'

Submittal Notes

:
Method Statement

Construction of Pipe Culverts

CONTENTS
1 INTRODUCTION .................................................................................................................................... 4

2 SCOPE .................................................................................................................................................... 4

3 REFERENCES ......................................................................................................................................... 4

4 RESPONSIBILITIES ............................................................................................................................... 5

5 WORK PROCESS.................................................................................................................................... 6

6 RESOURCES ........................................................................................................................................... 9

7 QUALITY CONTROL ............................................................................................................................ 10

8 ENVIRONMENTAL, HEALTS AND SAFETY PLAN .............................................................................. 10

9 ATTACHMENTS .................................................................................................................................. 12
 1 INTRODUCTION
This method statement describes the standard work process for Pipe Culverts (Attachment 1-Flow
Chart for Pipe Culvert Works). It includes :
■ Earthwork Operation of Pipe Culvert
■ Pipe Installation
■ Pipe Cover Concrete
■ Crushed Material Backfilling for Pipe Culvert
And Also this method statement provides information for the inspection & test procedure and
health & safety environmental plans for all pipe culvert works.

2 SCOPE
Pipe Culverts are load bearing structures. Pipe Culverts are used for allowing
uninterrupted flow in watercourses from one side of the motorway to the other. Culverts
are also constructed for providing passage for transfer of utility lines like electricity,
telephone from one side of an obstacle to another.

Pipe Culverts can be constructed by cast in situ or pre-cast method. Any method
chosen must satisfy the hydrological design and ensure safe service and easy
maintenance.
This method statement is applicable to all pipe culvert works in Kosovo Motorway Project. Any
deviation from this procedure shall be documented and approved in advance by the responsible
Drainage BLIO, QA Manager, Deputy Project Manager and Project Manager.

3 REFERENCES
■ Project Quality Assurance Program - QAP
■ Project Quality Control Program - QCP
■ General Technical Requirements for Road Works 2001, Volume II & Volume IV Earthwork,
Drainage, Retaining and Facing Walls, Concrete Works.
■ Project Environmental, Safety & Health Program

4 RESPONSIBILITIES
Project Manager {PM) I Deputy Project Manager (DPM}
The PM and DPM, are responsible for overall implementation of this procedure.
 Construction of Pipe Culvert

Drainage Manager (BLIO}

The BLIO is directly responsible for all pipe culvert works implementation and execution of this
procedure.

Engineering Department-Field Engineer {FE}

The (ED) FE is assigned to provide technical support via project responsible design engineer
consistent with demands of pipe culvert's design requirements. FE is responsible to ensure latest
design requirements are transferred to Drainage Superintendents and supervisors.

Drainage Superintendent (DSE)

The DSE is responsible for the supervision and coordination of manpower and equipment required
to achieve all drainage operations in accordance with the plans, specifications, ES&H programs and
Quality programs.

Drainage Supervisor {OS}

The OS has primary responsibility for quality control, quantity takeoffs, material requisition,
technical compliance and monitoring of all construction and testing activities associated with pipe
culverts. He is responsible for the supervision of subcontractor production and equipment required
to achieve all drainage operations in accordance with the plans, specifications, ES&H programs and
Quality programs. OS is responsible for preparing checklists and site dairies and submitting them to
the related departments. OS is also responsible for preparing daily and monthly production reports
and submitting them to EW BLIO.
Subcontractor is responsible to achieve work progress in accordance with BEGP plans, specifications,
ES&H programs and Quality programs. At each step of prod1:1ction, inspections will be performed on
Subcontractor and their production by OS. Subcontractor will organize the preparing formwork,
rebar and concrete for daily production.

Drainage Foremen (DF)

OF is responsible for controlling of Subcontractor's under the direction of DS. Foremen is also
responsible for ensuring BEGP ES&H and quality requirements are meet during installation and
production period.

Survey Engineer (SE)

Survey engineer and his survey team are responsible for applying required design data, coordinates
of Pipe culvert, earthwork operations and Pipe culvert Concrete work. They are needed for achieving
correct installation of Pipe Culverts.

Procurement Department (PD}

Procurement Department is responsible for purchasing and storing the suitable pipes from available
markets according to purchase orders.

