BOX CULVERT

General

 In this project there are 9 new box culverts to be built and 2 box culverts to be reconstructed and
1 culvert need to be widened. The sizes of culverts are 1x5m and 1x2m.

 Precast segmental box culvert construction method shall be adopted for this project to reduce
construction time and improve existing traffic mobility but the construction method for each
culvert will vary slightly when taking the existing ground levels, the height of the embankment,
the surrounding features such as the size and orientation of the existing stream, etc.

 It is intended this method statement will highlight the general method and supplementary
method statements will be submitted during construction stage should there is such a need to
address specific special issues that may arise in the construction of a particular culvert. The core
purpose of this construction method is to achieve quality, safety and environmental assurance in
the courses of work.

Figure : Section Of Propose Box Culvert

Culvert shall be arranged that it assembled earlier than embankment in every work area.

Every culvert shall be constructed according to the sequence of following,

Scheduling / Unloading / Placing

Figure: Unloading of culvert segment

 The procurement department shall order precast box culvert segments according to design
drawing provided by chief engineer of CHEC which approved by client.

 Procurement department shall maintain good coordination between manufacturer, transporter

and receiver to avoid unnecessary delays.

 To meet job requirement material department responsibility to educate production team to

specification of box culverts to be adopted.

 Machinery department shall be prepared with proper machines to handle the unloading and
stocking each section with out damaging segments.

 When unloading boxes, caution shall be exercised to ensure no personnel are in the path of the
box as it is being moved. The box shall be handled per manufacturer’s recommendations and
 only use recommend lifting equipment.

 Each section shall be thoroughly checked for damages and specification against the order invoice
upon arrival.

 If a box has been damaged it shall be set aside and recorded to ensure its proper order in
installation sequence. If damaged ends, chips and small cracks which doesn't have major defects
shall be repaired at site with client approval, while other irreparable shall be returned.

 Storing of segments shall be done as near to the final installation destination as possible. If
stacking of boxes is advisable, a flat surface with no rocks shall be chosen for the first layer and
the manufacture team recommendations for an acceptable stack height.

 Gaskets and sealing materials shall be stored in a cool dry place until needed. Rubber gaskets and
bulk mastic or preformed mastics should be kept clean and away from excessive heat.

Excavation & Dewatering

Figure: Excavation for box culvert

 Trenches shall be excavated to the dimensions and grade specified on the drawings. The width
of the trenches should be kept to the minimum required for installation of the segments.
 The trench width shall take into account the machinery needed to properly install the box
segments. Over excavated areas shall be back filled with approved materials and compacted to
the Standard Proctor density specified for the leveling course.
 Preparation of the site should establish a good level grade, using fine to medium granular
material. When ledge rock, compacted rocky, or other unyielding foundation material is
encountered, it shall be removed.
 The subgrade should be moderately firm to hard in-situ soil, stabilized soil or compacted fill
material. If unstable or unsuitable material is encountered, it shall be removed and replaced
with stable material approved by the client.
 Excavated material shall be stock pilled adjacent to the trench in order to quick back filling
purpose.
 In the case where the water table is located in the trench zone, dewatering methods shall be
adopted to remove the water.
 The future location of the water table must also be considered due to its effect on backfill
material and the box section. The presence of water around the box could cause flotation of the
box section, or migration of the backfill material. Migration of soil should be prevented.
 There are different methods that can be used to remove this water: pumping, ditching, and/or
piping of the water. all pumping water shall be through a filtered discharge.

Leveling Course

Figure: Laying leveling course

 100mm leveling course shall be laid on subgrade of culvert base.

 A proper foundation for a box culvert consists of specified bedding material shall be having
uniform flat surface characteristics as these could create stress concentrations in the box after
installation.
 The bedding layer of mixed sand and dry cement (cement proportion 200kg/m3) should be
100mm thick and flattened to an even thickness. Bed width shall be approximately 500mm
wider than the culvert.
 The bedding shall be perfectly flat, compacted and free from protrusions. If there is a risk of
migration from the surrounding soil into the backfill, the bedding shall be wrapped by
geosynthetic material
Erection

