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DIAP DAELIMJoint Venture
Tuas TerminalConstructors
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
CONSTRUCTION PLANFOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
1. General Information
2. Work Flow
2.1 Work Flow and Cycle Time Scheme
2.2. Site Utilization, Equipment and Manpower Plan
3. Method Statement
3.1 Base Slab Station
3.2 Slipform Station
3.3 Curing Station
4. QA/QC Plan
CONTENTS
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
1. General Information
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsGeneral Information
CAISSON FABRICATION
This method statement describes the Fabrication of Caissons at the Caisson Fabrication Yard for the Tuas
Terminal Phase 1 Reclamation, Wharf Construction and Dredging Project.
The caissons will be fabricated in a land-based designated casting yard by using the Double Gantry Hydraulic
Slipform System.
The caissons will be casted following 3 lined up steps by using the automatic transfer system ; Individual Pushing
Caisson Carrier Vehicle System (IP-CCV) from base slab casting area to the floating dock (F/D, 22,000 ton).
[Fabrication Yard, 13th Feb. 2016 ] [Caisson A-Type Shape]
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
CAISSON FABRICATIONType of Caisson
Type Size (LxWxH, m) Cell Volume ( ) Weight (ton) Q’ty (EA) Remarks
A-Type 39.90 28.00 28.15 8 5 5,900 15,200 184
B-Type 29.90 28.00 28.15 6 5 4,600 11,700 7
C-Type 39.90 28.00 28.15 8 5 5,800 14,700 21 With IntegratedCulvert
D-Type 33.00 28.00 28.15 7 5 5,000 12,800 2 Corner Caisson
E-Type 36.05 28.00 28.15 8 5 5,500 14,100 2 Corner Caisson
F-Type 39.90 28.00 28.15 8 5 6,100 15,500 1 Corner Caisson
G-Type 31.06/12.86 28.00 28.15 6 5 3,500 8,800 1 Trapezoidal Caisson
H-Type 40.73/22.53 28.00 28.15 8 5 5,000 12,900 1 Trapezoidal Caisson
J-Type 36.85/30.91 28.00 28.15 8 5 5,300 13,600 2 Trapezoidal Caisson
K-Type 39.90 28.00 28.15 8 5 5,900 15,100 1 Connection to Corner Caisson
Total 222
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsDrawings
CAISSON FABRICATION
A-Type Caisson (Total 184 EA)
39.90m 28.00m 28.15m
[Caisson A-Type Drawing]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsDrawings
CAISSON FABRICATION
Other Types (Total 38 EA)
Type B
Length 29.90 m
Breadth 28.00 m
Depth 28.15 m
Weight 11,700 ton
Quantity 7 EA
Type C
Length 39.90 m
Breadth 28.00 m
Depth 28.15 m
Weight 14,900 ton
Quantity 21 EA
Type D
Length 33.00 m
Breadth 28.00 m
Depth 28.15 m
Weight 12,800 ton
Quantity 2 EA
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsDrawings
CAISSON FABRICATION
Other Types (Total 38 EA)
Type E
Length 36.05 m
Breadth 28.00 m
Depth 28.15 m
Weight 14,100 ton
Quantity 2 EA
Type F
Length 39.90 m
Breadth 28.00 m
Depth 28.15 m
Weight 15,500 ton
Quantity 1 EA
Type G
Length 31.06m/12.86m
Breadth 28.00 m
Depth 28.15 m
Weight 8,800 ton
Quantity 1 EA
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsDrawings
CAISSON FABRICATION
Other Types (Total 38 EA)
Type H
Length 40.73m/22.53m
Breadth 28.00 m
Depth 28.15 m
Weight 12,900 ton
Quantity 1 EA
Type J
Length 36.85m/30.91m
Breadth 28.00 m
Depth 28.15 m
Weight 13,600 ton
Quantity 2 EA
Type K
Length 39.90 m
Breadth 28.00 m
Depth 28.15 m
Weight 15,142 ton
Quantity 1 EA
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
2. Work Flow
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
2. Work Flow2.1 Work Flow and Cycle Time Scheme
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
CAISSON FABRICATIONWork Flow
SERVICE STATION BASE SLAB STATION SLIPFORM STATION CURING STATION LOADING ONTO F/D
1) General preparation
works
