Method Statement for CASTING CONCRETE FOR BOX CULVERT

REVISION HISTORY
Rev. No.
Date

2016

CONTRACTOR-MAK

Prepared

Reviewed

Approved

SD

HH

HM

TABLE OF CONTENTS

1.0 Purpose

Revision History
First Submission following
award of Contract

ENGINEER

Status of
Approval

2.0 Scope of Work

3.0 Definitions
4.0 References
5.0 Materials
6.0 Plant & Equipment
7.0 Safety
8.0 Prior Activities
9.0 Procedure
10.0 Responsibilities
11.0 Attachments

1.0 Purpose
1.1 To ensure that the box culvert concrete activities after the installation of steel
reinforcement, formwork and all specified water stops and joints are executed safely and in
accordance with the contract requirements and that all quality assurance/ control activities
are conducted in a systematic manner, works are inspected and conformance is verified
and documented.
2

2.0 Scope of Work

2.1 This procedure is applicable to the following works associated with the Project titled,
Construction, Completion and Maintenance of Roads, Bridges, Storm Water Drainage,
Sewers and Other Services for Roads Connecting Sabah al Ahmad and Khiran New Towns
2.2 This method statement outlines the procedures to be followed in casting of reinforced
concrete for Box Culvert at locations shown on Contract drawings and as directed by the
Engineer.
3.0 Definitions
3.1 General Specifications
3.2 HSE
3.3 PPE
3.4 AFC
3.5 RFI
3.6 PM
3.7 CM
3.8 SE
3.9 LS
3.10
QA/QC
3.11
ME
3.12
ITP

MPW General Specifications for Kuwait Roads & Highways

Health, Safety & Environmental
Personal Protective Equipment
Approved for Construction
Request for Inspection
Project Manager
Construction Manager
Site Engineer
Land Surveyor
Quality Assurance/Quality Control
Material Engineer
Inspection and Testing Plan

4.0 References
4.1 Specifications
4.1.1 Project Drawings and Specifications
4.1.2 MPW General Specifications
4.2 Drawings
:
Document III Volume 3
4.3 BOQ
:
Bill No.6
5.0 Material
5.1 Concrete grade K350
5.2 Formwork / Shuttering
5.3 Steel Reinforcement
5.4 PVC Water Stop
5.5 Joint filler
5.6 Polysulphide joint sealant
5.7 Curing
5.8 Hessian cloth
5.9 Polythene sheet
5.10
Agent Release
5.11
Non-shrink Grout
5.12
Safety barrier
5.13
Warning tapes

6.0 Tools & Equipment

6.1 Surveying Instruments/Spirit level
6.2 Measuring tape
6.3 Hand Tools and Hammer
6.4 Broom
6.5 Safety Helmet
6.6 Rain Boot
6.7 Hand Gloves
6.8 Mask
6.9 Wire Nails
6.10
Air compressor
6.11
Generator
6.12
Grinder
6.13
Power Bending Machine
6.14
Steel Cutter
6.15
Ladders
6.16
Slump cone and Cube Molds
6.17
Concrete Temperature Gauge
6.18
Electric saw
6.19
Concrete vibrator
6.20
Hydraulic Crane
6.21
Concrete Mixers
7.0 Safety
7.1 Prior to the commencement of any activities, the workforce will receive an induction talk on
the Project site safety requirements. This induction talk will include both activity safety
issues, as well as general safety requirements.
7.2 Site Foreman/Supervisor will enforce that Personal Protective Equipment be worn by site
personnel at all times during construction activities.
7.3 Plant and Equipment will be provided with back-up alarms, lights, and all other applicable
safety devices. Certificates of worthiness will be provided before the equipment is used.
8.0 Prior Activities
8.1 Ensure that all related drawings & documents are the latest AFC revision.
8.2 Ensure having valid calibration certificates for the concrete plant instrument, survey
instruments and other related measuring & testing equipment.
8.3 Ensure that the formworks, steel reinforcement & embedded items have been fixed
according to the approved method statement, inspected & approved by the Engineer.
8.4 Ensure having adequate number & suitable type of concreting related equipment's &
trained and experienced operators and ensure providing stand by equipment as necessary.
9.0 Procedure
9.1 Pouring
4

9.1.1

At time of placing concrete, ensure that surfaces on which concrete is to be

placed have been protected as specified, cleaned with no debris, tying
wires, free water, and that temporary cleaning openings have been closed
and sealed. Steel reinforcement must be washed free of all dust and
contaminants before concreting.

9.1.2

Delivery of concrete shall be properly scheduled by a manner that ensures

the time elapsing between mixing & placing is as short as possible in
compliance with Project Specifications.

9.1.3

The concrete should be discharged through the reinforcement by a manner

not to cause uneven dispersal, segregation or loss of ingredients & not to
damage the formwork or any embedded items.

