Method Statement for Protective Coating

Work Methodology

References

1. Project Quality Plan (PQP)
2. Project Executive Plan (PEP)
3. Integrated Management System Manual (IMS)
4. Environmental Management Plan ((EMP)
5. Safety & Health Management Plan
6. Emergency& Response Plan (ERP)
7. Traffic Management Plan (TMP)
8. Survey Quality Plan (SQP)
9. Contract Specification
10. Approved Construction Drawing
11. Approved Shop Drawing
12. Other Related Method Statement

Materials

1. Estotect MMA PRIMER
2. Estotect MMA
3. Estopatch SRF
4. Estopatch Fine
5. Estobond Acryl

Plant and Equipment

1. Gloves
2. Goggles
3. Face Mask
4. Short Haired Roller
5. Adhesive Tape
6. Spreading trowel
7. Mixer
8. Sky Lift

Manpower

1. Site Supervisor
2. Operator
3. Painter

Construction Procedure

Surface Inspection

1. Segments would have to be inspected and approved by Consultant for application of protective coating (for any surfa imperfections). The substrate (new or existing) should be clean, sound and free from contamination such as mortar, loose particles, dust, paint splashes, oil and grease. Oil and grease contamination must be completely removed by grinding down to sound, clean concrete. Alternatively, captive/grit-blasting technique can be used to provide the required substrate.
2. Clean the substrate surface using broom/brush to remove dust debris. For stubborn dust stains, wipe the surface using clean damped cloth or sponge and use adequate water for such hard to clean surface if needed. (DO NOT use high pressure water jet to clean the surface as it may remove or increase the size of blowholes/pitted areas that has been patch repaired earlier).
3. Where these methods are considered impracticable, alternative methods may be considered but a clean, sound and dry substrate must still result. In particular it is essential that the substrate does not suffer from conditions of rising damp. Estop must approve any alternative preparations prior to commencement of work, as Estop will not accept responsibility under any other condition.

Application of Estopatch Fine

1. Repair should use a cement based material. The product most suitable for the repair of voids and holes shall be Estopatch Fine for equivalent cement based material. Blow holes and areas of pitting shall be patched and make good using Estopatch Fine mix with Estobond Acryl. This material use to concrete substrate before primer coating and MMA coating.
2. The Estopatch fine should be suitable for thin layer patching up to the thickness of 3mm, fine enough to fill blow holes, and able to bond well to the concrete substrate.
3. For powdery surface and loose particle, clean the substrate surface with running water (DO NOT use high pressure water jet onto the substrate surface as it may remove the blow holes/pitting areas that has been patched earlier).
4. For hard to reach areas, wipe surface to be repaired using a clean damped cloth.
5. Apply the Estopatch Fine mortar onto the prepared areas.
6. The diluted Estobond Acryl shall be added to Estopatch Fine at water powder ratio 0.18-0.22. Using handheld electric mixer (600 rpm) stir the products for at least 3 minutes until a homogeneous mortar paste is formed.
7. For dust stains, wipe surface with a clean damped cloth or sponge. Dilute Estobond Acryl with water at 1:10 ratio.
   

Application of Primary Coating

1. Prepared substrates should be primed using Estotect MMA Primer at 2 coats. Apply Estotect MMA Primer at the rate of 10-12 mm² per liter for total 2 coats with allowance of time to dry in between coating around 15-30 minutes (the time of drying shall varies with the weather). Apply the primary coating using a short hair roller/spray machine.

Application of Estotect MMA – 1 st Top Coat

1. After opening of the Estotect MMA tin, pre-mix the material with slow speed mechanical stirrer (400-600 rpm) for at least 1 minute or until the required consistency.
2. After application of Estotect MMA Primer, apply the first coat of Estotect MMA using a short hair roller/spray machine. Ensure all primed areas are fully blinded. Allow the surface to dry (approximately 4-6 hours or subject to weather condition) before proceeding to the second coat. For application of Estotect MMA, the coverage shall be between 5-6m² per liter (for total 2 coats).
3. The newly applied coating must be allowed to dry and cure for at least 4 hours.

