METHOD STATEMENT Page No.
: Page 1 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
METHOD STATEMENT FOR PRECAST POST
TENSIONED I-BEAMS AT :
1)RB011 : KAMPAR – TELUK INTAN (CH 218.608)
- UEC/MS/RB011/POT/012
2)RB012 : JALAN TEMOH – SG. LESONG (CH226.026)
- UEC/MS/RB012/ POT/016
3) BR583 : SG. CHIKUS
- UEC/MS/BR583/ POT/017
Prepared by Date Reviewed by Date Approved by Date
Sheikh Faizal 27/06/02 Mohd Fauzi 27/06/02 B.T Tee 27/06/02
IMPORTANT:
The information contained herein is the proprietary property of UE CONSTRUCTION SDN. BHD.
The holder agrees to the following:
1. Not to reproduce; copy; reveal; publish; or, distribute it in whole or any portion of in without authorisation;
and,
2. To maintain this document in confidence.
METHOD STATEMENT Page No. : Page 2 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
CONTENTS
1.0 SCOPE
2.0 MATERIAL
3.0 EQUIPMENT & RESOURCES
4.0 METHOD
5.0 QUALITY CONTROL PROCEDURE
6.0 HEALTH, SAFETY AND ENVIRONMENT
7.0 TRACK POSSESSION
8.0 SUMMARY OF FORMS
9.0 DOCUMENTATION
a) Appendix 1 - Casting Bed and Stacking Yard
b) Appendix 2 - Construction Sequence
c) Appendix 3 - Production Schedule
d) Appendix 4 - Product Information
e) Appendix 5 - Related Forms
METHOD STATEMENT Page No. : Page 3 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
1.0 SCOPE
This method statement describes the procedures for casting precast post–
tensioned I Beams. This is to include the proper sequencing of works, safety
requirement and logistic plan prior to the commencement of works at RB011 :
Jalan Kampar – Teluk Intan , RB012 : Jalan Temoh – Sg. Lesong and BR583-
Sg. Chikus.
The scope of works shall includes :
a) Casting and curing precast post–tensioned I beams in accordance with
approved shop drawings. These beams are to be casted and prestressed at
a casting yard situated at site.
b) Obtaining the relevant approval from local authorities, if required.
c) Installation of all necessary local traffic management, if required.
2.0 MATERIALS
Materials to be used will be :
a) Ready-mixed concrete G50/20
Ready-mixed concrete to be supplied by approved concrete supplier with
the dry-mix concrete batching plant at 60 m 3/hr capacity or Supermix Sdn
Bhd.
b) Steel reinforcement/tendon bars of various sizes
Steel reinforcement bar to be supplied by Malayawata Steel Berhad,
Perwaja Steel Sdn Bhd, Southern Steel Sdn Bhd or equivalent.
c) Post Tensioning System
The post – tensioning system used will be Genesis Structural System Sdn
Bhd and VSL Engineers Sdn Bhd bonded system for RB011 and RB012
respectively.
d) Compounded mould oil
Compounded mould oil to be supplied by Ssang Yong or equivalent
e) Horncure Curing Compound or equivalent
3.0 EQUIPMENT AND RESOURCES
3.1 Equipment
3.1.1 The following is a list of equipment to be used.
METHOD STATEMENT Page No. : Page 4 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
Item Plant Quantity Usage
a. 20 tons Crane 1 Fixing Mould, Concreting
b. Poker Vibrator and Engine 4 Concreting
c. Bripad 1 Uncoil Prestressing Strands
Cutting Prestressing
d. Disc Cutter 2
Strands
e. Stressing Jack 2 Stressing Cables
Hydraulic Stressing Pump
f. 2 Operating Jack
“CTC”
Mixing Cement Grout And
g. Grout Mixer Cum Pump 1
Grouting
h. 100 mm Test Cube Moulds 6 Making Grouting Test Cubes
i. Cutting Machine 1 Cutting of Reinforcement
j. Bending Machine 1 Bending of Reinforcement
3.1.2 All plants and machinery will be with valid documents or license.
3.2 Manpower
a) Site Engineer
b) Casting Supervisor
c) Minimum 7 labourers
4.0 METHOD
4.1 Work Methodology
Construction Processes – Refer to Attachment 2
Fabrication of Rebars And Tendons.
4.1.1 Reinforcement Bars
A cutting list will be prepared based on the construction drawings in
accordance to the cover and lapping requirement. Rebars for the beams
will be cut and bend at the casting yard.
METHOD STATEMENT Page No. : Page 5 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
4.1.2 Tendons
A cutting list for tendons will similarly be prepared taking into
consideration extra lengths for stressing and dead anchorage. The
required quantities of sheathing, couplers, casting and other
accessories will also be prepared at the same time.
4.1.3 Installation Of Rebars
Once the prefabricated rebar is ready, installation onto the casting bed
shall commence. At the same time, cable supports in the form of short
bars will be tied to the stirrups at the appropriate positions following
the required cable profile. Spacer blocks at the soffit will be installed
and securely tied to the stirrups.
4.1.4 Installation of Tendons
After stirrup cage is ready, sheathing of appropriate size will be
installed and tied to the cable supports using wires. After screwing tight
the coupler, the gap will be taped up to prevent any grout leakage
during concreting. Prefabricated strands are now ready to be installed.
The strands will be pushed in through the dead end of cables.
After all the strands for a cable has been pushed into the sheathing, the
anchor bars at the dead and will now be installed. At the same
instance, grout pipes are also installed.
After all tendons have been installed, the profiles of the cables are once
again checked. The cables’ support should be adjusted if necessary to
maintain the profile within + / - 5mm tolerance.
