Project: Plaridel Bypass Project, Phase I Date: Doc. No.

Bulacan, Province Mar. 11, 2011 MS-001

Method Statement
Bridge Deck Precast Construction By: wuo Rev. Nos.: 0

1. General

This Document is the Proposed Construction Method by BBR Philippines Corporation for the
Construction of Stay-In-Place Precast Plank Composite Deck of Bridge.

It is to be submitted to the Engineer for approval.

This Document may not be reproduced or copied without the written permission of BBR
Philippines Corporation.

Precast, stay-in-place (SIP) deck panels are precisely-designed and fabricated precast concrete
slabs spanning between beams. They serve as a form for the cast-in-place (CIP) deck concrete
and provide the principal positive moment reinforcement in the composite deck. That is, the
steel reinforcement in the panel is designed to resist the self-weight of the panel and the weight
of the field-placed concrete topping as a non-composite section. Then, after the field-placed
concrete topping cures, the SIP panel becomes an integral part of the composite deck that
resists all subsequent dead and live loads applied to the deck.

2. Materials Specifications

2.1 Reinforcing Steel

Reinforcing Steel Grade

Grade 60 for Reinforcing Bars ≥ 16mm diameter

Grade 40 for Reinforcing Bars ≤ 12mm diameter

2.2 Concrete Strength

Minimum Design Concrete Cylinder Strength @ Stripping shall be f'c = 18MPa.

Minimum Design Concrete Cylinder Strength @ 28 days shall be f'c = 28MPa.

BBR Construction Systems

Page 1
 Project: Plaridel Bypass Project, Phase I Date: Doc. No.
Bulacan, Province Mar. 11, 2011 MS-001

Method Statement
Bridge Deck Precast Construction By: wuo Rev. Nos.: 0

3. BBR’s Organizational Chart

BBR HOLDING, LTD.

HEAD OFFICE Zug, Switzerland

BBR HOLDINGS, LTD.

REGIONAL OFFICE Singapore

Rey Constantino D. Singh

General Manager
Contact No. 0917-535-6824

MANILA
OFFICE
Loida M. Arce BBR Philippines Corp
Technical Manager Tel. Nos. (02) 746-7237
(02) 638-7261
Fax No. (632) 638-7260
MmmmMMMMmp&Jack1

Martin L. Furigay
Project-In-Charge

Foreman

Leadmen
BBR Construction Systems

Page 2
 Project: Plaridel Bypass Project, Phase I Date: Doc. No.
Bulacan, Province Mar. 11, 2011 MS-001

Method Statement
Bridge Deck Precast Construction By: wuo Rev. Nos.: 0

Work Force

4. Construction Sequence

The Construction Sequence shall generally follow the various steps shown on the following
chart.

PRECAST CONSTRUCTION

Cutting and Preparation of

Bending of Reinf. Casting Bed
Steel Bars & Rebar & Steel Forms
Assembly

Installation of
Assembled Rebars to
Casting Bed

Fixing of Rebar, Lifting

Hook, Dowel Bars,
Spacer and Side forms

Pouring of Concrete
Inspection of
Installed Rebars and other
Concrete Curing Precast Plank Stripping
Miscellaneous Items Stocking of PC Planks

BBR Construction Systems

Page 3
 Project: Plaridel Bypass Project, Phase I Date: Doc. No.
Bulacan, Province Mar. 11, 2011 MS-001

Method Statement
Bridge Deck Precast Construction By: wuo Rev. Nos.: 0

PRECAST DECKING

Positioning and Sealing of Gaps

Setting of Precast between Precast
Plank on top of Panel
Beams

Installation of
Site-Placed
Reinforcement of
Deck Slab

Inspection of
Installed Rebars and other
Miscellaneous Items

Pouring of Concrete

Concrete Curing

5. CONSTRUCTION METHOD

A. Preparation of Casting Beds

B. Fabrication of Rebars
C. Fixing of Steel Reinforcement

BBR Construction Systems

Page 4
 Project: Plaridel Bypass Project, Phase I Date: Doc. No.
Bulacan, Province Mar. 11, 2011 MS-001

