1) Scope of Work

(a) General Description

1) The Bridges deck comprise cast in situ, post tensioned multi cell concrete
structures. In both cases the final road surface is provided by and overlay of
50-mm Asphaltic wearing course over the concrete block.

2) The post tensioning work will be carried out by the specialist Subcontractor
and the works relating to this will be covered under a separate method
statement.

2) Construction Sequence

(a) Overall Programme

1) False work staging will be set up at a height of approximately 5.5 to 6.5 m for
all structures. On completion of casting and post tensioning work, the staging
will be taken down then set up at new location of other structure. (copy of
deck construction programme is attached)

(b) Pour Sequence

1) A detailed layout of optional construction joint locations and pour sequence

has been provided in the contract drawings and this will form the basis for the
proposed method of construction. The deck has been divided into seven
section for all bridges except for BKEN-1 9 sections and 13 section for BKEN-
2 by introducing construction joints at 6.0m offset from the piers transversely
across the decks. This then provides four pours between 200 m2 400 m2
(plan area) for area marked A, B, C and D and three pours of 130m2 for areas
marked E, F & G. No of construction joint may charges in accordance to site
requirements.

2) The positive moment areas will be cast first (A, B, C & D) and followed by the
negative moment areas (E, F & G).

3) The pour sequence is shown on the attached plan and comprise the casting
of the bottom slab of the full width of the box girder in the stages shown down
includes webs. After pouring of all bottom slab and web, the top slab will be
cast on the same patterns, supported by temporary removable false work
within the box void.

4) Staging of the bridge will remain in place until all post-tensioning works is
completed.

5) Stage-2 of the abutments will be cast 30 days after of post tensioning is

completed.

3) False Work
 (a) A proprietary supporting system will be used for staging out the full plan areas
of each deck. The staging will comprise a braced structure (calculations will
submit separately) separating supporting primary and secondary beams
(aluminium, steel or timber beams).

(b) This will be overlaid with an 18mm decking plywood, which can provide the
final finishes as specified.

(c) Support for the cantilever slab will be built up timber carcassing form the
lower soffit level decks to the desired contour and profile. The cantilever
support system will be removed after 14 days of casting of the top slab.

(d) Adjustable jacks will be provided at head of the staging to allow the cross falls
and pre-camber for the entire deck. After casting of the we section, internal
box forms will be taken out and False work provided to the soffit of the top
slab. This will then be removed after 7 days of casting the top slab.

4) Post Tensioning

(a) The post tensioning works will be carried out for all the decks by a specialist
Subcontractor. A separate method statement and working drawings had been
submitted covering in detail the elements and procedures involved.

(b) During casting of the box girder, the post tensioning tendon ducts will be
installed to the approved profile within the web reinforcement, secured in
position by using additional approved steel chairs.

(c) All the webs, will be cast integral with the bottom slab.

5) Placement and Finishing of Concrete Box Girder

(a) Concrete Supply

1) Ready mix concrete to the approved mix design will be supplied by M/s.
National Ready Mix concrete. The average travel time for trucks from is
approximately 30 minutes, the plant to deck location.

Concrete will be batched from a fully automated plant capable of batching a

maximum 100 m3 / hr. Average production from this plant is in the region of
30-70 m3 / hr. (One supplier will be on standing even if not being used)

Concrete placement at site will be via truck mounted pumps. For deck slab
pours generally 2 Nos. will be employed for the pour. One pump will be
available on site as standby even if not used.

The max pour size is 225 m3 and the pour rate will be 40-45 m3 / hour, which
is governed by the finishing operations.

Where temperature permits the deck pours will be carried out during day or
night time.
 2) The cycle time to one load of 9 m3 of transmit mixer is

i. 15 min loading
ii. 15 min discharging
iii. 30 min travelling from batching plant to site.
iv. 30 min travelling from site to batching plant
v. 10 min washing.

1 hr. + 40 min.

Therefore to maintain continuous supply rate (45 m3/h/9m3) x 10/6 = 8.33

truck, consider 9 transmixer.

(b) Pre-pour inspection / procedure

Prior to commencement of batching the concrete for the pour, the following will
be checked.

1) All false work to be inspected for structural integrity soundness and

compliance with staging layout drawings.

2) All formwork to be re-checked for level including cross-falls and camber as

required (initial check / approval will be carried out prior to fixing of rebar)

3) Ensure that control stations are setup to check horizontal alignment back to
known points at each end of the structure and check the overall width at
several locations along the length of the deck.

