AIN SOKHNA PORT DEVELOPMENT

EGYPT

Method Statement – Deck Slab Construction

Date
15/12/2021
 AIN SOKHNA PORT DEVELOPMENT - EGYPT Doc. No:

Method Statement – Deck Slab Construction REV. No: 00

Table of Contents
1. SCOPE ........................................................................................................................................................................ 3
2. Reference documents. ............................................................................................................................................... 3
3. MATERIALS................................................................................................................................................................. 3
3.1. Form Work ........................................................................................................................................................ 3
3.2. Reinforcement .................................................................................................................................................. 3
3.3. Concrete............................................................................................................................................................ 3
4. SEQUENCE OF CONSTRUCTION OF DECK SLAB ........................................................................................................... 4
4.1. Pile head breaking ............................................................................................................................................ 4
4.2. Execution of transverse beams ........................................................................................................................ 5
4.2.1. Excavation till transverse bottom level ....................................................................................................... 5
4.2.2. Casting of plan concrete (blinding concrete) ............................................................................................... 5
4.2.3. Reinforcement fabrication and fixing for transverse beams ...................................................................... 5
4.2.4. Formwork for crossbeams............................................................................................................................ 6
4.2.5. Casting of crossbeams .................................................................................................................................. 7
4.2.6. Removal of form work ................................................................................................................................. 7
4.2.7. Protection of the concrete ........................................................................................................................... 7
4.3. Execution of deck slab ...................................................................................................................................... 7
4.3.1. Backfilling between beams .......................................................................................................................... 7
4.3.2. Fabrication of deck slab reinforcement ....................................................................................................... 8
4.3.3. Casting of deck slab ...................................................................................................................................... 8
4.3.4. Curing of slab. ............................................................................................................................................... 8
5. HEALTH AND SAFETY .................................................................................................................................................. 8
6. ENVIRONMENT .......................................................................................................................................................... 9
7. INSPECTION AND TESTING (QA/QC) ........................................................................................................................... 9
7.1. Controls on Formwork ..................................................................................................................................... 9
7.2. Controls on Reinforcement .............................................................................................................................. 9
7.3. Controls for Concrete Prior to Concreting ....................................................................................................... 9
7.4. Controls during Concreting ............................................................................................................................ 10

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 AIN SOKHNA PORT DEVELOPMENT - EGYPT Doc. No:

Method Statement – Deck Slab Construction REV. No: 00

1. SCOPE
This document describes the principles of the construction method proposed for the deck slab including
(Front Beam, Back Beam, Transverse Beams and RC Slab) works to be constructed for the “970 m length
for the container quay at Sokhna port” project, as well as the main equipment, which is anticipated, for
the execution of the works.

2. Reference documents.
- Project Technical Specifications
- Egyptian Code

3. MATERIALS
3.1. Form Work
Formwork will be done using metal or timber based on the site conditions and height of the casted element,
the metal form work shall be provided by an approved supplier with approved design for the dimensions,
location of supports and duration of usage.
3.2. Reinforcement
Ready-to-install reinforcement shall be prepared on site.
The reinforcement cages will be prefabricated according to approved design and shop drawings. They shall
be equipped with sufficient concrete spacers, lifting devices etc. to ensure a proper installation of the main
bars and stirrups. The different cage segments shall be spliced tightly with steel wires considering the required
lap length.
3.3. Concrete
Ready mix concrete complying with project specifications and ACI 336. 1-5 shall be used. Concrete should be
of average slump of 150mm. This means that at the beginning of pouring slump should about 180mm and
should not fall below 120 mm at the end of pouring (about 3 hours). Cement content is at least 350 kg/m3 as
per project specifications.
Additives shall be used to guarantee the required slump during the time of pouring the whole pile. A
retardation period of four to five hours in setting time is required to assure the integrity of concrete element.

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Method Statement – Deck Slab Construction REV. No: 00

4. SEQUENCE OF CONSTRUCTION OF DECK SLAB

The main steps in construction shall be as follows: -
4.1. Pile head breaking
The piling area will be excavated at least 10 CM below the piles cut-off level as per the approved shop drawings.
Excavation shall be done locally with earth moving equipment like mechanical excavators or manually if required.

As per the approved drawings, this pile cut-off level is +1.6M while the water level is expected to be 0.00 level thus no
groundwater expected in this event and no need for dewatering works to be considered in this phase.

After excavation is completed at the required level, surveying works will be done to mark the cut-off level for the
exposed piles, the exposed piles concrete shall be tested to obtain the required strength prior to the commencement
of the crushing works.

After the marking is done, a mechanical equipment is expected to start the crushing works, small jack hummers will
be mounted on mechanical equipment to allow for the crushing works. Kindly see the picture below.

