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Segment Lifting & Handling

This document provides a method statement for safely lifting and handling precast concrete segments at a precasting yard for a metro project in Ho Chi Minh City, Vietnam. It describes transferring segments between different areas using a lifting frame and gantry crane. Safety risks are assessed, required personnel, equipment, and materials are identified, and the step-by-step construction process is outlined, including fixing the lifting frame to segments and subsequently releasing them. Inspections will be conducted and records kept according to the project inspection test plan.

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ajit karandikar
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116 views

Segment Lifting & Handling

This document provides a method statement for safely lifting and handling precast concrete segments at a precasting yard for a metro project in Ho Chi Minh City, Vietnam. It describes transferring segments between different areas using a lifting frame and gantry crane. Safety risks are assessed, required personnel, equipment, and materials are identified, and the step-by-step construction process is outlined, including fixing the lifting frame to segments and subsequently releasing them. Inspections will be conducted and records kept according to the project inspection test plan.

Uploaded by

ajit karandikar
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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METHOD STATEMENT FOR SEGMENT LIFTING & HANDLING WORKS

INTRODUCTION

I) PURPOSE OF THE DOCUMENT

The purpose of this document is to describe the procedure of operation to be followed for the
lifting of concrete precast segments, and ensure that all works will be conducted safely in
accordance with the technical drawings, and the project specifications.

II) PROJECT DESCRIPTION

III) SCOPE OF WORK

This method statement defines the lifting of all precast concrete segments at the precasting
yard, composing the viaducts of HCMC Line 1 – Metro Project.

Included:

 Transfer segment from mould area to finishing area


 Transfer segment from finishing to storage area
 Transfer segment from storage area to trailers for segment delivery
 Transfer 1st of span segment from mould to another mould

Excluded:

 Lifting segment for span erection

REFERENCES

Specifications:

 Reference is made to clause 12.4.2 “Precast segment handling, storage and transport”
from Outline Construction Specification Package 2: Civil (Elevated & Depot).

Method Statement:

 Method Statement “Segment storage & stacking” – HCMC-261-CSYD-CWS-MST-00026

 Method Statement “Segment delivery & transportation” - HCMC-261-CSYD-CWS-MST-


00027
Drawing:

 Technical drawing “Precasting yard - Lifting of segment - Steel plate” FVR-TEC-DWG-


3140-020

All reference documents are intended to refer to the latest issued revision.

DEFINITIONS

In this Terms & conditions the meanings assigned to words and expressions shall be the
following:

 “PCY” means Precasting yard

 “Segment lifting frame” or “Spreader beam” means the frame that is required for the lifting
and transporting of the complete segment from the mould either to the finishing area or
storage area. This equipment shall be designed so that there is no permanent distortion
of the segment either during lifting, transport or placing on trailer prior to deliver on site.

Further definitions have been given in Section 1.5 “Definitions” of the Method Statement
“General precasting works at precasting yard” - HCMC-261-CSYD-CWS-MST-00012.

SAFETY & ENVIRONMENTAL RISKS

I) HAZARD ANALYSIS & RISK ASSESSMENT

Hazards Analysis and Risks assessment are carried out and attached in each Method
Statement. This document will identify all the hazards to ensure adequate control measures and
strategies are in place to mitigate as much as possible the risks (Appendix C).

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 and safety harness if required.

TOOLS AND EQUIPMENT

All tools & equipment shall be in safe condition before utilisation and fit for its purpose.

EMERGENCY RESPONSE

In the event of an accident/incident, response will be 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, proposing actions to ensure that the Accident/Incident will never happen
again, including for example: Toolbox Meeting (TBM) held by the Safety Officer to
ensure that Site Team (Workers, Supervisors & Engineers) fully understand methods &
risks.

CONSTRUCTION RESOURCES

PERSONNEL
The personnel involved are such as:

 PCY Supervisor
 Storage supervisor
 Gantry crane Operator (50 tons)
 Riggers

PLANT AND TOOLS


The following equipment shall be used for the purpose of segment handling:

 Gantry crane
 Spreader beam
 Slogging wrench for nut of 32mm diameter
 Sledge hammer

MATERIALS (DEXTRA OR EQUIVALENT)

 Fully threaded bars (32mm diameter)


 Spherical swivel nut (32mm diameter)
 Anchor swivel plate square (32mm diameter)

CONSTRUCTION PROCESS
PRELIMINARY
After completion of segment manufacturing, once the concrete reach 25MPa, the segment can
be lifted. 25MPa shall be confirmed by Main Contractor.
Then, the segment is lifted using a spreader beam, using 4 stress bar through designated lifting
holes. On the spreader beam, several locations of lifting holes are available, depending of the
type of segment to lift.

FIXING OF THE SPREADER BEAM ON THE SEGMENT


The following sub-sections outline the process which typically accomplishes the setting of the
spreader beam in place on the precast typical and pier segments:

1- The spreader beam is set up by the 50 Ton gantry crane around 10mm above its final
location on the segment to be lifted.

2- The spreader beam must visually hanged as much as possible aligned with the transversally
axis of the segment.

3- Carefully, the 50Ton gantry crane is used to lower down the spreader beam until it’s in
contact with segment’s top flange. Gantry crane operator shall be assisted by rigger.

4- Segment tightening:

The 4 fully threaded bars DEXTRA or equivalent (Appendix A) are inserted through the 4
designated lifting holes to connect typical / pier segment with the spreader beam as shown
below:

 For pier segment near stations, the following lifting holes must be used due to the reduction
of top flange’s dimension.

 Spherical swivel nut and anchor swivel plate square (32mm diameter) are installed below
the top flange and above the spreader beam.

 A steel plate shall be used as wedge between the swivel plate and concrete at the bottom of
flange.

 A rubber shall also be fixed to the bottom of spreader beam to avoid friction due to located
load points between the spreader beam and the top of concrete flange.

 The 4 hanging bars are manually tightened using a wrench and a hammer for the last
checking.

Stress bar shall be visually checked of any sign of bend, tread damage or any other defect
EACH TIME it is used for connecting the segment to the spreader beam.   All necessary safety
measures shall be taken during lifting and transporting the segments, including:
 During lifting and moving with segment, speed for winching up or lowering down of 50Ton
gantry crane shall be controlled in a safe manner by the operator and operated in low
speed.

 Segment lifting path shall be always kept clear of any worker or remedial works. Workers
have to stop working and move out of the lifting path prior to segment lifting.

 Segment shall be handled in full care to prevent any damage, especially on the shear keys
and the match-catch surfaces

RELEASE OF SEGMENT

Prior to transfer segment to finishing area, the following steps have to be carried out:

 The segment shall be placed on three appropriated concrete support blocks.

 When the segment is set down, remove threaded bars, plates and nuts (32mm diameter)

 The spreader is then lifted from the segment carefully to avoid any damage to the segment

INSPECTION & RECORDS

All Inspection / check-lists related to concrete strength for segment lifting will be identified in the
Inspection & test Plan. Refer to the ITP “Precast segment production”

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