Engineering Construction Methods Guidelines Cbs

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Civil Engineering

Buildings Practice

Construction Method

Statements

General Activities

P Eng Suraj Singh

Contents index

For navigation please click these pasted hyperlinks

Construction Method Statements for various

activities within civil engineering for plants works

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Site Preparation & Earth Work PROTECTION OF EXISTING

SERVICES RE-ROUTING OF 33KV CABLESConcrete Pipe Culverts

CONCRETING TO WALLS OF

CENTRAL CONTROL BUILDING / LABORATORY

CONCRETE PIPE CULVERTS

CULVERT CROSSINGS TO AVENUE E AND MAIN HIGHWAY.

PLACING CONCRETE ON SERVICE WATER TANK 58-TK-205 FOUNDATIONS

CONCRETE REPAIR

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CONSTRUCTION OF PIPE RACK BASES EXCAVATION IN Operating

Authority CONTROLLED AREAS CONSTRUCTION OF MAIN SUBSTATION REMOVALMATERIALS OF HAZARDOUS

CONSTRUCTION OF FLOOR SLAB

CENTRAL CONTROL BUILDING MORTAR FOR BLOCKWORK

CONTROL OF CAMP SEWAGE SYSTEM STRUCTURAL STEEL-PIPERACKS COMPRESSORS’ STRUCTURES

RCC COLUMN PLATE INSERTS

EXCAVATION FOR

132KV CABLE INTERCONNECTION

ROAD CROSSING FOR 132 KV ROUTE

NIGHT SHIFT WORKING - EARTHWORKS

GROUTING TO PIPE RACK FOUNDATION BASES

CEMENTITIOUS GROUTING TO FOUNDATION BASES

ETYLENE COMPRESSOR

MASSIVE FOUNDATION (CONCRETE POUR

PROPANE COMPRESSOR

MASSIVE FOUNDATION (CONCRETE POUR) PROPANE COMPRESSOR

MASSIVE FOUNDATION (CONCRETE POUR)

MASSIVE FOUNDATION (CONCRETE POUR

MASSIVE FOUNDATION (CONCRETE POUR PROPANE COMPRESSOR

MASSIVE FOUNDATION (CONCRETE POUR SEAWATER BASIN (WATER TIGHTNESS BS 8007 : 1987 ) SEAWATER BASIN (WATER TIGHTNESS BS 8007 : 1987 ) SEAWATER BASIN (WATER TIGHTNESS BS 8007 : 1987 ) ADMINISTRATION BUILDING

STAIR LANDING EXTENSION AT GRID 4 J

ADMINISTRATION BUILDING

STAIR LANDING EXTENSION AT GRID 4 J ADMINISTRATION BUILDING

STAIR LANDING EXTENSION AT GRID 4 J

FENCING

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CERAPlant Operating Authority TILES FLOORING SYSTEM

ADMINISTRATION BUILDING PLASTERING AND RENDERING

ADMINISTRATION BUILDING ROOFING SYSTEM

ROOFING SYSTEM BUILDINGS ROOFING SYSTEM

CRACKED GAS COMPRESSOR TABLE TOP CONCRETE POUR

WATER TIGHTNESS TESTS FOR THE COLLECTION SUMPS ACCORDING TO BS 8007 : 1987 SECTION 9

ADMINISTRATION BUILDING MARBLE FLOORING

ETHYLENE GAS COMPRESSOR

TABLE TOP POUR PROPANE GAS COMPRESSOR TABLE TOP POUR

EXPANSION JOINTS IN DITCHES

EXPANSION JOINTS IN DITCHES _{CONCRETE COATING}

USING MASTER SEAL 550 DEWATERING FOR THE 84” GRE PAIR LINE PARALLEL TO CORNICHE ROAD EAST WEST

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CERAPlant Operating Authority WALL TILES FIXING

BEDDING AND GRAVEL FILLING BENEATH 60 “ DIA PIPE COOLING WATER PIPE

EXTERNAL CONCRETE PROTECTION ADMINISTRATION BUILDING

ABOVE GROUND CONCRETE PROTECTION

USING MASTERSEAL 300 H

HAND EXCAVATION TO INSTALL

TELEPHONE DUCTS BETWEEN BOX NO. 20 TO TELECOM CENTRE

BACKFILLING OF THE WEST SIDE OF THE QUENCH TOWER FOUNDATION – (RIB)

EXCAVATION

-COOLING WATER OUTFALL CHAMBER

DRILLING OF HOLES ON

PIPE RACK & STRUCTURES ON SITE SITE OFFICE ESTABLISHMENT _{Welding of Earthing Lugs on}

East West Piperack (SR0099A &B)

FILLING AROUND ALL THE PIPES WITHIN THE Plant AREA

PRECASTING MAN HOLES CATCH BASIN AND VALVE CHAMBERS

TERMINATION DETAIL TO PROTECTIVE MEMBRANE AROUND RCC COLUMNS SUPPORTING THE STRUCTURAL STEEL

COLUMNS FOR PIPE RACKS CASE (1) WITH ALUMINIUM BEAD CASE (2) WITH REBATE

CASE (3) GRAVEL FILL CASE (4) PAVING

TERMINATION DETAIL TO PROTECTIVE MEMBRANE AROUND RCC COLUMNS SUPPORTING THE STRUCTURAL STEEL COLUMNS FOR PIPE RACKS

CASE (1) WITH ALUMINIUM BEAD CASE (2) WITH REBATE

CASE (3) GRAVEL FILL CASE (4) PAVING

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ROAD CROSSING FOR LAYING 2 PIPES 1 FOR 20” RAW ETHANE & 1 FOR 6” PROPANE

FIRST STREET Operating Authority ENTRY

ROAD CROSSING FOR LAYING 2 PIPES 1 FOR 20” RAW ETHANE

&

1 FOR 6” PROPANE

FIRST STREET Operating Authority ENTRY

DIRECTIONAL BORING FOR LAYING SLEEVES FOR 2 PIPES

1 # 20” RAW ETHANE &

1 # 6” PROPANE

Operating Authority Plant REFINERY ENTRY

2 #s ROAD CROSSINGS FOR LAYING

1 FOR 14” DESALINATED WATER 1 FOR 8”POTABLE WATER

&

1 FOR 20” RAW ETHANE 1 FOR 8” NATURAL GAS 1 FOR 6” PROPANE

AVENUE ‘C’ AT FIRE STATION

1 FOR 14” DESALINATED WATER 1 FOR 8”POTABLE WATER

&

1 FOR 20” RAW ETHANE 1 FOR 8” NATURAL GAS 1 FOR 6” PROPANE AVENUE ‘C’ AT FIRE STATION ADMINISTRATION BUILDING GRC PANEL FIXING

