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AS PREPARED BY:
TABLE OF CONTENTS
1. PURPOSE .................................................................................................. 3
2. SCOPE ....................................................................................................... 3
3. REFERENCES ........................................................................................... 3
4. DEFINITIONS ............................................................................................. 3
8. METHODOLOGY ....................................................................................... 9
9. DOCUMENTATION .................................................................................. 23
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
1. PURPOSE
This method statement aims at revealing the execution strategy and associated tasks involved in
completing the boundary wall using the Alternative Proposal’s solid precast concrete panels
(maximum of 120 mm thk. depending on final structural design), precast concrete columns &
cast-in-place concrete footings.
A “Tasks Risk Assessment” supports this method statement and can be found in Appendix-A.
2. SCOPE
This document aims at familiarizing the concerned parties with the details and sequence of the
relevant activities, and the planned utilization of resources for the safe delivery of the boundary
wall. As such, the method statement will address required key staff, their respective
responsibilities, the required equipment and tools necessary for completing the job, and the
methodology of execution, in a stepwise, chronological fashion.
The concerned boundary wall will serve as the security barrication around two locations
belonging to the Arab Potash Company (CLIENT): the A.P.C Plants location and the Numeira
location, stretching estimated lengths of ~3,300 m and ~2,200 m respectively, with visible height
3.6 m above ground level, and all as per client requirements. An optional accessory would be to
top the wall with metallic concertina and barbed wires upon request of the CLIENT.
3. REFERENCES
4. DEFINITIONS
Project Manager
Responsible for overall construction activities inclusive of ensuring that all safety measures
are implemented, and all required equipment & materials are available on site.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
Ensuring that execution is in line with the project’s allocated budget & time-frame.
Ensuring that all construction operations are carried out in accordance with the Project
Specifications, Construction Procedures and Drawings.
Attending meetings with CLIENT & SE to review progress and all issues concerning the
project.
Ensure that all the documentations are complete as per the project requirements and
company policies.
Field Engineer
Responsible for the day-to-day planning of excavations, backfilling, casting of footings and
the production and erection of the precast concrete panels and columns.
Ensuring the timely allocation of resources and materials to facilitate the timely completion of
the tasks and activities, all in accordance with project specifications, drawings and program
of work.
Liaison with all crews (production & erection) to maintain daily scheduled progress.
Monitoring day-to-day activities, progress reporting and task delegation. Over all in charge
of precast yard and erection site personnel.
Ensuring the cooperation of all work crews with the Safety Officer to implement all the
necessary safety & environmental protection measures as per the HSE Plan.
Coordination with the QC Inspector and raising completed works RFIs (as per ITP) with the
relevant drawings & checklists. Verify all inspection reports are carried out as per ITP.
Informing the QC inspector on the daily work plan (what is planned for concreting, erection,
excavation, backfilling etc…).
QC Inspector
Responsible for verifying that the quality and accuracy of product is being achieved,
processes are being implemented; controls are in place and records are being generated
and maintained.
Completion and filing of all inspection records under his control and reporting quality
concerns and discrepancies to Project Manager.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
Coordinating with Surveyor to make sure survey team is aware of daily work tasks and
locations to enable them to set out excavation coordinates, assist with erection tasks, and
wherever needed.
Coordinating with stockyard and shifting personnel regarding required pieces needed for
erection as per day plan and erection programme.
Safety Officer
To enforce and monitor compliance of all personnel in the production yards, steel yards,
storage areas and erection sites with the HSE plan.
Prepare daily / weekly safety tool box talks for each new task, making sure each team
leader is fully aware of the safety hazards involved in his, and the actions to be taken to
mitigate those hazards. (Refer to TRA in Appendix-A).
Directly reporting to Project Manager about safety and health related non-compliances and
concerns.
Fill out near-miss reports and accident reports. These to be submitted for record keeping
and circulation to company management.
Surveyor
Establish the control points by scouting existing reference points defined and indicated by
the CLIENT/Engineer.
Setting out of boundary wall path and identifying any obstructions that needs removal /
displacement.
Following up with excavation and earthworks team to make sure excavations course and
depth as per required.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
Providing markings for the placement of blinding pads, footings, and assist in achieving
correct columns plumbing and alignment during erection.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
20 ton
Flatbed For shifting and installation of
6 with 1 precast concrete columns and
Crane panels
(HIAB)
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
Compactor necks
5,000
litters For filling up equipment,
12 Diesel 1 (generator & light towers (if
Tank with required)
integrate
d pump
7.2 Materials
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
8. METHODOLOGY
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
Upon approval of design drawings and calculations, Work Shop Drawings for the
boundary wall elements (foundations, 120 mm precast concrete panels and
columns) will be produced for execution.
8.3.1 Submittals:-
Submission of Construction Program & CAR insurance within 14 days from Letter of
Commencement. Concrete Mix design from approved supplier to be submitted prior
to commencing of construction activities.
Upon reaching bottom of foundations (BOF) level, the ground must be trimmed
to receive the concrete blinding. Safety barrication (warning tape) to be provided
until pits are backfilled and ground is reinstated.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
or other debris.
The formwork will be tightly secured and QC inspected against a Forming
Checklist and the relevant drawings.
