Construction Method for Jetty English R3 1

Jetty Extension

CONSTRUCTION METHOD

PT. CEM ERLANG SAMUDRA KONTRINDO

PROJECT INFORMATION

Pr o y e k N a m e

Location Local

: Lontar Balaraja

Main Contractor : PT. SSP

Dration



:

: !"# H$

CONSTRUCTION METHOD

WORKLAYOUT DRAWING

PLTU 3 (1 x 315 MW) Jetty Extension

ACTIVITY AREA LAYOUT

Work Area Jetty Extension

Site Structure Organization

MANPOWER • Manpower • Core Manpower : 1. Project Manager 2. Site Manager 3. Safety Engineer 4. Supervisor 5. Superintendent . Esti!ator ". #ua$ity Contro$ %. '. 1(. 11.

&rafter Surveyor )d!inistrasion *ogisti+

◦

Manpower Support : 1.2. 3. 4. 5. .

,e$der -perator of Crane -perator of Pi$e a!!er Mec/anic Concrete wor+er 0ore!an

". S+i$$ wor+er

E#PME

EQUIPMENT LIST FOR LONTAR ETT! PROECT

N"

#e$cri%i"n ( BargeCe'erlang)incl*T+g,"a/ BargeCa'ar)incl*+g,"a-

( T*Me$.id

C"nac%er$"n T"n" 01(23644(3(5(0

( T*Me$.id

01(23644(3(5(0

 Crane 24T

( T*Me$.id

01(23644(3(5(0

4 Crane10T)$er7ice%iling-

( T*Me$.id

01(23644(3(5(0

6 Crane4084T

( T*Me$.id

01(23644(3(5(0

5 9a''er##628##64

( Pera:ang

1 Rigdia600

( Pera:ang

 'al,e
(( =en$e(00>?A (/ Tra@"la$ (2 Fladec<r+c< ( C"ldie$el

Pera:ang ( Medan ( Medan 6 T*a%i/8A'ir ( Pera:ang ( Pera:ang

(4 Eca7a"r

( Mera<8+$+@

(6 Pic<+%

( a
(5 O%era$i"nalcar

( a
Seia:an 01(235(53211( 01(235(53211( Se7en 01(/360663(5(6 01(23(2036561 01(235(53211( 01(235(53211( 01423((53/(25 A'in 014/3(423562

(1 C"nainerg+dang

/ a
014/3(423562

( C"nainer"@@ice

( a
014/3(423562

/0 Pla ,a.a

a
014/3(423562

/( Bar,ender

/ a
014/3(423562

// BarC+er

/ a
014/3(423562

/2 CCT? /L a'%+ $"r"

Welding Machine

Rel"caedFr"'

( T*Me$.id

2 Crane 40T

(0 =en$e (40 >?A

Barge ; Crane & Piling Rig

QT!

/4 ec$'all""l$

6 a
014/3(423562 014/3(423562 014/3(423562

Shi%%ingdae

Unl"adingdae

L"cai"n

Materia$ )nd Safety oo$s • Material Main Materia$s for t/is project : • Stee$ Pipe Pi$e dia "11 !! t614!!71181!*9322812 !* • ;eady!i< concrete C=3(>3'(( !3 • Stee$ ;e?ar > 1(((   • @o$$ard 5( 6% Pcs  0ender ype A dan ype & • Bantry ;ai$ Crane Span 25 !6 125 !* • Sa%ety Tool& Safety too$s reuired : o

Safety /e$!ed

o

Safety S/oes

o

and B$ove *ife Dac+et

o

Mas+er

o

,e$ding Safety Euip!ent

o

GENERAL ACILITYLAYOUT PLAN

PILING PLAN

!EAM " SLA! LAYOUT PLAN

CROSS SECTION

PILLING " PILE CAP DETAIL

PILLING "PILE CAP DETAIL

!EAM " SLAP PRECAST DETAIL

GENERAL ACTIVITY

Pre#i$inar% Wor& A. Preliminary Work Preli'inar :"r< $h"+ld ,e d"ne in @"+reen )(- da$ a@er c"''ence'en dae )SPM>- relea$ed a$ 'eni"ned in >e%%re$ N"* 10 Tah+n /000 "r a'end'en* F"r %reli'inar i :"+ld ,e d"ne D (* Ma
1. Project n!ormation "oar# A@er c"''ence'en dae hi$ %r".ec in@"r'ai"n ,"ard $h"+d ,e in$alled $""ne$ and ,"+ndar area in$alled a$ %r".ec direci"n a%%r"7al* The in@"r'ai"n i'%r"7e and e%lain "@ D