PAINTING ADMINISTRATION BUILDING PAINTING ADMINISTRATION BUILDING

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ROAD CROSSING FOR LAYING 2 PIPES 1 FOR 20” RAW ETHANE

&

1 FOR 6”PROPANE AVENUE ‘C’

EARTHWORKS SURVEY SYSTEM

ROAD CROSSING FOR LAYING 84”G R E PAIR SEAWATER COOLING LINES

AT

AVENUE ‘D’ / CORNICHE JUNCTION

ROAD CROSSING FOR LAYING 84”G R E PAIR SEAWATER COOLING LINES

AT

AVENUE ‘D’ / CORNICHE JUNCTION

TENNIS COURTS SURFACING

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PRECASTING LIGHTING POLES FOUNDATIONS

LIGHTING POLES FOUNDATIONS

SEA WATER SURGE BASIN CONCRETE PROTECTION MASTER SEAL 550

CONCRETE COATING OF STRUCTURES USING MASTERSEAL 550

SEAWATER SURGE BASIN

SEA WATER SURGE BASIN JOINT

SEAL PAINTING SUB STATIONS

PAINTING SUB STATIONS

ELECTRICAL & INSTRUMENTATION TRENCHES

ELECTRICAL & INSTRUMENTATION TRENCHES

PULL PITS

ROAD CROSSING TO MAKE GOOD

WEARING COURSE OVER COMPLETED

1# FOR 14” DESALINATED WATER &

1# FOR 8”POTABLE WATER AVENUE ‘C’

PULL PITS

ROAD CROSSING TO MAKE GOOD WEARING COURSE OVER COMPLETED

132 KV ELECTRIC CABLE AVENUE ‘C’

PULL PITS

ROAD CROSSING

TO MAKE GOOD (temporarily)

WEARING COURSE OVER COMPLETED

132 KV ELECTRIC CABLE AVENUE ‘C’ DRINKING WATER CONNECTION

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PROTECTION TO TRANSFORMER FOUNDATION SIDES IN SUB STATIONS WITH ALUMINIUM BEAD TERMINATION FOR BELOW GROUND AND MASTERSEAL 300H FOR ABOVE GROUND IN GRAVEL FILL AREA

TIMBER DOORS FIXING ADMINISTRATION BUILDING

GROUTING TO STEEL TANKS

BEARINGS ON RING BEAMS GROUTING TO STEEL TANKS _{BEARINGS ON RING BEAMS} EXCAVATION FOR CCB UNDERGROUND _{WATER TANK}

EXCAVATION FOR CCB

UNDERGROUND WATER TANK SOAKAWAY CHAMBERS EPOXY FLOORING

BUILDINGS

EPOXY FLOORING

BUILDINGS EPOXY FLOORINGBUILDINGS VINYL WALL COVERINGBUILDINGS DRY WALL LININGS

BUILDINGS RUBBER FLOORING (BUILDINGS) RUBBER FLOORING (BUILDINGS) RUBBER FLOORING (BUILDINGS) RUBBER FLOORING (BUILDINGS) RUBBER FLOORING (BUILDINGS)

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SUSPENDED CEILINGS

ALL BUILDINGS PIT 21 WATER CONNECTION

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CEMENT BASED NON SHRINK GROUTING TO FOUNDATION BASES

USING MASTERFLOW 928 T

REPAIR OF CONCRETE FLOOR SCREEDS

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REPAIR OF CONCRETE FLOOR SCREEDS

EPOXY GROUTING TO

VIBRATING INSTALLATION BASES USING MASTERFLOW 648 CP GENERAL FOUNDATIONS

KERBS & INTERLOCKING BLOCKS PAVING AROUND BUILDINGS

ERECTION OF STEEL STRUCTURES (FOR HIGHER LEVELS)

VINYL FLOORING BUILDINGS

CONCRETE PAVING CENTRAL CONTROL BUILDING CERAPlant Operating Authority TILES FLOORING SYSTEM

CONCRETE PLACEMENT

PRECAST RCC COVERS

CABLE & INSTRUMENTATION TRENCHES

BLACK TOP REPAIR IST STREET BETWEEN AVENUE C & B

REPAIR OF

SINGLE LEAF SWING GATES

REPAIR TO

FLOOR SCREED LEVELS

RESIN INJECTION TO LEAKING JOINT SEA WATER SURGE BASIN

FIRE WATER LINE EXCAVATION AROUND CONSUMER RECEIPT STATION

ROAD CROSSING FOR LAYING

1 FOR 20” RAW ETHANE 1 FOR 6” PROPANE

FIRST STREET

ROAD CROSSING FOR LAYING

1 FOR 20” RAW ETHANE 1 FOR 6” PROPANE

FIRST STREET

1 FOR 20” RAW ETHANE 1 FOR 8” NATURAL GAS 1 FOR 6” PROPANE &

1 FOR 14”DESALINATED WATER 1FOR 8” POTABLE WATER

AVENUE -D

TREATMENT TO MOVED EXPANSION JOINTS SEA WATER SURGE BASIN

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TESTING OF FRESH CONCRETE ON SITE

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ROAD CROSSING

TO INSTALL CULVERT FOR

1# 14” DESALINATED WATER

CORNICHE ROAD / ROAD C AT GUP GATE NOTH

ROAD CROSSING TO INSTALL CULVERT FOR

1 # 14” DESALINATED WATER

AVENUE ‘C’ ROAD GUP GATE EAST MAIN ENTRANCE

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REPLACEMENT OF MISALIGNED ANCHOR BOLTS

