Site Work Procedure - Falsework-formwork Inspection Rev A-kap-sav.docx

F005-600-7566

SITE WORK PROCEDURE

Title:

Falsework/ Formwork Structure Inspection – Concourse, Intermediate, Roof, Top of Station box and upper level Slab

Document No.

DOC/917A/KAP-SAV/ SWP/ 005

REFERENCES: [CEP/ JSEAs etc.] Date Accepted: Title/ Doc No.

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22 Jan 2014

DOC-917A-KAP-SAV -CEP-062 – Slab Construction RC Structure Works (KAP/SAV)

Scope The scope of this SWP covers the implementation of Formwork/ falsework inspection during concrete casting of Concourse, Intermediate, Roof, Top of station box and Upper Level Slab and other relevant structures This SWP shall be read in conjunction with relevant and approved CEP for concreting works onsite.

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Objective To provide detailed instructions and direction of falsework/ formwork inspection process during concrete casting and ensure consistent work practices are adopted by site personnel in accordance with the Construction Execution Procedure (CEP), Job Safety and Environmental Analysis (JSEA), M&W Specification and Contract requirements.

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Materials 

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Plant and Equipment    

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Contingency Falsework and formwork materials shall be available onsite.

Boom Lift Cranes and Man Box Emergency equipments Flood lights and torch

Responsibilities Attached in Appendix A is the Formwork/ False work Inspection Responsibility Matrix 

Project Manager/Deputy PM to review SWP and approve SWP on behalf of McConnell Dowell South East Asia Pte. Ltd (The Contractor).



Deputy PM/Construction Manager to review the SWP, ensure compliance with SWP; ensure the work is carried out in planned and safe manner, report to Project Manager.



Quality and Risk Manager to prepare the SWP, ensure compliance with SWP; ensure the work is carried out in safe manner, report to Project Manager.

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 1 of 9

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

Senior Engineer and Site Engineer to supervise the work in accordance with SWP, ensure the work is carried out in planned and safe manner, to coordinate with the sub-contractor, report to Construction Manager.



Superintendent to ensure personnel carries out work in accordance with SWP; ensure the work is carried out in safe manner; report to Construction Manager.



QA/QC Engineer to ensure work is carried out and completed in accordance with SWP; report to Quality & Risk Manager.



Safety Supervisor to carry out safety inspection, ensure work is carried out in planned and safe manner, conduct pre-start work meeting.



McConnell Dowell Subcontractor (Wai Fong) and (Sam Woo) Formwork Supervisor and/or Falsework Supervisor and/or other appointed inspectors are to carry out this works and perform the task in accordance with JSEA or Risk Assessment requirements and as per WSHA Formwork Structure requirements.

Work Method/ Sequence – Concourse, Intermediate, Roof, Top of station box and Upper Level Slab

6.1

Formwork/ Falsework Design Review

6.1.1

MacDow Senior Engineer and Site Engineer shall ensure that formwork/ falsework designs are reviewed and approved by MacDow Construction Manager and/or Project Manager. MacDow PM or CM may engage 3rd Party PE to review the formwork/ falsework designs independently.

6.1.2

MacDow Engineer to check and verify the drawings being used by Subcontractor Formwork Supervisor and Falsework Supervisor to ensure consistency of the design and approved drawings.

6.2

Formwork/ Falsework Delivery, Inspection and Testing (if required)

6.2.1

During delivery of formwork/ falsework materials, MacDow Site Engineer and the QA/QC Engineer will carry out surveillance inspection on formwork/ falsework materials being delivered onsite by Subcontractor. A responsibility matrix is prepared for formwork/ falsework inspection. Please refer to Appendix A for the responsibility matrix.

6.2.2

If during surveillance inspection the formwork/ falsework materials show some defects and surface corrosion, the Subcontractor (Wai Fong) for KAP and (Sam Woo) for SAV should propose a testing regime to verify the materials suitability. The testing regime and/or type of test should be agreed between the PE, Subcontractor (Wai Fong)/(Sam Woo) and MacDow.

6.2.3

All relevant test results should be reviewed by the PE and he should direct and advise the Subcontractor whether the materials are suitable for use or it shall be rejected.

6.2.4

The formwork/ falsework materials that are found severely damaged and corroded shall not be used. MacDow QA/QC Engineer will clearly marked and spray the rejected materials by yellow paint or any colour agreed by Subcontractor and MacDow. All badly damage and corroded supports, bracings, beams, scaffolds tubes etc will be segregated, marked or painted and shall not be allowed to use.

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 2 of 9

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6.2.5

6.3

Formwork/ Falsework Installation and Inspection – Prior to Rebar installation and formwork/ falsework loading

6.3.1

Subcontractor to commence installing and constructing formwork and falsework in accordance with PE’s approved drawings and relevant sketch. No rejected materials shall be used.

6.3.2

During installation stage, the Subcontractor (Wai Fong)/(Sam Woo) Engineer, Formwork Supervisor, MacDow Site Engineer and Quality Engineer will conduct a surveillance inspection on formwork and falsework materials being used and installed. In an event that badly defective and/or corroded or rejected materials are used and installed, it shall be removed and replaced.

6.3.3

Upon completion of formwork/ falsework erection on certain Gridline or area, the Formwork Supervisor and/ or Scaffold Supervisor and the PE appointed or nominated person shall conduct an inspection. The PE nominated inspector/ person shall be formally appointed by the PE who is responsible for the design the formwork structure. The appointed or nominated person must carry out the formwork structure inspection on PE’s behalf and send his inspection report to the PE. Based on the inspection report, the PE will issue a Certificate of Inspection stating that the formwork is safe for its intended use.

