Method Statement -Concrete Imprint

1.0       OBJECTIVE

To outline the method statements by which concrete imprint is carried out.

2.0       SCOPE

This method statement describes the method and procedures for concrete imprint works of the proposed (your project name)

This method statement details how formwork installation, reinforcement fabrication and concreting works are to be carried out.

3.0       REFERENCES

·      MS ISO 9001 Clause 7.5.1

·      Construction Drawings

·      Project Specifications     

4.0       RESPONSIBILITIES

·         Site Engineer

·         Site Supervisor

5.0       MATERIALS

   

·         Ready mixed concrete,

·         steel rods,

·         BRC,

·         formwork,

·         colour cement as per BQ - ,

·         Imprint mould etc.

6.0       HANDLING AND STORAGE OF MATERIALS

Handling        :  Transport ready mixed concrete to location of pour by mixer trucks. Place concrete by using machinery and equipment outlined below.

Storage         :  Nil

7.0       PLANT, MACHINERY AND EQUIPMENT

·         Mobile cranes

·         Mortar Mixer,

·         Concreting Buckets,

·         Vibrators,

·         Wheelbarrows, etc. as applicable.

 8.0         QUALITY CONTROL PROCEDURE

8.1      GENERAL

The inspection and testing procedure shall be governed by the specifications, approved construction drawings, related codes and standard. Joint inspection shall be carried out between the relevant parties.

Inspection Request Form (IRF) shall be issued at least 24 hours prior to the commencement of the works. Results of the inspection shall be recorded in the Inspection Checklist and shall be signed by respective consultant during the inspection.

8.2       MATERIAL QUALITY REQUIREMENT

All materials must comply with the requirement stated in the specifications, approved construction drawings, related codes and standards. This is to ensure the quality and standard of the works are adhered.

9.0       PREPARATORY WORKS

• Obtain approved architectural drawings, type, specification, colour and pattern for concrete imprint from the client / client’s representative.
• Obtain material submission approval from the resident architect.
• Set out the locations, panel edge lines and levels for formwork along with reference lines.
• Prepare necessary formwork panels to the required dimensions and sizes.
• Coat formwork surface evenly and thinly with release agent.

10.0       WORK METHODOLOGY

          10.1    Formwork

i.           Erect the formwork by providing sufficient struts including necessary bracing.

ii.          Seal gaps in formwork to avoid leakage of concrete.

iii.         Check for the required dimensions as per drawings.

                              

                                                            

       10.2   Reinforcement

i.           Cut the BRC to place it with spacer blocks with required dimensions and shape.

ii.          Place BRC as per drawings and tie them together using GI wire stands.

iii.         Ensure proper lapping and sufficient lap length as per specifications.

iv.        Submit Request for Inspection Form for joint inspection with client / client’s representative using Pre-Concreting Works Inspection Checklist.

v.         On completion of joint inspection, request client / client’s representative to sign on the Request for Inspection Form and file as per Project Filing Index.

                            

           10.3    Concreting Works

i.           Take concrete cube samples for quantity specified in the contract document.

ii.          Mark the location of pour for concrete received on the delivery docket and checklist as reference and identification.

iii.         Provide adequate equipment, machinery and manpower to carry out the concreting works.

iv.        Place concrete on designated locations using mobile crane/excavator with concrete buckets.

v.         Start concreting from a fresh location or a predetermined construction joint and continue uninterrupted up to the next predetermined construction joint or expansion joint.

vi.        If concreting is to commence from a construction joint, roughen the joint before placing the concrete when wire mesh is not available.

vii.       Compact concrete by mechanical vibrators. Ensure that concrete is worked into the corners of the structural members.

viii.      Once concrete is about to set, apply colour cement (hardener) to the concrete surface and then stamping with concrete mould as per manufacture requirement.

ix.        Carry out curing works by applying high efficiency curing compound.

x.         Forming the grooved lines/joints by sawing the hardened concrete with a diamond impregnated rotary bladed machine. Then install sealing compound onto the grooved lines/joints as per specification

xi.        Submit Request for Inspection Form for joint inspection with client / client’s representative using Post-Concreting Works Inspection Checklist.

11.0    HEALTH, SAFETY AND ENVIRONMENT

           11.1 General

  All site personnel shall comply with the HSE procedures and regulations. The site personnel shall be in proper safety working attire at all times during the construction period. Regular maintenance checking shall be conducted to all machineries, plants, equipment and scaffolding as working access at site.    

