KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

PARCO PROJECT
CONTRACT # 1762-112-2017

ENGINEERING, PROCUREMENT, CONSTRUCTION,

ERECTION, INSTALLATION, TESTING, COMMISSIONING,
START UP, AND HAND OVER OF MFM PIPELINE MOGAS
PROJECT (MFMMP), PHASE-II, EPC-II KOT BAHADUR
SHAH (KBS) PUMP STATION (PS-6)

Method Statement for Concrete

A Issued for 12nd Dec 2017 WJ SLJ LQ

Review

Revision Description Date PREP’D CHK’D APP’D

Shandong Kerui Petroleum Equipment Co., Ltd

IKAN Engineering Services (Pvt) Ltd.

KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

TABLE OF CONTENTS

1 PURPOSE.............................................................................................................................3

2 LEGENDS & ABBREVIATIONS................................................................................................3

3. SCOPE OF WORK................................................................................................................3

4. REFERENCE DOCUMENTS.....................................................................................................4

5. HEALTH, SAFETY AND WORK PERMITS.................................................................................4

6. RESPONSIBILITY.....................................................................................................................5

7. EQUIPMENT & TOOLS............................................................................................................6

8. MANPOWER..........................................................................................................................6

9. QUALITY CONTROL (QA/QC)..................................................................................................6

10. SURVEY WORK.......................................................................................................................7

11. CONCRETE REQUIREMENTS..................................................................................................7

12. PRODUCTION.......................................................................................................................8

13. FORM WORK.......................................................................................................................8

14. REBAR WORKS....................................................................................................................10

15. EMBEDDED ITEMS.............................................................................................................11

16. TRANSPORTING & CONVEYING..........................................................................................11

17. INSPECTION & PLACEMENT..............................................................................................12

18. COMPACTION....................................................................................................................12

19. QC REQUIREMENTS...........................................................................................................12

20. CURING.............................................................................................................................13

21. HOT WEATHER CONCRETE....................................................................................................13

22. COLD WEATHER CONCRETE.................................................................................................13

KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

1 PURPOSE

The Purpose of this Method Statement is to describe the activities related to the execution
of concrete structures in a safe manner and in accordance with the contract requirements
and that all quality assurance/control activities are undertaken in a systematic manner,
works inspected and in conformance with the relevant standards and codes , verified and
documented.

2 LEGENDS & ABBREVIATIONS

 Company: PAK-ARAB REFINERY LIMITED COMAPNY.

 Contractor: KERUI & IKAN Engineering Services (Pvt) Ltd.
 HSE: Healthy, Safety & Environment
 PPE: Personal Protective Equipment
 ACI: American Concrete Institute
 RFI: Request for Inspection
 BS: British Standard
 SRC: Sulphate-Resisting Cement
 OPC: Ordinary Portland Cement
 M.S.: Method Statement

3 SCOPE OF WORK

This method statement defines the procedure of form work, Curing of concrete, protection
of coating and blinding works within PARCO project, commencing from proportioning mixing
with mixture machine to its placing and consolidation at site, including quality control
during the project execution. All works shall be carried out in accordance with codes and
standards of practices

4 REFERENCE DOCUMENTS

Applicable codes & Standard

Project Specification
Project Quality plan
Quality Inspection Plan
Project Drawing
KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

5 HEALTH, SAFETY AND ENVIROMENT

Ensure that all Staff and workmen assigned to carry out the task have attended and
successfully completed the mandatory safety induction by PARCO
Toolbox talks shall be carried out on daily-basis by discipline supervisors emphasizing the
hazards that may be encountered & the hierarchy of control measures to be taken prior to
commencing the task.
Appropriate and correct Personal protective Equipment’s (PPE) shall be provided and worn
at all times.
Plant & Machinery that will be utilized must be in good working condition and shall have the
relevant valid documents, and shall have passed CLIENT inspection criteria.
Site supervisor shall closely monitor the activity and recommend mitigating control
measures, if unsafe acts and conditions have been observed during and throughout the
course of the work.
Good housekeeping standards shall be maintained during and throughout the course of the
work on daily basis to be carried out at the end of each work day.
Applicable HSE requirements and regulations shall be adhered to at all times throughout the
construction phase. Ensure that all personnel involved in the work have the necessary valid
gate passes.
6 RESPONSIBILITY