Figure: Segmental box culvert erection

 After completion of bedding, a line shall be set out to show limits where the base slab segment
of box culvert need to be placed.
 The segments shall be moved by crane or with any suitable machine and placed carefully at the
mark.
 A workman shall be in a position to guide the crane operator as the box is being aligned. The
workman in the alignment position should direct the crane operator to lower the box at set out
mark.
 Pay more attention while lifting and placing to avoid unnecessary damage to segments or
peoples who working there.
 When all base segment pieces are placed, backfill with approved material up-to construction
joint level. Make sure no soil or impurity trapped in construction joint area. Compact the
backfilled soil until it reach approved compaction level.
 After first phase of backfilling the wall segments shall be placed on base slab.
 Approved construction joint adhesive shall be applied on wall and base construction joint area
and make sure its free from soil and impurities.
 While wall segments attached to base segments, give proper supports from inside the base and
same time outer area shall be backfilled. Make sure wall part is vertical and joint is perfectly
attached.
 Leave few hours or day as per specification until joint get hardened and check verticalitty of wall
member.
 When join is hardened and back filling upto wall member construction joint level completed roof
slab member shall be placed.
 Apply constrcution joint adhesive to both joint area and make sure free from soil and other
impurities.
 Top slab segment shall be placed very carefully not disturbing verticality of wall member.
 Proper supports shall be given from inside the culvert to roof and make sure top is levelled and
joint is perfectly connected.
Back filling

Figure: Back filling

 Backfill shall be placed in uniform layers along the sides of the boxes and over the top of the box
sections. These layers should be no greater than the maximum allowed to achieve the required
density.
 The characteristics of the backfill material should be determined from the contract specifications
and should contain no debris, organic matter, frozen material or large stones.
 When vibratory methods are needed to compact the backfill material, care should be taken so
that no damage is done to the box section.
 When trench shields are removed take care not to disturb the installed boxes. Restraining the
box may be necessary to hold it in place. If any voids are created in the side fill material they
should be filled and compacted.
 Once the envelope of backfill material is placed and properly compacted, the remainder of the
fill or backfill should be placed and compacted to prevent settlement at the surface. Compaction
and org
VEHICLE UNDER PASS

Figure: Vehicular under pass below highway

General

 In this project there are three vehicles under pass (VUP) and one light vehicle underpass (LVUP)
proposed to construct. The sizes of under pass are 1x12m and 1x24m.

 Prior to commencement of VUP construction, the piling work shall be completed. After
completion of piling work with reference to design drawings proposed VUP area shall be
excavated inorder cut of the piles to design height.

 When pile hacking is done up to design length, pile caps shall be casted according to given
drawings.

 After completion of pile cap casting the conventional VUP construction method shall be adopted
to complete the task.

 CHEC will provide the Engineer with a cross section along the axis of each VUP in accordance
with the information provided in the schedules and the recommendations by the hydrologist.
 The construction of a VUP can be performed in two stages depending on the existing condition
where traffic can be allowed on the existing half. If the existing VUP condition is not satisfactory,
the VUP can be completed in one stage by providing a diversion road for the traffic. Pipes will be
provided to necessary location to accommodate drainage water. The VUP will be designed
according to above condition.

 The Engineer will provide his approval or instruct any variation relative to the setting out
information that may be required.The axis of the VUP will be set out in accordance.

 Bar cutting and bending schedules will be prepared and submitted to the Engineer for his review
and approval prior to commencement of the work.

Foundation

Foundation of VUP shall be bored piles and pile cap. According to design drawing piles shall be casted
in both sides of wall abutment of VUP

Figure: Piling layout of one of proposed VUP

Piling
 The pile boring operations shall be performed using the suitable rotary drill rigs depends on
the diameter, depth, and soil condition and construction method.

 The location of permanent bored piles shall be set out and pegged by the subcontractor’s
surveyor based on approved setting out drawings from consultant and control points at site.

 Prior to commencing any operations, the client representative will be required to verify all
associated technical information such as presence of services, pile coordinates, platform and
cut-off levels, validity of drawings etc.

 The drilling process will be continued to the designed founding depth or to the
 commencement of rock head level by using augers and drilling buckets.

 Pile lengths shall be as per the current construction drawings or as otherwise instructed by the
client/Engineer.

 At the point of encountering the rock head level, for examples, where the soil drilling tools
are unable to penetrate the strata any further, boring shall cease in order that the client’s
representative may verify the occurrence and confirm the rock socketing criteria.

