MASS FOUNDATIONS CONCRETE & TEMPERATURE CONTROL MONITORING

QA/QC Section: Method Statement

MASS FOUNDATIONS CONCRETE and TEMPERATURE CONTROL MONITERING

Document Section Page Amendment Date

: Mass Foundation Concrete & Temporary Control Monitoring : QA/QC Department : 20 :0 : 06/02/2007

Types of Document

Controlled Document Document No. Uncontrolled Document ITD-MS-022

06/12/07 For Approval

TK:

BN:

Revision

Date

Description of Status

Prepared by Approved by

Italian-Thai Development Public Company Limited

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QA/QC Section: Method Statement

Contents
1. 2. 3. 4. Purposes Scope of Work Safety Policy Work Method 4.1 Work Preparation 4.2 Work Procedure 4.3 Test and Monitoring of the Concrete Mass after Pouring 5. Outline of Sequence

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1.) PURPOSES
This method statement has been prepared to provide a general guide, special considerations to be given in relation to the heat of hydration for concrete pours. This method statement describes the work procedures to be carried out during an execution stage of mass foundations/structures of which the character of the concrete is technically specified as a structure with large dimensions simply figured of greater than 1.50 meters for all dimensions. In this case the cracks & temporary control is required both during the concrete mix control at concrete batching plant prior to concreting and its monitoring after the concrete is placed in order that the requirements stated in the Engineering Standard, Specification for Concrete Works e.g. a temperature differential between the interior of the concrete and any outside face will not exceed 20 C , can be maintained ( Basically , heat on the surface of the concrete is easily released toward the ambient whereas the center remains its high temperatures , this follows that the temperature difference will induce the internal restraint and subsequently introduce thermal contraction cracks. The method statement also includes details of temperature difference control procedure and all necessary temporary works such as curing method by thermal quilts, precaution barricade, temporary access and related activities which are required to undertake during a certain period. Special care and planning is required as the volume of pour is large in relation to those normally being place on Site.

2.) SCOPE OF WORK

This method statement includes e.g. concrete batching plant control including supply and delivery to Site, casting sequence , the method to control and prevent the concrete cold joint being introduced during concrete placing and a proper curing to maintain ,control temperature difference not to exceed the specified tolerance stated in the Engineering Standard , Specification for Concrete Works of which the method of monitoring will be included , and all incidentals necessary to complete the entire works.

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3.) SAFETY POLICY

One of the main aspects of this procedure is Safety and Health Control. This is to control occurrence of injuries as well as damage to equipment and properties during the entire execution period. In order to ensure a safe working environment during the entire execution period, the following safety measures will be implemented as follows:

Machinery and Equipment:

Prior to using any machinerys/equipment at site, it will be inspected and certified by qualified person. Periodic Preventive Maintenance will be made on all equipment and machineries. All operators and drivers are to be equipped with valid drivers/operators license or permit from concerned government agency. Only authorized drivers or operators will be allowed to operate machineries or equipment. Only authorized signalman will be assigned together with the operator or driver. All lifting equipment as well as its accessories such as sling wire, nylon sling, shackles, chain blocks crane hook and latch shall be inspected periodically.

Personal Protective Equipment:

Personal Protective Equipment (PPE) will be issued to all workers such as safety shoes, hardhat, working gloves, earplug, safety goggles (if required) and safety harness for workers who will be assigned in elevated places 1.6 meter and above. Wearing of the basic PPE will be enforced fully. All new recruits will undergo proper orientation and safety induction before they could be deployed at site for work.