4.1.5 Fixing of Steel Mould
Before the installation of side mould, live end prestressing casting will
be installed at the box out at the beam end mould. The castings will be
installed with the grouting hole on top. Subsequently, the side moulds
shall be cleaned and mould oil applied to the surface before they are
bolted together. The alignment of the mould will be controlled by
adjusting the turn buckles.
4.1.6 Concreting
Final inspection of rebar and formwork shall be carried out with SE and
recorded in the Pre-concreting checklist (DRB-F-E003).
METHOD STATEMENT Page No. : Page 6 of 13
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UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
Concrete grade 50/20 will be obtained from Supermix Sdn Bhd or other
approved ready mixed concrete suppliers. Concreting will commence
from one end of the beam. The concrete will be hoisted via a mobile
crane, in a concrete bucket, and to be discharge into the mould.
Internal and external poker vibrator powered by petrol engines or air-
compressor will be used to vibrate and compact the concrete.
The top surface of the beam will be trowel level and the surface shall be
kept rough.
8 nos of cubes shall be taken for every 10m3 of concreting works and to
be tested for 7 days, 28 days and 56 days.
4.1.7 Demoulding
The external formwork will be demoulded after 12 hours of casting.
Post-concreting checklist (DRB-F-E013) shall be used to record defects
of the beam (if any).
4.1.8 Curing
After completion of the demoulding of the side form, curing of the beam
will be done by spraying curing compound to the concrete surfaces. The
curing compound will be Horncure or equivalent.
4.1.9 Stressing
The cables will be stressed as per notes stated in the approved shop
drawings. At each stage, the extension against force applied will be
properly recorded in steps of 10Mpa and recorded in the Post-Tensioned
P.C Beam Stressing Record (DRB-F-B005).
Sequence of stressing shall refer to approved shop drawings.
Minimum concrete strength at transfer shall be 40N/mm2.
The actual extension obtained will be checked against the calculated
extension. The difference will be within ± 6% tolerance. All stressing
length of cables will be cut after approval of stressing records.
4.1.10Patching up
After the completion of stressing process, the extra length of tendon
will be cut, leaving approximate 20mm protruding from the anchorage
block. A grout pipe will be fixed into the grout inlet at the live end
METHOD STATEMENT Page No. : Page 7 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
anchorage. The box out will then be patched up properly using the
same grade of concrete as the beam.
4.1.11Grouting Cables
Grout of correct mixture (water cement ratio not exceed 0.45) will be
pumped into the tendon sheath in one continuous operation. Using
clamp, the outlet will be closed when the overflowing grout has attained
the inflow grout consistency. Subsequently the inlet valve will also be
closed. The grout strength at 7 days shall not be less than 17 N/mm 2.
Six numbers of 100mm test cubes will be casted for each grouting
operating and to be tested at 7 days and 28 days at Geolab, Tapah.
Twenty four hours after the grouting operation the beam will be given
final touching up, extra of grout hose out and it is now ready for
launching.
4.2 Handling And Storage
4.2.1 The beams shall be lifted with 2 units of 50mt crane and stock at the
casting yard as per Attachment 1.
5.0 QUALITY CONTROL PROCEDURE
Testing shall follow the procedure laid out in the DRB-HICOM Inspection &
Test Plan.
6.0 HEALTH, SAFETY AND ENVIRONMENT
6.1 Work will be carried out according to the Project Safety Plan.
6.2 Tool box meeting will be carried out on construction area at regular
interval to ensure compliance with the Safety Plan and familiarity with
accident and emergency procedures.
6.3 Conduct safety induction course to workers before commencement of
work.
6.4 Provide PPE to all workers including safety helmet, safety shoe, vest,
ear protector, etc.
6.5 Provide signboards to warn workers and public of dangers associated
with construction works.
METHOD STATEMENT Page No. : Page 8 of 13
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UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
6.6 Advanced traffic warning signs will be positioned in place along and at
entrance of access roads and designated flagman will be used when
working in the vicinity of existing road if required.
6.7 Ensure affected utilities are relocated or protected prior to
commencement of work.
6.8 Water browser will be used to control dust when necessary.
6.9 Inspect all machinery at site and ensure that it has valid document and
is safe to operate.
7.0 TRACK POSSESSION
Not applicable.
8.0 SUMMARY OF FORMS
List of forms to be used for the works is as follows:
a) Pre-Concreting Checklist [DRB-F-E003, Rev 1]
b) Post Tensioned P.C. Beam Stressing Record [DRB-F-B005, Rev 1]
c) Post-Concreting Checklist [DRB-F-E013, Rev 1]
d) Site Concreting Record [DRB-F-E018, Rev 1]
9.0 DOCUMENTATION
a) Appendix 1 - Casting Bed and Stacking Yard
b) Appendix 2 - Construction Sequence
c) Appendix 3 - Production Schedule
d) Appendix 4 - Product Information
e) Appendix 5 - Related Forms
METHOD STATEMENT Page No. : Page 9 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
APPENDIX 1
Casting Bed and Stacking Yard - to be submitted separately at a later
date.
METHOD STATEMENT Page No. : Page 10 of 13
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UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
APPENDIX 2
METHOD STATEMENT Page No. : Page 11 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
APPENDIX 3
Production Schedule - to be submitted separately at a later date.
METHOD STATEMENT Page No. : Page 12 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
APPENDIX 4
METHOD STATEMENT Page No. : Page 13 of 13
Revision : 1
Issued : JUNE 2002
UE Construction Sdn Bhd UEC/MS/POT/001
ELECTRIFIED DOUBLE TRACK PROJECT BETWEEN RAWANG AND IPOH
APPENDIX 5
