CM For Pile Cap Formwork Revise RE 12 Maret 2007 (Submitted)

METHOD STATEMENT
FOR
FORMWORK OF PILE CAP
CONSORTIUM OF INDONESIAN CONTRACTOR
SURAMADU APPROACH BRIDGE PROJECT
ADHI HUTAMA WASKITA WIJAYA

TABLE OF CONTENTS
1. Introduction __________________________________________________________________ 1
1.1 Resources ______________________________________________________________________ 3
1.1.1 Workman plan _______________________________________________________________________ 3
1.1.2 List of equipment_____________________________________________________________________ 3
1.2 Site layout______________________________________________________________________ 3
1.3 Pile cap formwork data _________________________________________________________ 3
2. Construction Program ________________________________________________________ 3
2.1 Description _____________________________________________________________________ 3
3. Formwork Structure__________________________________________________________ 4
3.1 Component of formwork ________________________________________________________ 4
3.2 Bottom plate____________________________________________________________________ 4
3.2.1 Type 1 _______________________________________________________________________________ 4
3.2.2 Type 2 _______________________________________________________________________________ 4
3.2.3 Type 3 _______________________________________________________________________________ 5
3.3 Side plate_______________________________________________________________________ 5
3.3.1 Type 1 _______________________________________________________________________________ 5
3.3.2 Type 2 _______________________________________________________________________________ 6
3.3.3 Type 3 _______________________________________________________________________________ 6
3.4 Suspension lifting system and jack-sinking system______________________________ 6
3.5 Inner bracing and guiding system ______________________________________________ 6
3.5.1 Guiding system_______________________________________________________________________ 6
3.5.2 Inner bracing_________________________________________________________________________ 6
4. Description of Work __________________________________________________________ 7
4.1 Fabrication and trial assembly of caisson _______________________________________ 7
4.2 Removal of drilling platform____________________________________________________ 7
4.3 Assembly of steel caisson_______________________________________________________ 8
4.4 Sinking steel caisson____________________________________________________________ 8
4.5 Monitoring of caisson construction______________________________________________ 9
4.6 Sealing of steel caisson _________________________________________________________ 9
4.7 Pile cutting ____________________________________________________________________11
4.8 Check caisson _________________________________________________________________11
5. Quality Assurance Plan______________________________________________________ 12
5.1 Quality plan control ___________________________________________________________12
5.2 Quality control organization ___________________________________________________12
5.3 Quality assurance system______________________________________________________12
5.3.1 Surveying ___________________________________________________________________________12
5.3.2 Key quality-checking item ___________________________________________________________13
5.3.3 Standard operation procedure _______________________________________________________13
i
6. Safety Plan__________________________________________________________________ 13
6.1 General safety measures ______________________________________________________13
6.2 Safety measures for assembly of caisson ______________________________________13
6.3 Safety measures for construction vessels ______________________________________13
6.4 Safety measures for submersible operation ____________________________________14
7. Document Control ___________________________________________________________ 14
Appendix -1 Shop Drawing

Appendix -2 Resources
Appendix -3 Construction Program
Appendix -4 Calculation Statement
Appendix -5 Standard Operation Procedure
ii
1. Introduction
This document describes the construction procedure of the construction of formwork
pile cap for the Suramadu Approach Bridges in Madura Strait. There are a total of
16 pile caps of pier shaft construction and 2 pile caps of V-pier construction. The
pile cap construction operation will be located in the submerged area within -0.99 m
to -2.190m depth. The designed highest water level is +1.3m while lowest water
level is -0.99m. The design flow speed is 1.68 m/s. The deduced maximum tide level
during the construction is +1.60m. The lowest tide level is -1.20m. Permanent steel
casings have already been installed at the correct location for each pile.
The design for each pier is different depend on site condition i.e. bracket position,
lifting lug position, and plain location of pile. There are three typical dimensions
which are type 1 for P45 and P48, type 2 for P41-42-51-52, and type 3 for the rest
pier. Entire pile cap is rectangular except special appearance in P49 which will need
a different formwork. It will be submitted later when the design has been approved.
When sea level reach lowest water level (-0.99m), the pile foundation does not
expose out of the water surface to ensure pleasing appearance.
This document will cover in detail the construction program, safety and all quality
assurance measures including laboratory testing related to the construction of pile
cap formwork.
Refer to the flow chart below for the sequence of the tasks in the pile cap formwork
procedure.
1
Remove drilling
platform
Complete survey of
Segment fabricator Approval of NCRs
pile location
Trial assembly in Cut bracket on casing, level Clear marine life and
land top opening of steel casing rust on casings wall
Install jack sinking Assemble bottom

and lifting system plate of caisson
Q1
Install guiding
system
Install inner
Assemble side plate
bracing
Q2
Move the formwork

down to design level
Seal the gap in

bottom plate
Q3
Concrete mixing Pouring sealing Monitoring of water

and delivery concrete level
Q4
Pump the water out

from bottom caisson
Weld beard rebar

around casing
Concrete mixing Concreting for 20cm thick

and delivery leveling layer of sealing concrete
Q5
Cut pile head
Q6
Pile cap
construction
1.1 Resources
1.1.1 Workman plan
Refer to Appendix -2 for complete workman plan involved in the pile cap formwork
construction.
1.1.2 List of equipment

Refer to Appendix -2 for complete list of equipment involved in the pile cap
formwork construction.
1.2 Site layout

During the pile cap construction there will be a workshop barge, a crane barge, a
batching plant barge and a formwork feeder barge located at pier. The feeder barge
for formwork will normally be situated at one end of the platform to erect the
formwork then moved to the other end to erect another side of formwork. To
facilitate efficient operations the equipment location and anchorage must be
carefully determined. Six (6) fender pipe will be installed at each pier to prevent
barge and formwork from collide.
1.3 Pile cap formwork data

Concrete Grade = C35
Steel Strength = 160Mpa
Table 1-1 Design parameter of pile cap formwork

No Item Level (m)
Type 1 Type 2 Type 3
1 Top level of pile cap +3.510 +2.510 2.010
2 Bottom level of pile cap -0.990 -0.990 -0.990
3 Top level of side formwork +3.710 +2.710 +2.210
4 Top level of sealing concrete -0.990 -0.990 -0.990
5 Bottom level of sealing concrete -2.190 -2.190 -2.190
2. Construction Program
2.1 Description
The construction of pile cap formwork will be begun after the bored pile operation
in one pile group has been finished. The first construction will be constructed on
pier 40 then continue to pier 45 and 48. 6 (six) formwork of pile cap shall be
erected to obey the tight schedule. The pile cap work will be started by the end of
March 2007 and completed on March 2008.
3
Second beam of formwork will be left on the bottom pile cap whilst main beam of
bottom formwork and side formwork shall be recycled to another pier location. Side
formwork shall be dismantled after curing concrete has finished.
Refer to Appendix -3 for a complete program of pile cap construction.
3. Formwork Structure
3.1 Component of formwork
The formwork of pile cap is steel caisson with single wall and with bottom. The
bottom plate and the side plate of steel caisson are of single-wall rib-plate structure.
The steel caisson is composed of bottom plate, side plate, inner bracing, suspending
and sinking system and guiding system.
3.2 Bottom plate

