874 MW SUKI KINARI

HYDROPOWER PROJECT

Construction Technical Scheme for T-Beams

Permanent Bridge

CGGC Suki Kinari Hydropower Project Management in Pakistan

October, 2018
 Contents

1. General………………………………………………………………………… 04

2. Locations………………………………………………………………………... 04

3. Construction Schedule……………………………………………………………04

4. Materials………………………………………………………………………….04

5. Equipment………………………………………………………………………..05

6. Construction Procedure…………………………………………………………..06

6.1 Preparation of casting bed (Yard)……………………………………………06

6.2 Mobilization………………………………………………………………….06

6.3 Fabrication of Reinforced steel Bars…………………………………………06

6.4 Setting Bottom Form…………………………………………………………07

6.5 Installation of Rebar…………………………………………………………..07

6.6 Installations of Ducts and End-Anchorage Devices………………………….07

6.7 Installation of Side Form……………………………………………………..07

6.8 Casting Concrete……………………………………………………………..08

6.9 Curing and Removal of Side Forms………………………………………….08

6.10 Stressing…………………………………………………………………….09

6.10.1 Preparatory Work…………………………………………………….09

6.10.2 Setting End-Anchor Blocks and Jacks……………………………….09

6.10.3 Pre Stressing………………………………………...………….…….09

6.10.4 Measure the camber of girder…………………………………..…….09

6.10.5 Cutting Strand at End of Anchorage…...……………………….…….09

6.11 Grouting………………………………..…………………………………….09

2
 6.11.1 Preparation Work………………………………………………………09

6.11.2 Check Ventilation and Cleaning PC Ducts…………………………….10

6.11.3 Mixing with approval mix proportion…………………………………10

6.11.4 Injection of Grout……………………………………………………...10

6.11.5 Cutting Grout Hose…………………………………………………….10

7 Quality Control………………………………………………………………….….10
7.1 Tolerance for Concrete Structures……………………………………..….10

8 Safety Control…………………………………………………………….…...……11

8.1 Joint Meeting………………………………………………………..……11

8.2 Basic Instruction………………………………………………………….11

8.3 Prevention accident during Stressing………………………………….…11

8.4 Prevention accident during Grouting ……………………………………11

8.5 Prevention of Accident by Heavy Machine……………………………...11

8.6 Prevention of Accident of Electrocution…………………………………11

8.7 Prevention of Accident in Night Shift Works…………………………....11

8.8 Existing Facilities………………………………………………………...11

9. Environmental Protection………………………………………………………….12

10. Attachments………………………………………………………………………13

10.1 Typical Structure Drawing of T-Beam…………………………………..13

10.2 Layout of T-Beam area Right Bank…………………………………….14

3
1. General
1.1 Preparation Statement
The method statement for T-Beam below describes the whole construction procedures including
material and equipment required for the casting of T-Beams. Detail of the procedures contained
herein may be reviewed periodically and modified based on actual requirement. Length T-Beam
will be fabricated to adapt with each span length in consideration with the width of carriageway-
Accurate quantity will be calculated based on approved working drawing. Typical structural
drawing of T-Beam is attached with method statement.
1.2 Overview
There are 12 T-Beams of 40m length (each) in this bridge. There are 4 side beams and 8 inside
beams having 144 ton (each).
2. Locations
Detailed and specific locations will be shown on attached Layout.
3. Construction Schedule
Construction Schedule will be referred to the approved Overall Schedule.
4. Materials and Manpower
4.1 Materials
Materials to be used for the production of T-Beams are as follows.
Table 1: Materials for T-Beam
No. Material Description Remarks

01 Reinforcing Steel Bar G-40 & G- General Specifications

60 ASTM A-6l5
02 Concrete 41MPa(Max. aggregate
size 25mm)

03 Pre-stressing Steel Wire General Specifications

ASTM A-416
04 Anchorage System

05 Grout System

4
Materials stocked on site will be kept off the ground and covered properly to protect from rain and
dirty.
4.2 Man Power
The bridge construction team have 37 persons responsible for all fabrication of steel, installation
of rebar, ducts, end anchorage devices, concrete production, transportation, pouring, stressing and
grouting. All technical workers are trained.
Table 2: Manpower for T-Beam

No. Description Manpower Remarks

01 Supervisory Staff 10 Project manager, site

engineers, survey
staff
02 Operators 06 Loader, Excavator,
Transit Mixers
03 Steel Fixers 08

