MS - Precast Wall Installation Rev 0

NISHIMATSU KTCCE JV
Contract EW3
Design and Construction of East-West Transmission Cable Tunnel
Document Number KTCCE/KTC/MS/0010 Revision number 0

Method Statement PRECAST INSTALLATION Effective Date 10 APR 16
METHOD STATEMENT
INSTALLATION OF PRECAST WALL PANEL
Prepared By Reviewed By
KTCCE ALLAN HEW
Senior Project Engineer Senior Construction Manageer
Brandon B. Arbon KTCCE
Signature :____________________ Signature :____________________
Date : ________________________ Date : ________________________
INSTALLATION OF SHEET PILE USING SILENT PILE

NISHIMATSU KTCCE JV
Contract EW3

Content
1 General 4
2 Resources Planning 4
3 Work Methodology 6-17
4 Hazard and Risk Analysis 17
5 Appendix I : Crane Specification and Lifting Plan
Appendix II : Design of Jumping Platform and

6
Propping System
7 Appendix III : Site Utilization Plan
8 Appendix IV : Precast Panel Installation Sequence
9 Appendix V : Grouting Material- Stocrete NSG
Appendix VI : Precast Panel Lifting Hook Design and

10
PE Endorsement
11 Appendix VII : Heavy Duty PVC Shim Plate
12 Appendix VIII : Risk Assessment

13 Appendix IX : Safe Work Procedure
14 Appendix X : Fall Prevention Plan

NISHIMATSU KTCCE JV
Contract EW3

Revision Sheet
Revision Effective Description/ Copy updated by

Number Date Summary of Revision Initials Date
0 13 Apr 2016 For Review and Approval

NISHIMATSU KTCCE JV
Contract EW3

1.0 General
This method statement is to describe and outline the work methodology and sequence
on installation of precast concrete wall panel for shaft internal RC structure.
2.0 Resources Planning
2.1 Materials
Item Description Remarks
Precast concrete wall panels Panel quantity and size refer to precast
1
design in separate submission
Stocrete NSG 25kg/bag For horizontal and vertical panel joints
2
grouting
Bostik NSG 25kg/bag For panel joint and uneven surface
3
patching
4 Heavy duty PVC shim plate For panel flatness adjustment
5 Backer rod For panel joint sealing up
2.2 Machinery and Equipment
Item Description Remarks

1 100/120 ton crane For hoisting
For using as working platform and wall
2 Jumping platform with propping system
support
3 Mobile tower access For reach to jumping platform
The precast concrete wall panel installation shall be carried out by means of crane
hoisting, jumping platform with propping support system and temporary mobile tower
access.

NISHIMATSU KTCCE JV
Contract EW3

1.100/120ton crawler telescopic type crane to be utilized to facilitate precast panel

hoisting and installation works. See attached crane specification in Appendix I
Wall prop
Jumping Platform
2.System jumping platform with wall propping system to be used as working platform
and assisting precast concrete wall panel support before panel joints grouting works.
See attached jumping platform and propping system design in Appendix II.
Mobile tower
access

NISHIMATSU KTCCE JV
Contract EW3

3.Temporary mobile tower access to be used for reaching to jumping platform when it
cant be directly accessed from permanent RC slab and grating.
2.3 Site Personnel

Item Description No of Person
1 Site Engineer 1
2 Site Supervisor 1
3 Safety Supervisor 1
4 Lifting Supervisor 1
5 Rigger man 1
6 Signalman 1
7 Precast Erection Workers 6
8 Crane Operators 1
3.0 Work Methodology
General Work Flow
a) Precast concrete wall panel off site fabrication,

b) Site preparation for receiving precast wall panel.
c) Precast wall panel delivery based on installation sequence after the panels
concrete reach to design required strength G40.
d) Construct the cast in situ RC stump along wall alignment
e) Precast wall installation procedure
3.1 Precast concrete wall panel off site fabrication
Upon obtained precast wall design shop drawing approval, the wall panels shall be
fabricated off site at HL precast yard, in the manner of follow planned precast concrete
wall panel site installation sequence to generate a proper fabrication schedule, which
would be referred on site and precast yard. The below attached photos showing the
panel fabrication process.