            11.2  Safety Programme

   Safety and health measures shall be provide to safeguard all people working at  sites and particular attention shall be paid to the areas which are near to the public.All workers shall be equipped with Personal Protective Equipments. Those personnel without PPE shall not be allowed to enter construction site/ work area.

            11.3  Environmental Programme

   Environmental enactments and stipulations shall be observed and there shall be no    open burning. There shall be control of diesel and lubricant spillage, machineries, plants and equipment combustion emission, dust and noise release (where it applies), through appropriate means.

Method Statement -Shear Stud Installation

1.0    OBJECTIVE

Outline the method statement for installation of shear stud for Station Concourse Level.

2.0    SCOPE

This method statement shall be used for shear stud installation works for (your project name).

This method statement is prepared based on current site condition; the method statement is subjected to revise / amendment as if the project site condition changes.

The longitudinal shear connection between the steel section and the concrete is provided by shear connectors, which normally take the form of studs welded to the top of the steel section. All connectors should be capable of resisting uplift forces caused by the tendency for the slab to separate from the beam as it bends. In the case of shear studs this is achieved by the head of the stud. Although shear connectors ensure adequate fixing of the decking to the beam, they are not needed simply to achieve this. They should only be used when it is desired to achieve composite action between the slab and the steel beam.

3.0    RESPONSIBILITY

·       Erection Supervisor

·       Site Supervisor

·       Project Engineer

4.0    MATERIALS

·       Shear stud connectors

 

5.0    PLANT, MACHINERY AND EQUIPMENT

·       Stud welding machine (400kg)

·       Generator set (4 ton)

·       Scaffolding

·       Spot light for night working purpose

·       Sky lift  

6.0    WORK METHODOLOGY

                                 I.       Before installing the shear stud connector, make sure all the painting has been removed and free from dust on top of the steel.

                               II.       Generator (4 ton) will be placed on the ground and stud welding machine (400kg) will locate on top of the hollow core slab.

                              III.       Mark all the shear stud location and make sure check by consultant before start the installation shear stud.

                             IV.       The working radius for the installation shear stud is 18m.

                               V.       Make sure the shear stud gun is perpendicular to the steel surface to ensure the shear stud is in 90 degree.

                             VI.       Once the shear stud is weld on the steel surface, make sure the shear stud is fully welded.

                            VII.       Bend testing should be conducted after the shear stud is weld on the steel beam. Practically 2-5 percent of the shear stud shall be tested and selected by consultant.

7.0    SAFETY ISSUES

For safety reasons there are precautions that need to be taken during installation.

·         Make daily check on all lifting equipment.

·         Make daily checks on all lifting slings.

·         Check that all access equipment is in good condition, including scaffolding and ladders.

·         Check weather conditions, strong winds are dangerous during erection and sheeting.

·         Check overhead electric lines before moving in.

·         Check that all installer have the correct personal safety equipment, helmet, safety shoes, safety harness and etc.

·         Check electric cables for hand tools, discard frayed or split cables.

·         Ensure permanent bracing and flange stays are installed as work proceeds.

·         Ensure that high strength bolts are used where indicated.

·         Maintain a clean and tidy. Thus avoid material loss or accident.

·         Ensure that high strength bolts are correctly tightened.

·         The site shall be kept clear of unnecessary obstruction.

·         First aid kit boxes will be provided at site office.

·         Workers to use safety harness for work at height and provision of scaffolding for access.

Method Statement -Concrete and Pile Repair

1.0 OBJECTIVE

This Work Method Statement is to outline the sequence of activities, method and resources needed for the operation of repairing for structural element.

 

2.0 SCOPE OF WORKS

This method statement shall be used for structural repair for (your project name). Details of the procedures contained herein may be modified based upon actual ground condition and site requirements.

 

3.0 REFERENCES

Ø  Construction Drawings

Ø  Approved Shop Drawings

Ø  Project Specifications

4.0 RESPONSIBILITIES

Ø  Safety Officer/Supervisor

Ø  Site Manager

Ø  Project Engineer

Ø  Site Supervisor

 

5.0 MATERIALS

Ø  Sika MonoTop – 610MY

Ø  Sika MonoTop – R

Ø  Sika Grout 215

Ø  Axel Mortar 302i

6.0 PLANT, MACHINERY AND EQUIPMENT

Mixer machine, wheelbarrows, wire brush, angle grinder, measuring tapes, and other handy tools.

 

7.0 HANDLING AND STORAGE OF MATERIALS

Handling             - Transport of materials shall be carried out by lorry or other suitable machinery.

