The purpose of this method is to describe the methodology involved in construction work for the Boiler foundation item and to detail out the steps to be taken in order to meet the technical requirements of VP1 BOT Thermal Power Plant.
AP APPROVED Approved AC APPROVED WITH COMMENT Contractor to revise the correction and resubmit NA NOT APPROVED Revise the correction and resubmit before proceeding RE REVIEWED Information acknowledged with no comment For Approval RC REVIEWED WITH COMMENT Information acknowledged with comments Note: Approval or comment does not relieve the Contractor of all obligations covered under contract Discipline: Civil 15 Jul 20 Date: A 02-Jul-2020 For Approval J.H CHOI K.S KIM D.H JEONG REV DATE DESCRIPTION Approved Checked Prepared OWNER VAN PHONG POWER COMPANY LIMITED PROJECT Van Phong BOT Thermal Power Plant Project Status □Approved □Approved with Comment □Not Approved □Reviewed OWNER’S ENGINEER Pöyry Switzerland Ltd EPC CONTRACTORS IHI–TESSC–CTCI–DHI CONSORTIUM PROJECT DOCUMENT No REV VP1-2-L4-C-HBA-10034 A DOCUMENT TITLE METHOD STATEMENT FOR BOILER FOUNDATION UNIT EPC EPC DOCUMENT No VP1-2-L4-C-HBA-10034 Doosan Heavy Industries and Construction 1|Page REV A VAN PHONG BOT THERMAL POWER PLANT PROJECT Table of Contents PREFACE - - REFERENCE - 2.1 Applicable Code and Standard - 2.2 Drawing and Method Statement - - MANPOWER & EQUIPMENT - - RESPONSIBILITIES - - PROCEDURE AND SEQUENCE - - CONSTRUCTION WORK - 6.1 Excavation and disposal - - 6.2 Lean concrete - 10 - 6.3 Reinforcement work - 10 - 6.4 Installation of embedded plate, box out (if any) - 13 - 6.5 Formwork - 14 - 6.6 Concrete work - 17 - 6.6.1 Construction Joint - 17 - 6.6.2 Massive concrete - 19 - INSPECTION AND TESTING - 24 ENVIRONMENT, HEALTH AND SAFETY (EHS) - 24 8.2 Job Safety Analysis - 54 Attachment #1 : Calculation sheet for Formwork - 63 Attachment #2 : Method Drawing - 64 Attachment #3 : Calculation for concrete supply - 65 - - - | Page Re v A VAN PHONG BOT THERMAL POWER PLANT PROJECT PREFACE The purpose of this method is to describe the methodology involved in construction work for the Boiler foundation item and to detail out the steps to be taken in order to meet the technical requirements of VP1 BOT Thermal Power Plant Project Van Phong BOT Thermal Power Plant Company/Owner Van Phong Power company limited(VPCL) Contractor DHI ITEM Boiler Foundation Unit REFERENCE 2.1 Applicable Code and Standard • ACI 347-Guide to formwork for concrete • ACI 304-Guide for measuring, mixing, transporting, and placing concrete • ACI 301-Specifications for structural concrete for buildings • ACI 318-Building Code Requirements for Structural Concrete • ACI-305R-Guide to hot weather concreting • ASTM C33: Standard specification for concrete aggregate • ASTM C94: Standard specification for Ready-mix concrete • ASTM C150: Standard specification for Portland cement • ASTM C494: Standard specification for Chemical admixture for Concrete • TCVN 1651:2008: Concrete reinforcement • Part III-2 Exhibit B1 Tech Spec Section • Part III-2 Exhibit B1 Appendix G Civil/Structure Technical Guideline • VP1-0-EPC-H-GEN-10511-Health, Safety and Environment Plan • VP1-C-L4-H-GEN-00003- HSE Risk Management • VP1-C-L4-H-GEN-00005- HSE accident and incident • VP1-C-L4-H-GEN-00009- Working at height • VP1-C-L4-H-GEN-00012- Lifting operations • VP1-C-L4-H-GEN-00020- Scaffolding • VP1-C-L4-H-GEN-00024- Hot work • VP1-C-L4-H-GEN-00026- Excavation • VP1-C-L4-H-GEN-00027- Permit to work - - | Page Re v A VAN PHONG BOT THERMAL POWER PLANT PROJECT 2.2 Drawing and Method Statement • VP1-C-L4-C-HBA-17501_ Boiler excavation drawing • VP1-0-L4-A-UYX-00201_ General Rebar Standards • VP1-C-L4-C-HBA-17101_ Boiler foundation plan drawing • VP1-C-L4-C-HBA-17102_ Boiler foundation section drawing • VP1-C-L4-C-HBA-17103_ Boiler foundation detail drawing • VP1-C-L4-C-HBA-17301_ Boiler foundation reinforcement drawing • VP1-0-L4-C-GEN-10007_ Method statement for General concrete work • VP1-0-L4-C-GEN-10008_ Method statement for Excavation and backfilling work MANPOWER & EQUIPMENT • Manpower mobilized for construction of the Boiler are listed as followings: No Position Quantity Site Manager 01 Site engineer 06 Safety supervisor 01 Surveyor 02 Crane operator 02 Roller operator 01 Worker 100 • Equipment mobilized for construction of the Boiler are listed as followings: No Equipment Unit Quantity Total station nos 02 Auto level nos 02 Crane nos 02 Excavator nos 02 Roller nos 02 Rammer nos 05 Plate compactor nos 02 Cutting machine nos 05 Bending machine nos 02 - - | Page Remark Re v A VAN PHONG BOT THERMAL POWER PLANT PROJECT Welding machine nos 10 10 Concrete pump truck nos 03 11 Concrete mixer truck nos 12 12 Concrete vibrator nos 12 13 Water pump nos 05 14 Troweling machine nos 01 15 Light nos 20 RESPONSIBILITIES • It is overall responsibility of Site Manager to organize resources prior to perform construction activities as per project specification in compliance with the quality, schedule & safety requirements • EHS Manager will ensure in coordination with Site Engineer that all measure/construction taken shall be maintained till completion of job • It is the responsibility of Construction Manager/Site Engineer that construction activities are executed according to the relevant project specification in compliance with the quality, schedule & safety requirements • Contractor will ensure that all works are performed safely according to the attachment • The relevant contractor Supervisor will ensure that the work is carried out in accordance with this method statement and project specification • The QC Inspector will ensure that the work is executed according to the requirements of quality dossier are fulfilled - - | Page Re v A VAN PHONG BOT THERMAL POWER PLANT PROJECT PROCEDURE AND SEQUENCE General Plan Due to the large dimension of foundation, detail of reinforcement, different of Bottom of foundation contractor shall divide foundation into 07 stage to ensure safety condition and quality of concrete (massive concrete): Vertical construction joint will be arranged between Stage [3], Stage [5], Stage [6], Stage [7]; Isolation joint surround Stage [1], Stage [2], Stage [4] Method statement for Fan will be separate and submit later - - | Page Re v A VAN PHONG BOT THERMAL POWER PLANT PROJECT Stage "2.4" should be written down Why Pulverizers concrete is divided into and ? 