BRAUNS EGYPT

In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

Construction of Lekela Substation 220 KV

Method Statement
For
Concrete Works Rev (01)

July 2020

Page 1 of 12
BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

INDEX
1. INTRODUCTION 4
1.1 SCOPE OF WORK 4
2. CREW & EQUIPMENT 4
2.1 PERSONNEL 4
2.2 EQUIPMENTS 4
SAFETY REGULATION 4
2.3.1 Personal Protective Equipments (PPE) 4
2.3.2 House Keeping 4
2.3.3 Equipment Control 4
2.3.4 Fire Control 4
2.3.5 Traffic Control 4
2.3.6 Falling From Heights Control 5
3. DEFINITION OF PROCESS 5
3.1 Generals 5
3.2 Materials 5
3.3 Batching and Mixing 5
3.4 Form Works 6
3.4.1 Generals 6
3.4.2 Form Tiles 6
3.4.3 Cleaning and Oiling Forms 6
3.4.4 Removal of Forms 6
3.4.5 Form Finishes 7
3.5 Steel Reinforcement 7
3.5.1 General 7
3.5.2 Materials 7
3.5.3 Delivery and Storage 8
3.5.4 Fabrication 8
3.5.5 Installation 8

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BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

3.6 Cast In Place Concrete 9

3.6.1 Preparation for Placing 9
3.6.2 Placing of Concrete 9
3.5.3 Compaction 10
3.5.4 Curing 10
3.6.5 Joints 11
3.6.6 Finishes 11
3.6.7 Tolerances 12
3.6.8 Repair of Defects 12
APPENDIX A ORGANIZATION CHART

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BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

1. INTRODUCTION
1.1 Scope of Work

• The method statement is prepared for concrete work for "Construction of Lekela

Substation 220 KV" with reference to following drawings

2. CREW & EQUIPMENTS

2.1 Personnel
• See Attached organization chart. (Appendix A)
2.2 Equipments
• Truck Mixers
• Concrete Pump
• Concrete Vibrators
• Steel Reinforcement Cutting Machine.
• Steel Reinforcement Bending Machine.
• Survey Equipment
• Concrete Finishing Helicopter

2.3 Safety Regulations

2.3.1 Personal Protective Equipments (PPE)
• PPE to be worn (Safety glasses, gloves, safety footwear and helmet and Harness).
2.3.2 House Keeping

• Wooden forms, Reinforced steel and all equipment should be arranged into groups
at appropriate place to gain safe and clean work place.
2.3.3 Equipment Control

• All equipment to be in good condition and inspected by safety supervisor.

• Every Equipment has its portable ABS Fire Extinguisher.
2.3.4 Traffic Control

• Access to be considered for truck and crane I equipments entry, Maximum speed for
vehicles is 20km/hr.

Page 4 of 12
BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

2.3.5 Falling from Heights Control

• Warning signs and caution tapes to be placed around area.

• Ground leveling before scaffold erection.
• All work platforms for foundation level shall be secured with handrails
• Life line shall be used where is necessary.
• For working at height safety harness shall be used all the time and all working scaffolds
and catwalks will be secured with kick plate and mid rails.

3. DEFINITION O F PROCESS

3.1 General

This method statement covers the performance of all concrete work for the permanent structures in
accordance with the drawings and contract specification including but not limited to the supply of
concrete materials, the supply erection and removal of formwork, the supply fabrication and erection
of steel reinforcement, mix design, sampling and testing, batching, placing and compaction of plastic
concrete and curing and protection of the in-situ concrete.

3.2 Materials
• All materials will be selected as per the contract and it will be tested according to the test
plan approved by the owner.
• The contractor will design the mix for the used class of concrete through the independent
laboratory approved by the owner.
• The contractor could start using the design mix after getting the owner approval.

• All the tests for concrete will be performed as per the test plan approved by the owner.

