Persero

PT. Waskita Karya

Construction Method, Building Project State Islamic University of Malang

CONSTRUCTION METHOD
BUILDING PROJECT
STATE ISLAMIC UNIVERSITY OF MALANG
Ministry Of Religious Affairs

A. Site Preparation

The project site is situated fronting Gajayana & Sumbersari street, Malang,
East Java. Consist of approx. 30 buildings and demolition any existing buildings
in a few place. Schedule duration of this project are 18 months
calendar, consist of structure, architecture, mechanical electrical and external
works.
For lighting and project activity power we combine between PLN and gensets.
We install one tower crane to serve administration/rectorate building as the
highest building in site and TC will be cover library building too.

Our project activity will not disturbance STAIN activity. We will be separate our
project and public area with fence. Project activity will be protected by
integrated security system, people who have not an ID card and any project
equipment rejected to access the project facility.

Project cleanness and safety is our primary concern besides accuracy of our
progress schedule and product quality.

B. Systems Planning

This project can be divided into the 4 group of the following building
components that consist of :
1. Administrative/ Rectorat Building
2. Library Building
3. Science Technology Faculty and Engineering Laboratory Building
4. Lecture Building A, B
5. Sport Center Building
6. Student Center Building
7. Language Faculty and Laboratory Building, Micro Teaching Laboratory
8. Multipurpose
9. Cafetaria
10.Islamic Research Building
11.At-Tarbiyah Mosque
12.Ta’mir Building
13.Mahad/Dormitory Building
14.Staff Housing
15.Water Tower
16.M/E Building
17.Public Lavatory
18.Business Center
19.Social Science Faculty & Lecture Building
20.Graduate Studies Building
21.Information Center Building
22.Dormitory Building
23.Greenhouse Building

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Construction Method, Building Project State Islamic University of Malang

24.Faculty Housing
25.Mechanical & Electrical Faculty Building
26.Faculty Apartments 01, 02 Building
27.Water tower
28.Musholla Building
29.External works

Because this is the large project and narrow works schedule, we need
resources that have capability to finish the project on time.

Foundation of buildings consist of mini bored pile and mini pile with variation
point between 18, 324, 464, 192 points, etc. depend on building.
Activities start from the first boring and pilling machine on selected building,
continue simultaneously to another buildings. It need coordination between
inspector every building to scheduling equipment needed.

After foundation works, structural, architectural and mechanical electrical

works continues from 1 st floor – roof floor. Every building works doing by
workers, no rolling workers, because limited schedule must be completed on
time.

Our partner sub contactor will be supply material scheduled, and we will be
check supply material for best product. Rejected material can not be install in
this project.
The Nominated sub contractors and direct contractors works shall be able to
commence on the third month and continue with minimum interruption.

1. Formworks and Scaffolding System

Because this project building do not need special treatment in building (not a
high rise building and don't have specific construction), we will use
conventional formworks and scaffolding system.

3. Concrete Supply & Handling

There is adequate site space for mobile mixers moving. Adequate mobile
mixers shall be available. For pouring we shall utilize static concrete pump,
mobile concrete pumps. Due to the location, concreting works could be
scheduled any time but if possible most of big volume pouring shall be done
nights for temperature constraint and convenience of workers.

4. Finishing Works

After completion of the structure, finishing works shall start ( brick works and
other as applicable ). Movement of materials shall be served. Work execution
could be done through several work with assigned area/tasks. Finishing
materials shall first be approved by management through submitted sample,
before purchase/delivery. Samples submittal shall be done as early as possible
to avoid unnecessary delay.
C. Management and Coordination

1. Site Organization Structure

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Construction Method, Building Project State Islamic University of Malang

To oversee the total site management shall be a Project Manager with the
support of deputy project manager, technical experts/advisors, construction
Manager and team supervisors as depicted in the Site organization Structure.
He shall be directly responsible to the executive committee. The project
manager (WK) shall have high qualification in terms of experience, known-how
technical and applied, management training and practice, and exposure to
handling of projects of this extent and magnitude. The other members of the
project team shall have similar qualifications.