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4.) WORK METHOD

4.1 Works Preparation a.) General: With a large concrete pour of this magnitude it is essential that
proper pre-construction planning methods and safety checks be in place prior to execution of the works. A mass pour is considered to be demanded a special attention to be given to logistical and technical considerations such as concrete supply, casting sequence , prevention to cold joint being introduced during concrete placing and temperature differential control by thermal quilts curing method etc. In addition the method of temperature difference for the selected points will be discussed, prepared prior to the work begin. Concrete Mix Control: It is a preparation against the possible effect to the concrete properties and construction operations. When these factors are explained to the relevant persons engaged to these activities therefore measures will be taken to eliminate or minimize undesirable effects that possibly introduced. This method defines lists of possible unfavorable effects and prevents practices intended to minimize them. Among these practices are such important measures as a pre-cooling ingredient, consideration of concrete temperature as placed, transportation time and curing technique. The method of concrete temperature control will be proposed into 2 options as follows: (a). using the same previous mix (300 ksc, cylinder, pump mix): use of ice as part of mixing water is effective in reducing concrete temperature, because on melting alone, to absorb heat. In this case there is no change in the previous design mix but it may encounter a difficulty to control the temperature differential between such selected points within the concrete mass to be within the specified figure stated in the Engineering Standard, Specification for Concrete Works. The sequence is as follows: (1). Spray cool water for every 30 minutes to the course aggregate stock. This will be done at least 2 hours in advance prior to mixing of concrete. (2). Add ice into the water for mixing of concrete to reduce the water temperature. The ice will be added until 8-10 Celsius Degree for water temperature is reached. The amount of ice added to the water is dependent on the air temperature at the certain mixing day.

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(3). Spray cool water to the trucks mixers to reduce the temperature of the trucks mixers. (4). At the batching, the first batch of the concrete shall be checked its temperature. The water temperature will be continued to reduce until the concrete temperature is lower than 33 Celsius Degree prior to the delivering to Site. (5) The above process (4) will be regularly done during the entire period of supply to ensure that the same degree of temperature always be maintained. (6) At the Site, upon a delivery of the concrete the fresh concrete will be re-measured whether the temperature is still within the specified tolerance.

(b). Using Low Heat Concrete (Recommended): mix design for low heat concrete mix (300 ksc. cylinder, pump mix) will be submitted for approval prior to use. In addition, trail mix will be done prior to use. Concrete Delivering: since the temperature rise can be increased with a
passage of time thus the period between mixing and delivery will be kept to an absolute minimum. Attention will be given to coordinating and dispatching of the mixing trucks with the rate of placement to avoid delays in delivery.

At Site all existing facilities, which are within the construction site radius considered to obstruct any work activities, will be removed or be provided with protection against damage, dust and dirt. Enclose the site construction area to control material equipment as well as to avoid any incident/ accident from/to others. Works should start confirmation of the permission and the handing over area of the work. Prepare, check and submit verified construction drawings of excavation areas to be attached as addition to this method statement distribute & details to all concerned parties as required. Planning: A pre-concreting meeting will be held internally and with concrete supplier to finalize agreement of the proposed concreting procedure. Access: Designated site access routes for concrete supply will be prepared and traffic control measures implemented. The proper access must be

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organized to enable a continuous transportation of the concrete during the entire period of pouring so that the required temperature of concrete pour will be maintained. Supply: Concrete batching plant capacity and numbers of delivery trucks will be planned to maintain a continuous supply of concrete so that an introducing to cold joint can be prevented. In addition to minimize temperature differentials occurred within the concrete mass during pour. Pouring: Concrete will be placed in a predetermined layering sequence to avoid any possibility of cold joint formation within the foundation. It is approximately the time spent in each poured layer will be not exceeded 60 minutes. Plant and Labor: A detailed equipment and manpower resources schedule will be prepared to ensure sufficient workforce in each pour. Quality Control: Sufficient quality control measures will be set up in place for checking concrete supply and deliveries throughout the duration of the pour. Contingency Measures: Large pours cannot readily be stopped due to failure in concrete supply or plant breakdown. For this reason, adequate back-up and standby facilities in all aspects will be provided.

b.) Formwork: ITD will provide sufficient forms and suitable access platforms to execute the work for the entire pouring stage.
Forms will be made of steel studs with steel plate sheathing lining the surface (e.g. 0.60x1.20m. steel panels), and include all necessary support bracings and fixings, steel props etc. The scaffolding access erected will be in compliance with BS Standard. Approved form release agent will be applied to the steel surface sheathing prior to lifting-in and erection of the clean forms this is to avoid the concrete stuck the forms that may introduce unfair face of concrete when the form is to be dismantled. construction design drawings.

c.) Rebar: Rebar will be supplied and fixed in accordance with the latest

Rebar will be cut and bent at the designated yard close to the work site in accordance with the latest bar bending schedules. Prior to calling off reinforcement, scheduled bars will be checked for discrepancies.