IN

FOUNDATION 55-VV-906 USING RENDEROC LAX TRA

REPLACEMENT OF MISALIGNED ANCHOR BOLTS

IN

FOUNDATION 55-VV-906 USING RENDEROC LAX TRA

BUILDINGS

SCREEDS FOR VINYL AND EPOXY FLOOR FINISHES

BUILDINGS

DIRECTIONAL BORING AT 3# LOCATIONS FOR 14”DESALINATED WATER PIPE CORNICHE ROAD NORTH OF Operating Authority

DIRECTIONAL BORING AT 3# LOCATIONS FOR 14”DESALINATED WATER PIPE CORNICHE ROAD

NORTH OF Operating Authority DIRECTIONAL BORING AT 3#

LOCATIONS FOR 14”DESALINATED WATER PIPE CORNICHE ROAD NORTH OF GUP

DIRECTIONAL BORING AT 3# LOCATIONS FOR 14”DESALINATED WATER PIPE CORNICHE ROAD NORTH OF GUP

EPOXY SKIRTING IN

CENTRAL CONTROL BUILDING & SUB STATIONS ON DRY LINING EPOXY SKIRTING

ON DRY LINING EPOXY SKIRTING ON DRY LINING ROAD SURFACE REINSTATEMENT

OVER BOX CULVERT CROSSINGS

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REPAIR TO LIFT

CLADDING PANEL

FIXING SHEETING PANELS WALL & ROOF CLADDING FIXING SHEETING PANELS

WALL & ROOF CLADDING ROAD CROSSINGAT FIRE STATION- FIRST STREET FOR LAYING

2 # 100 mm SLEEVES FOR TELEPHONE CABLES

SEA WATER SURGE BASIN CLOSING THE STRUCTURAL GAP ON THE ROOF, WALL & BASE SLAB

HDPE PIPES BUTT FUSION

ROAD CROSSINGS

TO CONSTRUCT BOX CULVERTS OFH 2 & 3

CORNICHE ROAD

ETHYLENE EXPORT

ROAD CROSSINGS

TO INSTALL CULVERTS OFH 4 & 5 CORNICHE ROAD ETHYLENE EXPORT

MDPE DRINKING WATER LINE – NY LINES

ROOF & SIDE CLADDING – Plant AREA FOUNDATIONS ALONG FENCE BELOW ‘

FERTIL OVER HEAD CONVEYOR’ FOR PIPE RACK LEADING TO SEA REINSTATEMENT TO

‘ DAMAGE CAUSED FLARE PIPE RACK COLUMN MEMBER 01537’ AT GRID 19A

REINSTATEMENT TO ‘ DAMAGE CAUSED FLARE PIPE RACK COLUMN MEMBER 01537’ AT GRID 19A

Maintenance Warehouse Overcoating

To Epoxy Painted Surface With

Mastertop Top Coat 44P Access to Corridors & Walkway Roads

Bituminous Concrete Surfacing

Roads

Bituminous Concrete Surfacing Excavation for 200 pair Telecom Route(Direct Buried) parallel to Avenue D & 3rd_street

Hand Excavation for 200 pair Telecom Route

(Direct Buried) parallel to Avenue C

200 pair Telecom Road Crossing

at Avenue D / 3rd_{Street Intersection}

along E 676976

Manual Excavation

@ Access road to GASCO camp

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Manual Excavation

@ Access road to Operating Authority camp

@ C / L, co-ordinate N 2666940 / avenue C

REMOVAL OF CONTAMINATED

SOIL BLINDING CONCRETE

REINFORCEMENT RECEIVAL &

FABRICATION REINFORCEMENT PLACEMENT

FORMWORK ERECTION

CONCRETE TO PAVED AREAS EXCAVATION & BACKFILL TO STRUCTURES

TELEPHONE CABLE TO SITE OFFICE

ELECTRIC CABLE FROM RLIP SUBSTATION TO Civil Contractor CAMP

WATER SUPPLY TO Civil Contractor CAMP

ADMINISTRATION BUILDING SUBSTRUCTURE

WASTE MANAGEMENT _{SEA WATER BASIN} EXCAVATION FOR ETHANE & PROPANE

GAS PIPELINE INTERCONNECTION

GENERAL

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#1

Site Preparation & Earth Work

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Index

Scope - Reference documents – Definitions – Responsibilities – Safety – Method – Equipment - Attachment

Scope

The purpose of this method statement is to define the sequence of activities for the site preparation works related to the Company Petrochemical project. The extent of these activities are defined upon the attached site plan (Not included with this statement). Refer to indicative google photos.

Reference documents

Specifications for:

Site preparation,Excavation & backfill for underground installations,Fill, Grading and Paving,Testing Laboratory,Geotechnical Investigation

Definitions

GE Geotechnical Engineer PSM Project Site Manager SE Site Engineer

SO Safety Officer

QM/QE Quaity Manager/Quality Engineer IS Infrastructure Superintendent ST Survey Team

PPE Personal Protective Equipment

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Responsibilities

It is an overall responsibility of the PSM to ensure that the site preparation activities are conducted according to the project specifications. PSM shall arrange all required resources. The IS shall ensure that the site preparation activities are conducted according to this method statement as well complying with all specifications.

The GE shall ensure that the activities are conducted according to the project specifications and this method statement.

Safety

Prior to the commencement of any activities, the workforce shall receive a toolbox talk on the project site as well as on general safety requirements. SO shall ensure that the persons being inducted on site are well aware of the safety procedure to be implemented on site for the activity concerned.All persons upon the site shall wear PPE issued to them. Where possible hazards may arise from excavation activities, the necessary safety measures shall be taken to prevent accident or injury at all times. This may include provision of signage, barriers, watchman and lighting.Where work upon existing services is required, the necessary authority, permits and safety equipment shall be attained prior to the activity commencing. Scanning of existing services shall be conducted by suitable methods.

Method

The survey team shall locate and mark all services that are present upon the site (This includes above ground services as well as buried services). These services, (Electric, telephone, gas, oil, chemical, water etc), shall be clearly marked using stakes and warning tapes, reflected upon a site drawing and the issues raised with the client.

The survey team shall also mark upon the site plan all obstructions, structures and developments. Any obstruction encountered during excavation activities shall be plotted and recorded.

Where hazardous material is encountered, it shall be identified and isolatedin compliance with the safety procedures under SO supervision. The client shall be informed & hazardous material be collected and removed to a licensed tipping place. The details of the material and tipping arrangements shall be documented for review by the client as appropriate. Refer to Method statement Removal of hazardous materials.

Existing structures, fences and developments shall be demolished in a safe manner as site-stripping activities proceed. The necessary permits, approvals and permission shall be obtained from the concerned authorities prior to the commencement of the activity. The method of removal of these existing elements shall usually be conducted by dozer or breaker. Where necessary otherwise, discussions on site shall be made concerning alternate methods of removal when the full extent of these structures are exposed.

The removal of the topsoil shall include all vegetation and rubbish material from the work site. Prior to the start of topsoil removal, the surveyor shall peg out the haul roads to be used by the construction equipment to execute all the site preparation activities. These roads shall be constructed by leveling of the existing terrain. Grade pegs shall be set to an agreed grid to

(9)

indicate existing grade and reduced grade. Dependant upon the quality of the existing soil where the roads is to be built, suitable compactable fill may be imported or re-located from other parts of the site. The material shall be approved by the GE & QM/QE jointly.

These roads shall be maintained as the work proceeds. Where required, water shall be spayed for dust control.

For general removal of the topsoil activities using appropriate equipment, the areas concerned shall be excavated and graded to levels that ensure adequate surface water drainage. The GE/QM/QE shall monitor the activity to ensure that the topsoil material is removed. Sampling and testing of the resultant material shall be conducted for specification compliance & proper compaction.

Upon completion of the topsoil removal activities where appropriate, the exposed surface shall be scarified, moistened and compacted to achieve the required density criteria. The areas shall be divided into manageable sections that be defined upon sketches. The GE shall monitor and test all sections. The results of the tests shall be recorded upon the relevant QC format. The number of tests conducted shall reflect the specification requirement.

In excavation areas, the GE shall review the material to be excavated to ascertain its suitability for re-use as fill material. This excavated material shall be transported to areas that require filling. The material shall be deposited onto the areas to receive filling, leveled, moisture conditioned and compacted. If necessary, stockpiling may be required.

The excavated areas shall be divided into manageable sections, which be defined upon sketches. The excavated areas shall be monitored by the GE to ensure that any unsuitable material does not appear. Where unsuitable material appears, it shall be removed. The excavated formation surface shall be treated by scarification, moistened and compacted according to the specification criteria. All areas shall be tested and the results recorded.

Where areas are to receive fill, the material that has been excavated shall be transported to the fill area, tipped, leveled, moisture conditioned and compacted. The material shall be spread and leveled in 200mm layers. The areas to be filled shall be divided into manageable sections that be defined upon a sketch. The fill layer shall be moistened and compacted to achieve the required specification criteria. No further fill activity shall be conducted upon an area that has not been approved and released by the GE. Attention shall be observed at edges and slopes, to ensure that compaction criteria are achieved. Additional layers of fill material shall be placed similarly as described above until the desired elevation has been achieved.

