Method Statement for Surface Rock Bolts and Dowels

NEOM Spine Infrastructure - Tunnel Access, Adit and Portal Formation

Work Order No. 000 – Main Contract

Work Order Title CRCC-Spine Tunnel Access, Adit and Portal-C028

Contract No. 4800000241

Contract Title Access Tunnel, Adit and Portal Formation

Document Title Method Statement for Surface Rock Bolts and Dowels
Report No. Revision 02
Reason for Issue For Approval Date 14-11-2021

Revision History Revision Date Revision Description

01 10-10-2021 For Approval
02 14-11-2021 Rectified the comments
03

Originator internal Review and Approval

Originator Name Position Signature
Prepared by Hakem Safwat Construction Manager
Reviewed by Kamal Gawargi Project Manager
Approved by Hossam Elsayed Project Director
 Method Statement for Surface Rock Bolts and Dowels
NEOM Spine Infrastructure - Tunnel Access, Adit and Portal Formation

METHOD STATEMENT
FOR
SURFACE ROCK BOLTS AND DOWELS

NEOM SPINE INFRASTRUCTURE TUNNEL

ACCESS, ADITS AND PORTAL FORMATION
Project No: 4800000241

Ref. No.
 Method Statement for Surface Rock Bolts and Dowels
NEOM Spine Infrastructure - Tunnel Access, Adit and Portal Formation
 Method Statement for Surface Rock Bolts and Dowels
NEOM Spine Infrastructure - Tunnel Access, Adit and Portal Formation

TABLE OF CONTENTS
S.No Description Page No.
1 General 2
2 Scope 2
3 Definitions and Interpretation 3
4 Job Responsibilities 4
5 Manpower 7
6 Equipment & Tools 7
7 Methodology / procedures 8
8 Quality Assurance & Quality Control 13
9 Health, Safety, And Welfare 14
APPENDIX A –Inspection Test Plan
APPENDIX B – Risk Assessment
10 APPENDIX C – MasterFlow 190 Data Sheet.
APPENDIX D – Drilling & Grouting Machine Profile.

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1- GENERAL
Soil nailing is a construction technique generally used for the stabilization of
naturally unstable slopes or securing of over-steepened existing slopes, as well as
the stabilization of retaining walls or embankments. For Underground applications,
soil nails are also referred to as rock bolts.
Conventional nail systems consisting of solid threaded bars are installed into per-
drilled holes and subsequently grouted.

2- SCOPE/OBJECTIVE/PURPOSE
This method statement outlines the procedures to be followed for drilling the
holes onwards fixing the rock bolts with approved grouting material &
stabilization of non-stable rock boulders at the locations indicated by CRCC
Geotechnical Engineer and approved by EPM accordingly.
Rock bolt activities carried out at following locations,
 East Site - ADITS - 1, 2 & 3
 West Site - ADITS - 4, 5 & 6

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3- DEFINITIONS AND INTERPRETATION
In this document, the following words and expressions could have the
following meaning as applicable and should be adapted to the words of the
contract.
 “Client” Project’s owner and its legal successors.
 “EPM” Consultant / Designer Engineer
 “Contractor” Main contractor who has been nominated by the Client
and the legal successors to execute the work.

 “Subcontractor” C ontractor who will execute a particular part of work
under control and supervision of the Main Contractor.


“Approved Drawings” Shop Drawings including calculations,
procedures,manuals approved by the Consultant


 “Approved Material” Material submittal approved by the Consultant
 “Approved Mock Up” Mock-Up approved by the Consultant / Client
 “MS” Method Statement
 “HSE” Health Safety & Environment
“ ITP” Inspection Testing Plan
“PM” Project Manager
“CM” Construction Manager
“SE” Site Engineer
“QC Engineer / Inspector” Responsible of Quality Control on Site
“Safety Officer” Responsible for the Safety Concerns at site
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 “Surveyor” Surveyor In charge for Surveying
“RA” Risk Assessment
“SCL” Sprayed Concrete Lining
“SRG” Shift Review Group
“RESS” Required Excavation and Support Sheet

4- JOB RESPONSIBILITIES

4.1 Project Manager (PM):

1- The PM is responsible for overall project execution, quality, and safety.
2- Adopt a leading role with respect to Contractor’s quality and safety
procedures.
3- The PM is responsible for the overall implementation of this method
statement.
4- The PM shall ensure that the key personnel are aware well by the
specifications and method statement.

