MS Cast Insitu Crossing Box Culvert

MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17) DARIPADA EMPAT (4) LORONG
KEPADA ENAM (6) LORONG, JOHOR- FASA 2B: DARI PERSIMPANGAN

BANDAR SERI ALAM / TAMAN RINTING KE PASIR GUDANG
MENAIKTARAF LEBUHRAYA PASIR

GUDANG (FT17) DARIPADA EMPAT (4)
KEPADA ENAM (6) LORONG,JOHOR – FASA
2B : DARI PERSIMPANGAN BANDAR SERI
ALAM/TAMAN RINTING KE PASIR
METHOD STATEMENT
Cast In-Situ Drainage
(Crossing Box Culvert)
WORK METHOD STATEMENT
For
MENAIKTARAF LEBUHRAYA PASIR GUDANG

(FT17) DARIPADA EMPAT (4) LORONG KEPADA
ENAM (6) LORONG, JOHOR – FASA 2B: DARI
PERSIMPANGAN BANDAR SERI ALAM/TAMAN
RINTING KE PASIR GUDANG
Contract No.:
JKR/IP/CKUB/227/2022
Prepared by Reviewed by Approved by
Name: Mohd Nizam Anuar Name: Ir. Hj. Idris Bin Mohamad Name:
Designation: Qa/Qc Designation: Project Manager Designation:
Project Introduction
a. Preface
The government of Malaysia intends to carry out the project for "Menaiktaraf Lebuhraya Pasir Gudang
(FT17) Daripada Empat (4) Lorong Kepada Enam (6) Lorong, Johor Phase 2B: Dari Persimpangan
Bandar Seri Alam/ Taman Rinting Ke Pasir Gudang". the road upgrading project is to upgrade Pasir
Gudang highway (FT17) is a four (4) lane dual carriageway route with U5 standard that connects the
second link highway (second link) to the interchange of Jalan Pasir Gudang. This road which connects
Johor Bahru city centre is the main route for heavy vehicles to the industrial area and Pasir Gudang port.
The existing Level of Service (LOS) is F and need to be upgraded. This project involves the phase 2B
project which will be upgraded starting from the interchange of Bandar Seri Alam/ Taman Rinting and
ending at the interchange of Pasir Gudang highway with a road length of approximately 5.0km.
b. Project Location and Layout Plant
Figure 1: Project Location and Layout Plan

1 CAST IN-SITU DRAINAGE (CROSSING BOX CULVERT)
1.1 Purpose of Method Statement
This method statement describes the general guidelines for the methodology and sequence of works for the Drainage Works
for Cast In Situ Crossing Box Culvert. This work shall comprise the supply of material and construction of Cast In Situ Crossing
Box Culverts inclusive of survey work, temporary works, side by side construction method such as site clearing, leveling,
excavation and shaping, placed bedding, fixing reinforcement, fixing formwork, pouring concrete and backfill with appropriated
compaction, all in accordance with the Specification and the details shown on the drawings.
1.2 Scope of Works
This method statement will cover for the drainage works (Cast In-Situ Box Culverts). This method statement introduces the
proposed activities to be undertaken and acts as a general methodology for the completion of drainage works. This has been
prepared to identify the work stages and the construction methodology for ensuring the works are carried out in compliance
with contract requirements. The construction of cast in-situ box culvert shall involve in 2 types of culvert for the overall
package. The size of box culvert as per below:
No. Culvert Type Quantity (nos) Chainage Drainage (CH)

i. CH 121
1.
ii. CH 200
iii. CH 300
Single Cell Box Culvert 10
iv. CH 1025
v. CH 1720
vi. CH 1723
vii. CH 2575
viii. CH 3600
ix. CH 4625
x. CH 4920
Existing Double Cell i. CH 3650

2.
1
Box Culvert
(Extension)
Table 1: Culvert type & location (CH)

1.3 Construction Methodology
1.3.1 In- Situ Box Culvert at Existing Road
The sequence of the construction in-situ box culvert at existing road as per flowchart (existing road) while, the
sequence of construction in-situ box culvert as per stage in Figure below:
Figure 2: Method of In-Situ Single Box Culvert

The typical construction sequence of workflow for the proposed works shall be in the following order:
Setting Out/ Survey Work/Invert level
Shop Drawing
Placed bedding material ( Lean Concrete)
Fixed reinforcement and Spacer Block
Fixing of Formwork
Concretting Work
Removal Formworks
Backfilling
• Workflow to be repeated for the other side of road