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 Construction of Pipe Culvert

QC Superintendent {QCSE}
QCSE is responsible for assisting DS to ensure all QA/QC program requirements during construction
and production period.

5 WORK PROCESS

5.1 Planning
The project estimated quantity of pipe culverts that take-offs will be reviewed during preplanning
stage.
DS will organize the start of work for pipe culvert includes;
• Organizing the Survey application.
• directing machines and Earthwork operations {leveling to bottom of lean concrete by open
cut excavation or fill.)
• Making MRs, purchasing and producing of corrugated pipes by BLIO.
• Provide the test and inspections.

5.2 Procurement
Procurement department shall search suitable markets and inform of suitable materials to
Engineering & Drainage Department with all required material's certifications.
Quality Control Department shall get SE client confirmation prior to procuring materials by
Procurement Department.

5.3 Installation of Corrugated Pipes

Prior to start of work, the vegetation and topsoil will be removed from the foundation
bottom. If trenches are required, they will be cut in such a manner that ensures the
pipes are laid in accordance with the design drawings. Culverts are usually located
at the lowest elevation of watercourses, where the foundation soil is generally
unsuitable. The unsuitable foundation soil will be replaced with stone material in
layers, as specified in the design. Each layer will be compacted prior to placement
of the subsequent
la
ye
r.

Bedding is required to level out any irregularities in the foundation and to

ensure uniform support along the barrel of each pipe section. The bedding will be
placed to uniform grade and line to ensure vertical alignment and to avoid

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PRISHTINE • HANI I ELEZIT MOTORWAY PROJECT Construction of Pipe Culvert

excessive stresses at joints. The bedding material shall be free of foreign matters
like rock fragments, roots, etc. that may cause unequal settlement.

All pipes will be laid in accordance with the design. Following the installation of pipes,
the ancillary concrete structures will be constructed. Ancillary concrete structures
include headwalls, wing walls, sumps, sump tops, aprons, drops and intakes.
These will be made of reinforced concrete and constructed as specified in design
drawings. The pipe jointing and the jointing of ancillary concrete structures to pipes
and other structures will be carried out in such a manner that the finished joints are
watertight. The pipe lifting holes will be closed with mortar before backfilling. The
coating will be applied on the dry and clean concrete surface.

Backfill will be built in layers placed and compacted evenly on both sides of the pipes
in order to obtain balanced loading. Compaction will be achieved with mechanized
hand compactors on each side of the pipe. Heavy construction equipment and
rollers will not be operated over or near the culvert until the minimum amount of fill
required around and over the pipes has been placed and compacted as specified
in the design. A typical pipe culvert is shown in Fig. 1.

Figure 1 - Pipe Culvert Operations

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 Construction of Pipe Culvert

At the beginning, Leveling starts to the bottom of lean concrete. When the leveling is complete, Lean
concrete will be pured. Then Installation of Corrugated Pipes can start. Installation of Corrugated
Pipes means the placing of culvert pipe with suitable lifting equipment at the axis of barrel and to
make connection of one concrete pipe to another.
After installation of all Corrugated pipes, Pipe Cover Concrete can start. It means Including
placement of concrete surround of concrete pipe culverts according to the design, insulated with
bituminous material and styrofoam. When the all insulation is finished, Backfilling material can be
done, after production will be complete.

5.4 Reporting
*Preparing the daily production report and concrete order for next day.
*Preparing Planned Quantities for each month.
*Giving the quantities for Quantity Tracking Department for each month.
*Preparing quantities for Subcontractor's payment with Quantity Tracking Department.
*Preparing site dairy and all checklist for pipe culvert works.
*Saving forms for ES&H applications on pipe culverts works.

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 Construction of Pipe Culvert

6 RESOURCES

6.1 Materials
• HOPE Corrugated Pipes
• Formworks
• Wire mesh

6.2 Plant and Equipment

r• Excavator

• Roller

. Boom truck
Concrete Trans mixer
• Concrete Pump
• Rough Terrain Crane
• Concrete Bucket
. Concrete Vibrator
• Diesel Generators
Air Compressor
Submersible Pump
• Water Truck·
• Light Plants

6.3 Manpower
F or this operation, we need approximately one foremen and 8 workers during construction
operations.

7 QUALITY CONTROL

During the Pipe Culvert production, ongoing Test and Inspections are;
*Concrete Compressive Strength, Fresh Concrete Testing, Concrete Pre Pour Inspection (Attachment
1- Concrete Pre Pour Checklist), Concrete Post Pour Inspection (Attachment 2- Concrete Post Pour
Checklist)/ 25939-000-QC-100-0001 Inspection and Test Plan Concrete and Structures
* F oundation Compaction Test Rev.(Earthwork&F oundation Checklist-Culverts&Underpasses)
/25939-000-QC-100-0007 Inspection and Test Plan Earthworks, Retaining Walls and Drainage.