4.2 Site Engineer (SE):

1- Site Engineer shall arrange all materials, equipment, safety related items,
manpower.

2- Direct the Site Forman, and workers to resort appropriate action for
the smooth execution of the works.

4.3 QC Engineer / Inspector:

1- CRCC QC Inspector will be responsible for all quality control procedures.

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 2- QC Engineer has responsibility for ensuring full compliance with the
prescribed QC requirements including the submission of inspection requests.
3- CRCC QC Inspectors will operate inspection regime to ensure that the work
is executed fully in accordance with the requirements of the contract
specifications and drawings prior to inspection requests being submitted
to the Consultant to minimize the need for re-inspections.
4.4 Safety Officer:
1- Safety Officer reports to Consultant Safety Engineer and coordinates with
SE, his responsibilities can be summarized in the following points:
2- Provides safety guidance and advice from the beginning of activities
until completion and conduct safety inductions to newly coming staff and
any site visitors, and must be full time in the site.
3- He will also raise all safety related issues observed at the work site to SE
for compliance.
4- Ensure that all work zones are barricaded, in addition to access roads.
5- Installing safety boards and signs in site in all entrances and construction
zones.
6- Determine the appropriate protective system needed to prevent potential
cave- in. be familiar with protective systems and how to use them.
7- Determine the appropriate methods to eliminate or control for all
hazards, including protection from potential cave-in.
8- Conduct site inspections in accordance with the requirements outlined in
safety plan and maintain necessary documentation.
9- Ensure appropriate personal protective equipment is provided and worn.

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4.5 Surveyor:
Surveyor under the direction of the nominated Site Engineer has the
responsibility to establish the main reference and levels to check the same at
regular intervals.
Also, he is responsible for:

1- Determining the precise location of construction lines, elevation, distances,

coordinates of points.
2- Prepare contour maps for the site, which is useful to determine, the locations
of bolts.
3- Decide the exact locations and coordinates of drilling points.
4- Record the results of surveys and verifies the accuracy of data.
5- Estimate quantity of performed and remaining quantities.

4.6 Supervisors / Foreman:

CRCC Supervisors have the overall responsibility for the supervision of
their allocated area including the direct supervision of the fixers and labors
involved and the strict implementation of safety rules and procedure.
4.7 Nozzleman:
Nozzleman shall responsible for groutingactivites and focused on
Rock Bolt grouting. Applies cement mortar or concrete to exposed earth,
grouting of rock bolts. Moves and holds supply hose as using rope sling or
harness.

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5- MANPOWER

The following skilled worker types will be available in site:

- Project Manager - Construction Manager

- Site Engineer/ Supervisor - HSE Engineer / Officer

- QC Engineer / Inspector - Surveyors, Geotechnical officer

- Forman / Supervisors - Professional Drilling Machine Operator

- Skilled Crane Operator - Grouting Machine/Nozzleman

- General labors - Skilled labors


- Operator - Environmental Officer

6- EQUIPMENT & TOOLS

 Cranes various loads.

 Drilling machines.
 Grout injection pumping machines.
 Water Tankers.
 Power supply generators.
 Air compressors.
 Various hand tools.

 Ropes & belts.

 All safety related items /Personal Protective Equipment & Hand tools.(PPE).
 Drilling rods. 
 Small water pump.
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  Rock Bolts
 Accelerator Dosing Unit.
 Scaffolding / Staging (if needed)
 Torque Wrench
The capacity, size, and numbers of the above equipment shall be judged in
accordance with site conditions, requirements, and work quantities.

7- METHODOLOGY / PROCEDURES
The following points according to the technical specifications and drawings:
 The exact location and length of the rock dowel/rock bolt shall be
determined on site, subject to designed rock slope stabilization measures
and based on Geotechnical data as per rock support stability class .
 Drilling machine shall use for drilling, as per site conditions.
 Holes shall be flushed with clean water before rock dowel/rock bolt
installation starts until the return water runs clear. Standing water shall
be blown out from the hole using compressed air after flushing, water &
air both are used to clean the hole.
 Qc Engineer shall verify the depth and dia of holes.
 Check the operational procedure of grouting mix & check the hose
pressure.
Grout Filling Option -1
 Fill up the grouting material in the hole & make full with pump hose and
additional Pvc pies(as per site requirement)
 Prior to lower the Rock Bolt proper centralizer / Special Spacer shall be
fitted to rock dowel/rock bolt before grouting to ensure an even annulus
of grout of minimum 10mm grout cover & C/c distance not more than
1.5m.
 Rock Bolts thread should be covered & Rock dowel/rock bolt shall be
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 inserted manually in the filled. Inclined and vertical both types holes shall
be filled by mentioned way.

