Ramhan Island Project

Phase 1A&3

Method Statement for Rebar fixing,

Formworks installation and pouring - Slabs
and Beams

Document No Date:

Originator ID Discipline Doc Type Floor/Level 3 Digit SR No Rev

29/08/2022
ACC ST MS FAF 009 0

List of Attachments
No Reference Description

1 ITP & Check List

2 Risk Assessments

3 Test Proposal Schedule

Revision History

Prepared By Reviewed By Approved By

Rev
Date Description
No Construction HSE Sr. Quality Sr. Project
Manager Manager manager Manager

0 29/08/2024

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 Contents

1.0 Purpose

2.0 Scope

3.0 References

4.0 Tools And Equipment’s

5.0 Materials

6.0 Responsibility

7.0 Sequence of Works

9.0 Quality Control Requirements

8.0 Safety

9.0 Risk Assessment

10.0 Attachments

1. ITP & ICL

2. RISK ASSESSMENT

3. TEST PROPOSAL SCHDULE

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1. Purpose:

To ensure that all related works of Slab Shuttering, Reinforcement and concrete work are
executed in accordance with the approved shop drawing, contract specification requirements,
hazards are analysed and safety precautions implemented and all quality assurance/ control
activities are conducted in systematic manner, works inspected and recorded.

2. Scope:

This work procedure applies to cast in place Slab Shuttering, Reinforcement and concrete works
and describes the methods of construction from pre-pour activities (formwork and
reinforcement) through concrete pour. The specific conditions of each pour and the concrete
pumps layout plan for the subsequent pours shall be forwarded to the Engineer after the
coordination with the enabling Contractors in due course prior operations (concrete supplying,
placing) to the post pour activities (curing, concrete sampling and testing).

3. Reference:

 Contract Technical Specification sec 03 30 00

 IFC Standard Details
 Structural drawings
 Approved Shop drawing and Bar bending schedule( BBS)
 Related Inspection and Test Plan ‘’ITP” for concrete works
 Project Quality Plan
 Project HSE Plan

4. Tools and Equipment:

 Power Generator 100KVA
 Air Compressor 240CFM
 Electrical/Diesel or Petrol Vibrator
 Power Float
 Surveying Instrumentation (Total Station and level machine)
 Manual tools for skilled & unskilled labours
 Projector Lights 500/1000W
 Concrete Pumps & including extensions
 Transit Mixers
 Slump & Thermometer to check workability of concrete on delivery
 Test cubes moulds to make sample (As per Spec. requirement)
 Mobile crane.

5. Materials:
 Approved Formwork systems
 Approved formwork releasing agent
 Approved Reinforcement and accessories
 Approved concrete spacers

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  Approved Ready mix Concrete
 Potable water
 Approved Curing Compound / hessian /Polythene sheet
6. Responsibility

6.1 Sr.Project Manager is overall responsible for the implementation of this method
statement with detail activities as delegated to the construction of RCC Slab.
6.2 Construction Manager

The Construction Manager shall be responsible for the overall implementation of this
method statement, and to ensure that section engineer, site engineer and general foremen
are well informed of its requirements. He is responsible for:-

 Providing all required resources in terms of Manpower, Equipment and Material.

 Ensure all submittal are made in timely manner
 Controlling the coordination between all involved parties to ensure Safety, Quality and
schedule requirements are met.
 Liaison with Mechanical, Electrical & Plumbing (MEP) contractor engineer for marking
out and installation of embedded items/cut outs.
 Controlling the progress of work and ensure final approval of method statement is
obtained before the casting scheduled date.
 Coordination with batching plant and confirming the casting date at least 2 days before
the scheduled date.
 Notifying QC engineer in-charge and issuing the request for Engineers inspection in
sufficient timely manner (normally 24 hours in advance) when work is ready for
inspection as detailed in the relevant Inspection & Test Plan (ITP).
 Accompanying Municipality engineer for inspection and final approval before the
scheduled casting date.
 Shall be responsible for the overall implementation of this procedure.
 Shall ensure that concreting works are carried out according to the specification,
drawings and method statements and as per project’s requirements
6.3 Section Engineer

The Section Engineer is responsible for the overall site operation and implements HSE.
He will ensure that the appropriate procedure is followed by all involved personnel taking
into consideration all relevant shop drawings & reference drawing, bench marks &
reference points and methodologies are correctly utilized.