NISHIMATSU KTCCE JV
Contract EW3

a. Form up the moulds base on

design dimension
b. Fix in reinforcement
c. Install grouting pipe
d. Install lifting points
e. Install vemo inserts
Casting concrete
Demolding

NISHIMATSU KTCCE JV
Contract EW3

Curing and storage at precast yard
3.2 Site preparation for precast wall panel temporary storage.
Constrain of working space is the specific of this project, therefore, proper site space
planning and utilization is important which shall be done prior any material delivery
and storage on site.
The delivered precast panels to be stored horizontally and properly stacked 4-5 layers
and separated by 3 by 4 inch timber spacer. The temporary storage area shall be
barricaded at designated location. Appendix III attached is the site utilization plan to
facilitate precast panel installation work
3.3 Precast panel delivery
Precast concrete wall panels shall be delivered based on planned schedule, which shall
be strictly tie in with installation sequence due to site space constrain, delivered panels

NISHIMATSU KTCCE JV
Contract EW3

shall be consumed immediately. See the attached precast installation sequence in

Appendix IV.
3.4 Construct the cast in situ RC stump along wall alignment
RC stump together with shaft base mass concrete to be in situ cast as to ensure flatness
and consistent level and alignment for receiving the first layer precast panel. T20 dowel
bars to be installed in accurate positions before casting.
The RC stump is approximately 1.4m in height from tunnel base level to shaft base
level. See below attached sketch.
3.5 Precast Wall Installation Procedure
Upon RC stump construction completion, precast concrete wall installation will be

started then.
First layer precast wall panel installation
1. Panels to be hoisted horizontally and down to ground, the bottom of panel to be rested
on two tires to prevent corner chip off and provide enough friction between the bottom

NISHIMATSU KTCCE JV
Contract EW3

of panel and ground when it is tilting towards upright position.
2. Use 6ton 2 legged wire rope sling rig to lifting points at panel top side, and slowly lift
upwards until in upright position. Lifting point design with PE endorsement is
attached in Appendix VI
3. Necessary preparation works shall be done at both ground level and shaft base,
remove plastic covers of vemo inserts and clean up the thread, fix up wall stopper,
jump platform features like foot plate and clevis shoes. The wall panel height is 2.5m,
platform ladder or mobile tower scaffold shall be used to reach to inserts position.
Meanwhile, heavy duty PVC shim plates would be placed on top of RC stumps for
level adjustment (see attached info of shim plate in Appendix VII)

NISHIMATSU KTCCE JV
Contract EW3

4. To urge all workers keep away from hoisting path to safe zone, workers at shaft base
must sheltered into tunnel,
5. Lift the precast panel and hoist down to shaft bottom, until the panel reaches to 1.5m
above installation level, workers at shaft base would only approach to the panel and
use tag line to control the panel in right position and match dowel bars with
preinstalled grouting pipes, continue lower down until the panel rests on RC stump.
6. Lock in the push and pull props to the prefixed foot plates on precast panel and on
shaft base slab, adjust props length to ensure the panels verticality and alignment is
correct, then carry out grouting for horizontal joints. (Stocrete NSG to be used as
grouting material see Appendix V)
7. Repeat the process 1 to 6 to install balanced first layer precast wall panels.
8. Stich up precast wall panel vertical joints, by
a. Fix in reinforcement
b. Closing formwork at one side of the panels
c. Casting concrete and pressure grouting are two available options.

NISHIMATSU KTCCE JV
Contract EW3

Subsequent layers of precast wall panels installation (Jumping platform to be used)
Upon first layer precast wall installation completed and panel joints grouting material
reached to design required G40 strength. Installation works will be moving forward to
higher levels as per design and planed installation sequence.
9. Assemble jumping platform at ground level, hoist down to shaft base, and hook up
to clevis shoes without manpower assistance.

NISHIMATSU KTCCE JV
Contract EW3

10. Workers to reach the jumping platform by scaffold tower to fix in the wing nuts
and tie rods on foot plate, and safety pin on clevis shoes.
11. Repeat preparation procedure 1 to 3.
12. Workers at shaft base, who is to receive, guide and control the hoisted precast
panel, shall be sheltered under designed shelter during hoisting down precast panel to
installation levels.
13. When the hoisted panel reaches to 1.5m above installation level and leans to
wall stoppers, workers at shaft base would only approach to the panel and use tag line
to control the panel in right position and match dowel bars with preinstalled grouting
pipes, continue lower down until the panel toe rests on top of wall.
14. Lock in the push and pull props to prefixed foot plates on precast panel and on
jump platform, adjust props length to ensure the panels verticality and alignment is
correct, then carry out grouting for horizontal joints.