Setting Out/Survey Works for Cast in – Situ Box Culverts
Setting Out/ Survey Work/Invert level
Side by side Construction Method RHS / LHS
Remove / Replace USM / Ground Treatment
Placed bedding material (Lean Concrete)
Fixed Reinforcement and Spacer Block
Fixing of Formwork
Concreting Works
Removal Formwork
Backfilling
The surveyor will set out the alignment, inlet and outlet invert level, gradient with reference points throughout
the site. Setting out works will be conducted by surveyor and rechecked by Consultant surveyor if any. All
levels and setting out shall be checked by surveyor before and after placing of concrete.
Foundation Preparation
i. For firm ground, final trimming using hand tools is carried out prior to blinding.
ii. For soft ground, extra excavation below the blinding level will be replaced using the granular materials
such as sand.
Placed Bedding Material (Lean Concrete)
The required platform level shall be checked prior to pouring of concrete blinding. A layer of 50mm concrete
blinding will be poured at the base of concrete structure and levelled by using trowel. The blinding layer shall
be laid immediately after excavation, draining and compacting of the bed area, in order to avoid disturbance
of soil by rain or ground water and as per requirement of Section 9 of the Specification for the class of
concrete specified on the Drawings or required by the Consultant.
Construction of Cast in Situ Box Culvert
The type and size of cast in situ box culvert to be constructed at each location shall be as shown on the
Drawings or as directed by the Consultant Supervision Team. Cast in situ box culverts shall not be
constructed at any location until the exact location, the lines, levels and grades, the length of culvert and
details of inlet and outlet structures have been confirmed by the Consultant Team. The sequence of
construction culvert divided into 3 stages as per below.
Stage 1 (Construction of culvert base slab)
Setting Out
Fixing rebar and spacer block
Installation formwork include groove line for construction joint
Inspection prior concreting including applying cement slurry
Concreting
Curing
Removal of Formwork
Stage 2 (Construction of culvert wall)
Setting Out
Installation formwork include groove line for construction joint
Concreting
Removal of formwork
Curing
Stage 2 (Construction of culvert top slab)
Setting Out
Installation formwork
Concreting
Curing
Removal of Formwork
Backfilling
Fixed Reinforcement and Spacer Block

The reinforcement shall be cut and bends and spacer block shall be installed to provide the concrete cover of
50mm. The reinforcement shall be inspected before box culvert formwork can be closed. The dimension of
the precast box culvert will be followed as per construction drawing.
i. Reinforcement bars
All reinforcement bars and BRC will be bent and cut at a centralized fabrication yard and transport to the
construction area by a lorry. The detail shall be referred to the approved construction drawings. The fabric
reinforcement bar will be lifted to its position by bar bender and tied together and must be rigid enough to avoid
displacement during concrete pouring. Sufficient spacer blocks shall be installed to provide cover to reinforcing
bars. Bar bending schedule to be produced by Contractor & checked prior to the commencement of work.
ii. Fixing of Formwork

Mobile crane or excavator shall be used to hoist and position the wall formwork. The formwork shall be tied
together using tie rod and proper propping shall be installed immediately. The Consultant Team shall be
notified for inspection on the level, verticality, formwork stability and cleanliness before concreting begin. The
plum bob shall be used for verticality check.
Formwork shall be placed on the required alignment and level and supported by adequate shoring where
necessary. Care shall be taken, when fixing the shoring and to ensure its stability and good ground condition.
The conventional method of formwork to be used. Shop drawing of the formwork will be submitted prior to
start works. Figure below show the sample of formwork fixing.
Figure 3: Formwork Fixing