04 Concrete Team 05

05 Stressing/Grouting Team 10

05 Labours 08

5. Equipment
Equipment for the production of T-Beams are shown below.
Table 3: Equipment for T-Beam
No. Item Quantity Remarks
01 Excavator 02
02 Loader 01
02 Bar Cutter 01
03 Bar Bender 01
04 Generator 02
05 Welding Machine 01

5
 06 Concrete Bucket 01
07 Concrete Vibrators 03
08 Static Vibrators 06
09 Batching Plant 01
10 Mixers 02
11 Lighting System 01
12 Formwork
13 Pre Stressing Jacks
14 Grouting System
15 Water Tank 01
16 Trolley Cart 02
17 Other minor tools.
Above stated schedule of equipment will be increased in quantity if required and necessary. Actual
equipment mobilized will be subject to inspection and approval of the Engineer.
6. Construction Procedure
6.1 Preparation of casting bed (Yard)
Site preparation for production yard will be carried out before mobilization of necessary materials
and equipment for production of T-Beams. Location of production yard is shown on drawings.
The Ground surrounding the working area will be level adequately and stable for good mobility of
equipments. Access to production yard with dewatering system will be set up adequately. For
foundation of casting bed, existing unsuitable material will be replaced to suitable material
and compacted adequately to prevent settlement of casting bed.
6.2 Mobilization
Materials and equipments for the work will be set up. And required approval such as for material
testing and calibration of stressing jack and pump will be confirmed. Prior to commencement of
works, all equipment and will be inspected according to Guide with attendance of the Engineer.
Approval of working drawings for T-Beams will be confirmed prior to commence production of
T-Beams.
6.3 Fabrication of Reinforced steel Bars
Details of reinforcing steel bar such as arrangement, location, dimension and shapes will be shown
on working drawings. (Reinforcing steel bar will be referred as “rebar” hereinafter). Rebar will be
fabricated in accordance with the shape and dimension as shown on approved working drawing.
Bar cutter equipment or other proper equipment will be used for cutting rebar. Bar bending

6
equipment or manual bending will be used for bending rebar to form the shape and dimension as
shown on working drawing.
Fabrication of rebar will be carried out by cold cutting and cold bending. Rebar fabrication by
application of heat will be in accordance with the Engineers instruction.
6.4 Setting Bottom Form
Formworks will be in accordance with the shape, lines and dimension shown on working drawings
.Forms will be constructed to prevent deformation due to applied load. The length of produced
girder will be confirmed on approved working drawings. All forms will be cleaned, free from dust,
grease or other foreign matter and will be treated with release agent before installation. Starters
will be made of concrete, to avoid uneven surface at bottom of girder.
6.5 Installation of Rebar
Rebar including embedded rebar for diaphragm will be installed in accordance with approved
working drawings. Concrete blocks with whip will be used as spacer. Spacer will be installed at
bottom and side of rebar in order to maintain the appropriate concrete covering. Fixing and splicing
of rebar will be done by iron wire. Splicing length and location will be in accordance with working
drawing. Ties at intersection of rebar will be installed sufficiently to prevent dislocation during
casting. Rebar will be tied at all intersections. Fixing by welding shall only be carried out if shown
on approved working drawing or as instructed by the Engineer. Installed rebar will be free from
rust, dirt, oil or other material that might reduce the bond.
6.6 Installations of Ducts and End-Anchorage Devices
PC duets will be installed in accordance with designed alignment and location shown on approved
working. PC duet will be fixed and supported by temporary rebar racks and tied adequately to
prevent dislocation during insertion of pre-stressing cable and during concrete casting. Connecting
PC duets will be carried out properly wrapped with vinyl tape to prevent inflow of cement past
into PC duets during casting concrete. Casting of anchorage device for stressing and bursting
reinforcement (reinforcing rebar for stressing end) will be installed in accordance with the location
and arrangement shown on approved working drawing. Holes for grouting will be protected by
plastic cap to prevent inflow obstruction. Any obstruction shall not be allowed to be in PC duct
before, during and after installation Pre-stressing cable will be installed manually in accordance
with the approved working drawing. Strand will be cut by disk cutter or other proper equipment
with case to prevent damage on strand. Exposed pre-stressing cable at end of girder will be covered
with proper material temporary to prevent damage, dirt and rust. Ducts will be taken care to prevent
dislocation of alignment. if displacement or damage of PC ducts will be happen, they will be
recovered. Location, alignment and condition of PC ducts and casting of anchorage devices will
be inspected by the Engineer in accordance with approved working drawing.
6.7 Installation of Side Form
Pro-fabricated metal form panels will be used for side forms. Layout of forms will be installed in
accordance with design of forms cased on approved working drawings. Temporary support will
be installed properly in accordance with design of form.

