Professional Documents
Culture Documents
PROJECT OFFICE,
SUITE 21-01,LEVEL 21,
MENARA SARAWAK ENTERPRISE ,
JALAN BUKIT MELDRUM,
80300 JOHOR BAHRU,
JOHOR DARUL TAKZIM.
PROFILE
NAME
MOHAMAD
NORSHAHIRA BINTI
SHAHI
IC NO.
820819-05-5346
MATRIKS NO.
CA030066
COURSE
DEGREE IN CIVIL
ENGINEERING
ADDRESS
TELEPHONE NO :
07-5203276
019-7463286
COMP. ADDRESS :
ENTERPRISE ,
JALAN BUKIT MELDRUM,
80300 JOHOR BAHRU,
JOHOR DARUL TAKZIM.
PROJECT
BERSEPADU
GERBANG SELATAN
DURATION
CONTENT
DESCRIPTION
PAGES
Profile
Acknowledgement
Introduction
Company Background
Management Policy
SMC Representatives
Organization Chart
Training Schedule
Work Description
1
3
5
9
12
18 a
19
25
Construction Of Bridge 1
Construction Method
i.
ii.
iii.
iv.
v.
vi.
vii.
Reinforcement
In situ Concrete Concreting Method
Curing
30
32
33
36
38
42
43
44
viii.
ix.
x.
xi.
Expansion Joint
Post Tensioning Stressing
Bearing
Construction of Parapet
Material
Machinery
Safety Plan
Comment
Conclusion
Appendix
Appendix
Appendix
Appendix
Appendix
46
48
58
64
69
70
71
74
75
1
2
3
4
paperwork
- pictures
- drawing
brochure
ACKNOWLEDGEMENT
It give me a great pleasure to express my greatest appreciation to all those people
who had helped me along the training until writing this report.
First and foremost, I would like to express my grateful to Allah SWT because
bring me here and give a good health. Secondly, I would like to thanks to my family for
all their support, love and prayer. Next, I also like to thank to these people:
En. Kamarudeen b. Ninggal (Project Manager)
En. Abdul Rahim b. Sumin @ Tulos (Construction Manager)
Mr. Eliseo S. Ramos (Sr. Planning Engineer)
Cik Zarinah bte Zailani (QA/QC)
En. Mohd Azmil Md Kusairi (Site Engineer)
Pn. Ramlah bte Ikan (Quantity Surveyor)
En.Wan Yaakob bin Hj Wan Nik ( Safety & Health Officer )
En. Isnin Bero (Sr.Site Supervisor)
Mr. Hashim bin Cheop (Sr. Surveyor)
En. Jony Masrizal bin Sjafrial (Supervisor)
Cik Intan Fazira bte. Paing ( Assistant QA/QC )
Cik Faridah bte. Tarmiji ( Assistant Planning )
And entire of SMC staff
for their guidance and knowledge, skill and for encouraging me through this practical
training since the first day I am in SMC. Thanks because guide and give me to perform
here. With their all accompany this report would be a reality. Once again, I am grateful
for all their helping me to complete my report successfully. Thank you..
DESIGN,CONSTRUCTION,COMPLETION,AND COMMISSIONING OF
INTERGRATED CUSTOMS IMMIGRATION AND QUARANTINE
COMPLEX :
AND ROAD BRIDGE,RAIL BRIDGE AND ASSOCIATED WORKS AT
JOHOR BAHRU,JOHOR :-PACKAGE ICW-01
COMPANY BACKGROUND
Company Name
Date of Incorporation
Company Registration No
: 232707 D
Business Address
Authorized Capital
:RM10000000
Paid up Capital
:RM5200000
Directors
Shareholders
Senior Management
Lawyer
Nature of Business
Registrations
Kontraktor-Kontraktor
Melayu
Malaysia
(ordinary member)
Master Builders Association Malaysia (ordinary member)
Dewan Perniagaan Melayu Malaysia DBKL (ordinary
member)
Tenaga Nasional BHD
Malaysia Resources Corporation BHD
MANAGEMENT POLICY
Company Policy
Seri Meraga Construction Sdn Bhd, has set up quality objectives as follows:
Project Completion
To complete all projects undertaken within the timeframe with proper
work planning and efficient utilization of resources and to ensure
Client Satisfaction
To ensure clients needs are satisfied and to maintain clients satisfaction
level minimum at 85% per project.
