TANGGAL TERBIT NOMOR DOKUMEN REV

WRK-01-RAPP-005 0
11 Mar 2019

DIBUAT CHECKED BY CHECKED BY

IM DWI
CONSTRUCTION OF NEW FUTONG JETTY

PARAF
Revisi

TGL
Rev-0
Rev-1

METHOD STATEMENT FOR GENERAL

CONCRETE
Rev-2
Rev-3
Rev-4
Rev-5

Review Seksi
SITE MANAGER

SUPERVISOR

terkait
TEKNIK
TEMBUSAN

QC
TGL

TGL

TGL

TGL

TGL:
1

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PT. Wijaya Karya Rekayasa Konstruksi

METHOD STATEMENT FOR GENERAL CONCRETE CASTING

1. GENERAL

Concrete work is the major item for civil works of PT Riau Andalan Pulp and Paper
Project. As main part of civil works, concrete works shall be carried out systematically in
a manner that satisfies the contract requirement. A general guideline is required when
specific method is not available for the particular job.

2. SCOPE & PURPOSE

The scope and purpose is to determine and describe guidelines for control and the
responsibility in the manufacture, transportation, setting and curing of concrete for
general concrete casting. Costing of massive pours (greater than 100 m3) will be subject
to detailed separate method statement.

3. R E F E R E N C E
The references for this method is as follows

 Concrete inspection form

 WRK Inspection and Test Plan (ITP)
 Technical Specification of Concrete Work (Owner Specification)
 Basic Drawing

4. MANUFACTURING

The concrete to be used in this project will be manufactured by our own Batching Plant with
productivity of capacity is 30 m3/hour and location inside area of power plant. Its
manufacturing of concrete shall be controlled by Batching Plant supervisor below
the management controll by Concrete Superintendent. The concrete transportation will
used two (2) agitator truck with each capacity max 7 m3 per mixer. Type and branch of
Batching Plan will confirm latter.

Prior to commencement of concrete pouring the batching plant supervisor shall :

 Accurately determine the volume and type of concrete to be poured

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 Pour start time and sequence

 Traffic management on site, route of transit mixers and stationary location

 Commencement time

 Expexted completion time

The type of cement will follow the contract and approved by owner. The supplier of
cement will confirm latter. Materials of stone for ready mix will use the material from borrow
area inside the plant. The material produce from our own stone crusher will divided into two
(2) dimention: type of stone 1/2 and 2/3. The material of sand will used from the quarry
around the site. The source of material location will be confirmed later.

The backup stone crusher and bathing plant shall be ready around the power plant
location with the distance no more than 100 km. The back up each supplier will be confirmed
later.

5. TRANSPORTATION

The transportation of ready mix concrete will used the agitator truck with capacity of mixer
max 7 m3. The number of agitator truck is 2 units. Each unit will drive by authorized driver
that have capability and driving license.

6. CONCRETE POURING

6.1 Prior Control

Before starting with a concrete pouring operation, prior quality controls inspection shall be
made in order to obtain certain permit for the concrete pouring of the structure element.
When the result is satisfactory, the authorization shall be given after final approval of
Owner. Such controls mainly could be listed as follow:

 In general concrete with a nominal course aggregate size of 38 mm will be used

 Volume of concrete to be poured will be calculated and the batching advised

accordingly together with the grade and aggregate size.

 Concrete with nominal aggregate size of 38 mm shall not be used in areas where the

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PT. Wijaya Karya Rekayasa Konstruksi

spacing of reinforcement is less than 50mm

 All concrete 300 mm or less in thickness unless otherwise indicated, the nominal
size (sieve) 19 mm

Superintendent to access how concrete to be pored and accessibility of transit mixer. Concrete
shall not be placed until all forms, rebar, embedded items and the surfaces upon the concrete
is to be placed have been cleaned up and approved by owner. Concrete shall deliver to the forms
by methods and equipment ensuring its required consistency without excessive loss of
slump or segregations. Concrete shall not be moved to its final location by the use of
vibrators.
 Ensure that there are sufficient vibrators of the acceptable type available including
spares.
 Ensure adequate access for personal to place and compact the concrete if necessary
provide platforms

6.1.1 Installation of Reinforcement

 Reinforcement shall be controlled for its grade, position, diameter, spacing, level, and
way of bending set forth in the applicable charts and reinforcement
configuration design.