2) Material temporary
stockpiling
3) Miscellaneous works
1) Soffit form installation
2) Rebar installation
3) Side form installation
4) Concrete casting
1) Slipform setting
2) Rebar installation
3) Concrete casting
4) Slipform jacking up
5) Repetition
1) Corrosion protection
2) Safety platform
Installation
3) Rectification works
1) F/D berthing
2) F/D level setting
3) Caisson loading
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
CAISSON FABRICATIONCycle Time Scheme
Day Scope of work
Duration(Day) 5 10 15 20 25 30
Step 1BaseSlab
Rebar Installation 3.5
Form Work 1.0
Concrete Casting 0.5
Horizontal Rebar 1.0Formwork Removal
& Surface Treatment1.0
Curing 1.5
Transfer to Next Step 0.5
Sub-Total 9.0
Step 2Slipform
Setting (Jacking down,Clean shutter & Lifting rebar)
1.0
Rebar Installation & Casting 6.5
Sliform Removal & Curing 1.0
Transfer to Next Step 0.5
Sub-Total 9.0
Step 3Curing
Defects Rectification& Application of Silane
5.0
Curing 3.0
Transfer to the F/D 1.0
Sub-Total 9.0 Total 27 Days
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
CAISSON FABRICATIONCycle Time Scheme
No. Description Duration (Day)Lane 1 Lane 2
Q’ty (Cycle) Amount (Day) Q’ty (Cycle) Amount (Day)
1
Caisson Casting
1) 1st, 2nd 16 2 32 2 32
2) 3rd, 4th 12 2 24 2 24
3) 5th ~ 9 105 945 109 981
Sub-Total 109 1,001 113 1,037
2Form Change 12 7 84 5 60
Sub-Total 7 84 5 60
Total 1,085(36 Months)
1,097(36 Months)
Lane 1 Lane 2
Lane 1 : A, B, C, D,G, H, K Type Caissons
Lane 2 : A, C, E, F, J Type Caissons
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
2. Work Flow2.2. Site Utilization, Equipment and Manpower Plan
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
CAISSON FABRICATIONSite Utilization and Equipment Plan
Service Station
Base SlabStation
SlipformStation
Curing Station
Floating Dock
Classification Spec. Q’ty(EA) Description
Tower Crane 24 ton 2Base Slab Station : Form & Rebar Works
Curing Station : Repairing & Others
Mobile Crane 80 ton 1Base Slab Station : Form & Rebar Works
Curing Station : Repairing & Others
Boom Lift 30 m 1 Curing Station : Repairing & Others
Fork Lift 7 ton 3 Rebar Transportation
Pump Car 45 m 3 Base Slab Station : Concrete Casting
Water Jet800bar
2 For Cleaning
Rebar Bending Machine
Coil in bar
1 Rebar Cutting & Bending
Generator640kW
1 Stand by in Fabrication YardB/P
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsManpower Plan (Indicative Only)
CAISSON FABRICATION
Classification Line – A(Man)
Line – B(Man)
Sub-Total(Man) Remark
General Manager 7 7
Shop Drawing 1 1
Safety / HR 6 6
Rebar Cut & Bending 46 46
Base Slab Station
Form Work 20 20 40
Rebar Work 36 36 72
Jack, Electric Operation 6 6 12
Slipform Station
Rebar Work 125 125 250
Concrete Casting Work 65 65 130
Jack Operation 11 11 22
Hoist Operation 20 20 40
Surface Treatment 4 4 8
Banksman 4 4 8
Curing StationSilane Painting 3 3 6
Surface Treatment 8 8 16
Heavy Equipment Operator
Forklift 3 3 6
Tower Crane 9 9
Crawler Crane 9 9
Total (Man) 689
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
3. Method Statement
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
3. Method Statement3.1 Base Slab Station
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsBase Slab Station
CAISSON FABRICATION
Sofit Form Setting Vinyl Sheet Rebar Work
Side Form Setting Concrete Pumping Caisson Transfer
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsBase Slab Station
CAISSON FABRICATION
Base Slab Casting Plan
3 Pump Cars (Each 40 m3/h, 48 m Boom)
per Each Lane
Total 11 hours work (1,300 m3 3 Pump
Cars X 40 3/h X 11 hours) per Each Lane
9 Vibrators (3 EA X 3 Pump Cars) per
Each Lane