9.1.4

Provision shall be taken for any expansion, contraction, construction joints

and/or water bar as specified & detailed in the AFC drawings.

9.1.5

No concrete shall be placed while the ambient temp is not within the
acceptable range as specified in Contract Documents.

9.1.6

Poured concrete shall be properly vibrated by mechanical vibrations for the

full depth of fresh concrete to ensure full compaction, Vibration shall in no
account be continuous after water or excess grout has appeared on the
surface.

9.1.7

Concrete shall not be placed in adverse conditions such as dust storms or

heavy rain.

9.1.8

Concrete must be finished before setting & hardening as specified or

advised by Engineer.

9.1.9

During the placing of all reinforced concrete, a competent steel fixer and a
competent carpenter shall be in attendance on each concreting gang. They
shall ensure the reinforcement embedded fittings and forms are kept in
position as work proceeds.

9.1.10 After concreting &upon striking the formworks, tying rod holes shall be filled
with an approved, pre-bagged, cementitious, non-shrink repair mortar,
applied and cured in accordance with manufacturer's instructions.
9.2 Activity Sequence
9.2.1

The activities pertaining to this Method Statement are:

9.2.1.1 Box Culvert blinding works under bottom slab (casting &curing).
9.2.1.2 Box Culvert bottom slab including bottom haunches (casting
&curing).
9.2.1.3 Box Culvert walls & top slab (casting &curing).

The sequence of these activities is part of the overall sequence of the box culvert
construction as shown in item 9.2.2
9.2.2 Box Culvert Activity Sequence for Panels Construction:
9.2.2.1 Box Culvert Activity Sequence for a single panel:
a)
Excavation to formation level
5

b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)
r)
s)
t)
u)
v)
w)

Setting out of blinding under culvert base slab.

Formwork for blinding
Casting of blinding
Curing of blinding
Setting out of base slab
Formwork for base slab
Steel Reinforcement of bottom slab & kicker
Installation of water stops
Casting of bottom slab & kicker
Striking shutters and curing of bottom slab
Setting out of vertical walls
Steel reinforcement of walls
Inner formworks of walls & top slab
Steel reinforcement of top slab and water stops installation
Close formwork of walls
Cast walls & top slab
Strike external wall shutters
Cure walls and top slab
Apply joint filler
Apply water proofing painting works for external surfaces to
start backfilling.
Striking internal formwork for walls and top slab
Install expansion joints.

Repeat the same sequence for other panels then Backfill in layers to
the required level.
9.3 Curing
9.3.1

As soon as concrete has set or immediately after striking formwork in

compliance with Clause 504.01.5, concrete surfaces shall covered with
Hessian cloth and continuously kept wet using potable water for a period of
7 days as specified in Clause 504.06 of the General Specifications. Hessian
cloth shall frequently be watered as necessary to be kept wet continuously.
Polythene sheets shall be laid on top of the Hessian clothes, properly sealed
to cover all surfaces and edges to preserve and maintain the moisture of the
Hessian clothes and concrete surfaces. Sealing shall be done in such a
manner that wind cannot get under the edges of the sheets and all joints in
the sheets must be fully taped together.

9.3.2

The concrete may be further cured by applying the approved curing

compound immediately after removing the polythene sheet and hessian
cloth, in accordance with Clause 504.06 Sub-clause (B. ii) of the general
specifications.

9.3.3

Direct access on the concrete finished surface before hardening is not

allowed Subsequent protection system should be started after elapsing the
curing period.

9.4.1

Sampling, testing & assessment of compliance of concrete shall be done in

accordance with the project particular specifications.

9.4.2

Testing shall be carried out in the Site laboratory.

9.4 Testing

9.4.3

Adequate quality control of the concrete mix on site shall be ensured in

accordance with clause 504.03.3 & 4.

9.4.4

The onsite tests must be carried out by a qualified technician under direct
supervision of QC Engineer in the presence of the Engineer's
representative.

9.4.5

Specific cubes referencing system shall be agreed with the Engineer for
traceable test reporting.

9.5 Inspections
9.5.1

10.0

The box culvert & manhole construction shall be adequately coordinated

with the Engineer. Inspections and tests will be carried out as required by
the Engineer and according to the Contract Specifications.

Responsibilities

10.1
The CM will coordinate with SE and ensure that necessary resources to implement
the approved method statement have been allocated to the task.
10.2
The SE will ensure that the site preparation activities are conducted according to
the approved method statement.
10.3
The ME will ensure that the materials being used are in accordance to the project
specifications, the approved method statement and ITP.
10.4
The HSE Manager along with his team will ensure implementation of all HSE
procedures related to the nature of the works being carried out and in accordance with
HSE plan.
11.0

Attachments

11.1
11.2

Inspection Testing Plan