 The final toe level of the pile shall be verified by the client’s representative. A detailed
record of all encountered ground conditions together with the associated times and type of
equipment and materials used will be recorded in the ‘Pile Bore Log’.
 Bentonite will be used as a drilling fluid to stabilize the bored hole.

 During the boring process, the bentonite slurry is kept as high as possible within the casing
and well above the existing ground water

 Upon completion of boring, the bottom of the bored hole is thoroughly

cleaned with the cleaning bucket prior to recycling of the bentonite.

 The reinforcement cage will be fabricated in lay-down sections, The length, type and size of the
steel cage will be according to contract drawings and specifications.

 Cages will be installed into the bored hole using a service crane of the required lifting capacity

 All pile shall then be concreted by using the (tremie) method.

 The self-compacting mixed concrete will be discharged through a tremie pipe, which is
lowered centrally to the bottom of the bored hole prior to filling it with concrete.
 One length shall be continuously embedded in the concrete during this process to ensure that
the discharge of concrete is below the level of the impurities, which might be present in the
top part of the rising head of concrete.
 All testing and sampling of the concrete shall be carried out as instructed by the Engineer or
Engineer’s representative.

Pile cap

 After approval for the location of foundations and underground utilities marking, excavation will
be commenced with the excavator within the outer limits of marking for all the foundations. Care
will be taken for the piles protection against any damage and existing utilities.
 Once the excavation is completed up to the foundation level, pile head breaking works will
commence.
 Marking will be made on each pile periphery at pile cut off level and a cut with grinder will be
made on the marking to prevent excess breaking of concrete below cut off level. Pile chipping /
breaking will be done with air compressor and pneumatic concrete breaker from top of existing
pile until cut off level.
 All the loose concrete debris will be removed with the use of Excavator. The area will be fine
leveled manually and sub base will be compacted with plate compactor / mini roller to the
required degree of compaction.
 1000 gauge polythene sheet is laid in the foundation area. Blinding concrete will be laid to a
thickness as specified in approved drawing by pump or by suitable methods.
 Reinforcement steel will be transported and lowered in position. Fixing of foundation
reinforcement will be carried out as per the approved drawings. Thereafter, Pedestal vertical
reinforcement will be fixed as per the approved drawings.
 Shuttering work shall be carried out after completion of reinforcement work. Plywood shall be
used to fabricate formwork around pile cap and steel props shall be used to support it.
 Reinforcement and shuttering works are subjected to inspection before proceeding to concrete
 works.
 Upon approval of reinforcement & shuttering, concrete of required grade will be transported to
site from approved supplier and placed into form work. The concrete compaction will be ensured
with concrete vibrators and needles which will be made available at site during the concrete
pour.
 The concrete will be laid upto the required levels and concrete surface will be finished smooth as
required. Concrete pump shall be used for pouring concrete wherever applicable.
 After the concrete is completely set, deshuttering will be carried out after a period as specified in
project specification.

Site Preparation

 The proposed excavation locations will be set out on site as per approved working drawings.

 Existing utilities such as electric power cable, telephone cable and water pipe in the vicinity of
the open-cut location will be identified by trial pit prior to any excavation works.

 Live utilities within the area will be diverted or protected before the construction works. If
required, the existing stream flow will be diverted so that the new construction works will not be
affected by the water flow.

 Pile shall be cut off according to design drawings, and pile caps shall be casted.

 All temporary works design will be submitted separately prior to commencement of excavation if
the open cut method will not be applied.

 Bed will be prepared on Engineers’ instruction either by compaction of the existing material or
by laying and compaction with the imported material.

Soft Ground Treatment Work and Excavation

Figure: Excavation
 Excavate to the formation of the VUP in accordance with the proposed cut profile.

 Where necessary, the slopes of the trench will be shored to ensure cutting angle. Slope will be
trimmed and benched to protect collapsing excess soil and steel/timber piles arranged for
shoring work.

 In the case of excess water along the trench, dewatering will be arranged with adequate water
pump.

 All excavated acceptable material shall be stockpiled in a tidy manner and used for backfilling.

 If VUP located in soft ground areas, construction work shall not be commenced prior to
completion of consolidation settlement of the embankment.

