CHAPTER THREE

Methodology

3.1 Introduction

This chapter briefly outlines the design procedure that was used for the design of the 180 000
m3 reinforced concrete tank for sewer storage, highlighting the stages of the design and the
design manuals/codes that were incorporated in designing the tank. A method statement for the
construction of the tank and the post construction structural assessment guide will also be
highlighted in this chapter.

3.2 Design Procedure

For the design of the 180 000m3 rectangular tank, the following stages were followed:
1. Determining the dimensions of the tank.
2. Determining the loading and moments
3. Designing according to serviceability limit state
4. Checks on the design using ultimate limit state
5. Determining the reinforcement

3.2.1 Dimensioning of the tank

The tank was sized, the capacity verified with the determined dimensions and the ground
conditions were evaluated. The tank was then tested for floatation after sizing. To test for
floatation, the total weight of the tank was compared to the up-thrust force caused by ground
water to determine if it floats or not. The minimum flotation safety factor used was 1.15,
according to BS 8007. When the water table rises, a tank with a safety factor of less than 1.15
will float.

3.2.2 Determining the loading and moments

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The rectangular sewer storage tank was designed to withstand the worst-case conditions in both
full and empty situations, as well as considering loading from vehicles. The forces accounted
for were the active pressure due to lateral earth pressure when the tank was empty, but the
passive soil pressure and vehicular surcharge were ignored since from calculation, the
maximum loading was then found to due to the tank being full. As a result, a design for a water-
filled tank was then pursued mostly making use of the design codes BS 8007 and BS 8110.

3.3 Design Philosophy

Design of the tank was done making use of mainly the ultimate limit state and the serviceability
limit state design philosophies. The primary design concept for the walls and foundation is
serviceability limit state, which takes into account the tank's cracking and water leakage. The
ultimate limit state was used to check the base and wall reinforcement requirements. The design
codes that were used were BS8110 and BS8007, as well as the PCA tables. Deflection limits
were set in accordance with the recommendations in BS 8110 PART 1 for non-liquid, as
deflection is only important in exceptional circumstances when it comes to liquid effects. The
most important factor to consider when designing the tank is that it has adequate crack resistance
and strength. To avoid corrosion, crack widths must be examined. Controlling the spacing and
width of cracks induced by thermal contraction, flexure, temperature, and moisture impacts is
necessary to ensure that the structure is impermeable. For the exposure conditions of reinforced
concrete, the following surface crack widths should be considered.

Crack control is a criterion of the serviceability limit state. For the exposure circumstances of
reinforced concrete according to BS 8110, 0.2mm was considered severe or very severe
exposure and 0.1mm for a critical authentic look. Following the design, drawings were created
for each element, specifying the necessary construction details as well as a bending schedule
making use of the AutoCAD software.

3.4: Method Statement

Purpose

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The purpose of the method statement is to describe the construction methods and the sequence
of activities to be used. The Construction activities will be in accordance with the contract
conditions, specifications and considering the field conditions.

Topography

The contractor’s surveyor shall carry out his on topographic survey in comparison with the
drawings supplied by the engineer. Then check the plane and elevation control point provided
by the applicant, for within the scope of the construction control points (including the coordinate
points and levelling points, etc.) to make the necessary protection, and timely make grids layout
, qualified experience calculation accuracy, then traverse points of encryption, level of repetition
and measurements such as encryption.
After receiving the construction drawings of the reservoir‘, the contractor’s surveyor shall check
the plane position and elevation of the reservoir according to the structure size of the reservoir,
and carry out setting out of the works, levelling cutting and filling of sections to reach the
proposed platform level for the construction of the RC reservoir.
Engineer and arch\led shall review all reservoir construction survey data.

Temporary works

3.4.1 Construction road service

The existing road is used as the construction road. According to the deployment and planning
of the site construction area, the construction area is defined by placing signs, etc. The
construction site is isolated from residence and social vehicles, and the road is constructed in
the site with TLB and grader.

3.4.2 Temporary facilities

Combined with the construction characteristics of (his project, on the premise of meeting the
requirements of construction operation and production management, build temporary fencing
and concrete mixing plant, etc. The purpose of temporary fencing is to provide security to entire
site. There is a gate for the site workers and deliveries to go in and out.
There is a security guard at the gate to control people and vehicles coming in and out.