2.3 2.2 2.4 Stage "2.5" should be written down 2.1 2.5 2.6 2.7 The stage from to will be carried out to follow the schedule of Anchor Bolts installation, Contractor will arrange enough manpower and equipment to conduct these stages Besides, the calculation of concrete supply has to prepare to make sure the eligible condition for cast concrete Between each stage, the Hy-rib permanent formwork will be used to avoid crack and so forth between construction joints The expression of Stages is different from Uni Why ? - - | Page Re v A VAN PHONG BOT THERMAL POWER PLANT PROJECT Construction Stage 1: SCC, Oil sump: 04 Phase - - | Page Re v A VAN PHONG BOT THERMAL POWER PLANT PROJECT Construction Stage 2, 3, 4, 5, 6: Massive concrete, Maximum thickness: 3m Where is Stage 7? • Vertical construction joint will be arranged between Stage [3], Stage [4], Stage [5], Stage [6] And Massive concrete will be describing in section 6.6 Concrete work Stage is three Pulverizers ? This is isolated joint ? CONSTRUCTION WORK 6.1 Excavation and disposal • The ratio 1:0.5 shall be applied for the slope of foundation, Typical section for excavation is shown in picture below Dimension of pit lager than dimension of foundation 2m for all direction for Scaffolding, formwork This sentence cannot be understood This figure is wondering Why is dewatering pipe in the concrete of SCC sump foundation ? Typical of dewatering for SCC sump In case of heavy rain, Contractor will use some water pumps to dewater; in addition, making - - | Page Re v A VAN PHONG BOT THERMAL POWER PLANT PROJECT trenchs to collect water need to carry out The layout of trench will be depended on the actual condition on site, particularly, avoid obstructing other activities and easily collect water 6.2 Lean concrete • Subgrade of foundation must be well compacted unless surface is rock and cleaned up to ensure the quality of lean concrete Any marshy ground position must be removed and compacted by good material Lean concrete plan will depend on the construction step • Lean concrete thickness 50mm (as design drawing), grade: 15Mpa • Lean concrete is casted before next activities such as rebar or formwork installation 6.3 Reinforcement work • Steel bars shall be stored on the site on racks or supports of sufficient height to keep the bars clear of the ground and steel bar shall be covered by plastic sheet in order to prevent corrosion by the sea environment • Bar bending schedule shall be submitted before commencement of work • Fabricating, installing foundation rebar comply with the approved design, project specification, ACI 117 and ACI 318, approved BBS Lap splicing method shall be used for rebar connection, the lap length shall comply with the approved design drawing and applied standard • Any kind of hot cutting and bending rebar shall not be allowed • Fabricated rebar will be transported from the workshop to construction site by lorry crane • Rebar shall be erected such as to form a rigid cage within the formwork, with every intersection being bound together with appropriate binding wire • Specified concrete cover shall be maintained by the use of precast concrete spacer blocks of the same grade as the concrete in which they are to be used - 10 - | P a g e Re v A STAGE #7: AXIS BF-BH, Quantity: 1787m3 HANDRAIL WORKING PLATFORM DETAIL A TOP LAYER BAR TUBE Ø48 CHAIR REBAR 600 SUPPORT BAR LEAN CONCRETE 250 