Method Statement for roof covering storage tanks

Project: …………………………………
Contract No: …………………..

Client: …………………………………….
Date: ………………………….
Prepared by: ………………………..

MS for ROOFING EXISTING CLEAR WATER TANKS (Revised)

Contents
1.0 Purpose and Scope .....................................................................................................2
2.0 Preparatory works.......................................................................................................2
3.0 General statement.......................................................................................................2
4.0 Work Methodology.......................................................................................................3
4.1 Cleaning of storage tanks.............................................................................................3
4.2 Setting out of new column bases and columns...............................................................3
4.3 Inserting of Re-bars.....................................................................................................3
4.4 Fixing of steel reinforcement bars.................................................................................3
4.5 Shuttering construction................................................................................................4
4.6 Checklist for a good formwork.....................................................................................4
4.6.1Formwork.................................................................................................................4
4.6.2Joint.........................................................................................................................4
4.6.3Ties and Fixings........................................................................................................4
4.6.4Finish.......................................................................................................................4
4.7 Loading, Mixing, and Discharging.................................................................................4
4.8 Concrete casting.........................................................................................................5
4.9 Striking of formwork...................................................................................................5
4.10 Cleaning of formwork................................................................................................5
4.11 Concrete Protection and Curing..................................................................................5
5.0 Construction of Roof structure and Roof covering..........................................................6
5.1 Sheet length...............................................................................................................6
5.2 Fastenings..................................................................................................................6
5.2.1 Setting of screws......................................................................................................6
5.3 Handling of Roofing sheets on site................................................................................7
5.4 Walking on roofs..........................................................................................................7
5.5 Installing of Roofing sheets..........................................................................................7.
5.6 General installation procedure of Roofing sheets............................................................7
5.6.1 Check flatness, slope and overhang........................................................................7
5.6.2 Orient sheets before lifting.....................................................................................8
5.6.3 Position first sheet.................................................................................................8
5.6.4 Position other sheets..............................................................................................8
5.6.5 Check alignment occasionally..................................................................................8
5.6.6 Side-lapping and positioning roofing sheets.............................................................9
5.7 Marking out, cutting and drilling..................................................................................9
5.7.1 Marking out...........................................................................................................9
5.7.2 Cutting..................................................................................................................9
5.7.3 Making holes.........................................................................................................9
5.7.4 Clean up..............................................................................................................10
 Method Statement for roof covering storage tanks

6.0 Constructing Blockwalls on Gables..............................................................................10

7.0 Installation of Doors, Exhaust, Ladders, Lighting.........................................................10
8.0 Important safety measures........................................................................................10
9.0 Staff to be available – Supervisors and Labours...........................................................10
10.0 Materials to be used .................................................................................................11
11.0 Equipment’s and tools to be used...............................................................................11
12.0 Attachments..............................................................................................................11
12.1 Approved Drawings....................................................................................................11
11.2 Work program ..........................................................................................................11

1.0 Purpose and Scope

The purpose of this Method Statement is to explain the proper intended procedures,
on how to construct new concrete columns including fixation of steel reinforcement
bars, construction of the shuttering, casting concrete and construction of roof
covering for three existing open clear water storage tanks, without exposing the
workers to injuries.

2.0 Preparatory works

 Submission of Design mix for concrete class C30 to the RE for reference only.
 Submission of request for inspection of shuttering arrangement for the various
stages of work to the RE for approval as per available drawings and on the base
of Contractor’s report. Respective Drawings shall be submitted.
 Submission of request for inspection of reinforcement arrangement to the RE,
before the shuttering is being closed, for approval
 No concrete shall be placed, prior to the approval by the Engineer.

3.0 General statement

Works to be executed shall include construction of new reinforced concrete columns

and ring beams inside existing open clear water storage tanks and timber roof
structure with IT5 sheets roofing covering materials including fascia boards with
rainwater gutter system.

IF operator TUWASA will allow to shutdown all the three existing open water storage
tanks at the same, this will be good and will enable us Contractor to complete works
at the shortest possible time.

Otherwise, we will demand to work on two tanks simultaneously and let the other
remaining one to continue operating.