Project Objective
To solve towards defect free engineering construction works within budgeted cost
and time allocated for the project.
between
client/ subcontractors
SMC REPRESENTATIVES
Project Director
Responsibility
Heads the SMC group to design & built Penang Elevated Highway Project.
Operation Director
Responsibilities
Manage the production team to ensure timely and successful completion of the works
Review, inspect, evaluate and report quality and progress of the work and
workmanship and adjust schedule if necessary.
Receive, analysis and report all progress reports, costs, schedules and other reports.
Construction Manager
Responsibilities
Prepare Project Quality Plan in connection with the Sr. Project Manager
Analysis of the programs of the work carried out and to be carried out, by preparing
statistical reports and suggesting actions for improvement
Preparation and collection of data and working out the job monthly report
QA/QC Engineer
Responsibilities
Site Engineers
Responsibilities
Safety Officer
Responsibilities
Check that all equipment are approved in compliance with the local law/ regulation
Check that the personnel protective equipment utilized by personnel are in good
conditions and compatible with health and welfare
Check that during the execution of all phases of work hygienic and safety rules are
applied
Inform all the workers about health and safety rules means or brochures, signals and
meetings
Performs and Record survey works of setting out of works carried out.
Document Controller
Responsibilities
Monitor submission status and maintain register in liaison with all departments
TRAINING SCHEDULE
DURATION
4/4 ~ 24/4/2005
25/4 ~ 16/5/2005
17/5 ~ 12/6/2005
Q.S DEPT.
SITE
QA/QC DEPT
TRAINEE
IRA
- Exposed about the company background & project that been going on by QA/QC
Engineer.
- Working under QS Department .
1. Check the total hours for normal and overtime working hours from subcontractor to
claim to main contractor after one month.
2. Updating and key in data for interim progress claim No. 18 to Gerbang Perdana
Sdn. Bhd. Gerbang Perdana Shd. Bhd is our client. ( please refer to Appendix 1
)
This progress must be done by sub-con to claim to main-con after once of the
works are completed.
3. Updating and key in data for interim progress claim (certificate No. 15) for
Geolab
(M). Sdn. Bhd and other sub-contractor. ( please refer to Appendix 1 )
Name of the subcontractor are :
Giga Engineering & Construction Sdn. Bhd for Superstructure for Bridge
1 and
Underpass 5 and variation order
GEOLAB (M) SDN BHD Provide all of testing for this project. Such as to
carry out
Field Density test, to carry out atterberg limit and to carry out the laboratory
test such
Study how to read plan or drawing and identified symbol on the drawing
2.
Update the daily material delivery record for wash sand. The updating is refer
from
the delivery order sort by a day.
3.
4.
Check the progress drainage work on site. Must to make sure the working
area are completed by the sub-contractor. ( please refer to Appendix 1 )
5.
Working for surveyor department. Find out and key in cross section from the
drawing the original ground level for L1, and L2. ( please refer Appendix 1 )
6.
Go to the site and see what have happen on site. Base from the job sheet that
have completed by the supervisor a day before. ( please refer to Appendix 1 )
7.
Learn and study the Daily Site Diary (why this diary have to do and how to
do it properly) . Site Engineer is responsible on it.
8.
Follow the M&E site supervisor and surveyor to detect the existing cable
before excavating. ( see how they work and use the instrument. )
9.
Study and read the method statement, Project Quality Plan (PQP) and Tender
for
INTERCHANGE NO.1.
2. Help the QA/QC TO prepare the paperwork for method statement. The title of
method statement is Traffic Lights Installation Procedures and Post
Tensioning
The most important thing before starting any progress of work is RIN. The request for
inspection (RIN) is a request form that request by the contaractor (SMCSB) for the
employers representative (Gerbang Perdana Sdn. Bhd.) to inspect the preparation or
completion of a certain element of the works or before proceeding with the next stage in
such work It responsible by the Engineer.
RIN shall be dated and numbered in an approved sequence and submitted for each of
the element of works. It shall state the precise element of works to be inspected, time and
date, and the relevant drawing reference number and revision for the works.
There have 3 carbon coppies. The original submitted to the employers representative
(Gerbang Perdana Sdn. Bhd.),one for contractors record office (SMCSB),and for
contractors work section (SMCSB site office). All the record with complete comment
from consultant and verification from Construction Manager In Charge, will update by
QA/QC department for Quality Record.