iii. Concreting Works

After all has been inspected and approval obtained for casting, the preparation for concreting may begin.
Access for concrete truck shall be prepared or if needed mobile crane shall be used to transport concrete
(G30) to its final position. Proper compaction/ vibrator shall be applied to eliminate voids in the concrete.
However care shall be taken not to over compaction/vibrator which tends to segregation and bulging or failure
of formwork. The formwork can be removed after 24 hours and curing shall start immediately. The process is
repeated for subsequent works.
Concrete shall be compacted by power driven immersion type poker vibrator. Vibrator shall be inserted
vertically into the full depth of the layer. Hold at the bottom for 5 to 15 seconds and pull vibrator up at a rate of
15 seconds. The underlaying fresh concrete laying shall be re-vibrated as to eliminate undesired cold joint
between the two layers. The vibrating of concrete ends when large air bubbles no longer escape and when
the sound of vibrator changes pitch or tone. Top layer of concrete shall be levelled to the required gradient
using steel trowel or wooden float. Concrete schedule to be submitted prior concreting works and Figure 5
below showing proposed construction joint.
iv. Curing
After pouring, concrete surface needs to be protected during hardening stage from harmful effects such as
sunshine, shrinkage cracks and water by applying approved curing compound, covering by gunny sack or
frequent watering.
v. Removal of formwork
Forms should not be removed until the concrete has sufficiently hardened in order that it can carry its own
weight safely and any other live loads it is subjected to. The supporting period ( the period between the
placing of concrete in forms and removal of forms) differ according to the type of cement used and the design
of formwork. The formwork can be removed after 24 hours and curing shall start immediately.
vi. Backfilling
Backfilling against in-situ box culverts and their appurtenant structures shall be carried out in accordance with
the construction methods described in Sub-Section 3.2.4 JKR Specification, using material conforming to the
requirements of Sub-Section 3.2.2.5 JKR Specification. Special care shall be taken to properly compact
backfill without disturbing or damaging the in-situ box culvert sections. Backfill shall be built up evenly
on both sides of each box culvert along its entire length. Vibratory plate compactor will be used for the
compaction work.
Unless otherwise approved by the Consultant Team, heavy plant and equipment shall not operate within
2.0m of any in situ box culvert until backfilling and where appropriate, pavement construction has advanced
to a stage which provides at least 300 mm of cover to the culvert.
1.3.2 In- Situ Existing Double Cell Box Culvert (Extension)
This in-situ existing double cell box culvert (extension) illustrates the step-by-step method that will
take to extend the box culvert. It will involve the following major procedures:
i. Roughening of the completed finished surface.

ii. Drilling of holes for the extension of rebars.
iii. Fixing of rebars using Sika Anchorfix 3030
Roughening of the Completed Finished Surface

The finished surface between the interface of old and new culvert will be roughened using
chipping hammer to create enough roughness to ensure good bonding of fresh concrete to the
old concrete. This work will be done using chipping hammer just to chip off the cement mortar
on the surface of the old concrete and the work will be carefully executed to ensure it would not
damage the integrity of the existing culvert.
Figure 4: Hacker Machine

Drilling of Holes for the Extension of Rebar
According to construction drawing, we would need to extend rebar with designation dowel-bar as
per sketches below:
Figure 5: Section Plan

Figure 6: Detail X (Section Plan)
Figure 7: Typical Cross Section
Holes will be marked at equal spacing as specified in the drawing and drilled according to the
recommended hole size and depth listed in the tables below. Each individual hole will then be
blown clean and brushed to ensure the holes are dust free for good bonding of the adhesive
epoxy later on.
Installation Parameter Bar
Anchor Diameter
Property
12 mm
Nominal Drill Hole do mm 16 mm

Diameter
Cleaning Brush do mm S18HF

Diameter
Torque Moment T Nm 40
Drill hole diameter: 16mm

Brush size: 18mm
Resistance Value For Reinforcing Bars In Uncracked Concrete
Combined Pullout & Concrete Cone Failure and Concrete Cone Failure I Temperature Range: -
40'C to +70'C
Anchor Diameter
Property
12 mm
Effective Embedment Depth = STD mm 110
Characteristic Resistance kN 53,91
Design Resistance kN 35,94
Controlling Resistance Pullout

Fixing the Rebars

Adhesive epoxy Sika Anchorflx 3030 will then be used to fill the holes and before it Is dry,
reinforcement bars will be inserted fully into the predrilled holes. Workers will ensure each hole is
fully covered with epoxy to ensure full bonding of the reinforcement bars.
Figure 8: Sika Anchorflx 3030

1.4 Plant and Machineries
Proposed Concrete plant:
i. Chin Keng Concrete Sdn Bhd

ii. LY Concrete Sdn Bhd
Proposed BRC:
i. Southern Steel Sdn Bhd
Machineries:
No. Type of Machine Unit
1 Excavator/Backhoe 1
2 Truck Concrete Mixer 1
3 Compacting Roller 1
4 Bar Cutting Machine 1
5 Bar Bending Machine 1
6 Portable Vibrator 1
7 Portable Water Pump 1
8 Survey Equipment 1
1.5 Manpower
i. Project Manager
ii. Construction Manager
iii. Project Engineer
iv. Senior Site Supervisor
v. QA/QC Officer
vi. Skilled Worker
1.6 QUALITY CONTROL/QUALITY ASSURANCE
For all the related works will refer to Quality Assurance Plan (QAP) and Inspection & Test Plan
(ITP) to ensure all work meets the standards and requirements as mentioned in contract.
Figure 9 :Inspection and Test Plan

