PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

CONTROLLED COPY NO.:

ISSUED TO NAME: DESIGNATION:

ISSUED BY SIGNATURE/DATE: OWNER: MCC CONTRACTOR: PUNJ LLOYD LIMITED

0 Rev Date Description of Revision

JV Prepared By

JV Checked

Engineer Reviewed By

Engineer Approved By

TABLE OF CONTENTS

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

1. 2. 3. 4. 5. 6. 7 8

SECTION 1 : PURPOSE SECTION 2 : SCOPE SECTION 3 : REFERENCES SECTION 4 : TERMS & DEFINITIONS SECTION 5 : RESPONSIBILITIES SECTION 6 : METHODOLOGY SECTION 7 : HEALTH, SAFETY & ENVIRONMENT SECTION 8 : QUALITY ASSURANCE & QUALITY CONTROL

3 3 3 4 4 5 12 13

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

1.0

SECTION 1: PURPOSE The purpose of the document is to establish uniform work methodology for execution of works related to structures primarily consisting of precast and in-situ concreting works.

2.0

SECTION 2: SCOPE This procedure is applicable to the execution team. It intends to co-relate and control all the tasks needed to be done in order to achieve satisfactory completion of works related to structures including concrete works, for both in-situ and precast concrete.

3.0

SECTION 3: REFERENCES Shall comply with requirements of MoRTH specifications, IRC and BIS specifications and standards for concrete works.

4.0

SECTION 4: TERMS & DEFINITIONS All terms used in the development of this procedure shall be as defined in MoRTH specifications, IRC and BIS specifications and standards. For the purpose of this document the term shall mean mandatory requirement and should mean recommended practices.

5.0

SECTION 5: RESPONSIBILITIES Following are the responsibilities and reporting structure of personnel involved in the scope of the procedure: Project Manager Shall report to the Project General Manager and shall be responsible for overall execution of the project activities as per specifications, within the schedule and as per project quality plan. Shall report to the Project Manager Shall be responsible for overall implementation, monitoring and control of construction activities pertaining to one stretch of the project. Shall report to the Project Manager Shall be responsible for inspection and extent of damage assessment of bridge and Cross Drainage structures Shall be responsible for preparation of plan for execution of repair works and supervision of Jacking operations and

Construction Manager

Construction Manager (Structures,Culvert & Drainage Works)

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

construction activities pertaining to bridge and CD works for the project. Site Engineers Shall report to Construction Manager Shall be responsible for execution and implementation of all site activities related to this procedure. Shall be responsible for concrete pouring. Shall be responsible for giving instruction for pouring of each concrete transit mixer upon clearance from Site QC Inspector. Shall also prepare daily site construction records. Shall report to Project Manager Shall be responsible for overall control and inspection of QC activities. Shall be responsible for performing quality check for taking slump test. Shall be responsible for decision of accepting or rejecting concrete. Shall report to Site Engineer. Shall be responsible for execution and implementation of all site activities related to this procedure for concrete pour under direct supervision of Site Engineer Shall report to the Supervisor Shall be responsible for all shuttering work as per drawings. Shall report to Supervisor Shall be responsible for all reinforcement work. Shall report to the Supervisor Shall be responsible for all Concrete Work.

Engineer QA / QC

Supervisor

Shuttering Foreman

Reinforcement Foreman Concrete Foreman

6.0 6.1

SECTION 6 : METHODOLOGY Materials The main components of concrete and concrete works shall be as follows:

Reinforcement General reinforcement steel shall be hot rolled high yield bars complying with the requirements of BIS