RIN NO : (ICW1/
To be assigned by Contractor
RIN must be submitted to the Construction Manager in advance. Refer to RIN Procedures for the time limit to submit RIN.
PPPP=Package Number, D=Discipline, TTT=Trade ID, XXX=Running number for that particular Package.
Construction Manager to revert a duplicate cover copy to Contractor. Contractor to forward original to relevant Consultant, immediately.
Hold Point (Formal approval required before proceeding with the next stage of works)
Results / Inspection passed.* The contractor is allowed to proceed with the next stage of works.
Please rectify the following. Re-inspection is required / not required.*
(*delete as appropriate)
.....
.....
Witness Point (For notification)
Witnessing not required. The contractor is allowed to proceed with the following works.
Works duly witnessed without further comments / with * the following comments
(*delete as appropriate)
.....
.
Commented By:
Consultant to return the original form to the Construction Manager or Senior Manager immediately after inspection.
Construction Manager to distribute copies with attachments and forward original to Engineering Department for compilation.
FORM-PR-CM-401 R3
CLIENT
KERAJAAN MALAYSIA
CONSULTANT
SMHB SDN.BHD.
CONTRACTOR
GERBANG PERDANA SDN.BHD.
SUB. CONTRACTOR
SERI MERAGA CONSTRUCTION SDN.BHD
CONTRACT TITLE
INTERCHANGE NO. 1 ( ICW 01 )
PROJECT INFORMATION :
Commencement Date :
Completion Date
Duration
647 Days
Cost
RM 134,857,803.53
Introduction
The Interchange No.1 is situated at the northern end of the CIQ Complex and functions to
facilitate traffic entering and existing the complex as well as traffic using Jalan Lingkaran
Dalam and Stulang Darat. This interchange consists of three tiers : The lowest tier (first
tier) is an underpass linking Jalan Stulang Darat and the new CIQ, second tier is a single
point diamond configuration with 2 phases of traffic light, and overpass bridge crossing
the single point diamond configuration will be as the 3rd tier. This construction of
Interchange will facilitate and further enchanced the traffic clearing system on the future
of the CIQ.
1) Permanent Works
The scope of the works for the contract for the contract for the Construction of
Interchange No. 1 includes, but is not limited to, the following.
major works
items in master time location chart, with critical path analysis.
Site clearing covers the whole site with the boundary at 2m beyond the top
of cut
slopes or the toe of embankment on both sides of the road.
Earthworks including the supply, lay and compact of suitable fill materials
and
temporary works where required.
Hydroseding of all cut and fill slopes: berms and all exposed earth surface
as
directed by the S.O.
phasing for
the proper and expeditious execution of this Contract.
works.
Earth drains, lined drains, pipe box culverts and all associated drainage
Four Bridges (two in piling only), one pedestrian bridge and their
associated
works.
traffic signs,
road kerbs and gutters, street lighting and traffic light etc.
All works incidental to the Contract as shown in the Bill of Quantities and
the
Drawings and all other work necessary for the proper construction,
completion
and maintenance of the Works as specified in the Contract Document
including
any modification arise within the terms of the Contract.
2) Temporary Works
It is intended that Contractor is to be responsible for managing, maintaining (daily
and continuously) and re-constructing as necessary, all prime existing temporary
sire access roads. Permanents at-grade roads such as, but not limited to, the road
related to Interchange No.1 and Internal CIQ road system will be used for general
construction site access for all contracts.
Project Location.
The Interchange No. 1 is situated at the northern end of the CIQ Complex and function
to facilitate traffic entering and exiting the complex as well as traffic using Jalan
Lingkaran Dalam and Jalan Stulang Darat. This interchange consists of three tiers, the
lowest tier (1st tier) is an underpass linking Jalan Stulang Darat and the new CIQ, the
second tier will be a single point diamond configuration with 2 phases of traffic light,
and an overpass bridge crossing the single point diamond configuration as the 3rd tier.
Under this Interchange No 1 are the structures of six underpasses, four bridge (two piling
works only), one pedestrian footbridge and around twenty two thousand metre squares of
retaining walls.
CONTRUCTION OF BRIDGE 1
PIER 1
PIER 2
ABUTMENT A
Prestress Coupler
position
Prestress Coupler
position
ABUTMENT B
PIER 3
Prestress Coupler
position
This bridge has four spans. The 2 side spans are 50 m. long while the middle 2 spans
are 75 m. long. Both the approaches to the abutment will be of reinforced soil wall
construction.