 Shall ensure that formworks are erect at correct level, reinforcements are fixed as per
approve drawings.
 Liason with MEP team for marking out and installation of embedded items/cut outs
Coordination on site with approved formwork.
 Notifying QC Engineer and issuing the IR in sufficient timely manner when work is
ready for inspection and as detailed in the relevant ITP to obtain necessary approvals for
pouring activities.

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  Controlling the progress of work and ensure final approval is obtained well ahead of
scheduled casting time
 To ensure that all equipment that he requires for the placement of the concrete is
available and in working condition, before concrete arrives on site.
 Shall ensure that concreting works are carried out according to the specification,
drawings and method statements
 Coordination with batching plant and confirming date well in advance of casting date.
 General coordination with all trades.

6.4 Site Engineer

The specific safety responsibilities of Site Engineers shall include, but not be limited to
the following;

 Reviewing all work and all new personnel for safety needs
 Complete familiarization with safety requirements is an integral part of the total job
responsibility
 Observe all permits to work systems at all times
 Attend safety meetings and promote safety among Foreman / Lead men & Workers
 Monitor Subcontractor compliance with the site safety requirements
 Close supervision with foreman for works to be executed and check its compliances as
per approved drawings.
 Responsible for the implementation of related QA/QC works as detailed in quality
procedure and quality plan for concreting works.
 Shall ensure that concreting works are carried out according to specification, drawings
and method statements
 Supervision of concrete operations and make sure required tools and manpower is already
available prior to commencement of different work stages.
 General coordination with all trades
6.5 Quality Manager shall be responsible for:

 Reviewing all relevant documentation and test reports and all handing over dossiers.
 Ensuring that all activities subject to inspection are recorded and cleared by the
consultant.
 Controlling and organizing the inspection works.
 Shall ensure that concrete works are carried out according to the specification, drawings
and method statements.
 Coordinate with other discipline engineers for ensuring that all other discipline activities
need to be inspected within construction program had been inspected and approved.
 Ensure the inspection are carried out in timely manner and documented
 Issuing and reviewing all laboratory test reports required

6.6 Quality control Engineer shall be responsible for:

 To inspect and ensure the compliance that construction work is carried out to the required
contract specification and approved shop drawings.

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  Informing the consultant when his presence is required to carry out the inspection as per
the approved ITP.
 Accompanying the consultant for inspection to release the hold points.
 Monitoring concrete received and conducting field testing and sampling of fresh concrete
according to requirements of specifications.
6.7 Site Surveyor

 Ensure that setting out, levels, dimensions carried out correctly and as per approved
drawings
 Ensure that the formwork provided for the required shape and dimensions are in
accordance with the drawings.
 Reference level for the top of the concrete shall be provided at the liner of forms
 Steel pins shall be provided at intermediate area as guide levels for the required concrete
level prior to casting slab concrete.
 Cross check finished level while pouring

6.8 HSE Manager

Along with his team of safety officers will ensure that construction staff implements all
safety procedures and precautions, safety measures related to the nature of works being
carried out and in accordance to the HSE Plan.

 Monitor implementation of Project HSE plan.

 Liason with construction team to ensure safe working environment
 Ensure all workers equipped with proper PPE throughout construction work
 To organize proper tool box meeting for supervisors and workers to disseminate the well
awareness of safety working during execution of works.
 Ensure all work platforms and fall protection in place
 Ensure first aid and emergency rescue is on standby at all times
 Notify CM/SE of any deficiencies in safety requirements

7. Sequence of Work:

7.1 Formwork

 Prefabricated formwork for slab to the correct sizes, shall be, of sufficient strength and
rigidity to prevent undue deflection during the pouring
 The formwork shall be formed using marine plywood facing with timber framing and
braced as necessary. Before fixing, the faces in contact with concrete will be coated, by
brush or spray, with an approved non-residual compound or as specified. Formwork
quality will be checked regularly and damaged plywood will be replaced as required
 Forms shall be placed, coated with approved release agent, aligned and secured by
necessary propping, providing safe and stable platforms for checking and concreting
operation.
 Ensure all formwork joints are suitably sealed prior to closing to prevent grout leakage.