Project Manager
Construction Manager
Site Engineer/Supervisor
QA/QC Engineer
Site HSE Engineer/Officer
Civil Site Foreman
All of the above personnel shall be responsible for the implementation of this Method
Statement. The Project Manager/Construction Manager/Site Supervisor/QA/QC Engineer
shall ensure that all drawings are approved/issued for construction prior to the actual site
work execution.
Site HSE Engineer/Officer shall enforce all safety requirements at the site during the
progress of the work and Civil Site Supervisor shall ensure at all times the compliance to
both technical and safety requirements.
7 EQUIPMENT & TOOLS

Mixture machine ( 1/3 bags capacity ).

Potable Water truck
Hand shovel, Pick Axe and various hand tools
KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

vibrators
Diesel operated air compressor
Bar bending machine
assorted masonry finishing tools, hammer
Carpentry tools for fabrication of shutters
8 MANPOWER

Civil Supervisor
Civil QA/QC Inspector
Safety officers
Surveyors
Masons
Scaffolders
Mixer Operators
Helpers
All personnel shall have valid IKAN Gate Passes and valid N.I.C.
KERUI/IKAN t will ensure as per there HSE policy that all personnel involve in the work are fit
for carrying out for Site activities.

9 QUALITY CONTROL (QA/QC)

QAQC Personnel shall ensure that the concreting work is carried out as per approved project
QA/QC Plans and specifications. This team will be responsible for all inspections and
submitting of reports and all QA/QC documents.
Area Engineer shall raise Request for Inspections to QAQC 24 hour’s minimum prior to
inspection.
10 SURVEY WORK

Surveyor shall be establishing the temporary stations, if required, with reference to the
permanent benchmark in a professional manner for the construction purpose.
Assign unique reference number to the each established survey station and ensure that the
survey stations are properly marked and protected.
Before carrying out the coordinates/ setting out operations, cross checking shall be done at
least between two survey stations to avoid any possible errors.
Structural reference Axis & Grid marks shall be available all the time for checking.
KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

11 CONCRETE REQUIREMENTS

The requirements of the mix designs for all concrete types shall be submitted for approval by
PARCO in accordance with relevant standards and codes of the specifications.
Concrete types to be used shall confirm codes of practice and standards shall be latest or
current edition.
Structural Concrete as per approved mixed design, reinforced concrete shall conform to the
relevant international and Pakistani standards and codes.
All concrete to be used shall be complying to project specification for both physical and
chemical property requirements.
Adding or mixing of water or concrete admixtures in the site shall not be allowed unless
permission or approval from the Client is obtained.
Concrete placement shall be complied with as per project specifications and requirements.
No concrete shall be placed or disposed of during severe rain, sandstorm or during extreme
temperatures of more than 300C ambient.
Concrete temperatures of more than 37 degree centigrade shall not be allowed for
placement and shall be discarded. All required embed shall be in-placed prior to concrete
pouring.
Concrete which has partially hardened shall not be re-tempered by the addition of cement
aggregate of water and/or re-compacted by vibrator. The batch shall be discarded and taken
away from the site.
12 PRODUCTION

Batching of materials shall be done by weight within an accuracy of ±3%.using batching

boxes of 1x1x 1.25 feet.
Concrete mixed on site shall be in a batch mixer of approved size and design. Mixing shall be
continuing for 1 minutes after adding water.
Admixture that have been approved, as per design mix shall be added by approved
automatic dosing equipment.
Where crushed ice is required to lower the mix temperature, it shall be melted first before
mixing.
Concrete which has partially hardened shall not be re-tempered by the addition of cement
aggregate of water. Transit mixers shall have their water tanks hose completely disconnected
from the drum.
13 FORM WORK