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To facilitate crane handling and avoid confusion during installation the specified cut and bent bars will be clearly grouped, bundled and tagged for identification before transporting to the workface. Rebar will be placed at a designated lay-down space and each tagged bundle will be properly segregated for easy retrieval and handling once installation of rebar starts. Following identification, rebar will be distributed either manually and/or by mobile crane directly to their final fixing location in line with the bar installation sequence. concrete pouring will only be executed during dry weather to avoid the possibility of stoppage due to rain. In addition in case of high temperature during the pouring day is encountered the pouring is preferred to be carried out during the night time. In case of sudden rain, plastic sheeting or canvas will be used to cover the concrete slab surface yet to set during concrete pouring. The plastic sheets will be provided sufficiently both for emergency case of sudden rain and for fully cover the whole concrete surface immediately once the concrete is reached its initial set. Pre-pour inspection of the rebar, form panels, embedded items and construction joints will be carried out before concrete pouring. Three (3) concrete pumps will be engaged for concrete pouring e.g. 2 pumps is organized for concrete pouring; the less will be at the workface for standby and will be on duty when the pouring pump is broken. The concrete pump arrangement will be prior arrangement for their highest efficiency when the concrete placement is to be carried. Internal-type concrete vibrators will be used for concrete compaction during concrete placing to ensure adequate vibration during the entire pouring stage.

d.) Concrete: Due to one-go casting of each raft foundations /structures the

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The plastic sheet will be used for curing purposes. This will be done immediately once the concrete is reached its stiffening time by fully cover the whole concrete surface and spread the sand (approximately 10 mm. thick.) onto the whole area of plastic sheets to prevent concrete temperature loss too quick and result high temperature differential between the surface and at the middle. Care must be taken during the entire curing (for a couple weeks) to ensure by reading its temperature by a thermocouple that the temperature at the middle of the concrete is low enough to result the difference of temperature in comparison with the surface not exceed 20 C.

4.2 Work Procedure

4.2.1 Survey Setting Out: The setting out will be made at the beginning stage of

the work by referring to the construction drawings. All reference points will be made as necessary for the entire work, develop method and cross-checking all setting-out will be operations. When principal lines and levels have been set out, it would be advised to the relevant persons.
4.2.2 Temporary Work Dewatering: As the bottom of the foundation is probably lower than water table level, therefore dewatering is considered as an important part of the entire execution. To draw off water the sump pit will be made below the working level. The water contained in the sump pit can be pumped out by means operation of the Submersible Pumps at the bottom of pit. The outlet of the pumps will toward the u-ditch within the vicinity where location will be prior planning. Slope Protection:

It is required that the excavation side slope will be maintained stabilized for the entire construction period of foundation. In case of deep excavation the slope will be made to steps to achieve the highest stability. go up/down the working area for transportation construction resources, temporary removal of excavated soil to stockyard area and backfilling after concreting works has been finished.

Accessible Ramp : The accessible ramp is provided for machine/equipment

Accessible Ladders/Stairs: Ladders/Stairs are to be provided and maintained

sufficiently for workers go up/down the working area during the execution stage of foundation.
Barricade/Sign: Barricade/Sign shall be provided and maintained, as precautionary measures during the entire stage of construction, to protect the work, workmen and safety of the public. In case of precaution against failure of lights, barricade will be equipped with suitable reflecting material. Barricade shall be made surrounding the construction boundary.

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4.2.3 Excavation and Pile Cut off

Locate the excavation boundary. This area is provided to stabilize of the side slope excavation during the entire execution stage. Start excavating to reach the required bottom elevation of the foundation in accordance with the latest construction drawings from one end towards the other end until the entire excavation is complete. The excavated soil will be relocated to stock within the vicinity area for backfilling purpose in the future. From the starting end, continue excavation between the piles rows until reach the require elevation in accordance with the construction drawing. The excavation between the piles rows by equipment will be done not too close to the piles to avoid a possible damage of piles. The remaining soil surrounding the piles will be removed by workmen in order that the piles not to obstruct equipment working. To avoid the piles damaged while equipment running on them, therefore the entrance access shall be provide during working inside the pile group boundary. Excavation to be carried out for the selected entrance access.