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 Dedicated formwork supervisors from formwork supplier will be present on site at the
initial stage of formwork assembly and erection.
 Site surveyor shall ensure that setting out, levels, dimensions carried out correctly and as
per approved drawing.
 Closing of formwork will proceed after all inspection (inclusive of MEP inspection where
required) are performed and approved.
 Formworks framing and bracing shall double check prior pouring.

7.2 Reinforcement Works

 The concrete reinforcing steel bars will be obtained from an approved source and
conform to the specified manufacturing standards.
 The material will be delivered o site cut and bent cold with diameter, shapes and sizes
conforming to those given on the bending schedules based on the approved shop drawing
including the required couplers where necessary.
 Most reinforcement will be fabricated off site and brought to site fabricated or tied in
cages where appropriate.
 All reinforcement will be stored free off the ground well covered and before installation
shall be free of oil, grease.
 Reinforcement bars shall then be shifted to the working location by mobile crane and
fixed to the accuracy shown on approved shop drawing with respect to number, diameter,
spacing and cover by the use of approved binding wire ties and spacer blocks
 Ensure that fixing is firm enough to prevent rebar displacement during concrete placing
 Lap length and vertical starter bars shall be as per specified drawings.
 Rebar’s will be inspected, but should have final inspection prior to pouring for overall
arrangement and cover to rebar’s

7.3 Prior to commencement of pouring

 Structural concrete works shall commence upon completion of reinforcement and

formwork activates.
 All the surfaces shall be clean. Foreign matters such as saw dust, wooden and wire pieces
shall be removed
 All the joints shall be water tight to prevent loss of grout
 Concrete shall be deposited at or near final position to avoid segregation due to lateral
flow
 Layers of concrete shall be integrated with previous layers by re-vibrating previous layer
 Surfaces of formworks shall be kept moist, standing water shall be removed before
concreting
 The concrete spacer blocks shall be made with the mix proportions and be same as slab
concrete
 All necessary spacer and chains shall be provided to maintain specific covers
 Required anchors, sleeves, dowel bars and other inserts shall be provided as per drawings

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 It shall be ensured that enough stand by vibrators, pokers, hand tools, hessian cloths and
polythene sheets are available.
7.4 Concrete Placement

i. Prior to concrete: ensure the following items are addressed and actioned

 Concrete design mix approved

 All inspections are performed and approved to proceed
 Confirmation of concrete order has been sent timely to batching plant
 Providing enough lighting to cover all the working areas (for night).
 Allocating and constructing a shaded area for concrete sampling with all necessary test
equipments
 The required staff ,manpower, and equipment are available and working properly (shall
be provided with pouring notification)
 The slab pouring area is cleaned from dust and debris.
 Reinforcement are cooled prior to placing the concrete by mist spraying Rechecking the
formwork side shutter for stability.

ii. Receiving and quality control:

 Upon commencement and receiving of transit mixers, the delivery tickets shall be
checked for mix grade, timing, and order. Prior to discharge a slump test, temp max as
per approved mix design will be conducted at concrete check point as per approved
design mix (Area will be designated for taking the slump, temperature and cube
sampling) in cases that the slump test failed, exceed the maximum allowed temperature
and exceed the allowable waiting time or travel time the identified truck mixer will be
rejected and immediately remove at site.
 Cube sampling to be taken as per the requirement of the relevant specification and will be
mark for proper identification of pour location QA/QC, consultant/consultants
representative. Cube sample (refer to ITP item no. 4.3 for nos. of cubes to be taken &
tested. It will be stored, cured, protected and will be tested based on the required
specification by the approved testing laboratory. Delivery tickets shall then be sent to the
document controller for instant logging.

