be done by using poker vibrators. Level of the slab and the surface
finish shall be maintained while doing the concreting. A careful attention shall be paid to
ensure whether the PT ducts, strands conduits and other service lines are not damaged; and
if there are damages, it shall be informed to the relevant sub-contractor.

After placing concrete

 Shovels and Mammoties will be used to spread out the concrete for Mason to level
the surface properly.
 While two Masons level the concrete, Surveyors and Site Supervisors will be double
checked the level of finished surface.
 When concrete is reaching to its initial set, final trowel finish will be achieved by
Masons
 After 24 hours of concrete pour side forms will be removed. Concrete surface will be
cleaned.
 Just after the concrete setting time, curing shall be carried out; but it shall be
coordinated with the setting out and marking program. For horizontal elements, wet
gunny bags or water ponding with sand barriers are used as curing methodologies.

Method statement for concrete work 6

 Figure 6.2 Sketch of concrete pouring using mobile crane

6.3 Column and Wall Concreting

The concrete grade of 50 N/mm2 and 70N/mm2 will be used for the vertical elements and
shall be cast by using tower crane/mobile crane & bucket in order to avoid concrete
segregation proper compaction shall be carried out by using poker vibrator and the shutter
vibrator. Just after concreting the column or wall, the verticality shall be checked and
corrected. For the curing purpose of vertical element curing agent“Polycure C” will be used.

Figure 6.3 Sketch for vertical element concreting

Method statement for concrete work 7

7.0 FURTHER CONSIDERATION
Concrete works shall be carried out by taking care of following items.

 Ensure that the PT ducts and strands are not damaged during the pour. However,
concrete around the anchorages needs adequate vibration to ensure a safe and sound
seating for the anchorage.

 For this loading with pump, in no case should the free fall of the concrete do not
exceed 500 mm,

 Concrete should be placed such a way that cold joints will not be formed.

 Polythene sheets or plastic canopies will be kept standby to use in sudden rain.

 Carpenters and Bar Benders will be kept standby to work in an unforeseen situation

 Final finishing required for concrete surface will be hand trowel semi rough finish

 Compaction will be done with poker vibrators as shown in Figure 6.2, when concrete
is pouring verify the slab concrete is thoroughly vibrated around the ducts, so that
no honey combs can occur.

Figure 6.4 Poker vibrating sequence for slab

Method statement for concrete work 8

  Verify the test samples are taken and kept on site to accurately represent the strength
of concrete at site conditions.

 Place the concrete in a manner to avoid direct impact to the ducts or displacement of
the ducts during all concrete placement and vibration.

8.0 PROCEDURE OF P CONE REPAIR WORK

 Hack and Remove the P cone cover
 Apply poly zinc to exposed thread bar to act as a protective layer against corrosion.
 In order to prepare the grout 280 mixture, water will be slowly added to grout 280
with a mixing ratio of 25kg of Grout 280(Lanko) to 1-2 liters of water
 Apply the L-bond (bonding agent) coat consisting of 1 part of Davco L-Bond to 2
parts of water.
 Before the L-bond dries, the filling of mixed Grout 280 should be commenced.
 Allow the Grout 280 to cure for a minimum of 48 hours.

9.0 QUALITY ASSURANCE AND QUALITY CHECK

9.1 Concrete Sampling & Testing Plan

 The concrete trucks must be stopped at the check point for the inspection of slump
test, temperature check and to obtain sample cubes for test.
 Eight numbers of specimens shall be made from each batch.
 For large volume of concrete, one set of specimen shall be taken every 50 meter cube;

 Three cubes will be tested after seven days curing and another three cubes to be
tested in 28 days and rest two cubes will be tested if 28th day strength of concrete is
not at a satisfactory level.

 For PT slabs extra three cubes shall be taken to test in three days.