6.1.2 General Formwork

 The location and geometry of forms shall be verified as per design and to their height
(axes, ratio, elevations) using the applicable documentation (specific drawing) in
its last revision. Likewise, the stability of the forms support structure and the capacity
thereof to withstand loads resulting from the filling of controlled. Form to be marked
with top surface level or other device to ensure that the proper level is achieved.

6.1.3 Control of Embedded Item and Grounding Wire

 Location, level and type of embedded plate shall be verified using the applicable
drawing and installation procedure or specification.

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PT. Wijaya Karya Rekayasa Konstruksi

6.2 Control During the Concrete Pour Stage

 A small batch shall be taken from each truck carrying concrete prior to its being set.
The following controls shall be made on the batch.
 6.2.1 Concrete Temperature
Temperature control shall be conducted in batching plan and site for every truck of
concrete. A thermometer is introduced in the mass concrete and is necessary to wait
until the reading stabilizes. At the time the reading is stabillized, it shall be read and the
temperature shall be recorded in recording form of concrete. The provisions set forth
by local standard shall be applicable for the evaluation of the results obtained.

6.2.2 Slump

Slump control shall be taken at site for every truck of concrete. It shall be verified that the
concrete slump measured shall not be less than 120 mm and not more than 140 mm as
per contract. The result shall be recorded in the concrete recording form in the site.

6.2.3 Visual Inspection

On inspecting the concrete to be placed it shall be checked that the mix is

homogeneous and pasty, the component materials are not disintegrated and that concrete
components are not segregated.

6.2.4 Manufacture of Test Specimen

The cylinder shall be manufactured in this stage to be assigned for compression strength test.
They shall be made pursuant to the provisions set forth in ACI or local standard. The
frequency for test cylinder shall be one set every 50 m3 or as specified in the contract. (A set
of specimens shall consist of a cylinder)

6.2.5 Temperature /Hot Weather Concreting

1. The temperature must be periodically controlled during the concrete pouring stage by
using a thermometer. The temperature measurement is specified is 38°C or less.

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2. In general massive pours will be carried out in late afternoon or night (subject to
separate method statement). Temperature measurement will be taken of all concrete during
pouring. Concrete with a temperature greater than 38°C will not be accepted.

3. When necessary before placing concrete immediate vicinity and

reinforcement bar shall be shielded from direct sunlight and cooled used a spray of
fresh water to prevent excessive surface absorption.

4. The fresh exposed concrete will be covered as soon as predictable possible to

excessive plastic shrinkage and rapid evaporation of water leading to rapid drying of
concrete.

5. Prevention of rapid water loss by use of approved curing agent applied as soon as
possible is accordance with manufacturer instructions is also acceptable for
exposed surface and surface not to be used as construction joint.

6.2.6 Compaction

During the concrete pouring, concrete vibrator will be used to ensure well -
compacted fresh concrete. Vibrator shall be inserted into and withdrawn slowly in the
fresh concrete down into the bottom of the newly poured concrete plus 1” into previously
poured concrete. Compaction shall be done gently in order not to produce impact or
void in the concrete.

Apllication of vibrator shall be at point uniformly spaced and not farther apart than
twice the radius over with vibration is visibly effective. Vibration shall continue
until the concrete is compacted to its maximum density, free of pockets, closes snugly
against all surfaces and is in complete contact with all reinforcement bars and other
embedded metal in the concrete. Temporary plastic sheet cover/shelter shall be
prepared in case of rain during the concrete pouring.

Under no circumstances shall vibrators be applied to on touch reinforcement bars or

formwork.

When all layers are placed and the final level concrete is likely to achieve, pour fresh
concrete to its final level with additional thickness of 5mm top accommodate shrinkage
therein. Finish the concrete surface by means of hand trowel or engine trowel, collect
and withdraw excessive concrete from the concrete surface.

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6.2.7 Compressive Strength

The grades of concrete shall comply with the following table having the minimum
compressive strength shown. The turbine foundations, turbine building, central
control building will be used Grade 30.

6.2.8 Compressive Test

Cylinder samples obtained from concrete placing shall be tested compressive strength.
The test shall be conducted in accordance with Material Approval for Concrete.

6.3 Control after Concrete Placing

6.3.1 Curing
Depending on the foundation one the following curing systems will be deployed.
1. Use of approved curing compound applied to the wet concrete surface in
accordance with the manufacturer’s instructions.

