Date: 28/8/2010 MS Number: 1000-211-V8-0000-01003 Revision No.

001

TABLE OF CONTENTS
1. TITLE

2. SCOPE OF WORK

2.1 General Description

2.2 Plant & Equipment
2.3 Materials
2.4 Site Planning & Preparation
2.5 Work Methodology
2.6 Organization, Responsibilities & Supervision
2.7 Work Force

3. HEALTH & SAFETY

3.1 Risk Assessment

3.2 ADPC Requirements
3.3 Protective & Safety Equipment
3.4 Contractual Requirements
3.5 Information to Personnel
3.6 Emergency Procedures
3.7 Permit Requirements

4. ENVIRONMENTAL ISSUES

4.1 Environmental Impact Assessment

4.2 ADPC Requirements
4.3 Contractual Requirements
4.4 Emergency Procedures
4.5 Preliminary Hazard Analysis

5. QUALITY ASSURANCE

5.1 Contractual Requirements

5.2 Critical Works
5.3 Follow up & Evaluation

6. APPENDICES

7. BRIEFING SHEET

8. REVIEW CHECKLIST

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1. TITLE: METHOD STATEMENT OF TRIAL MIX AT LABORATORY

AND BATCH PLANT

2. SCOPE OF WORK

2.1 General Description

This Work Method covers the process that needs to follow in order to make laboratory
trial mix and batch plant full scale trial mix for concrete of various grades. All mix
designs attached with method statement.

2.2 Plant & Equipment

1) Laboratory instruments for testing

Sr No Equipments Nos

1 Laboratory concrete mixer (40 liter) 1 no

2 Digital Weigh Balance (Max. 30kg) 1 no
3 Slump Cone with tamping rod and base plate 1 set
4 Digital Thermometer (-40 to 70 ) 1 no
5 Fresh Concrete density Mould 1 no
6 Air content test apparatus 1 set
7 Sieves (for aggregates) 1 set
8 Scoop 2 nos
9 Cube Moulds 30 nos
10 Cube Tamping Rod 2 nos
11 Cube Vibrating Table 1 no
12 Steel Rule 1 no
13 Compression Test Machine (Max. 2000kN) 1 no
14 Oven (Max. 200 ) 1 no

The equipment and instrument which requires calibration shall be calibrated periodically
and calibration certificates will be submitted before trial mix.

2) Batch Plant (Existing)

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The details of existing batch plant are listed below, and the status is as shown on
Figure no. 1 and Figure no. 2. The capacity of existing batch plant is 2 nos of 120m3/hr
mixing capacity, which is expected to be enough to cover the anticipated maximum
concrete production of the Project (2,500m3/day).

Batching Plant and other equipments

Sr No Equipments On Site
1 Batching Plant 120cum/hr 2 nos
2 Silo 150 ton 6 nos
3 Silo 50 ton 1 nos
4 Radial Conveyor 2 Set
5 Air Compressor 3 Sets
6 Water Chiller Plant 1 Set
7 Ice Plant 1 Set
8 Transit Mixers ( 9 m3) 15 nos
9 Wheel Loader (2.3 m3) 2 nos
10 Generators 4 nos
11 Main Water Tank 1 no
12 Chilled Water Tank 1 no
13 Hydrostatic Water Pumps 4 nos
14 Laboratory set up 1 set
15 Work shop set up 1 set
16 Aggregate storage bins with shade 1 set
17 Weighing Bridge 150t capacity 1 no
18 Washing area 1 Set

All the weighing system shall be calibrated periodically. Presently valid calibration
certificates for those in site attached in Appendix C. The batch plant shall have an
automatic system that records the amount of each constituent material in each batch.

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< Figure no.1 Existing Batch Plant>

<Figure no.2 Operation of Existing Batch Plant>

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The Arrangement of existing Batching Plant is shown in Figure No.3.

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2.3 Materials
1) Cement (OPC) :
National Cement Factory
Ras Al Khaimah Cement Company
Cemex Falcon LLC

2) GGBS:
Sharjah Cement Factory
Cemex Falcon LLC
National Cement Factory.

3) SILICA FUMES :
Fesil - Norway
Silicacrete Microsilica - China

4) Coarse Aggregate (10-20mm) :

Al Ahmedia (Source)
Al Barrak (Source)
Empire Crusher

5) Coarse Aggregate (5 - 10mm) :

Al Ahmedia (Source)
Al Barrak (Source)
Empire Crusher

6) Fine Aggregate (0 – 5 mm) :

Al Barrak (Source)
Empire Crusher

7) Fine Aggregate (Dune sand) :

Al Ain (Source)

8) Admixture:
Grace Construction Products
Corrotec Chemicals

9) Water:
ADEWA / Potable Water

2.4 Site Planning and Preparation

To confirm the initial design mix submitted laboratory trial mix shall be planned as per
specification Section 03 30 00, 32 13 13 and 31 62 50. Meanwhile, after get 7 days

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and 28 days strength results of laboratory trial, batch plant trial mix shall be done under
the full-scale production conditions using representative samples of cement and
agregates.