3.3 BATCHING AND MIXING

• Ready mixed concrete will be in accordance with the ACI, and any concrete batched off
the site may be used only with written agreement of the owner.
• Mixing shall continue for the number and at the rate of revolution recommended in
the manufactures or in the absence of the manufacture's instruction.
• No ready mixed concrete will be delivered to the site without the owner's approval.

Page 5 of 12
BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

3.4 Form Work

3.4.1 General
• The contractor will design, supply, erect and remove all formwork and false work
including all materials, equipment and labor necessary to form the cast in place
concrete structures and surfaces specified here in and on the drawings. Form
work will be designed in accordance with ACI 347.
• Form work will be strong enough to withstand without distortion all
pressures resulting from placing and vibration of the concrete and will be
rigidly and accurately fixed in position.

• Form work will be securely fastened to prevent loss of mortar and surfaces in contact
with concrete will be uniformly smooth and true with no local defects.

• Provision will be made for all required openings, offsets, recesses and embedded parts
and all exposed concrete edges or corners will have 25mmx25mm chamfers.
3.4.2 Form Tiles
• Form ties will not leave irregular holes or lead to repair marks that would
detract from the specified finishes.
• After removal of the forms embedded form ties will be cut not less than 3cm below
the formed face of the concrete except where finish class F1 is permitted in which
case form ties may be cut at the formed face.

3.4.3 CLEANING AND OILING FORMS

• When the concrete is placed in the forms the inside surfaces of the forms will be free
from incrustations of mortar or other foreign materials.
• Before placing the formwork surfaces will be oiled with a formwork oil of a proprietary
brand approved by the owner
• Oiling of forms will not produce chemical deterioration or stains on the concrete
surfaces.
• Marking of excavation borders with adequate offset, excavate the whole area to the
levels mentioned in the approved drawings.
3.4.4 REMOVAL OF FORMS
• Formwork will not be disturbed until the concrete has hardened adequately.
• The minimum time prior to removal of formwork will be as specified in ACl347
or as directed by the owner on the basis of site records and test results.
• The contractor will give advance notice of intention to remove formwork and obtain
the approval of the owner before proceeding.

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BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

3.4.5 FORMED FINISHES

• Materials and methods for formwork will be capable of achieving the following finishes
to formed surfaces:

Class of Finish Maximum Local Tolerances ( mm )

Abrupt Gradual
F1 -6, +6 -12, +12
F2 None -6, +6

• Finish F1 is a basic rough finish will be used for hidden buried surfaces or plastered
surfaces and will apply to formed surfaces for which no other finish is specified.
• Finish F2 shall be used for surfaces stated in the contract as fair face will
impart a dense even surface to the concrete with a regular pattern of horizontal and
vertical joints not less than 600mm a part unless otherwise specified or directed.

3.4.6 SCAFFOLDING OF SLABS AND BEAMS

• Cup lock scaffolding system will be used to install scaffolding and shuttering for slabs
and beams in interval suitable for working loads.

3.5 Steel Reinforcement

3.5.1 General
• This specifies requirements for the supply fabrication and installation of steel bar
reinforcement for cast in place concrete including all materials and measures
necessary to complete the reinforcement as shown on the drawings and specified
herein.
3.5.2 Material

• Bar reinforcement will conform to the relevant ASTM A615, Grade 60 or equivalent
• Wire fabric reinforcement will be in accordance with the requirement of ASTM A 185
or equivalent
• Bar supports, chairs and spacers will be selected by the contractor to maintain
specified concrete cover and avoid corrosion, subject to the owner’s approval.

Page 7 of 12
BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

3.5.3 DELIVERY AND STORAGE

• Reinforcement bars will be delivered to the site properly colour coded or tagged
according to size and length. When tagged, means will be provided to maintain
identification after bundles are broken.
• Reinforcement bars will be stored clear of the ground and segregated by size, length
and type.