Production procedure.

Verification exercise for fill activity had been conducted to establish the economical and effective method for the fill activity.

Import and place fill to controlled areas of approximately 25m wide by 100 - 150m long. Spread and level the imported fill.

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Add water to the fill layer by passing the water tanker over the fill layer. The water tanker should pass over the layer twice.

A time gap of approximately two hours is allowed for the water to soak into the fill material. The layer is now mixed with the grader until a uniform blend of moist material is achieved. Additional water is added by passing the water tanker over the layer in a uniform sequence. A time period of approximately one-hour is allowed for this water to soak into the fill layer.

The fill layer is mixed again with the grader leaving the fill level to the correct grade.

Vibrating rollers shall now compact the fill layer in a logical sequence that compacts the fill layer uniformly.

Testing of the layer shall be conducted according to specification requirements.

Equipment

Dozers & Graders, Vibrating drum rollers, Dumper trucks, Excavators & Loaders, Water tankers

Attachment

None. Refer to indicative google photos as incuded as a facility. Assume there was nothing prior to construction & whole site was filled for preparationworks.

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Protection of existing services

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Index

Scope - Reference documents – Definitions – Responsibilities – Safety – Method – Equipment - Attachment

Scope

The purpose of this method statement is to define the procedure that can be implemented, for the identification, protection and / or removal / relocation of existing services upon the site.

Reference documents

Specifications: Site preparation…, Fill…, Grading and Paving...(certain sections re to record

services within the specifications)

Definitions

SO Safety Officer

(11)

Responsibilities

It is the overall responsibility of the PSM to ensure that the identification, protection and / or removal / rerouting to existing services are conducted in a safe methodical sequence as defined by this method statement as well as directed by the relevant authorities.

The IS shall coordinate investigation of existing services with the Plant authorities. The ST shall accurately plot and record all existing services upon the site.

The SE shall ensure that the excavation is rightly carried out. The SO shall ensure that excavations are safely carried out.

Safety

Prior to the commencement of any activities, the workforce shall receive a safety induction talk on the project site safety requirements.

The necessary permits that may be required to work near these services shall be obtained. Any special conditions imposed upon these permits shall be implemented.

The use or restriction of specific mechanical equipment whilst locating these services shall be implemented. Generally, where appropriate, only manual excavation shall be carried out.

Method

From the existing record drawings provided by the relevant authorities controlling Plant, existing services shall be located and exposed by hand excavation.

The ST shall check and accurately record these services. A line of pegs shall be positioned to indicate the route of the existing services. The warning tape and / or nylon cord to indicate and protect the route of the service shall be provided. The ST shall inform the IS about the exact location of the services relative to the warning flags.

Should an existing service be disbanded or made redundant, that shall be exposed to allow for the inspection as well as confirmation of its status by the authorities. The IS through the EPC Contractor representative shall request the relevant authority to review the excavated service to confirm the status as well as instruct for necessary action required for removal or diversion. The redundant service shall be removed under the supervision of the IS according to the agreed criteria of that relevant authority.

Where an existing live service remains working or serving during the site preparation activity such as the 33KVA electric cable, that existing live service shall be protected in compliance with the regulations.

Upon location of the live service, the ST shall mark that location upon the ground using spray paint or small pegs. At necessary locations along the route of the existing live service indicated by the ST, small hand dug pits shall be excavated to expose live service to ensure its location. On ten meters (10m) either side of the route of the existing live service shall be erected posts at suitable centres. A nylon cord with warning tape streamers shall be strung between the posts to clearly indicate the service and its route.

Signboards that indicate what exactly the live service within the marked corridor is, shall also be displayed at sufficient locations conveniently within the view along the route.

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Where temporary roads cross existing cables, sufficient suitable fill material shall be placed on top of the cables to afford adequate protection by distributing the axle loadings safely.

The Safety Officer shall periodically check the condition of the barriers where necessary refurbishment is conducted.

Equipment

Excavation Tools, Survey Equipment, Pegs, Nylon cord, Warning tape.

Attachment

None. Attachments depends on the available record drawings. #3

Re-routing of 33kv cables

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Index

Scope- Reference documents- Definitions- Responsibilities- Safety- Method- Equipment- Attachment

Scope

The purpose of this method statement is to define the procedure that can be implemented for re-routing of the existing 33KV electric cable that crosses the project site. This method statement includes the location, excavation, isolation, re-routing, jointing, testing and backfill.

Reference documents

Site drawing, Record Drawings

Definitions

SO Safety Officer

Responsibilities

The EPC Contractor PSM shall ensure the required permits from Operating Authority are obtained prior to the commencement of this activity.

It is the overall responsibility of the PSM to ensure that the identification, protection and / or removal / rerouting to existing services are conducted in a safe methodical sequence as defined by this method statement as well as directed by the relevant authorities.

The IS shall coordinate investigation of existing services with the Plant authorities. The ST shall accurately plot and record all existing services upon the site.

(13)

The SO shall ensure that excavations are safely carried out & ensure that all safety issues are addressed as defined upon the work permits.

Safety

Prior to the commencement of any activities, the workforce shall receive a safety induction talk on the project site safety requirements.

The necessary permits that may be required to work near these services shall be obtained. Any special conditions imposed upon these permits shall be implemented.

Only specifically approved mechanical equipment whilst locating these services shall be used. Generally, where appropriate, only manual excavation shall be carried out.

Method

The existing route of the 33KV cable shall be identified, marked & a barrier erected on either side clearly defining the route across the site.

The route proposed for the new 33KV cable on the AFC drawing shall be identified & marked with pegs by the ST. Excavation shall commence to the line and required level.

The appropriate sand bed shall be placed within the trench.

The new cable supplied by EPC Contractor shall be laid into the trench according to established methods and standards that would include placing of the cable drum on a cable trolley and rollers. The cable shall be unwound from the cable drum by pulling. If required, a cable tugger fitted with load cell control may be utilized.

The new cable shall be correctly placed to line and level upon the sand bed. Wherever joints occur, sufficient cable overlap to allow for the jointing shall be provided.

The insulation value of the new cable shall be tested by 5KV motorized megger.

Upon the EPC Contractor Electrical Engineers approval, the cable shall be covered with dune sand to the required thickness evenly. Cable tiles shall be placed on top of the sand above the new cable.

The trench shall be backfilled with approved material. The backfill activity shall continue until the trench is completely filled. Route markers shall be placed with the splice joints surveyed and recorded.

Where joints occur to the cable either at the two termination points with the old cable or along the length of the new cable, the same technique shall be adopted.

An experienced cable jointer under the supervision of an electrical engineer shall conduct all the jointing.

Approved jointing kits shall be utilized. The manufacturers recommendations relating to the installation of these jointing kits shall be followed.

