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1、METHOD STATEMENT FOR BRIDGE, MICRO PILING, LOAD TEST AND CONCRETE WORKSCONSTRUCTION METHOD FOR THE BRIDGEOBJECTIVEThe objective of this method statement is to describe and outline a working methodology to ensure a fair degree of control， attention and consideration had been given to the construction2、 of Bridge over Sg。 Dapu, Sarawak.SCOPE OF WORKThe scope of work will cover the work methodology for:o Site Preparation o Pilling Work （Bored Pile）o Testing of Piles （PDA, Load Test and Pile Integrity Test*) o Construction of Foundation o Construction of Abutment o Construction of Pier o Constructio3、n of Girder Beam o Launching of Girder Beam o Construction of Bridge Deck o Finishing workWORK METHODOLOGY SITE PREPARATIONa. Prior of any construction being carried out， location for the construction of the bridge shall be identified and check by the surveyor。b. R。O.W。 shall be verified to ensure n4、o construction of permanent and temporary structures are out of the site boundaries.c. If the required area for construction is insufficient, negotiation with adjacent landowner shall be conducted for the rental of the land for bridge construction activities.d. Temporary crossing over different rive5、r shall be identified， assessed and constructed based on the most suitable solution available for each river crossing.e. In order for the construction of the bridge abutment and pier, a working platform shall be constructed。f. The surveyor shall identify and set on site the location of the abutments6、/piers for the bridgework.g. For the abutment or pier which is located at the riverbank or in the river, working platform shall be constructed by extension of the river outwards to the river.h. Suitable fill material from the earthwork activities shall be used to extend the riverbank outwards to the7、 center of the river。i. Adequate opening or gap shall be retained for the continuous flow of the river and also to provide access for the longboat travelling up and down stream of the river。j. Existing logs and tree trunks from the site clearing work shall be used as anchorage or temporary retaining8、 structure to retaining the fill material over the river bank where the working platform shall be constructed.k. The working platform shall be properly compacted and fill up to the required level for the safe operation of pilling and abutment/pier construction。l. Proper access shall be constructed t9、o enable access for the pilling machine and delivery of material including concrete supplies。m. The working platform shall be monitor from time to time to ensure its stability and safety。n. A well compacted and flat casting yard shall be prepared for the construction of the girder beam。o. The castin10、g yard for the girder beam shall be located at an area which will not interfere with other construction activities and close to the bridgework activities。 Access to the working casting yard shall be provided and maintained.p. A storage yard shall be prepared next to the casting yard to store all the11、 material required for the construction of the girder beam。q. Workers quarters shall be constructed close to the casting yard and shall be provided with the basic facilities and complied with the requirement of the local authorities.MICRO PILLINGPURPOSETo outline the method statement by which Micro 12、piles is carried out。SCOPEThe scope of works for this method statement is to construct the piling works for Micro piles according to specification， dimensions， setting out and site preparation per design drawings.REFERENCE DOCUMENTThe piling works shall be constructed in conformance to the following13、s:Contract Construction Drawing Contract SpecificationSEQUENCE OF ACTIVITIES, SPECIFIED REQUIREMENTS AND VERIFICATON ACTIVITIES. HANDLINGAll API pipes must be lifted and transferred accordingly.STORAGE OF MATERIALSAll API Pipes shall be placed on adequate support with adequate slippers in order to a14、void slipped off from the storage area。All pipes within a stack shall be in groups of the same size and length。PLANT， MACHINERY AND EQUIPMENTMicro piles piling rigs rotary wash and down the hole hammer type by using air flush come with water circulation wash, air compressor， welding sets, generators15、, concrete grouts mixer etc as applicable。PREPARATION WORKSObtain relevant approved construction drawing from structural consultant.Setting out for reference lines by marking on the peg。WORK METHODOLOGYa. The piles used for the project shall be as specified diameter. The size of the hole drill shall16、 be as per construction drawings.b. The piling points （position) shall first be set out by the surveyor to ensure all piles installed are as per indicated in the drawings。c. Off set the piling position and make sure that the pile position can be set back accuratelyd. Area where the pile is to be con17、structed must be cleared。