METHOD STATEMENT OF SEGMENT CASTING

1.0 PURPOSE:

This method statement describes the detailed procedure to be adopted for casting of segments in
this project.

2.0 SCOPE:

It is proposed to pre-cast box girder segments on long line beds. Segments for straight and curve
spans shall be cast on separate long beds.

The length of span varies from 60 mtr, 50 mtr, 45 mtr.

The scope of this method statement includes stacking of segments.

3.0 APPLICABILITY/ AREA OF APPLICABLE:

Total nos. of segments: 278 for MB 2-2, If segmental width 2.5 mtr.

 Alignment of soffit
 Alignment of bulkhead
 Survey
 Lowering of Rebar cage
 Movement of Internal shutter
 Final rebar adjustment and adjustment of sheathing
 Final survey and Rebar checking
 Concreting
 Loosening of external shutter
 Removal of Internal shutter
 Shifting of match cast segment

Total nos of span MB2-2

10 nos of 60 mtr span

1 nos of 50 mtr span

1 nos of 45 mtr span

4.0 Reference Documents:

 Technical specifications, Volume 4, Section 2, MCRP/South/P-II
 Technical specifications, Volume 5, Section 2, MCRP/South/P-II
 SHE Manual

5. METHODLOGY

5.1 MATERIALS:

SR.NO. DESCRIPTION SPECIFICATION

01 Concrete M50
02 Reinforcement Fe 500D
03 Sheathing pipe High Density Polyethlene Sheathing (HDPE)
04 Guide cone As per approved source
05 DE bonding agent (like Beeswax) As per approved source
 06 Segments embedment’s As per approved drawings
07 Shutter releasing agent form oil Reebol or equivalent

5.2 LIST OF MOULD AND EQUIPMENT IN CASTING YARD

SL.NO. DESCRIPTION NO’S

01 Long line casting beds for straight span As required
02 Long line casting beds for curved span As required
03 Casting of mould for pier segments As required
04 Batching plant CP-30 & CP-60 As required
05 Transit mixer As required
06 Shutter vibrators As required
07 Needle vibrators As required
08 Boom placer & Concrete pump Each one
09 Curing pump As required
10 Welding set As required
11 Crane 80 Ton capacity 02
12 Crane 20 Ton capacity 02

5.3 CASTING YARD

 Gantry at casting yard is of Sufficient height for lifting of one segment over the maximum
height of precast bed. without any obstruction.
 Sufficient area for rebar cage stacking is also provided.
 Rebar jig for segment 6 nos.
 Survey towers 05 nos
 Access road
 LIFTER

5.4 MOULD

There are three types of mould for casting of segments.

Pier head segment mould as per approved drawing ,

Intermediate segment mould as per approved drawing,

Curve span segment mould as per approved drawing.

Each mould comprises 3 major components Bulk head outer shutter, Bottom shutter, and Inner
shutters. Bottom shuttering is supported casting bed raft/Pedestal. Outer shutter are supported on
a movable trolley.

5.5 BOTTOM SHUTTERING

Bottom shuttering is supported on concrete bed provided in transverse direction of the casting bed.
Bottom shuttering is fabricated in the form of panels of appropriate sizes as mention below. Bottom
shutters shall be fixed for all segments on the long line casting bed.

5.7 SIDE SHUTTERS

Side shutters are mounted on a movable trolleys. Each long line casting bed shall have two such
mould so that two intermediate segments are cast simultaneously. One from each side.

Each pier head mould consists of the following

 Inner form assemble: Left and Right ( 2 nos)

 Soffit assemble: 1 nos
 Side shutter assemble with supporting truss: Left and Right end ( 2 nos)
 Bulkhead structure: 1 set
 Working plateform & access staircase: 1nos

Each standard mould consists of the following

 Inner form assemble: 2 nos

 Soffit assemble: 1 nos
 Side shutter assemble with supporting truss: Left and Right end ( 2 nos)
 Bulkhead structure: 1 set
 Working plateform & access staircase: 1nos

5.8 SEQUENCE OF CASTING:

In a typical casting sequence 60m span two pier segment shall be cast on two pier segments bed
simultaneously and brought and placed on movable trolleys placed at their final locations on either
side of long line bed. Two intermediate segments are match cast almost simultaneously starting
from either end.

The sequence of casting for span less than 60m will exactly same as mentioned for 60m span, except
that for casting of mid span segment one of its two neighbouring segments shall be lifted and re-
positioned on the bed.

Maintaining the correct length for the last segment to be cast. In doing so the outer shutter as well
as the inner shutter will overlap on the already cast segments on both the side, which shall be
suitably adjusted.

5.9 REBAR JIG:

6 no’s Rebar jig for each type of segment shall be fabricated to meet the required of 50mm clear
cover from all sides of concrete surface. Each gantry line will have sufficient no’s of rebar jigs.