• Pr".ec Na'e

D

• • • •

O:n:er C"nrac"r

D D

S+%er7i$i"n C"n$+lan

D

#+rai"n aci7i

D

$. "o%n#ary &ence • The B"+ndar "@ @ence $h"+ld ,e %ri"red ,e@"re he aci7i $ared* Ther@"re he aci7i d"ne in $a@e c"ndii"n and '"ni"ra,le and " $e%arae :ih "her aci7i "@ he c"nrac*

• Fence C"n$r+ci"n , c"r+gaed $eel :all $+%%"red , $rengh c"l+'n %"$ed ar"+nd he ,"+ndar +"ed a$ aci7i area @+nci"ned a$ $ec+ri @ence "@ aci7i area  c"n$r+ced in 5 da$* a* $e% "@ c"n$r+ci"n (*

Sa
/*

in$alling he @ence c"l+'n and $eel c"rr+gaed :all a$ he 'ain 'arial$*

2* area

" $renghen he c"l+'n c"+ld ,e $+%%"red , "her c"l+'n , he in$ide

,* ""l$D (*

+$ing $a: @"r :""den 'aerial*

/* $eel $ci$$"r @"r c"rr+gaed $eel :all * 2* And "her ""l$ +$ing @"r "her a$ he @ence c"n$r+ci"n ""l$ " ,e ,+ilded*

Security fence for the project 1

$

Back View of the Fence

Installing wall and column

3

Side View

'

Front View

3.

leanin Area

Cleaning area ai'ing " 'a
D

3 L"gging he ree$ 3 Tri''ing he gra$$ 3 M"7ing he r"c< and gar,age * ,* I'%le'enai"n D (- l"gging he ree$ c"+ld ,e d"ne , hea7 "r ligh e+i%'en )de%end "@ di@@ic+l-* /- Tri''ing he gra$$ ha7e n" high di@@ic+l c"+ld ,e d"ne , hand'an ""l$ 2- M"7ing he r"c< c"+ld ,e d"ne , ( G (0 %er$"nal$ and @"r he ,ig $ie handled , hea7 e+i%'en and all hard 'aerial$ $h"+ld ,e di$carded , he area*

Cleaning Area 1

Using Eca!ator

$

Cleaning "y ea!ator

3

Being Cleaned

'

Finish for Cleaning

'. Li*tin Area+ ,ec%rity+ an# ,a!ety Elecrici needed " e%edie he :"r< e$%eciall @"r nigh aci7i e7en "n he $ie "@ dar< area* Elecrici re$"+rced , he =enera"r 'achine de%ending "@ ca%aci "+%+ed @"r he lighing*

a. E-%iment / 3 =enera"r 3 Plier$ 3 Scre:dri7er )e$ %en3 Sci$$"r$ dll

0. Materials / 3 Ca,le 3 I$"lai"n a%e 3 La'% 3 S:ich 3 S"c
5. ,takin %t All aci7i "+lining , he $aind "@ $a
2 The"d"lie ) / Uni 2 L"ng Ta%e 40 G (00 ' 2 S'all a%e 4 ' 2 Waer Pa$$ Met*o# /

• The $a
• C"nr"lling he %"in , he ,ench 'ar< "r l"cal c""rdinae " $ae direci"n "@ %ile$ and he di$ance @"r he ,a$e "@ c"n$r+ci"n a$ he %lanning *