3000 SIDE BAR 600 3000 600 1500 600 CHAIR REBAR 0.5 BOTTOM LAYER BAR SECTION SPAPE OF CHAIR REBAR EXECUTION PLAN OF EXCAVATION WORK - UNIT #2 EXECUTION PLAN OF EXCAVATION WORK - UNIT #2 2.3 2.2 2.4 2.1 2.5 2.6 2.7 CONECTED FLYWOOD DETAL CONSTRUCTION JOIN GRAPHIC SCALE BOILER FOUNDATION 300 300 550 300 550 320 1220 1220 800 800 800 PILE SUPPORT Ø49 600 600 STEEL BOX 50x50x1.8mm SECTION 2-2 STEEL BOX 50x50x1.8mm 600 600 600 STEEL BOX 100x50x1.8mm 3200 600 STEEL BOX 100x50x1.8mm PLYWOOD 18mm 600 250 250 PLYWOOD 18mm 600 CONSTRUCTION JOINT AT TOP WALL 1220 SECTION 1-1 CONSTRUCTION JOINT AT BOTTOM WALL GRAPHIC SCALE BOILER FOUNDATION MS-DETAIL OF CONCRETE-FORM WORK VAN PHONG BOT THERMAL POWER PLANT PROJECT Attachment #3 : Calculation for concrete supply - 65 - | P a g e Re v A Tính tốn khả cung cấp bê tông / Calculation for Pump car capacity Thể tích khối móng/Foundation concrete volume :V1 (m3 ) Số lượng bơm mẻ đổ/Quantity pump cars: n1 = pumps Năng suất bơm bê tông lý thuyết/Ideal Capacity per pumps car : Pide = 60 m3 /h/pump Năng suất bơm bê tông thực tế/Actual Capacity per pumps car : Pact = 42 m3 /h/pump Thời gian đổ/Pour time: h1 = 24 h Tổng thể tích khối đổ/Total capacity : V2 = P x n1 x h1 = 3024 (m3) Hệ số an toàn/safety factor : V2/V1 Hạng mục/ Items Nội dung/Content 1) Kích thước/ Mat size bê tơng/ Concrete (V1) 2) Xe bơm bê tông/ pump cars 2709 m3 (Strength: fc=30Mpa ) Năng suất/ capacity 42 m3/h/pump Số lượng/ quantity xe bơm/pumps (1 back-up pumps) 3) Xe bê tông/ Agitator truck ( 8m3/ car) See detail below 4) Thời gian đổ bê tông/pouring time 5) Total capacity (m3) (V2) 6) Hệ số an toàn / Safety factor 24 giờ/h 3024 1.1 m3 Phân tích chu kỳ bê tơng / Analysis of cycle concrete supply Time periods table references from supplier Trạm/Batching Classification VIMECO Day Night 0.8 Time periods (min) Distance (km) 8.0 8.0 Transport 3.0 3.0 5.0 5.0 Casting 11.0 11.0 Washing 2.0 2.0 Turn back 3.0 3.0 Total 32 32 Waiting(slumping test ) Tính tốn số lượng xe bê tông 8m3 tối thiểu/Calculation for the amount of concrete truck 8m3 Chu kỳ xe 32 phút/Time periods 32 minutes for trip Thời gian đổ = 11 phút (~42m3 /h cho suất xe bơm bê tông) Casting=11 minutes(~42m3 /h capacity of truck mounted line pump) start ● 11 Truck ●11 Truck ● 11 ● Finish1 period Truck Total 33min Theo biểu đồ bơm cần xe bê tông Follow the chart: pump need concrete trucks Dự kiến trạm cấp từ bơm nên số xe bê tông tối thiểu cần thiết cho trạm bảng bên VIMECO will arrange pump trucks hence, the minimum of concrete trucks which need to provide Batching Vimeco Distance(km) 0.8 Max time periods(min) 32 Quantity of pump (nos) pumps Min agitator trucks (nos) Checking with the capacity of concrete supply from Vimeco As confirmation from Vimeco, Total of capacity of product Mix concrete is: Within 24 hours Tcap=T1+T2+T3= =(960+960+720)*3= Conclusion: 0.8 Product Tcap=7920m3>V2=3024m3 7920 m3 OK Page Checking the Pump truck and the concrete truck: Q pump truck = Q concrete truck = nos 10 >9(as requirement) OK OK T1 T2 T3 Page Tính tốn khả cung cấp bê tơng / Calculation for Pump car capacity Thể tích khối móng/Foundation concrete volume :V1 (m3 ) Số lượng bơm mẻ đổ/Quantity pump cars: n1 = pumps Năng suất bơm bê tông lý thuyết/Ideal Capacity per pumps car : Pide = 60 m3 /h/pump Năng suất bơm bê tông thực tế/Actual Capacity per pumps car : Pact = 42 m3 /h/pump Thời gian đổ/Pour time: h1 = 26 h Tổng thể tích khối đổ/Total capacity : V2 = P x n1 x h1 = 3276 (m3) Hệ số an toàn/safety factor : V2/V1 Hạng mục/ Items Nội dung/Content 1) Kích thước/ Mat size bê tông/ Concrete (V1) 2) Xe bơm bê tông/ pump cars 3034 m3 (Strength: fc=30Mpa ) Năng suất/ capacity 42 m3/h/pump Số lượng/ quantity xe bơm/pumps (1 back-up pumps) 3) Xe bê tông/ Agitator truck ( 8m3/ car) See detail below 4) Thời gian đổ bê tông/pouring time 5) Total capacity (m3) (V2) 6) Hệ số an toàn / Safety factor 26 giờ/h 3276 1.1 m3 Phân tích chu kỳ bê tơng / Analysis of cycle concrete supply Time periods table references from supplier Trạm/Batching Classification VIMECO Day Night 0.8 Time periods (min) Distance (km) 8.0 8.0 Transport 3.0 3.0 5.0 5.0 Casting 11.0 11.0 Washing 2.0 2.0 Turn back 3.0 3.0 Total 32 32 Waiting(slumping test ) Tính tốn số lượng xe bê tơng 8m3 tối thiểu/Calculation for the amount of concrete truck 8m3 Chu kỳ xe 32 phút/Time periods 32 minutes for trip Thời gian đổ = 11 phút (~42m3 /h cho suất xe bơm bê tông) Casting=11 minutes(~42m3 /h capacity of truck mounted line pump) start ● 11 Truck ●11 Truck ● 11 ● Finish1 period Truck Total 33min Theo biểu đồ bơm cần xe bê tông Follow the chart: pump need concrete trucks Dự kiến trạm cấp từ bơm nên số xe bê tông tối thiểu cần thiết cho trạm bảng bên VIMECO will arrange pump trucks hence, the minimum of concrete trucks which need to provide Batching Vimeco Distance(km) 0.8 Max time periods(min) 32 Quantity of pump (nos) pumps Min agitator trucks (nos) Checking with the capacity of concrete supply from Vimeco As confirmation from Vimeco, Total of capacity of product Mix concrete is: Within 26 hours Tcap=T1+T2+T3= =(960+960+720)*3*26/24= Conclusion: 0.8 Product Tcap=8580m3>V2=3276m3 8580 m3 OK Page Checking the Pump truck and the concrete truck: Q pump truck = Q concrete truck = nos 10 >9(as requirement) OK OK T1 T2 T3 Page Tính tốn khả cung cấp bê tông / Calculation for Pump car capacity Thể tích khối móng/Foundation concrete volume :V1 (m3 ) Số lượng bơm mẻ đổ/Quantity pump cars: n1 = pumps Năng suất bơm bê tông lý thuyết/Ideal Capacity per pumps car : Pide = 60 m3 /h/pump Năng suất bơm bê tông thực tế/Actual Capacity per pumps car : Pact = 42 m3 /h/pump Thời gian đổ/Pour time: h1 = 25 h Tổng thể tích khối đổ/Total capacity : V2 = P x n1 x h1 = 3150 (m3) Hệ số an toàn/safety factor : V2/V1 Hạng mục/ Items Nội dung/Content 1) Kích thước/ Mat size bê tông/ Concrete (V1) 2) Xe bơm bê tông/ pump cars 2843 m3 (Strength: fc=30Mpa ) Năng suất/ capacity 42 m3/h/pump Số lượng/ quantity xe bơm/pumps (1 back-up pumps) 3) Xe bê tông/ Agitator truck ( 8m3/ car) See detail below 4) Thời gian đổ bê tông/pouring time 5) Total capacity (m3) (V2) 6) Hệ số an toàn / Safety factor 25 giờ/h 3150 1.1 m3 Phân tích chu kỳ bê tông / Analysis of cycle concrete supply Time periods table references from supplier Trạm/Batching Classification VIMECO Day Night 0.8 Time periods (min) Distance (km) 8.0 8.0 Transport 3.0 3.0 5.0 5.0 Casting 11.0 11.0 Washing 2.0 2.0 Turn back 3.0 3.0 Total 32 32 Waiting(slumping test ) Tính tốn số lượng xe bê tông 8m3 tối thiểu/Calculation for