7
All forms will be cleaned, free from dust, grease or other foreign matter and will be treated with
the release-agent before installation. Holes on side form for embedded rebar for diaphragm will be
made at proper location with proper dimension. Clearance around embedded rebar on forms will
be closed by foam or other proper material to prevent leakage of cement past during casting
concrete as far as possible. Block out of lifting holes at end of girder will be set before closure of
forms with reinforcement for lifting holes. Gap at joints of forms will be in-filled by packing to
prevent leakage. The gap between metal forms and supporting beam will be also in-filled by
suitable material
6.8 Casting Concrete
Concrete pump will be used for casting concrete of T-beams. Water will be sprayed on form, rebar
and surface of bottom form prior to concrete casting. Casting will be carried out layer by layer of
approximately 50cm and casting concrete will be proceeded from one end going to the opposite
end. The vibrators will be of type with proper frequency. The number of vibrators will be sufficient
to consolidate the concrete properly, At least 2 spare vibrators will be available on standby at site
to maintain immediate continuity in case of breakdown. Static vibrator (external vibrator) will be
set on outside forms. Vibrator will be penetrated into the previously cast layer through the new
casting layer. Operation of vibrator will be taken care not to damage ducts. And especially
anchorage location at end of girder will be taken care to compact concrete strictly to prevent any
defect of concrete because this portion will not be allowed to apply any remedial and repair of
concrete. Flexible vibrators will be used to compact concrete for each layer. And secondary static
vibrators on side forms will be operated properly. Concrete vibrators will not be used to transport
concrete inside the formwork during casting. Concrete condition will be closely monitored to avoid
concrete to harden before casting the next layer. Splattered and loose concrete on surface of form
will be removed before placing concrete. Lightness of the formworks will be inspected and
monitored regularly during casting to prevent deformation or displacement of forms and leaks at
the formworks. In case displacement occurs, they will be immediate adjusted to before concrete
placing continues. Installed rebar will be taken with care to prevent dislocation during casting
concrete. In case dislocation occurs, they will be immediate adjusted to before concrete placing
continues. Installed PC duets with PC cable will be taken with care to prevent dislocation during
casting concrete. In case dislocation and damage occurs, they will be immediate adjusted to before
concrete placing continues. In-situ testing for concrete will be carried out per each delivery truck
in accordance with approved Inspection and Test Plan. Sample of concrete will be taken to make
specimen for compressive testing. In case of rainfall, pooling water will be removed on the surface
of concrete before making the surface level. And plastic vinyl sheet will be installed covering all
areas of concreting. In emergency case due to pump breakdown, will be replaced with crane or
bucket.
6.9 Curing and Removal of Side Forms
Exposed surface of girder (top surface of girder) will be covered by wet burlaps or other suitable
fabric material. After one day of casting concrete, side forms will be dismantled. And girders will
be covered by wet burlaps or other suitable material immediately. Removal of forms will be taken
care not to damage or injure concrete surface and embedded rebar of girder. In case that the girders

8
will be stocked for a long time after casting, surface of embedded exposed rebar such as for
diaphragm and deck slab will be covered by cement paste to prevent corrosion and rust.
6.10 Stressing
6.10.1 Preparatory Work
Prior to commencement of works, all equipment and will be inspected according to Guide Form
approval with attendance of the Engineer. Calibration of pre stressing jack and pump will be
carried out by approved authorized laboratory. Certificate of above calibration will be reported to
the Engineer for approval, which shall show the relation of reading manometer and actual applied
force by jack. Combination of jack and pump will be clarified.
6.10.2 Setting End-Anchor Blocks and Jacks
End-anchorage will be set Wedges, and jacks will be set at both end of girder. One side of jack
(Jack A), another side of jack (Jack B).
6.10.3 Pre Stressing
Pre-stressing force is provided on Jack A, Marking to measure Elongation will be given on pre-
stressing cable at end of Jack A. And marking to measure pull-in will be given on pre-stressing
cable at end of Jack B. Pre-stressing is continued step by step with interval on Jack A up to final
pressure During each step of pre-stressing up to final, reading manometer on Jack A and Jack B
and elongation at Jack A and pull-in at Jack B will be recorded After final pressure is applied,
Jacks will be released pressure. Pre-stressing will be applied by both jacks. Pre-stressing will be
carried out step by step with equal intervals. Elongation will be measured at each step and plotted
on Pre-stressing chart. Pre-stressing cannot be allowed to apply more than absolute upper limit of
pre-stressing. After measure elongation at final pre-stressing force, pressure on jacks will be
released. After measuring pull-in, pressure on jacks will be release all. And jacks will be removed.
Shift to Next Pre-stressing Cable. Jack will be set on next PC cable and continue same sequence
of pre-stressing as above mentioned.
6.10.4 Measure the camber of girder
Using tapes applied at 5 locations: 0; 1/4L; 1/2L.
6.10.5 Cutting Strand at End of Anchorage
Strand will be out after approval of pre-stressing result by the Engineer. Strand after cutting will
be at least 3cm from the face of Anchor head.
Cutting of strand will be carried out by disk cutter.
6.11 Grouting
6.11.1 Preparation Work
Prior to commencement of grouting works inspection of mobilization of equipment and labor will
be taken for the approval of the Engineer. Grouting PC ducts (PC grout) will be in accordance to
specification. Materials and proportion of grout is proposed separately. Equipment such as grout