Form oil will be applied evenly to the inner surfaces of the shutters, and the next
step will be to insert the rebar and anchor bolts.
The anchor J-bolts (for the column-to-foundation connection) will be cast-in the
footing. Steel fixers will utilize a template that secures the four bolts in their
relative positions, and the template to be centered horizontally within the footing
form, and levelled properly. Once properly aligned and levelled, the exposed
threads are to be covered with masking tape to avoid being splashed by
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
Notes:
Slump of 125mm ± 25 is found within limits, elapsed time between batching
and placing of concrete shall not exceed specs requirements.
The Temperature of the concrete at the time of placing not to exceed 32°C.
Ambient temperature shall be 38°C Maximum.
In hot weather, cooled water shall be used for mixing concrete. If
necessary, crushed or flaked ice shall be added. This procedure shall be
performed under strict control to ensure the total amount of water added
remains under the prescribed limits.
After initial setting, hand floating & troweling is done to achieve the desired slick
finish of the top face of the elements.
The form shutters will be kept for a sufficient period of time to retain moisture
within the casted footings, and the top surface will be cured appropriately by
keeping moist for three days after casting.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
The mould inner surfaces will be cleaned and free of dirt or other debris. After
each casting cycle the shutter surfaces should be cleaned from any concrete
residues with scrappers. The shutters will be visually inspected to identify any
wear and/or deformation that must be remedied before next casting.
The mould shutters will be secured and QC inspected and checked for
squareness and correct dimensions and a Forming Checklist (refer to ITP & QC
Plan) is filled out, where inaccuracies are found, they must be adjusted
accordingly. PCI Manual 120-99 chapter 8 and PCI manual 135-00 shall be
referred to as international standards to govern allowable tolerances in
production of precast/pre-stressed elements.
Next, Mould release agent will be applied evenly to all inner surfaces of the
shutters.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
The steel reinforcement bar/WWF mesh size, number, spacing and clear cover
will be indicated by the approved production shop drawings. A shaded steel yard
will be set up onsite for the fabrication of the steel reinforcement cages, cutting
and bending making ready for insertion into the moulds. Local design standards
governs the placement of reinforcement with regard to cover, lap lengths etc…
Lifting inserts will be fixed to the rebar in the elements according to location and
specifications provided in the shop drawings. These will be engineered based
on precast element dimensions and weight, and the fixing information will be
reflected on handling drawings. The lifting anchors may be either flush with the
surface or recessed. Where appearance is a factor, a recessed embedment
may be used as it can be concealed with grout.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
Any other cast-in items (electrical conduits, back boxes or block-outs), if any, will
be tied to the main reinforcement at the specified locations and as per details
provided in the shop drawings.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
No water should be added on site and cube samples are taken for
compressive testing as per QC Plan. Drop height should be restricted to no
more than 1 m, and proper vibration using external needle vibrators (and
mould vibrators where seen fit) so as to retain no appreciable amount of
entrapped air. The vibrator should draw through each successive deposit of
fresh concrete into the previous placement to ensure adequate blending.
Screeders will be used to maintain thickness and levelling after spreading.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
trowels/floats finished.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
capacity, and the stripping process must be done under the supervision and
instructions of the production yard’s rigging supervisor. The elements are
then transported on board a flat trailer to the stockyard. In case of defects or
damages, the QC engineer shall be informed immediately.
The stacking of the panels, columns and footing elements in their final
positions in racks and on sufficient dunnage to eliminate risk of tipping over
or deflection. Damp proofing coal tar epoxy will be applied in the stockyard
to columns’ submerged portions prior to shifting to erection location.
3. The erection crew will offload the column of the flat bed using the
erection site’s mobile crane with adequate capacity, and under
the supervision of the site erection supervisor. The rigging belt is
attached to the column from a hole provided at top of the column
for erection
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
7. The gap between the column base plate and top of footing, also
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
The procedure for backfilling and associated tasks (watering, compaction &
testing) has been discussed in section 8.4.1. It is however re-iterated here.
The backfilling process begins right after column erection is completed. The
tipper trucks supply the approved selected back fill, and the backhoe loader fills
the pits with the soil in layers and each layer is properly compacted, until finish
ground level (FGL) is reached.
Accessories like concertina wire and barbed wire (as per instructions of CLIENT)
can then be fitted after completion of all erection and backfilling works HC.
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Method Statement: Alternative Option - Construction of Boundary Wall
Using Solid Precast Concrete Panels, Precast Concrete Columns & CIS Concrete Isolated Footings
Fig.19 Bringing Ground Level Back to Desired Level and Preforming Touch up Works
9. DOCUMENTATION
The work inspection notice for all the above tasks will be in accordance with ITP and QC Plan.
The inspection requests will be raised to the consultant in advance to confirm time of field
check. All documentation and inspection reports will be signed by the QC engineer and kept
for internal use and a copy sent to the supervision engineer attached with the inspection
requests.
Good housekeeping will be observed in all working areas. Construction wastes will be
segregated and disposed to an approved dump yard.
Nominated skilled persons carrying out the works will be qualified, properly equipped
and provided with the all the necessary PPE required against the potential hazards, and
trained for the safe manual handling techniques.
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