3.5.4 Fabrication

• Prior to fabrication of steel reinforcement, the contractor will submit detailed

construction drawings and bar bending schedules, prepared in accordance
with the ACI manual of standard practice for detailing concrete structures for
the approval of the owner.
• All fabrication will be in strict accordance with the approval drawings
and bending schedules and will meet the following fabrication tolerances:

Sheared Length ± 25 𝑚𝑚
Depth of Truss bars − 12 𝑚𝑚
Stirrups, Ties and spirals ± 12 𝑚𝑚
Location of all other bends ± 12 𝑚𝑚

3.5.5 Installation
• Prior to installation all mild steel should be straight, therefore: -
1. Cast Footing or pedestal dimension (0.6m x 0.6m) with fixed angel in the
centre (profile 70 x 70 x 7mm)
2. Straightness the mild steel on the ground in lines.
3. Fix the mild steel in the angle that fixed in the pedestal.
4. Fix the other end of the line in the loader and start pulling until the line be
straight.
• Prior to installation all loose mill scale, rust, oil, paint and any other coating which
would destroy or reduce bond between steel and concrete will be removed.

• All steel reinforcement will be installed positively secured and supported in strict
accordance with the approval drawings and bending schedules. Placing tolerances
for reinforcement shall be in accordance with ACI 377.

Page 8 of 12
BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

• On completion of installation of steel reinforcement, the contractor will notify the

owner that it is ready for inspection. No reinforcement will be covered up without
the prior approval of the owner.
3.6 Cast in Place Concrete

3.6.1 PREPARATIONFOR PLACING

• All water, wood scraps and other debris will be removed from areas where
concrete is to be placed and the areas thoroughly cleaned to ensure proper
placement and bonding of the concrete.
• Forms will be oiled and sub-grades damp but not wet, when concrete is placed.

• When fresh concrete is to be placed on set concrete, a 1.0cm thick layer of

mortar will be applied by brush on the dry surface before the fresh concrete
is placed.
• The mortar shall contain the same proportions of sand and cement as
the concrete mix.
• At construction joints the concrete surface will be roughened by air-water
jet, after it has reached its final set but not more than 12 hours after its
placing was complete so as to expose the aggregate.
• All equipment an d materials required for the proper placing, vibrating,
finishing and curing of the concrete will be at hand prior to the placing of
concrete.
• The contractor will notify the owner when all preparation a s specified
above have been completed and are ready for inspection. No concrete will
be placed without the prior approval of the owner.
3.6.2 PLACING OF CONCRETE
• Concrete shall be deposited as nearly as possible to its final position and will be placed
in layers not more than 30cm thick. Concrete will be placed at such a rate that it is at all
times plastic and will flow readily around reinforcement and embedded parts.
• Once placing is started it will be continuous operation until the lift
is completed.
• The area of placement will not be more than that which can be completed in one pour
in compliance with this specification.
• The time between placing of successive layers forming a lift will be short enough to
permit a vibrator to penetrate.
• The lower layer while the upper layer is being compacted. The minimum time
between completion of a lift and the commencement of placing of a succeeding lift
shall be 72hours.

