Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Method statement for Spillway Hydraulic Surfaces
1. PURPOSE
The purpose of this document is to define the guidelines for the preparation of the concreting work for
Spillway Hydraulic Surfaces of Houay Ka-ouane hydropower’s Main Dam and to ensure the safe execution
of all the concrete works during construction and commission phases of the project so as to eliminate the
risk of injury or damage to personnel, equipment and property.
2. ACRONYM AND DEFINITIONS
EMPLOYER: Houay Ka-ouane Power Sole Company Limited
EMPLOYER’S CONSULTANTS: LJ Hydro Consultancy
PROJECT: Houay Ka-ouane Hydropower
WORK: Main Dam
CONTRACTOR: Trung Hieu Construction Joint Stock Company
3. SCOPE OF WORK
Main Dam Spillway of Houay Ka-ouane Hydropower Project include 3 block, B4 (from Sand discharge
culvert to KN4, B5 (from KN4 to KN5) and B6 (from KN5 to KN6) and left wall and right wall. The Spillway
structures upstream part are Piano key weirs (PKW), midle part are transition and downstream part are
flip bucket, transition and flip bucket installed on ogee structure. 26,953.79m3 concrete is demanded to
fulfill spillway, include 4,064.13 m3 is required for hydraulic surfaces. Numbers of methods to accomplish
various hydraulic surfaces are including, fabricated formwork, screed pipe and manual trowelling
application. Fulfilled surfaces have to be protected of either impact or any pollutants. Errors have to
identify through comparison of surveys for performed surfaces with that of templates before placement,
and then should be corrected in conjunction with adjacent blocks or next lifts.
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
General view of spillway structures, located on riverbed, milde of Main Dam
The Spillway hydraulic surface include 3 blocks:
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Sand discharge culvet
KN4
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
KN4
KN5
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
KN5
KN6
This method statement cover the concreting work of ogee parts, include transitions and flip buckets:
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
KN4
KN5
4. RESPONSIBILITIES
CONTRACTOR is responsible for ensuring that work activities are conducted safely and that personnel are
not placed at risk from the hazards associated with the activities covered by this method statement.
PROJECT MANAGER: Mr. NGUYEN VAN, KIEN
HSSE PERSONNEL: Mr. KHONESAVANH VINAVONG
CONSTRUCTION MANAGER: Mr. TITH PHOMMANY
QAQC PERSONNEL: Mr. PAPATH THAMMAVONG
SITE ENGINEER: Mr. TONGYA VALENGYA
SURVEYOR: LUELAO SOUPOUR
5. METHOD STATEMENT
5.1 Blocking the spillway hydraulic surface
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
The spillway hydraulic surface have three part, upstream part are Piano Key Weirs:
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
CJ1
Milde parts are transition:
CJ1
CJ2
Downstream parts are flip-buckets:
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
CJ2
5.2 SEQUETIAL CONCRETING
5.2.1 Flip bucket parts
B4FB1-B5FB1-B5FB3-B6FB2-B4FB2-B5FB2-B6FB1-B6FB3
B4WB1-BWB2-B5WB1-B5WB2-B5WB3-B6WB1-B6WB2
5.2.2 Transition parts
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
B4T1-B5T1-B5T3-B6T2-B4T2-B5T2-B6T1-B6T3
5.3. Cleaning of Placement Surfaces
Core of dam, underneath stair shaped mass concrete (block 5).
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Stair cleaning as a global prerequisite removes every detrimental materials of previous surface, including
dead concrete, slurries, and etc. To provide more adhesion in between fresh and previously casted
concrete, surface was scratched. Debris is removed by water jet and surface is dried by air jet application
afterwards.
5.4 Spillway Hydraulic Surfaces Joints
Hydraulic Surfaces of spillway floor are benefitted of two joint types, construction joints (CJ), and
contraction joints (CTJ) in cross direction. It is noticeable that CJ are used at longitudinal and vertical
direction as well.
CJ1, CJ2, CJ3 are used at longitudinal construction joint, CSJ KN4, KN5, KN6 are contraction joint indicate
in the figure above.
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
The Contraction Joint will follow detailed design and shop drawing, longitudinal will arrangement the
galvanized waterstop, to side of flip bucket wall exposed to water so no need water stop on vertical
construction joint, cross construction joint will be in no water exposed so no need water stop also.