(14)

Upon completion of the jointing of the new cable length, the entire length of the new cable shall be tested. The cable shall be subjected to a pressure test of 67KV DC for 15 minutes on the cable between each core and earth. The remaining cores shall be connected to earth. The engineer shall measure the leakage current. All readings shall be recorded upon the appropriate form. The testing shall be witnessed by the EPC Contractor engineer.

Prior to the excavation at the points where the new cable is to be connected to existing 33KV cable, the necessary permits shall be obtained. EPC Contractor method statement for conducting cable Diversion shall be complied with.

The old cable shall be hand dug. An area sufficient to conduct the jointing of the cable shall be excavated.

Electrical engineer in coordination with the EPC Contractor engineer shall ensure that the old cables are identified and isolated under the supervision of the Refinery Supervisor within the appropriate substation. The necessary earthing and isolation to the cables shall be conducted prior to the commencement of jointing the old cable to the new.

The cables shall be jointed in the same manner as described previously.

Once the cables have been jointed, these shall be tested by mega test at 5KV and HV test at 53KVDC to establish its integrity and insulation.

The disbanded cable shall be removed from the new jointed cable by excavating and rolling the cable to allow the new cable route corridor to be covered with sand, cable tiles and backfill material.

Upon completion of the cable testing activities, the Refinery Electrical engineer shall authorize the energizing of the new cable route.

The disbanded cable route shall be excavated to expose the old cable. The old cable shall be removed onto the surplus cable drums from which the new cable was coiled. These drums shall be stored on site for EPC Contractor disposal.

A program to be developed by all parties of power outage windows shall be produced for the tie-in activities of the cables.

Equipment

Excavator,Dump trucks,Cable drum trolley,Cable rollers,Cable tugger with load cell

Attachment

EPC Contractor standard method statement for cable diversion.

(Since this statement may be submitted by the Civil Works subcontractor on behalf of the EPC

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Concrete Pipe Culverts

Index

Scope-Reference documents-Definitions-Responsibilities-Safety-Method-Equipment-Attachment

Scope

The purpose of this Statement is to define the sequence and methodology for the laying, jointing and testing of the concrete pipe culverts.

Reference documents

Specification….,Drawing No….

Definitions

SO Safety Officer

Responsibilities

The CS shall Plan and Resource the concrete culvert laying activities to ensure that these are Carried out complying with the contract documents.

The Construction Foreman shall actually execute the works controlling the workforce as necessary all according to the directions by the site engineer or the superintendant.

Safety

Prior to the commencement of any activities, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any adopted process that may have a particular Safety risk, shall be assessed, shortcomings analysed and addressed accordingly meeting the operational requirement.

Method

Setting Out

The edge co-ordinates of the concrete pipe shall be calculated from the information on IFC drawing. Allowing for the 1:1.5 slope, the edges shall be fixed in such a way that full length of pipes are used avoiding unnecessary cutting. The center line and the actual trench width shall be set out by marking on ground.

Excavation

The trench shall be excavated to the correct width, length and formation by using a Hydraulic backhoe. Once the bulk excavation is completed, wooden pegs with elevation marked on them shall be used for indication to complete the remaining excavation to accurate formation levels. The formation shall be watered and compacted with a plate compactor to achieve compaction

(16)

of 90% of MDD in accordance with specification documents. The compacted formation shall be inspected and field tested prior to the commencement of the Bedding activity.

Bedding

Once the excavation is approved, Bedding material shall be placed to a thickness of 150mm, watered and compacted in accordance with the specification. The compacted surface shall be inspected & field samples tested for approval.

Pipe Work

The socket positions shall be marked on the Bedding and Hand excavated to ensure that the barrel of the pipe rests firmly on the bedding with spigot ends remaining clean for installing the gaskets.

The concrete pipes shall be transported from the store to the location of the trench and gently lowered keeping the socket end upstream into the trenches with a crane using belt slings only. The pipes shall be laid back to back to the correct orientation. The spigot end of the pipes shall be cleaned using a cloth with special care taken to clean the recess which shall be lubricated with liquid soap following gasket placement in position.

Supports shall be placed at one end. The spigot shall be so placed that the gasket is in contact with the entry taper at the socket evenly all around.

The spigot shall then be drawn into the socket using a 5 tonTirfor. Jointing shall be carried out. Upon completion of the Jointing operation, the Bedding material shall be packed below the pipes so that the barrel rests firmly on the bedding keeping the pipe intact. The top elevation of the pipe shall be checked to ensure that the pipe lebvel is accurate. The operation shall be repeated until all the pipes are laid. The completed pipework shall be inspected and approved. Each joint shall be visually inspected from inside the pipe.

Backfill

Once the pipes are laid to the True gradient and alignment as described above, Bedding Material shall be carefully placed along the sides and in between the pipes by means of a backhoe. The bedding and surround material shall be placed in layers and watered and compacted until the bedding and surround material reaches 300mm above the top of the pipe. Excavated suitable material shall then be placed in 200mm layer, compacted, inspected and tested.

A list of Do’s and Don’t’s provided by the manufacturer is attached herewith.

Equipment

Crane 20Ton 1 No / Flat Bed TrailorPart time / Excavator Backhoe1 No / Trifor 5 To 2Nos / Fork liftParttime / Plate Compactor1 No / Water Tanker Part time

Labour

ForemanNo. 1 / PipefitterNos. 2 / LabourersNos. 4

Attachment

Manufacture’s datasheet.

(17)

#5

Concreting to walls of

Central control building / laboratory

Super – structure activities

Top

Index

Scope / Reference documents / Definitions / Formwork Design / Method

Scope

The purpose of this method statement is to define the procedure that shall be adopted for the erection of formwork and placement of structural concrete to the wall sections of the CCB.

Reference documents

Specification Concrete Construction, Formwork and Coating. Specification Concrete Buildings.

Drawing No.

Definitions

E Engineer

PSM Project Site Manager. CM Construction Manager.

Formwork system

The basic formwork supporting system shall be as designed and supplied by M / s. Giffin Scaffco. The supplier of formwork shall provide all design drawings for approval as well as for implementation. Additional bracing and support props shall be added by Civil Contractor in compliance with the formwork design provided by the supplier. Surface forming materials such as plies & timber scantlings etc. shall be added by the civil contractor. Upon completion of the suspended slab formwork system particularly, Civil Contractor Site Engineer shall check and confirm the adequacy of the system. If so required, the whole form work shall then be checked by the supplier’s expert & the adequacy certified in as by third party.

Method

The surveyor shall set out, check the line and levels to establish the correct positions. The wall starter bars shall be installed in place in accordance with the IFC drawings for the foundations. The kicker to the base of the wall sections shall be planned to be cast along with the foundation.

The vertical and horizontal reinforcement to the wall shall be installed according to the IFC drawings. Where service inserts (ducts pipes etc) are shown on IFC drawings, these shall be securely located,installed as well as checked.

The continuity testing of the reinforcement for the cathodic protection requirement shall be conducted and witnessed by the QC department. The results shall be recorded. Connection bosses shall be fixed as detailed on the approved drawings.

(18)

One side of the formwork shall be erected and braced. A safe means of access to a working platform as well as working platform shall be erected for this formwork. This access shall allow the steel fixers, carpenters and concrete crew a safe working area.