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3.4.3 Temporary water service

This project obtains water nearby. If the construction needs, the site will install 10cubic meter
JoJo tanks and equipped with 18 tons of water trucks to transport construction water for each
working area and to spray the water to control the dust.

3.4.4 Temporary electrical service

The construction site is equipped with distribution box and electricity meter, and equipped with
generator to prevent power failure in the site power‘ tools and concrete mixing station can be
used normally.

3.4.5 Material storage and construction machinery parking

Set up security room on site, to be manned by the special security guard responsible for the
supervision of machinery and materials.

3.4.6 Site setting out

Site setting out was completed after handover the site. Three temporary benchmarks will be
established at site for further levels checking and quick references for further land survey.
Position of temporary facilities included dimension are showing below.

3.5 Initial works

3.5.1 Excavations

The excavation starts after setting out the site and remove topsoil, Excavation of 180m*
reservoir platforms, in between reservoir platform, access roads, boundary fences will be done
as per the drawing, which shows the final formation levels. Two excavators with one jack
hammer, two TLB and tipper mucks will be provided to complete this operation. Control
blasting can be used for hard rock exaction. Excavate in all materials and dispose of surplus
unsuitable material within à free haul distance of 2km.

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3.5.2 Site clearance

The contractor shall carry out site clearances for the reservoir platform. Excavated gravels and
suitable materials shall be stockpiled on site and it will be used for replacing unsuitable
materials. Remove topsoil to a depth 150mm prior to carry out bulk excavation below reservoir,
stockpile and maintain for reinstatement.

3.5.3 Site levelling

The Contractor shall carry out excavations for formation level since the location of construction
is sloping, this is done to achieve levelling.

3.5.4 Unsuitable materials

Disposal for unsuitable materials will be taken to a designated area instructed by the engineer.
During excavation, unsuitable material will be found and will be replaced with the material
which is indicted by the engineer will achieved design strength. Laboratory test of materials
will be carried out and result confirmed by the engineer for using replacement of unsuitable
materials below the formation level of floor. The Engineer also confirmed the contractor for
replacing unsuitable materials below the formation level of wall footing with design strength
concrete.

3.5.5 Hard rock excavation

Hard-rock materials if encountered shall be cut by jack hammers or if need be controlled

blasting and also be stockpiled separately from unsuitable excavations. Stockpiled gravel will
be used after completion stage for reinstatement.

3.5.6 Excavations for subsoil drainage

Drainage trench depth will be 300mm below floor slab level. The excavation for drainage should
be done as per the revised construction drawing.19mm stone subsoil drain wrapped in kaytech
grade 2 filter fabric.

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3.5.7 Excavations strip footings

Strip footing is 500mm below surface level and it is silting at the level with 50mm allowance
for blinding layer. The length of the Footing is 60m.The height of the strip footing is 350mm
and the width is 1500mm, Excavations for the strip footing should be wider 500mm for each
side. Strip footing details included dimension are showing below.

3.5.8 Excavation floor slab

Excavation for concrete floor will be make allowance for 150mm concrete slab, 100mm no-fine
concrete and 50mm concrete blinding. The excavations for floor slab should be done as per
construction drawing. Please see the attached drawing for floor foundation details below.

3.5.9 De-watering and groundwater control

The cut off drain around the perimeter of the site towards which ground slopes will be
implemented. The water will be drained down the sloping sides and drain out of the site during
heavy rains. If there is water that collects on site, the pump will be used to pump the water away
from the site. A diesel or petrol driven vacuum self- priming pump is the most reliable to keep
the process going, Drainage trench with 100mm UPVC pipe and in6pection Chambers are going
to be installed below floor slab to drain the water of reservoir if the leakage can be experienced
in future.

3.6 Concrete Works

Different classes of concrete will be used on RC Reservoir On different sections as per

specifications and standards. A batching plant shall be erected for concrete mixing on site. The
contractor shall follow the mix design specifications and submit to the engineers for approval.
Concrete tests shall be conducted and submitted to the laboratory for testing of various concrete
expected characteristics. The tests results shall lien be forwarded to the engineer for approval.

According to Mixed Design Result (mixed design result are given in next pages), Slump of each
classes of concrete are as follows Six test cubes will be made for each pour, three which will be
tested after 7 days and the other three after 28 days respectively. If the pours exceeding as

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required by the Engineer, additional sets of cubes should be taken. Engineer will be available
on site to check the quality of concrete before casting.