3.2.1 Type 1
The bottom plate of caisson is of 6mm-thick steel plate as the face plate. The
main beam laid in transverse direction of bridge is of 2IWF350.175.7.11 shaped
steel. The secondary beam is channel steel [10 and the secondary beam adjacent
to casing is Channel steel 2[10.
The spacing between main beams is 2600mm and 2900mm respectively.
250.250.10 steel plate will be used as couple plate for main beam with 1833mm
spacing. To stabilize the main beam in support position, 20mm stiffener plate
shall be welded in the IWF350.175.7.11 steel beam. The spacing between
secondary beams is 550mm.
6mm thick face plate is placed above the secondary beam and welded.
Secondary beam will be left after the sealing concrete is finished whereas the
main beam will be pulled out for recycling to other location.
To meet the situation that the 80ton floating crane is operated as the main
lifting equipment, the bottom plate of caisson will be prefabricated piece by piece
and assembled and welded in the site. The bottom plate will be divide into 8
(eight) pieces where the weight is 13.542ton.
3.2.2 Type 2
main beam laid perpendicular with bridge direction is of 2IWF350.175.7.11
shaped steel. The secondary beam is Channel steel IWF100.100.6.8 and the
secondary beam adjacent to casing is Channel steel 2IWF100.100.6.8.
4
The bottom plate will be divided into 3 (three) pieces where the weight is
15.377ton.
3.2.3 Type 3
main beam laid perpendicular with bridge direction is of 2IWF350.175.7.11
shaped steel. The secondary beam is channel steel [10 and the secondary beam
adjacent to casing is Channel steel 2[10.
The bottom plate will be divide into 3 (three) pieces where the weight is
15.181ton.
3.3 Side plate

6mm thick steel plate is used as the face plate for side plate, which longitudinal
and transverse rib forms single-wall rib plate structure. The secondary and
main rib forms the skeleton structure. Both of the structures are used as
bearing structure.
The first layer of face plate of side plate is of Channel steel [8 rib with the
spacing of 40cm. The second layer of vertical rib is IWF350.175.7.11 shaped
steel with the spacing of 130cm. The hoop of main rib is IWF450.200.14.9
shaped steel. 3 hoops are set along the vertical direction with the spacing
136cm in upper hoops and 154cm in lower hoops.
For the simplicity of removing side plate underwater, every piece of side plate
shall be connected by M20 bolts. The piece of side plates below -0.5m level is
connected by stainless steel bolts.
3.3.1 Type 1
The side plate will be divided into 18 segments with 6.00m height. There are 3
types of side panel to meet the capacity of crane. Width of type A panel is
9.00m whilst width for type B and Type C is about 5.30m and 8.00m
respectively.
Lifting weight for Type A, Type B and Type C panel is 7.272ton, 4.101ton and
6.448ton respectively.
5
3.3.2 Type 2
respectively.
3.3.3 Type 3
respectively.
3.4 Suspension lifting system and jack-sinking system

Two pieces of IWF350.175.7.11 shaped steel are placed on the top mouth of steel
casing and used as beam (the level of top mouth of steel casing is +3.50m). The
lifting boom is of 32 fine rolled twisted steel bars. The lifting boom is connected
with the main beam. For formwork type 1, 25 sets of jacking system will be used
whilst formwork type 2 and 3 use 16 sets per each pier.
3.5 Inner bracing and guiding system

3.5.1 Guiding system
After sinking, IWF350.175.7.11 shaped steel shall be installed between side plate
and adjacent pile casing. Connection between side plate and adjacent pile casing will
be by welding. Length of the shaped steel will be adjusted according to the site
condition. Guiding system will be released before pile cutting is conducted.
3.5.2 Inner bracing
a. Type 1
As the large dimension of formwork for type 1, there are 9 (nine) truss for
inner bracing. Two stories of truss will be erected during construction of pile
cap. The placing of truss will be set as shown in the shop drawing.
The first story of inner bracing is made of IWF350.175.7.11 shaped steel for
the horizontal rib and Channel steel [10 for the horizontal and diagonal rib. The
lower layer of IWF350.175.7.11 shaped steel shall be placed on level -0.290m
and the upper layer will be placed on level +1.710m. The spacing for diagonal
and horizontal rib is 189.3cm and placed along truss direction.
The second story of inner bracing is made of IWF350.175.7.11 shaped for lower
layer and 400mm steel pipe for upper layer. The lower layer of the second
story is the upper layer of the first story. The 400mm steel pipe is placed in
6
top of formwork with elevation +3.910m. To stabilize the steel pipe position, the
pipe will be connected to highest hoop then welded thru steel plate 20mm.
b. Type 2
6 (six) truss for inner bracing are set inside of the caisson of the pile cap type
2. The placing of truss will be set as shown in the shop drawing. The placing of
inner bracing has considered the allowable deformation of side formwork
therefore maximum spacing of inner bracing is 750cm.
The lower layer of vertical rib is made of IWF350.175.7.11 shaped steel and
placed on level +1.210m whilst the upper layer is made of 400mm steel pipe
and placed on level +2.910m. The diagonal and vertical rib of truss is made of
Channel steel [10. The connection of truss is similar with inner bracing type 1.
c. Type 3
6 (six) truss for inner bracing are set inside of the caisson of the pile cap type
3. The placing of truss will be set as shown in the shop drawing. Maximum
spacing of inner bracing is 750cm.
The lower layer of vertical rib is made of IWF350.175.7.11 shaped steel and
placed on level +0.710m whilst the upper layer is made of 400mm steel pipe
and placed on level +2.410m. The diagonal and vertical rib of truss is made of
Channel steel [10. The connection of truss is similar with inner bracing type 1.
4. Description of Work
4.1 Fabrication and trial assembly of caisson
Pile cap formwork shall be fabricated in casting yard piece by piece. The
fabrication team shall fabricate the formwork in strict accordance with the
design requirement. Every department shall strengthen the control of working
procedure to ensure the quality.
Semi-finished product of caisson shall be stacked in class, and marked with sole
identification. While stacking, the measures shall be taken to prevent the
deformation.
Checking the weld quality, all the welding joints on the face plate of side plate
shall be checked kerosene to observe whether there is any leakage. The length
and the thickness of weld joint shall meet the requirement indicated in the
drawing. Otherwise it will not be checked and accepted.
After the processing of every individual plate of the caisson is finished, the trial
assembly of adjoining plates shall be conducted to check the error and quality of
caisson processing. The checking standard shall meet the relevant specification
and standard.
4.2 Removal of drilling platform

After the construction of bored pile is completed, the plate, main beam and
distributing beam of drilling platform shall be removed. The material of
7
platform can be recycled timely to another pier location. The bracket for drilling
platform on the steel casing shall be cut.
The design centre of the pile will be firstly set out on steel casing. The
fabrication of steel caisson formwork will be depended on steel casing position.
The casing position will be used to make the formwork precisely. The survey
team and site technical engineers will survey the gradient and plan location of
steel casing.
A complete survey shall be conducted to ensure the existing location of lifting
hook and earlier bracket. They therefore will not obstruct the sinking of the
caisson.
Before assembly of caisson bottom plate, the marine life remains attached to the
wall of steel casing above the level of -2.190m shall be cleared or removed to
ensure that the friction on clamp can be achieved the designed strength.
4.3 Assembly of steel caisson