1.7 SAFETY AND HEALTH
1.7.1 General Safety & Health Regulation
Occupational, Safety and Health Management Plan and Environment Management Plan are
used to ensure compliance to Healthy, Safety and Environment Management requirement.
Complying, implement and enforce the regulation in line with Occupational Safety and Health
Act 1994, Factory and Machineries Act 1967, EnvironmentQuality Act 1974 and other applicable
Act and Regulations.
1.7.2 Mobile Equipment and Machineries.
Periodic maintenance shall be carried out to all machinery and equipment at site. Inspection on
machinery shall be conducted with tag as proof of inspection and registered before allowed to
work site.
Machinery and Equipment shall be always maintained in good order and in good working
conditions.
A Competent Safety officer must be at site as responsible for site safety. The traffic teams
will monitor any works with regards to traffic separation.
ATTACHMENT 1
DBC NO. 03 DBC NO. 06
DBC NO. 04
DBC NO. 10
DBC NO. 15
DBC NO. 31
ATTACHMENT 2
ACTIVATION TIME :
CROSS SECTION MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17)DARIPADA EMPAT(4) LORONG KEPADA ENAM (6) LORONG, Monday to Sunday
JOHOR – FASA 2B : DARI PERSIMPANGAN BANDAR SERI ALAM/TAMAN RINTING/KE PASIR GUDANG
LEFT LANE WORK AREA TOWARDS PELABUHAN JOHOR
Plastic barrier or safety cones
Working Area 3.5 m 3.5 m MEDIAN
LL RL
LEFT LANE WORK AREA TOWARDS JOHOR BAHARU
Working Area 3.5 m 3.5 m MEDIAN
LL RL
REVISION DESCRIPTION OF AMENDMENT DATE APPROVED DESIGN BY : TIYA BINA PROJECT TITLE :
TIYA BINA SDN BHD
MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17)DARIPADA EMPAT(4) LORONG KEPADA ENAM (6) LORONG,
63, 1ST FLOOR , LOT 9908, BLOCK H, DRAWN BY : RAHIM JOHOR – FASA 2B : DARI PERSIMPANGAN BANDAR SERI ALAM/TAMAN RINTING/KE PASIR GUDANG
RH PLAZA, 900B, 93350, KUCHING,
SARAWAK REVISION
CHECKED BY : MAZLAN DRAWING TITLE :
CROSS SECTION FOR VERGE CLOSURE – PELABUHAN BOUND AND JOHOR BAHARU BOUND NO :
PERUNDING IRZI SDN BHD DATE :
11-2, JALAN IMPIAN PERDANA 1, SHEET :
SAUJANA IMPIAN, 43000 KAJANG DRAWING NO : EPB/PMO/TIYA/PASIR GUDANG/AWA/CROSS SEC/BOTH BOUND/0001
SELANGOR SCALE : N.T.S
ACTIVATION TIME :
CROSS SECTION – MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17)DARIPADA EMPAT(4) LORONG KEPADA ENAM (6) LORONG, Monday to Sunday
MEDIAN WORKS JOHOR – FASA 2B : DARI PERSIMPANGAN BANDAR SERI ALAM/TAMAN RINTING/KE PASIR GUDANG
TOWARDS PELABUHAN JOHOR TOWARDS JOHOR BAHARU TOWARDS JOHOR BAHARU
Working Area
3.5 m 3.5 m 3.5 m 3.5 m

