J&P Document number:

M ET H O D CP 300(a)-QCP-038
S T AT E M E N T
J&P (O) Ltd. /
Page: 1 of 7
J&P–AVAX S.A. J.V.

Document Title:

METHOD STATEMENT
KERBS PRE-CASTING & INSTALLATION

Issue Date : 11-10-2005

Revision Date: 11-10-2005 Revision No. : 0

Issued By : QA/QC Engineer:

Approved By : Deputy Project Manager:

Approved By : Senior Project Manager:

F-P.810/1-0
 J&P Document number:
M ET H O D CP 300(a)-QCP-038
S T AT E M E N T
J&P (O) Ltd. /
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J&P–AVAX S.A. J.V.

1. SCOPE

The scope of this procedure covers the activities involved in the pre-
casting and installation of kerbs for the Underground Car Park ensuring
that the works and materials conform to the requirements specified in
the Contract (IFC) Drawings, approved Shop Drawings and Project
Specifications.

2. FIELD OF APPLICATION

2.1 Basement perimeter driveway concrete curb of the Underground

Car Park.

2.2 Kerbs for the edges of basement parking isles of the

Underground Car Park.

3. REFERENCES

3.1 Qatar Construction Specifications (QCS)

Section 6 Part 8 (Kerbs, Footways and Paved Areas)

3.2 Drawing No. A-1B1 Rev. 4 (IFC; UCP)

Basement Plan

3.3 Drawing No. A-406 Rev. 3 (IFC; UCP)

Symbol of Parking

3.4 Letter to Public Works Authority/Building Engineering Department

Ref. No. HMC/02B/1959
Date: 17-Sep-05
Subject: Clarification of OCP Scope of Work

3.5 Bill Of Quantities (Underground Car Park)

Page No. 4/8/4 Items E & F

4. MATERIALS

4.1 OPC 30/20 & 20/20

Material Submittal No. CP300(a)-MS-03/005 Rev. 01 & 02 (Code
B)

4.2 Ordinary Portland Cement (OPC)

Material Submittal No. CP300(a)-MS-03/004 Rev. 00 (Code B)

F-P.810/1-0
 J&P Document number:
M ET H O D CP 300(a)-QCP-038
S T AT E M E N T
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J&P–AVAX S.A. J.V.

4.3 Sand

4.4 Water

4.5 Concresive® 1450

High Performance Styrene Free Epoxyacrylate Based Fixing
Compound
Supplier: degussa - MBT
Material Submittal No. CP300(a)-MS-UCP-15-082 Rev. 00 (Code
B)
* Product Data Sheet attached

4.6 Masterflow ® 520

High Strength, Non-Shrink Cementitious Construction Grout
Supplier: degussa - MBT
Material Submittal No. CP300(a)-MS-UCP-03/075 Rev. 00 (Code
B)
* Product Data Sheet attached

4.7 Hunton Fiber Board Joint Filler

Material Submittal No. CP300(a)-(BOTH)-MS-03/014 Rev. 02
(Code A)
* Product Data Sheet attached

5. TOOLS/EQUIPMENTS

5.1 Formworks and accessories

5.2 Mechanical Drill

5.3 Air Compressor

5.4 Mechanical Mortar/Grout Mixer or Drill & Paddle

5.5 Truck Boom/Truck & Forklift

5.6 Dispenser Gun

5.7 Trowel

6. RESPONSIBILITIES ON SITE

6.1 Kerbs pre-casting and installation works and related activities

shall be undertaken by a dedicated group headed by a Foreman
under the over-all supervision of the responsible Site Engineer.
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M ET H O D CP 300(a)-QCP-038
S T AT E M E N T
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6.2 The Land Surveyor shall be responsible for the correct lay-out of
the alignment and elevation of the pre-cast concrete kerbs.

6.3 Kerbs pre-casting and installation activity shall be carried out

under surveillance point.

6.4 The Site Engineer shall be responsible for the quality aspect of
the work and compliance with this Method Statement and Project
Specifications.

6.5 Health, Safety and Environmental issues are addressed in

accordance with the approved HSE Plan (Document Submittal
No. CP 300(a)- DS-BOTH-01 /008; Code A) under the
supervision of the Site Safety Officers.

7. WORK PROCEDURE

7.1 Formworks shall be assembled with provisions for the 2-12 mmØ
dowels to be installed 200mm from the ends of the placed kerbs.
This shall be done by placing removable 18 mmØ PVC pipes at
the required locations on the formworks prior to kerb pre-casting.

7.2 Each kerb shall be pre-cast in 0.90-meter length using OPC 30/20
as approved for CP300(a) works.

The kerb cross-section shall be as shown in Detail 15 of Drawing

No. A-406 Rev. 3 of the Underground Car Park. Shorter length of
kerbs shall be pre-cast for curved sections of the perimeter
driveway and parking isles. The 18 mmØ PVC pipe provisions for
the dowels shall be removed from the kerb mould before concrete
finally sets.

Fabrication tolerance shall be 3 mm in any one dimension and

end faces shall be truly perpendicular to the base.

7.3 Cure the pre-cast concrete kerbs by moisture retaining cover for
at least 7 days in accordance with Method Statement on Curing of
Concrete Structures (Document Submittal No. CP300(a)-DS-
BOTH-03-026; Code B).