The bridge parapet will be precast and stitched to the deck slab. Grade 50/20
concrete will be used for deck slab.
Construction Method
( General Notes : A copy of drawing for construction Bridge 1 is attached herein
Appendix 3 )
The vertical profile for Bridge No. 1 is shown on drawing no. W/GSB/ICHIR/ICW01/CE/PP/340 to 342. The levels provided here refers to the finished road level on
top of the bridge. Drawing no. W/GSB/ICHIR/ICW-01/CE/ST/2103 has also specified
the structural deck level and the cut-of level (thus the pile cap level) at the pier
locations.
The super elevation for Bridge No. 1 is shown on drawing no. C/GSB/ICHIR/ICW01/CE/SE/354.
Reinforcement bars to be laid in accordance to drawing no. C/GSB/ICHIR/ICW01/CE/ST/2108. . As for the abutments, the reinforcement detailing is as shown
on drawing no.. C/GSB/ICHIR/ICW-01/CE/ST/2107.
Grade 40 concrete to be used for the pile cap. Concrete will be placed using crane
and bucket.
Concreting of the pile cap will be done in a single pour. Soon after the top of the pile
cap has been trowelled, it shall be covered with a layer of hessian cloth or plastic
sheeting to minimise shrinkage cracks.
Fix steel mould. The 1st lift height varies from less than a metre to about 3.1 m.
Grade 40 concrete to be used and concreting will be done using crane and skip.
In-situ Trapezoidal
Box Section
3 rd concreting
lift
2 nd concreting
lift
1st concreting
lift
Pier column
The cast in-situ box girder is a trapezoidal section with a top slab width of
9.9m. and a bottom slab width of 3.8 m. The depth of the box girder is 3.5 m.
The box girder section are to be prestressed with continuity tendons from
abutment to abutment.
Two of the side spans are 50 m. while the middle two spans are 75 m.
b) Construction Sequence
For the construction of the in-situ box girder deck section, each carriageway
will be divided into 23 segments as shown in Figure 1 above. Each of the
segment shall be about 11 m. long.
Therefore the first stressing of the box section would only be carried out after 6
segments have been concreted. Similarly the 2nd round of stressing will only be done
after segment 13 have been completed.
Heavy-duty support shoring will be used to support the box girder deck segments.
The soffit of the base slab will be formed using 12-mm. plywood supported on
timber
bearers.
The external curved web together with the two deck flanges will be formed using
steel mould, while the internal web will be formed using timber and plywood
sheathing.
The internal soffit form for the deck shall be made of 12 mm. thick plywood
supported using timber.
After each panel of 11 m. has been cast, the external web form together with the
internal form will be moved over to the next panel.
Each segment would be cast in either two or three lifts. The dimensional detail of a
typical segment is as shown in Figure 1 below.
Drawing No. GEC/0401/BR1-2/1 also indicates the number of concreting lifts required
for the various segments. The three lifts are required to enable the dismantling of the
internal formwork. The joint locations for the 2nd and 3rd lifts are as shown in the
sectional details on Drawing No. GEC/0401/BR1-2/2. Between the 1st and 2nd lift a 50
mm groove line has been introduced to ensure a neat, straight and horizontal construction
joint throughout the full length of the bridge box girder section. The dimensional details
of the groove line are shown in Figure 1 above.
The horizontal groove line is located at 900 mm from the soffit of the box section. The
horizontal construction line is located at this position for the following reasons:
To be above the splay of 125 mm (note that the thickest section of the base slab is
750 mm, near the pier diaphragm location);
To be below the lowest prestressing couplers at C.J. 1, 2 and 3;
To accommodate the two and three casting for each segment, there are some changes in
the reinforcement lapping position, which has been proposed. Attached drawing no.
GEC/0401/BR1-2/3 showing the changes in the location of rebars lapping for bar mark 07
and additional lapping for bar mark 01.
There will be a set of base mould for casting the 1st lift. For the base slab (or 1st lift) the
casting sequence will be from Segment 1 at Abutment A and moving towards Pier 1 and
then Pier 2. However it is to be noted that Segment 21 base slab shall not be cast until
the stressing at C.J. 3 (near Pier 3) has been completed. This is necessary because the
lowest coupler position at C.J. 3 is rather low and therefore is not possible to fit in the
stressing jack if Segment 21 base is cast. Hence Segment 21 will be skipped and casting
of the base slab may proceed on Segment 22. Once stressing at C.J. 3 (at the end of
Segment 20) has been completed, the castings of base slab Segment 21 may be proceed.