Page 9 of 12
BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

• Pneumatic placing and pumping of concrete may only be used with the approval of
the owner. In such a case discharge lines will be horizontal or inclined upwards. The
discharge end will not be more than 3m from the point of placement and shall supply
a continuous stream of concrete without air pockets. Aluminium piping will not be
used.
• During hot weather special precautions as directed or approved by the owner will be
taken to ensure that the temperature of concrete when it is placed does not exceed
30 degrees centigrade.
3.6.3 COMPACTION
• Concrete will be compacted by mechanical vibrators electrically or pneumatically
driven.
• Immersion vibrators will operate when fully immersed at speeds of not less than 7000
impulses per minute for vibrating heads of less than 1 cm diameter and 6000impulses
per minute for heads 10cm or greater in diameter. They will be slowly immersed and
withdrawn vertically at spacing of 30cm to 50cm with vibration periods of 10 to 15
seconds for each penetration and will penetrate into the layer below.
• Vibrators will not come into contact with reinforcement or embedded parts.
3.6.4 CURING
• Concrete surfaces shall be kept continuously moist for at least 14 days after placing
and until the concrete temperature produced by heat of hydration of the cement
has peaked and fallen at least 1 Centigrade.
• Initial curing of exposed surfaces shall be performed by atomized water spray
positioned so that all surfaces to be cured are constantly moist or by a continuous
layer of burlap kept constantly wet.
• Hand sprinkling shall not be used except in conjunction with the burlap alternative.
• Forms capable of moisture loss such as plywood forms will be regularly sprinkled with
water to avoid loss of moisture from formed surfaces of the concrete.
• A curing compound complying with ASTM C309 may be used after getting the owner
approval and will be applied in strict accordance with the manufacturer's
recommendations.

Page 10 of 12
BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

3.6.5 JOINTS
• Where shown on the drawings or directed by the owner, construction joints shall be
provided and preparation for these shall be in accordance with the section 5.2.3.5.12
of the contract.
• Where the contractor proposes additional construction joints he will first submit
drawings and obtain the approval of the owner.
• Expansion joints will be constructed only at the locations and in accordance with the
details shown on the drawings and approved by the owner.
• Expansion joints in slabs and beams shall be fitted with metal angles at all corners.
3.6.6 FINISHES
• Finishes for formed surfaces shall be class F1 or F2 as specified in the item
3.4.5 where abrupt irregularities mean offsets or fins caused by displaced forms and
gradual irregularities shall be deviations from a plane surface measured with a
template 1.5m long.
• Finishes for unformed surfaces will be class U1 or U3 for which irregularities shall be
defined as above except that gradual irregularities shall be measured with a template
3.0m long.
• Finish U1 will be achieved by screeding concrete surfaces to the required slopes and
grades and removing gradual irregularities exceeding ±1 mm
• Finish U3 will be achieved by screeding, mechanical, floating and trowelling concrete
surfaces to the required slopes and grades removing gradual irregularities exceeding
±6mm and finishing edges and joints with edging tools.
• Where shown on the drawings or directed by the owner special architectural concrete
finishes shall be provided as specified in Architectural Work, Technical Specifications of
this document.

Page 11 of 12
BRAUNS EGYPT
In front of 34 saint gieni St. Roushdy

Tel No. 002- 035446231 & 0105339344

Fax No. 002- 035232570

E mail :brauns@braunsegypt.com

3.6.7 TOLERANCES
• The lines and levels for concrete structures will be achieved to within the following
tolerances:

Criterion Height or Lenght Maximum Tolerance (cm)

Up to 3m 0.5
3m to 6m 1.0
1- Vertical
6m to 15m 2.0
15m to 22m 2.5
Up to 3m 0.5
2- Elevation 3m to 6m 1.0
6m to 15m 2.0
6m 1.0
3- Lines in Plan
15m 2.5
4- Thickness All 0.5

• Any concrete structure which does not comply with the above tolerances will
be repaired as specified or removed and reconstructed if so directed by the owner.
3.6.8 REPAIR OF DEFECTS
• The contractor will submit proposals for the repair of defects the extent of which will
be clearly marked on the concrete surface, in accordance with the USSR Concrete
Manual.
• All materials and procedures will be subject to approval by the owner on a step by step
basis.
• Honeycombed areas will be cut back to sound concrete and where necessary the depth
of cutting will be increased but will not result in partial exposure of reinforcement.
• Edges of repaired areas will be undercut and all friable materials removed using a sharp
chipping tool.
• Wherever possible repairs will be carried out while the concrete is still green and curing
will be interrupted for the shortest time and smallest area practicable. Materials and
procedures specified or directed for repairs may include use of proprietary non shrink
grout; epoxy or latex based bonding agents, epoxy compounds and cementious grout,
mortar and concrete.

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