All new reinforced concrete columns and beams shall be made class C30 as
recommended by our Designer and noted in the drawings which approval has been
issued by Engineer’s letter dated on 23rd May 2014 and with reference.no
TUWASA/WSDP/010/HB together with an absolute water proof layer of plaster of 20
mm thickness, on all columns, which are going to be exposed to water.

4.0 Work Methodology

 Method Statement for roof covering storage tanks

4.1 Cleaning of storage tanks

When Operator TUWASA shutdown the entry of clear water from the filters to the
existing clear water storage tanks, we shall remove all sludge deposits which are
normally found in abundance at the bottom of the tanks.

Sludge deposits shall be removed through existing collecting open channel at the
middle of the storage tank towards existing sludge drain pipe up to the disposal
pond.

We will use clean water and wire brushes and blooms to make the concrete floor
and wall surfaces of the storage tanks clean and make sure that all the surfaces are
completely dried ready for marking and setting out

At this stage, we shall also remove the existing mild steel pipe handrails and discard
away to the disposal.

4.2 Setting out of new column bases and columns

After the floors of the tanks are clean we shall set out on the ground for the new
column bases and new columns in accordance to the new revised contractor’s design
and when this work is completed we will request Engineers to check and when is
approved we will start fixing reinforcement steel bars

The setting out of the new column bases shall be 650x650mm and new columns
type1 and type2 shall be 250x250mm

We shall use equipment's such as theodolite, leveling machine, square, measuring

tapes, manila ropes, marker pens, wooden pegs etc so as to ensure the column
bases and new columns are accurately positioned.

4.3 Inserting of Re-bars

We shall drill holes on existing ground concrete floors in order to insert re-bars of
12mm for column bases and 16mm for new columns using heavy duty drill machines
and mechanical hammers

Reinforcement steel re-bars will be cut to the required sizes, and made clean by
brushing to remove rubbish, rust and stains and finally inserted into already drilled
holes on the existing concrete floor of the storage tank

4.4 Fixing Reinforcements for Columns and Beams

Fixing of Steel reinforcement bars for new columns and ring beams inside existing
open clear water storage tanks as per the approved drawing numbers WP08-06 and
WP00-07, which;
 Method Statement for roof covering storage tanks

 Reinforcement steel bars of sizes 8, 12, and 16mm diameter all these
diameters has been approved. shall be cleaned to remove dust, rust and
stains and cut and bent to the required sizes and shapes, hence fixed into
respective positions according to the structural drawings and bar bending
schedule in reference to BS4449, structural use of reinforcements.
 Any loose binder or ties along the splices of reinforcement steel shall be re-
tightened and shall be bend inward, the free ends of the binding wire or ties.
 Concrete spacers of at least class 30 concrete, 30 mm thickness shall be used
in sufficient numbers, on the steel bars as distance keepers to the formwork.

4.5 Shuttering construction for Columns and Beams

We shall use Resin bonded Marine plywood sheets are attached to 50 x 100mm and
50 x 150mm timber supports/frames to make up panels of required sizes. By use of
marine plywood panels of sizes 1200 mm x 2400 mm, it is possible to effect fixing
and dismantling easier.
4.6 Checklist for a good formwork

4.6.1 Formwork

 Correct position, Line and level, Accuracy within permitted tolerances

 Shape of members, Verticality (plumb), Correct angles for batters etc.
 Anchoring to the ground in order to avoid lifting off during casting.

4.6.2 Joints

 Formwork joints to be flush and tight and No nails protruding into the concrete.
 Formwork joints to be sealed and Construction joints strutted and supported.

4.6.3 Ties and Fixings

 Correct number, Correct lengths.

 Tight enough and not too tight and Fitted with the proper washers.

4.6.4 Finish

 All forms perfectly cleaned out.

 Release agents correctly applied.

4.7 Loading, Mixing, and Discharging of concrete

The loading method includes the order of loading the constituents into the mixer and
also the duration of the loading period, it takes 8-10min minutes to produce 0.5 m 3
of concrete No other timing will be accepted for the planning, until it is proved that it
can be done shorter. The duration of this period depends on how long the
constituents are mixed dry (3 minutes) before the addition of water and how fast
the constituents are loaded.
 Method Statement for roof covering storage tanks

Consider from experience: the loading period is extended from the time when the
first constituent is fed into the mixer to when all the constituents are in the mixer (Six
(6) minutes). Also add the time for discharging the content.