All service openings shall be boxed for block outs / ducted onto the formwork.

The height and width of the wall section shall be agreed with EPC Contractor/ Engineer. The wall height shall terminate near the underside of the roof slab, where the remaining top part of the wall can be cast along with the roof slab.

The walls shall be prepared and cast in sections not exceeding 6.0m length where a construction and or contraction joint shall be formed using plywood. After all the inspections of the preparatory works, the concrete pouring activity shall be carried out in lifts not more than 450 mm layers. This concrete surface at joint location shall be scabbled prior to the next section is formed formed. Where applicable, the laboratory portion outer wall form shall be erected with the profile strips prefixed to the formwork. The remaining wall form shall be erected and braced. A safe means of access to a working platform as well as working platform shall be erected for this formwork. This access shall allow the steel fixers, carpenters and concrete crew a safe working area.

The surveyor shall check the alignment of the wall.

The preparatory works shall be checked by the site engineer who then request the QC.

The finished reinforcement and formwork configuration shall be inspected on an ongoing basis by the Civil Contractor QC department who in turn obtain concrete pouring permission from EPC Contractor. Having obtained approval, the structural concrete shall be poured by pumping. Curing shall be carried out according to the specification requirements.

Equipment

Crane. Concrete Pump. Vibrators Hand Tools.

Attachment

None. #6

Concrete pipe culverts

Top

Index

Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment

(19)

Scope

The purpose of this Method Statement is to define the sequence and methodology for the laying, jointing and testing of the concrete pipe culverts.

Reference documents

Specification Specification Drawing No.

Definitions

E Engineer

PSM Project Site Manager.

CS Construction Superintendent

Responsibilities

The CS shall Plan and Resource the concrete lining activities, to ensure that they are Constructed according to the Drawings and Specification.

The Construction Foreman shall actually execute the works, directing the workforce as necessary.

Safety

Prior to the commencement of any activities, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that may have a particular Safety risk, shall be assessed and addressed as required in consultation with the safety engineer.

Method

Setting Out

The edge co-ordinates of the pipe shall be calculated from the information on the drawing as well as allowing for the 1:1.5 slope & fixed in such a way that full length of pipes are used without pipe cutting. The center line and the actual width shall be marked on ground.

Excavation

The trench shall be excavated to the correct width, length and formation by using a Hydraulic backhoe. Once the bulk excavation is completed, wooden pegs shall be used showing the elevations marked on them to guide & complete the excavation to required formation levels. The formation shall be watered and compacted using a plate compactor to achieve compaction of 90% of MDD in accordance with specification. The compacted formation shall be inspected and field compaction tested prior to the commencement of the Bedding activity.

Bedding

Once the excavation is completed & approved, Bedding material shall be placed to a thickness of 150mm, watered and compacted in compliance with the specifications. The compacted surface shall be inspected, tested and approved.

Pipe Work

The socket positions shall be setout on the Bedding. Manual excavation shall be carried out for socket portion to ensure that the barrel of the pipe rests firmly on the bedding. It shall also be ensured that spigot ends remain clean to the same standard as were while installing the gaskets. The concrete pipes shall be transported from the store to the location of the trench and gently lowered into the trenches with a crane using belt slings only. The socket end shall be placed upstream. The pipes shall be laid back to back to the correct orientation. The spigot

(20)

end of the pipes shall be cleaned using a cloth with special care taken to clean the recess which be lubricated with liquid soap following which the gasket placed in position. Supports shall be placed at one end. The spigot shall be so placed that the gasket is in contact with the entry taper/bevel at the socket evenly on circumference. The spigot shall then be drawn into the socket using a 5 tonTirfor. Upon completion of the Jointing operation, the Bedding material shall be packed below the pipes so that the barrel rests firmly on the bedding and the pipe doesn’t move. The top elevation of the pipe shall be checked to ensure that the laid pipe is accurately placed to the correct alignment and elevations. The operation shall be repeated until all the pipes are laid. The completed pipework shall be inspected and approved. Each joint shall be visually inspected from inside the pipe if accessible.

Backfill

Once the pipes have been laid to the True gradient and alignment as described above, Bedding Material shall be carefully placed along the sides and in between the pipes by means of a backhoe. The bedding and surround material shall be placed in layers, watered and compacted until the surround material reaches 300mm above the top of the pipe. Excavated suitable material shall then be used in compacted layers of 200mm inspected and tested until the backfilling operations are completed.

A list of Do’s and Don’t’s provided by the manufacturer is attached herewith.

Equipment

Crane 20Ton 1 No. Flat Bed Trailor Part time Excavator Backhoe 1 No. Trifor 5 Ton 2 Nos. Fork lift Part time Plate Compactor 1 No. Water Tanker Part time

Labour Foreman No. 1 Pipefitter Nos. 2 Labourers Nos. 4

Attachment

Manufacture’s datasheet. #7

Culvert crossings to avenue e and main

highway.

Top

Index

Scope

(21)

Definitions Responsibilities Safety Method Equipment Attachment

Scope

The purpose of this statement is to define the sequence and methodology for the excavation, placement of culvert pipes, backfill and reinstatement to the culvert crossings on avenue E and the main highway next to the retention pond.

Reference documents

Drawing No: Drawing No:

Definitions

E Engineer

Responsibilities

The CM shall plan and resource the culvert construction operation, including the permissions required from all authorities concerned.

The Construction Foreman shall control and monitor these activities, directing the workforce as necessary.

Safety

Prior to the commencement of any activities, the labour force shall receive a tool box talk on the project site safety requirements. Any process that may have a particular safety risk, shall be assessed and addressed as required.

Method

The route of the culvert trench shall be set-out by the surveyor. The existing services such as the fibre optic cable shall be located and protected. The cable shall be supported across the excavation, placed within a PVC duct, wrapped with polythene & tied to the support.

The traffic diversion scheme wilth all signs installed shall be implemented according to the attachment and monitored regularly by the safety department to ensure a smooth traffic management. Concrete barriers shall be placed at the head of the diversion. The ditch along the side of the diversion shall be barricaded with nylon rope bearing warning tape.

The initial excavation shall commence at the drainage ditch to the west side of avenue E and extend across avenue E up to the fibre optic cable location.

The trench shall be excavated using appropriate equipment while dump trucks collect the surplus excavated earth to be removed from site to the spoil area. Material that is to be reused shall be stockpiled. The excavated asphalt shall be deposited at the tip area in the pre-agreed location. Any damage to the existing asphalt shall be repaired during the reinstatement operation.

(22)

The sides of the excavation shall be sloped where the excavation depth exceeds 1.2 m. A ladder shall be provided for ingress and egress of the excavation. Ladder shall be located every 8 m if so required depending on length of excavation.

A banksman shall be provided to monitor the excavation machine operations.

The bottom of the excavated trench shall be inspected by the EPC Contractor engineer prior to the compaction activity commences. All unsuitable material shall be removed.

Inspection and testing of the compaction shall be conducted by the site test laboratory. The field density test results shall be submitted for approval.

