Method Statement for Segment Delivery and Transportation

May 15, 2015

Casting Yard, Construction, Method Statement

1. INTRODUCTION

1.1 Purpose of the Document

The purpose of this method statement is to define a procedure for the delivery and transportation of precast segments from Precast Yard to erection of the viaducts of HCMC Line1 – Metro Project in consideration of the following: - Delivery routes - Dimension and weight restrictions - Application of permit for related segments

1.2 Project Description

Ho Chi Minh City Urban Railway Construction Project – Ben Thanh – Suoi Tien section (Line 1), Contract Package 2 consists of approximately 12 km long of elevated viaduct structures, erected by span-by-span method. All activities related to the construction of reinforced concrete precast segments will be carried out in the Precasting Yard, located in Road 11, Long Bình Ward, District 9, HCMC

Figure 1: General layout – Precasting Yard

1.3 Scope of works

The scope of this method statement includes: - loading and lashing segment onto trailer at precast yard - identifying any obstacles along delivery route - Comparing segment parameters against statutory regulation on good height, width, length, weight - Checking any restriction of trailer movement time - Requirement of permits from Department of Transportation - Courtesy practice of informing relevant government departments of approved permit - target delivery duration of 1 span Works at site such as localized traffic management at delivery point, unloading and lifting of segment shall be covered under separate method statement under segment erection section.

2. SAFETY AND ENVIRONMENTAL RISKS

2.1 Hazard and Risk Assessment (HRA)

HRA are carried out by HSE department and attached in this Method Statement. This document will identify all the hazards and ensure adequate control measures are in place to reduce as much as possible the risks All personnel carrying out the work will be properly trained by experienced Supervision. Besides, all personnel shall wear the appropriate PPE (Personal Protective Equipment), such as Safety shoes, safety helmet or safety harness if required.

2.2 Tools & Equipment

All tools & equipment shall be in safe condition before utilisation and fit for its purpose. Before each shift, equipment shall be visually checked for the mechanical and structural soundness.

2.3 Emergency Response

In the event of an accident/incident, response will carried out in the appropriate procedure, such as: - Remedial Actions, proposing actions to ensure that the Accident/Incident will be fully fixed, as required, managed by the Responsible within a target date. - Preventive Actions, Tool-Box Talk (TBT) will be held by the Safety Officer for Site Personnel. It will reinforce safety requirements prior to commencement of the work and will ensure that Site personnel fully understand method & risk.

3. CONSTRUCTION RESOURCES

3.1 Personnel

The personnel involved are such as: - Precasting Yard (PCY) Supervisors, - Gantry crane Operator, - Rigging operatives, - Workers, - Drivers.

3.2 Equipment, Tools & Materials

The following equipment shall be used for purpose of segment delivery and transportation works: - Gantry crane 50T, - Semi-trailer 50T, - Lifting beams / spreader beams / stress bar D32, - Chains / hoists / turnbuckles / shackles, - Steel plates / plastic blocks,
- Timber blocks / bolts / rubber / nails, - Hand tools.

4. PRECAST DESIGN INFORMATION

4.1 Pier segment:

Fixed Longitudinal and transverse dimension - length x width (1775mm x 11100mm)
height without parapet starter bar – 2480mm
maximum height including parapet starter bar – 2880mm (Abutment A to Pier DBP1)
weight 41 tons

4.2 Typical segment:

longitudinal dimension range depends on type of typical segments indicated in table below Type S1 S2 S3 S4 S5 S6 longitudinal dimension(width) Minimum Maximum 2850mm 2850mm
2110mm 2850mm
2210mm 2850mm
2425mm 2850mm
2425mm 2850mm
2090mm 2850mm
transverse dimension (length) is fixed - 11100mm
height without parapet starter bar – 2030mm
maximum height including parapet starter bar – 2430mm (Abutment A to Pier DBP1)
weight vary from 31.5 to 43 tons

5. SEGMENT LOADING

5.1 Support and Lashing

Typical segment will be supported by two 100mm thick timber blocks placed on the trailer in order to assure a statically determined support condition. The timber blocks shall be assembled from 5 nos of hardwood timber elements (100mm x 100mm, 1500mm or 2000mm of length) and connected by 3 tie bars 20 and wing nuts (refers to appendix A-figure 1).

Rubber plates of 10mm thick will be used between the concrete segment and the timber blocks to prevent concentrated point load. These rubbers plates shall be fixed by iron nails on the timber blocks The chain shall be placed as near as possible to the web. For pier segments, due to its outline configuration, 2 others timber supports are added to stabilize the pier segment. As shown below:

These timber blocks is assembled from 5 nos of hardwood timber elements (100mm x 200mm, 1500mm or 1650mm of length) and connected by 3 tie bars 20 and wing-nuts (refers to appendix A – figure 2). Rubber plates of 10mm thick is placed between the concrete segment and the timber blocks to prevent concentrated point load. These rubbers plates shall be fixed by iron nails on the timber blocks.

