QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

Bottom Slab Concrete Method Statement

Document Section Page Amendment Date 0 30 October 2011 Bottom Slab Concrete Method Statement QA/QC Department

30 Oct. 2011

For approval Description of Status Prepared by Approved by

Revision Date

NORTH JEDDAH PUMPING STATION

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

Contents

1. 2. 3. 4.

Purposes Scope of Work Safety Policy Work Method 4.1. 4.2. 4.3. Work Preparation Work Procedure Test and Monitoring of the Concrete Mass after Pouring

5.

Outline of Sequence

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

1. PURPOSES
This method statement has been prepared to provide a general guide, special Considerations to be given in relation to the concreting of bottom slab for three shafts in NORTH JEDDAH PUMPING STATION Project.

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, 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 all necessary temporary works such as curing method, 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.

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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, and all incidentals necessary to complete the entire works.

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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 machinerys/equipment at site, it was inspected and certified by qualified company (TUV). Periodic Preventive Maintenance will be made on all equipment and machineries. All operators and drivers are equipped with valid drivers/operators license. Only authorized drivers or operators will be allowed to operate machineries or equipment. 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 were inspected.

Personal Protective Equipment:

As usual safety rules in project personal Protective Equipment (PPE) will be issued to all workers such as safety shoes, hardhat, working gloves, safety goggles (if required) and safety harness for workers who will be assigned in elevated places 2.0 meter and above. Wearing of the basic PPE will be enforced fully.

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

4. WORK METHOD
4.1. Works Preparation
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, curing method etc. Concrete Mix Control: It is a preparation against the possible effect to the concrete properties and construction operations. This method defines lists of possible unfavorable effects and prevents practices intended to minimize them. 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 as follows:

a.) General:

using the mix design No. (127/2011/270/32/100) and use of ice as part of mixing water is effective in reducing concrete temperature, because of melting alone, to absorb heat. The sequence is as follows (if required) : (1) Spray cool water for every (30 -60) 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 remeasured whether the temperature is still within the specified tolerance.

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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, 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 patch plant staff to finalize agreement of the proposed concreting procedure. Access: Designated site access routes for concrete supply will be prepared and passage time 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.

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

Supply: Concrete batching plant capacity and numbers of delivery trucks were 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. Tow (2) Patching plant with 80 q.m per hour for each will be prepared. Eight (8) concrete delivery trucks Pouring: Concrete will be placed in a predetermined layering sequence to avoid any possibility of cold joint formation within the foundation. It is approximately about 60 cm in each poured layer. Plant and Labor: A detailed equipment and manpower resources schedule are prepared to ensure sufficient workforce in each pour. 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: 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.) Rebar:

Rebar will be supplied and fixed in accordance with the latest construction design drawings.

Rebar will be supplied cut and bent to the designated yard close to the work site in accordance with the latest bar bending schedules. To facilitate crane handling and avoid confusion during installation the specified cut and bent bars will be clearly grouped, for identification before moving 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 in stages by cranes to their fixing location in line with the bar installation sequence. Due to one-go casting of each layer of bottom slab the 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 (4:00 pm10:00 am). One (1) fixed concrete pump with stationary boom will be engaged for concrete pouring in addition to three (3) crawler cranes 250 ton with three (3) skips with 9 q.m capacities for each for concrete pouring.

d.) Concrete:

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

More three (3) cranes with tow (2) skips will be at the workface for standby and will be on duty when any pouring equipment is broken. The concrete pump, cranes arrangement will be prior arrangement for their highest efficiency when the concrete placement is to be carried. Concrete vibrators will be used for concrete compaction during concrete placing to ensure adequate vibration during the entire pouring stage. The cold water will be used for curing purposes. This will be done immediately once the concrete is finished by fully spray the whole concrete surface with cold water from the chiller of batch plant 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 a week) to ensure that the temperature at the middle of the concrete is low enough to result the difference of temperature in comparison with the surface as the mock up which did for the trial mix.

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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. When principal 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 on level (-42.5) too lower than water table level, therefore dewatering is considered as an important part of the entire execution. To draw off water the three (3) deep wells were made below the working level in each shaft. The water can be pumped out by means operation of the Submersible Pumps at the bottom of wells. The outlet of the pumps will toward the up side balance water tank then to the discharge point.

After finish concreting a steel plug with 2 inch hole and valve will welding in a proper way to the casing of wells then after complete dewatering activities the wells will grouting with a high pressure by cement. Accessible Crane: cranes are to be provided and maintained sufficiently for workers go up/down the working area during the execution stage of bottom slab. Barricade/Sign: Barricade/Sign shall be provided and maintained, as precautionary measures during the entire stage of construction, to protect the work, equipments, workmen and safety of the labors. Barricade was made surrounding the shafts. Lighting: The location will be provided with enough number of tower light for safety and work procedure in case of pouring concrete at night.