2. Placement of wet Hessian sacking to the semi dry concrete surface, hessian sacking
to be kept constantly moist during the curing period by application of clean water.

3. Providing a sand dam around the perimeter of the horizontal surface and flood
with clean water.

4. Immediately following removal of side form to beams, pedestals and

columns the exposed surface will be coated with an approved curing
compound placed in according with the manufacturer’s instructions.

5. When applying curing compound care will be taken to protect exposed

reinforcement form spray.

6.3.2 Surface Treatment

A . Gener al
Surface treatment of structural concrete shall mean a finish which is an integral part of
the structural concrete. Surface treatment shall conform to requirements and uses
specified in this clause unless otherwise indicated.
B . Exposed Surface Finish

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Upon removal of forms, all fins and other projections shall be removed and offsets
levelled. All voids, holes, honeycomb or other damaged surface shall be cleaned back to
solid concrete, saturated with water and filled with cement mortar of same composition as
that used in the concrete. The concrete shall be finished free from streaks, discolorations
or other imperfections so as to produce an extremely smooth, dense and true finish of
uniform color.

C. Unexposed Surface Finish

Upon removal of forms, all voids, holes, honeycomb or other damaged surfaces shall
be cleaned back solid concrete, saturated with water and filled with cement mortar of
same composition as that used in the concrete

D. Rough Slab Finish

Surface treatment of structural concrete shall mean a finish which is an integral part
of the structural concrete. Surface treatment shall conform to requirements and uses
specified in this clause unless otherwise indicated.
Top surface of structural concrete slabs and equipment foundations shall be level unless
otherwise indicated. Screeds shall be used for all structural slabs and shall be
securely and accurately set to elevations indicated. After concrete has been
compacted by vibrating, it shall be keep to required level. After keeping level, and
when concrete has partially hardened so that it will retain impression of a broom, it
shall be brushed with a stiff-bristled broom and all laitance and scum removed. The
brushing shall expose some of the aggregate and score the surface to provide
mechanical bond for separate finish. Surface shall be levelling and shall then be floated
to be smooth and compact surface and after floating the surface of concrete shall be
steel trowel to a smooth, slate like surface.

E. Monolithic Finish

Monolithic finish is one produced on structural concrete slabs which are poured all
at one time with one concrete mix. Concrete for structural slabs with monolithic finish
shall be of the dries consistency possible to work with a sawing motion of levelling.

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Surface shall be firstly, and than be floated to a smooth, compact surface. Any water
sheen shall be allowed to evaporate or removed prior to floating operation by
covering surface with burlap or similar material. Spreading of cement or cement-
sand mixture directly on top on concrete will not be permitted.

After floating, the surface of concrete shall be covered by floor hardener and shall be
steel trowel to a smooth, slate like surface. Final trowel shall be done after concrete
is so hard that no mortar accumulates on trowel and ringing sound is produced as
trowel is drawn over surface.
F. Float Finish
Surface shall be levelling firstly, and than shall be base coat to be smooth and
compact surface. After base coat, surface shall be floated after concrete has
hardened sufficiently to retain the float finish and water sheen disappeared.
G. Steel Trowel Finish
The same requirements apply as for monolithic finish; expect that consistency of
concrete shall be as used for the portion of work for which steel trowel finish is
specified. Surface shall be levelling and shall then be floated to be smooth and
compact surface. After floating the surface of concrete shall be steel trowel to a
smooth, slate like surface and this finish shall be used for stair treads. Floor area where
resilient tile finishes (asphalt, rubber, vinyl, etc) are indicated required.
H. Broom Finish
The surface shall be levelling firstly, and then shall be floated to a smooth,
compact surface. Following the bull floating, the surface shall be brushed with a
medium stiff bristled broom but only after the concrete has hardened sufficiently to
retain the scoring. The stroke shall be square across the surface and shall be made as
to produce regular scoring without tearing the surface or exposing any aggregate.
The scoring shall run transverse to the direction of traffic.

This finish shall be used for sidewalk. It shall be used for other surface only if
specifically indicated.
6.3.3 Removal of Formwork
It is very important to ensure that fresh concrete is well supported before it is self supporting.
The formwork removal shall be executed as per the following:

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- Columns walls : 2 days

- Side form of column : 2 days

- Side form of beam : 2 days

- Bottom form of beam : 7 days

- Side form slab : 1 days

- Bottom form of slab : 14 days

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