Application of Estopatch SRF

1. This material use after primer coating and 1st coating of MMA before 2 nd coat of Estotect MMA silver grey.
2. Concrete substrate to be patch with Estopatch Fine for repair of voids, blowhole in accordance to the method statement.
3. After concrete surface preparation, apply 2 coats of Estotect MMA Primer in accordance to the method statement.
4. After priming coats, apply 1 st coat of Estotect MMA silver grey in accordance to the method statement.
5. If any visible blow hole / pinholes appear after 1 st coating of Estotect MMA silver grey, it shall be patched by using Estopatch SRF mixed with Estotect MMA silver grey accordingly.
6. After completing all necessary repairs, continue with the 2 nd coating of Estotect MMA silver grey with roller.

Application of Estotect MMA 2 nd Top Coat – Final Coat

1. Application of the final top coat shall be carried out at the site to ensure consistent colour shading. A skylift as shown in Figure 1 below shall be used for the application of the protective coating for the box girder superstructure at site. A skylift would allow flexibility in the control of the movement directly by the painter himself.
2. Clean the substrate surface using broom/brush to remove dust debris. For stubborn dust stains, wipe the surface using clean damped cloth or sponge and adequate water for such hard to clean surface if needed.
3. After opening of the Estotect MMA tin, stir the material with slow speed mechanical stirrer (400-600 rpm) for at least 1 minute or until the required consistency.
4. Apply the final (2 nd coat) of Estotect MMA using a short hair roller/spray machine. Allow the surface to dry (approximately 4-6 hours or subject to weather condition). For application of Estotect MMA, the total coverage shall be between 5-6m² per liter (for total 2 coats) therefore for application of one coat, the coverage of 2.5-3m² per liter shall be observed.
5. The newly applied coating must be allowed to dry and cure for at least 24 hours.

Method Statement for Rectification of Shrinkage Crack

Work Methodology

Construction Procedure

References

1. Project Quality Plan(PQP)
2. Project Executive Plan (PEP)
3. Integrated Management System Manual (IMS)
4. Environmental Management Plan ((EMP)
5. Safety & Health Management Plan
6. Emergency& Response Plan (ERP)
7. Traffic Management Plan (TMP)
8. Survey Quality Plan (SQP)
9. Contract Specification
10. Approved Construction Drawing
11. Approved Shop Drawing
12. Other Related Method Statement

Materials

1. Nitofill EPLV or equivalent

Plant and Equipment

1. Air Compressor
2. Electrical Rotary Mixer

Manpower

1. Site Supervisor
2. General Worker

Construction Procedure

1. The surface shall be cleaned and any dust and unsound material shall be removed.
2. The cracks and treated surface shall be blown with air compressor to make it dry and clean.
3. After preparation concrete surface done, entire hardener and base resin contents shall be thoroughly mixed until liquid becomes clear.
4. The mix resin shall be applied till the shrinkage crack line is being filled.
5. The filling shall be allowed to cure for 24 hours and shall be left undisturbed for this time.
6. A set of grout cube to be taken and tested for 7 days.

Method Statement for Rectification of Honeycomb

Work Methodology

Construction Procedure

References

1. Project Quality Plan(PQP)
2. Project Executive Plan (PEP)
3. Integrated Management System Manual (IMS)
4. Environmental Management Plan ((EMP)
5. Safety & Health Management Plan
6. Emergency& Response Plan (ERP)
7. Traffic Management Plan (TMP)
8. Survey Quality Plan (SQP)
9. Contract Specification
10. Approved Construction Drawing
11. Approved Shop Drawing
12. Other Related Method Statement

Materials

1. Estogrout MP50
2. Estogrout MP70
3. Estobond Acryl

Plant and Equipment

1. Chipping Hammer
2. Concrete Cutter
3. Air Compressor

Manpower

1. Site Engineer
2. Site Supervisor
3. General Worker

Construction Procedure

1. Chipped off and remove of all unsound and cracked concrete until to the sound concrete.
2. Cut the perimeter of repair area to be at least 12mm depth to prevent feather edging.
3. Clean loose dirt and dust from the prepared surface using air compressor and clean water.
4. Mix the Estogrout MP50 with water and Estobond Acryl as bonding agent by using supplier recommended mix proportion for general repair on honeycomb that is not exceeding 15mm in thickness or at larger area bigger than a palm of hand size.
5. Patch grout mix onto the prepared concrete surface and continue patching in sequence until the entire surface is filled with grout.
6. Otherwise, mix the Estogrout MP70 with water by using supplier recommended mix proportion if the honeycombing is extensive and penetrates down to the reinforcement or even deeper.
7. Install grout tight formwork and secures formwork with suitable ties. Pump grout mix into the formwork assembly through the inlet ports and continue grouting in sequence until the entire formwork is filled with grout.
8. After the grouting has set by next day, execute required cleaning, dismantled formwork.
9. To make good final finished surface the joint required to grinding.
10. Finally surface will be painted with anti-carbonation painted product by Estop “ESTOTECT MMA”.

