PERTAMINA CILACEP RU IV

METHOD OF STATEMENT ON PLACEMENT & FIELD JOINTING OF AKS HDPE LINED R.C STRUCTURES AERATED PONDS & EQUALISATION POND 1. Dimension of AKS Liners Proposed 2.5mm thick AKS HDPE liners will be supply & delivered t project site in rolls of 3.0m wide and to any desired length for wall panels and flat sheets of size 2.0m width x 10m long for floor slabs. 2. Prefabrication Standard rolls of AKS liner will be cut to pre-determined sizes to suit the wall formwork dimensions. 3. Sequence of Works On Site 3.1 Construction of R.C. sub-structures including R.C. floor slabs with completed top level approximately 15mm below proposed finished level to cater for installation of AKS liners after completion of R.C. walls and/or super-structures.

3.2 Casting of R.C. kickers for walls construction. Proposed maximum height of 100mm for kickers to facilitate placement of AKS wall panels. 3.3 3.4 Erection of steel reinforcement bars for walls. Placement of AKS pre-cut panels (of 3m width) from floor slab for the entire height of walls. Procedures as follows: Liners leaning against the kickers shall have studs removed before placement. AKS panels shall be placed with the smooth surfaces against the formworks. Each AKS panel will be temporary join against adjacent panel by H-profile and securely tighten the 2 panels together with H-profile by steel wires. Lean each AKS panel against the erected steel bars and temporary secure in position by tying steel wires around the studs of AKS panel and against the steel bars. For corners, remove one row of studs at the designed location before bending the AKS panel 90 degree with the help of Leister Hot Air Blower. Adopt similar procedures to complete the placement of AKS panels for the entire walls. 3.5 Erection of internal formwork (only) can commence immediately after 2 to 3 panels of AKS have been erected. 3.6 Once the internal formworks are in position (that is properly strutted), remove the steel wires securing the erected AKS panel against steel bars and push the AKS panels against the internal formworks from outside with timbers and/or extended

tools. Tie steel wires around the studs of AKS panels before pulling the wires backwardly against the top edge of internal formworks by nails. 3.7. Place plastic reinforcement spacers (or precast concrete type) at strategic locations between the steel reinforcement bars and erected AKS panels to push the in-place AKS panel tightly against the formworks so that they cannot move away from the formworks. 3.8 Once the AKS panels are in secured against the internal formworks, erect the external formworks and securely fasten these formworks before casting concrete. Remove the internal formworks and inspect the cast-in-place AKS panels and indentify and mark any surface damages on the liners.

3.9

3.10 Cut the remaining H-profiles on the surface between the AKS panels and inspect and clean/remove any surface contaminants and/or grout stains on each joint before welding works commence. 3.11 Welding of these joints by extrusion welding method with the following procedures: Thin copper wires shall be placed along each joint to facilitate high voltage spark testing. Surface preparation to remove any surface contaminants along each joint shall be carried out using a Bosch angle grinder with fine textured sanding disk. Immediately following this, welding shall be executed by means of a potable rod extrusion speed nozzle welding equipment wherein a molten bead of HDPE extrudate will be deposited on top of the joint. A combination of molten HDPE extrudate and required contact pressure will create a homogeneous, secure weld seam along the joint. QA/QC inspection and non-destructive testing using high voltage (20KV) spark tester shall be conducted on all welded seams to ensure its security and homogeneity. 3.12 Upon completion of welding works and QC testing with spark tester, remove all construction materials and debris on the floor slab including thorough washing of floor slab surfaces with hydraulic jet and water. 3.13 It is a normal practice that floor is the last area to be lined and the most effective method to install AKS is by relining technique with the assistance of self-leveling grouts to the existing slab. Prior to installing the floor panel, existing concrete surface shall be prepared to meet the specific conditions to ensure successful installation proper cohesion between concrete surface and proposed grouting materials. Specific instructions for concrete surface preparation shall be according to grout manufacturers recommendations. Installation of floor panels with a grid method shall be adopted to segregate the areas for separate operations. Use timbers (of thickness 12mm to 13mm) to form supports for each AKS panel for installing on the floor slab.

 Mix grouts and pour in one continuous process into the installation section to the desired level above existing concrete slab. Place AKS panels with anchor knobs inwardly facing the grouts. Apply force to push in the AKS panels from one end to the other, to eliminate air trapped beneath the AKS and grouts. When completed, check the entire section to ensure there is no void formed and place counter-weights at strategic positions to hold down the AKS. Allow the grouts to set before removing the counter-weights. Once the entire floor area is completed, the adjacent panels will be jointed by extrusion welding technique. 3.14 Commence extrusion welding to adjacent panels in accordance to procedures mentioned under Clause 3.11, above.

4.

Final Inspection and Acceptance of Works Final inspection of all completely installed area shall be conducted in the presence of S.O., the Main Contractor representative and installation supervisor to ensure that the work is done to the satisfaction of the Owner and/or their Consultants. Completion Certificate shall be issued upon satisfactory completion of all remedy works.

Submitted By: GREEN COSMOS MARKETING PTE LTD 2 Woodlands Sector 1 #05-23 Woodlands Spectrum Singapore 738068 Tel.: (65) 6853 3835 Fax: (65) 6853 3823 Email: greencosmos@pacific.net.sg