Method statement for concrete work 9

9.2. Inspection for Construction

 Inspection shall be carried out by the Site Engineers along with QA/QC Engineer as
per the standards and specifications.
 After removal of formwork the element shall be checked for level dimension and
surface defects, any non-conformity will be brought to attention of QAQC engineer
before rectification.
 Inspection shall be carried out while progressing of the work & approval shall be
granted without affecting to the progress of the work.
 Check lists reports will be provided to the Quality Assurance/controlling engineer
(please refer Annexure-B)

10.0 SAFETY PLAN

 All works shall comply with safety procedure or instruction set out in project safety
plan
 Basic PPE to be worn by all staff and laborers.
 Trained operator would be engaged to control or operate heavy equipment machine.
 Provide sufficient lighting whenever night casting

Refer the Sanken Lanka Safety Manual for other safety precaution and regulations.

11.0 REFERENCES
 Structural Specifications
 BS Standard

12.0 ANNEXURES

12.1 Annexure A – Mixed designs reports

12.2 Annexure B – Quality check forms

Method statement for concrete work 10

Annexure A
Doc.No. 7/R/B-2
Revision. 01
Date . 31/12/2011.
Design No. : 40N/60/20/SKCC-01 CONCRETE MIX DESIGN DATA Page. 01 of 01

( British Method of Design of Normal Concrete Mixes )

SANKEN CONSTRUCTION (PVT) LTD. , NO. 295 , MADAMPITIYA ROAD , COLOMBO 14. TEL. 522221 : FAX . 522942
BATCHING PLANT - TEL. / FAX. 2521834 - 5,2525728.

CONC. GRADE : 40 N / mm 2 DESIGN FLOW SLUMP : 600 ± 50 mm

Stage Item Reference or Values

Calculation
01 1.1 Characteristic strength Specified Compressive 40 N/mm 2 at 28 Days
Proportion defective 5 percent
2 2
1.2 Standard deviation 6.0 N/mm or no data - N/mm
1.3 Margin C1 (k = 1.64 ) 1.64 x 6 = 10 N/mm
2

or Specified - N/mm 2
1.4 Target mean strength C2 40 + 10 = 50 N/mm
2

1.5 Cement type Specified (OPC / SRPC / RHPC/PPC) PPC

1.6 Aggregate type : Coarse Crushed Granite (Holcim PPC)
Aggregate type : Fine Manufacture Sand
1.7 Free water / cement ratio Table 2, Fig 4 -
1.8 Maximum free water / cement ratio Specified 0.36 Use the lower value 0.36

02 2.1 Slump or V-B Specified Flow Slump 600 mm or V-B - s

2.2 Maximum aggregate size Specified 20 mm
2.3 Free water content Table 3 (use as a guide) 146 kg/m 3

03 3.1 Cement content C3 146 / 0.36 = 406 kg/m 3

3
3.2 Maximum cement content Specified 500 kg/m
3
3.3 Minimum cement content Specified - kg/m
use 3.1 if < 3.2
use 3.3 if > 3.1 406 kg/m 3
3.4 Modified free water/cement ratio
0.36

04 4.1 Relative density of aggregate (SSD) 2.69 known / Assumed

4.2 Concrete density Fig 5 = 2470 kg/m 3
4.3 Total aggregate content C4 2470 - 146 - 406 = 1918 kg/m 3

05 5.1 Grading of Fine aggregate Percentage passing 600 m m sieve Maximum 50 Minimum 30 percent
5.2 Proportion of Fine aggregate Fig 6 - to - selected 52 percent
5.3 Fine aggregate content C5 1918 x 0.52 = 997 kg/m 3
5.4 Coarse aggregate content C5 1918 - 997 = kg/m 3
921

Quantities Cement Water Fine Coarse Admixture 1

(kg) (kg) aggregate aggregate Hypercrete HS
(kg) (kg) ( ml )
3
Per 1 m 406 146 997 921 4263