Page 9 of 17
 Construction of Pipe Culvert

QCSE shall make required compaction test, concrete test and inspections for executed works in
compliance with QC programs.

8 ENVIRONMENTAL, HEALTS AND SAFETY PLAN

Construction of pipe culverts mainly contains concrete works and reinforcing steel
workmanship. For initial works like excavation and after works like spreading
and compacting of fill please see corresponding method statements. For concrete
works, anyone who uses or works around concrete and cement should understand the
potential health hazards and follow safe handling procedures to prevent harmful
exposures. There are some applications of concrete that necessitate the addition of
other materials that could adversely affect health if improperly handled. Additions
may include alkaline compounds (such as lime) that are corrosive to human
tissue, small amounts of crystalline silica that are abrasive to skin and causes
damage to lungs or small amounts of chromium that can cause allergic reactions.
The risk of illness or injury from these additions in the concrete depends on the level
and length of exposure and the sensitivity of the individual. Material Safety Data
Sheets (MSDS) must be made available to employees working_ with any substance
which can adversely affect their health. MSDS will identify the correct personal
protective equipment (PPE) required to use that product safely.

Adverse health effects from concrete or cement are generally the result of
exposure through skin contact, eye contact or inhalation.

• Skin Contact - getting cement dust or wet concrete on your skin can cause
burns, rashes, and skin irritations. Sometimes workers become allergic if they've
had skin contact with cement over a long period of time.
• Eye Contact - getting concrete or cement dust in your eyes may cause immediate
or delayed irritation of the eyes. Depending upon how much and for how long you
get the dust in your eyes, effects to your eyes can range from redness to painful
chemical burns.
• Inhalation - inhaling cement dust may occur when workers empty bags of cement
to make concrete. When sanding, grinding, cutting, drilling or breaking up concrete, the
dust generated has the same hazards as the dust from cement. Exposure to
cement or concrete dust can cause nose and throat irritation. Long term exposure to
concrete dust containing crystalline silica can lead to a disabling lung disease called
silicosis.

Page lOof 17
 Construction of Pipe Culvert

There are ways to prevent or control negative health effects when working with
concrete and cement.

First of all, dress for protection. Wear alkali resistant gloves, long sleeves and pants
to reduce skin exposure to concrete or cement dust, and waterproof boots that are
taller than the concrete is deep. Wear safety glasses with side shields to protect the
eyes or if it's very dusty, goggles. Don't wear contact lenses. When dust can't be
avoided, wear employer-approved respiratory protection. And remember to wash your
hands and face before eating, drinking, smoking or using the toilet at the end of the
day. Secondly, follow all safe work practices and procedures. Work in ways that
minimize the release of cement dust. Stay out of dusty areas, when possible. If it's
necessary to kneel on fresh concrete, use a dry board or waterproof kneepads. Finally,
if wet or dry concrete gets on your skin, wash it off as soon as possible.

Workers should also be aware of possibility of injury by improper makeshift

ladders, platforms and stairs, falling concrete forms if the forms are improperly chocked,
braced or cribbed.

For equipment safety during construction of culverts, be sure that trucks and
other vehicles are in good working order, including audible back-up warning signals,
before operating them and avoid overloading hoists, cranes and forklifts.

For reinforcing steel workmanship, addition to PPE, machines and equipments should
be in safe condition to operate during rebar bending, cutting, cage rolling, etc.
Unguarded machinery used in the manufacturing process can lead to worker injuries.
Thus, ensure that guards are in place to protect workers on power I mechanic tools
before using them.
While carrying the reinforcing steel, lift properly and get a coworker to help if the
product is too heavy. Use hand trucks or forklifts when possible.