e. Upon confirmation of pile position, verticality of the pile will be checked by using spirit level.f. Mobilizing the micro piles piling rig into position.g. Drill with temporary casing until firm strata is encountered. The drilling technique used shall be both rotary wash 18、and down the hole hammer。h. Drill with appropriate tool until hard strata or rock is encountered or drill the hole to the required depth. If the length of the API is required to extend further to meet the required strata， API pipe shall be joined up by butt welding.i. Upon confirmation, flash the ho19、le until it is reasonable clean, then move the machine to the next position。j. Insert the pile reinforcement into position and prepare the grout in accordance to construction drawing details as specified in drawing as well as take the necessary number of cubes for testing. （6 pieces per set， 2 for 720、 days strength, 2 for 28 days strength and the remaining 2 pieces for reference）。 One set of test cube shall be taken for every batch of grout that being prepared for the mentioned work.k. Pumping the grout to the drilled and cleaned pile position by inserting the tremie pipes or 32 mm HDPE pipes un21、til the bottom portion of the pile， pump to flush the grout out of the drilled and cleaned hole until the acceptable grout is being flushed out at the top portion of the pile. Clean up the area around the pile.l. Repeat the whole process for the next pile.SAFETY PRECAUTION FOR PILING WORKWorkers sha22、ll follow approved HSE plan while carry out piling work。 Personal Protective Equipment (PPE), warning signage, tool box meeting, competent operators, etc， shall be implemented and maintained during the phase of works。EXPECTED OUTCOMESThe micro piles works are completely constructed according to the 23、construction drawings and specification。TESTING OF PILES PDA TESTa. Upon completion of the pilling work。 PDA test shall be conducted。b. The Resident Engineer shall select the pile to be tested based on the allocation provided by the contract for pile.c. Pile head shall be prepared before PDA test is24、 being carried out.d. For Bored Pile， the top of the pile is to be provided with a steel sleeve for confinement /restraint against bursting of the concrete during impact from the hammer。 The steel sleeve can either be installed during concreting of the pile or it can be a buildup section of the pile25、 to be constructed over the top of the installed pile after selection of the pile to be tested. The concrete at the top of the pile is to be finished level and be of comparable strength with the pile proper to receive the impact from the drop hammer.e. Two pairs of strain transducers and acceleromet26、ers are to be attached to the sides of the pile top at approximately diametrically opposing positions. Where possible, the sensors are to be attached at 1。5 times or more the diameter of the pile below the top of the pile。 The sensors are attached to the concrete of the pile using mechanical anchors27、 installed into 6mm nominal diameter holes drilled about 40mm into the concrete。f. After the sensors have been installed onto the pile， the sensors are connected to the Pile Driving Analyser （PDA） using signal cables. A system check is then conducted and the relevant details of the pile are keyed in28、to the PDA。g. When the setup is ready， a test impact will be carried out to check the system and effectiveness of the selected parameters。 Appropriate adjustments to the hammer such as height of drop, positioning and cushioning will be carried out where necessary. Similarly， fine adjustment of the s29、ensors may be carried out if necessary. Further impacts for the Acceptance Test on the pile are then carried out。 The test will be terminated upon successful demonstration that the mobilized pile resistance equals or exceeds the required test load。h. The data for each impact will be stored, printed 30、and submitted to the consultant for their perusal.STATIC LOAD TESTa. Upon completion of the pilling work. Static load Test shall be carried out on the Resident Engineer selected pile for testing。b. The Resident Engineer shall select the pile to be tested based on the allocation provided by the contr31、act for both bored pile.c. The loading for the static load test for Bored Pile shall be as per the specifications for 600 mm diameter and 1000 mm diameter pile。d. The ground surrounding the test pile shall be well compacted in order to set up the static load test.e. Sufficient length of Pile above t32、he compacted ground shall be maintained in order to carry out the test.f. The Kentledge System is assembled with care。 Extra care shall be taken during the placement and stacking of the I beam.g. Extra care shall be taken when placing the concrete block onto the I beam frame.h. The number of concret33、e block to be place shall vary pending the loading required.i. The geometry of the arrangement shall also aim to minimize interaction between the test pile， reaction system and reference beam support.j. A hydraulic Jack and calibrated load cell reacting against the main girder and the test pile is p34、laced。 