MEDIAN
LL RL RL LL
TIYA BINA SDN BHD
SARAWAK REVISION
CROSS SECTION FOR MEDIAN CLOSURE NO :
SAUJANA IMPIAN, 43000 KAJANG DRAWING NO : EPB/PMO/TIYA/PASIR GUDANG/AWA/CROSS SEC/MEDIAN -002
ACTIVATION TIME :
TPYICAL PLAN - MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17)DARIPADA EMPAT(4) LORONG KEPADA ENAM (6) LORONG, Monday to Sunday
Verge closure JOHOR – FASA 2B : DARI PERSIMPANGAN BANDAR SERI ALAM/TAMAN RINTING/KE PASIR GUDANG
SHOULDER
MEDIAN
SHOULDER
300 m 50 m 50 m 50 m 50 m
500 m 150 m 150 m 30m
TRANSITION BUFFER
ADVANCE WARNING AREA AREA AREA WORK AREA TERMINATION AREA
TIYA BINA SDN BHD
SARAWAK REVISION
TPYCAL SECTION FOR VERGE CLOSURE NO :
SAUJANA IMPIAN, 43000 KAJANG DRAWING NO : EPB/PMO/TIYA/PASIR GUDANG/AWA/TYPCAL-003
ACTIVATION TIME :
TPYICAL PLAN – MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17)DARIPADA EMPAT(4) LORONG KEPADA ENAM (6) LORONG, Monday to Sunday
Slow lane closure JOHOR – FASA 2B : DARI PERSIMPANGAN BANDAR SERI ALAM/TAMAN RINTING/KE PASIR GUDANG
SHOULDER
MEDIAN
SHOULDER
300 m 50 m 50 m 50 m 50 m
500 m 150 m 150 m 30m
TRANSITION BUFFER
TIYA BINA SDN BHD
SARAWAK REVISION
TPYCAL SECTION FOR SLOW LANE CLOSURE NO :
ACTIVATION TIME :
TPYICAL PLAN – MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17)DARIPADA EMPAT(4) LORONG KEPADA ENAM (6) LORONG, Monday to Sunday
Fast lane closure JOHOR – FASA 2B : DARI PERSIMPANGAN BANDAR SERI ALAM/TAMAN RINTING/KE PASIR GUDANG
SHOULDER
MEDIAN
SHOULDER
300 m 50 m 50 m 50 m 50 m
500 m 150 m 150 m 30m
TRANSITION BUFFER
TIYA BINA SDN BHD
SARAWAK REVISION
TPYCAL SECTION FOR FAST LANE CLOSURE NO :
ACTIVATION TIME :
TEMPORARY MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17)DARIPADA EMPAT(4) LORONG KEPADA ENAM (6) LORONG, Monday to Sunday
SIGNBOARD - DETAIL JOHOR – FASA 2B : DARI PERSIMPANGAN BANDAR SERI ALAM/TAMAN RINTING/KE PASIR GUDANG
TIYA BINA SDN BHD
SARAWAK REVISION
CHECKED BY : MAZLAN DRAWING TITLE : TEMPORARY SIGNBOARD DETAIL
NO :
SAUJANA IMPIAN, 43000 KAJANG DRAWING NO : EPB/PMO/TIYA/PASIR GUDANG/TEMP SIGN – DETAIL/006
ACTIVATION TIME :
DETAIL PLASTIC BARRIER MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17)DARIPADA EMPAT(4) LORONG KEPADA ENAM (6) LORONG, Monday to Sunday
& SAFETY CONES JOHOR – FASA 2B : DARI PERSIMPANGAN BANDAR SERI ALAM/TAMAN RINTING/KE PASIR GUDANG
TIYA BINA SDN BHD
SARAWAK REVISION
DETAIL PLASTIC BARRIER NO :
SAUJANA IMPIAN, 43000 KAJANG DRAWING NO : EPB/PMO/TIYA/PASIR GUDANG/DETAIL PLASTIC BARRIER/007
ATTACHMENT 3
Department: HSE RA Leader: Approved Reference Number
by
Process: MS CULVERT AND DRAINAGE WORKS RA Member 1: Amran Abd Rahman
RA Member 2: Signature:
Process/Activity Location: FT 17-P2B
Name:
Original Assessment date: 5/7/2023 RA Member 3:
RA Member 4: Designation: Project Manager

Last review date: 5/7/2023
Date: 5/7/2023
Next review date: RA Member 5:
HAZARD IDENTIFICATION RISK EVALUATION RISK CONTROL
Possible
RP Implementation
Ref Work Activity Hazard injury/ill- Existing risk controls S L Additional Controls S L RPN Due Date Remarks
N Person
health
1 Mobilization
Mobilization, loading and

1a Physical Hazard: 1. Fatality 1. Proper planning for machineries B 3 3B 1. Pre- Task talk B 2 2B 1. Machine
unloading of Machineries
1. Traffic Accident 2. Bodily injury crossing, parking and movement. 2. Proper planning for safer 2. Operator Driver
and Equipment
2. Hit by 3. Property 2. Only competence and approved route 3. Project Manager
Machineries damages workers are allow
3. Improper manual 4. Road/highwa 3. To ensure traffic management as per
handling y/traffic approved TMP
blockage 4. Only approved machineries allow
5. To ensure proper lighting for night
works
6. To provide proper PPE for workers
7. Fire extinguisher and first aid kit
available
Unrestricted
2 Survey works
1. To provide proper PPE 1. Pre-task talk Lead Surveyor