The bottom plate of caisson will be assembled by floating crane, and temporarily
fixed on the steel casing. The location shall be within the allowable tolerance.
Install some of jack-sinking system by which the relative position of the
adjoining plates shall be adjusted and assembled.
After the assembly of bottom plate is finished, the remaining jack-sinking
system and suspension lifting system shall be installed. The first layer of
guiding system on the steel casing around the pile cap shall be installed. Then
the level of the bottom plate of caisson will be adjusted ready for assembly of
side plate of caisson.
Assembly of side plate of caisson; the side plate of caisson will be installed piece
by piece by 80ton floating crane. Every piece of side plate of caisson will be
temporarily fixed to the adjoining steel casing by shaped steel. The adjoining two
pieces of side plates of caisson will be assembled. After adjusting, the horizontal
hoops will be welded. The joints of side plates of caisson shall be watertight.
Install inner bracing; after the assembly of side plate is finished, the truss inner
bracing will be installed. The horizontal position of steel pipe is set above the
side formwork and left until the last pouring concrete is finished.
All the joints shall be strictly controlled. The special persons shall be assigned
for that purpose. Carefully check every weld joint to ensure the weld joint meet
the requirement
4.4 Sinking steel caisson

The sinking caisson shall be conducted at the time when the wind is gentle and
the water flow speed is little. The barge shall be set at two sides of pier with
anti-collision fender.
Before sinking the caisson, the temporarily connection between the side plate
and the steel casing will be released. The caisson sinking of 15cm is one travel.
The sinking process shall be coordinated and directed uniformly. The sinking
speed shall be controlled to ensure all sinking points in synchronism. Observe if
8
the bottom plate of caisson has enough space around the steel casing, therefore
the size of reserved hole in bottom plate of caisson can be timely revised.
When the panel of bottom plate of caisson is sunken to the level +0.5m, the
sinking of the caisson shall be temporarily stopped. At this time, the second
layer of guiding system will be installed. According to the actual deviation and
inclination of steel casing, the size of hole in bottom of plate of caisson will be
estimated. Revise the hole in bottom plate of caisson around the steel casing.
Then continue sinking to the designed level, -2.190m.
During caisson sinking process, special persons shall be assigned to observe the
change of water head inside and outside of caisson to keep the water head
consistent with the caisson water head condition. If necessary, it will be adjusted
by water pump.
Steel caisson will be deflection-rectified and position-adjusted by horizontal jack,
guiding system and jack-sinking system.
Horizontal jacking system is only used at the time when the steel caisson is
deflected and out of position. Jacking will be placed between steel casing and
side formwork.
The oxidation layer iron rust and the attached marine life in the wall of steel
casing shall be cleaned for the second time to ensure the cohesion between the
sealing concrete and the steel casing. Divers will place the clogging plate around
the steel casing, and install Channel steel using bolt then weld the extension
Channel steel into the casing above the elevation of sea water. Finally the divers
will fill the spacing between the casing and the bottom plate of the casing by
high pressure sponge so as to prevent the cement from leaking.
4.5 Monitoring of caisson construction

During the caisson sinking, uniform and horizontal sinking shall be assured. The
deviation caused by the asynchronous sinking shall be controlled within more
than 5mm.
After the caisson is sunken to the position, the plan and the level deviation of
the caisson shall be measured and adjusted. If it meets the requirement, the
steel caisson shall be timely fixed to the steel casing.
4.6 Sealing of steel caisson

Concreting will be done by 3 (three) division for P45 and P48 whilst for others
piers will be done by 2 (two) division. The largest volume for sealing concrete of
pile cap is done at P45 and P48. The total volume for one pier of those piers is
1140m3.
After the caisson is sunken to the position, the underwater sealing concrete
shall be poured by tremie method. Every time, one division will be concreted
continuously. 2 (two) pieces of tremie will be arranged for every division. In
order to ensure the initial tremie could be embedded at more than 0.6m by the
first batch of concrete, the quantity of the first batch of concrete shall be not
less than 8.0m3. The funnel for storage of the first batch of concrete shall be of
the funnel with the capacity at least 9.0m3. When the concrete is spread and
9
buried in the adjoining tremie, the water in the adjoining tremie shall be
drained. Concreting one by one until the concreting for one division is finished.
At every time, about 300 m3 sealing concrete will be poured for every division.
Two batching plant with the respective capacity of 40 m3/hour will be used. Two
concrete pumps with the capacity of 40 m3/hour will prepared for delivery of
concrete.
As the volume of sealing concrete is large, retarding agent will be applied for
the job mix formula of the concrete to extend the retarding time and ensure all
the pouring of sealing concrete should be finished before initial setting.
Altogether 2 (two) tremies will be arranged and numbered. The distance of
tremie from the bottom plate is 10~15cm. Funnel, concrete delivery pump and
pump pipes shall be installed in the 230 feet workshop barge. When all
preparations are ready, the first batch of sealing concrete can be poured. In
order to make the underwater concrete surface from some gradient and bury
the bottom mouth of the tremie and ensure concrete quality after every batch is
poured, the concrete with slump of 182cm shall be proposed.
Concreting shall be conducted by 6 tremies in one side then move to other side
simultaneously as shown in Figure 4-1.
1 4 1 4 1 4 1 4 1 4
Move Move
Tremie
2 5 2 5 2 5 2 5 2 5
3 6 3 6 3 6 3 6 3 6
Figure 4-1 Sequence of concreting of sealing concrete
The concreting for sealing concrete is sequenced as follow; start from the tremie
at the side close to the platform and then other tremie at the other side. During
the concreting, the tremie is not lifted as the concrete surface ascends so as to
ensure the minimum burying depth of the tremie is controlled within range 20-
60cm. During the concreting, site technicians will measure the concrete height
and monitor spreading condition by measuring scale. Divers are responsible for
levelling top surface of concrete.
Check sealing concrete; when pouring of the sealing concrete is finished and the
concrete strength reaches the designated grade, the quality of sealing concrete
shall be checked by water-pumping method to check the tightness, concrete
surface quality, flatness etc. If the leakage is serious, drilling and grouting
10
method will be applied for remedying that. The loose mortar and concrete on the
surface will be cleared.
4.7 Pile cutting

When levelling course of sealing concrete reaches the designated strength, the
cutting of steel casing shall be started. The quality of sealing concrete shall be
checked again. If sealing concrete has little leakage, the fast setting waterproof
mortar or coating materials will be applied for stopping water.
Before the pile head is chiselled, protection shall be made for the corresponding
rebar of reinforcement cage which shall be adjusted according to the design
drawings. Then air pick will be applied to cut the pile head to reach the design
level. Meanwhile, the concrete surface shall be fresh.
4.8 Check caisson