4.2.4 Pile Cut off

The piles will be cut off at elevations as specified in accordance with the latest construction drawings. The sequence of the pile cut off is as follows. a) Measure and marking the cut off level(s) around the each piles. b) Cut around the pile with the grinder machine approximately 20-30 mm. deep this is to control cracks not to introduce below the grinded level. c) Chip off concrete at the ground joint and remain the reinforcing wires exposed in order to leave the upper part of pile above cut off level is stable. Continue the same procedure for the next piles in advance. d) Chip off the remaining concrete above the grinded level by means of hydraulic jack hammer. At the cut off level, make an even level of the pile head be the hammer. e) Remove the remaining concrete on the rebar using the hammer and clean with fresh water. f) Touch up the concrete around the piles at the cut off level.

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4.2.5 Concreting Works :

(a)Setting out:

Upon a completion of piles cut off a compaction of the soil beneath the lean concrete will be carried out throughout the whole area. A compaction will be conducted properly to reach the requirements mentioned in the Engineering standard e.g. 95% of the optimum dry density. This must be presented with test reports accepted by CTCIT prior to the lean concrete placement. A surveyor will then establish the reference lines and mark for the lean concrete boundary by white chalk. The carpenters will set the forms using a set of 100x100 mm. cross-sectional area steel tube nails alongside the both edge to the earth. A set of pegs will be located throughout the placing area to show the placing level thereafter. After confirming for its conformity e.g. the correctness of level and alignment, the lean concrete will be poured. After QC inspection of the lean concrete base layer then construction of the foundation will follow: Before work starts CTCIT/ITD surveyors will jointly establish baselines and TBM (Temporary Bench Mark) positions from which co-ordinates and elevations will be taken to set out the foundation works. After survey check, set out the center of the foundation then tape distance from the center to the outer perimeter edge as specified in the construction drawings. By holding at the center, a chainman at the far end rotates the tape around the center point, and marks the position of the circumference onto the foundation base lean concrete.

(b). Formwork:
Formwork installation will commence as soon as the blinding concrete has hardened sufficiently for trafficking and setting-out points have been surveyed and checked. Place the formwork kicker plates made of timber around the foundation outline marked on the blinding and fix down with concrete nails. Erect the side forms onto the kicker plates. This can be done using 0.60x1.20 m. steel panel connected together panel by panel at the both side by mean of bolts. Brace the form to the excavation profile and plumb to true line and level using a plumb bob. Continue to install the 0.06x1.20m. Steel panels together, one by one onto the timber kicker plate for the complete foundation circumference.

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As work proceeds ensure forms are connected tightly together and braced against displacement to prevent leakage of mortar at the joints during placement of the concrete. Leave open some part of the forms to provide access for the workmen during rebar and concrete placement. Mark the concreting surface level onto the forms. For a full description of the general techniques and procedures necessary for fabricating and installing formwork refer to ITD-MS-009 General Formworks Method Statement.

(c) Rebar
Rebar installation will commence simultaneously as the formwork progresses. A mobile crane and manual workers will be used for rebar installation. Rebar placement will follow the installation sequence detailed in the construction shop drawings and bar bending schedules. Throughout the fixing procedure ITD will provide all necessary control setting-out points to ensure correct location, spacing, verticality and cover is maintained during bar placement. The cover and location of rebar will be accurately controlled by using sufficient concrete spacers, special support chairs and tying wire to secure reinforcement in the correct position during succeeding operations. Cover will comply with the design requirements indicated on the reinforcement drawings. Concrete spacers will be produced to the desired cover with the same strength of concrete foundation. Bars will be tied with tire-wire. All the rebar will be accurately located and securely fixed in the correct position. Reinforcement will be inspected by survey/ site supervision prior to, and after erection of formwork, to check quantity, cleanliness, fixing and cover. Set the remaining forms and make an opening at the bottom of the selected area to allow removal of unwanted debris. Clean the area at the final stage using air compressor and wet forms with water immediately prior to placing concrete. After dismantling, the forms will be cleaned and sprayed with form-oil for re-use. For a full description of the general techniques and procedures necessary for fabricating and installing reinforcement refer to ITD-MS-010 Reinforcing Steel Method Statement.