Rig operator will be manoeuvring around the exposed pile section to allow or concrete crushing without damaging the
exposed steel, however exposed reinforcement may need to be bended to allow for crushing of the concrete in the
middle section

The small jackhammers will allow for crushing the concrete in small
particles to allow for the crushed concrete to be demobilizing from
site and avoid cracks in the main shaft of the pile

Based on site condition, manual chipping may be expected to allow

for crushing the concrete in the narrows area and for more accurate
levelling of the pile head if required.

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Method Statement – Deck Slab Construction REV. No: 00

4.2. Execution of transverse beams

4.2.1. Excavation till transverse bottom level
After the completion of the piles, Diaphragm wall and barrettes for at least 50 meter wide (length to allow for a single
casting with expansion joint), piles will be trimmed at the cut-off level, cleaned with metal brush and allow for rough
surface. Excavation shall allow for the depth of 10 cm below the design level of the cross beams, rear beams and front
capping beam (20CM below the piles cut-off level) using mechanical excavator. The soil shall be shifted and stockpiled
in a designated area

4.2.2. Casting of plan concrete (blinding concrete)

After excavation, the exposed soil shall be levelled and well compacted. The height of the blinding concrete shall be
minimum of 10Cm with no reinforcement, the shatter that shall be used is temporary 10CM high timber. Concreting
of the plain will be done using ready-mix concrete mixers

4.2.3. Reinforcement fabrication and fixing for transverse beams

Steel reinforcement shall be cut and bend as per the
approved shop drawings, and the overlap will comply
with the project specs. Fixation with Tie wire shall be
done according to project specs and common
practices.

The height of the steel of the beam shall cover the

length of the beam and the overlap length inside the
upper slab, for the front and rear beam the stirrups are
considered into 2 different section, both sections shall
be done in that stage, section 1 height is 1.6M to cover
the length of the transverse beam and section 2 is 2.0M
hat cover the whole capping and rear beam height,
both stirrups shall be installed as the concreting stage
will cover whole section 1 and partially section 2

Piles longitudinal reinforcement are expected to be

1.5M thus it is all embedded in the beam high and has
no additional requirement to be considered while
casting the beams.

Beams top reinforcement shall not be installed, only

the stirrups shall be fixed and the top reinforcement
shall be replaced and casted while installing the top
slab reinforcement.

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Method Statement – Deck Slab Construction REV. No: 00

4.2.4. Formwork for crossbeams

Formwork shall be done using metal form work dedicated for beam sections, the form work will be provided by
approved third party, supports shall be done using either tie rods or jacking system or a combination of both.

For the front beam and rear beam, a need for side supports shall be considered as per the site condition. Please
refer to the picture below

Back beam mid piles1 mid piles 2 Front beam

For the middle piles tie rods may be considered for lateral support in addition to the bracings, final design shall be
submit for the consultant’s approval prior to supplying the form works.

Section for the form works support for the transverse beams

Detailed design for the form work (height, thickness, location of tie rods and bracing system if required) shall be
submit though an approved subcontractor to carry out the supply of the form work.

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4.2.5. Casting of crossbeams

Crossbeams shall be casted in a sequence to allow for the vibrator to compact the concrete easily to avoid
honeycombs or and finishing related issues through the casting. The maximum height of a portion to allow for
casting shall be 0.45M, the concrete will be supplied contentiously in a sequence to allow for casting different beams
in parallel to the vibrating works

Casing sequence of concrete

4 levels to allow for 40CM height casting and vibration (Below 45CM)

4.2.6. Removal of form work

The removal of the form work can be done within 5-7 day as it is only on the sides and the concrete can carry its own
weight, the erection will be done on the normal procedures as per the manufacturer’s recommendations.

Request will be sent to the consultant prior to dismantling the form work.

4.2.7. Protection of the concrete

Proper curing shall be done to the concrete continuously for at least 5 days after the dismantling the form works.

Protection of the sides of the concrete shall be done by the approved materials from the consultant, the isolation
shall comply with the project specs and consultant approvals and comments. Protection an isolation works shall be
conducted on the both sides of the concrete beams after the curing is completed.

4.3. Execution of deck slab

4.3.1. Backfilling between beams
After the curing of the beams
concrete surface and isolation
works, proper backfilling and
compaction shall be considered for
the span between the beams
horizontally to allow for the casting
of the slab, backfilling will be done
for levelling supporting the bottom
section of the slab. Plain concrete
is expected on the top of the backfilling works.
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Method Statement – Deck Slab Construction REV. No: 00

4.3.2. Fabrication of deck slab reinforcement

After the completion of the backfilling works and backfilling with the bottom slab level (+2.1) polythene sheets shall
be applied on the exposed soil, bottom reinforcement shall be fixed and fabricated as per the approved shop
drawings and inspected by the consultant. Bottom mesh shall interfere with the exposed stirrups of the front, rear
and transverse beams.