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QA/QC Section: Method Statement

Bottom Slab Concrete

4.2.3 Concreting Works: (a) Setting out:

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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. A surveyor will then establish the reference mark for the lean concrete. A set of pegs will be located throughout the placing area to show the placing level thereafter. After confirming for its conformity, the lean concrete will be poured. After QC inspection of the lean concrete base layer then construction of the bottom slab will follow: Before work starts surveyors will establish TBM (Temporary Bench Mark) positions from which co-ordinates and elevations will be taken to set out the bottom slab works. (b) Rebar: Rebar installation will commence simultaneously as the surveying Progresses after lean concrete. Cranes (tower, crawler) 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 surveyor will provide all necessary control setting-out points to ensure correct location, spacing 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, tying wire and pressing couplers 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 bottom slab. Bars will be tied with tire-wire and pressing couplers. All the rebar will be accurately located and fixed in the correct position. Reinforcement will be inspected by site supervision to check quantity, cleanliness, fixing and cover. Clean the area at the final stage using air compressor and wet forms with water immediately prior to placing concrete. After survey check, set out the center of the shaft .

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

( c ) Concrete Final inspection . Concrete will be moved from the batcher to the point of deposition via concrete truck mixers. Adequate back-up supply shall be available. It will be placed from the truck mixer via fixed concrete pump and skips with cranes to maintain a minimum placing rate of 160 cu/m /hr. In the event of a batcher delay or breakdown, supply of concrete will be maintained by the nominated back-up source. The site Engineer shall ensure that safe access, adequate vibrators and compressors are available prior to the commencement of concreting. Concrete delivery will be in a closed interval. A minimum of 5 numbers of 50mm vibrators shall be used for compaction.

(d) Concrete Supply Concrete will be as approved trial mix No.(127/2011/270/32/100). The volume supply for bottom slab is 160 cu-m/hr (for each layer of pour( two (2) separate batching plants of 80 m3/hr capacity each will be used to supply concrete. To meet the demand a detailed study of the transportation times in relation to the number of trucks have been carefully calculated as follows:

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QA/QC Section: Method Statement

Bottom Slab Concrete

Batching Plants Control Plant capacity: 80 m3/hr

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Time/Distance to workface: 5 minutes Transportation Control Mixing and truck loading = 5 minutes Delivery to site = 3 minutes Park/pour set-up = 5 minutes Pumping = 4 minutes Return to plant= 3 minutes Min truck roundtrip time = 20 minutes One (1) truck (9m3) can therefore deliver 60/20 x 9 = 27 m3/hr Minimum number of trucks required to pump 160m3/hr = 160/27= 5.9 6 trucks Total of concrete trucks required to supply 160 cu-m/hr 9 trucks will be available on the site (e) Conveying One (1) fixed pump will be installed for the bottom slab pour. Concrete pump max output 80m3/hr with 24metre horizontal delivery booms. Suitable pump truck standing area and concrete truck delivery area will be constructed at designated locations around the shaft. Three (3) crawler cranes (250 ton) with three (3) skips for 9 cu-m for each will be use for pouring bottom slab.

(f) Pouring A continuous supply and placement of concrete will be maintained throughout the pouring sequence to avoid any possibility of cold joint formation. the time between succeeding layers will be 6 hours. Thickness of pouring layers is 600mm approximately e.g. 3 layers in total. Successive batches of concrete will be placed on the edge of previous batches to maintain progressive filling of each layer without segregation. The elevation of the concrete pouring will be controlled with string among the center and surround the interior circumference.

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

4.3 Test and Monitoring of the bottom slab concrete after Poured As soon as the concreting has finished a cold water will be spread fully the concrete surface. The cold water will be maintained for a week.

5. OUTLINE OF SEQUENCE
To illustrate the previous description this outline of sequence is made as the following steps: 1. Excavation will be carried out, in each shaft till the required level. It should be concentrated closely. 2. Upon a completion of excavation, the bedding soil will be adjusted finally by shewel confirmed by survey. The compaction to the bedding soil will be carried by small compacting roller. Survey will then mark for level. Upon a completion to the above the lean concrete will be poured. 3. Rebar will be preceded. Detailed fixing and erection will be carefully done. 4. A survey works will be made to ensure the correctness installation for rebar's position, level, alignment etc. 5. Upon a confirmation of pre-concrete inspection , the concrete will be poured following the method described on 4.2.3 (c) concrete ,(d) concrete supply ,(e) conveying respectively. When the concrete finish the approved curing compound will be immediately applied thoroughly all the final exposed surface. NORTH JEDDAH PUMPING STATION P a g e | 14

QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

NORTH JEDDAH PUMPING STATION

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

NORTH JEDDAH PUMPING STATION

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

NORTH JEDDAH PUMPING STATION

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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QA/QC Section: Method Statement

Bottom Slab Concrete

ABULJADAYEL CO. FOR MAINTENANCE & CONTRACTING

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