iii. Placing:

 Concrete placing shall be carried as per plans Concrete placement sequence shall be
planned in a manner so that to have minimum re-positioning of the transit mixer/concrete
pump/crane
 Concrete shall be transported from the transit mixers to the discharge point by concrete
pumps where pouring shall commence from one side of the RCC Slab and ending by the
opposite one.
 Concrete shall be compacted by suitable size vibrators and shall be placed promptly to
prevent cold joint formation until reaching the top of the slab.

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 Concreting will proceed on the same sequence until reaching the other end of the slab.
 The concreting of the beams of slab will take in advance prior to slab areas.
 Slab concrete floor level shall be controlled by surveyor and by using 10 mm L shape
steel level pins fixed to the top of upper reinforcement at convenient locations and
marked to the true level; these temporary guides shall then be removed by masons
simultaneously with the proceeding of surface trowelling.
 Concrete surface shall then be floated to produce a uniform free surface, and after the
disappearance of the moisture film, the same shall be power floated to produce firm
smooth surface depending on the required type of finish and immediately covered with
polythene sheet.
 Pouring shall be planned /scheduled when the weather condition is favorable and adverse
exposure of the concrete to the environment can be avoided.
 The delivery end of the chutes and pump hoses shall kept as close as possible to the
delivery points, the drop height shall be minimized to 1.2m to avoid segregation.
 Concrete will be deposited continuously or where this is impractical at such times will
ensure the previous layer is still in plastic state and cold joints avoided.
 The concrete will arrive at the site and approved for use by the consultant in charge to
verify concrete class.

iv. Vibration
 Trained operators will be assigned to this activity
 The size of vibrating pokers shall be decided considering the layout of reinforcement and
shall ensure consistent mass is obtained without segregation
 Vibration shall be withdrawn slowly to prevent formation of voids and shall not be placed
against compacted concrete.

v. Finishing

 The final working up of the surface shall be done by means of steel float and aluminium
sections to obtain uniform surface free from irregularities.
 Surface finishes shall be done as per project specs section 03 30 00 clause 3.21 or as
indicated in the finishes drawings to receive subsequent finishes.
 The concrete surface shall be covered Hessen soon after surface finishing

vi. Post concrete for curing:

 Immediately after the surface initial setting, area shall be cured either by applying curing
compound by roller /sprayer to the required coverage or area to be cured by water with
hessian cloth.

vii. Testing.

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  Cube sample shall be taken and compressive strength test shall be carried out at as per
attached concrete test proposal.

viii. Removal of formwork

 The periods Removal of forms after casting will be in accordance with project
specification Sec 03 30 00 clause 3.20.3 mentioned below or as agreed with the Engineer.

Element Duration
Beam sides, walls & columns (unloaded) 24 hrs
Slabs (props left in place) 4 days
Waffle slab moulds (props to ribs 3 days
remaining
Beam soffits & flat slabs (props left in 7 days
place)
Props to slabs between beams 10 days
Props to beams, flat slabs & waffle slab 14 days
ribs
Props to cantilevers 28 days

8 QUALITY CONTROL REQUIREMENTS

 Quality Control shall be implemented at all stages of this Work Procedure through the
use of I.R’s, Checklists, and verifying records with necessary clearances.
 Data obtained from Field Sampling and Testing (Slump, Concrete temperature, Ambient
temperature, and number Designation of cubes taken) shall be recorded on “Concrete
Pour Card” form.
 Concrete compression test reports will be obtained from 3rd party laboratory and sent to
the Engineer.
 Inspection and test requirements of contract documents will be incorporated in the
attached inspection and test plans.

9 SAFETY
Concrete Burns

 Concrete and wet cement can cause skin irritation and blisters commonly called Concrete
burns. These are caused when the chemicals in the wet cement attack your skin causing a
reaction. Because the concrete is in direct contact and may stay there for some time it eats
into your skin causing a deep injury rather than just a surface effect.