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

All reinforcement shall be free from loose scale, rust oil, grease or any other matter that may impair the bond between concrete and the reinforcement or cause corrosion of either. A copy of manufacturers test certificates for each consignment of reinforcement shall be submitted to engineer. Cement Cement shall be of standard brand and Ordinary Portland cement 43 grade confirming to BIS shall be used At the time of use, all cement shall be free flowing and free from lumps. Aggregates Aggregates suitable for the manufacture of concrete shall not contain any deleterious, organic or other harmful matter. Aggregates shall consist of crushed, hard, clean, durable rock or washed sand or a combination thereof, obtained from approved sources and having the properties as per the relevant BIS standards Water Water for all construction activities except the sub grade shall be clean and free from harmful matter. In particular, the sulphate content and chloride content shall be within the permissible limits. Admixtures Admixtures of approved brands, manufacturers and chemical compositions shall be used whenever required. Tying Wire Tying wire for reinforcement work conforming to BIS specifications shall be used for binding reinforcements in concrete work. Tying wire shall be 1.6mm diameter soft annealed iron wire.

6.2

Ready Mixed Concrete All requirements of this specification in respect of materials, testing, storage, batching and mixing, shall apply equally to the source and supply of RMC.

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

6.3

Design of Concrete Mixes The proposed concrete mix design shall include details of cement type, cement content, size and grading of aggregate, water content, design slump measured, manufacturer of air entraining agent and the required dose per m3, manufacturer of plasticizers, dispersing agent or any other admixture and the required dose per m3. After the concrete mix design, trial mix for each class of concrete and tests shall be carried out for authentication of the design mixes to be used in production of concrete.

6.4

Batching and Mixing of Concrete The cement and aggregates shall be batched by weight. Water shall be measured by volume / weight and admixture shall be dispensed by electronically controlled flow meter. The measured material shall be batched and charged into mixer so as to prevent loss of any material. The normal drum capacity of the mixer shall not be exceeded. After mixing for the required time, each batch shall be discharged completely from the mixer.

6.5

Placing Concrete Concrete operations shall be planned such that a bay or panel is completed on an approved construction joint, except for in extreme emergencies when creating temporary construction joints with approval from the Engineer shall terminate such pours. Concrete shall be placed and consolidated prior to initial set and in no case more than 2 hours after cement is added to the mix. The concrete shall be compacted in its final position within 30 minutes of discharge from the transit mixer. Concreting shall be carried out continuously and fresh concrete shall not be placed against in-situ concrete, which has been in position for more than 30 minutes, unless a construction joint has been formed. Concrete shall be placed as near as possible to its final position in such a manner as to avoid segregation of the concrete, displacement of the reinforcement, formwork and embedded items.

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

Concrete shall not be placed in standing water in the formwork.

Generally concrete shall be deposited in horizontal layers to a compacted depth not exceeding 500 mm and each layer shall be well consolidated before the subsequent layer is placed. Concrete shall not be dropped into place from a height exceeding 1.50 meters. Elephant trunking shall be used to reduce free fall heights to less than 1.5 meters. 6.6 Compacting Concrete All structural concrete shall be compacted by means of approved mechanical vibrators of immersion type with suitable size of needles. Sufficient standby vibrators shall be retained at site during Concreting operations to ensure that spare equipment is always available in the event of breakdown. Trained workmen shall operate vibrators. Compaction shall commence as soon as there is sufficient concrete within the formwork to immerse the vibrator and continue during the concrete placing operation so that at no time there be large volume of uncompacted concrete in the formwork. Needle of the vibrator shall be immersed vertically into the concrete so that concrete is compacted uniformly. Where the underlying layer is also fresh concrete the vibrator shall also penetrate that layer by atleast 100 mm to ensure that the surfaces knit together. Vibrators shall not be used to work the concrete along the moulds or within 100 mm of the formwork and shall not be allowed to touch the reinforcement. 6.7 Construction Joints Construction joints shall be formed at right angles to the axis of the member concerned and in horizontal or inclined members the joint shall be formed by the insertion of rigid stopping-off forms. Before fresh concrete is placed against the joint the surface shall be cleaned of all loose material and all free water removed from the form. 6.8 Curing Formwork in place method for formed surfaces of concrete.