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
5.5 Fabricated Formwork Assembling
5.5.1 Flip buckets
5.5.1.1 Hydraulic surface
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
5.5.1.2 Flip bucket wall
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
5.5.2 Transition Parts
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
5.5.3 Template Considerations
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Template preparation is accomplished in two phases. Sine a longitudinal water stop is planned 45 cm
under final surface, formwork is installed from stairs’ surface to beneath water stop level at first. In
second phase molds are installed on water stop up to required height, using steel planks.
5.6 Elevation Control
The most common method for execution of hydraulic surfaces is usage of pipe or profile segments as
template. These segments are fabricated proportionate to surface geometric features. Usually
reinforced made T-shape props are constructed so that, on which template could be fixed in proper
spaces, then final surface could be achieved via pulling an metal bar over the section.
Dividing surface into smaller areas, make it possible to ensure flawless, smooth surfaces by plank and
metal trowel application more easily.
Insufficient progress speed because of the extent of hydraulic surfaces, necessity of employment of
experienced skillful persons and strict technical tolerances available made us to speculate of other
supplemental options. Thus appropriate bars were planned to resolve problem and facilitate concrete
placement in different curved surfaces as well.
To ease construction and enhance final surface quality as well, following measures were carried out:
1) Existing anchorage system was used for reinforcement fixation and facade accomplishment as well.
2) Horizontal reinforcement of beneath network template at corresponding level which is responsible to
ensure proper concrete coverage over main reinforcement, was pointy welded to reinforcement.
3) After beneath reinforcement was fulfilled, formatting and concrete casting of first layer was
performed.
4) Points were determined and perforated by pneumatic rotating hammers, and then reinforcement
bars were planted for anchorage. Anchorage reinforcement was applied as chassis for upper network as
well. Seating for working plank spacers and screed pipes by which final surface will be specified, are
secured as well.
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
5) Superjacent reinforcement network is completed at this step. Finally slab spacers’ sittings are
installed on columns mentioned in above article using weld with the aid of surveying. Slab spacers’
seating is liable for establishment plank for concrete placing workers as well as required space for screed
pipes to be installed.
6) Before section preparation and resurveying, screed pipes have to be installed as the last requirement
before concrete placement.
5.6.1 Surface formwork
5.6.2 Screed Pipes Installation
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
5.7 Establishment Plank Spacer for Manual Trowelling
Except for facades provided by formwork, other faces had to smoothly be prepared by skillful persons.
These facades are including;
Metal Trowel facade Ogee, and others structures in which metal trowel is needed after screed pipe
operation. Metal trowel finishing has to be conducted by enough pressure to produce a compact, uniform,
and smooth surface.
This method is favorable for apron concrete placement in flat or moderate slope surfaces. Sequences are
as following:
1) In order to install upper reinforcement, establishment plank spacers, screed pipes by which final surface
is specified, and point excavation pattern has to be proposed.
2) Assigned points are pierced by rotating hammer and φ25 reinforcement segments are planted in as
columns, by which reinforcement network is fixed and establishment plank, as well as its spacer holders
are installed Figure below:
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
3) To complete overhead reinforcement network, space holder seat for slabs are welded to columns.
4) Before section preparation, surveying recheck, and concrete placement in final phase, screed pipes
were installed on space holder seats that are capable to adjust height.
5) After concrete placement and vibration in consecutive layers, workers pull screed bar on screed pipes
and remove excess concrete from top layer like the figure below:
6) Then surface is finished via manual trowelling. Further finishing job is performed in two or three steps
by metal trowel, if it was necessary.
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
7) Screed pipes are brought off the section during finishing procedure and before concrete setting, and
then were replaced by fresh concrete.
8) When masons fulfill their job and concrete completes its setting process, slab is covered by gunny or
plastic sheets and water curing get started afterwards in suitable time.
9) After concrete setting completion, apron space holders are replaced by repair grouts.
5.8 Concrete Placement
Concrete has been transferred to section by mobile crane and bucket for different conditions see Figure
blow:
Concrete was placed and vibrated in an appropriate thickness. When underneath template was filled,
the screed pipe get started.