Following this, casting of Segment 7 web and deck slab will be skipped and instead work
will be proceed on Segment 8 to 13. Segment 7 is skipped to enable the prestressing
tendons are treaded into the ducts and locked into the couples at C.J. 1 (i.e. end of
Segment 6). (Only after all the tendons have been locked into C.J. 1, the web and deck
slab of Segment 7 would be cast.) The
web and deck slab of Segments 7, 11, 12 and 13 shall also be cast separately to enable
dismantling of the internal form.
Similarly at C.J. 2, Segment 14 would be skipped and would only be cast after the
tendons have been treaded in from C.J. 3 (at the end of Segment 20). Here again the web
and deck slabs for Segments 14, 18, 19 and 20 would be cast separately to enable the
dismantling of the internal formwork.
Again at C.J. 3, Segment 21 would be skipped and cast last, after all other segments have
been completed. The deck slab for Segments 21 and 24 would be cast separately to
enable the dismantling of the internal formwork.
In summary the sequence of casting for the web and deck slab shall be as follows:
Segment 1 2 3 4 5 6
From C.J. 1 to C.J. 2 :
8 9 10 11 12 13 7
From C.J. 2 to C.J. 3:
15 16 17 18 19 20 14
From C.J. 3 to Abutment B :
22 23 24 21
Reinforcement
All the reinforcing bars shall be high yield deformed bars (460 N/mm2 ) or mild steel bars
(Fy = 250 N/mm2 ) complying to B.S 4449 : 1988. The bending of bar reinforcement
shall be in accordance with B.S 4466 ; 1989.
Minimum lap and anchorage for reinforced concrete must be :
BAR SIZE
T10
450
T12
550
T16
750
T20
900
T25
1125
1450
T32
Robin engine pokers (60 mm. dia. Pokers) will be used for vibrating and
compacting the concrete.
The unformed surface of the deck slab shall be trowelled with a timber trowel
LOCATION
CONCRETE GRADE
(N/mm2) / mm
Blinding
C15/20
C40/20
Pile Caps
C40/20
Abutment Walls
C40/20
Piers
C40/20
Bearing Plints
C50/20
Parapet
C40/20
Curing
Curing Compounds
Liquid curing compounds for use of concrete can comply with the following :
i.
ii.
iii.
iv.
The compound can not be poisonous, odorous or explosive and shall not
react chemically with cement.
v.
Curing compounds can be stored and used strictly in accordance with the
manufacturer instructions.
vi.
Curing of concrete shall be done using SIKA Antisol-S concrete curing compound. This
compound shall be sprayed onto the concrete surface after the formwork has been
dismantled
Expansion Joint
A flat and level monolithic haunch or recess should be formed in the structural
deck to accommodate the DR Joint and the transition strips. At the design stage, care
should be taken to locate the reinforcement avoiding the position of the bridge joint
anchor studs.
In the interest of achieving a smooth traffic ride over the joint, the wearing
course should be machine laid continuously over the structural joint and subsequently
removed by cutting just prior to installing the bridge joint.
The removal of the surfacing over the joint in the deck is facilitated by placing a
hardboard bond breaker of a width slightly less than the combined width of joint and the
transition strips prior to the laying of wearing course.
Depending on the temperature of the deck slab during installation, the DR joint
unit may required to be pre-compress or pre-extending to suit the relative position of the
bridge deck.
The DR joint module installation width and the new bolt hole center have been determined the joint mo
The exposed concrete should be roughen and the final level of bed adjusted
using epoxy mortar. A leveling template is used to achieve the required recess depth i.e.
75mm in the case of model DR 165.
The bridge joint modules centered over the expansion joint in the deck may be used as templates fo
The final bolt holes should be drilled and studs installed using chemical fixing anchors.
Each bridge joint unit may then laid into position on beads of sealant, plain clipped
washers supplied with each unit located, and the assembly bolted down.
Subsequent modules should then be located and fixed in the same way, the sealant
first being applied to the tongue and groove edges to each unit prior to jacking into
position to ensure substantially waterproof junction.
The fixing nuts should be tightened to the required torque and Isoflex resin
transition strips laid level with the wearing surface.
Following final torque checks on fixing nut, the bolt caps should be filled with
sealant to protect the stud against corrosion. The joint is allowed to cool to ambient
temperature and may be
trafficked in 2-3
hours.