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(d) Concrete
Final inspection with CTCIT. Concrete will be moved from the batcher to the point of deposition via concrete truck mixers. Adequate back-up supply shall be available prior to calling for concrete. It will be placed from the truck mixer via concrete pumps to maintain a minimum placing rate of 100 cu/m per hr. In the event of a batcher or pump delay or breakdown, supply of concrete will be maintained by the nominated back-up source and back-up pump. The site Engineer shall ensure that safe access, back-up pump, adequate vibrators and compressors are available prior to the commencement of concreting. Concrete delivery shall be in a closed interval. A minimum of 5 numbers of 50mm vibrators shall be used for compaction. For a full description of the general techniques and procedures necessary for placing and compacting concrete refer to ITD-MS-008 Concrete Works Method Statement

(e) Concrete Supply

Concrete will be as approved trial pumping mix. The volume supply for raft foundation is 100 cu-m/hr (for each layer of pour) To minimize any risk of breakdown two (2) separate batching plants of 50m3/hr capacity each will be used to supply concrete. To meet the demand a detailed study of the transportation times in relation to the number of trucks have been carefully calculated as follows: Batching Plants Control CPAC MAP TA PUT BATCHING PLANT 1 Plant capacity: 50m3/hr Time/Distance to workface: 30 minutes CPAC MAP TA PUT BATCHING PLANT 2 Plant capacity: 50m3/hr Time/Distance to workface: 30 minutes CPAC NIKOMKUR BATCHING PLANT 3 (EMERGENCY BACKUP SUPPLY)

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Plant capacity: 50m3/hr Time/Distance to workface: 60 minutes Transportation Control CPAC SITE BATCHING PLANT 1 (50m3/hr) Mixing and truck loading = 5 minutes Delivery to site = 30 minutes Park/pour set-up = 5 minutes Pumping = 8 minutes Return to plant= 30 minutes Min truck roundtrip time = 78 minutes One (1) truck (5m3) can therefore deliver 60/78 x 5 = 4 m3/hr Minimum number of trucks required to pump 50m3/hr = 50/4= 12.5 trucks, 13 trucks CPAC SITE BATCHING PLANT 2 (50m3/hr) Mixing and truck loading = 5 minutes Delivery to site = 30 minutes Park/pour set-up = 5 minutes Pumping = 8 minutes Return to plant= 30 minutes Min truck roundtrip time = 78 minutes One (1) truck (5m3) can therefore deliver 60/78 x 5 = 4 m3/hr Minimum number of trucks required to pump 50m3/hr = 50/4= 12.5 trucks, 13 trucks Total of concrete trucks required to supply 100 cu-m/hr = 26 trucks

(f) Conveying
Three (3) pumps will be mobilized for the foundation pour. Concrete pump max output 50m3/hr each with 28metre horizontal delivery booms. Two pumps will be used for pouring concrete at any one time in a predetermined rotating sequence around the perimeter of the foundation. Suitable pump truck standing area and concrete truck delivery area will be constructed at designated locations around the foundation. The third (stand-by) pump will be re-located in turn to its assigned pouring position at the workface during the pouring sequence.

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(g) Pouring
For a full description of the general techniques and procedures necessary for pouring and compacting concrete refer to ITD-MS-008 Concrete Works Method Statement for the PTT Phenol Project. In addition, the following measures will be adopted A continuous supply and placement of concrete will be maintained throughout the pouring sequence to avoid any possibility of cold joint formation. Concrete lifetime between succeeding layers shall not exceed 120 minutes therefore not taking mixing time + transportation time + parking time into the account the pouring time should not be exceeded 60 minutes , to prevent a formation of cold joint. Thickness of pouring layers is 300mm approximately e.g.7 layers in total. Pouring concrete will begin with two (2) pumps working simultaneously together from the one end to the other end. Successive batches of concrete will be placed on the edge of previous batches to maintain progressive filling of each layer without segregation. The two pumps are set up in designated pouring locations around the perimeter of the foundation and rotated in a predetermined sequence as the pour progresses. The rotating pump sequence is repeated until the foundation pour is complete. The leading edge of each layer should not be vibrated until being covered with fresh concrete to avoid segregation and bleeding out at the face. The elevation of the concrete pouring will be controlled with string among the center and chamfer surround the interior circumference.

