Doc.

No: MMSC/MSBOC/012019/Rev-0

May Modern Steel Construction Co., Ltd.

No.15, 153 Street, Tamwe Township, Yangon, Myanmar.
Phone: +95 5127369, +95 1558851, +95 1557731, Fax: +95 1551969.
Email ID: kmhtwe27@gmail.com, Website: www.maymodernsteel.com.

Method statement for box culvert construction

Project : Yangon Mandalay Railway Improvement (Phase 1)

Client : Myanmar Railways (MR)
Lead consultant : Japan International Cooperation Agency (JICA)
Contractor :
Sub-Contractor : May Modern Steel Construction Co., Ltd.

Revision Record

This table is a record of all revisions of the document identified below by number and title.
All previous revisions are hereby superseded and are to be destroyed.

Rev Date Prepared Checked Approved Description of Revisions

0         Initial issue
           
           

Document Protection Statement

The information and Method statement for production procedure provided herein shall not be
duplicated, disclosed or disseminated by the recipient in whole or in part for any purpose
whatsoever without the prior written permission from May Modern Steel Construction Co., Ltd.

Purpose

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The purpose of this method statement is to define the procedure for the sequence of works for the
cast in place box culvert construction at the Project site location, considering all the necessary
quality and safety aspects of the work activities.

Scope of work

The all process related to the cast in place box culvert construction at the Project site location, which
includes the following process. The main works will include activities such as setting out,
excavations, blinding, reinforcement and formwork, batching, mixing and casting, curing and
backfilling. All works will only commence upon acceptance and/or approval of previously completed
work at every stage of the construction.

Box Culvert Construction Procedure:

The working sequence will be described as the following

01-Project Site setting out, excavations

The Site preparation for cast in place box culvert construction will be carried out before the
mobilization of necessary materials and equipment for construction of box culvert. Prior to the
commencement of the site clearing. The ground surrounding the working area will be leveled
adequate and suitable for good mobility of equipment. a permit to execution of work will be issued
by the Safety officer/site engineer/Supervisor and all persons involved in the task will be fully
briefed.

02-Foundation:

The foundation of box culvert base material is Rail pile (Type 37A) will be installed accordance with
the placing location and dimension as shown on approved working drawing.

03-Rebar Work:

The Reinforcing Steel Bar/Rebar Fabrication takes place in contractor shop floor, Rebar will be
fabricated in accordance with the shape and dimension and bar bend schedules as shown on
approved working drawing. Fabrication of rebar will be carried out by cutting and bending.

The fabrication finished rebar will be made up into bundles and then transported to the construction
site according to the installation schedule. Each bundle of rebar will be shipped with a tag indicating
the relevant information.

There the rebar stirrups are then grouped `in the Casting area and then placed at a specific
predetermined distance with the support provided before fixing at the exact position

Girder pretension strand wire fitting

The Strands will be used as tendons to apply specified stress and here the seven-strand wire of
ASTM A416 Grade 270 and diameter of 12.7mm will be used as per the drawings. Pre-stressing
strands are cut to the appropriate length in the Shop Floor and then packed and sealed neatly to
prevent it from the damage and dust and then moved to the site location. This will ensure that, the

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strands will not have to keep in the open space on the site and also it will not get damaged. The Pre-
Stressing strands are carefully handled at all times to prevent kinks, nicks, bends, or other defects.
The strands will be the same type, size and number specified and located and spaced as shown on
the detail drawings. The strands will be cleaned from all kind dust, dirt or any oil and then inserted
or pushed into the End stressing beam through the end formwork with one strand at a time. All
tendons will be placed in the location as shown in the drawing.

Girder pretension strand wire Stressing

The major part of this production process is the Stressing of tendons with high force, so the grips or
the wedge at the ends will be fix with more care. Stressing anchorage components will be fixed at
the Active end and the Dead end of the Setup. The tendons will be inspected for free of major
bends, cuts or damage. After the complete Setup of Tendon and Inspection, the stress will be
applied at the active end gradually. The gradual stress will be applied at Strands one by one.

Each wire/strand is stressed to the required load using a pressure measurement device on the pump
or a load cell in the jack, calibrated to the actual load in the wire/strand. The wire/strand will not be
overstressed to ensure safety. Periodic checking of the applied load will be carried out by a suitable
method. Stressing of wires/strands will be carried out as prescribed order for the designed pattern.
In certain circumstances, in the absence of a specified order, stressing starts from the center of the
group and works outwards, the operatives will pass the stressing gun between themselves to stress
alternate wires/strands away from the center of the pattern. If staged stressing/elongation is
required, then this will be repeated after an appropriate time has elapsed and bedding of barrels
and wedges is confirmed.