 Where possible local soft ground treatment such as removal & replacement of the unsuitable
material for foundation of VUP shall be carried out as per the Engineer’s instructions.

Placing of blinding layer

Figure: Placing binding layer for VUP

 Remove any pockets of soft material or loose rock at the bottom of all formation and inspection
shall be carried out with Engineer and approval to be obtained before commencing blinding
concrete.

 Blinding layer (Concrete Grade 15/40) will be placed to a thickness of 100mm or as instructed by
the Engineer. The top surface will be levelled off well to maintain the specified cover to
reinforcements.
Steel Fixing & Formwork for Base Slab

Figure: Typical photo showing formwork & steel fixing of base slab of the VUP

 All reinforcement shall be tested, cut, bended, placed, supported and secured in accordance with
the requirement of the Standard Specification.

 Fix the steel reinforcement of the base slab, wall and the top slab providing required concrete
cover from the outermost reinforcement as per approved drawings and approved bar bending
schedule. Cover will be maintained by using concrete cover blocks which are made from same
concrete grade.

 The top mat of reinforcement shall be supported on steel chairs made from reinforcing bar.

 Set out the location of the base slab on completing blinding layer.

 Erect formwork and props for the base slab. Release agent which is approved by the Engineer will
be applied before fixing and contamination to the reinforcement shall be avoided.

 Mark the concrete top level of the base slab on the formwork.

 All starter bars for the wall shall be securely fixed and braced to prevent movement during the
concrete pouring.
Concreting

 An inspection sheet will be forwarded to the Engineer and get the Engineer’s approval for
concreting the base slab of the VUP.

 All concrete will be placed within the times specified in standard specification as to avoid
segregation and the displacement of reinforcement bars.

 Clean the area inside the formwork and apply mould release agent as approved by the Engineer.

 The concrete will be mixed in grades as shown in the drawings at site for construction. The raw
material will be batched by volume according to the proportions prescribed in the approved mix
designs. Measurable water buckets shall be used to measure the quantity of water to ensure the
prescribed water cement ratio. If admixtures to be added it is mixed with water and added in
accordance to the manufactures instructions. The concrete will be checked for uniformity and
the consistency before being discharged from the mixer.

 Concrete shall be poured without displacing any reinforcement bar, cover block or without
exerting any extra pressure on formwork. The surface of the pour shall be kept vertical as much
as possible. Where the pour height exceed 1.2m either chute or a suitable mechanism shall be
deployed to avoid segregation as much as practicable. Porker vibrator of having a porker
diameter of 25mm or 40mm shall be used and always immerse in the concrete in vertical
direction. Surface of the concrete shall be finished and smoothed to required level.

 Test cubes shall be casted as directed by engineer or one set of cubes for 10 cu meters of
concrete. Three numbers of cubes will be casted from a single concrete and 1 will be tested in 7
days and balance in 28 days. Slump tests shall be carried out in randomly selected batched for
each concrete grade per day, adopting specified slump.

Curing and Removal of formwork/false work

 All concrete surfaces will be kept wet for minimum 7 days after placing by using water spraying
or using liquid membrane curing compound to the concrete surface for better result.

 Burlap or polyethylene sheet will be covered to keep moisture for unformed surface.

 Formwork and false work will be dismantled after achieving the minimum time requirement as
specified in the Standard Specification. soffit formwork shall be kept for at least 14 days prior to
removal.

 Immediately after form removal, the Engineer will be requested to inspect the base concrete.
Any defects will be rectified as instructed in accordance to the specification

Construction of wall and Top slab

 Reinforcement steel for the walls of the VUP will be fixed as per the approved drawings and
schedules. The Engineer will be notified to inspect the reinforcements before covering with
formwork.

 Formwork - (Smooth face) for sides of the walls will be erected in accordance with the approved
drawings showing the form tie arrangements, member sizes, spacing, etc. Release agent which is
approved by the Engineer will be applied before fixing and contamination to the reinforcement
shall be avoided.

 An inspection sheet will be forwarded to the Engineer to receive the Engineer’s approval for
concreting the walls of the VUP.

 Following receipt of the Engineer’s approval, concreting of the walls according to mentioned
concrete in the drawing. Concrete will be compacted by means of Poker Vibrators. Concrete
sampling & testing and curing will be carried out as per specified quality control testing.

 The formwork of the sides of walls will be normally after 24 hours from placing.