5.2 Checks Implemented

Check prior to loading: - Driver licence and truck license validity is checked - The permit by DOT is consistent with the truck license Check during loading: - Ensure access to loading bay and gantry crane is clear of any obstacles. - Trailer to be switched off in neutral gear and hand brake applied before loading commences. - Ensure support timber blocks and rubber plates are correctly fixed on trailer bed and are in good condition and if not, to be changed. - Segments are identified in the storage yard; lifted using the 50tons gantry crane and placed onto trailer - Once segment is placed in the correct position, the segment is secured using cargo chain transversely at 2 locations. The cargo chain capacity is 5 ton and is fastened to approximately 3 ton tension force. - To prevent the chain from damaging the edges of the precast elements, 10mm thick steel plates and the HDPE blocks (150mm x 30mm x 10mm) are used as pads. (refers to appendix B)
Check upon completion of loading - The trailer driver and FVR storage supervisor shall check the loaded segment is secured and safe to transport and the segment hasn’t suffer any damage during loading.

5.3 Instruction and Driver Compliance

Instruction shall be given to the driver related to: - Erection site where the segment to be delivered - The pre-planned delivery route which the driver must follow - The positioning of trailer for unloading at erection site - Any other special requirement at the erection site The driver shall then signed the delivery inspection form. All truck/trailer driver shall: - switch-on designated mobile phone during segment delivery. This will allow immediate communication with driver for any special instruction, if needed - adhere to speed limits and obey all road rules. At the PCY and the erection site, the speed is limited at 5km/h. - adhere to safety regulation and wear all PPE when exiting the truck at PCY and at erection site. - inform FVR storage supervisor immediately if there is any incident, such as trailer breakdown, traffic jam or any disturbance to the delivery - sign up delivery inspection form before and after segment delivery - always keep truck and semi-trailer clean from any rubbish, trash or debris

6. SEGMENT DELIVERY ROUTE, REGULATION & REQUIREMENT

6.1 Delivery Route

Starting from the PCY, the delivery route runs along Road 11 and the Hanoi Highway both ways until erection location.

Detail route along Road 11 from the PCY (point A) to the intersection of Hanoi Highway (point B) is shown below:

Detail of route of left turn from Dien Bien Phu Road to Road 602:

Sections of the delivery route along Hanoi Highway are attached (refer Appendix C).The delivery route is specified in the permit for the segment delivery. Thus, the segment delivery is permitted along the route mentioned inclusive of travelling on existing underpass or bridges which is part of Hanoi Highway.

6.2 Dimension and Weight Restriction

6.2.1 Regulation

i) Height Restriction The maximum height of cargo from road level shall not exceed 4.35m.This is based on Circular No. 03/2011/TT-BGTVT dated 22 Feb 2011 which amend clause 3 Article 17 of Circular 07/2010/TT-BGTVT dated 11 Feb 2010 to “..maximum cargo fill height is 4.35m , measured from the highest point of the road surface upwards;…..” ii) Width restriction The maximum width of cargo is restricted to 2.5m. This is based on Clause 1 (b) of Article 12 of Circular 07/2010/TT-BGTVT which specifies that any cargo which “..is more than 2.5m in width;” shall be classified as “super-length cargo..” requiring a permit. iii) Load/weight restriction Clause 2 of Article 12 of Circular 07/2010/TT-BGTVT specifies that “…cargoes with a load of more than 32 tons” shall be classified as “extra-load” cargoes requiring a permit. iv) Height Clearance Under bridge or Warning Sign Portal along Delivery Route Based on survey of the segment delivery route, the minimum existing clearance is 4.5m. This occurs at warning sign portal and bridge near Vista, Thao Dien. v) Trailer Movement Time for Segment Delivery There is no time restriction for trailer movement along the delivery route from PCY to Saigon Bridge. For trailer movement over Saigon Bridge and roads after Saigon Bridge, current regulation restrict trailer movement from 12:00 midnight to 06:00am only.

No time restriction for trailer movement from the PCY to Saigon Bridge (Thao Dien) is specify under section Annex of People Committee of Ho Chi Minh City Decision No. 66/2011/QD-UBND dated 22nd October 2011 which specify as follows: a) “1. Corridor 1(not limited time)” for “Road 1, Thu Duc District, from Nguyen Van Ba Road to Branch of Saigon River” The restriction for trailer movement across Saigon Bridge and roads after Saigon Bridge is mentioned under section Annex of the same above decision which specify as follows: b) “8. Heavy trucks are allowed running from 24:00 hour of previous day to 06:00am on routes: Dien Bien Phu road (throughout road); February 3rd road (throughout route); Bach dang-Phan Dang Luu-Hoang Van Thu roads: Nguyen thi Minh Khai road (throughout route); Trans Hung Dao (throughout route); Nam Ky Khoi Nghia-Nguyen Van Troi roads, Ly Thuong Kiet road(throughout route)”

vi) Trailer movement along Road 602 after left turn of Dien Bien Phu Road For movement of trailer along Road 602, application of permit shall be submitted inclusive of traffic management scheme to DOT for their approval.