2.5 Work Methodology

1) Laboratory trial mix

All the materials to be used for laboratory test shall be taken from the daily delivery. And
stack it inside laboratory. The aggregates shall be fully saturated and shall have surface
moistures.

Trail mix calculations shall be prepared according to the contract specification.

Moisture content of all coarse aggregate and fine aggregate shall be determined
before weighing aggregate for trial mix.

Moisture content and water absorption shall be applied to mix design aggregate
weights and necessary water adjustment shall be done.

Appropriate quantities of cement, GGBS, coarse aggregates, fine aggregate, water

and admixture shall be weigh on digital balance accurately.

Laboratory mixer shall be made wet from inside with water and cement.

All water and cement shall be drain out before feeding actual trial mix ingredients.

Coarse and fine aggregate shall be taken in to the mixer drum. Subsequently 75 % of
gauged water shall be added and mixed for 30 – 60 seconds.

Add cement and GGBS and balance 25% water with gauged admixture quantity and
mix till get homogenous mix is obtained.

Admixture dosage shall be adjusted till get the required workability.

After mixing for each grade of concrete, the concrete shall be discharged to concrete
sample pan to check workability and air content, temperature accordingly. Testing
method shall be applied as below;

Fresh concrete shall be subjected to following tests

Workability (Slump test) for 0, 15, 30, 45 & 60 minutes
Flow test wherever required
Fresh & hardened concrete density
Air content of concrete
Setting time of concrete
Concrete temperature

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Concrete cubes shall be casted and subjected for following tests

2 for 1 day compressive strength test

2 for 3 day compressive strength test
2 for 7 day compressive strength test
2 for 28 day compressive strength test
15 for durability test specified in section 03 3000 clause 1.10.1(g)

2) B/P trial mix

After confirming the characteristics of mix design for laboratory test, batch plant trial
shall be conducted under full-scale production conditions using representative samples
of cement and aggregates.

Three separate batches shall be produced each on a separate day. Testing method
shall be applied as below

Slump test for 0, 15, 30, 45 & 60 minutes

Flow test wherever required
Fresh concrete density
Air content of concrete
Concrete temperature

Concrete cubes shall be casted and subjected for following tests

2 for 3 day compressive strength test

2 for 7 day compressive strength test
2 for 28 day compressive strength test
2 for 56 day compressive strength test
15 for durability test specified in section 03 3000 clause 1.10.1(g)

FOR REINFORCED CONCRETE

2 for 3 day compressive strength test

2 for 7 day compressive strength test
2 for 28 day compressive strength test
2 for 56 day compressive strength test
3 for water penetration test (BS EN 12390 Part 8 at 28 days)
3 for Water Absorption test (BS1881 Part 122)
3 for Initial Surface Absorption test (BS 1881 Part 208)
3 for Rapid Chloride Permeability test (AASHTO T 277)
3 for Porosity test (RILEM CPC 11.3)

FOR UNREINFORCED CONCRETE

2 for 3 day compressive strength test

2 for 7 day compressive strength test
2 for 28 day compressive strength test
2 for 56 day compressive strength test

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2.6 Organization, Responsibility & Supervision

All the preparation of material and test shall be planned by plant QC Engineer and
conducted under supervision of QC supervisor.

The batch plant operator and supervisor should have sufficient experience in the
mixing of double blended mixes including GGBS.

2.7 Workforce

Refer to above Batch Plant Organization Chart.

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3. HEALTH & SAFETY

3.1 Risk Assessment

See Appendix A, Risk Assessments for trial mix at laboratory and batch plant

3.2 ADPC Requirements

The following sections of the KIZP contractor Health and Safety Requirements (Exhibit
B, Attachment 10, of the contract) are applicable to the concrete works (trial mix).

3.3 Protective & Safety Equipment

The following Protective and Safety Equipment are applicable for concrete works. All
concrete production and delivery personnel will be handed out these items during their site
induction. The Protective & Safety Equipment has to be according the specification and
requirements in the contract.

- Helmets
- Safety glasses
- Safety shoes
- Safety Masks
- Work gloves
- High visibility vests
- Ear Plugs

3.4 Contractual Requirements

Health Requirements (Exhibit B, Attachment 10, of the Contract), the works described in
this Method Statement must be executed in compliance with the Health & Safety
Requirements. In addition, the works described in this method statement must be executed
in full compliance with;

- All rules and regulations as outlined in the HEC Health and Safety Plan are
applicable to the concrete works, refer to Project Health and Safety Plan,
1000-211-V8-0000-00017.

3.5 Information to Personnel

Pre Task Briefings

Every work day will start of with a pre task meeting. The health and safety aspects of the
works of the coming day will be discussed. Any health and safety issues which have

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occurred on site, or need special attention will be discussed and evaluated. A log of
attending personnel will be kept and will be made available to the client.

3.6 Emergency Procedures

In case of Emergency situation, the contractor should follow Emergency Evacuation

Procedure as shown in Appendix – B.