5.10 REBAR CAGE:

The rebar shall be cut & bend by using cutting and bending at the centralized reinforcement yard
adjacent to the casting yard as per approved BBS.

The bars shall then be shifted to the respective rebar jigs where they shall be tied by using binding
wire in the required position according to approved drawings. The sheathing shall be fitted inside
the rebar cage at the required position as detailed in approved tendons profile drawings and held in
position using suitable chairs and hooks. The cage shall be lifted with structure frame holding the
cage in manner to any distortion while lifting and placing in position inside the casting mould. The
cage shall be lifted and placed in the casting mould by the suitable crane.

5.11 MOULD PREPARATION:

Mould preparation shall be started as soon as the segment shifted from the mould to stacking yard.
It shall be properly cleaned and shuttering oil shall be applied. Alignment and levels shall be ensured
and checked before shifting rebar cage to the mould.

Form checklist shall fill and approved from the Consultant Engineer.

5.12 SHEAR KEY

The shear key orientation in segments given to cater match casting operation (segment face will
have female shear keys at joint of infill concrete / grout material) is provided as per our approved
drawing. The shear key pattern and details as given in client reference drawing is adopted.

Shear key is made of hard wood or steel to required pattern and is screwed on to the end shutter
forms.

5.13 SHEATHING & GUIDE CONE FIXING:

HDPE duct as per approved vendor and the properties as per the technical specifications. The
required tests shall be conducted as per the technical specifications.

Guide Cone:

Testing will be conducted as per specification for guide cone. Profiling (Layout of HDPE ducts) shall
be carried out according to the ordinates given in the approved drawing.

HDPE duct will be fixed as per the X, Y, & Z Ordinates given in the drawings.

Cone boxes will be fixed at required location. Fixing of guide cones to the cone box shall be done by
using bolt and the guide ring and bursting reinforcement if required shall be placed in position at
rebar jig. These cone boxes will be permanently welded / bolted to end block shutters and shall be
approved from Consultant Engineer prior to use.

Cable supports / chairs shall be welded to the secondary reinforcement and duct will be tied with
the help of binding wire, so as to avoid displacement of cable during concreting. However care will
be taken in providing smooth profile and there will not be sudden kinks. HDPE pipe will be fixed over
supports. At the end of the cable, HDPE duct shall be inserted in the guide collar provided to
accommodate the HDPE duct and the joint sealed with heat shrink tape to avoid ingress of slurry
during concreting. Threads of guide bolts can be protected by M.S. threaded sleeve / PVC sleeve. For
proper matching of C/L of duct of previously cast segment and the segment to the cast, one end of
HDPE pipe inserted to the rubber ball pin provided in the bulkhead in one end and match cast
segment in other end. Joints will be sealed by putty. Grout / air vent pipe will be provided in the
cable, having length of 20m or more with proper plug arrangement.

Layout of the tendon will be marked on the pre-fabricated cage as per the drawings of the respective
segment.

5.14 CONCRETING:

The sequences of concrete shall be as follows:

 Soffit slab
 Half height of web-1
 Half height of web-2
 Remaining height of web-1
  Remaining height of web-2
 Deck slab including cantilevers on both sides

The concrete with a slump as per approved mix design shall be produced at the centralized batching
plant, and transported to location by transit mixers. The concrete shall be placed in above
mentioned sequence by concrete boom placer / pump. The concrete shall be vibrated by the both
shutter vibrators fitted to the shutter as well as needle vibrators of various diameter like 40mm,
60mm. Roughing of top flange and soffit slab of the segment shall be done in required locations
where secondary pour is to be carried out.

For separation of match-cast segments a suitable bond breaking material (such as concure WB or
equal product) shall be used on the surface of previously cast segment as approved by Consultant.

5.15 GEOMETRY CONTROL & SURVEY PLATES:

A survey tower on one side and target pole on the opposite side of the casting bed shall be
constructed to exercise to geometric control. Two plates shall be embedded along centre line of
segment, two on each side of centre line. After casting the segment, its centre line shall be clearly
marked on these plates. Nail / Bolt shall be embedded at the centre of each of top flanges for
measurement of levels.

In casting on long line bottom shuttering is fixed to the raft as per actual soffit profile. Thus the only
control required is matching of centre line along the crown and top levels of the top flanges during
subsequent casting operations.

5.16 CURVED SEGMENTS:

With help of global coordinates offset of both centre insert plates from bed centreline shall be
calculated and transfer to the bottom soffit and with same offset bottom segment shall be aligned.

5.17 CURING OF SEGMENTS:

Curing of concrete shall be complete and continuous with water. Minimum wet curing shall be for
seven days followed by moist curing by spraying water / sprinkler system, which shall be maintained
up to a total period of at least 14 days from the date of casting. As an alternative, the segments can
also be cured by applying curing compound duly approved for use. After casting the segments curing
compound shall be applied on all exposed surface after initial set is achieved and the surface is moist
and free surface water has disappeared from concrete surface.