6.2.2 FVR Requirement

a. Height of loaded segments from road level Majority of segment is typical segments without parapet starter bar and the height from road level is 3.82m.

For typical segment with parapet starter bar, the height from road level is 3.919m. This is the maximum height from road level for typical segments. For pier segment without starter bar, the height from road level is 3.97m

For pier segment with starter bar, the height from road level is 4.37m. This is the maximum height for segment delivery. b. Width of loaded segment within trailer width The maximum width of segment is 2850mm. This is within the trailer body width and thus should not pose any extra hazard to other road users. c. Load weight The segment weight is from 41 to 43 tons. d. Non-restriction of delivery time of segment FVR schedule the delivery time for segment on 24-hour basis without any restriction time imposed on the trailer movement. e. Access to Road 602 (after left turn from Dien Bien Phu Road) Segments for section abutment A1 to pier P3-07 cannot be lifted directly from under the launching gantry as there is restricted or no access under the gantry. Therefore, the segment shall be unloaded from the trailer by crane at a dedicated point along Road 602. The segment is then lifted onto a special trailer which is placed on the erected deck to transport segment towards abutment A1. Therefore, access along Road 602 is needed. 7. APPLICATION OF PERMIT FOR TRAILER DELIVERING SEGMENTS Based on FVR requirement and as per provision in the following Circulars and Decision: a. Circular No. 03/2011/TT-BGTVT dated 22 Feb 2011 b. Circular 07/2010/TT-BGTVT dated 11 Feb 2010 c. People Committee of Ho Chi Minh City Decision No. 66/2011/QD-UBND dated 22nd October 2011 Permit for transportation of segment shall be applied to HCMC Department of Transportation (DOT). As detailed in section 5.2, the permit shall cover the following: - “super-length” cargo for delivery height aspect - “super-length” cargo for width aspect - “extra-load” cargo for weight and axle-load related aspect - delivery route including movement over Saigon Bridge - non-restriction of trailer movement time - access along Road 602 The permit is issued by HCMC DOT to the owner of the trailers and thus the permit shall be applied on behalf of FVR by the appointed transporter company. Typical permit issued by DOT is as per Appendix D. Permit is to be issued for each trailer for typical validity period of 30 to 60 days. Therefore, the permit will be renewed continually period over the project duration.

Specific Permit from Police Department is not required. Upon permit approval from Department of Transportation (DOT), a meeting with the presence of DOT, Police, Traffic Inspector will be held to inform the approval of the DOT permit to the related departments for their knowledge and concurrence. The permit approval shall also be made known to the People Committee of the respective district along the delivery route. Information on the periodical renewal shall be also dissipated to the related parties.

8. TARGET DELIVERY PER SPAN

The target erection is 3 days cycle for each span. There are 3 launching gantries; so the schedule call for 6 spans erection every week or 1 span per day. 66% of spans in the project is 35m type. Each 35m span consists of 13 segments. FVR target is to deliver 1 span or 13 segments within 8 hours duration. Based on 5 trailers, all 13 nos of segments can be delivered and unloaded off the trailers within 8 hours period (refer Appendix E). Around 5 to 8 trailers shall be permanently mobilized and working full time for the segment delivery.

9. ACTIVITY HOLD POINT

For HSE they are: - Permit to work. - Hazard and Risk Assessment (HRA). - Safety induction and toolbox talk completed - Plant and equipment safety checks complete

10. INSPECTION AND RECORDS

Inspection sheets and all the other documents to be collected.

11. APPENDICES

APPENDIX A: TIMBER BLOCK SUPPORTS ASSEMBLY

Figure 1: Timber block supports for typical segment assembly (1500 or 2000mm of length)

Figure 2: Timber block supports for pier segment assembly (1500 or 1650mm of length)

APPENDIX B: SHOP DRAWING OF STEEL PLATE

Figure 3: Steel plate

Figure 4: Steel plate with HDPE blocks

APPENDIX C: SECTION DELIVERY ROUTES ALONG HANOI HIGHWAY

Segment delivery route

Crane location for lifting segment on erected span for backfeeding of segment along deck

APPENDIX D: TYPICAL PERMIT ISSUED BY DOT

APPENDIX E: DELIVERY CYCLE OF 1 SPAN

APPENDIX F: HAZARD AND RISK ASSESSMENT