PENSWASTAAN PENYELENGGARAAN JALAN JALAN PERSEKUTUAN DI

SEMENANJUNG MALAYSIA (ZON SELATAN)

METHOD OF STATEMENT FOR INSTALLATION OF BOX CULVERT

1.0

OBJECTIVE
1.1This method statement is to describe the outline construction methods for
the installation of in-situ Box Culvert structure across the road.

2.0

3.0

LIST OF EQUIPMENT AND MECHINERIES

2.1

The following equipment and machineries shall be used,

Hydraulic Excavator

Mobile Crane

Pile Rig

Ready - made concrete/ concrete mixer

Welding Set

Compactor Roller

Backhoe

Portable Water Pump

Haulage tippers for disposal of spoils

Small tools

Site Engineer

Site Supervisor

Survey team & equipment

CONSTRUCTION METHODS
3.1

Introduction
3.1.1 This method statement applies to all personnel involved in the
construction

and

supervision

of

the

works

including

the

Consultants site staff required for inspection and approval of

the works.

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3.1.2

Material for permanent construction such as concrete mix,

reinforcement etc shall be submitted by the Site Engineer in the
form of samples, technical brochures and all approvals in
writing

to

be

obtained

from

the

consultant

prior

to

commencement of the works.

3.1.3 The invert level of the box culvert at inlet and outlet points shall
be determined using survey equipment and marked at site on
timber peg for easy reference.
3.1.4 The Survey Team shall ensure that all setting out works are in
order. Survey field data for later reproduction of as-built
drawings shall be kept and documented by the supervisor.
3.1.5 Backfilling materials to be used as bedding or backfilling
(crusher run, sand) shall be stockpiled at strategic area before
laying works commencing.

3.2

Traffic Management
3.2.1 The installation of traffic safety devices shall follow the
approved Traffic Management Plan. The devices and signboards
must comply with the specifications.
3.2.2 Prior to commencement of physical works, traffic management
and all lane closure programs shall be checked and approved by
respective

Traffic

Safety

Officer

before

the

construction

activities can commence.

3.2.3 The traffic team member must wear suitable clothing to ensure
they can be seen clearly by the road users.
3.2.4 Flagman to be stationed at both ends of the road closure to
guide the road users and to control the flow of traffic.

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3.3

Cutting of Road Surface

3.3.1 The first step is to demarcate the excavation area. Lines are
drawn on the road surface to mark the width of the trench.
3.3.2 Normally the trench width will be slightly wider (i.e 600mm on
each side) than the width of the Box-culvert to be installed
works. This will be the working space during laying of BoxCulvert and also for manual compaction of backfilling material.
3.3.3 A breaker will be used to cut the top surface of the road along
the marked lines to ensure the cut section will be neat in
appearance and with less damage to the adjacent road during
the excavation work.

3.4

Excavation
3.4.1 Prior to the excavation works, the area shall probably marked
as a guide to control the longitudinal alignment of the culvert
crossing.
3.4.2 Excavator shall be used for the excavation works as it can
expedite the work progress.
3.4.3 The excavation work must be followed immediately with the
bedding preparation and also laying of the Box-culvert. This is
to avoid excavation wall from collapsing and to control the
water level inside the trench. The length of the excavated
trench shall not be more than 10m.
3.4.4 The supervisor must monitor the excavation work and check the
level from time to time to avoid over excavation and to ensure
the correct gradient for the laying work is achieved.

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3.4.5 Water pump of suitable capacity shall be operating to keep the

excavated trench essentially dried.
3.4.6 The excavated soil shall be stockpiled nearby and shall be used
as backfilling material if found suitable. Unsuitable soil shall be
removed from site a soon as possible.

3.5

Piling Works
3.5.1 Pile need to be supplied by approved pile manufacturer with
SIRIM endorsement with minimum structural capacities and
concrete grade as specified.
3.5.2 Care shall be taken to ensure piles are not damaged or broken
during transportation lifting and handling.
3.5.3 The stock area/ yard shall have sufficient space for handling,
lifting, maneuver of lifting cranes and transportation vehicle.
3.5.4 Before allowing the pile rigs to enter site, ensure there are no
overhead cables or obstructions which could be damaged by
ring movements.
3.5.5 Ensure that the site has been suitably prepared and its level,
and that any services have been clearly identified, protected
and diverted as necessary by the main contractor.
3.5.6 The pile position shall be set out using pins/ pegs.
3.5.7 Two reference steel pins or pegs shall be located equidistant
from the pile center location pin.
3.5.8 The RC pile would then be pitched and positioned into the exact
pile position such that the reference pins/ pegs are equidistant
from the pile face.
3.5.9 Vertical plumb lines to sight the sides of the pile from two
different directions would be used to check and control the
verticality of the piles during driving.

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3.5.10 A carpenter spirit level shall be used regularly during the

course of the piling as an additional measurement to monitor
the verticality of the pile.
3.5.11 A thick hardwood cushion shall be placed at the pile head
during the driving and shall be replaced at regular intervals.
3.5.12 Connection of pile segments shall be done by means of
continuous all round butt weld along the circumferential grove
of mild steel plate of the pile as recommended by supplier.
3.5.13 A full time recorder man shall be attached to the pile-driving
rig to record the blows during the driving process.
3.5.14 The final set of each pile shall be recorded either as the
penetration in mm per 10 blows or as the number of blows
required by set calculation (Hileys Formula).This shall be
submitted prior to the commencement of piling works.
3.5.15 Set of driven piles,
The set for particular site and working load cannot be
established until preliminary piles have been driven and the
driving records checked against the ground conditions assumed
in design. The set may have to be modified as a result of
loading test.
3.5.16 Tolerance in plan position, the maximum permitted deviation of
the pile center from the center points shown on the Drawings
shall not exceed 75mm in any direction.
3.5.17 The maximum permitted deviation of the finished pile from the
vertical is in 1 in 75
3.5.18 When a pile has been driven to the required set, the head of
the pile shall be cut off using the air breaker.
3.5.19 The cut shall be to the level specified or indicated in the
engineers drawing.

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3.6 Preparation for Foundation

3.6.1 The foundation shall be prepared as shown in the drawings and
a joint inspection with the consultant site staff shall carried out
and recorded in the Request for Inspection form.
3.6.2 Dewatering by water pumps may be required to enable a dry
surface for working.
3.6.3 When the excavation level is reached, the soil shall be leveled
and compacted to ensure strong support layer.
3.6.4 Crusher run (hardcore) shall be placed, leveled and compacted
as bedding to support the box culvert.
3.6.5 The supervisor must check the thickness of compacted hardcore
layer and also the gradient to ensure when the culvert was
installed, water will flow in the intended direction.
3.6.6 Where

blinding

immediately

layer

after

the

is

required,

foundation

it

should

preparation

be
has

placed
been

completed to protect it from inclement weather.

3.7
A

In-Situ Box Culvert Construction

Slab
3.7.1 The area of the proposed slab shall be set out with timber
shuttering supported in place to cast the concrete slab.
3.7.2 A minimum 30/20 concrete mix shall be used. This will ensure a
concrete of 30N/mm2 and the biggest aggregate size of 20mm.
3.7.3 The required reinforcement bars shall high tensile bars be
placed in position, ensuring the required cover and the slab
length is maintained.
3.7.4 Place and compact the concrete to the finishing depth, making
sure the concrete is under the channels.
3.7.5 The slab shall be compacted using a vibrating screed and poker
vibrator, to ensure the removal air trapped during the mixing
process.

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Wall
3.7.6

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