Staking #ut E$uipment

%aterpass %aterpass & "oard

'easuring "y (heodolite

. Water an# &irst Ai# E%lanai"n D a* Waer Clean Waer "r Waer "@ :"r< $+%%lied , he ,"reh"le$ :aer re$"+rce "r "her re$"+rce$ in acc"rdance :ih he echnical $%eci@icai"n * Clean :aer need$ @"r D

• • • • •

C"ncree 'iing %la$ering and '"rar* C+ring i'e "@ c"ncree T"ile )MC>Mechanical e+i%'en e$ Oher$*

E+i%'en " %r"c+re D 3 B"re 'achine 3 9"$e 3 B"re Pi%e 3 e P+'% 3 Oher$ @"r $+%%"r

4. Mo0iliation an# 6emo0iliation / F"r '",iliai"n and de'",iliai"n need e+i%'en " ,e @+nci"ned , he i'e n+',er and al$" @"r he 'an%":er* F"r he +n$%eci@ied :"r
,* Fir$ Aid )P2>Fir$ aid i$ he $+%%"r aci7i $h"+ld ,e nece$$ar %"$ed a $ie @"r acciden ca$e @"r he :"r
•

C+re :"+nd$

• W"+nd c"7er • Medicine • Oher$ $+%%"r @ir$ aid*

First Aid Bo

'o"ili)ation and *emo"ili)ation 1

Crane Ser'ice (# T

$

Pile Crane )## T an* Hammer 3

Ser'ice Bar-e

'

Pile& Mo+ili,ation

7. 6oc%mentation+ A#ministration reort an# As "%ilt 6ra8in The aci7i needed @"r d"c+'enai"n "@ he aci7i @r"' he ,eginning +nil (00H %r"gre$$ achie7e'en  incl+de all daa " $+%%"r he d"c+'en* * A$ B+il #ra:ing D A$ ,+il dra:ing i$ he @inal dra:ing a$ he ac+al $ie i'%le'enai"n @"r he ,a$ic re$%"n$i,iliie$ "@ he aci7i " ,e a%%r"7ed* T""l$ +$ing D 3 ( $e ca'era 3 ( $e c"'%+er and "her $+%%"r 3 A2 %a%er* 3 Priner $ie A2 and A* #+rai"n "@ hi$ aci7i %r"ceed a$ he %r".ec d+rai"n

Pre#i$inar%Wor& C'art FLOW CHART MATERIAL SUPPLY

FLOW CHART OF SHOP DRAWING

FIRST PREPARATION MEETING

PROPOSAL OF MATERIAL NO CORRECTION OF CALULATION

MUTUAL CHECK (MC -0 )

SURVEY

CHECK

SHOP DRAWING

YES

NO

APPROVED MATERIAL

CHECK

YES

SUPPLY OF MATERIAL

APPROVED DRAWING

NO CHECK

PERMIT OF ACTIVITY NO

YES CHECK

MATERIAL USED IN ACTIVITY

YES WORK EXECUTION

FLOW CHART QUALITY CONTROL

PROPOSAL OF ACTIVITY NO

CHECK

YES WORK EXECUTION NO

CHECK

NO

YES

MAINTENANCE

CHECK

YES CERTIFIED

CIVIL WORK (ETTY E)TENSION *+, - ./ M

1 . Stee$ Pipe Supp$y /e Stee$ Pipe of Pi$es wi$$ use dia!eter "11.2 !! 12  14 !! t/ic+ness and t/e $engt/ per seg!en 24924 ! as t/e drawing and ?i$$ of #uantity and : c$ass ) 252 Brade 3 )SM. /e Pi$es transported fro! @ojonegara ?y t/e sea to $ocation and direct$y using fro! t/e servic ?arge ?y t/e secure ?arge fro! t/e da!ages

1 . ransportation$$ustration

1

$

'

21.. 3. 4. 5. .