2a Survey works: Physical Hazard:
1. Fatality 2. Proper planning B 3 3B 2. Inspect all the materials and B 2 2B 1. Site Supervisor
Establish the station, 1. Hit by vehicles
2. Burn 3. Only approved and standard equipment equipment before proceeding
block, TBM and OGL
2. Fall, Slip and Trip 3. Poisonous and tools allow with works.
3. Heat 4. Closed monitoring during work in
progress
Biological Hazard:
1. Poisonous animal 5. To stop all activities if extreme weather
or insect
3 Excavation Works
A 2 2A 1. Pre-job talks A 1 1A 1. Site Engineer/ TBA

3a Excavation of Trench Physical Hazard: 1. Fatality 1. Pre-job inspection, identify and remove Supervisor
2. Double check all the
1. Underground 2. Physical services location
services location
services injury 2. Tool box talks
2. Struck/Hit by 3. Electrocution 3. Proper PPE 3. Re-Inspect vehicles and
machinery. 4. Ergonomic 4. Competent machine operator machinery before proceed
3. Improper 5. Proper planning for access and egress of with work
Manual dumping truck and other vehicles
Handling 6. Excavate earth to be remove and dispose
4. Extreme accordingly – License and approved
weather dumping area
7. Sufficient manpower including banksman
Biological Hazard: 8. Proper storage of earth for reuse
1. Poisonous 9. Transporting out earth to comply with
animal or insect relevant regulation – Traffic act and local
council.
10. Maintain cleanliness of transporting
vehicle’s, storage area and worksite.
11. Only approved vehicles and machinery
allow
12. Inspect all the machinery and vehicle
13. Stop works if extreme weather-
Thunderstorm, Heavy rain etc.
14. To provide cleaning facilities for dumping
truck
15. Traffic management as per approve TMP
4 Pipe Laying Works
4a Temporary Diversion, Physical Hazard: 1. Physical 1. All surface runoff water, subsoil drain C 2 2C 1. Pre-job talks C 1 1C Site Engineer/ TBA
Pumping and Dewatering 1. Improper Manual injury and slotted drain outflow within the area Supervisor
Handling 2. Ergonomics shall be channeled pit into a catch pit
issues 2. Redirect to main channel stream by a
gravity flow temporary earth drain or
Unrestricted
pumping system complete with 6 inches
hosepipe
3. All perimeter drains shall be maintained
regularly especially during monsoon
seasons.
4. Sufficient manpower
5. To provide proper PPE
4b Laying Sand Bedding Physical Hazard: 1. Physical 1. Proper PPE – including ear plug C 2 2C 1. Pre-job talks C 1 1C Site Engineer/ TBA
Material 1. Improper injury 2. Sufficient manpower for rotation works 2. Re- inspect all machine and Supervisor
manual handling 2. Ergonomics 3. Traffic management as per approved vehicle before proceed
- Compaction Works 3. Hearing loss TMP with works
Noise Hazard 4. Only approved machine and equipment
allow
1. Pre-job talks
4c Pipe Joining and Laying Physical Hazard: a. Serious injury 1. To provide proper PPE A 2 2A 2. Re-Inspect vehicles and A 1 1A Site Engineer/ TBA
1. Improper manual b. Ergonomics 2. Ensure all the lifting gear has been machinery before proceed Supervisor
handling issues inspected and approved with work
2. Falling object c. Health issues 3. Sufficient manpower for lifting and traffic
3. Hit by lift management
material 4. Only approved machine and vehicles
allow – PMA validity
Chemical Hazard 5. Proper arrangement for access and
egress for vehicles and machinery at site
6. Traffic management as per approved
TMP
7. Sufficient lighting for night works
8. Stop works if extreme weather-
Thunderstorm, Heavy rain etc
5 Housekeeping
5a Housekeeping Physical Hazard: 1. Fatality 1. Ensure traffic management as per B 3 3B 1. Pre-task talk B 2 2B Lead Surveyor
1. Hit by vehicles 2. Dehydration approved TMP 2. Ensure everything clear from Site Supervisor
3. Health Risk - 2. Ensure no materiel or equipment left sites
Health Hazard: Chronic behind
1. Heat 3. To provide proper PPE
2. Dust 4. Kept the team hydrated.
5. Close monitoring during work in
progress.
Unrestricted
Permit-to-Work (PTW) based on the nature of work (e.g. Hot Works, Working at Height and Confined Space) must be
obtained prior to any commencement of work. A copy of the PTW must be clearly displayed at the hoarding of the
construction site.
Definition Rating A B C D E
Standard Definition:
Likely to occur many times or has occurred
frequently Frequent 5 5A 5B 5C 5D 5E
Environmental Criteria:
Expected to happen or at least happen once a day
Likely to occurs some times or has occurred
infrequently
Occasional 4 4A 4B 4C 4D 4E
Can happen frequently or at least happen once a
week
Unlikely, but possible to occur or has occurred
rarely
Remote 3 3A 3B 3C 3D 3E
Chance to happen is relatively high or happen
Between once a week and once in 3 months
Very unlikely to occur or not known has occurred
Environmental Criteria: Improbable 2 2A 2B 2C 2D 2E
Could happen, however very rare or happen
between once in 3 months and two years
Almost inconceivable that the event may occur
Extremely
Improbable
1 1A 1B 1C 1D 1E
The probability to happen is extremely small or
happen between once in 2 years and once per life
Unrestricted
of site
Severity
Catastrophic Hazardous Major Minor Negligible
A B C D E
Productivity/ Staff
Total Disruption Considerable effect, Significant reduction in Operating limitations. Very slight/ negligible,
affecting all operations curtailment of services / safety margins, a Major disruption on few people and/ or
and people operation. Prolonged reduction in the ability operation for 1 day operations affected
closure of operational area of the operators to cope Limited effect, affects Loss on non-key staff and
Mass loss of key and Major disruption on with adverse operating wider operations and low effect on morale
non-key staff, and severe operation for 2 to 4 weeks conditions as a result of more people
drop in morale Large reduction in safety increase in workload, or Loss of one or more key
margins, physical distress as a result of conditions staff and minor effect on
or a workload such that the impairing their morale
operators cannot be relied efficiency
upon to perform their tasks Major disruption on
accurately or completely operation for 2 weeks
Loss of a key team/ group Loss of several key and
of staff and significant non-key staff and major
drop in morale drop in morale
Safety & Security/ Health/ Injury/ Fatality