2. Coordination Meetings.

The project team shall arrange for a weekly meeting with the Owner or his
authorized representatives in such time and day most convenient for all
concerned. In essence this meeting shall be for total project coordination,
exchange of opinions, work progress, problems and solutions, priorities,
conflicts, etc. and to bring closer the Contractor and the owner or his
authorized representatives to the total understanding of the project, its
schedule, its purpose and the investments involved by both parties. The
importance of this coordination meeting is invaluable. Minutes of every
meeting shall be prepared and agreed by all parties concerned before
distribution to parties concerned.

3. Project Reporting

To keep the Owner guided/Informed of the project status on a weekly basis,

the Contractor if so required shall prepare and submit project weekly report.
Among others this report includes the actual cumulative work progress status
up to the period covered, progress breakdown of all structures undertaken,
projections for the next period, Manpower report., equipment report, list of
activities, subcontractors, etc. It shall also show list of inquiries required by
Contractor from Owner /representatives, indicating milestone as well as those
overdue. Through this report the Contractor identities to the Owner the overall
project status and problems encountered as well as potential obstacles. It
shall assist the Owner in his action/decision making.

On the other hand, the monthly report shall be prepared/submitted with the
primary purpose of progress claim. All claims by Contractor shall be properly
supported by documented evidences. The detailed accomplishment of the
project are shown and plotted against the original S-Curve to define the actual
performance against the schedule. Among others, the report shall include
summary monthly report on manpower, equipment, materials, accidents if
any and other relevant safety/security reports, and progress photos showing
work progress between periods. Accomplishment projections for the next
month shall also be included with respect to original schedule. For cash flow
progress and project monitoring both weekly and monthly reports are
essential/import ant project documents.

4. Work to he Carried nut by Employer’s Own Forces and Employer’s

Contractors

The main contractor shall manage and coordinate all Employer’s Own Forces
and Other Contractors in so tar as work schedule and quality are concerned
with respect to sequence/timing of works to the overall work program. All

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Construction Method, Building Project State Islamic University of Malang

access equipment., storage facilities, power and lighting and necessary

support facilities are the responsibility of the main contractor.

5. Safety/Security and Sanitation

Usually lightly taken by most but in reality carry big impact on project morale
are the safety/security and sanitation aspects of the site. For this particular
project owning Lu LLS proximity to existing operational establishments, the
safety/security needs as well as the sanitation requirement levels are very
high. These scope of responsibilities cover riot, only the Contractor but the
Owner's side as well and could even extend to third parties. Particular
attention and concern shall be exercised by the contractor in order to
accomplish both missions converge in it’s provision/implementation.
Experienced security personnel, safety teams, site medical attendants/aides,
safety equipment end stringent regulations such as safety work gears
(helmets, shoes, buckles, nets, platforms, fire extinguishers, etc.), sanitation
facilities on the structures under construction and within the project shall be
adequately provided. The contractor shall leave nothing to chance when it
comes to safety/security and sanitation of site.

D. Technical Work

1. Earthwork

a. Excavation

Excavation works here means the excavation for Tower, Basement.

The equipment shall include:
1. Excavator. effective capacity = 50 cum/hour
2. Dump truck, capacity = 4 cum.
Surplus excavated material is removed out Site.

b. Backfilling

We assume that all of the back fill materials could be from excavations. To
fulfill back filling work, the equipment to be used include

1. Bulldozer capacity = 60 cum/hours

2. Fibro roller
3. Stamper

c. Backfilling method

Bulldozer will be used for hauling the soil from stock pile and borrow area to
the excavation area for back filling. The whole back filling is compacted layer
by layer every 30 cm thick with the fibro compactor while sprayed by enough
water to achieve the optimum compaction. For the other areas difficult to be
compacted by fibro compactor, the compaction is executed by
stumper/tamping rammer.

d. Disposal of Excess Materials

Disposal area of surplus excavated material is near the site.