 Immediately after form removal, if there are any defects, the Engineer will be requested to
inspect the base concrete before rectifying defects.

Back filling

 The excavated either sides of the VUPt will be backfilled with Embankment or material as shown
on the drawing & that will be placed in layers of which the thickness will be 200mm after
compaction or as otherwise agreed with the Engineer following compaction trials. Backfilled
layers will be compacted using plate compactor and/or rammer. Backfilling and compacting will
be carried out as per the approved drawings.

 The backfilling will be commenced only after the foundation concrete or masonry has been in
position for at least 7 days and in a manner not to cause undue thrust on any part of the
foundation

 Backfilling shall be done parallel on both sides of the structure where possible or the level
difference of backfill of two sides will be kept at a minimum.

 Density testing will be done as specified in the Technical Specifications. Frequency of testing will
be as per Test Plan or otherwise instructed.

Safety Management and Control

 VUP work is closely tied to excavation and embankment works and safety matters highlighted in
Method Statement will also be observed in this work.

 All staff and labour assigned to the works will initially have gone through a safety induction.
 Accordingly, the general principles of safety applicable to the project works will be in effect. Site
engineer and/or site supervisor will be responsible for implementing the safety procedures.

 In addition, special emphasis will be placed on the safe handling of reinforcements and concrete.
Also, in trench conditions, the stability of the side walls will be considered and the site manager
will be responsible for choosing an appropriate method (battered slopes or side supports, as
required) to ensure the safety of the workers in the trench.

Quality Control

 To ensure that the steps of the procedure are fully complied with during the activities such as
setting out, excavation, embankment filling, formwork, re-bar fixing, concreting, backfilling etc.
certain inspections and verifications will be carried out as described in the above procedures.

 Concrete slump shall be checked for whether it is 75 +25mm and cubes shall cast for every pour
of concrete and tested for 28 days strength of Standard specification.

MINOR BRIDGES

General

In this project we have scope of three minor bridges. One at the begning of highway and remain two
bridges construct for service roads next to via duct.

construction method for each bridges shall be slightly vary when taking the existing ground levels, the
height of the embankment, the surrounding features such as the size and orientation of the existing
stream, etc.

CHEC will maintain an adequate number of trained and experienced supervisors and foremen at the
site to supervise and control work. All construction other than concrete will be confirmed to the
requirements prescribed in other sections of the specification for the several items of work entering
into complete structure.

Foundation Work

Piling
 The pile boring operations shall be performed using the suitable rotary drill rigs depends on
the diameter, depth, and soil condition and construction method.

 The location of permanent bored piles shall be set out and pegged by the subcontractor’s
surveyor based on approved setting out drawings from consultant and control points at site.

 Prior to commencing any operations, the client representative will be required to verify all
associated technical information such as presence of services, pile coordinates, platform and
cut-off levels, validity of drawings etc.

 The drilling process will be continued to the designed founding depth or to the
commencement of rock head level by using augers and drilling buckets.

 Pile lengths shall be as per the current construction drawings or as otherwise instructed by the
client/Engineer.

 At the point of encountering the rock head level, for examples, where the soil drilling tools
are unable to penetrate the strata any further, boring shall cease in order that the client’s
representative may verify the occurrence and confirm the rock socketing criteria.

 The final toe level of the pile shall be verified by the client’s representative. A detailed
record of all encountered ground conditions together with the associated times and type of
equipment and materials used will be recorded in the ‘Pile Bore Log’.
 Bentonite will be used as a drilling fluid to stabilize the bored hole.

 During the boring process, the bentonite slurry is kept as high as possible within the casing
and well above the existing ground water

 Upon completion of boring, the bottom of the bored hole is thoroughly

cleaned with the cleaning bucket prior to recycling of the bentonite.

 The reinforcement cage will be fabricated in lay-down sections, The length, type and size of the
steel cage will be according to contract drawings and specifications.

 Cages will be installed into the bored hole using a service crane of the required lifting capacity

 All pile shall then be concreted by using the (tremie) method.