4.8 Concrete casting for Columns and Beams

Concrete shall be transported as soon as possible after mixing, by methods which

will prevent the segregation, loss or contamination of the ingredients. Proper
bridging arrangements for traffic over reinforcement shall be provided so that the
reinforcement is not distorted, damaged or displaced.

Concrete shall be compacted properly by using mechanical vibrators, two numbers

will be deployed. At least one extra vibrator shall be available in case of any
shortage or of any mechanical problem.

One set of cubes consisting of 8 [2.302.4] cubes are to be taken for testing ( 4 Nos
of cubes to be tested on 7th days, and 3 4 cubes to be tested after the 28th day.
[Test according to Specs Cl. 2.302.4 Pg VII-58 Last Para.& vii-59 2nd para].

4.9 Striking formwork of Columns and Beams

The specification gives guidance on when forms can be struck and these times may
be governed by the size and shape of the member, the concrete mix, and the
weather.
To strike the column form, ties and clamps shall be loosened gradually, a little at a
time.
To remove the props, they shall be released evenly in small stages starting at the
middle of the span and working out towards the supports. This can avoid
overloading of the props at the centre of the span due to large deflection at the
centre.
4.10 Cleaning formwork of columns and Beams
Forms shall be cleaned with a stiff brush to remove any grout; a timber scraper shall
be used for stubborn bits of grout.
shall have a coat of release agent applied for protection if they are not going to be
re-used immediately.
Any depressions, splits and nail holes shall be repaired with plastic wood or similar
material, followed by a light rubbing down.
Before concreting, the insides of the forms should be cleaned. Where the forms are
deep, temporary openings should be provided for inspection.
4.11 Concrete Protection and Curing for Columns and Beams

Curing is the process of controlling the rate and extent of moisture loss from
concrete during cement hydration at least for a period of 7 days.

It provides time for the hydration of the cement to occur and ensures that the
hydration process is not hindered by lack of water.
 Method Statement for roof covering storage tanks

Newly placed concrete shall be protected by approved means of white PE sheets

shall be used to cover the fresh concrete and to avoid evaporation. from rain, drying
winds, sun and contact with substances which can adversely affect it.
5.0 Construction of Roof structure and Roof covering

We shall fix steel scaffolding inside the storage tanks to provide working platform for
labour and passage of materials during construction of roof structure and roof
covering.

Roof structure comprising of treated timber members shall be made by 100x150mm

rafters and purlins fixed together by bolts and nails in accordance to new revised
drawings

After the roof structure is accurately completed, we shall ask the Engineer to check
before fixing IT5 roofing sheets.

All required construction materials shall be lifted by our manual labour and whenever
it becomes necessary we shall use crane which is mounted on truck.

5.1 Sheet length

Modern production methods enable corrugated sheet to be produced in lengths

much longer than is usually required. This means that most roofs can be covered in
a single row of sheets, eliminating the need for overlapping joins which are a major
source of corrosion.
These advantages need to be weighed against the change in appearance that full-
length sheets bring. On steeply sloping roofs of short sheets the joins can be seen as
the shadow line of the overlapping sheet and, less obviously, the additional nailing
needed at the join.
These provide a distinct horizontal element to the appearance of many roofs and
their loss may lead to a change in the character of the roof.
On the other hand, there can be little objection to full-length sheets on planes of a
roof that are not readily visible.

5.2 Fastenings

Traditional slot-headed roofing screws (or nails) and washers should be used on
those parts of a roof that contribute to the building’s appearance, while modern
hexagonal nut-headed screws should only be used on less visible parts of a roof.

5.2.1 Setting of screws

Fasteners with sealing washers should be tightened only until the washer is gripped
firmly enough to provide a weathertight seal. The fasteners should not be over-
tightened because this may split the sealing washer or deform the sheet, either of
which could lead to water penetration.
 Method Statement for roof covering storage tanks

When the screw is properly tightened :

• into timber: the screw must penetrate the timber by the same amount that the
recommended screw would do if there were no insulation, i.e. same embedment.
Site trial of screw fixing may need to be conducted to determine the suitability of the
selected screw.