Per trial mix of 0.04 m 3 16.24 5.84 39.88 36.84 170.52

# Cement Brand is Holcim Extra

*** SELF COMPACTING CONCRETE***
* Designed as per BS 5328.

1
 Doc.No. 7/R/B-2
Revision. 01
Design No. : 50N/60/20/SKCC-01 CONCRETE MIX DESIGN DATA Date . 31/12/2011.
Page. 01 of 01
( British Method Of Design Of Normal Concrete Mixes )
SANKEN CONSTRUCTION (PVT) LTD. , NO. 295 , MADAMPITIYA ROAD , COLOMBO 14. TEL. 522221 : FAX. 522942
BATCHING PLANT - TEL. / FAX. 2521834 - 5,2525728.
2
CONC. GRADE : 50 N / mm DESIGN FLOW SLUMP : 600 ± 50 mm

Stage Item Reference or Values

Calculation
01 1.1 Characteristic strength Specified Compressive 50 N/mm 2 at 28 Days
Proportion defective 5 percent
1.2 Standard deviation 6.0 N/mm 2 or no data - N/mm 2
2
1.3 Margin C1 (k = 1.64 ) 1.64 x 6.0 = 10 N/mm
2
1.4 Target mean strength C2 & Para 8.1 50 + 10 = 60 N/mm
1.5 Cement type Specified (PPC / SRPC / RHPC) PPC
1.6 Aggregate type : Coarse Crushed Granite (Holcim PPC)
Aggregate type : Fine Manufacture Sand
1.7 Free water / cement ratio Table 2 , Fig 4 -
1.8 Maximum free water / cement ratio Specified 0.33 Use the lower value 0.33

02 2.1 Slump or V-B Specified flow Slump 600 ± 50 mm or V-B - s

2.2 Maximum aggregate size Specified 20 mm
2.3 Free water content Table 3 & Para 8.2 144
190 kg/m 3

03 3.1 Cement content C3 144 / 0.32 = 450 kg/m 3

3
3.2 Maximum cement content Specified 500 kg/m
3.3 Minimum cement content Specified - kg/m 3
use 3.1 if < 3.2
use 3.3 if > 3.1 450 kg/m 3
3.4 Modified free water/cement ratio 0.32

04 4.1 Relative density of aggregate (SSD) 2.69 known / assumed

4.2 Concrete density Fig 5 & Para 8.3 2470 kg/m 3
4.3 Total aggregate content C4 2470 - 450 - 144 = 1876 kg/m 3

05 5.1 Grading of Fine aggregate Percentage passing 600 m m sieve Maximum 50 Minimum 30 percent
5.2 Proportion of Fine aggregate - to - selected = 54 percent
3
5.3 Fine aggregate content C5 1875 x 0.54 = 1013 kg/m
3
5.4 Coarse aggregate content C5 1875 - 1013 = kg/m
863

Quantities Cement Water Fine Coarse Admixture 1

(kg) (kg) aggregate aggregate Hypercrete HS
(kg) (kg) (ml)
Per m 3 450 144 1013 863 4725

3
Per trial mix of 0.04 m 18.00 5.76 40.52 34.52 180

# Cement Brand is Holcim Extra

# Designed as per BS 5328. *** SELF COMPACTING CONCRETE***

2
 Doc.No. 7/R/B-2
Revision. 01
70N/20/20/SKCC-01 CONCRETE MIX DESIGN DATA Date . 31/12/2011.
Page. 01 of 01
( British Method Of Design Of Normal Concrete Mixes )
SANKEN CONSTRUTION (PVT) LTD. , NO. 295 , MADAMPITIYA ROAD , COLOMBO 14. TEL. 522221 : FAX. 522942
BATCHING PLANT - TEL. / FAX. 2521834 -5, 2525728.
CONC. GRADE : 70 N / mm 2 DESIGN SLUMP 200 mm

Stage Item Reference or Values

Calculation
01 1.1 Characteristic strength Specified Compressive 70 N/mm 2 at 28 Days
Proportion defective 5 percent
1.2 Standard deviation 6.0 N/mm 2 or no data - N/mm 2
1.3 Margin C1 (k = 1.64 ) 1.64 x 9.0 = 15 N/mm 2
1.4 Target mean strength C2 & Para 8.1 70 + 15 = 85 N/mm 2