Method Statement
Bridge Deck Precast Construction By: wuo Rev. Nos.: 0

D. Form Works
E. Placing of Concrete
F. Curing of Concrete
G. Precast Plank Stripping
H. Stocking of Precast Plank
I. Erection of Precast Plank

A. PREPARATION OF CASTING BEDS

i) Where applicable the casting beds shall rest on a level, well compacted base.

ii) Prepare the casting beds in accordance to applicable lines and grades for the fabrication
of the Precast Plank Panel.

iii) The casting beds shall be formed appropriately prior to pouring of ready-mixed lean
concrete to a minimum thickness of 100mm.

iv) As the pouring proceeds, all embedment necessary in anchoring the fabricated steel
forms shall be placed accordingly.

v) The surface of the casting beds shall be finished as smooth as can be achieved to obtain
the required finish underneath.

B. FABRICATION OF REINFORCING STEEL BARS

i) A Reinforcing Steel Bar is prepared in accordance with the Approved Shop Drawings.
Cut and Bend using Bar Bending machine.

C. FIXING OF STEEL REINFORCEMENT

i) The Reinforcing Steel Bars shall be assembled as one unit to be transferred into the
Casting Bed in accordance to the approved drawings.

ii) Concrete Spacers shall be appropriately spaced and installed and checked after the
Reinforcing Steel Bar is finally rested to its final position on the Casting Bed.

BBR Construction Systems

Page 5
 Project: Plaridel Bypass Project, Phase I Date: Doc. No.
Bulacan, Province Mar. 11, 2011 MS-001

Method Statement
Bridge Deck Precast Construction By: wuo Rev. Nos.: 0

D. FORMWORKS

i) All Surfaces of the Steel Form that will make contact with the Concrete must be
applied with Form Oil.

ii) Fixing of Braces and Stays temporarily holding the Forms in correct position and
alignment.

E. PLACING OF CONCRETE

i) Discharge of Concrete shall not be from a great height.

ii) Proper compaction shall be applied and particular attention shall be paid of the
Concrete edges.

iii) The ready-mixed concrete shall be delivered at site with the maximum workability and
handling properties to meet the essential qualities of concrete required for pre-stressed
concrete girders. To obtain the best results for workability retention the use of
admixtures such as plasticizer is an acceptable option in concrete production.

iv) The Quality Assurance requirements for concreting works shall be observed. Sampling,
testing, frequency of testing and curing of cylinder samples shall be in accordance with
the accepted methods and specifications.

F. CURING OF CONCRETE

i) Curing for precast, concrete members shall begin as soon as practicable after concrete
placement to prevent moisture loss. The members will be enclosed with watered
Burlaps for at least three (3) days or as required to achieve the design strength of the
members.

G. PRECAST PLANK STRIPPING

i) Removable inserts, fastenings, and form parts shall be released and/or removed prior to
stripping. Care shall be exercised in removing the precast concrete unit from the form
to prevent damage. The minimum concrete strength, number and location of lifting
points for handling of units, and details of lifting devices shall be shown on the shop
drawings. Units shall only be stripped at points indicated on the approved shop
drawings or as approved by authorized personnel. Initial lifting from the form shall be
made cautiously

H. STOCKING OF PRECAST PLANK

BBR Construction Systems

Page 6
 Project: Plaridel Bypass Project, Phase I Date: Doc. No.
Bulacan, Province Mar. 11, 2011 MS-001

Method Statement
Bridge Deck Precast Construction By: wuo Rev. Nos.: 0

i) The storage area shall be laid out in a manner to help ensure delivery and storage of the
units without damage. Units shall be supported and stored on unyielding supports at the
designated blocking point locations. The supports shall be on a firm, level, and well-
drained surface. Unit identification marks shall be visible.

I. PRECAST ERECTION

i) Clear the site for truck and crane access ensuring room for crane outriggers,
counterweight tail swing, boom swing and under hook and overhead obstructions.

ii) Check that the means of temporary support, including false work is adequate for the
intended purpose and located correctly prior to the precast elements being placed.

iii) Using Chain Block carefully positioned all precast panel into proper location and
orientation. Make sure the bearing end of Precast panel had been established as
indicated in the plan.

BBR Construction Systems

Page 7