In case any breakage of the stressed strand during the process, the behavior of the strand can’t be
predicted and it will cause serious damage to the workers around. So that, the protection cover will
be installed on the end to ensure the safety of the operators stressing the strands and also during
this period an exclusion zone is imposed and only operatives authorized for stressing will be allowed
in the area, since the integrity of all pretension members is based on the development of uniformly
high bond on all strands and reinforcing, the necessity of clean strands and reinforcing is important
and the same will be maintained.

Girder formwork Mould arrangements

For the construction of precast concrete girders, the Forming will be carried on steel framed
formwork. The mould design and manufacturing will be executed based on Standard design criteria
and Material Specifications of the contractor. However, the overall dimensions and layout are in
general accordance with project requirements. The Mould will be designed in a way that the Force
or the weight of the concrete will not affect the mould or its surface in any way. The design also
ensures that the concrete should get access to the entire needed place for effective compacting.
Installation of Pre-fabricated formwork steel Mould panels will be used for forms. Layout of the
forms will be installed in accordance with design of forms cased on approved working drawings. The
bottom frame of the Formwork will be installed at first and levelled properly and to kept that in the
position and to ensure that there is no dislocation, it will be clipped to the bottom arrangement.
Then the side frames installation will follow the order of installing the center frame first, followed by
the frames of two ends. The same procedure will be followed for the installation of another side

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formwork. The Frames will be fitted up by means of the Bolt & Nuts at the ends. The connection
between the individual frames will be designed in a manner that there should not be any leakage
while casting concrete in the Mould. To Keep the Frames in position and to prevent the dislocation,
the Anchor will be inserted on the side frames. The place for the diaphragm connections will be
covered by fitting the pipe in the required place, which ensures that no concrete will enter into it
while casting the girder.
Temporary support will be installed properly in accordance with design of the form. The Bracing
angle fitting will be installed to support the formwork. All forms will be cleaned, free from dust,
grease or other foreign matter and will be treated with the approved form-release-agent before
installation.
Gap at the joints of the forms will be in-filled by packing to prevent leakage of cement past of casting
concrete. The gap between metal form and supporting beam will be also in-filled with suitable
material such as a cleat to prevent displacement of forms, before the closure of forms, inside of the
forms will be cleaned properly.

After completion of installation of formwork mould panels, the responsible person will check the
formwork mold arrangements, such as levels, surface and overall dimensions of the layout and place
level strips if necessary, to mark the exact level Clearance around formwork mould panels.

Rebar installation procedure

The rebar’s installation procedure will be supervised by the site engineers of the contractor in
accordance with approved working drawings fixing and splicing of rebar will be done by approved
wires. Splicing length and location will be in accordance with working drawing. Ties at intersection of
rebar will be installed sufficiently to prevent dislocation during concrete casting. Rebar will be tied at
all intersections. Fixing by welding will only be carried out if shown on approved working drawing or
as instructed by the Engineer. Installed rebar will be free from rust, dirt, oil or other material that
might reduce the bond.

The supports, chairs and spacers with various shapes and dimensions will be placed underneath or at
the sides of rebar to ensure the correct concrete cover required. The prefabricated rebar cages will
be tied firmly to keep rebar configuration undisturbed during the hoisting operations. The rods for
lifting will be placed as per the drawing provided by the Client. After being placed, all reinforcement
is inspected and approved before the casting process takes place. The positions of the bars, both
during and after the placement of the concrete, must not be altered.

Casting of concrete Girders

The Fresh concrete will be batched from the supplier of concrete. Concrete will be delivered direct
to the site and to be received by Quality Engineer/Supervisor for checking of the required criteria of
concrete. The QC Engineer/Supervisor will make sure the concrete delivered is as per the approved
design mix for the suitable member to be cast.

No concrete shall be placed without the approval. In this process the concrete mix will be designed
to flow around the stressing wires/strands that are placed within a specially shaped mould that
forms the final shape of the Girder. Casting will be carried out layer by layer and casting concrete will
be proceeded from one end going to the opposite end. As the casting of a unit requires more than
one concrete placement, concrete delivery shall be scheduled so that the preceding placement is still

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plastic when the new concrete is placed (to avoid cold joints). Concrete condition will be closely
monitored to avoid concrete to harden before casting the next layer. The new concrete will be
placed within standard time after placing the previous below contact layer. Special care will be taken
to deposit the concrete in its final position in each part of the form.