Major security breech Major security breech Security breech Security breech resulting Negligible Impact and No
resulting in interruption resulting in interruption of resulting in interruption in interruption of requirement for treatment
of operation for more operation for 12 hours of operation for 3 to 6 operation 1 to 3 hours
than 24 hours hours
Single fatality and/or First Aid injuries only
Multiple deaths &/or multiple injuries Individual serious
multiple serious injuries injury or recurring
minor injuries need
professional treatment,
hospitalization, follow
up treatment
No fatality
Legal & Compliance
Major breach in legal and Major breach in legal and Breach in legal and Breach in legal and Negligible Impact
compliance issue compliance issue effecting compliance issue compliance issue
effecting in government in regulator and resulting in regulator resulting in amendment
investigation management investigation inquiry. to process and procedures
Image & Reputation
Major adverse publicity Adverse publicity in either Probable adverse No external publicity, None
Unrestricted
in either local or local or international external criticism of criticism by affected
international press which press; limited to news Board/ Management managers/ customers; but
attracts newspaper reported/ criticism by Any event that may still tarnish the reputation
editorial/ feature article external (e.g. key tarnish Malaysia of Malaysia Airports
and censure regulators stakeholders, regulator, Airports reputation with
Longstanding political high profile media) a specific customers,
implications, possible group or 3rd party and
reorganization and even summons, claims or
prosecution writs served on a Group
Company, irrespective
of amount, or adverse
publicity limited to
“letters to NST Forum
or similar pages
Financial Loss
Losses exceeding Losses between RM12mil Losses between Losses between RM400k Losses less than RM400k
RM30mil to RM30mil RM5mil to RM12mil to RM5mil
GSE/ Aircraft/ Equipment Damage
Destruction / write off Require serious, Require major repair of Some repair require Slight damage to GSE/
immediate repair of GSE/ GSE/ equipment equipment. E.g.
equipment No damage to aircraft scratching of paintwork
Possible limited
Major damage to aircraft damage to aircraft No damage to aircraft
Emergency Procedure
Yes, e.g. Full rescue and Yes, e.g. possible removal Yes, Increased in scope Use of emergency Not instigated
emergency plan, full of equipment, AFRS of time. E.g. closure of procedures. Limited in
deployment of AFRS, attendance, first aid/triage operating area, scope and time. E.g.
use of fire retardant, at location, use of fire attendance by AFRS temporary isolation area,
rescue/recovery of retardants and rescue brief attendance by
victims activities AFRS
Environmental Impact
Unrestricted
Severe environmental Damage sufficiently to On site release No environmental
damage. Damage attack the environment immediately contained, damage
sufficiently to attack the at site. Limited loss of local environmental Poses little or no threat
environmental at national discharges of known impact at confined space (or opportunity) to the
level. Repeated exceed of toxicity. Potential for Minor clean-up, No legal environment or the
environmental related or single exceed of breach, Site procedure organisation.
statutory or prescribed environmental related variation
limit. statutory requirement Requires further research
Major legal i.e. EQA to establish the true
breach/penalty, Media Legal breach, extent of any threat or
interest, Local ecosystem Disruption of opportunity
damage (off-site) operations, Major
Aspect and impact are clean-up
controlled but poses great Aspect and impact are
threat (or opportunity) to controlled and poses
the environment or the only a moderate threat
organisation (or opportunity) to the
environment or the
organization
Assessment Risk Index Suggested Criteria
Extreme Unacceptable under the existing circumstances. Urgent action required as soon as practicable or IMMEDIATELY
should a risk occur.
Requires Board’s and Senior Management’s attention and continuously monitored.
High Risk control / mitigation requires management decision. Urgent action required as part of the next budget cycle or
earlier.
HODs / Senior Management is required to address the risk
Medium Acceptable after review of the operation. A review must be conducted as soon as possible to determine if the risk
level can be reduced to the point where it becomes acceptable to Malaysia Airports.
HODs’ attention is required to address the risk
Unrestricted
Low Acceptable. No further action required, unless the risk can be reduced further at little or no cost.
Unrestricted