3

5

Praondsupcotirotnat?ioynfain?rfiac?articoantion area *oading on factory ransportation to site n$oading on site -n site Project area



4

Pi#ing S0eci1ication • Pi$ing of Detty E
Pi$e SPP dia "11.2 !! /ic+ness of p i$e 12 !! and 14 !! *eng/t Per poin t 4% ! 724924! Aertica$ pi$ing 6 3 points

• i$t pi$ing 6 1(5 points

)/ 0oint& o% Pile

Piles ,%ly *art Pha$e "@ he %r"c+re'en "@ $eel Pi%e D

Start

Factory Observation

No

Test

Spec

Yes

Ordering

Transport Order

Unloading

Finish

4. Pi$ing )ctivity -nce Pi$ing wor+ starts it /as to ?e continued wit/out interrupted e
?erical Piling Ill+$rai"nJ Lea#erB9i 33 M Pile >ammer ? '5@ 1. ,U9:E;<= $. PL<=

ra8ler rane 1 T P9E,,U9E "M

$

• • • • •

Pile$ SPP dia 5((*/ '' Tich
Til Piling Ill+$rai"nJ Lea#erB9i 33 M Pile >ammer ? '5@ 1. ,U9:E;<= $ . P L < =

• Pile$ SPP dia 5((*/ '' • Thic
$ •

Lengh Per P"in 1 '

• N+',er "@ Pile$ K (04 P"in • "ining K (04 P"in

9AWLE9 9A
&LAT "A9=E

ross ,ection

Pi#ing Pro2e3ure Re$%"n$i,ili

Fl": Char

#e$cri%i"n

#"c+'en S+

Sar #eer'ine he c""rdinae$ and ele7ai"n @"r he @"+ndai"n and $ie clearance

S+r7e"r

S+r7eing Pr".ec Manager Pr".ec Manager Pr".ec Manager Pr".ec Manager

Pr".ec Manager

Technical 'anager

Piling e+i%'en '",iliai"n

E+i%'en M",iliai"n

A$ he S%eci@ica

Ordering and Neg"iai"n Pile 'aerial $+%%l

Pile$ Tran$%"rai"n Unl"ading , Crane Ser7ice

Tran$%"rai"n

Piling Pr"ce$$

Unl"ading

Final Chec<

Piling Pr"ce$$

Final Chec<

O:ner

Re%air i@ n" Agree Re%air

Agree " Fini$h

Agree N"

O:ner

C"n$r+ci"n #ra

e$

Fini$h

C"n$r+ci"n #ra Ele7ai"n #a #e$ign

C"n$r+ci"n #ra Ele7ai"n #aa #e$ign C"n$r+ci"n =+ideline C"n$r+ci"n # Ele7ai"n #aa #e$ign

C"n$r+ci"n =+ideline

C"n$r+ci"n #r Ele7ai"n #a #e$ign

In7e$igai"n Re

P+nch Li$

TOC and FA

[ FLOWCHART of. PILING WORK (SPP) ]

#ie$el ha''er :"r
,tart

N" O< *eck alinment an# con#ition

M"7e he %ile @r"' he $"c< %ile , cra:ler crane , he $ea +$ing $er7ice ,arge

Re%air

O< Tran$%"rai"n "@ he %ile$

Unl"ading %r"ce$$ and in$all " he rig and ha''er

!e *eck EleCation an# &inal ,et

P"$ii"ning "@ %iling e+i%'en :ih $+r7e e+i%'en he"d"lie @r"' / direci"n

e$ S"% %iling

N" Position c*eck 0y t*eo#olite

!e$

N" CE> Ele7ai"n TOP "@ Pile O<

Anch"ring he ,arge

&<,>

C+ "@ Pile

Pi#ing I##u2tration

Theodolite

1

Total Station

SE?ICE BAR=E

LITING PILES ILLUSTRATION

STOC> OF PILES PLACE#

Theodolite

1

Total Station

SE?ICE BAR=E

. Connection of Stee$ Pi$e

Sp$icing of pi$es i!p$e!ented ?y way of we$ded. )$$ we$ding wo s/ou$d ?e in accordance wit/ ),S &1.1 standards. Concrete p pi$es ?efore sp$iced c$an during we$ding !ust ?e /e$d tig/t$y wi a s$ing and a C$a!p fair$y rigid construction to ensure t/at a
1OINTIN2 PROCESS O3 PILE 1

P,T<<=

$

3

Wel#in rocess

Pile jointin

5

'