 These are usually caused by wet concrete constantly rubbing against the skin at the splash
zone just above the rubber boots. It may occur from concrete getting inside the boots and
rubbing against the feet. It is not common but can occur so take precautions.

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 Prevention is much better than cure so

 Always wear rubber Wellington boots when concreting even for shallow slabs or walls.
 If you tuck trousers inside your boots, tape the boots to the trousers to stop concrete
falling inside.
 Wear water proof leggings outside the boots – this is the best protection
 Wear waterproof gloves to protect your hands. Check the wrist area as set concrete may
get stuck on the cuff and rub the skin causing an infected cut.
 Wear safety glasses, (impact goggles are not necessary) to protect your eyes against
splashes. This includes pump operators and lab men.
 Clean up thoroughly before you go home, don’t wait until after a long ride to remove the
concrete, it’s doing the damage all the time you’re sitting in the car / minibu.
 SeIf-wet concrete does come into contact with your body or eyes wash the affected area
as soon as you can. Check the area to see if a ‘burn’ develops, then see your doctor.

Concrete Works
Ensure that-
Good access and working platforms are supplied to the men
 Falsework and shutters are checked prior to loading out with men and materials
 Edge protection is in place to stop men and materials falling
 Manual handling of heavy items has been minimised.
 Men have correct PPE, including leggings and safety glasses
 If it’s a big pour or going to finish late, have a second shift take over halfway through.
 If power floating a slab, it may be a late finish, have lights and welfare prepared? Can the
men get off the pour safely at midnight?
 Check men are aware of cement burns from wet concrete. If clothing is scrunched up
inside rubber boots this may cause blisters.
 Never allow climbing the shutter or standards or rebar cage.
 Wear a harness if you need to go outside the guard rails,
 Check all equipment is in good order and working before the concrete arrives
 Do not heap up concrete in the middle of a slab, get it levelled out quickly, by
manoeuvring the pump line or skip. Avoid men manhandling the concrete - its heavy
stuff.
 Clean up spilt concrete as soon as possible as the working platform now becomes
slippery and increases the possibility of a tripping accident. Cement dries out scaffold
boards making them brittle.
 It’s not a race, far better to take a little longer and produce a good product than rush it and
have to scabble high spots or jack hammer it out the following day.

Working with mobile Concrete Pumps

 Only properly trained and certificated persons may operate a concrete pump.
 Trainee operators must be supervised by a competent person
 Employ a banksman to control revering vehicles. Keep people and hands clear of pinch
points.

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  Lifting the hopper grill must stop / cut out the drive to the augers.
 Watch your fingers between the truck mixer chute and the hopper
 Don’t go behind the truck mixer to adjust the chute until the wagon has stopped.
 Reverse or reduce the pressure before investigating any blockage
 Ensure clips are locking the pump line collars
 Keep non-essential personnel away from the pump and pipeline
 Use the standard crane signals to control the boom. Some pumps have remote control
 Plan the location of the pump and truck mixer route well in advance
 Pump lines do wear out over time so check that the walls are not ruptured and are rigidly
connected and bends secured. Have some spares lined up just in case.
 Fit check slings on the elephants trunking to stop it falling, if it comes loose
 Switch of the pump engine before any work on pump moving parts
 A “catch-basket” or skip restraint should be fitted to the discharge end of the pipeline to
catch wash-out balls or wads,
 Compressed air should be introduced into the pipeline through a purpose made washout
adapter, equipped with an inlet and an emergency pressure release
 Open the inlet gently to allow a slow build-up of pressure and movement of the washout
balls or wads along the pipeline commences. This movement should be controlled
throughout the length of the pipeline.
 Prevent a violent discharge by opening the pressure release valve before the washout
balls or wads are due to be discharged. Never look into the pipe to see if the sponge is
about to arrive, you might be ‘rendered’.

10 ATTACHMENTS
1. ITP & ICL
2. RISK ASSESSMENT

3. TEST PROPOSAL SCHDULE

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