MATERIALS
Strands
0.62
Nominal Diameter
15.7mm
Nominal Area
150mm2
Nominal weight
1.18kg/m
Tensile strength
1770N/mm2
Modulus of elasticity
195kN/mm2
265kN
BS
Ducts
The sheathing consists of corrugated spiral ducts made from galvanized steel
strips of 0.3 to 0.4mm thick cut in lengths of 5.5 m.
Anchorages
The type of anchorages commonly used are Flat Anchorage (FA), Multiplane
Anchorages (MA), Couplers Plate Anchorage and Bond Head (Dead End)
Anchorages. The purpose of the anchorages are when the strands are stressed, the
Friction of coefficient u
recommendation
Wobble factor k
Draw in of wedge
6mm (approximately)
Stressing anchorage
Loss in jack
Suitable ropes or slings shall be used for loading and unloading in order to avoid
mechanical damage to the strand coil.
The component must be handled and stored such that any contamination,
mechanically damage or corrosion can be avoided.
Tendon alignment and height shall take precedent over reinforcement whenever
there is a clashing point(obstruction).
The Multiplane Anchor is fixed to the end formwork by support bars to avoid any
displacement during concreting.
The Multiplane Anchor must be orientated perpendicularly to the cable axis and
with the grout hose connection at the top of the duct.
If the side formwork is to be erected early, the main contractor has to arrange for
hole protrusion to be made for each anchorage to accommodate protruding duct
and strands.
Tolerances for vertical tendon profiles are 10mm for all high and low points.
Tolerance for horizontal profiles are 150mm (to avoid small M&E openings or
Support bars and bar-chairs are placed at intervals of each 1m (approx) and
secured with binding wire to avoid any movement during concreting.
Care should be taken during concreting to avoid grout hoses from being embedded
in concrete or removed completely.
Care should be taken to avoid damaging ducts with tie bars of the formwork.
Check visually axis of ducts and fixation at supports and anchorages before
concreting.
STRESSING
Stressing shall not commence unless the main contractor has confirmed that the
concrete for the pour to be stressed has achieved the minimum cube strength as
required.
Preparation for stressing
dirt.
At the beginning of stressing the strands are locked in the jack pulling
head.
When the jack has reached the end of its stroke or the desired force has
been obtained, the pressure in the jack is released and the strands become
locked uniformly by the wedges in the wedge plate.
Stripping of formwork can be carried out after full stressing of beam / slab
is completed.
GROUTING
Proposed grout mix
= 3-4 min
Viscosity
Compressive strength.
Viscosity test
It is the measurement of time that the grout takes to completely flow out of
the cone.
178 mm
Filled Level
76 mm
191 mm
38 mm
12.7 mm
During trial mix period, compressive strength test shall be carried out.
After 18 to 24 hours, remove cubes from mould and store in water storage
tank.
minimum of 17 N/mm2
28 days
minimum of 30 N/mm2
Grouting of tendons
After the trial mix is done and a suitable mix is determined, than the
grouting is ready to proceed.
All ducts must be flushed thoroughly with compressed air to remove all
entrapped water and to check for chokages.
After this is completed and the mix is ready, start injecting grout from the
inlet hose of the tendon.
Grout must flow out from outlet until visible residual water and entrapped
air has been removed. Lock the outlet hose.
Continue pumping until the desired pressure of 3-5 bar is achieved. Close
the inlet hose and proceed to the next tendon.
Bearing
MECHANICAL POT BEARING
Method Of Work
Before casting of the sub-structure. Polystyrene blocks or PVC pipes is used for
forming the blockouts (recesses) for the bottom cast in sockets. The dimensions of the
cast in sockets would be as indicated in the drawing no
W/GSB/ICHIR/ICW01/CE/ST/2115.
The blockout plan area or diameter must be at least 50mm larger than the cast in
sockets. The setting out of these blockouts to be checked and confirmed by the
engineer prior to casting the sub-structure
The blockouts and concrete surface area where the bearing is to be positioned
should be cleaned and roughen prior to installing the bearing.
The centerline at the bearing to be marked by the surveyor and confirmed by the
engineer. Positioning the bearing to correct height and orientation by means of 4 sets
Masking tape/sponge strips are to be used to seal the butt joint between the
bearing top plate and superstructure formwork. This is to avoid ingress of concrete
into the pot bearing.