 The self-compacting mixed concrete will be discharged through a tremie pipe, which is
lowered centrally to the bottom of the bored hole prior to filling it with concrete.
 One length shall be continuously embedded in the concrete during this process to ensure that
the discharge of concrete is below the level of the impurities, which might be present in the
top part of the rising head of concrete.
 All testing and sampling of the concrete shall be carried out as instructed by the Engineer or
Engineer’s representative.
Pile cap

 After approval for the location of foundations and underground utilities marking, excavation will
be commenced with the excavator within the outer limits of marking for all the foundations. Care
will be taken for the piles protection against any damage and existing utilities.
 Once the excavation is completed up to the foundation level, pile head breaking works will
commence.
 Marking will be made on each pile periphery at pile cut off level and a cut with grinder will be
made on the marking to prevent excess breaking of concrete below cut off level. Pile chipping /
breaking will be done with air compressor and pneumatic concrete breaker from top of existing
pile until cut off level.
 All the loose concrete debris will be removed with the use of Excavator. The area will be fine
leveled manually and sub base will be compacted with plate compactor / mini roller to the
required degree of compaction.
 1000 gauge polythene sheet is laid in the foundation area. Blinding concrete will be laid to a
thickness as specified in approved drawing by pump or by suitable methods.
 Reinforcement steel will be transported and lowered in position. Fixing of foundation
reinforcement will be carried out as per the approved drawings. Thereafter, Pedestal vertical
reinforcement will be fixed as per the approved drawings.
 Shuttering work shall be carried out after completion of reinforcement work. Plywood shall be
used to fabricate formwork around pile cap and steel props shall be used to support it.
 Reinforcement and shuttering works are subjected to inspection before proceeding to concrete
works.
 Upon approval of reinforcement & shuttering, concrete of required grade will be transported to
site from approved supplier and placed into form work. The concrete compaction will be ensured
with concrete vibrators and needles which will be made available at site during the concrete
pour.
 The concrete will be laid upto the required levels and concrete surface will be finished smooth as
required. Concrete pump shall be used for pouring concrete wherever applicable.
 After the concrete is completely set, deshuttering will be carried out after a period as specified in
project specification.

Abutment
 Figure: Full retaining abutment

 The designed drawing shall be got approval from client prior to commencement of execution.

 The co ordinates of abutment and pier locations are marked at site. The working and benching
area has to be considered while doing the survey marking.

 For the free flow of traffic, Road diversions will be made and traffic signs are to be displayed.

 Original ground level shall be recorded. Excavator and dumpers are used for excavation.
Dewatering pumps are used for sucking the seepage water from excavation pit. To prevent
collapse while doing excavation sloping and benching or shoring has to be provided as per site
condition. The excavated material shall be stacked / reused in order to avoid obstruction to other
construction activities.

 Founding level has to be checked. Leveling and dressing will be done manually. Compaction shall
be done by Baby roller /plate compactor if required. For laying PCC wooden/steel shutter shall be
used. Founding level, survey marking and bed preparation will be checked at site with approved
drawings by concessionaire and independent consultant.

 Abutment/pier starter has to be marked over the footing. Reinforcement tying and shuttering
works will be done as per approved drawings. Approval will be got from clients in all respects to
pour concrete.

 Bar bending schedule will be prepared and get approved from clients. Cutting and bending of
reinforcement will be done in centralized steel yard. Placing in position and Tying of
reinforcement will be done at site.

 After completion of reinforcement, outer formwork shall be positioned with suitable supports.
The inside surface of formwork shall be cleaned perfectly with wire brush; emery paper etc. and
any undulation if noticed will be flushed with metal putty.
 After completion of formwork, the concern authority has to be informed and the structure has to
be checked. Concreting shall be done by concrete pump/crane and bucket. Needle vibrators shall
be used for proper compaction. Concrete cubes (150 x 150 x 150) shall be cast as per
requirements.

 Once concrete achieved its initial strength, curing shall be carried out till the completion of
curing period.

 After concrete attained sufficient strength, Formwork shall be removed from the position and
moved to the subsequent activity. After removing the shuttering, any honeycomb if noticed shall
be finished with cement grout

 Backfilling around the abutment walls will be done in layers to ensure adequate compaction and
with very great care to ensure that no fill material falls into the stream. If necessary due to
constraints of space, debris netting may be erected on the bank of the stream and this to be
continually monitored during filling and cleared of material whenever necessary. Once back fill is
complete, safety edge protection will be erected.