6%00in an# ,trent*en !or ile jointin

Cutting pi$es !ade after t/e po$e $eve$ !easured in accordance wit/ t/e /ig/ trest$e or pier and t/e rest of t/e po$es t/at do not fit any!ore cutting wit/ cutting torc/ uses -
8 Cuts Stake

Theodolite

1

Total Station

SE?ICE BAR=E

NOTE PAPER AND PILE CALENDRING

Theodolite

1

Total Station

SE?ICE BAR=E

PAPER O PDA TEST

D. S"% Seel Plae @"r c"ncree %"+ring "@ %ile  K (0 In$allai"n "@ $eel %lae$ ca$ %ile$ $"% a@er c+ing $a
Use# ,to Plate

FLOWCHART OF CONCRETE WORK Start

FLOW CHART STEEL WORK

Start

FLOW CHART Formwork

PROPOSAL

Preparation of Steel Work

MATERIAL START

Proposal Shop Drawing Of Steel Work

Job mix design and Trial mix

Pengajuan Sample /Contoh besi yang akan dipakai

No Drawing Approval

No

PROPOSE FORMWORK MATERIAL

No

Check

Material Approval

Yes

Yes Preparation Of bending Chart and Bar Bending Schedule

Yes

Ordering Of Steel material

Preparation Of Eqipments

FORMWORK FABRICATION IN WORKSHOP

Temporary Storage Steel Fabrication in Workshop

PREPARATION Main Material Of Concrete

MATERIAL SUPPLIED

NO

Preparation Area for Pouring Concrete

INSTALLING CONCRETE PRECAST FORMWORK NO

Installing Rebar

Yes CHECK

No Check Yes

Pouring Concrete

YES POURING CONCRETE

Finish

Check

Finish

FLOW CHART CONCRETE WORK

1. Prearation o! c%ttins ile rein!orcement an# ile *ea# I'%le'enai"n "@ c"ncree ca$ing i$ d"ne a@er he in$allai"n "@ @"r':"r< and rein@"rce'en i$ c"'%leed in hi$ ca$e he i'%le'enai"n "@ he ca$ing i$ d"ne $i'+lane"+$l @"r all @"+ndai"n$ and c"l+'n$ a a cerain heigh $" ha i :ill $%eed +% he i'e :hich $ar$ @r"' he @"+ndai"n "@ he @"+ndr and c"nin+ed he ne* P"+ring @re$h c"ncree in" @"r':"r< +$ing a ca$ "r +$e g+er$ c"ncree %+'% 8 Eca7a"r 8 ,+c3240 )@c 20Rein@"rced C"ncree W"r< +$ing c"ncree $eel $cre: )SNI- ar"+nd he %ile and ir"n a$ ir"n $irr+%$ in @a,ricaing ad7ance a$ '+ch a$ // $e$ and ada%ed " he head dia'eer in c"ncree hen $eel rein@"rce'en :ill ,e :elded in each $a
9e0aran#&orm8ork

&inis*oncretin

11. oncrete ontents o! Pile C"ncree %"+ring "@ %ile D a* C"ncree %ile$ $+@@ing +$ing read 'i c"ncree +ali > G 240 )@c 20,* I'%le'enai"n acc"rding he ei$ing 'ea$+re$ in he %lan dra:ing* c* Rein@"rce'en a$$e',led "+$ide acc"rding " he i'age :ih he l":er end rein@"rcing $eel@"r':"r<* %lae :elded a  K (0 '' )$eel %lae $"% c"ncree- $" ha i $er7e a$ a ,a$i$ d* C"ncree ca$ing i$ d"ne , +$ing 7i,ra"r " %re7en $egregai"n "@ c"ncree* e* Charging %ile$ :ih c"ncree ,egin$ :ih he cl"$ing "@ he %"le :ih a $eel %lae )S ca$- h+ng 8 :elded a he l":er end "@ rein@"rcing $+@@ing $+@@ing in$ered $ rein@"rce'en a@er he ne " d" ca$ing he c"ncree* E+i%'en +$edD C"ncree P"le C"nen$ D Rein@"rce'en

