Project:

Al Arish Simple Cycle Power Plant

Project No.
10143
Contractor: Employer:

Document Title:
METHOD STATEMENT FOR
MASS CONCRETE
Document No.:
HAC-10143-MS-CIV-002
If, despite best endeavors, a conflict should arise between this method statement and the project specification
the requirements of the latter shall be observed and this document revised, accordingly.
Prepared Checked Approved
Rev. Issue Date
Constr. Manager HSE Quality Project Manager

00 March 2022
 Al Arish Simple Cycle Power Plant
Project No. 10143
HAC-10143-MS-CIV-002

Table of Contents
1.0 Scope: ............................................................................................................................................... 3
2.0 Purpose:............................................................................................................................................ 3
3.0 References: ...................................................................................................................................... 3
4.0 Responsibilities: ............................................................................................................................... 3
4.1. Project Manager:.......................................................................................................................... 3
4.2. Construction manager: ................................................................................................................ 3
4.3. Technical office Manager: ........................................................................................................... 3
4.4. Site Engineer: ............................................................................................................................... 3
4.5. QC Engineer:................................................................................................................................. 3
4.6. Laboratory Technician: ................................................................................................................ 4
4.7. Safety Officer: ............................................................................................................................... 4
4.8. Lifting Team:................................................................................................................................. 4
4.9. Supervisors, Foremen and Subcontractor(s): ............................................................................ 4
4.10. Fitters and welders: ................................................................................................................. 4
5.0 Methodology: .................................................................................................................................... 5
5.1. Execution of “Mass Concrete”..................................................................................................... 5
5.1.1. Scope. ................................................................................................................................... 5
5.1.2. Definition. ............................................................................................................................. 5
5.1.3. References. .......................................................................................................................... 5
5.1.4. Fresh concrete placement and temperature control. ....................................................... 5
5.1.5. Procedure of thermal curing ............................................................................................... 6
6.0 Finally ................................................................................................................................................ 6
7.0 Materials matrix ............................................................................................................................... 8
8.0 Tools / Equipment ........................................................................................................................... 8
9.0 Health, Safety and Environmental Requirements ......................................................................... 9
 Al Arish Simple Cycle Power Plant
Project No. 10143
HAC-10143-MS-CIV-002

1.0 Scope:
This method statement details the method and sequence for execution of mass concrete elements
as indicated in project specs No. 10143-9-3PS-C00Z-01 Rev. 1 – Civil work - Exhibit D - Technical
Specifications Clause No. 9.11 Reinforced Concrete Work.
2.0 Purpose:
Execution of mass concrete elements methodology.
3.0 References:
• Project Specification–10143-9-3PS-C00Z-01 Rev.1.
• Approved shop drawings.
• All related Standards.

4.0 Responsibilities:
4.1. Project Manager:
• Monitoring all project activities regarding to project schedule.

4.2. Construction manager:

• Assigning areas of responsibilities of site engineer.
• Expending areas of concern to best achieve project schedule.
• Coordinate with technical office manager to ensure timely availability and approval of
materials, method statement, and shop drawings.
• Liaison with technical office manager for advice required regarding changes, missing
information, clarification.

4.3. Technical office Manager:

• Technical and engineering issue management.
• Ensure that the site uses the latest shop drawing issue for construction.

4.4. Site Engineer:

• Assigning areas of responsibilities to supervisors, foreman and subcontractors.
• Continuous monitoring of all aspects of works progression, (surveying, safety barriers
installation, etc.) and overseeing the performance of casting in accordance with
prescribed method and products.
• Inspection of all aspects of the casting works.
• Liaising with QC Engineer regarding work progression and availability of hold point
inspections.

4.5. QC Engineer:
• Shall report to the QA/QC Manager.
• Ensuring that the project inspection test plan(s) (ITP) has been briefed to and is then
followed by the construction team.
• Hold point Inspection for cast-in-place concrete.
• Inspect all the material delivered to the site with approval inspection.
• Coordinate with the third-party laboratory for all test for fresh and hard concrete
samples.
 Al Arish Simple Cycle Power Plant
Project No. 10143
HAC-10143-MS-CIV-002

4.6. Laboratory Technician:

• Sampling of soil as applicable for the soil replacement before casting the blinding
concrete.
• Testing of the fresh concrete slump, temperature and workability.
• Monitoring the casting and take samples of concrete for testing.
• Testing hard cubes according to standers and reporting of results.