1.5 Cement type Specified (OPC / SRPC / PPC/CF) PPC+SF

1.6 Aggregate type : Coarse Crushed Granite
Aggregate type : Fine Manufacture Sand
1.7 Free water / cement ratio Table 2 , Fig 4 0.30
1.8 Maximum free water / cement ratio Specified - Use the lower value 0.30

02 2.1 Slump or V-B Specified Slump 200 ± 25 mm or V-B - s

2.2 Maximum aggregate size Specified 20 mm
2.3 Free water content Table 3 & Para 8.2 144 kg/m 3

03 3.1 Cement content C3 144 / 0.24 = 600 kg/m 3

3.2 Maximum Cement content Specified - kg/m 3
3.3 Minimum Cement content Specified 390 kg/m 3
use 3.1 if < 3.2
600 kg/m 3
3.4 Modified free water/cement ratio
0.24

04 4.1 Relative density of aggregate (SSD) 2.70 known / assumed

4.2 Concrete density Fig 5 & Para 8.3 2528 kg/m 3
4.3 Total aggregate content C4 2528 - 600 - 144 = 1784 kg/m 3

05 5.1 Grading of Fine aggregate Percentage passing 600 m m sieve Maximum 50 Minimum 30 percent
5.2 Proportion of Fine aggregate 33 to 51 selected = 36 percent
5.3 Fine aggregate content C5 1784 x 0.364 = 650 kg/m 3
5.4 Coarse aggregate content C5 1784 - 650 = kg/m 3
1134

Quantities Cement Water Fine Coarse Silica Admixture 1

(kg) (kg) aggregate aggregate Fume Hypercrete HS
(kg) (kg) (kg) (ml)
Per m 3 564 144 650 1134 36 6300

Per trial mix of 0.04 m 3 22.56 5.76 26.00 45.36 1.44 252.00

**PPC- 564 kg + SILICA FUME - 36 kg

* Designed as per BS 5328.

Annexure B
SANKEN CONSTRUCTION PVT.LTD. QUALITY RECORDS LEVEL-3

Record No: 7/R/33

Revision No: 02
SANKEN CONSTRUCTION Date of Issue: 31/12/2011
Page No: 1OF1
CONSTRUCTION
PROJECT : ……
SKCC3…………………….
Title: APPROVAL SHEET FOR STRUCTURAL WORK

Sheet No
Ref No
Building Block
Floor Location / Grid
Item
Re Inspection Date Date
Rectification
bar Inspection Time Time
form Inspection Date Date
Rectification
work Inspection Time Time
Result of Inspection by Result of Inspection By Consultant
General Item Contractor First Second
Defects Partially
OK Not OK Defects OK Not OK OK Not OK approved
A Overall 1 Location
2 Grid line
3 Dimension
4 Floor height / level
B Form work 1 Condition
2 Position
3 Fixity / bracing
4 Level
5 Verticallity / Alignment
6 Floor height / level
7 Cleanliness
8 Gaps
9 Openings / Drops
10 Stop boards
C Re bar 1 Position
2 No & Size
3 Anchorage
4 Lapping
5 Cover
6 Cleanliness
7 Spacing
8 Dowel bars / Starter bars
9 Links
D M&E 1 Penetration
Services 2 Conduits

E Others 1 Joint
2 Spacers
3 Drops
4 water proofing
F Concreting 1 Grade
2 Slump
3 No of test cubes
3
4 Estimated volume m
5 Pouring method
6 Concrete finish level
7 Expected Pouring date
8 Pouring time
Date & time of receiving check list by consultant
Date & time of submitting comments of the inspection by consultant

Comments

………………………………………………..
Final Approval by Consultant.

38

Note : This format should not be changed without prior approval of Q.M.S. Organizing Committee 1