7.4 Cut the required number of 12 mmØ x 200mm dowels.

7.5 Cured concrete kerbs shall be placed on wooden pallets and shall
be delivered to installation areas using truck boom or truck and

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M ET H O D CP 300(a)-QCP-038
S T AT E M E N T
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Page: 5 of 7
J&P–AVAX S.A. J.V.

forklift. Care shall be taken in order not to damage or break the

kerbs during loading and unloading.

7.6 Clean the area for kerb installation with compressed air to remove
dust and other materials detrimental to setting out and mortar
bond for the laying of the kerbs.

7.7 The Land Surveyor shall be responsible for the correct layout of
the alignment and elevation of the kerbs.

7.8 Mix the mortar for the setting bed of the kerbs at a ratio of 1:3
(Cement:Sand) until the desired consistency is achieved.

7.9 Lay the kerbs true to alignment and elevation with approximately
25mm thick mortar bedding. Laying tolerance shall be +/-3mm at
each end of an element to the designated lines and grades.

All excess mortar protruding out of the kerb base (driveway side)
shall be removed and the mortar joint pointed flush.

7.10 Joints between kerbs shall have a width of 4mm. A 20 mm

movement joint between kerb shall be provided at 10 m intervals
along straight lengths. Bitumen impregnated joint filler board shall
extend through the kerb, bed, and backing and shall be trimmed
to the finished profile of the kerb.

7.11 After the kerb has been laid, a contiguous backing of OPC 20/20
concrete shall be poured. It shall be triangular in cross-section,
sloping at approximately 45 o and extending to a width of 100 mm
from the base of the kerb.

7.12 Allow mortar bedding and OPC 20/20 concrete backing to set
then cure by moisture retaining cover for at least 7 days in
accordance with Method Statement on Curing of Concrete
Structures (Document Submittal No. CP300(a)-DS-BOTH-03-026;
Code B).

7.13 With the kerbs set in the correct alignment and elevation, drill 16
mmØ holes into the base concrete through the 18mmØ open hole
at the top of the pre-cast concrete kerbs. The drill equipment/bit
shall be suitably marked to ensure that the drill hole goes through
the base concrete to a depth of at least 100mm.

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7.14 Clean the drilled holes through the open hole at the top of the
kerbs using compressed air to remove dust and loose concrete. If
dowel installation will not be carried out immediately, all open
holes shall be temporarily plugged.

7.15 To start dowel installation, fix the mixer nozzle to the front end of
the Concresive® 1450 resin cartridge then fit it into a special
dispenser gun. The resin and hardener component of
Concresive® 1450 shall be mixed within the dispenser gun at the
ratio of 10:1 by volume as per manufacturer’s recommendation.

7.16 Remove hole plug, if any, then apply Concresive® 1450 directly
into the drilled holes on the base concrete. Application shall start
at the base of the hole going up until sufficient volume is placed
(around 3 trigger pulls on the dispenser gun).

7.17 Insert the 12 mmØ x 200mm dowels inside the holes sufficiently
filled with Concresive® 1450, ensuring that top of dowel show that
it has reached at least 100mm into the base concrete.

7.18 Allow Concresive® 1450 to set. Curing time takes 30 minutes at

20oC, 25 minutes at 30oC and 15 minutes at 40 oC as per
manufacturer’s recommendation.

7.19 Clean the remaining dowel hole with compressed air, ensuring it
is free of dirt and contaminants that could impair adhesion.

7.20 Soak the remaining portion of the hole with water to minimise
absorption.

7.21 Use compressed air to remove any standing water inside the
hole.

7.22 Damp down the interior surface of the grout mixer with water prior
to mixing the initial batch of Masterflow ® 520. Ensure the mixer is
damp but free of standing water. Pour the pre-measured volume
of water (max. 4.5 litres/25 kg, bag) into the mixer then slowly add
Masterflow ® 520, mix continuously for 3 to 5 minutes until a
smooth, uniform, lump free consistency is achieved.

7.23 Pour the mixed grout into the prepared kerb holes using suitable
tool.

F-P.810/1-0
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M ET H O D CP 300(a)-QCP-038
S T AT E M E N T
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J&P–AVAX S.A. J.V.

7.24 Immediately after placing Masterflow ® 520 grout, cover all

exposed grout with clean wet hessian and keep moist until grout
surface is ready to be finished. Finish the top surface of the grout
to match the top of kerb.

7.25 Clean the exposed surfaces of the kerb of all excess grout and
mortar.

8. SAFETY PROCEDURES

8.1 The Site Engineer shall physically inspect the kerb pre-casting
and installation areas to confirm that they are cleared of any
hazard and/or obstructions that may hinder access or proper
execution of the work.

8.2 The Site Engineer shall ensure that all personnel engaged in
kerbs pre-casting and installation work and related activities are
wearing the required Personal Protective Equipments (PPE).

8.3 Health, Safety and Environmental issues shall be addressed in

accordance with the approved HSE Plan (Document Submittal
No. CP 300(a)- DS-BOTH-01 /008; Code A).

8.4 Additional precautions shall be implemented in accordance with

product Material Safety Data Sheets.

9. REVISIONS

Rev. 0 Date: 11-Oct-05

F-P.810/1-0