A steel plate is place between the test pile and the hydraulic jack in which the dial gauge will measure the movement of the steel plate。k. Four (4) numbers of dial gauges is fix to an independent steel support frame to measure the displacement of the steel plate.l. Movement of the pile head 35、shall be measure using the four （4) numbers of dial gauges and checked with leveling instrument against a scale ruler fixed to their holder。 Another scale ruler shall be fixed as independent references point or bench mark to be rested on the ground protected and firmed inserted into the ground. m. A36、ll testing equipment shall be protected against any disturbance prior to and throughout the load test.n. The loading sequences shall follow the Resident Engineers specification including the step and duration.o. Records shall be kept throughout the testing period and submitted to the consultant for 37、their perusal at the end of the loading test。PILE INTEGRITY TESTa. Once all the bored pile had been completed Pile Integrity Test can be carried out on all the bored pile。b. The top of the bored pile shall be prepared for the test to be carried out.c. A small accelerometer is to be held on the pile，38、 parallel with its axis。d. The pile will then be struck with the hammer provided by the testing equipment for a number of times predetermined and deem necessary by the testing team。e. The data from the sonic method shall be stored into the equipment and submitted to the Consultant for their perusal.39、f. The same process is repeated until all the bored piles are being tested。ABUTMENTa. Upon the completion of the pilling work, as built survey shall be carried out on the piles and submit for the consultant perusal, o Once the pilling work had been approved, the construction of the abutment shall be40、gin with the construction of Pile Cap。 o Surveyor shall off set the dimension of the abutment for control during the construction process。b. The working platform is then excavated down to the cut off level of the pile。c. Once the excavation has reach the required level, a layer of lean concrete shal41、l be pour to prepare a working area for the construction of the pile cap。d. As the piles had been exposed， the pile head shall be hack and cut to the required level。 Extra length of the pile shall be removed from site.e. The inside of the pile shall then be roughened and the starter bar inserted int42、o the pile as per the construction drawing.f. Reinforcement work shall then be carried out on the pile cap while the formworks are being prepared.g. Prior of any casting。 Site Engineer shall check the dimension and reinforcement detail to the construction drawing.h. Once the Site Engineer is satisfi43、ed with the work, a joint inspection shall be carried out by the R.E。/C。O。W. and the contractors representative for approval of casting.i. Only with the approval from the consultants representative shall the casting be allowed.j. Concreting shall be carried out with the supervision of the C.O。W。 and44、 the Site Supervisor.k. Concrete shall be pour into the structure evenly by alternating the pouring location。 Proper compaction shall be achieved with the use of the concrete vibrator.l. Concreting work shall continue until the finishing level had being achieved and the finishing level being properl45、y compacted and screed.m. Formwork shall be left overnight for the setting of the concrete and removed once the site engineer is satisfied with the strength and hardness of the structure。n. Upon the removal of the formwork， curing shall be applied to the structure. This is achieved by either using a46、 curing compound or damp gunny sag.o. The abutment shall be cast in 3 sequences. First section shall be the pile cap and then continue with the abutment wall and finally ends with the wing wall casting.p. The construction shall then move onto the construction of the abutment wall starting with the r47、einforced work and then the formwork and finished with concreting work。q. The same process shall be repeated for the abutment wing wall。PIERa. Upon the completion of the bored pilling work， an as built survey shall be carried out and submit for consultant perusal。b. Once the pilling work had been ap48、proved， the construction of the pier shall begin with the construction of Pile Cap. c. Surveyor shall off set the dimension of the pier for control during the construction process.d. The working platform is then excavated down to the cut off level of the bored pile。e. Once the excavation has reach t49、he required level， a layer of lean concrete shall be pour to prepare a working area for the construction of the pile cap。f. As the bored piles had been exposed, the pile head shall be hack and cut to the required level。 