The Contractor will give 24hours notice to the Engineer and engineer for inspection before
casting concrete. Concrete blinding under drainage trench will be cast first and the drainage
pipes will follow on top of concrete blinding as specified in drawings, 9mm stone sub soil drain
wrapped in Kay-tech grade 2 filter bricks as indicated in the drawings will be placed around and
on top of 100mm diameter slotted PVC drainage pipe. 100mm now fines concrete wit! follow
afterwards.

3.6.1 Building layer under sub-soil drainage

20Mpa/19mm stone mass concrete with 50mn thickness concrete blinding will follow after
casting crusher stone around the sub-soil drain. The sequence of casting should be done as per
attached blinding panel’s layout.

3.6.2 Concrete blinding to strip footings

The surface will first be clean up before placing blinding concrete. A blower will be used to take
away any dust or any loose excavated materials between the rocks. It is mentioned that concrete
blinding already been done at site.

3.6.3 Concrete blinding to the underside of concrete floor slab

Concrete blinding will follow after casting concrete blinding layer to column footings. The sub-
soil drain will be wrapped in Kay-tech grade 2 filter fabrics or similar approved, 19mi›i stone
will used around sub-soil drain.

3.6.4 Concrete to Structures

35 MPa/19mm concrete will be used on the floor slab.

3.6.5 No-lines concrete

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No-fines concrete at the level below floor slab and will follow after concrete blinding. This will
be joined to no-fine concrete of sub-soil drainage. The estimated volume of concrete is 25m3
under floor slab. A mixture consists of ordinary Portland cement and coarse aggregate only, the
proportions of cement and stone shall be one part by volume of cement to eight parts by Volume
of stone. hmm stone will be used. 5mm thick mortar will be provided on the top of no-fines
concrete.

3.6.6 Concrete to strip footing & wall kicker

The strip footing with wall kicker jointly will be casted as per attached strip footings layout
specifications. Poker vibrator will be used to compact the concrete. Concrete Pump will be used
to control delivery the concrete. All equipment and estimated material will be checked and
verified by the Engineer and QA/QG prior to start casting for them workability.

3.6.7 Concrete to reservoir wall

The wall will be casted as per attached wall layout specification and Drawings. Pokes vibrator
will be used to compact the concrete. Concrete bucket with crane truck will be used to control
delivery the concrete. Kickers to be formed on the strip footing prior to erecting reinforcement
and formwork to wall as per construction drawing

3.6.8 Floor slab

The floor slab will be casted as per floor slab layout & sequence of work table. One groups will
be engaged to execute the work. Poker vibrator will be used to compact the concrete. Concrete
bucket with crane truck will be used to control delivery the concrete.

3.6.9 Construction, Expansion Joint & Movement joints

Construction joints, expansion joints and movement joints to be opened a day after every pour;
All joints will be cleaned for removing all dirt and loose particles. All joints surface will be kept
continuously wet by Blow off / scrabbling until next lift of fresh concrete within 12 hours is to
be placed against them, If the concrete placing duration older than 7 days at any type of joints

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places, the formation of concrete joints at surfaces will be done with concrete adhesive by the
Engineer’s approval.

3.6.10 Placing of concrete

The contractor will give at least 48 hours' notice to the Engineer of his intention to place
concrete. Concrete will not be allowed to fall freely through a height of more than 1.2m and a
hopper with funnel will be used for reducing the concrete freely falling height as specified in
the specification. A demonstration of concrete poring system through hopper will be shown to
the Engineer in field prior to placing concreting. No vertical or inclined construction joints of
any kind will be permitted in continuous walls unless they have specifically ordered or
authorized by the Engineer. The placing of concrete shah! commence at a convenient point of
the perimeter of the wall and shall proceed both ways simultaneously so that fresh concrete
meets old concrete. Any rest passes, such as for meals, wilt be avoided as far as possible, and
the Contractor shall be ready to make the operation continuous by working in shifts.

Beneath all structural members, or elsewhere if so ordered by the Engineer, or shown on

drawings, the bottom of the excavation is to be covered by a blinding layer (screech) in grade
specified concrete to a specified depth to prevent disturbance of the ground and to serve as an
even and accurately positioned won king base for setting steel and placing foundations concrete.

The blinding layer shall be laid immediately after excavation formation Levels have been
reached, trimmed and have been inspected by the engineer, the blinding should be cast within
seven days after excavations, then the non-fine concrete will follow afterwards.