the amount of concrete truck 8m3 Chu kỳ xe 32 phút/Time periods 32 minutes for trip Thời gian đổ = 11 phút (~42m3 /h cho suất xe bơm bê tông) Casting=11 minutes(~42m3 /h capacity of truck mounted line pump) start ● 11 Truck ●11 Truck ● 11 ● Finish1 period Truck Total 33min Theo biểu đồ bơm cần xe bê tông Follow the chart: pump need concrete trucks Dự kiến trạm cấp từ bơm nên số xe bê tông tối thiểu cần thiết cho trạm bảng bên VIMECO will arrange pump trucks hence, the minimum of concrete trucks which need to provide Batching Vimeco Distance(km) 0.8 Max time periods(min) 32 Quantity of pump (nos) pumps Min agitator trucks (nos) Checking with the capacity of concrete supply from Vimeco As confirmation from Vimeco, Total of capacity of product Mix concrete is: Within 25 hours Tcap=T1+T2+T3= =(960+960+720)*3*25/24= Conclusion: 0.8 Product Tcap=8250m3>V2=3150m3 8250 m3 OK Page Checking the Pump truck and the concrete truck: Q pump truck = Q concrete truck = nos 10 >9(as requirement) OK OK T1 T2 T3 Page Tính tốn khả cung cấp bê tơng / Calculation for Pump car capacity Thể tích khối móng/Foundation concrete volume :V1 (m3 ) Số lượng bơm mẻ đổ/Quantity pump cars: n1 = pumps Năng suất bơm bê tông lý thuyết/Ideal Capacity per pumps car : Pide = 60 m3 /h/pump Năng suất bơm bê tông thực tế/Actual Capacity per pumps car : Pact = 42 m3 /h/pump Thời gian đổ/Pour time: h1 = 16 h Tổng thể tích khối đổ/Total capacity : V2 = P x n1 x h1 = 2016 (m3) Hệ số an toàn/safety factor : V2/V1 Hạng mục/ Items Nội dung/Content 1) Kích thước/ Mat size bê tơng/ Concrete (V1) 2) Xe bơm bê tông/ pump cars 1787 m3 (Strength: fc=30Mpa ) Năng suất/ capacity 42 m3/h/pump Số lượng/ quantity xe bơm/pumps (1 back-up pumps) 3) Xe bê tông/ Agitator truck ( 8m3/ car) See detail below 4) Thời gian đổ bê tông/pouring time 5) Total capacity (m3) (V2) 6) Hệ số an toàn / Safety factor 16 giờ/h 2016 1.1 m3 Phân tích chu kỳ bê tơng / Analysis of cycle concrete supply Time periods table references from supplier Trạm/Batching Classification VIMECO Day Night 0.8 Time periods (min) Distance (km) 8.0 8.0 Transport 3.0 3.0 5.0 5.0 Casting 11.0 11.0 Washing 2.0 2.0 Turn back 3.0 3.0 Total 32 32 Waiting(slumping test ) Tính tốn số lượng xe bê tông 8m3 tối thiểu/Calculation for the amount of concrete truck 8m3 Chu kỳ xe 32 phút/Time periods 32 minutes for trip Thời gian đổ = 11 phút (~42m3 /h cho suất xe bơm bê tông) Casting=11 minutes(~42m3 /h capacity of truck mounted line pump) start ● 11 Truck ●11 Truck ● 11 ● Finish1 period Truck Total 33min Theo biểu đồ bơm cần xe bê tông Follow the chart: pump need concrete trucks Dự kiến trạm cấp từ bơm nên số xe bê tông tối thiểu cần thiết cho trạm bảng bên VIMECO will arrange pump trucks hence, the minimum of concrete trucks which need to provide Batching Vimeco Distance(km) 0.8 Max time periods(min) 32 Quantity of pump (nos) pumps Min agitator trucks (nos) Checking with the capacity of concrete supply from Vimeco As confirmation from Vimeco, Total of capacity of product Mix concrete is: Within 16 hours Tcap=T1+T2+T3= =(960+960+720)*3*16/24= Conclusion: 0.8 Product Tcap=5280m3>V2=2016m3 5280 m3 OK Page Checking the Pump truck and the concrete truck: Q pump truck = Q concrete truck = nos 10 >9(as requirement) OK OK T1 T2 T3 Page