Remove temporary transportation brackets, after the superstructure has achieved the
strength.
Once the deck has been constructed, if required, the bearing can be removed by
first removing the attachment bolts followed by the bolts of the external lateral
guides, if any. The deck is required to be jacked up by approximately 15mm. The
jacking force would be the dead load plus any superimposed dead load (i.e. DL +
SDL). The jacking locations are to be confirmed with the consulting engineer prior to
jacking.
The top slide plate can then be slided out horizontally along the direction of
traffic, hammer to break the bond of silicon grease if required. This is the followed by
removal of the piston plate and finally the cylinder pot/ bearing base plate.
This method is preferred because it is easier and lighter to remove component after
component in lieu of the entire bearing in one single operation.
Removal of the whole bearing is recommended after the transit brackets have been
fastened (if access of crane is possible).
Construction of Parapet
CASTING OF PCP PANELS
a.
Area been allocated for this purpose is the previous lot 20289. This area will be
levelled and laid with suitable material, compacted and well drained in order to
prevent ponding of rainwater causing breeding of mosquitoes. Area will be always
kept tidy and orderly. Area is divided into three thus; cutting and bending yard,
casting yard and storage area.
b.
Steel Mould
Steel mould will be used in the casting of parapet panels to achieved F3 finish thus;
typical PCP panel and PCP panel with street lighting base. The mould shop drawing
will be submitted to the engineer to check conformity to the construction drawing
prior to fabrication. Once fabrication completed, the steel mould will be inspected in
the factory in conformity with the approved shop drawing. Rectification if any has to
be carried out in the factory prior to delivery of the mould to the casting yard. The
steel mould will be placed in the casting yard area in an orderly manner to allow
sufficient working space for the installation of reinforcement and cast in items,
assembly, casting process, disassembly and lifting of completed PCP panel product.
c.
Reinforcement
Reinforcing bars to be used in the casting of parapet panel must be free from rust and
oil substance that will cause inferior effect. The reinforcement will be cut, bend and
assemble (using tie wires) according to the construction drawing. Completed
reinforcement (rebar cages) will be store in an orderly manner covered with plastic
sheets ready for use.
d.
Cast in items
Sufficient quantity of J- bolts, uPVC electrical conduits cut in to length and other
cast in items must be kept available in the casting yard in order not to delay any
casting of parapet panel.
e.
Concrete
f.
III. Close the mould and tighten all necessary bolts and nuts. Any gaps must be
sealed properly to prevent concrete leak during concreting.
IV. Prepare necessary checklist and call for inspection. Rectification if any has to be
carried out prior to concreting.
V. Once everything is ready, order the concrete. Sampling (slump and cubes) if
required has to be carried out prior to concreting.
VI. Pour the concrete carefully and vibrate using poker until concrete reach mould
brim. Trowels smooth the exposed portion of the panel before concrete harden.
VII. Once the concrete set (minimum 10 Kn/ mm2), open the mould and lift (using
backhoe) carefully the harden PC panel and transfer to the store yard.
VIII. Next casting, refer to procedure 1 and so on.
g.
Any remedial works or patching will be carried out using approved grout material.
From the store yard, the accepted PCP panel will be transported to the erection
site. The PCP panel will be lifted and position using mobile crane. One set of
turnbuckle complete with necessary accessories will be installed to hold each PCP
panel in position (refer to sketch no. ). This turnbuckle will then be anchored to
the concrete up stand. Panel to install side by side with a gap of 20 mm.
Adjustment of the PCP panel to achieved the desired alignment, verticality and
level by turning the turnbuckle and providing shim pad. When the PCP panel is in
place, minimum one number of distribution steel bar will be fixed through the
links to connect the PCP panel to the RC copping. This is to protect parapet from
dropping during the fixation.
b.
After installing sufficient numbers of PCP panel, the balance distribution bars can
be place accordingly. Alignment, verticality and levels must be check again in this
stage prior to installing the formwork. Gaps between formwork, PCP panel and
copping beam must be sealed off to avoid any concrete leakage during the casting.
Once everything in order, prepare checklist and call for final inspection. Order
concrete and cast. As much as possible concrete will be poured direct in the stitch
kerb from the
truck. The exposed portion of the stitch kerb will be smooth troweled finish
before the concrete hardens.
c.
Finishing works
Once concrete achieved the minimum strength (10 N/mm2), dismantle the
formwork and remove the turnbuckle. Carryout patching works if any.