Top mesh will be installed and fabricated as per the approved drawings in addition to the beams top reinforcement.
All steel reinforcement shall comply with the project specs and approved drawings.

In pattern of construction joint additional preparations may be required for the fabrication of the work, in the case
of a construction joint additional works may be considered based on the consultant approvals.

4.3.3. Casting of deck slab

Upon the final inspection of the reinforcement, casting shall be permitted to allow for casting the section, the casing
will cover the slab area, top portion of the front and wall beams, the whole thickness is 40CM thus no need for hit-
and-rest technique in casting (casting can be done on all the sections at one.

A minimum of 2 pumps shall be used to allow for the casting, length of the pump is decided based on the site
conditions. The concreting shall be in continuous matter along with the vibration to avoid cold joints.

Upon casting the top level of the concrete will be maintained as per the approved drawings (+2.5) and finishing shall
consider using levelling machines like power trowel or equivalent.

4.3.4. Curing of slab.

Curing of the concrete shall be ongoing for at least 3 days by using water. The curing could be done using curing
agent if specified by the consultant.

5. HEALTH AND SAFETY

In addition to the ordinary health and safety, the following shall be considered:
 Concreting works
- All workers dealing with concrete shall wear gloves.
- Only the foreman shall guide the crane operator for moving the tremie pipes.
- After concreting, the remaining portion of the pile shall be backfilled with excavated material.
 Moving and lifting equipment
- Lifting loads shall be always less than the maximum safe capacity of the equipment.
- No load shall be left suspended by the equipment.
- No work shall take place under lifted loads.

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Method Statement – Deck Slab Construction REV. No: 00

6. ENVIRONMENT
In addition to the ordinary environmental rules, the following shall be considered to protect the
ground against pollution
- Used oil shall be collected while changing in order not to contaminate the ground and shall be
disposed safely in designated areas.
- Equipment shall be fuel fed by manual pumps through hoses in order to avoid spillage on the ground.

7. INSPECTION AND TESTING (QA/QC)

7.1. Controls on Formwork
Formworks shall be inspected in dimensions, alignments and location of lateral supports (Tie rods or bracings)
as per the project specs by the consultant before casing the concrete.

Surveying points shall be marked for the exact location of the inner side of the form works (4 corners) before
the erection of the works, skilled form workers shall fix the form sides to fit the exact side (2 point) that should
hold the shatter. Initial check shall be done by the surveyor prior to the final check by the consultant.

7.2. Controls on Reinforcement

Reinforcement shall comply with the project specs and consultant comments if any, all reinforcement steel
bars shall be stored and kept in a dry area covered to avoid in contact with water, reinforcement stirrups shall
be fabricated in site with suitable machinery to do the bending works without considering any damage to the
steel.

A copy of the steel delivery note shall be provided to the consultant along with the material inspection request
(MIR) for his approval and visual inspection if required.

Upon delivery to the site, a sample shall be collected from the steel to allow for destructive testing. The sample
shall be tested in a certified lab with tensile destructive tests to define the tensile strength for at least 1 sample
from each supplier. Additional tests may be required subject to the satisfaction of the consultant.

7.3. Controls for Concrete Prior to Concreting

All tests related to concrete or its constituents shall be covered by the Main contractor.

Before the actual concreting, slump tests have to be made to confirm the workability of the concrete in
addition to concrete sampling. Concrete samples shall be done to cover the project test requirements.

Sampling will be done by the supplier’s certified technician, box dimensions shall be 150x150x150mm as per
the Egyptian standards. Preparation of the cube shall be done by the technician after checking the slump of
the vehicle, random checking will be done on the ordered quantity.

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Method Statement – Deck Slab Construction REV. No: 00

The dismantle of the cubes shall be done after 2 days of casting to allow for concretes initial settlement, the
cubes will be marked by the name of the element and the casted day, then stored in a cold designated area
before sending it to the lab for testing,

7.4. Controls during Concreting

The concrete will be delivered to site in ready-mix trucks in sufficient quality and quantity to guarantee the
workability and a continuous concreting procedure without any interruption.

Concreting will be performed by pouring the concrete continuously into the hopper and through the pump
then passed to the formwork in layers if required. The height of each concrete layer shall not exceed 45CM
to allow for proper vibration and compaction works to be conducted on the freshly casted concrete.

The total volume of concrete consumed by each element will be calculated and compared to the theoretical
volume of the same element to define the overcasting and wastage.

Concrete testing will be reported to the consultant for his satisfaction and approvals.

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