Method Statement 8 Oct

METHOD STATEMENT FOR INSTALLATION
1.1 GENERAL
This method statement shall be viewed with the NCRTC document for Method Statement of Slab
Track System for PORR Slab in the Underground Section. The Floating Track Slab with discrete
bearing for the Steel Spring MSS system is supported on the 1st stage concrete/ tunnel invert (U/G
track) by means of a steel spring element to transfer the load to the substructure. These discrete
bearings are all-time accessible from the top and provide advantages for night maintenance. This
Document shall be read in conjunction with latest revisions of all the drawing and documents
indicated in reference.
1.2 SURFACE PREPARATION
The surface of 1st stage concrete tunnel invert (U/G track) shall be cleaned of any loose material,
dust, and debris. There should not be any undulations/ extrusion like nails, metal wire gravels, etc.
exceeding 2-3mm in height, water should not be present on the surface. The location of Steel
Springs shall be marked by GERB personnel and the surface shall be made flat (trowel-finish) within
a tolerance of ± 3 mm.
Fig 1 - Nails on the surface Fig 2 - Concrete Gravels
Fig 3 – First Stage Concrete Area below FST (Black Highlight)
GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

2403, 4th Floor, B-36, ETT Tower-2 E-mail : gerbindia@vsnl.com
Noida Expressway, Sector 132 Website : www.gerb.in
NOIDA – 201 302 (U.P.), INDIA
An ISO 9001:2008 & OHSAS 18001 : 2007 Certified Company
Wholly owned by GERB – Germany
Fig 4 - Dirt removing by Air Blower Fig 5 Surface Grinding for Levelling Undulations
In case top of first stage concrete differs (higher or lower) from the desired the level accounting
tolerance as stated above, same shall be made good to required level by chipping or grouting with
Fosroc Conbextra GP2 or equivalent make and grade in a band of 600 mm wide i.e. 300 mm on
either side of center line of GSI or KYM elements as marked at site and for a full width of 2500 mm
of floating slab i.e. 1250 mm with respect to floating track slab center line as shown in below section.
Fig 6 – Schematic Details for Levelling (600 mm x 2500 mm) at MSS Locations

1.3 DRAINAGE
The track drainage shall be provided on the second stage concrete as per drainage provisions
already considered and shown in project General Arrangement (GA) Drawings. However, in small
stretch in down line and in upline (if so required though not envisaged at this stage), central drain
in first stage concrete shall be provided as per details indicated in GA drawings. Schematic details
shown in Figure below
Details - Z
Figure 7 – Drainage Details for Central Drain in First Stage Concrete
1.4 DE-BONDING SHEET

A debonding sheet customized and supplied by GERB shall be used to prevent bonding of track
slab with the first stage concrete. It shall be laid on the 1st stage concrete and all the joints shall be
taped/ sealed properly to prevent leakage of slurry. This debonding sheet is not required at transition
zone below stiffness transition material.
Fig 8 – Typical Site Picture showing Debonding sheet placed over First Stage Concrete
1.5 REINFORCEMENT
Steel housings shall be marked and placed as per the eneral arrangement drawings under the
supervision of GERB installation engineer. Reinforcement shall then be placed as per the track slab
reinforcement drawings and suitable shuttering / formwork shall be placed at sides and other
opening areas
Fig 9 - Schematic Details of Reinforcement at Site
1.6 SACRIFICIAL FORMWORK /EMBEDDED PLATE
At the end of each FST, suitable notch at each end of the FST is envisaged to install the KYM
steel spring elements. Notch shall be provided as per the dimension details indicated in the

GA Drawings. 10 thick L shape steel plate with lugs shall be provided by others at site and
shall be used as embedded plate as well as formwork for the notch.
KYM elements shall be placed after installation of GSI elements under GERB supervision.
Levelling shall be done using necessary shims to be supplied by GERB.
L Shape Steel
embedment w/ lugs
Plan Section
Fig 10 – Schematic Details of Notch for KYM Elements at each FST end
Section Detail - X
Fig 11 – Sacrificial Formwork/Embedment Plate at each FST end for KYM Element
1.7 LAYING OF TRANSITION MATERIAL

Transition material mat shall be laid directly over first stage concrete. Suitable Tape supplied
by GERB shall be used to cover the joints of transition material sheet from the top as shown
in below Figure. Over the transition material mat, a thin sheet shall be laid covering the full
width of transition material before laying of reinforcements of track slab.
Tape by GERB
Cover Sheet by GERB
1.8 CASTING OF TRACKSLAB
Concreting of floating track slab (second stage concrete) shall be done as per engineering drawings
provided by GERB. It is recommended that the full segment of the slab is cast without interruption
except under unavoidable circumstances.
Needle vibrators may be used to ensure that the required concrete quality is achieved by avoiding
honey-combing in the slab.