9
mixer and pump will be set as per approved by Engineer. Grout hose will be set (connected) with
pre-installed hose in T-Beams firmly.

6.11.2 Check Ventilation and Cleaning PC Ducts

Air hose from air compressor will be connected with one side of grout hose. And air will be
provided into ducts. Ventilation of ducts will be checked by air at another side of grout hose. At
same time, excess water or other foreign material will be blown out. If ventilation cannot be
confirmed, duct has stuck. In such case location and condition of stuck will be investigated and
countermeasure to recover will be proposed.
6.11.3 Mixing with approval mix proportion
Actual mixing per batch shall conform to the approved mix proportion. After mixing is completed,
grout shall pass through a screen with maximum clear openings.Grout will be used within 30
minutes after mixing.
6.11.4 Injection of Grout
All grout vents will be opened. Grout hose of pump will be connected with one side of grout vent
of T-Beam. Grout will be pumped through the duct and flow continuously at first outlet after inlet.
Until no visible slugs of water or air are ejected and the consistency of grout is equivalent to that
of grout injected at which time the outlet will be closed. Pumping pressure at inlet shall not exceed
from design. After closure of outlet, Pressure will be maintained for one minute. After one minute
with pressure inlet pumping pressure will be released and condition of grout at inlet hose will be
confirmed whether grout has back flow or reducing.
6.11.5 Cutting Grout Hose
After completion of grouting process, excess grout hole will be cut on surface of concrete of T-
Beam.
Girder shall not be moved within 48hours after grouting.
7 Quality Control
The whole procedure will be thoroughly checked by the engineer in charge for operation. Quality
control will be carried out in accordance with this Method Statement and other applicable
Specifications. Inspection Checklists are subject to revision in accordance with the Engineer’s
instruction.
Each PCI girder will be uniquely and permanently marked so as to show name of girder (no. of
girder) and casting date.
7.1 Tolerance for Concrete Structures
In general, Tolerance for Concrete Structures will be in accordance to the Specifications.

10
8 Safety Control
Prior to starting of works, the following particular matters are to be through to all members
working in the construction site in order to complete the substructure work efficiently without any
accident or casualty.
8.1 Joint Meeting
Prior to start any activity, a joint meeting with relevant staffs will be held for the purpose of general
explanation on the whole contents of works as well as the method for the implementation of
efficient work.
8.2 Basic Instruction
All workers shall wear Personal Protective Equipment at all times, such as helmet, safety shoes,
hand gloves and working uniform.
8.3 Prevention accident during Stressing
Workers shall not be allowed to stay at the backside of stressing jack during stressing and
measuring.
8.4 Prevention accident during Grouting
Coordination will be carried out especially when closing grout hose to prevent bursting due to
applied pressure.
8.5 Prevention of Accident by Heavy Machine
Only skilled operator will be allowed to operate equipment on site. Stability of working area and
foundation of equipment will be checked particularly at locations of outrigger and track pad of
cranes.
8.6 Prevention of Accident of Electrocution
Electric generating equipment will be properly protected and properly installed with earth
connection. Electric wires will be connected with electrical tapes to prevent electric leakage. Only
skilled operator will be allowed to operate equipment on site.
8.7 Prevention of Accident in Night Shift Works
Sufficient quantity of lighting system will be provided for night shift works especially installed at
working platforms. If necessary all of the surrounding working area will be lighted up.
8.8 Existing Facilities
Existing facilities at surrounding area will be taken with care not to damage.

11
9 Environmental Control
Responsibility for surrounding environment during works shall comply with the Condition of
Contract. If any other problems occurred in the site, applicable counter measures or prevention
action shall be considered immediately and executed as soon as possible.

12
Attachment A:

13
Attachment B:

14