3.6.11 Steel reinforcement

Fabrication on site

Total reinforcement is estimated for RC reservoir is approximately 20 Tones, Steel

reinforcement for strip footings, wall, and roof slab will follow immediately after blinding with
different dates of casting. Reinforcement will be placed before erection of formwork. The
minimum concrete cover for RC reservoir shall be following the specific.

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Rover blocks for RC reservoir shall be manufactured from concrete of grade, durability, densely
and impermeability as stated on the specifications. The size of the cover blocks shall be 60mm
x 60mm, with a thickness equal to the specified cover. The blocks shall be protected against
early drying and shrinkage due to sun and wind, by being kept continually wet while still in the
mould. Water-bars will be fixed to the reinforcement before casting the concrete if necessary.

3.6.12 Steel reinforcement to the wall

Steel reinforcement for the footing follows after blinding layer with the starters. Wall
reinforcement will be fixed after the stripping of formwork to the kickers. The reinforcement
will be fixed from the kickers to the half of the wall and then from the half of the wall to the
end of the wall.

3.6.13 Mesh reinforcement to floor slab

Mesh ref 500- terminates at 40mm from joint around, will be fixed at the centre of concrete
floor slab.

3.7 Formwork

Demonstration of Formwork sample of footing and wall will be erected at site prior to
commencement of work. A detailed drawing of form work will be provided by contractor and
accepted by the Engineer. No pour will be commenced until the Engineer inspects the erection
of form-works. The quality of formwork to the external surfaces shall be such that no after-
treatment e.g. nabbing down will be necessary. The formwork expected shall be a feature of the
finished surface which be to degree of accuracy 1 tolerance, joints between panels shall be
sealed tightly to prevent local honey-combing or leaching of concrete. The proposed formwork
system will be approved & signed by a professional engineer. Joints between panels shall be
expected to form horizontal and vertical lines which shall be spaced evenly on the formed
concrete surface and shall be even and smooth,

All visible corners shall have 20mm x 20mm chamfer as required on the specifications.
Formwork ties in water-retaining structures shall be a water-bar type approved by the Engineer.
The contractors will be expected to ensure that his formwork compatible with the ties.

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After removal of ties all ferrules are to be drilled out of the concrete to provide an oversized
reamed hole free of all remnants of the ferrule and blown out to remove all dust and other loose
material. The surface of the hole is to be primed by well wetting with a cement latex slurry and
the hole should filled by caulking with a cementous mortar consisting of 1-part cement to 2-part
concrete sand by volume. Prior to filling
Idols test samples of the proposed mortar should be prepared, allowed to dry, then checked to
ensure (resulting colour is as similar as possible to the colour of the surrounding concrete
surface. The grout should be well folded into the holes to completely fill it and provide a dense,
void free plug After that the surface should be trowelled to finish flush with the surrounding
area.

3.7.1 Formwork to the footing

Erection of formwork to the footing will be done as per approved drawing which is
demonstrated at site. Shutter oil to be used to spread formwork before erection and after
dismantling.

3.7.2 Formwork to columns footing, column and column Heads

Formwork with metal strong backs to be used. A crane will used for handling formwork into
positions. This section will be divided into three sections, first section from the kicked to the
half of the columns, secondly from half of the columns to the underside of columns heads and
lastly the head.

3.7.3 Formwork to the reservoir wall

The wall first erection will be from kicker to one-fourth of the wall, half of the wall, three-fourth
of the wall and lastly up to the underside of roof slab. Shutter is to be used to spread formwork
before erection and after dismantling. A details drawing will be provided by the contractor.

3.7.4 Formwork to sides of concrete slab

Sides of strip footing and kicker will be used as formwork to the sides o[ floor slab.

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3.8 Access scaffolding

The common access scaffolding will be used by the Contractor to support a working platform.
The scaffolding will provide access during construction of reservoir wall and it has been broken
down into the following members:

Standards, The base plate, The sole board Ledger, ledger braces Swivel coupler, Joint pins &
Scaffold boards, Scaffold tubes

Access scaffolding shop drawing will be submitted to Engineer for approval prior erection of
form work & concrete work. A details drawing will be submitted to the Engineer for approval
prior to erection.