Concrete will be casted within 1 hour after
mixing for preventing construction joint
Wall Joint Section Exposed aggregates
with water jet for bonding
After removal the inner formwork, all
concrete defects will be rectified
Pum
p C
ar 1
Pum
p C
ar 2
Pum
p C
ar 3
[Base Slab Casting Sequence]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsBase Slab Station
CAISSON FABRICATION
Individual Pushing Caisson Carrier Vehicle System (IP-CCV)
84 EA (6 Lines X 14 Rows) per Each Lane
Lifting Capacity : 21,000 ton
(250 ton X 84 EA)
Pushing Capacity : 2,100 ton
Horizontal Speed : 10 m/h
Min. Base Slab Strength : 11 MPa
Soffit Form
Steel Track and Track Slab
Base Slab
Step 0
[Concept of the IP-CCV]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsBase Slab Station
CAISSON FABRICATION
Individual Pushing Caisson Carrier Vehicle System (IP-CCV)
84 EA (14 Lines X 6 Rows) per Each Lane
Lifting Capacity : 21,000 ton
(250 ton X 84 EA)
Pushing Capacity : 2,100 ton
Horizontal Speed : 10 m/h
Min. Base Slab Strength : 11 MPa
Steel Track and Track Slab
Base Slab
LiftingStep 1
[Concept of the IP-CCV]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsBase Slab Station
CAISSON FABRICATION
Individual Pushing Caisson Carrier Vehicle System (IP-CCV)
84 EA (14 Lines X 6 Rows) per Each Lane
Lifting Capacity : 21,000 ton
(250 ton X 84 EA)
Pushing Capacity : 2,100 ton
Horizontal Speed : 10 m/h
Min. Base Slab Strength : 11 MPa
Steel Track and Track Slab
Base Slab
Pushing
Step 2
[Concept of the IP-CCV]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsBase Slab Station
CAISSON FABRICATION
Individual Pushing Caisson Carrier Vehicle System (IP-CCV)
84 EA (14 Lines X 6 Rows) per Each Lane
Lifting Capacity : 21,000 ton
(250 ton X 84 EA)
Pushing Capacity : 2,100 ton
Horizontal Speed : 10 m/h
Min. Base Slab Strength : 11 MPa
Steel Track and Track Slab
Base Slab
Step 3Descending
[Concept of the IP-CCV]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsBase Slab Station
CAISSON FABRICATION
Individual Pushing Caisson Carrier Vehicle System (IP-CCV)
84 EA (14 Lines X 6 Rows) per Each Lane
Lifting Capacity : 21,000 ton
(250 ton X 84 EA)
Pushing Capacity : 2,100 ton
Horizontal Speed : 10 m/h
Min. Base Slab Strength : 11 MPa
Steel Track and Track Slab
Base Slab
Step 3
Pulling Back
[Concept of the IP-CCV]
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
3. Method Statement3.2 Slipform Station
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Slipform System
Working DeckConcrete Vibration, Installation of Horizontal Rebar
Upper Deck Storing of Rebar, Installation of Vertical Rebar, Operation of winches
Hanging DeckSurface Treatment, Inspection
Upper Deck
Hanging Deck
Working Deck
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Setting of Slipform Slipform & Base Slab Docking Rebar Work
Slipforming (Casting) Corbel Installation Dowel Bar
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Jack Up System
36 EA X 42 ton (1,512 ton) Rod Climbing
Jacks per Each Lane
Total Load = 1,059 ton (70%)
Live Load = 541 ton
Dead Load = 581 ton per Each LaneSlipform
Jack Up System
Lane 12 EA X 18 Set
Hydraulic Jacks
Lane 22 EA X 18 Set
Hydraulic Jacks
[Arrangement of Hydraulic Jacks] [Concept of Grip Jaw Climbing]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Concrete Supply
Mixer Trucks Concrete Hopper
Hopper Lifting with Winch Positioning
at Upper Deck Hole Using Plastic Tube
16 Vibrators per Each Lane
10 ~ 20 cm/h Climbing Rate
Sufficient Supply Ability
Plastic Tube
HopperOn-Site
B/P
Desc. Calculation
B/PCapacity
Spec. : 240 m3/hOperating Ratio : 80% (Assumption)
Supply Quantity : 192 m3/h
CaissonCasting(Max.)