For concrete placement of slabs following points are contemplated:
1) In order to put rather confined surface of slab at workers disposal, step method was opted for concrete
placement.
2) Fresh concrete is poured in between screed rails and become compacted. Then an metal screed bar is
placed on rails with a person at each end and pulled over the rails until all excess concrete is removed.
First state of finishing job is accomplished by plank trowel afterwards.
3) Surface finishing was complemented in two or three further steps by metal trowel.
4) In an appropriate time during finishing process and before concrete setting time inception, screed pipes
were replaced by fresh concrete.
5) When masons’ labor was fulfilled, whole slab surface was covered by linen or plastic sheets to prevent
fast evaporation. Then water curing has got started in a suitable time afterwards. And finally;
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
6) Apron spacers have to be taken away of slab concrete when its setting was performed and residual
flaws has to be repaired using concrete repair materials.
Concrete placement underneath formwork.
5.9. Concrete Surface Facade
When sceed pipe over concrete, provided surfaces were finished by metal, plank, or plastic trowels.
An establishment plank or platform was hanged under formwork and skillful masons were stand on to
make concrete surface smoothly finished using trowel see figure below:
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
6. QUALITY CONTROL
Since hydraulic surfaces are of utmost importance, following hints are beneficial and have to be
implemented:
1) Formwork, final surface, and water stop position have to be controlled by executive as well as survey
inspectors at each section accurately.
2) Water stop has to be accurately located according to shop drawings. It has to be fixed so that its bulb
could be seen at mold axis from template inside.
3) Final surfaces, on which prospective traffic is probable, have to be protected by sand coverage.
4) Before every screed or template installation, face control at least in 10 cm of near edge is necessary for
adjacent concrete.
5) We have to conform to executive sequences such as preparation, anchor and tool box installation, and
locating installation place for CJ molds before apron as well as face reinforcement preparation according
to shop drawings.
6) Edges as well as horizontal and vertical hydraulic faces should be surveyed before formwork
installation. Then existent errors have to be calculated and appropriate decisions were made.
7) Accomplished surfaces should be sufficiently protected of every impacts and massive vehicles’ traffic.
For instance sand materials are qualified for mutual obligations; impact defense and protecting surface of
slurries or fresh concrete.
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
8) Surveys of executed sections have to be compared with that of molds before concrete placement. Then
probable errors can be identified and corrected in conjunction with adjacent blocks and next lifts for
current block itself.
In order to prevent mold displacement and conform to authorized tolerances for molds, following points
should be considered:
1) Bracket foot has to be completely settled in beneath lift concrete. Mold foot should have minimum
overlap of about 10 cm with beneath lift concrete.
2) Horizontal metal props have to be in same direction to control the shape of hydraulic spillway surface.
3) Seamless wood beams are so beneficial.
4) Thorough consistency between template assembling group and executive team is essential.
5) In order to prevent displacement or shear occurrence for bolts in hydraulic formwork, first hydraulic
lift has to be accomplished using molds with no consoles.
7. SAFETY & ENVIRONMENT
The following key areas of construction shall be adhered by all site personal working on site.
• Personnel Protective Equipment
The personnel protective equipment (PPE) will be provided to the workers onsite includes the following:-
- Safety helmets (hard hat)
- Safety vest
- Safety boots
- Safety glasses
- Dust mask
- Working gloves (if necessary)
- Ear plugs (if necessary)
• House keeping
Housekeeping is an essential part of safety for the daily routine. Housekeeping
would include the following items:-
- Maintain access / egress to all working area.
- Store and stack all construction materials in safe and orderly manner.
- Avoid littering around the jobsite.
• Environment Issues
Main Dam Concreting Method statement for spillway hydraulic surface
Trung Hieu Construction Joint Stock Company
Houay Ka-ouane hydropower project
Temporary drains / sediment pond / silt fence will be constructed and maintained throughout
construction periods to ensure compliance to ESCP requirement. Water browser will be deployed at site
to control the dust surface.
In summation, in order to achieve safe, free risk and healthy working environment that including loss
prevention, every practicable step must be taken by each and everyone engaged in this project site.
Main Dam Concreting Method statement for spillway hydraulic surface