All required construction/control/expansion joints shall follow only drawings and Project
specifications.
Wall/slab construction joint required as per approved drawings shall be keyed on-cast kicker
of not more than 150mm in height with approved water-stop or water-bar in-place prior to
KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

concreting. Construction joint key size and dimensions shall be provided as per Approved
drawings.
20mm X 20mm groove to be provided for control joints wherever indicated in the drawing.
Cement slurry or other approved bonding agent for old concrete to new concrete shall be
applied prior to pouring the second stage of concrete.
Form-work shall be installed in conformity to shapes, lines, elevations, and dimensions of
the concrete.
Form-works shall be prepared and arranged as to be readily dismantled and removed from
cast concrete without any shock, disturbance or damage.
Form-work shall be sufficiently strong and tight to prevent leakage of slurry. Seal the gaps
between form plywood by the use of foam tape to produce a smooth concrete surface.
Form-work shall be property braced by shoring jacks/diagonal bracing and tied with tie rods
to prevent change in position or shape due to loads imposed during placement and
consolidation of concrete.
Form-work vertical and horizontal studs/whalers to be of adequate size and spacing.
Form-work shall be in good condition and acceptable to CLIENT representative for the
particular work and shall be made from dressed boards, plywood, or metal.
Form-work material shall be free from any foreign material prior to their use. The internal
side of forms that shall touch the concrete surface shall be coated with approved non-
staining form-release agent prior to placement of reinforcing bars. Forms shall be free from
any foreign material prior to application of form-release agent.
All tie rod holes and other gaps to be properly plugged / covered prior to re-installation or
re-use and form-works with deformity and warping surface of plywood due to over exposed
from the weather should not be used anymore.
Chamfer strip of 25mm on exposed corners from below and above ground and/or plastic
fillets of 25mm at interior corners of the concrete members shall be provided.
Casting window openings shall be provided in the form-work/shutter as directed by the
Client to facilitate proper concrete placement and compaction/vibration.
All Embedded items like anchor bolts, steel plate and other embedded items shall be
positioned as per drawings and project specification and firmly secured in position by
wooden or steel templates. Angle bars used as embedment (i.e.: cable trench) shall be hot-
dip galvanized steel.
Pre-pouring inspection shall be done prior to concreting
Upon receipt of PARCO approval for concrete casting the re-bar and form-work that has
been inspected shall be slightly sprayed with a small amount of potable water prior to
concrete pouring. This will help lower the re-bar temperature (in the case of extreme hot
weather condition), thereby maintaining the concrete temperature as well.
Required concrete cover shall be followed as follows:
KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

-Concrete in contact with soil – 70mm

- Concrete above ground exposed to weather – 50mm
- Concrete concealed or not exposed to weather - 30-40mm
Concrete protection by means of damped proofing work shall be done as per approved
Method Statement for Waterproofing Works to be elaborated in the submission of the
relevant Method Statement.
14 REBAR WORKS

Bar bending schedule/plan/details shall be verified and approval by CLIENT prior to

commencement of works.
All reinforcing bars shall be free from mill scale or any rust and epoxy coated prior to any
installation.
Any Fabricated bars that were installed and had been observed to be defective during the
inspection either due to excessive rust, wrong size, wrong fabrication and other major
defects has to be removed, replaced or rectified immediately prior to the concrete pouring.
Inspection checklist has to be satisfied and signed. (Ref Form No: EQL-004) Note: Please
refer to PARCO approved ITP Plan for checklist.
All reinforcing bars shall be cut & bent according to size and shape as per approved bar
bending schedule
All Cutting and bending shall be done on cold bending method
The cut lengths are to be grouped according to the mark numbers as per bar bending
schedule and should be identified with tags.
Re-bar setting shall be carried out after approved survey layout is issued. Reinforcing bar
spacing shall be chalk-marked prior to installation.
Minimum concrete cover to reinforcing bar shall be provided and maintained as required in
the approved project specification and as noted/indicated in the drawings.
Concrete spacer blocks shall be used to maintain the required concrete cover to reinforcing
bars. The concrete spacer blocks shall be made with the same concrete strength and mix
being used in the concrete structure. Necessary chair bars shall be provided of the same size
of the main reinforcement to support the main reinforcement bars as & when required.
Concrete cover shall comply as mention of in form-work.
General requirements for lapping and anchorage length shall comply with approved
drawing.
All reinforcement bars shall be kept and stockpiled with proper covering for moisture
protection and shall not be in direct contact with the ground to avoid corrosion. Rust color
like corrosion of the re-bar due to prolonged exposure to weather should be cleaned by wire
brushing or other approved methods before concreting.
KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