3.7 Permit Requirements

Not applicable.

4. ENVIRONMENTAL ISSUES

4.1 Environmental Risk Assessment

See Appendix A, Environmental Assessments for trial mix at laboratory and batch plant

4.2 ADPC Requirements

The following sections of the HSE Plan and Construction Environmental Management
Plan are applicable to the Concrete Works described in this Method Statement;

CEMP Environmental Control to be followed in accordance to contract requirements,

Exhibit “B”, Attachment 11.

4.3 Contractual Requirements

In accordance with Particular Conditions – Environmental, Safety and Health

Requirements (Exhibit B, Attachment 11, of the Contract), the works described in the
Method Statement must be executed in compliance with the Environmental Requirements.
In addition, the works described in this Method Statement must be executed in full
compliance with:

- Construction Environmental Control Plan

The works shall be performed in an environmentally sound manner and in compliance with
Applicable Law, Applicable Codes and Standards and all provisions of the Contract
regarding the environment, including HDEC’s HSE procedures.

All non-hazardous and hazardous waste generated during the execution of the works, will
be collected in destined location, until they can discharged. The waste will be collected,

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transported and disposed of by EAD approved Environmental Service Providers. The

following waste products have a significant chance of being generated during the concrete
works:

- Household waste (which will be separated into paper, plastic, glass, metal
and other waste)
- Sewage
- Used oil

4.4 Emergency Procedures

In case of environmental emergency, the contractor should follow the Emergency

Procedure.

4.5 Preliminary Hazard Analysis (PHA)- Refer to Appendix A

5. QUALITY ASSURANCE

Type Submitted (Y/N) Doc Reference

Inspection & Test Plan To be submitted 1000-211-V8-0000-02002
Issue for Construction Yes 1000-211-V8-0000-01003
Specification Yes Section 03 30 00
Material Submittal To be submitted To be advised
Drawings No N/A
Other

5.1 Contractual Requirements

The following Contract specification and drawings are applicable to the quality
assurance of the concrete works:

- Exhibit ”D” – section 03 30 00: Cast-in-Placed Concrete Materials and

Methods
- Exhibit “B” – Particular Conditions, Attachment 8 , 9, 10 and 11
- Exhibit “D” – Part 1, Appendix-B

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5.2 Critical Works

The most important concrete work will be the operating of batching plant and compression
test equipment.

5.3 Follow up & Evaluation

Concrete shall be assumed to have achieved its characteristic strength at 28 days;

1) Preliminary target mean strength shall be achieved greater than the specified
minimum cube strength.
2) The total chloride content arising from all ingredients in a mix including cement,
water and admixtures shall not exceed 0.1% chloride ion as a percentage of the
mass of cement in the mix.
3) The total sulphate content expressed as SO3 of all the ingredients in a mix
including cement, water and admixtures shall not exceed 3.7 % of the mass of
cement in the mix.
4) The average strength of the nine cubes from the three separate B/P trial mixes at
28days is not less than 3.5N/mm2 below the target mean strength.
5) The range of the strength of the three cube results in any one batch should not
exceed 15% of the average of that batch. If exceed, the trial mixes shall be
repeated.

6 APPENDICES

- Appendix A : Risk Assessments and Environmental Risk Assessment for

Trial mix at Laboratory and Batch Plant
: Preliminary Hazard Analysis

- Appendix B : Emergency Procedures

- Appendix C : Calibration certificate for Laboratory Instrument

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Appendix A : Risk Assessments and Environmental Risk Assessment for

Trial mix at Laboratory and Batch Plant

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Appendix B : Emergency Procedures

EMERGENCY EVACUATION
PROCEDURE
(SERIOUS ACCIDENTS)

Supervisor at WORKING LOCATION should call

SAFETY COORDINATOR to report the accident and for
assistance.

SAFETY COORDINATOR calls for an AMBULANCE

999 informing the LOCATION where to pick up the
VICTIM.

FIRST AID to be immediately applied to the VICTIM by a

MEDICALLY knowledgeable PERSON who is nearest
the ACCIDENT SITE.

TRANSPORT to proceed straight to Pick up point where

an AMBULANCE / 24 Hour BUS will be waiting.

All incidents must be reported to ADPC through HSE

Manager by Fax.
Major/fatal incidents must be reported by phone first.
Tel: 050-220-4830
Contact Safety Coordinator Tel:050-617-2256

The VICTIM should be transported immediately to AL

RABHA HOSPITAL (Abu Dhabi) for MEDICAL
TREATMENT

For NON-SERIOUS CASES, the assigned PICK-UP is

always on STANBY to transport the sick to AL RABHA
HOSPITAL for treatment.

Y. C. Ha Project Manager 050-614-1003

Oswald Mallillin HSE Manager 050-144-4685
TBA Safety Coordinator TBA
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Appendix C : Calibration certificate for Laboratory Instruments

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7 BREIFING SHEET

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8 REVIEW CHECKLIST

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