4.7. Safety Officer:

Shall be responsible to ensure that all site activities are carried out in full compliance with
the attached risk assessment, the HSE plan and current best safety practice.
Safety supervisor should be present full time at work location.
4.8. Lifting Team:
Undergone Lifting supervisor, crane operator and riggers safety course and possess valid
certificate. Co-ordinate all lifting activities and supervise all lifting operation by any lifting
equipment in accordance with the lifting procedure and brief all operators, riggers and
signalmen on the lifting procedure. Ensure that only registered crane operators, appointed
riggers and signal men participate in any lifting operation involving the use of any lifting
equipment. Ensure that the ground conditions are safe for any lifting operation to be
performed by any crane. Shall follow instruction to ensure that works are carried out
properlyand safely.
4.9. Supervisors, Foremen and Subcontractor(s):
Shall report to the Site Engineer, shall be responsible for the day-to-day planning and
supervise the works to ensure that these are carried out in full compliance with the
Method statement, the HSE plan and current best safety practice.
4.10. Fitters and welders:
Shall report to the Supervisor, to do fit up work under the supervision of
Foremen/Supervisor and edge preparation for pipes and fittings as per drawing
requirements. Maintaining welding requirements such as root gap as per WPS and
checking the welding requirements according to WPS, and follow accordingly.to do proper
grinding work without slag and under cuts and welding operation according to WPS.
 Al Arish Simple Cycle Power Plant
Project No. 10143
HAC-10143-MS-CIV-002

5.0 Methodology:
5.1. Execution of “Mass Concrete”.
5.1.1. Scope.
This section covers requirements for mass concrete as designated in Contract Documents.
As indicated in project specs clause 9.11. – Reinforced Concrete work
“The provisions of "Mass Concrete" shall be applied to the following structures:
• CTG Foundation.
• Stack Foundation.”
This for summarize thermal curing process employed for mass concrete.
5.1.2. Definition.
Mass concrete defined as “any volume of concrete with dimensions large enough to require that
measures be taken to cope with generation of heat from hydration of the cement and attendant
volume change to minimize cracking” This is as per ACI 301M-4
5.1.3. References.
• Project specification No. 99999-9-3PS-DP02-01
• American Concrete Institute
o (ACI-207) “Guide to Mass Concrete”
o (ACI-301M) “Specification for structural concrete”
o (ACI-305R) “Hot Weather Concreting”

5.1.4. Fresh concrete placement and temperature control.

• Placing temperatures when deposited at the point of placement shall not exceed 21° C.
as indicated in Exhibit D -Technical Specification 10143-9-3PS-C00Z-01 clause 9.11.1
• Concrete flow to be continuous to avoid the cold joint.
• Place concrete in layers not more than 450 mm thick. Extend vibrator heads into the
previously placed layer of concrete.
• Adequate curing to be conducted immediately after concrete placing finish to reduce
hydration temperature and to control variation of temperature between core and
surface and also between surface and ambient temperature.
• The concrete must be protected from high temperature, direct sunlight, low humidity
and drying winds.
• Concrete should also be protected against thermal shrinkage cracking from rapid
temperature drops at the exposed surface. This protection by providing thermal
protection so that it cools gradually at a rate that will not cause cracks.
• Curing and protection: Mass concrete is best cured with water, which provides
additional cooling benefit in warm weather.
o Preservation of moisture: Cure mass concrete for proper curing period till
achieve ACI requirements.
o Control of concrete surface temperature: “Cool the concrete gradually so that
the drop in concrete surface temperature during curing period does not exceed
11° C in any 24 hours period”. ACI 301M-8.32.4. Control of concrete surface
temperature
 Al Arish Simple Cycle Power Plant
Project No. 10143
HAC-10143-MS-CIV-002