Extra length of the pile shall be removed from site.g. Reinforcement work shall 50、then be carried out on the pile cap while the formworks are being prepared.h. Prior of any casting， joint inspection shall be carried out by the R.E./C。O。W. and the contractors representative。i. Only with the approval from the consultants representative shall the casting be allowed。j. Concreting sha51、ll be carried out with the supervision of the C.O.W. and the Site Supervisor。k. Concrete shall be pour into the structure evenly by alternating the pouring location。 Proper compaction shall be achieved with the use of the concrete vibrator.l. Concreting work shall continue until the finishing level 52、had being achieved and the finishing level being properly compacted and screed。m. Formwork shall be left overnight for the setting of the concrete and removed once the site engineer is satisfied with the strength and hardness of the structure.n. Upon the removal of the formwork, curing shall be appl53、ied to the structure. This is achieved by either using a curing compound or damp gunny sag.o. The pier shall be cast in 4 sequences. First section shall be the pile cap and then continue with the pier column， and then the pier head shall follow and finally ends with the parapet casting。p. For the ca54、sting of the pier column， pipe sleeves are cast into the pier column at an approved interval。q. By using the previously casted pipe sleeves in the pier column， temporary decking shall be erected to form the falsework for the Pier Head。r. Once the pier head had been casted， the construction work shal55、l proceed to the construction of the Pier parapet。GIRDER BEAMa. Prior of the construction of the 40 m and 30 m length girder beam。 Casting location shall be preselected and approved by the consultant.b. Care shall be taken so that the casting yard shall not obstruct any other construction activities56、 and the location shall be convenience enough for the launching of the Girder Beam.c. The casting yard shall be trimmed and levelled to the required level and compacted to the satisfactory of the Site Engineer。d. 5 rows of timber layer consist of 2 number of 2 x 3 x 10 which is stack on top of each 57、other are arrange continuously along the girder length。 The timber layer is spread wide enough to support the girder beam and the steel form above them. e. Minimum of 3 rows of first layer would be arranged directly under the base of the girder beam 。f. A layer of 2 x 3 x 4 are then arrange on top o58、f the first layer but perpendicular to the girder length。g. Third layer consisted of 1 x 3 x 10 are then laid continuously on top of the 2 x 3 layer along the length of the girder beam， o Finally, layer of 12。5mm thick plywood saw to size are then placed on top of the third layer to support the rein59、forcement and to content the concrete.h. Reinforcement is then place on top of the plywood。 Post tensioning cable and other related works are then place inside of the girder beam。 Box out for the post tensioning work shall be properly secure to the reinforcement。i. At each end of the girder beam， a 60、pipe sleeve is place at a distance of 1 to 1.2 m away from end of the beam and 200 to 250 mm above the bottom of the beam. These pipe sleeves shall be used for lifting point during the transportation and launching of the girder beam。j. For the girder beam which will be place on the edge of the abutm61、ent and pier, a series of pipe sleeves shall be place in the girder beam at the interval of 1.8 m.k. These pipe sleeves shall act as part of the supporting falsework during the construction of the deck and parapet wall, o Joint inspection between the C.O.W. and site engineer shall be carried out on 62、the reinforcement before the formwork is place onto the girder beam.l. Upon the completion of reinforcement work and the post tensioning work， the formwork shall be erected onto the girder beam reinforcement.m. Stop End for both end of the girder beam shall be erected first。 Any box out for the post63、 tensioning work shall be properly secure onto the Stop End formwork。n. The length of the girder beam shall be check and a string line is pull between both ends to check for beam alignment.o. The erection of the steel formwork shall be carried out with extreme care. Lifting equipment with adequate l64、ifting capacity shall be used to lift the steel form into place.p. The steel formwork is secure on the top and bottom with wooden clamps at pre-determined intervals。 The top clamps shall sit on the top of the steel form while the bottom clamps shall be feed through the timber support layer to secure65、 the bottom part of the steel formwork。q. Props are provided at both side of the steel formwork to ensure the verticality of the steel formwork.r. Inspection shall be carried out to make sure the steel formwork is properly secure and ready for concreting.s. Upon the satisfactory of inspection betwee66、n the C。O。W。 and the Site Engineer， concreting of the girder beam shall proceed.t. Concrete shall be delivered to site using concrete mixer truck。 