NISHIMATSU KTCCE JV
Contract EW3

15. Repeat same procedure for the rest of second layer precast wall panels.
16. Stitching up vertical joints, by
a. Fix in reinforcement
b. Closing formwork at one side of the panels
c. Casting concrete and pressure grouting are two available options.
17. Upon second layer precast wall installation completion and panel joints grout
reaching to design strength, workers to go up the jumping platform by scaffold tower
and to release and dismantle props, wing nuts and safety pins,
18. After item 17 has been done, jumping platform to be lifted up to hook on layer
precast wall and prepare to receive third layer walls.
19. Repeat the same procedure for the subsequent layers precast wall installation, please
refer to below attached illustration of precast wall installation sequence.

NISHIMATSU KTCCE JV
Contract EW3


NISHIMATSU KTCCE JV
Contract EW3


NISHIMATSU KTCCE JV
Contract EW3

4.0 Hazard and Risk Analysis
4.1 Safe work procedure

See Appendix IX
4.2 Risk Assessment

See Appendix VIII

NISHIMATSU KTCCE JV
Contract EW3

Appendix I : Crane Specification and Lifting Plan

NISHIMATSU KTCCE JV
Contract EW3

Appendix II : Design of Jumping Platform and Propping System

NISHIMATSU KTCCE JV
Contract EW3

Appendix III : Site Utilization Plan

NISHIMATSU KTCCE JV
Contract EW3

Appendix IV : Precast Panel Installation Sequence

NISHIMATSU KTCCE JV
Contract EW3

Appendix V : Grouting Material- Stocrete NSG

NISHIMATSU KTCCE JV
Contract EW3

Appendix VI : Precast Panel Lifting Point Design and PE

Endorsement

NISHIMATSU KTCCE JV
Contract EW3

Appendix VII : Heavy Duty PVC Shim Plate

NISHIMATSU KTCCE JV
Contract EW3

Appendix VIII : Risk Assessment

NISHIMATSU KTCCE JV
Contract EW3

Appendix IX : Safe Work Procedure

NISHIMATSU KTCCE JV
Contract EW3

Appendix X : Fall Prevention Plan

MS - Precast Wall Installation Rev 0

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NISHIMATSU KTCCE JV

Document Number KTCCE/KTC/MS/0010 Revision number 0

INSTALLATION OF PRECAST WALL PANEL

KTCCE ALLAN HEW

Senior Project Engineer Senior Construction Manageer

Brandon B. Arbon KTCCE

Signature :____________________ Signature :____________________

Date : ________________________ Date : ________________________

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

3 Work Methodology 6-17

4 Hazard and Risk Analysis 17

5 Appendix I : Crane Specification and Lifting Plan

Appendix II : Design of Jumping Platform and

7 Appendix III : Site Utilization Plan

8 Appendix IV : Precast Panel Installation Sequence

9 Appendix V : Grouting Material- Stocrete NSG

Appendix VI : Precast Panel Lifting Hook Design and

11 Appendix VII : Heavy Duty PVC Shim Plate

12 Appendix VIII : Risk Assessment

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

Revision Effective Description/ Copy updated by

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

2.0 Resources Planning

5 Backer rod For panel joint sealing up

2.2 Machinery and Equipment

Item Description Remarks

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

1.100/120ton crawler telescopic type crane to be utilized to facilitate precast panel

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

2.3 Site Personnel

3.0 Work Methodology

General Work Flow

a) Precast concrete wall panel off site fabrication,

3.1 Precast concrete wall panel off site fabrication

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

a. Form up the moulds base on

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

Curing and storage at precast yard

3.2 Site preparation for precast wall panel temporary storage.

3.3 Precast panel delivery

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

shall be consumed immediately. See the attached precast installation sequence in

3.4 Construct the cast in situ RC stump along wall alignment

3.5 Precast Wall Installation Procedure

Upon RC stump construction completion, precast concrete wall installation will be

First layer precast wall panel installation

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

of panel and ground when it is tilting towards upright position.

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

grouting material see Appendix V)

8. Stich up precast wall panel vertical joints, by

INSTALLATION OF SHEET PILE USING SILENT PILE

Document Number KTCCE/KTC/MS/0010 Revision number 0

Signature : Signature :

Date : Date :