Method Statement for Ultrasonic Pulse Velocity (UPV)

Work Methodology

Construction Procedure

1. Identify and mark test location.
2. Measure path length of test location.
3. Apply grease onto the concrete surface using scraper.
4. Calibrate the Pundit tester with calibration rod to 20.8 µs.
5. Start UPV test with putting transmitter onto the greased concrete surface and receiver onto the opposite side.
6. Record the transit time as displayed at the LCD of Pundit tester.
7. Repeat step 4 three (3) times to get another three (3) reading.
8. Pulse velocity was calculated by path length divided by average transit time thru the structure.
9. Contour graph shall be plotted using pulse velocity at each location on gridline.
10. Result analysis based on guideline from “Non-destructive Testing of Concrete” by Singapore Concrete Institute, 1995.

Method Statement for Pile Integrity Test (PIT)

Work Methodology

Materials

1. Not applicable

Plant and Equipment

1. PIT-Collector
2. Accelerometer
3. Rubber Tip Hammer

Manpower

1. Site Engineer
2. Site Supervisor
3. General Worker
4. Traffic Management Personnel

Construction Procedure

Traffic Management

1. All related signages and traffic devices need to be arranged on site before commencement of work on site. Please refer  to Traffic Management Plan.

Transportation (Mobilisation of Plants and Equipments)

1. During mobilisation of plants and equipments, proper traffic management need to be carried out and control. This is to ensure that the traffic was not affected by the movement of the mobilisation activities. The unloading of plants and equipments shall be done carefully.

Pile Head Preparation

1. The specialist engineer shall ensure that the pile head shall be clean, free from water, laitance, loose concrete, overspilled concrete and blinding concrete and be readily accessible for the purpose of testing.

Test Procedure

1. Request for Inspection (RFI) shall be submitted online not later than 5.00 pm or 24 hours before date and time of inspection to be conducted based on the Consultant working day (Monday to Saturday). RFIs on Sunday or Monday need to be submitted to the Consultant by Friday.
2. Low strain integrity testing should only be carried out on cast in-situ piles after (seven) 7 days or more from the date of pile casting unless otherwise approved.
3. The accelerometer (which is connected to the PIT-Collector) is attached onto the pile by an adhesive medium (vaseline or grease).
4. A handheld rubber tip hammer is impacted on to the pile top to generate a “low strain” compressive impact wave downward the pile.
5. The PIT-Collector will graphically display the velocity records.

Data Interpretation and Reporting

1. The interpretation of the test records shall be carried out by an engineer with at least three (3) years experience in dynamic pile testing. Major faults existing within the effective length shall be quickly identified and made known.
2. A full report shall be prepared within 7 days from the completion of testing.
3. The report shall include the plotted results and the specialist interpretation.

Method Statement for Sonic Logging Test

Work Methodology

References

1. Project Quality Plan(PQP)
2. Project Executive Plan (PEP)
3. Integrated Management System Manual (IMS)
4. Environmental Management Plan ((EMP)
5. Safety & Health Management Plan
6. Emergency& Response Plan (ERP)
7. Traffic Management Plan (TMP)
8. Survey Quality Plan (SQP)
9. Contract Specification
10. Approved Construction Drawing
11. Approved Shop Drawing
12. Other Related Method Statement

Materials

1. MS Pipes (minimum internal diameter of 50 mm)
2. Cement (OPC)

Plant and Equipment

1. Digital data acquisition equipment (PDI Cross-Hole Analyzer, CHA)

Manpower

1. Site Engineer/Site Supervisor
2. Traffic Controller
3. General Worker

Construction Procedure

Traffic Management

1. All related signages and traffic devices need to be arranged on site before commencement of work on site. Please refer to Traffic Management Plan.

Transportation (Mobilisation of Plants and Equipments)

1. During mobilisation of plants and equipments, proper traffic management need to be carried out and controlled. This is to ensure that the traffic will not affected by the movement of the mobilisation activities. The unloading of plants and equipments shall be done carefully.