5.3 Handling of Roofing sheets on site

On this work, we shall reduce handling time by lifting bundles of corrugated sheets
with a crane direct from the delivery truck onto the roof frame. We shall use a
spreader bar for a long sheets. For small to medium size corrugated sheets, without
mechanical handling facilities, we shall unload sheets by hand and pass them up to
the roof one at a time.

5.4 Walking on roofs

We shall ensure that we walk on roofing carefully, to avoid damage to either the
roofing or we our-self.
Generally, we shall keep our weight evenly distributed over the soles of both feet to
avoid concentrating our weight on either heels or toes.
When walking across the ribs, it is better to walk over or close to the roofing
supports. (Usually over fastener locations.)
We shall be more careful when moving between supports and not to walk in the pan
immediately adjacent to flashings or translucent sheeting.
Always we will take particular care when walking on wet or newly laid sheets
particularly on steeply pitched roofs.
If there will be heavy foot traffic on a roof, we shall provide a temporary walkway or
working platform with consideration of hand rails to minimize damage.

5.5 Installing of Roofing sheets

In order to maximize water tightness, we shall always place roof screws through the
crests.
Always we shall drive the screws perpendicular to the roofing, and in the centre of
the corrugation or rib.

The following procedures are described for roofs;

5.6 General installation procedure of Roofing sheets

5.6.1 Check flatness, slope and overhang

Before starting work ensure that:

 the supports for your cladding are truly in the same plane;
 The minimum roof slopes conform to the standard (Low -roof -pitches);
 The overhangs of sheets from the top and bottom supports don’t exceed those
specified and whilst also overhanging a nominal length into gutters.
 Method Statement for roof covering storage tanks

 To Make any necessary adjustments before starting laying sheets, because they
will be difficult or impossible to rectify later.

5.6.2 Orient sheets before lifting

It is much easier and safer to turn sheets on the ground than up on the roof. Before
lifting sheets on to the roof, check that they are the correct way up and the
overlapping side is towards the edge of the roof from which installation will start.
Place bundles of sheets over or near firm supports, not at mid span of roof
members.

5.6.3 Position first sheet

With particular care, position the first sheet before fixing to ensure that it is correctly
located in relation to other parts of the building.
Check that the sheet:
 is aligned with the end-wall (or its barge or fascia), bearing in mind the type of
flashing or capping treatment to be used; and
 Aligns correctly at its ends in relation to the gutter and ridge
 Fix the sheet

5.6.4 Position other sheets

After fixing the first sheet in position, align the following sheets using:
 The long edge of the previous sheet; and
 A measurement from the end of the sheet to the fascia or purlin at the gutter.
It is important that you keep the gutter-end of all sheets in a straight line.

Fix the sheet by either:

 Fixing each sheet completely, before laying the next; or
 Fix the sheet sufficiently to ensure it can’t move, complete laying all sheets, then
return to place all the intermediate fasteners later.

5.6.5 Check alignment occasionally

Occasionally check that the sheets are still parallel with the first sheet, by taking two
measurements across the width of the fixed roofing.
At about half way through the job, perform a similar check but take the
measurements from the finishing line to aim for the final sheet to be parallel with
the end of the roof. If the measurements are not close enough, lay subsequent
sheets very slightly out of parallel to gradually correct the error by:
 Properly align and fix a lap, then
 Fix the other edge of the sheet, placing the fasteners slightly closer or further
from where they would normally be if there was no error. (Gradually correct the
error by placing the fasteners in such a way as to slowly bring the sheets back
into correct alignment.)
 Method Statement for roof covering storage tanks

5.6.6 Side-lapping and positioning roofing sheets

To prevent moisture being drawn into laps by capillary action, the edges of sheets
are slightly modified have the edges of the sheet over-curved and all have flutes
formed into the underlapping ribs.

It is important that sheets be lapped correctly. This means there should only be one
overlap/underlap - double lapping is not recommended.
After fixing the first sheet, place the next (and subsequent) sheet with its side lap
snugly over the previous sheet . Secure the sheet firmly in place until each end of
the sheet has been fixed.
You can do this easily by:
 Align the bottom edge accurately by a measurement from the end of the sheet
to the fascia or purlin at the gutter;
 Clamp the lap with a pair of vice grips
 At the top of the sheet: nestle the side lap snugly, check alignment, and fix the
sheet with a fastener

5.7 Marking out, cutting and drilling

5.7.1 Marking out

A pencil of any colour may be used except black or so-called lead pencils. Don’t use
black pencils to mark roofing or walling because the graphite content can create an
electric cell when wet and thus cause deterioration of the finish. You can also use a
string line with chalk dust, or a fine, felt-tipped marker.