The surveyor shall monitor the line and level of the excavation regularly & provide level pins for the pipe bedding.

Approved bedding material shall be placed and compacted to the required levels and density values. The site test laboratory shall conduct the field density tests & reported accordingly. The concrete culvert pipes shall be placed correctly to the line and level as shown on the IFC drawing.

The pipes shall be inspected for damage prior to placement. No damaged pipes shall be placed. The spigot head on the culvert pipe shall be on the up stream end of the pipe. A pair of nylon strap shall be used to lift the pipes using a 50 ton crane and place the pipes correctly in to the trench. Backfill material shall be placed around the pipes in layers of 150mm thickness duly compacted & tested by the laboratory. Backfill operations shall continue up to the existing road formation level.

When the backfill activity is completed, asphalt repair to the existing highway shall be conducted & avenue E road construction shall be reinstated. The traffic management scheme shall be removed to allow the re-use of avenue E.

A temporary security fence outside the existing RRD area shall be erected to allow the culvert construction to continue east towards the retention pond. The temporary security fence shall be erected to the agreement and requirements of the security police. When this activity is completed and approved by the security police, the existing security fence can be cut and rolled back sufficiently to allow the construction activities to be conducted.

The next section for the culvert trench shall be excavated taking care of where existing services have been exposed to be well protected.

The trench formation shall be inspected, compacted and tested as previously described. Pipe bedding shall be placed, compacted and tested as previously described.

The pipes shall be installed within the trench after inspection for transit damage is completed. Backfill around the pipes shall be placed, compacted and tested.

The backfill shall be reinstated above the pipe surround up to existing ground level.

Reinstatement of any existing services shall be done. The fibre optic cable shall be left protected by the PVC duct and polythene sheet, then surrounded with concrete.

The existing security fence shall be replaced. The existing fabric shall be re-erected onto the existing poles which shall be re concreted in position. The barbed wire shall be re placed using new material where required.

(23)

The final section of the culvert trench shall be set-out and excavated in the same sequence as the previous sections.

The compaction and testing of the pipe bedding shall be carried out.

The placement of the pipes to the correct line and level shall be carried out.

The backfilling of the pipe surround shall be conducted. The reinstatement of the backfill above the pipe surround material shall be conducted. The site test laboratory shall conduct the field density testing. The inlet and outlet chambers of the crossing shall be constructed. Refer to the method statement for chambers. This procedure shall be similarly followed in principle for any other culvert crossings on avenue E.

Equipment

Excavators. Dump trucks. Compactors.

Attachment

None. #8

Placing concrete on service

Water tank 58-tk-205 foundations

Top

Index

Scope Safety Method Equipment Attachment

Scope

The purpose of this method statement is to define the sequence and methodology for the placing of concrete on service water tank foundations.

Reference documents

Specification

Definitions

E Engineer

Responsibilities

The CM shall plan and resource the concrete repair activities, to ensure that they are implemented according to this method statement.

The Construction Foreman shall monitor the concrete repair activities, directing the workforce as necessary.

(24)

Safety

Prior to the commencement of the concrete pour, the labour force shall receive a tool box talk on safety requirements with special care taken to ensure adequate lighting arrangements are made. We propose to use 2 Nos. Tower lights each with 4 X 1000 Watts bulbs. Accers platforms shall be provided all around the ground beam on the outside formwork, 2 Nos. Aluminium ladders shall be placed at opposite ends to reach the Accers platforms from the ground levels. The accers platform shall be provided with Hand Rails all around.

Method

Preparatory works shall be carried out for the form works in circular profile for which due provisions shall be made for the specialist form. This form shall be well supported & anchored to resist ecpected forces during the our. As parallel activity, rebars shall be placed & fixed in the correct positions duly inspected.

It is proposed to cast the Ring beam in two pours. Stopend forms shall be placed at opposite locations across the full width and depth to establish construction joints. The concrete shall be poured onto the section in one go 300 to 450 mm high around and compacted with suitable vibrators. Care shall be taken to ensure that concrete is placed and compacted in its final position within the time permissible form the time of batching to the time it should be compacted in accordance with the concrete production specification that may be generally 1 to 2 hours. Concrete delivery shall be planned accordingly to quantity & duration of pour to enable a smooth concreting operation. Concrete shall be continually poured from the start to the concrete por finish. No cold jointshall be allowed to form. All flash setting shall be avoided by keeping the rebars lower than the air temperature. Proper vibration shall be effected. After the concrete is completed, proper method of curing shall be carried out & continued for specified number of days. All tests for on site concreting shall be conducted by the RMC laboratory staff duly recorded.

Equipment

Concrete pump, concrete trucks, vibrators,

Attachment

None. #9

Concrete repair

Top

Index

Scope Reference documents Definitions Responsibilities Safety +Method Equipment Attachment

(25)

Scope

The purpose of this method statement, is to define the criteria for the concrete repair to all structures.

Reference documents

Specification

Definitions

E Engineer

Responsibilities

The CM shall plan and resource the concrete repair activities, to ensure that they are implemented according to this method statement.

The Construction Foreman shall monitor the concrete repair activities, directing the workforce as necessary.

Safety

Prior to the commencement of any activities, the labour force shall receive a tool box talk on the project site safety requirements. Any process that is adopted that may have a particular safety risk, shall be assessed and addressed as required.

Method

Upon removal of the formwork, the concrete surface shall be inspected by the Site engineer & foreman to check surface defects.

Where no surface imperfections have occurred, the concrete surface shall be cured according to the relevant procedure. Minor defects as described in A – D below shall be repaired as soon as practical. More significant defects as described in E – H shall be subject to joint inspection / agreement between Civil Contractor, EPC Contractor and Company.

A.

Pin holes / blow holes

Where small defects to the concrete surface has occurred such as pin holes or holes smaller than 3mm in diameter or depth, the surface shall be repaired using Nitomortar FC with an approved bonding agent. This surface repair shall be conducted as soon as the formwork is removed whilst the concrete is still green. The repair shall then be cured in accordance with manufacturer’s instructions or agreed procedures using water or curing agent as appropriate. B.

Sand runs / scouring

Water movement inside the shutter can result in a streaky appearance giving loose sandy finish. Where this occurs, any loose material shall be removed by stiff brushing and then repaired as described in A above.

C.

Plastic shrinkage cracks

Cracking caused by plastic shrinkage due to inadequate curing and protection of horizontal surfaces usually results in a series of diagonal cracks. These should be repaired by brushing dry cement powder directly into the cracks while the concrete is less than 3 days old and covering with damp hessian.

(26)

D.

Minor misalignments (Typically Less than 2cm)

Misalignments due to shutter movements etc, should be ground back to provide a smooth transition between areas. Where occurring at joints between panels, the ground profile length should be 2-3 times the size of the maximum misalignment. Following grinding, the surface should be reinstated as in A above. Care should be taken to ensure that concrete cover is maintained per specifications at all times.

E.