Compaction will be assisted with an external vibration (Form Vibrator). Vibrators will not be used to
distribute the concrete in the forms. Extreme care will be taken not to damage the wires/strands.
Suitable means will be used for placing concrete without segregation. The concrete mixture will not
be dropped from greater heights, which affect the process or the quality of the Girder. The cast area
or member will be protected by placing barricades to prevent damage to the concrete.

Girders Formwork Mould Dismantling

Precast Pretensioned Concrete Girders steel framed formwork moulds can be removed from an
element when the concrete has achieved its setting time. Removal will be takes place on the next
day of pouring concrete. Removal will be carried out with care in order not to damage the edges of
the element and the embedded rebars (if any).

After removal of the structure member there are some concrete still remain on the bottom flanges
of the Formwork Mould, which may appear as an irregularity on the next Girders. So, tops of the
Formwork Mould will be cleaned properly, thereby it will be kept clean of any possible contaminates
during the next pour of another Concrete Girders structure.

The exposing rebar and the strands will be protected by means of covering it with the suitable
protection to prevent the rebar from the rust while the curing process takes place and also after the
finishing of curing. Extreme care will be taken to cover the opening for the de-bonded strands, which
ensures that there is no way for water to enter into the girder and thereby the strands and the
Reinforcement steel bars inside will be protected from the rusting and other contaminants.

Curing of concrete Girders

After the safe removal of the formwork mould from the concrete girder the curing of the concrete
will be takes place to protect the concrete against loss of moisture required for hydration. The
concrete will be cured by means of covering the concrete with specially stitched wet burlaps or
gunny sacks.

The specially stitched burlaps ensure the efficient contact with the surface of the Concrete girder, so
that all the surface will be cured uniformly. Special care will be taken to ensure that the burlaps are
always wet and the fresh water (no salt water) will be sprayed on the burlaps to make it wet always,
thereby the concrete will be maintained with moisture and kept within the recommended
temperature range by means of using the Tarpaulin sheet covered over the wet burlaps. The use of
the Tarpaulin sheet ensures the efficient curing of the Girder at all time.

Girder pretensioned stress relieving and strand wire cutting

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When concrete girder achieves enough compressive strength, connection between strand wires and
anchors is released and pre-stressed elements will be made. Concrete strength will be checked
before de-stressing and to check for design strength accordance with the concreting procedures, as
approved on the approved shop drawings.

De-stressing must not be undertaken until such time as the concrete has achieved sufficient maturity
to prevent loss of tension. The Cutting of wires/strands will be carried out with care as the
unrestrained ends of the wires/strands have a tendency to retract suddenly, and in the case of
strands can splay out in an unpredictable way. Extreme care will be taken when cutting
wires/strands with the operatives need to stand in a position of safety where the retracting wires
will not strike them upon releasing the stored energy.

In order to reduce the likelihood of the concrete cracking during de-tensioning of the strands, the
Pre-stressing strands will be cut using a symmetrical cutting sequence. Unless otherwise mentioned
in the contract document, strands shall be de-tensioned from the inner most strands to the outer
strands. To avoid sudden transfer of the strand force to the member when cutting pre-stressing
strands with an electric powered cutter, strands will be cut slowly to avoid cutting all of the wires in
the strand at once.

Resource Manpower Requirements

Project Manager Construction Manager

Project Engineer QA/QC Engineer / Inspector

HSE Engineer/Officer Foremen/ Works Supervisor

Pre Tension Technician / Coordinator Helpers (skilled, semi-skilled)

Tools and Equipment requirement

Bolster Hoe
Boning Rods Line and Pins
Bump Cutter Measuring Box
Chain Lewis and Pin, Lewis Pick Axe
Chisel Putty Knife
Crowbar Trowel
Digging Bar Wedge
End Frames Sledge Hammer
Float Spade
Head Pan Straight Edge Brushes
Mono strand stressing Jack /Hydraulic Pump Theodolite /Total station
Earth Rammer Vibrator Dumpy Level
Concrete vibrator Water Level

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Water Tanks Spirit Level, Right Angle, Plumb Bob

Masonry tools (Necessary hand tools) Tamping Rod
Wheel Barrows Slump Cone
Gantry Crane Circular Saw
Launching girders Arrangements Chain Blocks & Ceiling Ropes
Sand Screen Machine Crane Lifting

Material requirements

Item Material Grade Remarks

Concrete C45 fc’ 45 MPa (450 KSC)
Strand ASTM A416 Grade 270, Fpu = 1860 Seven Wire Strands, Ø 12.7mm
Rebar A615 Grade 40, Fy = 275 MPa (2,800 KSC) Ø 12, 16, 20, 25 mm

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Responsibilities for Production and Erection

Project Manager

I. Ensuring that the project works in his zone are carried out in accordance with the project
requirements specified in the relevant specifications, procedures and drawings, considering
safety and quality of the work activities accordance with the project plan.
II. To ensure that all the equipment required to execute the works according to the
construction programmer are available, in good condition, and provide any additional
equipment that might be required.
III. To co-ordinate with the clients, Construction Manager, Project Engineer, Safety Engineer and
Foreman for a safe and proper execution of the works.
IV. To guide specific attention to all safety measures in coordination with the safety
officer/engineer.