5.7.2 Cutting

Whenever possible, we shall minimize site-work by using roofing sheets already cut
to length in the factory.
For cutting thin metal on site, we recommend to use a power saw with a metal-
cutting blade because it produces fewer damaging hot metal particles and leaves
less resultant burr than does a carborundum disc.

Cut materials over the ground and not over other materials where hot particles can
fall and cause damage to finishes especially pre-painted finishes. It is best to have
the exterior colour finish of a pre-painted sheet facing down, however it is important
to protect the paint finish of the roofing sheets

5.7.3 Making holes

Holes are often made by drilling or cutting by hole saw or jig saw. Mask the area
around the hole to protect paint from damage by swarf.
 Method Statement for roof covering storage tanks

5.7.4 Clean up

 Swarf (metal scraps and/or abrasive particles resulting from cutting and drilling)
left on the surfaces of materials will cause rust stains which can lead to reduced
life of the material.
 Sweep or hose all metallic swarf and other debris from roof areas and gutters at
the end of each day and at the completion of the installation.

6.0 Construction of Blockwalls on Gables

We shall extend steel pipes scaffolding inside and outside of the storage tanks on
the gable sides to provide working platform for labour and passage of materials
during construction of gable walls.

Walls on gable sides of storage tanks shall be constructed using cement sand blocks
and cement-sand mortar laid to accommodate a thickness of 230mm.

Walls shall be plastered and painted on both sides by our qualified skilled labour.
Mortar for block laying and walls plastering shall be mixed in the concrete mixer and
not by hand.

7.0 Installation of Doors, Exhaust, Ladders and lighting

When construction of columns, beams, walls and roofing covering is completed,

finally we shall install electrical lighting system, fixing access ladders, required Doors
and all necessary ventilation system as per contractor’s approved design.

8.0 Important safety measures

1. All work execution shall comply with safety procedures or instructions set out
in project safety plan and municipality rules and regulations. The respective
documents to be submitted to RE for approval at least 2 weeks ahead of a
planned operation.
2. Basic personal protective equipments (PPE) to be worn by all staff and
labourers at all times, during execution of work.
3. Qualified operators will be engaged to control and/or operate the heavy
equipment, machine, vibrators and the concrete mixers.
4. Provide sufficient lighting in preparation of possible night casting. We plan to
have 10 spot lights placed at the work site, which shall be located at Concrete
mixer (2nos), at the varying pouring locations (4nos), and 2nos at the
location of material loading.
5. PPE that will be used during the work includes gum boots, rubber gloves,
leather gloves, overalls, dust masks, safety goggles, hard hats, safety boots,
work gloves of suitable material, ear plugs and face masks, whenever
necessary.
 Method Statement for roof covering storage tanks

9.0 Staff to be available – Supervisors and Labours

No. Description Qty

1 Engineer 2
2 Technician 4
3 Skilled labor 8
4 Unskilled labor 60
5 Drivers 2
6 Plant operators 4

10.0 Materials to be used

S.no Material Description Material Quantity

1 IT5 Roofing sheets 2100m2
2 Marine plywoods 1200x2400x18mm thick 176 pcs
3 Reinforcement bars 11352 kg
4 Concrete Class C30 96m3
5 Cement in Bags of 50 kg 776 bags
6 Sand Material 68 tons
7 Aggregates 20 mm 72 tons
8 Aggregates 10 mm 46 tons
9 100x150 treated timber MEMBERS 3260m

11.0 Equipment’s and tools to be used

No. Description Qty Type Capacity

1 Dumper 2
2 Concrete vibrators 4 63mm diameter
3 Wheel barrows 10
4 Shovel 26
5 Water tank 2000l 2 Simtank
6 Hammer 8
7 Truck mounted crane 1
8 Plastic Bucket 1 20L
9 Concrete Mixer 2 JDC350 500L
10 Steel bar cutting machine 1

12.0 Attachments

12.1 Approved Drawings

12.2 Work program