1.9 INSTALLATION OF PORR TRACK SLAB
The PORR track slab and the LWR Rails shall be installed and adjusted at 30mm down with respect
to the final designed rail level. During placing of PORR slabs over second stage concrete 2 pieces
of buffer plank shall be placed between 2 PORR slabs at each ends of 2400 long gap over foam
sheet 270mmx2400mmx40 mm thick so that during grouting for PORR slab, lids over the housing
remain accessible post grouting and design gap of 270 mm remains available for ease of opening
the lid in future.
Both foam pieces and buffer plank (preferably wooden) shall be removed after grouting is over.
During the installation of spring elements, the final rail level shall be achieved using shims as per
standard GERB practice. The lifting of the track slab shall be carried out only after curing of grout
and second stage concrete.
Buffer Plank (preferably wooden &

reusable) 270mmx600mmx50mm thick
(by others) placed centrally over 40 mm
thick foam sheet 270mmx2400mm,
40mm thick (by GERB) which shall be
placed over steel housing gap between
PORR Slab

Foam Sheet (TYP) Buffer Plank (TYP)
1.10 ACCESS TO STEEL SPRING ELEMENT
In view of 270 mm gap between PORR slabs, lid of the housing of steel spring element which is
circular in shape matching with housing at top shall be modified slightly at the edges along the
longitudinal direction of track so that total width of lid is reduced slightly by 2 to 3 mm to provide
extra ease while opening of the housing lid in post installation situation. Lid can any way always be
slightly tilted also while opening which is otherwise is not regular event as such.
About 268 mm

1.11 LIFTING OF THE FLOATING TRACK SLAB
The lifting of the floating track slab (second stage concrete) shall be performed only after the
concrete has gained the design strength as per the below installation guidelines
Remove the housing lid, placing of steel spring unit
Lifting process is done by compressing the spring unit with the help of
hydraulic jacks and then shimming to the desired height by hydraulic
jacks and other tools, supplied by GERB on returnable basis.
The Track slab can be adjusted to an accuracy of zero tolerance
Once the final desired rail level is achieved, the shims are locked with a
locking plate and the lid is sealed.
The gaps between the two adjacent sides of track slabs (second stage
concrete with and without MSS/Tunnel wall as the case may be) both in
the longitudinal and lateral direction are covered with an EPDM sheet to
prevent the ingress of any dust particles and debris.

1.12 MANPOWER AND TOOLS
GERB shall provide a “Hydraulic Jacking System” for the lifting and installation of a floating track
slab. This shall also comprise of E-pumps (110, 220 V) or hand pumps, jacking devices, manifolds
with pressure gauges, compression adaptors, and hoses. During installation of Spring units / lifting
of slab, the track contractor shall provide the required workmen for transporting the material to the
location and to assist GERB installation team.
Usually, with 4 to 5 workmen and 2 GERB engineers, a single slab of approximately 100 m can be
installed in one day. More teams can be assigned depending on project schedule requirement.

1.13 REFERENCES
No Description
Dwg/Doc No
1 General Arrangement Drawing with MSS N1351723-01-DN to 08-DN
2 Reinforcement Drawings - Downline N1351723-12 to 35 DN
3 Bar Bending Schedule N1351723/BBS -12 to 35 DN
Dynamic & Static Analysis Report of Floating Track

4 23-1738-A
Slab - FST 2 to 7
Dynamic & Static Analysis Report of Floating Track

5 23-1738-B
Slab - FST 1 & 8
6 Nothing Eastin Coordinates N1351723/DN/NEC

7 Misc Dwg -Steel Embedment details at Notch area N1351723/Misc/Sketch-1
8 General Arrangement Drawing with MSS N1351723- 1 UP to 10-UP
9 Reinforcement Drawings N1351723 - 12 to 40-UP
10 Bar Bending Schedule N1351723/BBS -12 to 40-UP
11 North- East Coordinates N1351723/UP/NEC


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METHOD STATEMENT FOR INSTALLATION

1.2 SURFACE PREPARATION

Fig 1 - Nails on the surface Fig 2 - Concrete Gravels

Fig 3 – First Stage Concrete Area below FST (Black Highlight)

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

Figure 7 – Drainage Details for Central Drain in First Stage Concrete

1.4 DE-BONDING SHEET

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

Fig 9 - Schematic Details of Reinforcement at Site

1.6 SACRIFICIAL FORMWORK /EMBEDDED PLATE

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

1.7 LAYING OF TRANSITION MATERIAL

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

Cover Sheet by GERB

1.8 CASTING OF TRACKSLAB

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

Buffer Plank (preferably wooden &

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

1.10 ACCESS TO STEEL SPRING ELEMENT

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

Remove the housing lid, placing of steel spring unit

The Track slab can be adjusted to an accuracy of zero tolerance

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

Dynamic & Static Analysis Report of Floating Track

Dynamic & Static Analysis Report of Floating Track

6 Nothing Eastin Coordinates N1351723/DN/NEC

GERB Vibration Control Systems Pvt Ltd. Tel : 91-120-4751600

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