These above and more safety instructions are delivered to the personnel by safety
inductions during their first day on the project, safety tool box briefings daily each morning
before start of the work, special training for special site applications and meetings about
general safety conditions of the project. Requirements are covered in the Kosovo
Motorway Project Risk Assessment document and Project Environmental, Safety &
Health Program.

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 Construction of Pipe Culvert

9 ATTACHMENTS
Attachmentl- Earthwork &Foundation Checklist Rev.(Culverts& Underpasses)
Attachment2- Concrete Pre Pour Checklist
Attachment3- Concrete Post Pour Checklist
Attachment4- Risk Assessment for Construction of Pipe Culvert

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 Construction of Pipe Culvert

Attachmentl- Earthwork &Foundation Checklist (Culverts& Underpasses)

TOPSOIL REMOVAL, ROADWAY EXCAVATION D ESIGN GRADE, ROADWAY EMBANKMENT BOTTOM, OVER
EXCAVATION FILL & STRUCTURE FOUNDATION
INSPECTION CHECKLIST

Document Number: 25Q3Q-•........-OC-........••..........

Dale: -----
I
Section:
Location:
Description of work:
Conform
No Controlled ltNIS Responsibility Remarks
YES NO N.IA

I. Topsoi and/or Over Exeavalion u per design Site Superintendent

2. M.Jlerial I soil befow topsol suitJble for fil Site Superintendent

3, Excavation design grade suitable for road construction Surveyor

Structure foond.ltion grade 511itabte for found3tion

4.
conS1rUction SUrveyo!

M.Jlerial sources for emb:lnkment fill .anc!lor over � SUperintendent

5.
excavation fill .n approued .

Benches through !he layers meet the TechnlC31 Specs

«I. requirements
Site Superintendent

Trial Section was carried out and work in5tJuctions on the

7. QC Superintendent
field were e51ablished

8. IITJl{OVefflellt by polymer ge<9id I geotextile QC Superintendent

BNring Capacity (on r03d bed & structure foundation

g_ QC Superintendent
base)

10 Geometrical characteristics Surveyor

11. Elev.ltion ···--·······-··---··--.... -... , ............. Swveyor

12. M.aterial of embankm!nt andbacltfill suit.lbleforuse QC Superintendent

c-�:

Site Superintendent Survey Superintendent QC Superintendent

N.JIM

Signature

SupHVising EnginHr
O.e

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PRISHTINE - HANI I ELEZIT MOTORWAY PROJECT Construction of Pipe Culvert

Attachment2- Concrete Pre Pour Checklist

PRE-CONCRETING INSPECTION CHECKLIST

Document Number. ....•.•.•...-..•...•.•.

D;ate: _t_l ___

Sect�n:________
Structure:------------------------------
L-tion: ______________________________
Description ofworti: __________________________

Conform
N<, Controlled Items Responsibility Rem;arlts
YES NO NIA
Approved DocurMnts ;are issued ;and ;avililable in the
I. Site � 1
field or site office (Speclficiltions. IFC drilwinp, MS. Supervisor
ITP illld form fGr reoords)
II. BLINDING (LEAN) CONCRETE
1 Ear1hwcrt f01S1dation bilse compxtedand compatible as QC Field Superi ntenderi
· -desim forio.,,n-crete
Site�� I
Supervisc,
3. Concrete mixlure is as per� mix design OC Field Superimenden
ID. STRUCTURAL CONCRETE
1. -

1.3 Handoversurveydal3 Survey Superintendell

1.b FOll'llwcrt setting out Survey Supefinlendelt

1.c FOll'llworil po5ition according to setting out Si.r,,ey Superinlend!R

l .d ;,i::!!i:or size l"ls the size of the 51Mtural element Sisvey Supemendelt

Formwcrt Slr.30l!S on W1ich ooncrete to be plaoed Site Supe,irelldeni I

1.e checked
Supervis-or
Formwcrt � sealing and suppo,t elements Site S11pem:e11deut 1
l.f checked
Supervisor