Pile Preparation

1. The Main Contractor shall ensure that 50mm MS pipe for probes are installed in accordance to the engineer’s specifications during pile casting.
2. The tubes should be properly connected by welding and capped to prevent any foreign material from falling in. There should be tied to the steel bars and about 100mm to 200 mm above the pile toe all the way to the top of pile.

Test Procedure

1. Request for Inspection (RFI) shall be submitted online not later than 5.00 pm or 24 hours before date and time of inspection to be conducted based on the Consultant working day (Monday to Saturday). RFIs on Sunday and/or Monday need to be submitted to the Consultant by Friday.
2. Sonic Logging should only be carried out on cast in-situ piles after seven (7) days or more from the date of pile casting unless otherwise allowed and/or instructed. This is to allow the concrete time to cure.
3. The cap is removed prior to testing and filled with clean water. The emitter and receiver probes are lowered to the respective tubes to be logged. They are then raised simultaneously up the tubes. Logging can also be done top down. The pulse generated by the emitter probe is received by the receiver probe and the meter wheel placed on top of the tubes acts as the depth sensor.
4. The Sonic Integrity Logger will graphically display the records.

Data Interpretation and Reporting

1. The interpretation of the test records shall be carried out by an engineer with experience in dynamic pile testing. Major inconsistency existed within the effective length shall be quickly identified and made known.
2. A full report shall be prepared within seven (7) working days from the completion of testing. The report shall include the plotted results and the specialist interpretation.

After Testing

1. After testing the MS pipes shall be filled with cement grout (OPC) to cover the holes.

Method Statement for Tree Cutting

Work Methodology

Construction Procedure

References

1. Project Quality Plan(PQP)
2. Project Executive Plan (PEP)
3. Integrated Management System Manual (IMS)
4. Environmental Management Plan ((EMP)
5. Safety & Health Management Plan
6. Emergency& Response Plan (ERP)
7. Traffic Management Plan (TMP)
8. Survey Quality Plan (SQP)
9. Contract Specification
10. Approved Construction Drawing
11. Approved Shop Drawing
12. Other Related Method Statement

Materials

1. Nil

Plant and Equipment

1. Crane (where required)
2. Sky Lift
3. Tipper Lorry
4. ¾ inches Nylon Rope

Manpower

1. Site Engineer/Site Supervisor
2. Foreman
3. Crane Operator
4. Sky Lift Operator
5. Traffic Controller
6. General Worker

Activities’ Pre-requisite

1. Re-confirm with surveyor the actual line of ROW and the area was released for construction work site possession.
2. Execute, piloting/locating of underground services to ensure the area is free from any live/in service utilities and these utilities will not get damage during site clearance work in progress. This inclusive of identify over-head services that may required extra precaution need to be exercised during trees cutting.
3. Mark and carry out registration (inventory) of all trees or stakeholders’ vegetation within ROW that are to be removed/cut.
4. Arrange and carry out site audit of prepared inventory with relevant parties/authorities for verification. Subsequent to this event, forward the verified inventory list to obtain approval from relevant authorities for cutting of registered trees. This inclusive of identify other nearby properties that may required extra precaution need to be exercised during trees cutting.
5. Request Traffic Management to organize required planning and obtaining appropriate approval for road/line temporary close.
6. Administrate relocation of utilities if there are over head lines within the work area which are affecting/obstructing trees cutting activities.

Cutting of Trees

1. Ensure all requirements stated in specification are implemented and accordingly approved for trees cutting activities.
2. Activate Traffic Controller, and mobilise required machinery/equipment to work site.
3. Execute pruning of the whole tree and cutting of branches shall only to be carried out for branches size not more than 50mm in diameter for area which near to public/traffic. In all event of tree cutting, sky lift must be used and only for chain saw operator. Using of sky lift for lifting or lowering of loads is prohibited.
4. As the pruning work completed, carry out cutting of leftover branches for the length of not more than stated in specification (cut into a length suited to fit the dump truck for hauling and disposal). Where required ¾ inches Nylon Rope is to be used to control the fall of off cut branch. Cutting of bigger diameter more than 350mm of tree branches/trunks must be carried out with assistance of suitable crane.
5. Dig up the earth on the front portion of the trunk until its main roots are exposed and extracted. With the use of backhoe, excavate the stump until it is uprooted. Ensure that the backhoe is positioned in a way that when the tree is pushed, it will fall completely to the ground without hitting or falling on other objects.