Lane 1 : 20 cm/h x 171.4 m2 = 34.3 m3/hLane 2 : 20 cm/h x 171.4 m2 = 34.3 m3/h
Requirement Quantity : 68.6 m3/h (38%)
[Concept of Concrete Supply]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Rebar Work Plan
Cut & Bend Gantry Tower Rolling Up
Temporary Storage on the Upper Deck
Fabrication
Horizontal Supply : Rebar Slide Guide
Spacer Installation at Yoke Leg
The Upper Deck Stability (Please Refer
Details Below)
Vertical Rebar Supply
Horizontal Rebar Supply
RebarSlideGuide
Concrete coverdepth = 50~75mm
Space
Rebar Moving Roller
Vertical direction : 2 ton × 6 bundle × 6 column = 72 tonHorizontal direction : 2 ton × 4 bundle × 9 row = 72 ton
Total = 144 ton(67%)
* Capacity of the upper deck for storage of rebar is 216 ton
[Rebar Storage Plan]
[Rebar Supply Plan]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Corbel Installation
Slipform Climbing and Concrete Casting
H-Beam Installation
Bracket Installation and Positioning
Hatch Removal
Corbel Form and Tie Installation
Rebar Fabrication
Slipform Climbing and Concrete Casting
Corbel Form and Bracket Dismantling
[Concept of Corbel Installation]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Corbel Installation
Hatch
[Concept of Corbel Installation]
Slip Form
Slipform Climbing and Concrete Casting
H-Beam Installation
Bracket Installation and Positioning
Hatch Removal
Corbel Form and Tie Installation
Rebar Fabrication
Slipform Climbing and Concrete Casting
Corbel Form and Bracket Dismantling
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Corbel Installation
Bracket Installation
H-Beam 100 x 100
Hatch Removal
[Concept of Corbel Installation]
Slip Form
Slipform Climbing and Concrete Casting
H-Beam Installation
Bracket Installation and Positioning
Hatch Removal
Corbel Form and Tie Installation
Rebar Fabrication
Slipform Climbing and Concrete Casting
Corbel Form and Bracket Dismantling
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Corbel Installation
H-Beam 100 x 100
[Concept of Corbel Installation]
Slip Form
Corbel Form
Tie Slipform Climbing and Concrete Casting
H-Beam Installation
Bracket Installation and Positioning
Hatch Removal
Corbel Form and Tie Installation
Rebar Fabrication
Slipform Climbing and Concrete Casting
Corbel Form and Bracket Dismantling
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Corbel Installation
H-Beam 100 x 100
[Concept of Corbel Installation]
Slip Form
Tie
Rebar
Slipform Climbing and Concrete Casting
H-Beam Installation
Bracket Installation and Positioning
Hatch Removal
Corbel Form and Tie Installation
Rebar Fabrication
Slipform Climbing and Concrete Casting
Corbel Form and Bracket Dismantling
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Corbel Installation
[Concept of Corbel Installation]
Slip Form
Slipform Climbing and Concrete Casting
H-Beam Installation
Bracket Installation and Positioning
Hatch Removal
Corbel Form and Tie Installation
Rebar Fabrication
Slipform Climbing and Concrete Casting
Corbel Form and Bracket Dismantling
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Corbel Installation
Form and Bracket
Dismantling
[Concept of Corbel Installation]
Slipform Climbing and Concrete Casting
H-Beam Installation
Bracket Installation and Positioning
Hatch Removal
Corbel Form and Tie Installation
Rebar Fabrication
Slipform Climbing and Concrete Casting
Corbel Form and Bracket Dismantling
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsSlipform Station
CAISSON FABRICATION
Corbel Installation
[Concept of Corbel Installation]
Slipform Climbing and Concrete Casting
H-Beam Installation
Bracket Installation and Positioning
Hatch Removal
Corbel Form and Tie Installation
Rebar Fabrication
Slipform Climbing and Concrete Casting
Corbel Form and Bracket Dismantling
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
3. Method Statement3.3 Curing Station
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsCuring Station
CAISSON FABRICATION
Silane Application Safety Platform Installation Loading onto F/D
Rectification Works
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
Proposed Suppliers (Waiting Approval)
Curing Station
CAISSON FABRICATION
Silane Application
All Concrete Surfaces above -1.0m CD
Approximately 930,000 m2
Silane Requirement
AkyltriethoxysilaneContent (%) 98 %
Nitrite Content (%) < 1 %
Chloride Content (ppm) <= 20 ppm
Specific Gravity 0.88
Viscosity (mPa s ) 0.95 mPa s
Application2 Layers coat applications
>= 300ml/m2 per coat>= 18 min. Interval
Spray Equipment 4 + 1 set (backup) planning, <= 70 kPa
Acceptance Criteria(PyGC Test) Minimum 0.05%
Warranty Contractor and supplier jointly guarantee for 10 years
BASF South East Asia Pte Ltd (Germany)
Dow Corning Singapore Pte Ltd (USA)
KCC Singapore Pte Ltd (South Korea)
Evonik South East Asia Pte Ltd (Germany)
[Silane Application Plan]
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
4. QA/QC Plan
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsQA/QC Plan
CAISSON FABRICATION
Base Slab Station
No. Description Acceptance Criteria Frequency DDJV Sub-Con
SO Rep.