ISOMETRIC VIEW
(SHOWING INSTALLATION OF FORMWORK)
MATERIAL
Material Description
Suppliers
1. Concrete
2. Rebar
3. Bearing
4. Expansion Joint
MACHINERY RESOURCES
The following plant and machinery resources will be deployed for the construction of
Bridge No. 1 :-
7. Heavy-duty shoring;
SAFETY PLAN
It is Seri Meraga Construction Sdn Bhd. policy to perform all our works with due
regard to safety, practice safe working methods, and create a risk free, healthy
working environment.
The following key areas in construction shall be adhered by all site personnel,
working on Bridge No. 1. They are not an all inclusive set of rules, but a guidance of
the level of care and attention on safety matters, that every site personnel shall
observe and follow.
o Safety belt or harness, for workers who will be working on elevated areas;
o Hand gloves, for steel workers;
o Eye goggles / face protective shield, for workers involve in welding works
or grinding and hacking works;
o Safety vest, for workers involve in traffic control;
o Rain coat, when required to work in the rain;
Housekeeping
Housekeeping is an essential part of construction safety. This should be part of
our daily routine. Housekeeping would include the following work items:
o Maintain an obstruction free access/egress to all working areas;
o Store and stack all construction materials in a safe and orderly manner;
o Avoid littering around the jobsite;
o Do not throw anything from height;
o Do not leave timbers with nails lying around, the nails are to be remove or
bent over;
Elevated Workplace
When a person is required to work at height or an elevated workplace, all open
sides shall be adequately guarded, and the working platform must be strong, rigid
and capable of withstanding the imposed load.
A safe means of access/egress such as stairways or ladders must be made
available.
Shoring/Falsework
Timber shoring or sheet pile used for retaining wall be adequately design to
withstand the imposed loads.
Shoring and props, where used shall be securely held in position, suitably spaced
with adequate footing. It should also be adequately braced horizontally and
diagonally in both
Prestressing Works
Whenever any post-tensioning works are being carried out, ensure no workers are
working in front of the stressing jacks until the cables have been adequately
locked.
In summation, in order to achieve a safe, risk free and healthy working environment,
including loss prevention, every practicable step must be taken by each and everyone
engaged in this project site.
COMMENT
After 10 weeks I have been here to complete my industrial training, personally I
can say that there are a little bit of differences between theoretical and practical. I say that
because I can see many actual progress on site. Such as I can see the tendon on bridge,
how to fixing rebar, how to cut and bending rebar, construction sequence of road, and
many more.
All that I have learn from my training was explain clearly what have I learned
from my lectures before. I agree that expose on construction activities can make me
more confident to figure out all the incoming subject that I had to learn on next semester.
The relationship between me and all staff is fine. They all give their cooperation
and concern to me. They always give me a hand when I need a help. They not mean to
teach me and spend time for me to explain something about work although they busy. I
think I am luckily to be here.
CONCLUSION
After 10 weeks in training, I have exposed myself on construction activities
whether on site or office. I gain a lot of information and experience with actual site
working condition throughout from my industrial training.
Site activities are new for me. It is exciting and new for me to learn and get
information for our working experience. It is my pleasure and great opportunity to joint
and gain experience from a big company like Seri Meraga Construction Sdn. Bhd.
.Therefore it is a big project such as Project Gerbang Selatan Bersepadu.
A part from this experience that I have gain, I am capable to communicate with
various type of people. I am able to interpret various type of work either it is complicated
or not. It is important to me to know how work will progress and the important it is. I
also learn something new and quite challenging. For example when a critical time on site
happens such as when diesel is not enough to ensure the machineries move and works as
daily, when sand wash is not delivered, when weather becomes unstable : raining
everyday, and when the company have a internal problem such as not enough workers to
monitoring works on site. I learn from the site coordinator how to solve this problem
smoothly.
From the experience I get, I learned new Method and Technology in construction
field. More over, it is a practice to me with what I learned previously from textbooks and
lecture.
I have improve my interpersonal skills a lot from this industrial training. I also
become more confident and more open minded in making decision in whatever condition.
I think involving this project are great opportunities to gain experience and contribute
before developing my future career. It is very useful to me.
It is a great time for me have an experience with this company and many senior
staff which have more experience to learn a lot. I hope that I can be such a good worker
in the future and become a good successful engineer. It is a great to get involve in this
project. Thank you to all staff.