Requirement for tolerance of dimension; when separately processing the bottom
plate and the side plate of caisson, the processing tolerance shall meet the
requirement in the drawing and the relevant specification. After the processing
is finished, the trial assembly of overall steel caisson will be conducted to check
processing tolerance and processing quality of steel caisson. After the assembly
of the overall caisson is finished, it shall be checked and accepted according to
the following standards.
Table 4-1 Allowable tolerance after the steel caisson is assembled to a whole body
Checking item Allowable tolerance Checking method
Length (mm) 20 To be measured by steel
ruler
Overall caisson Width (mm) 20
dimension Height (mm) 20
Diagonal (mm) 20
Flatness of inner surface of side To be measured by 2m-
5
formwork (mm) ruler
Flatness of the surface of the two To be measured by 2m-
2
adjoining formwork (mm) ruler
Level or elevation (mm) To be measured by
10
levelling instrument
Axis deviation (mm) 10 To be measured
Checking the weld quality; all the welding joints on the wall of side plates shall
be checked with kerosene to see if there is any leakage. The length and the
thickness of weld joint shall meet the requirement as indicated in the drawing.
Otherwise it will not be checked and accepted.
11
After the assembly of caisson in site is finished, cleaning shall be conducted
inside the caisson to ensure it is clean.
After the pile head is cut, the top surface of concrete of pile head is 15cm
higher than the bottom of pile cap. Meanwhile the fresh concrete surface will be
available.
5. Quality Assurance Plan

5.1 Quality plan control
During site activity, quality control shall be executed according to quality plan as
shown in flowchart on Figure 1-1. Quality checker engineer shall check and control
the following item:
Q1 = - Checking assembly of bottom plate
- Checking the quality of weld
- Checking the quality of beam
- Checking the quality of plate
- Checking the dimension following the specification
Q2 = - Checking assembly of side plate
- Checking the quality of plate
- Checking the dimension
- Checking the flatness of the surface
- Checking the verticality
Q3 = - Checking sealing system
- Checking the elevation
- Checking the dimension
Q4 = - Checking elevation of top concrete
- Checking embedded depth of tremie
Q5 = - Checking elevation of top concrete
- Checking the flatness of concrete surface
Q6 = - Checking elevation of pile head
5.2 Quality control organization

Conduct quality checking. Quality checking engineer shall check and control the
quality of raw materials, processing and installation. Upon the completion of every
itemized works, a quality analysis discussion will be held.
5.3 Quality assurance system

5.3.1 Surveying
Survey team will conduct the construction control network. After the
construction of pile foundation is finished, complete and full re-surveying of the
control network will be conducted.
12
5.3.2 Key quality-checking item
The processing quality of segments will be controlled to ensure the installation
quality in site. The removal of marine life and surface oxidized rust on the wall
of steel casing will be strictly checked to ensure the expected function of clamp
can be achieved.
5.3.3 Standard operation procedure

Please refer to Appendix -5 for Standard Operation Procedure and the checklist of
pile caps formwork installation.
6. Safety Plan
6.1 General safety measures
Carry out relevant stipulations regarding site safety.
Fireproof measures shall be taken for construction site, material warehouse and
oil depot.
The site electromechanical equipment shall strictly comply with operation codes
and shall be periodically checked, maintained and serviced.
The entire worker in site shall wear the safety helmet, life jacket, and safety
shoes.
Persons shall be assigned to be on duty for 24hours to collect such information
regarding weather forecast, the number of applicable days for construction, etc.
Strictly implement all kinds of laws and regulations involved in offshore safety
to ensure safety.
6.2 Safety measures for assembly of caisson

Every day persons will be assigned to obtain weather information and deliver it
and make records.
When lifting segments of pre-cast formwork or supporting beam, no persons
shall stand or pass under the lifting boom and lifted objects. The slinger shall be
firmly connected for use. If necessary, the wind cable shall be set for lifted
objects to keep stable lifting.
All kinds of slinger, cable devices, connection fittings, fasteners and its
accessories used for the equipment shall have detailed specifications data and
technical requirement. The operation personnel, especially the operation staff of
special post shall acquire the effective Operation Certificate. The teams or shifts
shall conduct safety explanation. Written records or signatures are required.
6.3 Safety measures for construction vessels

Offshore high-frequency telephone and GPS-GSM system terminal equipment for
the construction vessels or barges and transport vessels will be prepared to
assure smooth communication.
13
Strengthen the management for the dispatching and berthing of site vessels.
During the construction of caisson, anti collision pile shall be installed around
the steel caisson to ensure safety of caisson.
6.4 Safety measures for submersible operation

During the construction of caisson, operation of the divers will be conducted in
shallow water area. The divers shall prepare complete diving equipment for
operation in shallow-water area.
Every person in operation team shall have the following equipment. One set of
diving suit, one pair of diving boots, one piece of submersible soft pipe, one
piece of sinking rope and one piece of signal rope, pressure-reducing ladder,
telephone device and air supply equipment.
The operation staffs shall be fully provided according to the stipulations.
Generally altogether 8~9 persons are needed for diving operation in shallow
water area. Of that, 2 persons are divers, who will work by shift. 1 signal man
(safety rope). 1 person in charge of air pipe, equipping and loading and
unloading. 4 persons in charge of compressing air with every shift of 2 persons,
shift will be changed at every half hour. 1 person for other items.
Doctor shall be prepared for diving operation. The divers shall receive physical
examination before diving.
7. Document Control
During construction all document control procedures shall be strictly adhered to.
All documents pertaining to the quality control and testing of concrete as well as
raw materials shall be sorted and stored in easily accessible, properly indexed
files.
This should include but not be limited to all certificates to proceed with work
and all completion of work certificates as well as variation orders and survey
data.
14
Appendix 1
Shop Drawing
Appendix 2
Resources
List of Equipment
Formwork of Pile Cap Work
No Item Qty Remarks
1 Feedeer Barge 1 unit 180feet
2 Workshop Barge 1 unit 180feet
3 Batching Plant Barge 2 unit
4 Crane Barge 1 unit 80t
5 Tug Boat 2 unit Malindo Gold, 2x420PK

Andatu, 2x350PK
6 Concrete Pump 2 unit
7 Submersible Diving Equipment 2 unit
8 Sinking Equipment 1 unit
9 Electric Welding Machines 10 unit
10 Air Compressor 2 unit
11 Water Pumps 5 unit
12 Screw Jack 50 unit

List of Equipment
Batching Plant
No Item Qty Remarks
Indo Beton's batching plant
1 Batching Plant Barge 240 ft 1
Material BP barge cap 500 m3
2 Feeder Barge 210 ft 1
Material feeder barge cap 1000 m3
3 Silo for SBC Cement 160ton 3 120ton + 2 silo container
@20ton
4 Silo for Fly Ash 60ton 1 cap 40 Ton + 1 silo con-
tainer @20ton
5 Concrete Pump with Long Boom 1 27 m'
6 Loader 1
0
7 Chiller 1 4 C/hour
8 Electric Winch 2 cap 2 Ton
9 Anchorage 2 Current Type @ 1 Ton
2 Frog Type @ 1 Ton
10 Tug Boat 1 1000 PK
11 Generator Set 1 150 Kva
Standar Beton Indonesia's batching plant