5.18 DE-SHUTTERING:

The shuttering shall be removed only after the concrete has attained sufficient strength. This shall be
ensured by testing the cubes of the respective segments. The internal form shall be collapsed using
the turn buckles and moved outwards. The frame supporting internal and outer shutters shall be
shifted to next location by moving it on rails.

5.19 LIFTING OF SEGMENTS:

The match cast segments shall be lifted with a lifing frame through the lifting holes provided at the
time of casting of the segments.

The segment shall be lifted from the soffit shutter by the 80 ton capacity gantry crane placed at the
stacking yard. The lifting of segment shall be done after it attains sufficient cube strength.
5.20 CASTING OF CURVED SPAN:

Casting of curved spans shall be done on long line curved bed. The width of bed for curved span
shall be as per approved drawing. As per curvature maintain required gaps between two tables of
soffit and it shall be added by inserting mild steel wedges welded/bolted to the bed and surface
finished using girders. The shape of these wedges will vary with length of the span to be cast, radius
of its plan curvature.

6.0 MOULD ERECTION STAGE:

The whole assembly shall be erected as per the drawings and the skilled gang shall be engaged for
the erection of moulds.

The access of the soffit slab with the ladder and handrail arrangement shall be provided. A separate
working plateform shall be provided at the soffit level for carrying out the concreting and shuttering
works.

A similar plateform with hand rail arrangement shall be provided near the sides of wet cast segment
for movement of workman during shuttering and concreting works.

Doka staircase shall be provided to access the top of the mould and fixed bulkhead , a plateform
with handrail will be provided on the top of the fixed bulkhead for movement of persons and
materials. Each mould shall be connected at the fixed bulkhead level with the adjacent mould by
means of a proper walkway so that the bottom space is free for working comfortably at the ground
level. The proper barricading in all working plateforms at top level shall ensure that there is no loose
material shall be kept on this working plateform.

7.0 GANTRY ERECTION STAGE:

The lifting tools like sling, dee shackles etc. shall be checked for their working condition and their
lifting capacity shall be tested prior to start to the gantry erection work. Only skilled labours like
riggers/khalasi shall be engaged for the gantry erection work.

Gantry legs shall be anchored with the concrete stoppers during erection to prevent the slippage of
gantry. Fall arrestor shall be provide for the access to the gantry top along with proper ladder
arrangement.

It will be ensured that there is no live electric cable around the vicinity of gantry erection area.

The gantry cable shall be of sufficient length with minimum joints during working. The verticality of
the gantry erected shall be assessed and the load test shall be carried out for every ( with minimum
1.25 times the safe carrying load) before allowing the gantry for routine works.

The limit switch for all the gantries shall be provided. Two persons shall be deputed on either sides
of the gantry to prevent any collision during the gantry movement on gantry track.

The periodically checks will be done for every gantry at regular interval to assess the gantry working
condition and condition of the track. Proper alarming system shall be provided in every gantry.

8.0 CASTING OF SEGMENT:

Proper housekeeping shall be maintained during the casting the segment.

Proper PPE’s shall be provided for the gang that will be engaged in the casting operation.
The tools and tackles shall be inspected thoroughly before start casting operation.

Proper barricading will be made along the edge of the match cast segment during concreting works
to restrict the area of movement.

9.0 SHIFTING OF SEGMENTS:

Properly designed strong back shall be used for the lifting of segment after it is cast and while
shifting it to stack yard or from stack yard to the trailer.

The tackle arrangement for lifting the tool shall be followed as specified in the drawings. The lifting
tackles shall be assessed based on their capacity prior to the lifting of segment. No movement of any
persons will be ensured underneath the segment in shifting lifting/ mode. A proper seating
arrangement for segment at stack yard or on trailer shall be designed to maintain the stability of the
segment.

The stacking area is capable of storing 150-160 Nos. for precast segments equivalent to three month
stock.

10.0 FORMATS:
 Format for Request for Inspection (RFI)
 Format for Reinforcement inspection checklist
 Format for form work inspection checklist
 Format for embedment’s checklist
 Format for safty checklist
 Format for Sheathing profile checklist
 Format for concrete inspection checklist
 Format for concrete pour card slump report

11.0 CYCLE TIME – SEGMENT PRECASTING

 Align and fix outside shutter panel 0.5 days
 Positioning re-bar cage & fixing cable Ducts 0.5 days
 Checking and inspection 0.5 days
 Fixing end forms, Inside shutter & Inspection 1.0 days
 Concreting 0.5 days
 Curing in bed (Till 25 N/mm2 strength) 3.0 days
 Removal from bed 0.5 days

Total 6.5 days

Note: (1) Outer shutter panel moved to next segment after concrete in segments attains
10N/mm2 (Approx 1.5 days after concreting)

(2) Inside shutter panel moved to next segment (Approx 2.5 days after concreting)