15 EMBEDDED ITEMS

All embedded items plan/details/sketches shall be reviewed and verified by Site Civil
Engineer as per drawings prior to commencement of works.
All embedded items and inserts shall be installed on location true to line, level, vertical,
alignment in correct position/orientation as indicated/shown in the drawings.
Due care shall be provided during installation so as to avoid damage and/or deformation of
the materials including galvanized coating material. Scratches on the galvanized coat shall be
repaired by applying approved cold galvanized coating material.
Installed anchor bolts and other inserts shall be supported adequately and should be strong
enough to avoid any movement and displacement during concrete pouring operations.
The anchor bolts and embedded plates external faces shall be protected against contact
with the fresh concrete by using 1000-gauge polyethylene sheet or masking tape as cover.
16 TRANSPORTING & CONVEYING

Concrete free-fall shall not be allowed beyond 1.50 meters high nor shall it be dropped
through dense reinforcing bars that may result to segregation of the aggregates in the mix.
The use of chute and bucket shall be allowed to be able to properly place the concrete in a
difficult situation or constrained spaces. This method of casting shall be monitored closely
by the QC Inspector and the Civil Supervisor.
Transport duration of the concrete from mixing point to the disposal time shall be as per
approved duration stated on the approved mix design. Record of casting shall be maintained
and the said records shall be submitted to PARCO together with the pouring receipts.
17 INSPECTION & PLACEMENT

After each batching mix is completed the QAQC personnel shall immediately check the
temperature and slump prior to pouring. Slump & temperature checking will continue to be
done for all batching mixes received at the site. Keep all records of slump & temperature
together with the concrete trip receipts.
Pouring of concrete shall only be allowed to start once the slump and temperature is
accepted by PARCO representative.
Only PARCO approved/inspected concrete structures shall be allowed for concrete casting.
Concrete shall not be cast unless the positioning, fixing & condition of the reinforcement
around items to be embedded, the cleanliness, alignment & suitability of the containing
surface have all been previously examined & approved by PARCO.
Concrete that does not meet the requirements for slump and temperature shall be rejected,
discarded and immediately removed from the site.
Concrete placement of a structure having more than 500mm thick or depth of concrete shall
be poured in layers of not more than 300mm in depth. Concrete shall be deposited in
regular courses or layers not exceeding 300mm thickness unless otherwise directed.
KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

Concrete shall be compacted to its final position within two hours from the time of
introduction of cement into the aggregates.
Interval between deliveries of batches shall not exceed twenty (20) minutes. If the interval
exceeds 20minutes the fresh concrete shall not be placed against the already poured
concrete.
Placement of concrete shall generally be in accordance with present specifications 2.1ACI
304-R (or BS equivalent).
18 COMPACTION

Compaction of fresh Concrete shall be in accordance with standard procedure. Extra care
shall be taken during consolidation of concrete since over-vibration of fresh concrete will
result to segregation of course & fine aggregates.
Electric or pneumatic vibrators shall be used for compaction. They shall not be used to
transport concrete within the forms nor use it as a tool to remove concrete from the
reinforcement.
Air bubbles resulting during the mixing and casting shall be removed.
19 QC REQUIREMENTS

SLUMP TEST

Slump tests shall be carried out on fresh concrete, at the time prior to placement; random
sampling shall be carried out at the place of mixing and during pouring. Target Slump for
structural concrete shall be as per Design slump of the approved mix design.
CUBE SAMPLING & TESTING

Sampling and Testing shall be carried out using relevant sections and procedure set out in as
per specifications.
20 CURING

Curing shall be maintained for at least seven (7) days to a maximum of fourteen (14) days
from the date of casting.
Concrete shall be covered in one of -wet hessian cloth is used after completion of surface
finishing works and as soon as the mix starts to harden.
Water pending may also be adopted on exposed horizontal concrete surface.
No curing compound shall be used without the approval of the Client
21 HOT WEATHER CONCRETE

During Hot Weather the site Supervisor shall take all necessary instruction to ensure that
the temperature of the mixed concrete does not exceed specified temperature.
KR/PARCO/PS-6/MS-0001 METHOD STATEMENT

These measures shall include, but not be limited to shading of aggregate, spraying water on
aggregate, linking the mixing water to a chilled unit, chill the mix ingredient with ice & when
ice is used in the mix, maintain the correct amount of water.

22 COLD WEATHER CONCRETE

During Cold weather, the concrete mixture and its temperature should be adapted to the
construction procedure/Specs and ambient weather condition. Stop concreting when the
ambient temperature reaches about 2C on a falling thermometer