1 Batching Plant Barge 180 ft 1
Material BP barge cap 300 m3
2 Feeder Barge 150 ft 1
Material feeder barge cap 300 m3
3 Silo for SBC Cement 2 cap 45 Ton & 50 Ton
4 Silo for Fly Ash 1 cap 40 Ton
5 Concrete Pump with Long Boom 1 27 m'
6 Loader 1
7 Chiller 1 70C/hour
8 Electric Winch 4 cap 2 Ton
9 Anchorage 2 Frog Type @ 1 Ton
10 Tug Boat 1 640 PK
11 Generator Set 1 150 Kva
Workman Plan
Formwork of Pile Cap Work
No Item Qty Remarks
1 Welder 8
2 Diver 2
3 Lifting Worker 100
4 Concrete Worker 10
5 Mechanical 10
6 Unskill Labour 10
Appendix 3
Construction Program
SCHEDULE FOR COMPLETION OF APPROACH BRIDGE
DRAFT-R.00
ID Task Name Duration Start 2007 2008

March April May June July August eptemb October ovemb ecemb January ebruar March April May June July August eptemb October ovemb ecemb January
1 BORED PILE WORKS 515 days Thu Jul 20, '06
118 PILE CAP WORKS 357 days Mon Mar 19, '07
119 PC-P 40 70 days Mon Mar 19, '07
120 Remove Platform & Install Bottom + Side F.W (SF-A1) 25 days Mon Mar 19, '07 4/12
121 sealing concrete, pile cutting, inst. rebar & concreting 45 days Fri Apr 13, '07 5/27
122 PC-P 45 75 days Tue May 1, '07
123 Remove Platform & Install Bottom + Side F.W (SF-B1) 30 days Tue May 1, '07 5/30
124 sealing concrete, pile cutting, inst. rebar & concreting 45 days Thu May 31, '07 7/14
125 PC-P 48 75 days Sat May 26, '07
126 Remove Platform & Install Bottom + Side F.W (SF-B2) 30 days Sat May 26, '07 6/24
127 sealing concrete, pile cutting, inst. rebar & concreting 45 days Mon Jun 25, '07 8/8
128 PC-P 43 70 days Thu May 17, '07
129 Remove Platform & Install Bottom + Side F.W (SF-A.2) 25 days Thu May 17, '07 6/10
130 sealing concrete, pile cutting, inst. rebar & concreting 45 days Mon Jun 11, '07 7/25
131 PC-P 39 70 days Mon Jun 11, '07
132 Remove Platform & Install Bottom + Side F.W (SF-A1) 25 days Mon Jun 11, '07 7/5
133 sealing concrete, pile cutting, inst. rebar & concreting 45 days Fri Jul 6, '07 8/20
134 PC-P 38 70 days Sun Jul 29, '07
135 Remove Platform & Install Bottom + Side F.W (SF-B1-1) 25 days Sun Jul 29, '07 8/23
136 sealing concrete, pile cutting, inst. rebar & concreting 45 days Fri Aug 24, '07 10/7
137 PC-P 41 70 days Sun Aug 26, '07
138 Remove Platform & Install Bottom + Side F.W (SF-C1) 25 days Sun Aug 26, '07 9/19
139 sealing concrete, pile cutting, inst. rebar & concreting 45 days Thu Sep 20, '07 11/10
140 PC-P 37 70 days Sat Aug 18, '07
141 Remove Platform & Install Bottom + Side F.W (SF-B1-2) 25 days Sat Aug 18, '07 9/11
142 sealing concrete, pile cutting, inst. rebar & concreting 45 days Wed Sep 12, '07 11/2
143 PC-P 42 70 days Sun Nov 25, '07
144 Remove Platform & Install Bottom + Side F.W (SF-C1) 25 days Sun Nov 25, '07 12/19
145 sealing concrete, pile cutting, inst. rebar & concreting 45 days Thu Dec 20, '07 2/2
146 PC-P 56 70 days Tue Sep 4, '07
Task Progress Summary External Tasks Deadline

Date: Thu 4/26/07
Split Milestone Project Summary External Milestone
SOFT TARGET Page 1 Prepared by: Aris Purwanto

Checked by: Sutupo Broto
SCHEDULE FOR COMPLETION OF APPROACH BRIDGE
DRAFT-R.00
ID Task Name Duration Start 2007 2008

March April May June July August eptemb October ovemb ecemb January ebruar March April May June July August eptemb October ovemb ecemb January
147 Remove Platform & Install Bottom + Side F.W (SF-A1) 25 days Tue Sep 4, '07 9/28
148 sealing concrete, pile cutting, inst. rebar & concreting 45 days Sat Sep 29, '07 11/19
149 PC-P 44 70 days Mon Sep 10, '07
150 Remove Platform & Install Bottom + Side F.W (SF-A2) 25 days Mon Sep 10, '07 10/4
151 sealing concrete, pile cutting, inst. rebar & concreting 45 days Fri Oct 5, '07 11/25
152 PC-P 49 70 days Thu Oct 4, '07
153 Remove Platform & Install Bottom + Side F.W (SF-B2-2) 25 days Thu Oct 4, '07 11/4
154 sealing concrete, pile cutting, inst. rebar & concreting 45 days Mon Nov 5, '07 12/19
155 PC-P 55 70 days Wed Nov 21, '07
156 Remove Platform & Install Bottom + Side F.W (SF-B1-1) 25 days Wed Nov 21, '07 12/15
157 sealing concrete, pile cutting, inst. rebar & concreting 45 days Sun Dec 16, '07 1/29
158 PC-P 51 70 days Mon Sep 24, '07
159 Remove Platform & Install Bottom + Side F.W (SF-B2-1) 25 days Mon Sep 24, '07 10/25
160 sealing concrete, pile cutting, inst. rebar & concreting 45 days Fri Oct 26, '07 12/9
161 PC-P 54 70 days Mon Dec 10, '07
162 Remove Platform & Install Bottom + Side F.W (SF-A2) 25 days Mon Dec 10, '07 1/3
163 sealing concrete, pile cutting, inst. rebar & concreting 45 days Fri Jan 4, '08 2/17
164 PC-P 50 70 days Tue Jan 8, '08
165 Remove Platform & Install Bottom + Side F.W (SF-B2-2) 25 days Tue Jan 8, '08 2/1
166 sealing concrete, pile cutting, inst. rebar & concreting 45 days Sat Feb 2, '08 3/17
167 PC-P 52 70 days Fri Jan 4, '08
168 Remove Platform & Install Bottom + Side F.W (SF-B2-1) 25 days Fri Jan 4, '08 1/28
169 sealing concrete, pile cutting, inst. rebar & concreting 45 days Tue Jan 29, '08 3/13
170 PC-P 53 70 days Thu Jan 3, '08
171 Remove Platform & Install Bottom + Side F.W (SF-B1-2) 25 days Thu Jan 3, '08 1/27
172 sealing concrete, pile cutting, inst. rebar & concreting 45 days Mon Jan 28, '08 3/12
173 PIER WORK 347 days Mon May 28, '07
191 V -PIER WORK 195 days Sun Jul 8, '07
196 SUPER STRUCTURE 490 days Sat Jul 7, '07
286 ACCESSORIAL CONSTRUCTION 181 days Wed Jun 25, '08
Task Progress Summary External Tasks Deadline

Date: Thu 4/26/07
Split Milestone Project Summary External Milestone
SOFT TARGET Page 2 Prepared by: Aris Purwanto