 After completion of abutment/pier cap, pedestals will be cast and bearings to be fixed as per the
approved drawing and specifications.

Back filling

 The excavated either sides of the abutment will be backfilled with Embankment or material as
shown on the drawing & that will be placed in layers of which the thickness will be 200mm after
compaction or as otherwise agreed with the Engineer following compaction trials. Backfilled
layers will be compacted using plate compactor and/or rammer. Backfilling and compacting will
be carried out as per the approved drawings.

 The backfilling will be commenced only after the foundation concrete or masonry has been in
position for at least 7 days and in a manner not to cause undue thrust on any part of the
foundation

 Backfilling shall be done parallel on both sides of the structure where possible or the level
difference of backfill of two sides will be kept at a minimum.

 Density testing will be done as specified in the Technical Specifications. Frequency of testing will
be as per Test Plan or otherwise instructed.
Bridge Deck

I Beam Transportation

 The I beam is hoisted in the prefabricated yard by the gantry crane of the pier, and transported
by the beam truck along the bridge deck to the rear of the bridge.

 The beam truck is separated type and driven in both directions. The distance between the two
vehicles is arranged according to the position of the fulcrum. The movable turntable is arranged
at the fulcrum to avoid damaging the concrete structural member.

I Beam Installation

Figure: Installation of I girders

 Assembly of Launching Girder Machine-The launching girder machine is assembled by 50t cranes,
and the assembly sequence is: legs → main beam → crane → wire rope and circuit. After the
 launching girder machine is installed and debugged, the hoisting work can be carried out with
the consent of the engineer.

 Feeding Beams and Lifting- When the I beam is transported to the trolley in front of launching
girder machine which is facing the front end of the I beam, the front crane lifts the I beam, and
when the rear power part of the beam trolley is pushed forward with the crane to advance to
the rear end of the I beam, the operation shall stop and the rear trolley binds the beam and lift
up, then the beam trolley shall back off from the beam feeding area.

 Installation of Bearing- Before the beam is installed, the bearing must be installed first. When the
bearing is installed, the center line and the elevation of the bearing should be marked on the
bearing plinth. The height and plane position of the bearing should meet the design and
specification requirements. It can be fixed firmly afterwards.

 Put Down Beam and Install in Place- The two cranes move forward synchronously to bring the I
beam to the longitudinal installation position. The traverse hydraulic system of launching girder
machine is used to move the machine in traverse to make the I beam reach the lateral
installation position.

 Launching Girder Machine Crossing Spans- All steel bars of wet joint of each I beam are
connected in the transverse direction, and then the launching girder machine can cross the span,
and the bridge machine crossing-over adopts self-balancing system.

Bridge Deck Construction

Figure: Deck concreting

 After the installation of the I-beam is completed a certain number of spans and ready for bridge
deck construction, the construction of the diaphragm and wet joint is carried out.

 When paving the bridge deck, the working slot of the expansion joint should be reserved
according to the position and size shown on the drawing, and special attention should be paid to
the installation of the expansion joint.

 The concrete is batched by the mixing plant and transported to the site by tanker. It is directly
 paved by hand and laid evenly. The concrete surface should be straight and flat, and the cross
slope should be found. When constructing bridge decks, set up vertical and horizontal planks on
the steel mesh to prevent construction workers and equipment from stepping on the steel mesh.

 The asphalt concrete of bridge deck is vibrated and leveled, and then smoothed with a leveling
machine before the concrete is initially set.

Safety Management and control

 Production I-Beam work consists of tensioning activities and handling pre-cast concrete I-Beams
and heavy loads. Several numbers of heavy equipment will be used for these
operations.Therefore, safety measures have to be adopted prior to the commencement of work.
The operational conditions of the equipment and other supporting cables to be used for these
tasks have to be thoroughly examined before starting work. The physical condition of the
working crew engaged specially the operators and helpers should also be satisfactory.

 All working areas, walkways, platforms, etc. will be kept clear of scrap, debris, small tools and
accumulation of mud, grease, oil or other slippery substances.

 Loads will not be hoisted, swung or suspended over anyone and will be controlled by tag lines

 All staff and labour assigned to the works will initially have gone through a safety induction.
Accordingly, the general principles of safety applicable to the project works will be in effect. Site
engineer and/or site supervisor will be responsible for implementing the safety procedure