Honey combing / segregation / minor voids

The repair shall be conducted as soon as the formwork is removed and the repair method agreed with EPC Contractor / Engineer. It shall require chipping the repair area free of laitance and exposing any voids. The repair area shall then be soaked, an approved bonding agent applied followed by working on with an approved mortar such as Master Flow 544 before the area dries out.. The materials shall be mixed using the bonding agent and not water. The mixed material shall be trowelled firmly into the repair area. Incase, the depth of the repair exceed 15mm, the repair shall be conducted in two layers providing a scratch coat on the first layer. The repair shall then be cured in accordance with the agreed procedure using water or curing compound as appropriate.

F.

Major voids (Typically Deeper than 5cm)

This repair shall consist of chipping the affected area to remove any laitance and voids. Where reinforcement is exposed in a void, the surrounding concrete shall be chipped away to provide adequate space to place fresh concrete around the reinforcement including removal of all soft concrete. (Note- a distance of one and a half times the stone size must be allowed around all exposed reinforcement). Formwork shall be provided to retain the fresh concrete. The chipped area shall be soaked in and primed with a bonding agent. The bonding agent shall not be allowed to dry. Fresh concrete of the same grade as the surrounding concrete shall be used to fill in the void. The repair shall be water cured along with the parent concrete. The surface finishes to the repair shall be as the same standard as the surrounding concrete.

G.

Plastic settlement cracks

Cracking caused by settlement of concrete usually in deep lifts or at changes in section can result in a series of cracks which mirror the reinforcement pattern in horizontal surfaces or appear to arch on vertical surfaces. Any such cracks should be chased out to a depth of 10-15mm and filled with an epoxy mortar such as Nitomortar FC as in A above.

H.

Pourous / spongy surface

Where inadequate vibration and poor finishing techniques have caused excessive bleeding, horizontal surfaces can appear spongy and pourous. In this case all affected surfaces should be ground back to good concrete usually only 2-3mm below the surface. The surface should then be reinstated using Nitomortar as in A above. This type of defect often occurs with plastic settlement cracks which should be treated as In G above.

(27)

All repairs noted above shall be recorded on the post-pour inspection form (QCF). It is not necessary to raise a non-conformance report provided the repairs are carried out as indicated above and agreed with EPC Contractor where necessary. Any repairs not covered by the above procedure shall be dealt with on a case-by-case basis and agreed with EPC Contractor and Company before commencing repairs.

Equipment

Hand Tools.

Attachment

None.

#10

Construction of pipe rack bases

Top

Index

Scope Reference Documents Definition Responsibilities Safety Method Equipment Attachment

Scope

The purpose of this method statement is to define the sequence and methodology for the Construction of the pipes rack bare foundations

.

Documents

Specifications

Drawing No:

Definitions

E Engineer

PSM Project Site Manager CM Construction Manager

CS Construction Superintendent

Responsibilties

The CS shall plan and resource the Construction of Pipe Rack Bases activities, to ensure that they are Constructed according to the Drawings and Specification

.

The Construction Foreman shall actually execute the works, directing the workforce as necessary.

(28)

Safety

Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed as required

.

Method

It is proposed to cast the pipe rack bases and the columns at actual locations at site. The method of Construction of the pipe rack bases can be summarized in the following activities. Setting Out Excavation Blinding Concrete Formwork Steel Reinforcement Concrete Construction Concrete Protection

Construction of Columns with Anchor Bolts Backfilling

Grouting

Setting Out- Pipe Rack Bases

The center lines of the Anchor bolt group shall be set out and offset provided 2m on either side of the foundation as reference line for blinding using manual methods of setting out.

Excavation

The bases shall be excavated with excavator, sides trimmed to avoid caving in. The formation shall be compacted, inspected, field tested and approved prior to the commencement of the blinding

.

Blinding Concrete

The formation area to receive the blinding shal be prepared to the design levels & profiles. C20 PBFC grade concrete shall be placed to a minimum thickness of 50mm and the top surface smoothened by steel trowel. Curing shall be carried out for the blinding concrete for at least two days. Prior to the placement of the precast pipe rack base on it, mass concrete infill shall be placed as required in accordance with the drawings as necessary.

Site Precast Yard for foundations

A precast yard shall be constructed on site at the location indicated in the attached sketch. A wind shield fence 2m high shall be erected on the Northern boundary as indicated in the proposed location in accordance with clause ……… of the specification.

Steel Formwork

Steel Forms as shown in the attached sketch shall be used for casting the pipe rack base foundations. The forms should be easily struck as well placed in position.

Separate forms shall be used for the bases and columns . The base slab formwork shall have 100mm high suspended kicker.

Fosroc reebol mould release oil shall be used. The template for anchor bolts for piperack base type1, 3 & 5 shall be a 100mm wide strip of steel plate across the width of the column steel

(29)

formwork at the top. The template for piperack type 2, 4, 6, & 7 shall be similar in Construction type with 2 plates and a connecting piece.

Anchor Bolts & Steel Reinforcement

Steel Reinforcement cut and bent to the required shape and size shall be available on site. Reinforcement shall be timely fixed in place on the casting beds.

Lifting Hooks

Lifting hooks shall be inserted into the correct location & properly fastened so as not to be dislocated during concrete pouring.

Casting Concrete

Formwork applied with a fresh coat of mould release oil shall be placed in position around the already assembled steel reinforcement. Lifting recess plugs shall be installed in position with a Template. All supports shall be fixed in position. Inspection shall be conducted to the ITP requirement. The Base shall be poured and compacted with vibrators. The surfaces shall be smoothened with steel trowel. Curing shall ne carried out. Formwork for the column shall be installed the following day. The plumb and alignment shall be checked and the anchor bolts with sleeves installed and held in position by the template . The widths of the template shall be kept to the minimum to allow room for concrete vibrators. Once the column is cast, the formwork shall be stripped after 36hrs and the concrete cured for a minimum period of 7 days

.

Protective Coatings

Once the curing is completed as stated above, the polythene sheets and hessian shall be removed and the concrete faces allowed to dry for atleast 24hrs during which time minor repairs such as filling up of blow holes etc. shall be carried out. The faces shall be wiped clean with a wet sponge and surface prepared to receive the first coat of protective painting.

Fosroc Nitocote ET 402 shall be mixed with a slow speed electric drill and spray applied with an airless sprayer equipment to the required thickness of 1mm as a single high build coat in accordance with the manufacture’s instructions.

The column and the top sides of the boxes, vertical faces shall be painted as described above. The bottom of the base slab shall be left without painting.

Traceability

The pipe rack bases shall be numbered and the date & time of casting marked on the concrete.

Lifting, Transportation and Installation

After completion of the curing, certified cranes of required capacity shall be used to lift the pipe rack base from the casting bed to the flat low bed trailor. The bases shall be transported to the actual location of installation.

On location preparatory pf preceeding activities shall be completed prior to the transportation of the bases. The screed shall be cast accurately to the actual dimension of the bone of the pipe rack foundation. Using a jack of adequate capacity, the unit shall be moved to the correct position accurately. The crane shall be used to lift the pipe rack base from the Trailor down onto the screed surface.

The position of Anchor bolts shall be rechecked with a Theodalite and accuracy of the installation certified by a surveyor.