3.9 Curing and protection

Concrete curing compound component will be used for curing as specified and approved by the
engineer. Concrete curing compound CHRYSO CURE WP which is a low viscosity petroleum
resin-emulsion curing controlled for spraying onto the surface of concrete to give and effective
and economical method of curing which is approved by engineer. CHRYSO Cure WP is a spray
applied to newly place concrete, care being taken to ensure complete coverage of the surface.
Various types of spraying equipment can be used, i.e., Knapsack or motorized sprayers. Brush
application can be used for small areas. CHRYSO CURE WP should be applied as soon as
possible after concrete has been finished, i.e, trowelled, tamped or textures as required, but
generally within 30 minutes or earlier if in conditions host sun or strong drying winds.

The nozzle of spray should be held some 30cm to 50 cm from the surface and passed slowly
back and forth to ensure through coverage. Immediately after use, spraying equipment should
be cleaned out, especially the line and nozzle with a mild detergent solution or Chryso solvent.
On vertical surfaces or soffits of concrete which may be partially dried out after being retained
in shuttering for several days, it is imperative that concrete should be well wetted before
applying the curing compound. To ensure the ultimate breakdown of the CHRYSO Cure WP
film, heavier coating should be avoided.

3.9.1 Grouting of pipes/specials through walls

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Grouting should be done where entry holes for pipe/specials have been provided in the walls.
Before commencing the positioning in holes of any pipes/specials, we should follow the
following sequence; should remove all shuttering and boxing remaining in the holes.

It should thoroughly clean and scrabble the sides of the holes. After accurately positioning the
pipes/specials in the respective holes, we show Id fix the pipes/specials in suitable manner to
prevent movement.

Immediately prior to grouping being carried out by the placing of the mortar and concrete
around the pipes, the surface of the existing concrete should saturate with water. All surplus
water should be removed and the surface covered with a layer approximately 2 nine thick of
mortar consisting of 3 parts concrete sand and 1-part cement.

The concrete ingredients will be mixed and placed as dry as possible to obtain a dense,
waterproof concrete. If any watertight seal is required, the concrete should be carefully worked
out around the puddle flange and also vibrated in layers to obviate any falling away from
pipe/specials surface of the concrete already placed.

3.10 Completion stage:

3.10.1 Source of Raw Sewer

The source of sewer will be coming from Mpumalanga high-density suburb.

3.10.2 Testing a leakage for Floor Slab

Floor slab shall be tested by flooding the floor with water to a minimum depth of 50mm after
all inlet and outlet pipes have been closed, sealing the outlets from the under-floor drainage
system and pressurizing the under-floor drainage system with compressed air to a pressure
equivalent to 400mm head of water. The floor shall then be inspected for leakages and all visible
leakages shall be repaired to the satisfaction of the Engineer and shall again be subjected to the
same test.

3.10.3 Complete Checking

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A thorough inspection shall be done to ensure that all joints are properly sealed and that all inlet
and outlet pipes are closed. The structure shall be filled with water to it maximum operating
level at a gate that shall ensure a maximum rise in water level of 2, 0 m in 24 hours in four
stages up to top water level. The level of the water, shall be carefully noted and recorded by the
Engineer. If there are no visible leakages the structure shall be allowed to remain filled for a
saturation period of at least two weeks, or such longer time as may be required, to permit
complete saturation of the concrete. As soon as the water surface reasonably steady after filling,
the water level is to be established and recorded by means a hook of gauge and should be
measured & recorded by the engineer, in relation to fixed bench mark each successive 24 hours
of less and the results graphed so as to establish the progressive rate of absorption and leakage.
In the event that the steps to be taken by the contractor prove ineffective in reducing, the rate of
drop in water level can be done over a period of 7 days to less than equivalent of one litre per
m2 of wetted concrete surface at least 24 hours.
If any leakages are visible, the water test shall be aborted, depending on the seriousness of the
leakages or damp spots and the leakages/damp spot should repaired in a manner and to a
standard acceptable to the engineer or instruction by the engineer before another water tightness
test shall be done.

3.10.4 Booster pump and pump House

Construction of the pump house shall be carried out close to the reservoir on the location and
coordinates supplied by the engineer. The pump capacity shall follow the engineer specification
of Q=15.7m3/hr. A 13dm electric motor shall be installed; the contractor shall create shop
drawings and submit to the engineer for approval.
All fittings shall be from a certified supplier, upon delivery the contractor shall show the
engineer for inspection and approval of installation tests shall be done prior to final installations
under the inspection of the engineer for its approval.

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