Construction Manager
I. Ensure area is ready and safe to start the works.
II. Set up, required equipment and plant through discussion with the Project Manager and
Project Engineer/Works Supervisor.
III. Ensure the works are carried out according to the specification, quality and approved shop
drawings.

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IV. Liaise and co-ordinate with the Project Manager for the agreed sequence of works with
respect to the construction program.
V. Allocation of required manpower through co-ordination with the Project Manager.
VI. Provide the risk assessments for the works in hand.
VII. Take precautionary measures with regards to protecting works from hot weather, wind, rain
and sun.

Project Engineer

I. The engineer will carry out his duties in a manner that will be coordinated by the project
manager on a daily basis, and will ensure proper distribution of the workforce and
equipment at required locations.
II. To be aware of test frequencies related to the formation level.
III. To co-ordinate with the Safety Officer to maintain a safe working and proper housekeeping
of the site. To comply with the safety measures and ensure that all Safety Officer Teams are
aware of the same to prevent accident and loss.
IV. To monitor and check all activities and ensure that works will be carried out according to
specifications, quality and approved drawings.
V. To inform the QC Inspector of the areas ready for inspection.

QA/QC Engineer / Inspector

I. Ensuring that Consultant/Client inspection requests are implemented.

II. Compilation of all necessary quality control checklists
III. Assisting Consultants during the Inspections.
IV. Coordinating with the third party lab regarding tests and results.
V. The control of work performance by means of checking the work before consultants’
inspection and issuing RFIs & punch lists as necessary.
VI. Controlling all inspection activities on-site in line with Inspection Test Plans and Completion
of documentation to verify the work performed.
HSE Engineer/Officer
I. To ensure implementation of all safety measures related to the nature of works being
carried out, and in accordance with the Project Safety Plan.
II. To ensure that all the persons involved in the works are aware of their responsibilities, and
that they have enough understanding of the safety procedures.
III. The safety officer in co-ordination with the Project Manager will ensure that all the
implemented safety measures are effective enough to maintain safe working on the site.

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IV. To maintain continuous inspections of the site activities, advise and train persons on a daily
basis to prevent accidents and personnel injury.
V. To give special concern to housekeeping, and ensure that the site is maintained clean and
tidy.
VI. To ensure all the relevant safety sign boards for different works are in place.
Foremen/ Works Supervisor
I. Ensure the works are progressed in the sequence as agreed with the Project Manager.
II. Liaise with the Project / Construction Manager for the allocation of the work force, ensuring
adequate manpower is available.
III. Liaise with the site manager to ensure all the required plant / materials are available to
construct the works.
IV. Full time supervision will be required to ensure the works are carried out in accordance to
specifications, quality and approved drawings.

Health, Safety, Environment (HSE)

The entire works will be carried out as per the guidelines established in the Project Specific HSE Plan.
The sufficient safety signs to notify public on the construction activities will be maintained without
any need arise and also ensure that the required protections are in place prior to starting work. The
works will start getting approval officially by the Client or Consultant, and Utmost importance will be
given to the safety of personnel and protection of existing above /underground Services. It will be
ensured that the personnel involved are thoroughly aware of the “Contractor”/ Employer Safety
regulations. To achieve the above, the following will also be ensured:

I. Tool Box Meetings will be conducted before starting the works.

II. All personnel will be provided with the suitable Personal Protective Equipment.
III. Site staff to make sure that people use the necessary PPE’s while working at height and
edges.
IV. Required permits will be obtained from the Engineer concerned before starting the works.
V. The area must be clearly barricaded and sign boards must be fixed not to allow movement of
people and traffic.
VI. People should not be allowed to work in the area where stressing jobs are in progress.
VII. Site Engineer/Supervisors must make sure that necessary platforms are available for the
people to perform stressing jobs prior to starting the job.
VIII. All people must be properly trained prior to starting jobs and all hazards must be conveyed
to them by the way of Tool Box meeting.
IX. Jacks used for the job must be of good quality.
X. Site staff must make sure that excess pressure is not exerted during the stressing jobs that
could lead to breakage of strands/tendons.

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