MS Cast Insitu Crossing Box Culvert

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MS Cast Insitu Crossing Box Culvert

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MENAIKTARAF LEBUHRAYA PASIR GUDANG (FT17) DARIPADA EMPAT (4) LORONG

KEPADA ENAM (6) LORONG, JOHOR- FASA 2B: DARI PERSIMPANGAN

MENAIKTARAF LEBUHRAYA PASIR

WORK METHOD STATEMENT

MENAIKTARAF LEBUHRAYA PASIR GUDANG

Prepared by Reviewed by Approved by

b. Project Location and Layout Plant

Figure 1: Project Location and Layout Plan

1 CAST IN-SITU DRAINAGE (CROSSING BOX CULVERT)

1.1 Purpose of Method Statement

1.2 Scope of Works

No. Culvert Type Quantity (nos) Chainage Drainage (CH)

Existing Double Cell i. CH 3650

Table 1: Culvert type & location (CH)

1.3 Construction Methodology

1.3.1 In- Situ Box Culvert at Existing Road

Figure 2: Method of In-Situ Single Box Culvert

Setting Out/ Survey Work/Invert level

Placed bedding material ( Lean Concrete)

Fixed reinforcement and Spacer Block

• Workflow to be repeated for the other side of road

Setting Out/Survey Works for Cast in – Situ Box Culverts

Setting Out/ Survey Work/Invert level

Side by side Construction Method RHS / LHS

Remove / Replace USM / Ground Treatment

Placed bedding material (Lean Concrete)

Fixed Reinforcement and Spacer Block

Placed Bedding Material (Lean Concrete)

Construction of Cast in Situ Box Culvert

Stage 1 (Construction of culvert base slab)

Fixing rebar and spacer block

Installation formwork include groove line for construction joint

Inspection prior concreting including applying cement slurry

Stage 2 (Construction of culvert wall)

Fixing rebar and spacer block

Installation formwork include groove line for construction joint

Inspection prior concreting including applying cement slurry

Stage 2 (Construction of culvert top slab)

Fixing rebar and spacer block

Inspection prior concreting including applying cement slurry

Fixed Reinforcement and Spacer Block

ii. Fixing of Formwork

Figure 3: Formwork Fixing

iii. Concreting Works

1.3.2 In- Situ Existing Double Cell Box Culvert (Extension)

i. Roughening of the completed finished surface.

Roughening of the Completed Finished Surface

Figure 4: Hacker Machine

Drilling of Holes for the Extension of Rebar

Figure 5: Section Plan

Figure 6: Detail X (Section Plan)

Figure 7: Typical Cross Section

Installation Parameter Bar

Nominal Drill Hole do mm 16 mm

Cleaning Brush do mm S18HF

Drill hole diameter: 16mm

Resistance Value For Reinforcing Bars In Uncracked Concrete

Effective Embedment Depth = STD mm 110

Characteristic Resistance kN 53,91

Design Resistance kN 35,94

Controlling Resistance Pullout

Fixing the Rebars