(h) Backfilling
Backfilling will be done in loose layers not more than 250mm in thickness. Suitable vibrator plate/rollers and/or water will be used to achieve the compaction requirements for each layer field density test will be performed to check the soil compaction to95% maximum dry density. Any embedded cableway conduits and earthing /grounding wires, drainage pipes and trenches etc. should be installed simultaneously with the backfilling layers. After completion and curing of the third stage concrete pour then the second stage fill will be carried out up to grade level below proposed finished ground level

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4.3

Test and Monitoring of the Concrete Mass after Poured

As soon as the concrete has reached its stiffening time approximately 1 hour after pouring a set of plastic sheet will be covered fully the concrete surface. Sand will be filled fully onto the whole area where the plastics sheet cover with approximately 10mm. thick. The plastics cover and the side forms will be maintained for a couple weeks until the temperature differential at any selected points in the mass concrete are not exceeded 20 C.

To ensure that the temperature differential will be controlled a set of measuring apparatus will be set as shown by the above sketch. The measurement purposes are to finding the temperature development within the concrete mass. The results will show peak temperature and the temperature differential for such measuring points. As previously explained, sets of thermocouples will be installed and embedded to the concrete at the bottom, middle and top e.g. top and bottom sets will be approximately 50 cm of measuring from the edges. The heat generated will be converted to the circuit and sent to the data logger which will record and show information of temperature measure. In general case the temperature differential at any selected points should not exceed 33 C. The maximum temperature of mass concrete will peak at 48 hours after pour and will be constant for 7 days and will decrease to the air temperature after 14 days

Equipment Installation:
Temperatures will be measured at 4 levels e.g. ambient, top, middle and bottom. The end of each thermocouple wire(s) were fixed to the designated position to the concrete mass prior to pouring. The others ends were

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linked to the rear panel of the data logger which is set to read the temperature at every 30 minutes for at least 3 days.

5.) OUTLINE OF SEQUENCE

To illustrate the previous description this outline of sequence is made as the following steps:

1) Excavation will be carried out, between the plies rows, from one end to the other end as shown on the sketch by backhoe. It should be concentrated closely during the entire excavation by backhoe so as not to damage the piles. The remaining soil stuck to the piles will be removed by men.

2) Upon a completion of excavation, the bedding soil will be adjusted finally by men confirmed by survey. The compaction to the bedding soil will be carried by small compacting roller until the required density is achieved confirmed by test results. Survey will then mark for level and pouring boundary. Upon a completion to the above the lean concrete will be poured.

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3) Piles cutting off will be carried out following the method stated on 4.2.4 previously.

4) Rebar and formwork will be preceded simultaneously. Detailed fixing and erection will be carefully followed the method described on 4.2.5 (b) formwork, (c) rebar work respectively.

5) A set of anchor bolts will be installed following the latest construction drawings. A joint survey CTCIT/ITD will be made to ensure their correctness installation for its position, level, verticality, alignment etc. In addition for their firm installation in order that they will not be moved and affected during the entire execution stage of pouring. In addition sets of thermocouples will be erected and fixed to at the designated points and will be left permanent to the concrete e.g. the others ends will be kept outside the concrete mass to connect to the rear panel of the data logger (temperature reading meter) thereafter

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6) Upon a confirmation of pre-concrete inspection , the concrete will be poured following the method described on 4.2.5 (d) concrete ,(e) concrete supply ,(h) conveying respectively.

As soon as the concrete has reached its stiffening time approximately 1 hour after pouring a set of plastic sheet will be covered fully the concrete surface. Sand will be filled fully onto the whole area where the plastics sheet cover with approximately 10mm. thick. The plastics cover and the side forms will be maintained for a couple weeks until the temperature differential at any selected points in the mass concrete are not exceeded 20 C. 7) As soon as the concrete has reached its stiffening time approximately 1 hour after pouring a set of plastic sheet will be covered fully the concrete surface. Sand will be filled fully onto the whole area where the plastics sheet cover with approximately 10mm. thick. The plastics cover and the side forms will be maintained for a couple weeks until the temperature differential at any selected points in the mass concrete are not exceeded 20 C. Conduct a temperature differential test and monitoring. When the concrete reaches the required strength verified by crushing test the form will be dismantled. Once the side forms are removed the approved curing compound will be immediately applied thoroughly all the exposed surface.

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8) While the forms being dismantled, all the unwanted materials associated with the concrete e.g. debris, concrete laitance etc, will be removed. Upon a completion of the above, backfilling work surround the foundation will be carried out in horizontal layers. Each layer will not exceed 30 mm. thick and a test results for the compaction test for each layer will be obtained prior to next layer filling.

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