5.1.5. Procedure of thermal curing

5.1.5.1. Pre place Mass Concrete
• Type K thermocouples will be placed inside concrete element prior to pouring. A
minimum of 2 should be placed in the center of it and 4 to 8 should be placed around
the bottom and top edges, depending on the concrete quantity to be poured.
Thermocouples should be labeled to be easy to monitoring of concrete temperature.
• Side formwork will be insulated by using of 50 mm Styrofoam.
• Spray water prior to casting to moist forms and cool steel reinforcement bars.
5.1.5.2. During Mass Concrete placement
• Concrete temperature to be kept as low as practically possible during casting time
• Top surface of concrete will be protected to prevent rapid evaporation of mixing water.
• Start finishing of top concrete surface using polyethylene sheets.
• Thermocouples should be labeled to be easy to monitoring of concrete temperature.
• Side formwork will be insulated by using of 50 mm Styrofoam if required.
• Spray water prior to casting to moist forms and cool steel reinforcement bars.
5.1.5.3. Post placement of Mass Concrete
• When concrete reaches initial set, the polyethylene sheet shall be removed and wet
hessian sheets to be laid on concrete surface. The wet hessian will be covered by
polyethylene sheets with minimum overlap 200 mm and kept continuously damped
during curing period.
• Side shutter will be stripped as soon as possible after attain strength to withstand the
initial shock of release. The exposed concrete surface(s) will be protected by draping
hessian and polyethylene sheets from the top surface and be continuously water cured.
• The ambient, concrete edge and concrete core temperatures will be recorded at every 2
hours at the first five days and every 6 hours for the remaining curing period.
• Thermal curing is deemed to be over when the temperature at the core of concrete
decreases sufficiently with respect to coldest day ambient temperature.

6.0 Finally
o Curing water should not be more than approximately 11° C cooler than the
concrete, because induced surface strains may cause cracking
o The curing should be continued until the temperature deferential between
the concrete the concrete core and the coldest daily ambient temperature is
less than 21° C. and the temperature differential between the concrete
surface and the ambient air is less than 14° C
o For vertical elements (walls, piers, and columns, …) shutter will not be
removed till complete the normal water and thermal curing.
o Temperature readings measuring devices to be inspected before concrete
placement and reading tables checked as well.
Al Arish Simple Cycle Power Plant
Project No. 10143
HAC-10143-MS-CIV-002
 Al Arish Simple Cycle Power Plant
Project No. 10143
HAC-10143-MS-CIV-002

7.0 Materials matrix

• Concrete grade for reinforced concrete C350 with cement type II
• Reinforcement bars
• Approved Bonding agent
• Approved Water stops if required
• Steel tying wire
• Formwork

8.0 Tools / Equipment

• Mobile crane.
• Survey instruments and measuring tools (e.g., measure tape, ...)
• Scaffolding, Ladders and wood and Wood Panels for formwork and Tie rods.
• Concrete finishing helicopter and Concrete vibrators
• Concrete Batch Plant- Main and Concrete truck mixers
• Water trucks or tanks
• Air compressor
• Electric Hammer equipment and other Manual tools
 Al Arish Simple Cycle Power Plant
Project No. 10143
HAC-10143-MS-CIV-002

9.0 Health, Safety and Environmental Requirements

In accordance with the Subcontract provisions and specifications, all the HSE
requirements are to be followed.
• All relevant personal protection equipment (PPE) shall be provided to all
personnel involved in the works and wearing of PPE shall be enforced by the team
as a whole All site personal shall wear the following PPE at all times:

▪ Safety boots.
▪ Safety helmets.
▪ High visibility Vest.

• Utilities shall be clearly marked and identified. Signboards identifying the type
of utilities shall be displayed at the relevant locations indicating limits of their
limits.
• Only allowed persons are permitted into the work zone. The barricades shall
be kept interlocked and continues at all the times. Any accident shall be promptly
reported to the safety department for further investigations and action.
• Barrier shall be added for the excavated borders.
• Caution tape shall be provided to all excavated area.
• Housekeeping and removing any unrequired materials to be ensured all the
time.