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

Vertical surfaces shall be covered with hessian as soon as possible after the concrete has been placed and kept wet for the required period. Formed surfaces shall be similarly protected if the formwork is removed before the stipulated period of curing has elapsed. The minimum curing period shall be as per BIS standards Precast concrete elements shall be cured with Accelerated methods of curing 6.9 Fixing Reinforcement Reinforcement shall be cut and bent to the shape and dimensions shown on the drawings in accordance with the requirements and tolerances. Reinforcement shall not be heated before bending. All reinforcement shall be fixed rigidly in position. At intersections the bars shall be bound together with tying wire and the loose ends of the wire shall be turned towards the inside of the member. Reinforcement shall only be spliced or welded where shown on the drawings and all welding procedures shall be subject to approval of Engineer. Where concrete spacer blocks are used they shall not exceed 50 mm square in section and shall be pre-cast from concrete of similar grade. Each concrete spacer block shall be securely fixed to the reinforcement with wire or clip. The wire or clip shall embedded in the center of the spacer block so that it does not subsequently cause rust marks on the concrete surface. Scaffold boards shall be provided to ensure that walking upon or other operations do not displace the reinforcement. During concreting operations a competent steel fixer shall be in attendance to ensure that the reinforcement is maintained in position.

Formwork Formwork shall be so designed and constructed that the finished concrete is to the shape, size, position and finish shown on the drawings. Formwork shall be designed to safely support all loads that might be applied until the concrete has hardened sufficiently to support such loads itself. Formwork shall be sufficiently watertight to prevent the loss of liquids. Formwork shall fit to the previous lift tightly to avoid lipping and loss of grout.

Before concrete is placed the formwork shall be thoroughly cleaned and inner surfaces shall be coated with suitable release agents. Formwork shall not be removed until the concrete has attained sufficient strength to support its own weight and any incidental additional loads without damage.

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

6.10

Pre-cast Concrete Units It is envisaged to pre-cast drain cover panels, Planks and girders for the approach span of the flyovers incase pretensioned I girders are adopted for the construction of the approach spans. The pre-casting yard will be set up at Site Facilities Camp. Unless otherwise noted all specifications of material and workmanship of concrete shall apply to pre-cast concrete units. The concrete shall be placed in one continuous operation rising uniformly in the mould. A record of each pre-cast member shall be kept tabulating identification mark and number, concrete grade, date of casting and details of test cubes. Pre-cast units shall be provided with lifting holes or loops at locations shown in the drawing.

6.12 Miscellaneous Works Bridge bearings, Elastic type Expansion Joint, Filler type Expansion Joint and other miscellaneous bridge works shall be carried out as per MoRTH specifications Manufacturer Test Certificate shall be submitted for all raw materials and testing shall be carried out as per relevant specification. Preformed joint fillers shall conform to relevant specifications Water proofing shall be installed as per the manufacturers instructions. Prefabricated cold applied sheet membrane shall be used for water proofing.

SECTION 7 : HEALTH, SAFETY & ENVIRONMENT Following measure but not limited to here under shall be taken for the execution of all activities under Structures. Risk Assessment of each activity shall be done before starting any activity. 1 2 3 Only authorized equipment / personnel will be allowed within the working area. All utilities shall be identified and protected. All lifting tools and tackles shall be periodically inspected against any damage.

PUNJ LLOYD LTD.

METHOD STATEMENT FOR STRUCTURES- BRIDGES & CULVERTS PROJECT: REHABILITATION AND UPGRADING OF N1 ROAD
BETWEEN NAMIALO AND RIO LURIO (149.7 KM) IN NAMPULA PROVINCE LOT1

4 5 6 7 8.0

All equipment including batching plant, transit mixer, pumps and vibrators shall be maintained in good working condition as per maintenance schedule. All workmen supervisors and engineers shall use proper personnel protection gears. All employees shall follow the employee Health & Safety Rules. Environment protection shall be adhered to.

SECTION 8 : QUALITY ASSURANCE & QUALITY CONTROL Quality assurance & quality control QA/QC shall be as per Checklist and corresponding Inspection Plan for Concreting.