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Construction Method, Building Project State Islamic University of Malang

e. Traffic Management

Particularly during the hauling / disposal of excess excavation, trucks coming

in and out of site shall be properly supervised to create minimum traffic
problems. Adequate washing facilities and cleaning teams shall be maintained
to keep trucks clean and roads free of dirt/mud.

2. Concrete Works

a. Mix Design and Trial Mixes

To obtain efficiency and the required quality of concrete, some mix design and
trial mix with various material shall be prepared. The material must be
obtainable in the market, adequate stock, and if possible the sources of
material are located near the project.

Materials needed for preparation of concrete are Portland cement, sand, and
split or crushed stones. Samples of materials will he taken to be tested in the
laboratory. Test results, which conform to the specification will be chosen.

Then various mix design can he prepared. Mix design shall indicate water
cement. ratio, water content, aggregate gradation, slump, air content, and
strength. With accurate calculation the weight proportion of port land cement,
sand, and split needed for 1 (one) cubic meter concrete of each type of
mixture can be determined. Trial mixes for each type will then he carried out
then the test specimen be made.

Nine test samples shall be made taken from every mix design which
subsequently will be tested at the age of 3 days, 7 days, 14 days, and 28
days. Based on the sample test strength result at the laboratory some mix
design which conform the specification be selected. Among the mix design
which meet the requirement of the specification, one which is the most
efficient will be chosen and submitted to the Engineer [or his approval. other
mix designs which also meet the requirement, If necessary will be submitted
as an alternative.

The approved mix design will become a standard of mixture for concrete
production which will be used it, the execution of the works.

Those test samples can be made in dimension of cube with 15 cm or 20 cm

side, or cylinder having 6 inches diameter and 12 inches length.

While waiting for testing, the test samples shall always be cured in an
approved manner by watering continuously or covered by wet material or
soaked in the water.

b. Quality Control

To assure the achievement of high quality which conform to the required

specification, it is necessary to conduct quality control activities by doing
inspection regularly upon materials used on the construction like installation
of formwork, pouring, compacting and curing of concrete. As a consequence it

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Construction Method, Building Project State Islamic University of Malang

needs selection of workers and maintenance of equipment and other means

regularly used in the execution of works.

c. Placing/Pouring

Several methods will be used to pour concrete , depending on the location of

formworks concerned.
1.1. Pouring using bucket, which is lifted by tackle or bucket cranes for slab
or other parts of structure must be adequate for easy handling.
1.2. Pouring using chutes made from canvas for walls, columns or other
parts of structure which has variable thickness or height. Using the
chute means to reduce concrete drop in order to prevent segregation.
Concrete shall be conveyed directly from truck mixers to buckets which
are lifted by tackle or bucket crane.

d. Concrete Compaction.

The purpose of concrete compaction is to limit air voids, so that the

compaction of concrete can be attained, and produce good bond between
concrete and reinforcement or other matters which are round within concrete.

Equipment to be used for the purpose is vibrator with a diameters of 1.5”, 2”

and 2,5” . Speed of about 5,000 to 9,000 vibrations/minute. Using of the
vibrator must he done carefully, and precisely considering the construction of
structure especially if some parts are exposed. Using equipment inaccurately
could carry negative effect to the concrete, among other things are
segregation, moving of bar reinforcement, damage to formworks etc. Internal
vibration will be done by internal vibrator directly into fresh concrete.

e. Curing or concrete

The newly poured concrete prior to initial set must be adequately Cured to
prevent hydration.

Curing shall be done by the following methods

1.1. Concrete slabs shall always be watered continuously or covered with

water during minimum 14 days or covered by wet canvass or covered
by curing compound. For concrete slab with a extreme thickness (mass
concrete), the slab shall be covered by plastic-sheet then covered by
sand about 30 cm thick and on the Lop shall be covered by canvass and
under water.

1.2. For the vertical walls or columns shall be covered by wet canvass, or
sprinkled by water or curing compound, or suspend the removal of the
formwork or apply water constantly for 24 hours. Temperature inside
and outside concrete with an extreme thickness should her monitored
wherever possible.

f. Concrete Joints

Location of Concrete joints must be known before hard. The location of

concrete joint to be effective must be under the minimum load/stress.