Centralizer / Special
Spacer for Rock Bolts

Grout Filling Option -2

 After cleaning the holes, rock bolts shall insert with centralizer / Special
Spacer
 After that 8mm Pvc shall insert at the bottom of hole and connect with
the grouting pump house pipe and start the grouting.
 Records of installation of rock dowel/rock bolt shall be kept by the
contractor and a copy shall be submitted to the employer's representative
within 7 days after installation. The records shall contain details of the
location, length, inclination and level of each rock dowel/rock bolt
installed.
 For rock dowel where couplers are used to join lengths of bar, the
strength of the coupler shall be taken into account when determining
permissible working loads. Rock dowel and accessories shall be stored in
clean dry condition and at the time of installation shall be free from rust
and scale, or other physical damage and from any deleterious matter.
 A continuous geological record of the strata encountered during

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 excavation shall be made by CRCC.

 ITP to be submitted to the consultant to approve the start of work.

 The coordinates of the rock bolts are determined according to the

recommendations on the based of RESS & Geotechnical stability report.
 - The grouting material that will be injected is MasterFlow 190
manufactured by (Master Builders Solutions, mixing and injection shall be
done according to the specifications of the manufacturer data sheet that
(0.345 water /powder ratio) and maximum 8.75 liters of water shall be
used per cement grout bag of (25) kg. slowly mixed for 3-4 minutes, as
samples of the grouting are taken during the injection process for
laboratory testing and under the supervision of the supervising engineer.

 Pull out test - criteria shall be identify by 3rd party under the instructions of
EPM. All samples shall be taken under the supervision of consultant and 3rd
representative. Independent party will perform this test with calibrated
equipment and gauges.

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 MasterFlow 190

 Fill up water and add Masterflow under EPM supervision and mix up as per
3-5minutes.
 Start the grouting from bottom of hole and fill up all, Volume loss due to
cracks shall be noticed and refill the remaining hole by grouting material.
 During the grouting if material blocked in pipe then following steps shall
taken,
1. Removed the Pipe
2. Knocking/Hammering properly
3. Cleaning with high pressure water.
 In surface and slop stabilization, only rock bolts or spot bolts shall use and
did not use the Self Drilling bolts for slop protection.
 As per the recommendation in Geotechnical report, Spot bolts will be fixed
at site.Spot Bolts installed selectively as required by the ground conditions
to maintain a safe slop stabilization as part of RESS after the geotechnical
engineers mapping.
 .As per site rock conditions and slop stability purpose, shall not use the
Swellex bolts.
Base Plat Flushing Option -1
 After the immediate of grouting, fix a additional base plate and during the
shotcrete fill up that gapes and fix the base plate on the top of additional
base plate with proper flushing.

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Base Plat Flushing Option -2
 Using the Jeckhamber where applicable and brake the additional rock to
make a proper flushing of base plate.
Base Plat Flushing Option -3
 After filling the grout materia, use EMECO S88 for grouting pad
preparation.

Grouting machine details

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 Drill Machine Computerized 3-boom drilling jumbo

8- QUALITY ASSURANCE & QUALITY CONTROL

Certificates for Compliance
Acceptability of the following materials will be based upon documentation furnished
by the manufacturer identifying material and certifying compliance with the
requirements specifications.
- Master Flow 190 (Attached)
- Accelerator
Quality Requirements
 Verify that field conditions are acceptable and are ready to receive work.
 Verify Depth, space and Dia of Holes.
 Verify the Cleaning of holes by Air compressors.
 Ensure correct placement of Rock Bolts with sufficient cover.
uninterrupted applications.
 Beginning of installation means the Contractor accepts that the
existing conditions meet the above criteria.
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 9- HEALTH, SAFETY AND ENVIRONMENTAL
All the operation relevant to the rock bolt & grouting works will be programmed and
executed in a safe manner complying with all the relevant regulations, so as not to cause
danger.
The activities will be carried out either during the day shift and/or night shift, depending
on the site convenience, the specific working hours will be established and then informally
communicated to the EPM.
The operations will be carried out as per the recommendations contained in the latest of
the Health and Safety Plan and in the latest version of this Method Statement.
During all working operations, the rules mentioned below must be respected.
General Requirements for Drilling & Grouting:
The following safety precautions will be utilized during the works”
 Too Box meetings will be conducted daily for mutual understanding of the
works (before starting any shift).
 High visibility clothing, helmet and steel toe-capped boots will be worn at all
times on-site during work.
 Nozzle man & Operators will be equipped with helmet-mounted face shield and
safety goggles, including an appropriate nose mask.
 Safe access to and from the working place
  A safe place and system to work will be established.
  avoid excessive tiredness deriving for hand/arm vibrations.