6.3.4

The Certificate of Inspection must be signed and endorsed by the PE and send to MacDow by Wai Fong/Sam Woo representative. MacDow Senior Engineer will forward a copy of the Certificate of Inspection to LTA and/or QPS for record and reference.

6.3.5

The formwork structure is now ready to be loaded with reinforcing bars and other necessary construction tools and equipments.

6.4

Formwork/ Falsework Inspection Prior to Cast

6.4.1

On the completion of reinforcement assembly/ installation, an inspection by the PE shall be conducted to the formwork structure. The PE will be accompanied by Wai Fong/Sam Woo Project Manager and/or Engineer, MacDow Senior Engineer, Construction Manager and/or PM and the QPS.

6.4.2

The PE will endorse and issue a Certificate of Supervision (COS) for the formwork structure to Wai Fong and MacDow accordingly.

6.4.3

Concurrent to PE inspection, MacDow Senior Engineer, Subcontractor Engineer, Formwork Supervisor and Scaffold Supervisor must conduct an independent and internal Formwork Inspection using MacDow form F020-600-[SIN]. Once the check sheet F020-600-[SIN] is signed off by the Formwork Supervisor and MCD Senior Engineer and/or Site Engineer with the COS being issued by the PE, the formwork/ falsework can now be released for concrete casting.

6.4.4

Subcontractor must comply with the proposed casting sequence as casting procedure for roof slab.

6.5

Formwork/ Falsework Inspection during Casting

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 3 of 9

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6.5.1

Commence concrete casting of roof slab or similar structure as scheduled.

6.5.2

When the concrete roof slab has reached minimum 300mm thickness, the Project Manager and/or the Construction Manager will appoint personnel to carry out formwork/ falsework inspection e.g. Formwork Supervisor (as per WSHA requirement) etc. Please refer to responsibility Matrix in Appendix A.

6.5.3

Before the appointed personnel can enter the formwork/ falsework, the concrete casting operation, if necessary should cease temporarily during inspection. The Formwork Supervisor or the appointed person must check the formwork/ falsework for leaks, deformity, movements and other irregularities on the structures. If the casting is temporarily cease, the inspection must be carried out as quickly as possible to prevent potential concrete cold joints that will affect the quality of the concrete and integrity of the structure.

6.5.4

In an event of irregularities or formwork leaks, the formwork/ falsework defects shall be repaired immediately and reinspected by the Formwork Supervisor and/or appointed person before recommencing the casting. Note: Formwork leaks are considered if a continuous outflow of the fresh concrete including coarse aggregates from the formworks.

6.5.5

Once the defect or leak rectification is completed, recommence the casting.

6.5.6

If the inspection is required in between certain slab thickness, the Formwork Supervisor and/or appointed personnel are to carry out the inspection and should repeat the process of inspection above.

6.5.7

Casting Completed.

6.6

Formwork/ Falsework Dismantling and Striking

6.6.1

The Site Engineer and/or the Senior Engineer shall prepare and raise the Request for Permit to Continue (Load/ Unload) before dismantling and striking of formwork and/or falsework.

6.6.2

The Site Engineer or Senior Engineer shall ensure that the age of the concrete of the cast slab and its strength complied with the requirement of the Specification and relevant Standard.

6.6.3

Once the permit is approved and authorised by the Construction Manager and/or the PM or the designated and authorised personnel by the PM, the formwork/ falsework removal and striking can commence.

6.6.4

Formwork Supervisor shall ensure formwork and falsework are remove safely.

7.0

Records 1. 2. 3. 4. 5.

Inspection Record For Formwork F020-600-[SIN] Request For Permit to Continue/ Load/ Unload Certificate of Inspection (COI) from the PE prior to install the reinforcement Certificate of Supervision (COS) by the PE prior to concrete casting Concrete cube test results

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 4 of 9

F005-600-7566

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Relevant Attachments Appendix A: Formwork/ Falsework Inspection Responsibility Matrix Appendix B: Temporary Works Design and Inspection Process Flowchart Appendix C: Inspection Record For Formwork F020-600-[SIN] Request For Permit to Continue/ Load/ Unload Appendix D - JSEA

Prepared by:

Rick Abcede/Moises Villaroza

Reviewed by:

Ian Thompson/ WaiFong/Sam Woo

Reviewed by:

Frank Hemmert

Approved by;

Barry Mclean

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 5 of 9

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Appendix A: Formwork/ Falsework Inspection Responsibility Matrix

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 6 of 9

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Appendix B: Temporary Works Design and Inspection Process Flowchart

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 7 of 9

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Appendix C: Inspection Record For Formwork F020-600-[SIN] Request For Permit to Continue/ Load/ Unload

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 8 of 9

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Appendix D: Job Safety and Environmental Analysis

Project : C917A Completion Contract for Design and Construction of Sixth Avenue (SAV) and King Albert Park (KAP) Stations and Tunnels for DTL2 Land Transport Authority Date : 220114 Doc. Title: Falsework/ Formwork Structure – Concourse,Intermediate, Roof, Top of station box and Upper Level Slab Rev: 0 Doc. No.: DOC/917A/ KAP-SAV/ SWP/ 005 Page: 9 of 9