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Construction Method, Building Project State Islamic University of Malang

Locating of concrete joint should be in such manner as not to obstruct the

following concreting operation.
Prior to pouring new concrete against construction joints, Surfaces of joints
shall be thoroughly roughened, cleaned by compressed air or the like and all
laitance removed and reinforcement clean. Then cast surface joint with
calbond material. Joint sealants shall be provided in joints of concrete
construction where indicated. Immediately before new concrete is placed, the
surface of the old concrete already cleaned, shall be covered with a mixture
thoroughly brushed into old concrete.

For the watertight structure, the surface of old concrete shall be covered with
polyvinyl acrylic concrete bonding agent as approved by engineer before
placing of new concrete. Before the mixture of water and neat cement or
concrete bonding agent has become dry, pouring of new concrete must be
done immediately.

On the vertical joint metalath or expanded metal shall be used to produce

effected bund between old and new concrete at the joint.

3. Steel Reinforcement

Construction of concrete to the project needs steel reinforcement with various

diameters, and two types of strength characteristics as follows :

a. Mild steel plain bar = 240 N/mm2

b. High tensile deformed bar = 400 N/mm2

Delivery of reinforcement bars to project site in bundles marked with tags

indicating bar size, length and brand unloading must be done carefully to
prevent damage.

Store materials over dry ground, well drained area and protected from mud,
dirt, paint, corrosion etc. Certified copies of mill test reports, evidencing
compliance with the requirements of these specifications, will be submitted
with all deliveries of reinforcing steel.

Before placing, clean thoroughly reinforcement from loose rust, mill, scale,
dirt, oil and other coating.

Reinforcement shall he placed and fixed as follows:

- Bars in slabs shall be held in proper location during placing of concrete by
spacers, supporters, or other necessary supports and ties.
- Bars in concrete walls and columns shall be held in position and to proper
clearance by means of metal spacers.

4. Formworks

Formwork is designed to withstand the hydrostatic pressure of concrete and

dead weight, construction loads a rid vibration of vibrator equipment during
construction.

Installation of formworks shall be such that removal shall he easy to avoid its
damage or other concrete elements. The formwork is designed using plywood

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Construction Method, Building Project State Islamic University of Malang

which will be supported by Kamper beams and the like as formwork panel or if
possible steel.

a. Formwork of Column

The dimension of column is large enough, that's why pouring concrete

will be easy and fast. The fresh concrete will have enormous pressure on
formworks. To keep the strength of formwork, the steel frame with
clamps or bolt will be used. The support used for formwork of column
means to arrange the plumb of formwork and to keep the stabilization
and precision or formwork. Column shoes will be made with the same
quality of concrete ± 5 cm high.

b. Formwork for Walls

The same as the column formwork, the weight will press at the both
sides of formwork.
For stabilizing the pressure in the formwork we shall use tie rods which
also act as separators. The interval and position of tie rods separators
shall be calculated carefully.

c. Formwork for Beam, Girder and Slab.

Formwork beam and slab are different from other type of formwork. It
will be Loaded by dead load of concrete equipment and manpower. This
structure of form shall be stabilized to avoid any settlement, steel
members will be used as supports.

d. Removal or Formwork & Support

Generally, removal of formwork will be done after the concrete is strong

enough. The removal of formwork of column and walls will be done 1 day
after. Although in few projects we remove the formwork 4-6 hours after
pouring concrete. For root slab the removal of formwork will be started
after removing supports under beams.
5. Conclusion

We appreciate to do this project, simple description above will be detailed on

site. May be in progress will be arise a new idea that support our method
adjust with drawing. Detail plan and method will be made while project
progress.

We hope our simple explanation give clear description of step by step our
method in this project. Thank’s.

Surabaya, August 12, 2005

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PT. Waskita Karya

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Construction Method, Building Project State Islamic University of Malang

Ir. Desi Arryani

East Java Branch Manager