Storage               - Covered and raised above floor level.

 

8.0 WORK METHODOLOGY 

Method 1 – Re-cast Concrete Structure

              i.            Identify and demarcate the member which needs to be demolished.

            ii.            Erect adequate temporary props to support the affected slab and beam.

           iii.            Demolish the severe concrete structure by means of hacking with pneumatic tools. Ensure the edge of the concrete is clean, sound and free from dirt or dust.

           iv.            Care should be taken not to damage the existing reinforcement.

            v.            Bonding Preparation - Apply one coat of bonding agent Sika Monotop – 610MY at the edge of existing concrete to receive new concrete.

           vi.            Formwork – Erect formworks at the demolished area and secure the formwork with suitable ties.

         vii.            Request for work inspection as per inspection checklist for concreting.

        viii.            Pour the concrete with waterproofing admixture to the prepared formwork. Ensure the concrete has sufficient vibration during concreting.

           ix.            On completion carryout joint inspection to sign on inspection checklist for post concrete.

Method 2 - Concrete Repair- Formwork Grouting

         i.            Based on structural repair layout, mark on existing structure such as concrete honeycomb.

        ii.            Surface Preparation - Cut and hack around at demarcated honeycomb area with suitable tool and equipment.  Ensure all loose concrete must be removed down to sound concrete. (Note: Do not use an impact hammer greater than 15 pound)

      iii.            Clean existing reinforcement and clean/remove debris or loose concrete fragments from the rectification area.

      iv.            Request for work inspection as per inspection checklist for concrete repair.

        v.            Formwork –Install formworks that cover the size of the repair area including place a layer of sponge at the perimeter with suitable tied.

      vi.            Install Inlet and Outlet - Drill two rows (upper and lower part) of 25mmØ holes on the formwork to insert 25mmØ UPVC pipe with spacing of 600mm c/c.

     vii.            Mix the pre-bagged polymer modified shrinkage compensated high strength grout – Sika Grout with adequate water in a mixing drum. 6mm to 10mm aggregate shall be added and mixed with the grout at a ratio of 1:1 by weight to minimize heat generation.

   viii.            The Sika Grout 215 concrete grout is then poured into the pump. Pump the grout into the form work with the lowers injection port until the grout is going out from the upper port.

      ix.            Curing - Leave the formwork in place for at least 24 hours. Upon removal of the formwork, cure the exposed surfaces immediately with water.

        x.            On completion carryout joint inspection to sign on inspection checklist for concrete repair.

 

Method 3 - Concrete Repair- Formwork Grouting for honeycomb depth > 20mm

              i.            Based on structural repair layout, mark on existing structure such as concrete honeycomb.

            ii.            Surface Preparation - Cut and hack around at demarcated honeycomb area with suitable tool and equipment.  Ensure all loose concrete must be removed down to sound concrete. (Note: Do not use an impact hammer greater than 15 pound)

           iii.            Clean existing reinforcement and clean/remove debris or loose concrete fragments from the rectification area.

           iv.            Request for work inspection as per inspection checklist for concrete repair.

            v.            Formwork –Install formworks that cover the size of the repair area including place a layer of sponge at the perimeter with suitable tied.

           vi.            Install Inlet and Outlet - Drill two rows (upper and lower part) of 25mmØ holes on the formwork to insert 25mmØ UPVC pipe with spacing of 600mm c/c.

         vii.            Flowable Sika Grout 215 - Place about 4.0 to 4.4 litres clean water into clean container; add the whole bag of Sika Grout 215 (25kg) while continuously mixing. After mixing, stir lightly with a spatula for few seconds to release any entrapped air.

        viii.            The Sika Grout 215 concrete grout is then poured into the pump. Pump the grout into the formwork with the lowers injection port until the grout is going out from the upper port.

           ix.            Curing - Leave the formwork in place for at least 24 hours. Upon removal of the formwork, cure the exposed surfaces immediately with water.

            x.            On completion carryout joint inspection to sign on inspection checklist for concrete repair.