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Personnel
  All personnel involved in the work shall attend a site induction, prior to
commencing work on the site.
  Safety helmets, boots, hi-visibility vest and safety glasses are mandatory as
well as an approved coverall at work site as per site safety requirements.
  Additional PPE (Personal Protective Equipment) shall be supplied as per the
work operation or as the risk assessment details.
  All personnel shall adhere to the site rules and the safety standards
associated with the operation of the works and the site requirements.
  Adequate welfare facilities will be provided for all the workers.

First Aid and Emergency Services

  First aid box shall be provided at the site. The first aid box will be supervised
on site by the safety officer.
  First aid shall be readily available during all working hours.
  In addition, emergency ambulance can be called for any unwanted major
accident.

Working during Night Shift

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When working during the night, all the areas of intervention and the related routes will be
provided with appropriate lighting and brightly visible signage whenever hazards are
present. Following rules will be implemented:
 Ensure warning signs are well maintained, illuminated and visible at all time.
 Ensure that the site has all the necessary lighting to work safely at night,
including spotlights on particular work areas.
 Ensure workers to worn fluorescent vests to make them visible to other
workers and machine operators.  
Work Equipment
  All equipment & plant shall be visually checked by the safety officer as it
arrived at the site, items of plant and equipment that is not fit for purpose will
either be removed for site of placed in a quarantined area for repair.
 All vehicles entering into the process area shall be the subject of a safety
 inspection prior to commencing works operations.
 All personnel involved in the construction will be trained in appropriate
construction and safety procedure and provided with adequate safety
equipment.
Daily Safety Inspections
 A daily site safety inspection will be conducted by the safety officers:
 Defects will be recorded on the “daily observation sheet” and closed out in an
appropriate time period with the appropriate person.
 Defects that are too serious to continue will be stopped at the time of
inspection.  

Traffic Management

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 Adequate traffic routes shall be clearly defined around the site with the correct
signage and lighting.
 A speed limit of 10kph shall be imposed on the site.
 Vehicles shall be cleaned where necessary prior to leaving site to ensure no
excess material id transform onto the highway.
 Flagman will be deployed where required and when vehicles are reversing.
 Any vehicles not fit for purpose shall be removed for site.
 All drivers shall have the correct license for vehicle they are driving.
 All drivers shall adhere to the PPE requirements for the site.

Hazardous Materials
 Hazardous material will be stored and used in line with the Manufacturer
Safety Data Sheet (MSDS).
 MSDS information will be kept at prominent locations at the site (i.e. safety
dept., stores etc.)
 All personnel working with the hazardous materials will be made aware of the
contents of the MSDS.
 All personnel working with the hazardous materials will be issued with the
appropriate PPE.
 Hazardous material stocks will be kept to a minimum on site and brought onto
site as and when required.
Fire Safety
During site set up, a fire risk assessment shall be conducted and reviewed at an
appropriate time period dependent on the conditions. A site specific fire and emergency
plan shall be complied for the hazards that will be present on the site and the location in
relation to hospitals routes etc. Following points for fire safety must be respected:

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 Appropriate firefighting equipment shall be installed as required.
 All firefighting equipment shall be inspected on a weekly basis. 
 A log of file extinguishers and inspections shall be kept.
 Fire extinguishers used in the open atmosphere shall be kept in an appropriate
cabinet to protect them from the environment.
 All fire extinguishers shall be easily visible.
 An adequate number of personnel shall be trained in the use of fire
extinguishers.
 Waste shall be removed from site on a regular basis, in order to keep
combustible material to a minimum.
 Adequate exit signs shall be placed at strategic locations.
 Flammable liquids will be marked with the appropriate labels.

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 ITP (Inspection & Test Plan)

 Risk Assessment

 Environmental Impact Report

(EIR)

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