3rd Party
1 RebarRebar shall be in accordance with Shop DrawingsSpacer bars, Supporting stools, and distance pieces to be inspected and approved by SO Rep.
3 visual inspections R R A
2 FormworkFormwork fixed in accordance to Shop DrawingsForms shall be cleaned and wettedConcrete cover 50 mm
Simultaneous visual inspection with the last rebar inspection
R R A
3Concrete
Temperature Monitoring
Temperature shall not exceed 70 CTemperature differential not exceed 20 C
Once for the second base slab casting
R A R
4Removal of Form Bolts (D-Cones)
Bolt holes shall be completely filled with approved sealing material Bolts shall not be placed within 50mm of any RebarScrew spacer cones between the bolt and formwork shall be removed promptly
For every form bolt (plastic cone) used during fabrication
R R A
5
Concrete Surface (Post-Casting) for Exposed Aggregate,
Laitance, Defect
Surface finish by screeding within tolerance of 3mm of true level and gradeEnsure that exposed aggregate surfaces are adequately preparedLaitance will be removedDefects will be patched with approved material under the permission of the SO Rep.
All concrete surfaces to be inspected for each base slab
R R A
6Movement of
Caisson
Prior approval from SO Rep.Concrete Cubes strength should be at least 10 MPa at 1.5 days
Every each caisson R R A
[R : Responsible, A : Approval]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsQA/QC Plan
CAISSON FABRICATION
Slipform Station
No. Description Acceptance Criteria Frequency DDJV Sub-Con
SO Rep.
3rd Party
1 Rebar
Rebar shall be in accordance with Shop DrawingsSpacer Bars, Supporting Stools, and distance pieces to be inspected and approved by SO Rep.Rebar verticality check with bubble level instrument
1 visual inspection for every 1.0 m
R R A
2 Formwork
Formwork fixed in accordance to Shop DrawingsForms shall be cleaned and wettedConcrete cover
1) Caisson External Face of Front Wall = 75 mm 2) Caisson External and Internal Wall = 50 mm
Simultaneous visual inspection for every 1.0 m
R R A
3
Concrete Surface (Post-Casting) for Exposed Aggregate,
Laitance, Defect
Surface Finish by screeding within tolerance of 3mm of true level and gradeEnsure that exposed aggregate surfaces are adequately preparedLaitance will be removedDefects will be patched with approved material under the permission of the SO Rep.
Inspected for every 1.0 m of concrete deposited
R R A
4Spraying of
Curing Compound
Spraying of approved curing compound for concrete surfaces above -1.0m CDTop and Side Surfaces of concrete to be kept moist for a period of four days after the concrete is placed
Outer surfaces to be sprayed for every 1.0 m
5Movement of
Caisson
Prior approval from SO Rep.Concrete Cubes strength (Slab sample) should be at least 40 MPa at 10 days
Every each caisson R R A
[R : Responsible, A : Approval]
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsQA/QC Plan
CAISSON FABRICATION
Curing Station
No. Description Acceptance Criteria Frequency DDJV Sub-Con
SO Rep.
3rd Party
1Concrete Surface (Caisson Cells)
Surface Finish by screeding within tolerance of 3mm of true level and gradeLaitance will be removedDefects will be patched with approved material. No repair of any concrete surface will be allowed without the permission of the SO Rep.