4) Surveying control points will be fixed to monitor false work settlement,

observe bridge movements due to temperature, shrinkage, and pre-
stressing in relation to first stage abutment and movement of 1 st stage in
relation to first stage of abutment and movements of 1 st stage in relation to a
fixed point outside the bridge.

5) Inspect all form surfaces to ensure tightness and alignment of joint,

acceptable surface finish, cleanliness and cover of release oil.

6) Inspect reinforcement to ensue compliance with approved working drawings

including size, number position and laps of all bars. Ensure that correct
cover is maintained within tolerance and that sufficient spacer blocks are
provided.

7) Inspect all post tensioning ducts for position, minimum spacing (50mm)
between the ducts, profile alignment fixing and joint preparation.

8) Ensure that all construction joint stop ends are securely fixed.

9) On completion of the above, the deck will be inspected by the Engineer.

 10)After approval to pour is given by the consultant, concrete will be ordered.

11) When high ambient temperature exist reinforcement ahead of the pour will be
covered with shading and fog mist of water will be sprayed on the
reinforcement. Precautionary measures to be taken as per specs (4/30).

12)Concrete shall not be placed if any of the following conditions apply:-

Air temperature in the shade exceeds 40 degree c.

Concrete temperature is greater than 32 degree c.
Concrete slump is outside the specified limits of 75mm and 125mm.

(c) Bottom Slab Pour

1) For each slab pour a plan will be prepared showing the following:-

Location of slab to be cast.

Position of concrete pumps.
Volume rate of pour and number of truck mixers.
Direction of placement of concrete.

Placement of the concrete will commence from the low points of the slab in
one layer (220mm) with web sections being filled after the bottom slab to be
completed. The concrete will follow the direction of the slab pour being
brought up behind. Compaction of this web section will be completed before
floating of the adjacent slab is carried out. Work generally will be carried out
as per the approved mock sample.

2) Compaction of the concrete will be with 75 mm and 50mm vibrating pokers

the number employed will be dependent upon the size of the pour.

3) Timber rails or steel pipe will be employed to control the level and the
concrete will be floated to produce a uniform surface free from screed marks.

4) All exposed concrete construction joint surfaces will be treated with a retarder
and jet washed off immediately after stripping the shutter.

(d) Web Pours

1) Concrete will be placed in layers not exceeding 250mm and compacted using
50 and 25mm vibrating pokers.

2) The top surface will be struck off to the correct level and the surface retrader
applied, which will then be washed 12 hrs. later to expose the aggregate.

(e) Deck Slab Pour

 1) Temporary false work will be setup in the box girder voids to supoort the soffit
of the decks slab.

2) The profile of the deck soffit will be checked in conjunction with the Engineers
and Surveyors.

3) Reinforcement will be fixed in accordance with the approved working

drawings.

4) Level control points will be provided in the girder stems at 2.5m longitudinally
and 8.0 transversely to allow string lining and dipping to check the grade as
the placement and finishing of deck progress.

5) Timber or steel rails will be also provided to control the finished level with
particular attention being paid grade or comber changes.

6) Concrete will be placed by mobile pumps in a single layer of the deck, with
placement following the pattern and movement shown on the plan prepared
for each section pour. The concrete will be compacted using 75mm
pneumatic internal vibrators and top surface will be vibrated using vibrating
beam. (Specification of the beam is attached) The number of pokers used will
generally be three per pump with a fourth on standby.

7) Instead of timber rail use 50mm steel screed tube for top slab (supported on
rebar cage) and 40mm for bottom slab.

8) When the concrete has hardened sufficiently the surface will be floated by
hand or by power float machine and then a brush finish will be applied.

6) Curing

(a) After the finishing texture has been applied and the concrete surface has
hardened, a fog mist of clan water will be sprayed over the surface (if the mist
foggy or fine enough, it should be applied soon after finishing when the
concrete is still semi-set). Wet Hessain will then be kept on the fresh concrete
for 24 hours after which the structure shall be water cured.

(b) The main deck soffit staging will remain in place until the post tensioning of
the bridge has been successfully completed

Note: for normal water cure, the Hessain is to be covered with plastic sheeting to retain
moisture.

7) Striking of Formwork

(a) The box forms and cantilever wings supporting the slab of the deck will be
struck and removed after the concrete has achieved its 28 day characteristic
strength. If striking is planned to be done before 14 days period, the extra
cubes will be cast and cured in the actual structure conditions.

(b) The main deck soffit staging will remain in place until the post tensioning of
the bridge has been successfully completed.
8) Safety

(a) The companys health and safety plan will be followed at all times and a full
time Safety Officer will be on site to ensure that standards are.