 

Method 4 - Concrete Hand Patch Repair (for area < 0.5m2 at depth < 20mm)

              i.            Based on structural layout, mark on existing structure such as concrete honeycomb.

            ii.            Cut around demarcated honeycomb area to eliminate feather edge.

           iii.            Surface Preparation - Repair area shall be clean, sound and free from all loosely adhering particles.

           iv.            Bonding Preparation - Apply one coat of bonding agent Sika Monotop – 610MY “wet on wet” to the rectify area.

            v.            Request for work inspection as per inspection checklist for concrete repair.

           vi.            Concrete Mixing - The cement mortar Sika Monotop – R should be mixed in a clean drum. Place 3.4-3.5 litres of water into the drum and add Sika Monotop - R slowly while mixing.

         vii.            Application - Work wet on wet the mixed mortar well into the rectify substrate, using a placing suitable tool, compact well. Steel trowel the final coat if required.

        viii.            On completion carryout joint inspection to sign on inspection checklist for concrete repair.

 

Method 5 – Injection Grouting for Rectification of Spun Pile

              i.            Based on piling layout, mark on the affected pile.

            ii.            Request for work inspection as per inspection checklist for concrete repair.

           iii.            Clean existing reinforcement and clean/remove debris or loose concrete fragments from the rectification area.

           iv.            Flowable Sika Grout 215 - Place about 4.0 to 4.4 litres clean water into clean container; add the whole bag of Sika Grout 215 (25kg) while continuously mixing. After mixing, stir lightly with a spatula for few seconds to release any entrapped air.

            v.            Insert the 75mm UPVC pipe into the pile hole.

           vi.            The Sika Grout 215 concrete grout is then poured into the pipe.

         vii.            Curing – Cover the pile head for at least 24 hours. Upon removal of the cover, cure the exposed surfaces immediately with water.

        viii.            On completion carryout joint inspection to sign on inspection checklist for concrete repair.

 

Method 6 – Pile Head Repair

              i.            Based on piling layout, mark on the affected pile.

            ii.            Request for work inspection as per inspection checklist for concrete repair.

           iii.            Ensure that the base is properly prepared, removed of all loose concrete debris, oil, dirt and is then primed with Axel Primer S at 50 microns DFT for stubborn surface (if any).

           iv.            After the floor is prepared, mix Axel Mortar 301i with Part A and B with a hopper or mixer drill for 5 minutes until the mix is homogeneous. Trowel the mix over the prepared floor with a metal trowel. Use Axel Solvent 914 to clean trowel before each application for smooth finishing.

            v.            After the pile has been hacked or prepared, mix Axel Mortar 302i with a hopper, mixer drill or hand mix (for small quantity) for 5 minutes and then mould the grout to a “moth ball” and press it over the prepared surface. Use a glove and wet it with soap water to even out the grout to a smooth finish.

           vi.            Only use spatula hand mixing for small quantity batching.

 

Method 7 – Broken/Damaged Pile Repair

              i.            Based on piling layout, mark on the affected pile.

            ii.            Request for work inspection as per inspection checklist for concrete repair.

           iii.            Ensure that the base is properly prepared, removed of all loose concrete debris, oil, dirt and is then primed with Axel Primer S at 50 microns DFT for stubborn surface (if any).

           iv.            After the floor is prepared, mix Axel Mortar 301i with Part A and B with a hopper or mixer drill for 5 minutes until the mix is homogeneous. Trowel the mix over the prepared floor with a metal trowel. Use Axel Solvent 914 to clean trowel before each application for smooth finishing.

            v.            After the pile has been hacked or prepared, mix Axel Mortar 302i with a hopper, mixer drill or hand mix (for small quantity) for 5 minutes and then mould the grout to a “moth ball” and press it over the prepared surface. Use a glove and wet it with soap water to even out the grout to a smooth finish.

           vi.            Only use spatula hand mixing for small quantity batching.

 

9.0 HEALTH, SAFETY & ENVIRONMENT PROGRAMME

 

9.1  Health & Safety

Ø  Safety induction to be conducted to all new workers that involved to this activity and safety toolbox meeting shall be conducted every day to remind the workers about concerning the safety.

Ø  All workers shall be provided with PPE (Personal Protective Equipment) and shall be always worn on site. Safety Officer / Safety Supervisor shall ensure all the workers wear all the safety equipment provided.

Ø  All workers shall be advised to report any accident or injury to supervisor.

Ø  Proper and adequate provision of temporary signage’s and barricades at diversion and temporary haul road as necessary (if applicable).

Ø  Permit to work must be applied for night works (if any).

 

9.2  Environment

Ø  All workers shall educate on good environmental management practices and well-disciplined to environment.

Ø  The garbage bin shall be provided at the working area and supervisor shall ensure its must be collected regularly and disposed-off at the approved dumpsite.

Ø  All workers shall ensure that all tools and equipment machinery are in good condition to avoid any oil leakage that could harm to environment.