Checked by: Sutupo Broto
Appendix 4
Calculation Statement
Project : Suramadu Approach Bridge
Subject : Pile Cap Formwork
Location : Approach Bridge
Friction Capacity of Sealing Concrete
Pile Type
Parameter Unit
A B C
Pile Data
Diameter m 2.29 1.89 1.89
Width m 36.80 25.50 25.50
Length m 25.80 16.00 12.00
Number of pile/pier nos 35.00 18.00 18.00
specific gravity of sealing concrete kN/m3 24.00 24.00 24.00
specific gravity of pile cap concrete kN/m3 25.00 25.00 25.00
1st concrete height of pile cap m 1.50 1.50 1.50
Sealing concrete height m 1.00 1.00 1.00
Levelling concrete height m 0.20 0.20 0.20
Binding force of under water concrete Kpa 120.00 120.00 120.00
Binding force of dry poured concrete Kpa 1,500.00 1,500.00 1,500.00
Lowest Water Level m -0.99 -0.99 -0.99
Highest Water Level m 1.30 1.30 1.30
Lowest formwork level m -2.19 -2.19 -2.19
specific gravity of sea water kN/m3 10.25 10.25 10.25
Load and Force

Formwork weight kN 2,402.10 1,315.15 1,274.37
Deadweight of sealing concrete kN 19,326.85 8,580.02 6,132.02
Deadweight of levelling concrete kN 3,865.37 1,716.00 1,226.40
Deadweight of Pile Cap concrete kN 35,604.00 15,300.00 11,475.00
Uplift force during HWL kN 33,963.84 14,595.18 10,946.39
Uplift force during LWL kN 11,678.11 5,018.40 3,763.80
Friction of sealing concrete kN 30,215.84 12,825.24 12,825.24
Friction of levelling concrete kN 75,539.60 32,063.09 32,063.09
Resistant safety coefficient

During pouring sealing concrete 2.47 2.73 3.62
During pouring pile cap concrete 3.88 3.64 4.90
Location: Pier 37,38 and of one type
Distribution Beam
Calculation of Distribution beam
- IWF beam will be used as main beam where will be laid below the bottom plate of caisson
Working load acted in the beam shall came from deadweight of sealing concrete. Height of sealing
concrete is 1.2 m. Floating load will be determined in lowest water level, - 0.99
m so the floating load will be 12.0663 kN/m2. Total load which will be sustained by
distribution beam is 16.1865 kN/m2.
As mean width area of load which supported by distribution beam is 0.45 m, distri-
load of beam will be 8.74 kN/m'
8.74
`
2.45
from software program, obtained:

M= 6.56 kNm M1x = 1 kNm
N= 1.00 kN L= 2.45 m
V= 10.71 kN
Where, M= Maximum moment (kNm)
N= Axial force (kN)
V= Shear force (kN)
L= Length of beam (m)
Minimum resistance moment

W = M/s = 40.99 cm^3
Used : CH 100x48x 10
Section characteristics:(single beam)
Wx = 47.3 cm^3 H= 100 mm
Ix= 198.3 cm^4 B= 48 mm
Iy= 25.6 cm^4 tw= 5.3 mm
A= 12.74 cm^2 ts= 8.5 mm
= 160 Mpa iy= 1.52 cm
Section control
L/h = 24.5
1.25b/ts= 7.058824
L/H > 1.25b/ts
h/tw= 18.86792 < 75

undeformed shape section
1/6 hb = 13.83333 mm
Page 1 2nd Beam3P37

Distribution Beam
27.666667
1/6 hb 100
Marked area:
A arsir = 409.4663333 mm2
Determine slenderness of column

0.5 I y 2EA
i ytepi = = 49.20817511 mm nx = = 710.13
A 1.5 2N
L nx
A'= = 49.78847507 = 1.00
i ytepi n x 1
E
g = = 136.0349523
0 . 7 .
A '
s = = 0.365997666
g
Type of Column is Medium column r = 1.1510182
r = 1 (omega equation if the slenderness is 0.1838 > )
1.41
r = = (omega equation if the slenderness is 0.1838 < < 1)
1.593 s
= 2.381. s =
2
(omega equation if the slenderness is > 1)
kip = 139.0074

5
= =
M 1x 0.76
kip 8 3
M 2x
<1 so, = 1
Interaction equation check:

N nx M x
+ 0 .85 = 1,189.24 kg/cm2 < 1600 kg/cm2
A nx 1 Wx
Done
- Shear capacity check

V
fv =
d .t w
fv = 202.0258 kg/cm2 < 1200 kg/cm2
Page 2 2nd Beam3P37

Main Beam
Calculation of main beam
IWF beam will be used as main beam where the distribution will be laid in it. Reactions from dis-
tribution beam will be sustained by main beam and we convert the reactions into working load.
47.39022222
4.5

M= 136.60 kNm M1x = 1 kNm
N= 10.45 kN L= 4.5 m
V= 106.63 kN
N= Axial force (kN)
V= Shear force (kN)

W = M/s = 853.77 cm^3
Used : 2IWF 350.175 126.28

Section characteristics:
Wx = 1246.3 cm^3 H= 280 mm
Ix= 14146.63 cm^4 B= 294 mm
Iy= 8952.4828 cm^4 tw= 17 mm
A= 109.798 cm^2 ts= 13.7 mm
= 160 Mpa iy= 11.3609 cm
Section control
L/h = 16.07143
1.25b/ts= 26.82482
L/H < 1.25b/ts
h/tw= 16.47059 < 75

deformed shape section
1/6 hb = 42.1 mm
84.2
1/6 hb 280
Page 1 MainBP37
Main Beam
Marked area:
A arsir = 4042.114 mm2

0.5 I y 2EA
i ytepi = = 132.2839702 mm nx = = 1,254.57
A 1.5 2N
L nx
A'= = 34.01772712 = 1.00
i ytepi n x 1
E
g = = 136.0349523
0 . 7 .
A '
s = = 0.250066079
g
1.41
1.593 s
= 2.381. s =
2
kip = 152.1627

5
= =
M 1x 0.66
kip 8 3
M 2x
<1 so, = 1

N nx M x
+ 0 .85 = 942.41 kg/cm2 < 1600 kg/cm2
A nx 1 Wx
Done
Shear capacity check

V
fv =
d .t w
fv = 224.0084 kg/cm2 < 1200 kg/cm2
Deflection Check
5 ql 4
= = 8.52 mm < 11.25 mm
384 EI
OK
Page 2 MainBP37
Location : Pier 37,38 and of one type
Wall for Side Formwork
Loading Criteria
As with all formwork, the fist step in detailed design is to estimate the magnitude and distribution
of pressure and loads acting on the formwork. ACI Committee 347 recommends designing for
the same lateral pressure as for wall forms, considering temperature and rate of rise concrete
in the forms. According to ACI, for R=2ft, p= 28.728 kN/m2
Wall thickness in mass concrete is idealized with huge wall and according to SKSNI T-15-1991-03,
the horizontal pressure is 90 KN/m2. Pouring concrete shall be by 0.50m layer then
poured again with 0.5m thickness until construction joint layer. The concrete pressure when con-
creting is finished at height 4.5 m is 105.948 kN/m2. Because concreting
height in last segment is less than 2m, concrete pressure will be constant from 0m up to
0.68 m.
1.46
b
3.82
1.54
a
1.5 0.68
Calculation for formwork capacity will be determined using following formula:

1 2 2 .5 4
M = ql (1) f = ql ..(2)
10 384
Calculation of Side Formwork
- Horizontal beam used CH8
Wx = 30.3 cm^3 H= 80 mm
Ix= 101.3 cm^4 B= 43 mm
Iy= 16.6 cm^4 tw= 5 mm
A= 20.24 cm^2 ts= 8 mm
= 160 Mpa iy= 1.42 cm
E= 2.10E+05 Mpa
Strength calculation
M
steel = M = 4848000 Nmm
W
subtitute value of M into equation(1) where the value of q is determine from p.l
so required length (l) is 813.654506 mm
Deflection calculation
1
f max = l
500 will be subtitute to equation(2)
then required length (l) is 519.100994 mm
so minimum space between horizontal beam is 510 mm
- Vertical beam used I28a
Construction Method Page 1 4/26/2007

Location : Pier 37,38 and of one type

Section characteristics (single beam):
Wx = 672.4952741 cm^3 H= 280 mm
Ix= 7115 cm^4 B= 122 mm
Iy= 27.36 cm^4 tw= 8.5 mm
A= 55.4 cm^2 ts= 13.7 mm
= 160 Mpa iy= 10.58 cm
E= 2.10E+05 Mpa
M
steel = M = 107599243.9 Nmm
W
then determine q = p.l = 45.9 N/mm
1
f max = l
- Steel Wales
The wales will be placed in 1.5 m, and 3 m from bottom formwork.
The average of inclemental load is 26.79503 kN/m which occurred in 2.23
m from the top of formwork. Load on support b is 13.39751 kN/m', so Rb =
29.87645 kN Load on support a is 36.34751 kN/m', so Ra = 82.50885 kN
Allowable shear strength is 92.8 Mpa, then shear force on the structure will be determine
using following formula 3V so V = 514.112 kN
=
2A
Used IWF 450x200x76

Wx = 1490 cm^3 H= 450 mm
Ix= 33500 cm^4 B= 200 mm
Iy= 1870 cm^4 tw= 9 mm
A= 96.76 cm^2 ts= 14 mm
= 160 Mpa iy= 4.4 cm
E= 2.10E+05 Mpa
load on the wales, w= 38.37621149 kN/m'

M
steel = M = 2.38E+08 Nmm
W

Location: P45,48
Distribution Beam
10.68
`
2.45

M= 8.02 kNm M1x = 1 kNm
N= 1.00 kN L= 2.45 m
V= 13.09 kN
N= Axial force (kN)
V= Shear force (kN)

W = M/s = 50.10 cm^3
Used : CH 100x48 10
Wx = 47.3 cm^3 H= 100 mm
Ix= 198.3 cm^4 B= 48 mm
Iy= 25.6 cm^4 tw= 5.3 mm
A= 12.74 cm^2 ts= 8.5 mm
= 160 Mpa iy= 1.52 cm
Section control
L/h = 24.5
1.25b/ts= 7.058824
L/H > 1.25b/ts
h/tw= 18.86792 < 75

1/6 hb = 13.83333 mm
Page 1 2nd Beam3P45

Location: P45,48
Distribution Beam
27.666667
1/6 hb 100
Marked area:
A arsir = 409.4663333 mm2

0.5 I y 2EA
i ytepi = = 49.20817511 mm nx = = 710.13
A 1.5 2N
L nx
A'= = 49.78847507 = 1.00
i ytepi n x 1
E
g = = 136.0349523
0 . 7 .
A '
s = = 0.365997666
g
1.41
1.593 s
= 2.381. s =
2
kip = 139.0074

5
= =
M 1x 0.75
kip 8 3
M 2x
<1 so, = 1

N nx M x
+ 0 .85 = 1,451.51 kg/cm2 < 1600 kg/cm2
A nx 1 Wx
Done

V
fv =
d .t w
fv = 246.9205 kg/cm2 < 1200 kg/cm2
Page 2 2nd Beam3P45

Location: P45,48
Main Beam
47.39022222
5.5

M= 97.89 kNm M1x = 1 kNm
N= 10.45 kN L= 5.5 m
V= 71.03 kN
N= Axial force (kN)
V= Shear force (kN)

W = M/s = 611.83 cm^3
Used : 2IWF 350.175 126.28

Wx = 1246.3 cm^3 H= 280 mm
Ix= 14146.63 cm^4 B= 294 mm
Iy= 8952.4828 cm^4 tw= 17 mm
A= 109.798 cm^2 ts= 13.7 mm
= 160 Mpa iy= 11.3609 cm
Section control
L/h = 19.64286
1.25b/ts= 26.82482
L/H < 1.25b/ts
h/tw= 16.47059 < 75

1/6 hb = 42.1 mm
84.2
1/6 hb 280
Page 1 MainBP45
Location: P45,48
Main Beam
Marked area:
A arsir = 4042.114 mm2

0.5 I y 2EA
i ytepi = = 132.2839702 mm nx = = 839.84
A 1.5 2N
L nx
A'= = 41.57722204 = 1.00
i ytepi n x 1
E
g = = 136.0349523
0 . 7 .
A '
s = = 0.305636319
g
1.41
1.593 s
= 2.381. s =
2
kip = 145.8569

5
= =
M 1x 0.69
kip 8 3
M 2x
<1 so, = 1

N nx M x
+ 0 .85 = 678.89 kg/cm2 < 1600 kg/cm2
A nx 1 Wx
Done

V
fv =
d .t w
fv = 149.2275 kg/cm2 < 1200 kg/cm2
Deflection Check
5 ql 4
= = 19.01 mm > 13.75 mm
384 EI
Recheck
Page 2 MainBP45
Location : P45,48
Loading Criteria
creting is finished at height 6 m is 141.264 kN/m2. Because concreting
2.18 m.
2.96
b
3.82
1.54
a
1.5 2.18

1 2 2 .5 4
M = ql (1) f = ql ..(2)
10 384
Wx = 30.3 cm^3 H= 80 mm
Ix= 101.3 cm^4 B= 43 mm
Iy= 16.6 cm^4 tw= 5 mm
A= 20.24 cm^2 ts= 8 mm
= 160 Mpa iy= 1.42 cm
E= 2.10E+05 Mpa
M
steel = M = 4848000 Nmm
W
1
f max = l

Location : P45,48

Wx = 672.4952741 cm^3 H= 280 mm
Ix= 7115 cm^4 B= 122 mm
Iy= 27.36 cm^4 tw= 8.5 mm
A= 55.4 cm^2 ts= 13.7 mm
= 160 Mpa iy= 10.58 cm
E= 2.10E+05 Mpa
M
steel = M = 107599243.9 Nmm
W
1
f max = l
- Steel Wales
=
2A
Used IWF 450x200x76

Wx = 1490 cm^3 H= 450 mm
Ix= 33500 cm^4 B= 200 mm
Iy= 1870 cm^4 tw= 9 mm
A= 96.76 cm^2 ts= 14 mm
= 160 Mpa iy= 4.4 cm
E= 2.10E+05 Mpa

M
W

Location: P41,42,51,52
Distribution Beam
8.04
`
4.31

M= 18.67 kNm M1x = 1 kNm
N= 1.00 kN L= 4.31 m
V= 17.33 kN
N= Axial force (kN)
V= Shear force (kN)