Site Sllpe(ilmlliffl I
1.g WllM Stop plaoed �g to design
Supervisor
2. rnaNF• II

2.3 Reinfolcement setting out Site Superifandent I

Supervisor

2.b Bars.' C3IJll5 stored in !he field psoperly Site SupMirteodem I

Supervisor

2.c Tempera1Ure during bending Site Suplrirceodem I

Supenrisor

2.d Bending aocordingto drllwings Site� I

Supervisor

Rebar number, 03ffleter and position at different cross Site� I

2·1 sections cl the SI\ICIU!e eletllelt is 30C01ding ID design SuperviSDf

Page 14 of 17
 Construction of Pipe Culvert

Oisunce becweetl st� SlimJps d.3ff'Eller aid bracing Site Supe(iuteodert I

ZJ method inocoldng 10 de5ign Supen,iS0f
l..eng1h d reinforcemslt br.; Iha wll be Ollll!IIJ!:l)ed in Site Supenrnndert,
2.g analher sruclule eleml!nt is accoldng to design
Supervisor
Sj:lioes position 30d Oftf13')1l� leng1tl d reimtrcing bats Site Superirteode,cI
2.h is llllllOldng 10 design Supen,isor

Number and quality of the spices be1ween tenlfotcerneff Site $,,peli111eodef'tI

2., bats Supe!ViSOf

Sile�l!ICI
2j Welding quarrty- if applQbte Supervisor

Site�l!ICI
:B Foon!Mllk position � cl reb.n ctJring concreting Supervisor

Concrete coverthldmess (sp.Jeer blocks)311d number of Site�ertl

2.t covers .re c:omptiant. Supen,isor

Site�l!ltl
2.m lnduded pieces (position, cfmer51cns 3nd mcing) Supermor
�- ME.C,.IT U-IIEIUI

3.a Surf3ce vibrators Site SupetRi!1Ide!1 /

Supe!Visor
S•�eni:/
3.b Stressing pct Supen,iSOf

3.c Stelrn o..rmv system Site�l!I"« I

Supervisor
,. CONCRETE

4.a Concrete mixtl.lfl! is .115 per� mil design QC Field Superintenden

Req.lired llle.lSUl'l!5 .re taken regardng ambient

4.b QC Field Superintenden
�
Haldened OllrlCf'l!'te surtace lhal oomes in oontaa with Site $,,pelisce.ldM I
4.c fresh ocrnnte
Supervisor
lllil-t-•nble

Site Supei�ldtnt / Supenisor Sine)' Superintendent QC Field Superi11te11dent

Name

Sigmture

Supenising EnoiM«

o•

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 PRISHTINE - HANI I ELEZIT MOTORWAY PROJECT Construction of Pipe Culvert

Attachment3- Concrete Post Pour Checklist

POST-CONCRETING INSPECTION
CHECKLIST

Document Number: ..............

Date: _ / _/ ___
Section:
Structure:
Location:
Conform
No Controlled Responsibility Remarks
YES NO N/A
Items

Pre Concreting Inspection Checklist signed and Site Superintendent I

1·
submitted to QC department Supervisor

Suitable Concrete Curing done according to weathe1 .

S'tI e Su_penntendent 1
2. conditions, concrete mixture, work conditions anc
Superv,sor
structure exposure

Concrete Curing Time is enough according to weathe1 .

3. conditions, concrete mixture, work conditions ano
s' e Su_penn
S't tendent 1
structure exposure upervisor

Concrete Surface Finish (If any segragation,

4. QC Fielc
cracks, honeycombs, holes etc., proper repair Superintendent
'
Release & removal of formwork - until concrete has
gained adequate strength to
• withstand surface damage due to formwork removal
• take on all forces influencing the element
• avoid deformation in excess of the specified. Site Superintendent /
5. For example: Supervisor
• 10·% of concrete class strength for slabs with
max 6 m span and all prestressed beams
• 85 % of concrete class for slabs with span
6m

6. Dimensions of structure elements according to design Survey Superintendent

Elevation of top and bottom of structure

7. Survey Superintendent
elements according to design

Construction joints constructed according to design Site Superintendent /

8. or specifications Supervisor

N/A -Not applicable

Note: For Item 5, concrete strength to be provided by QC

Site Superintendent / Supervisor Survey Superintendent QC Field Superintendent

Name

Signature

Supervising Engineer
Date

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PRISHTINE - HANI I ELEZIT MOTORWAY PROJECT Construction of Pipe Culvert

Attachment4- Risk Assessment for Construction of Pipe Culvert

RISK ASSESSMENT

-llllll•II.IAY

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Page 17 of 17