All surfaces of concrete for all caisson cells
R R A
2Final Dimension
Checking
Dimensions of Caissons will be surveyed; Tolerance for Formworks and Concrete Surface Finishes:
1) Variation in cross-sectional dimensions : +/- 6mm 2) Departure from alignment : +/- 6mm per 6m 3) Finished surface level of deck slab : +/- 3 mm
Verticality of Caisson Walls are surveyed;
Every each caisson R R A
3Post-SilaneApplication
Concrete Testing
Area of coring to be marked by SO Rep. to be tested for depth of penetration The test core shall be assigned an identification number
1 EA / 500 mm2 of concrete surface applied with Silane
R R A R
4Marking of
Caisson LabelClear and legible markings
Every each caisson R R A
[R : Responsible, A : Approval]
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
THANK YOU !
CONSTRUCTION PLAN FOR CAISSON FABRICATION Tuas Terminal Phase 1 Reclamation, Wharf Construction and Dredging
DIAP DAELIMJoint Venture
Tuas TerminalConstructorsRectification Works
CAISSON FABRICATION
Damage Cases Rectification Works
Re-cast Concrete Structure
Erect temporary propsHacking with pneumatic toolsBonding agent material coating at the edge of existing concreteErect formworks Casting (G40 concrete with waterproofing admixture)
Concrete Repair- Formwork Grouting
Cut and hack around at demarcated honeycomb area Erect formworks Install inlet and outlet (25mmØ UPVC pipe , 600mm c/c)Grouting (Sika Grout 215)
Concrete Hand Patch Repair (for area < 0.5m2 at depth < 20mm)
Cut around demarcated honeycomb area Apply one coat of bonding agent (Sika Monotop – 610MY)Casting the cement mortar (Sika Monotop – R)
Crack Repair (for width < 0.05mm)
Clean the cracksSeal the surfaces (epoxy or polyester or other proper material)If Extremely high injection pressures V cut depth of 13 mm and width of 20 mmInstall the entry and venting portsEpoxy injection
Repair of Damage with exposed Steel Reinforcement
With a jack hammer, cut out 2 cm deep in 90 angle the perimeter of breakingClean the surfaceMixing : Non-shrink mortar (or micro concrete), fiber reinforced and polymer modified powderInfill the mixing material and curing
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
Measures for Temperature Control (Minimizing Heat of Hydration)
Preliminary Analysis & Mock-up Test and Plan of Temperature Monitoring
Temperature Control on Base Slab
CAISSON FABRICATION
PBFC (Low Heat Cement)will be used
Optimizing Content of Cementat Mix Design
Precooling Aggregateusing Shelter
Type of CementComposition of Cement
Relevant StandardOPC GGBS
PBFCfor Base Slab
30% 70% BS EN 146
Specification of
Concrete
W/C(%)
S/a(%)
Unit Weight (kg/m3)
WC (PBFC)
S G AD1 AD2OPC GGBS
G50 PBFC S3 36.0 46.1 155 129 301 812 950 0.96 5.29
Analysis ofHeat of Hydration
Mock-up Test forTemperature Monitoring
Plan ofTemperature Monitoring
100
400
400
100 Thermocouple
100
275
275
100
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
Further Measures for Temperature Control
This method is to adopted if original measures can not satisfy the requirement:
Temperature Control on Base Slab
CAISSON FABRICATION
Spraying Water on the Aggregate(only for Granite) Change the Placing Time
Change the Componentof PBFC
Cooling the Mixing Waterwith ICE
DIAP DAELIMJoint Venture
Tuas TerminalConstructors
Specifications
This method statement is prepared according to the following specifications:
Codes and standards (BSI – DIN – ICE – ISO …)
Criteria
CAISSON FABRICATION
Document Number Document Title
30/06.C18 PART BTECHNICAL SPECIFICATION
Chapter 8. CAISSON CONSTRUCTION TO ENGINEER'S DESIGN
30/06.C18 PART BTECHNICAL SPECIFICATION
Chapter 9. STRUCTURAL WORKS
Singapore Standard (SS)
SS EN 1992-1-1:2004 Eurocode 2
Design of concrete structures
British Standard(BSI)
BS 4449 Steel for the reinforcement of concrete.