W = M/s = 116.70 cm^3
Used : IWF 2 100x100 34.4

Wx = 176.157 cm^3 H= 100 mm
Ix= 738.1 cm^4 B= 203 mm
Iy= 1383 cm^4 tw= 12 mm
A= 42.08 cm^2 ts= 8 mm
= 160 Mpa iy= 5.73 cm
Section control
L/h = 43.1
1.25b/ts= 31.71875
L/H > 1.25b/ts
h/tw= 8.333333 < 75

1/6 hb = 14 mm
Page 1 2nd Beam3P41

Distribution Beam
28
1/6 hb 100
Marked area:
A arsir = 1627.36 mm2

0.5 I y 2EA
i ytepi = = 47.6212495 mm nx = = 709.82
A 1.5 2N
L nx
A'= = 90.50581506 = 1.00
i ytepi n x 1
E
g = = 136.0349523
0 . 7 .
A '
s = = 0.665312947
g
1.41
1.593 s
= 2.381. s =
2
kip = 105.0425

5
= =
M 1x 0.97
kip 8 3
M 2x
<1 so, = 1

N nx M x
+ 0 .85 = 905.88 kg/cm2 < 1600 kg/cm2
A nx 1 Wx
Done

V
fv =
d .t w
fv = 144.4111 kg/cm2 < 1200 kg/cm2
Page 2 2nd Beam3P41

Main Beam
47.39022222
4.5

M= 109.21 kNm M1x = 1 kNm
N= 10.45 kN L= 4.5 m
V= 97.77 kN
N= Axial force (kN)
V= Shear force (kN)

W = M/s = 682.58 cm^3
Used : 2IWF 350.175 126.28

Wx = 1246.3 cm^3 H= 280 mm
Ix= 14146.63 cm^4 B= 294 mm
Iy= 8952.4828 cm^4 tw= 17 mm
A= 109.798 cm^2 ts= 13.7 mm
= 160 Mpa iy= 11.3609 cm
Section control
L/h = 16.07143
1.25b/ts= 26.82482
L/H < 1.25b/ts
h/tw= 16.47059 < 75

1/6 hb = 42.1 mm
84.2
1/6 hb 280
Page 1 MainBP41
Main Beam
Marked area:
A arsir = 4042.114 mm2

0.5 I y 2EA
i ytepi = = 132.2839702 mm nx = = 1,254.57
A 1.5 2N
L nx
A'= = 34.01772712 = 1.00
i ytepi n x 1
E
g = = 136.0349523
0 . 7 .
A '
s = = 0.250066079
g
1.41
1.593 s
= 2.381. s =
2
kip = 152.1627

5
= =
M 1x 0.66
kip 8 3
M 2x
<1 so, = 1

N nx M x
+ 0 .85 = 755.45 kg/cm2 < 1600 kg/cm2
A nx 1 Wx
Done

V
fv =
d .t w
fv = 205.4034 kg/cm2 < 1200 kg/cm2
Deflection Check
5 ql 4
= = 8.52 mm < 11.25 mm
384 EI
OK
Page 2 MainBP41
Location : P41,42,51,52
Loading Criteria
creting is finished at height 5 m is 117.72 kN/m2. Because concreting
1.18 m.
1.96
b
3.82
1.54
a
1.5 1.18

1 2 2 .5 4
M = ql (1) f = ql ..(2)
10 384
Wx = 30.3 cm^3 H= 80 mm
Ix= 101.3 cm^4 B= 43 mm
Iy= 16.6 cm^4 tw= 5 mm
A= 20.24 cm^2 ts= 8 mm
= 160 Mpa iy= 1.42 cm
E= 2.10E+05 Mpa
M
steel = M = 4848000 Nmm
W
1
f max = l

Location : P41,42,51,52

Wx = 672.4952741 cm^3 H= 280 mm
Ix= 7115 cm^4 B= 122 mm
Iy= 27.36 cm^4 tw= 8.5 mm
A= 55.4 cm^2 ts= 13.7 mm
= 160 Mpa iy= 10.58 cm
E= 2.10E+05 Mpa
M
steel = M = 107599243.9 Nmm
W
1
f max = l
- Steel Wales
=
2A
Used IWF 450x200x76

Wx = 1490 cm^3 H= 450 mm
Ix= 33500 cm^4 B= 200 mm
Iy= 1870 cm^4 tw= 9 mm
A= 96.76 cm^2 ts= 14 mm
= 160 Mpa iy= 4.4 cm
E= 2.10E+05 Mpa

M
W

CM For Pile Cap Formwork Revise RE 12 Maret 2007 (Submitted)

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

CM For Pile Cap Formwork Revise RE 12 Maret 2007 (Submitted)

Загружено:

Авторское право:

Доступные форматы

METHOD STATEMENT

CONSORTIUM OF INDONESIAN CONTRACTOR

SURAMADU APPROACH BRIDGE PROJECT

ADHI HUTAMA WASKITA WIJAYA

Appendix -1 Shop Drawing

Install jack sinking Assemble bottom

Move the formwork

Seal the gap in

Concrete mixing Pouring sealing Monitoring of water

Pump the water out

Weld beard rebar

Concrete mixing Concreting for 20cm thick

Cut pile head

1.1.2 List of equipment

1.2 Site layout

1.3 Pile cap formwork data

Table 1-1 Design parameter of pile cap formwork

3.2 Bottom plate

3.3 Side plate

3.4 Suspension lifting system and jack-sinking system

3.5 Inner bracing and guiding system

3.5.2 Inner bracing

4.2 Removal of drilling platform

4.3 Assembly of steel caisson

4.4 Sinking steel caisson

4.5 Monitoring of caisson construction

4.6 Sealing of steel caisson

Figure 4-1 Sequence of concreting of sealing concrete

4.7 Pile cutting

4.8 Check caisson

5. Quality Assurance Plan

5.2 Quality control organization

5.3 Quality assurance system

5.3.3 Standard operation procedure

6.2 Safety measures for assembly of caisson

6.3 Safety measures for construction vessels

6.4 Safety measures for submersible operation

1 Feedeer Barge 1 unit 180feet

2 Workshop Barge 1 unit 180feet

3 Batching Plant Barge 2 unit

4 Crane Barge 1 unit 80t

5 Tug Boat 2 unit Malindo Gold, 2x420PK

6 Concrete Pump 2 unit

7 Submersible Diving Equipment 2 unit

8 Sinking Equipment 1 unit

9 Electric Welding Machines 10 unit

10 Air Compressor 2 unit

11 Water Pumps 5 unit

12 Screw Jack 50 unit

Standar Beton Indonesia's batching plant

3 Lifting Worker 100

ID Task Name Duration Start 2007 2008

119 PC-P 40 70 days Mon Mar 19, '07

122 PC-P 45 75 days Tue May 1, '07

125 PC-P 48 75 days Sat May 26, '07

128 PC-P 43 70 days Thu May 17, '07

131 PC-P 39 70 days Mon Jun 11, '07

134 PC-P 38 70 days Sun Jul 29, '07

137 PC-P 41 70 days Sun Aug 26, '07

140 PC-P 37 70 days Sat Aug 18, '07

143 PC-P 42 70 days Sun Nov 25, '07

146 PC-P 56 70 days Tue Sep 4, '07

Task Progress Summary External Tasks Deadline