The concrete is then discharge into the concreting bucket and by the mean of lifting equipment; the concrete bucket is lift to the concreting location an67、d discharge into the formwork.u. Concreting work shall start from one end and towards the other end. The concrete level inside the formwork is raised evenly by adding concrete into the formwork along the girder beam.v. Continuous supply of concrete is critical to avoid cold joint.w. Vibrator shall b68、e used to vibrate the compact the concrete inside the formwork. The steel formwork s tapped with hammer from time to time to assist in the flow of the concrete through the web section of the girder beam。x. Extra care shall be taken to ensure concrete flows into the flange of the girder beam and not 69、trapped at the web of the girder beam。y. Once the concrete had reached the required level。 The top of the concrete level shall be levelled and make good。Check shall be carried out on the post tensioning duct with the use air compressor to ensure that the post tensioning duct are not damaged and bloc70、ked.z. The concreted girder beam is left overnight to set.LAUNCHINGa. The I Beam Girders shall be transport to the position for launching by two purposed built Prime Mover Units。b. The I Beam Girders shall be lifted from their casting position into the Prime Mover Unit using 2 nos of lifting crane e71、ach at one end of the I Beam Girder.c. A Banksman shall be responsible for the lifting operation. The working area of the cranes and the Prime Mover Units shall be kept clear of unauthorized personnel。d. Instruction on the lifting operation shall only be given by the Banksman.e. The Banksman shall e72、nsure the lifting operation is safe and all the lifting equipment including the crane and cable are to the required capacity and strength.f. The I beam is then lifted simultaneously by both crane at each end of the I beam, swing towards the Prime Mover Unit and slowly lower down onto the Prime Mover73、 Unit. The lifting of the I beam is kept as low as possible。g. The I beam is then secure in place on the Prime Mover Unit by using chain and strap in order not to damage the I Beam Girder during the transport。h. The Prime Mover Unit shall then transport the I Beam Girder to the launching position。 T74、he travelling speed of the Prime Mover Unit shall not exceed 15 km/h while moving the I Beam Girder.i. Lifting crane （2 nos） is position at each side of the Abutment (Pier).j. The Prime Mover Units shall position themselves with the I beam girder at the temporary crossing alongside the abutment as d75、emonstrated on PIC 1.k. By attaching the lifting point at both end of the I beam girder, both crane would lift the I beam from the Prime Mover Unit into position on the abutment.l. The I beam shall be lifted from the Prime Mover Unit, swing towards in abutment and position into place with the assist76、ance of a tag line。m. With the assistance of tagline， the I beam shall be lower and position into place at the abutment on top of the rubber bearing as demonstrated in PIC 2。n. Timber struts are used to brace the I beam once it is on position to avoid it from tipping over。BRIDGE DECKa. Upon the comp77、letion of the launching of the girder beam. Falsework are erected to provide working area and to support the reinforcement for the bridge deck。b. By using the gap between and girder beam and the pipe sleeve along the edge beam， falsework are erected along the girder beam.c. The reinforcement is then78、 place on top of the falsework。 Any box out for the opening shall be indicated and securely fix onto the falsework to prevent movement during concreting。d. The bridge deck shall be poured in 2 sections, the bridge deck and the parapet wall.e. Each concrete pour shall be for one complete bridge span。79、 Movement joint shall be inspectedf. Upon the completion of the reinforcement work for the bridge deck， join inspection shall be carried out between the C。O.W. and the Site Engineer and once approved, concreting shall proceed。g. The construction of the parapet wall shall proceed after the constructi80、on of the bridge deck with the reinforcement work first and then the formwork and finished with the concreting work.h. Care shall be taken to avoid falling object from the working platform into the river。HEALTH, SAFETY。 SECURITY AND ENVIRONMENTa. All work on site shall adhere to the approved Occupat81、ional Health and Safety Plan.b. Supervisor in charge of the construction area will be responsible for ensuring adherence to safe work method statement.c. Safety Officer will survey implementation of safe work method statement procedures.d. Environmentally contaminating waste such as oils, grease， chemical, etc shall not be discharge into site drains and shall be treated as schedule waste。e. The following Personnel Protective Equipment （PPE) and safety and health related equipment are deemed the minimum protective equipment required for carrying out the works: Safety Helmet Safety Boot