C"ncreing

(* Blender /* Re,ar ,ender 2* Plier$ * T:eeer$

(* C"ncree Mier /* Ser7ice Crane 2* B+c
1

$

,l%m Test

9ea#y Mix oncrete

'

&ill oncrete to ile 0y 0%cket

3

,amle o! %0e ?@'

5

13. oncrete "eam Precast C"ncree ,l"c< 'a3240 )@c 20- The %ha$e "@ hi$ :"r< a$ @"ll":$ a* Re%lace he %lae hic
Euip!ent used : Concrete Po$e Contents: ;einforce!ent 1. /e cutter 2. ?ending stee$ reinforce!ent 3. ang 4. Coc+atoo 7tweeHers

.

Concreting 1. Concrete Mi
(

9ea#y Mix ?@'

/

,l%m Test



9e0ar o! Precast 0eam

%0e ?@'

4

Po%rin9ea#ymix?@'

Precast0eamPo%rin

1'. oncrete ,la0 Precast

F"r he 'an+@ac+re "@ %reca$ c"ncree @l""r hr"+gh :"r< %r"ce$$ $age$ a$ @"ll":$D a* Re%lace he %lae hic
Euip!ent used: Concrete Po$e Contents: ;einforce!ent 1. /e cutter 2. ?ending stee$ reinforce!ent 3. ang 4.C oc+atoo7 tweeHers

Concreting 1. Concrete Mi
3a+rication4 Erection Preaca&t Beam 1

Po%rin oncrete o! Precast "eam

$

Precast "eam Erection

3

Erection "eam Precast

'

"eam Precast nstalle#

2antri Crane Rail 1

rane 9ail 9ei!orcement

$

nstallin =an try rane 9ail

'

&inis*in o! =antry rane 9ail

)( Den&oti0 Corro&ion Protection &ensotip Corrosion protection is process a of pi$ing protectio n against rust. Corrosion of stee$ in seawater is very co!p$icated. Many factors suc/ as te!perature sa$inity disso$ved o
E+i%'en +$ed @"r he in$allai"nD (* L"c< Pa$ /* Ti'e$ @"r reaining e'%"rar den$"i% 2* 9a''er lile ,"l h"le " h"le %+nch * The can"e and %"n""n ir"n dr+' 4* #i7ing e+i%'en

Corrosion protection for t/e sta+e sp$as/ Hone areas can ?e done in severa$ ways a!ong ot/ers 1. Syste! concrete jac+et F ?$an+et concrete.syste! /is did notsurvive too $ong./e ua$ity of t/is syste! is deter!ined at t/e ti!e of casting and in case of da!age wi$$ ?e difficu$t to repair 2. Syste! jac+et &PE 7/ig/ density petro$atu!. n t/is syste! first po$e t/e is coated wit/ a paste&enso 7e paste and t/en wrapped wit/ tape and !arine pi$ing outer !ateria$ is protected ?y t/e &PE

Pi$e $ocated at t/e su?!erged Hone can ?e effective$y protected ?y wearing a cat/ode current 7c protection for !eta$ receiving direct current fro! t/e environ!ent suc/ as t/e cat/ode e$ectric ce$$s. Corr wet environ!ents are usua$$y acco!panied ?y cessation of direct current generated ?y t/e e$ectric potentia difference on certain corrosion ce$$. /e use of current fro! an outside source is uite capa?$e of stopping t corrosion and restore t/e f$ow of current to t/e !eta$. ec/no$ogica$ aspects to consider is /ow to provide s

f$ow to every part of t/e sta+e in t/e su?!erged inner Hone $ong ti!e and easi$y. /e portions were not uite current ?egins to corrode w/i$e t/e part t/at receives too !uc/ current wi$$ ?e da!aged ?y t/e cover of or !ateria$.

In&tallin- Proce&& o% Den&oti0 Protection %or coro&ion 1

$

Cla'% "@ den$"i%

#en$"i% and ,"l %lae

'

C"r"$i"nC"7er

Plae $ri% @"r den$"i% ,"

5

C"rr"$i"nC"7ering

Fini$hing

1. . nstallation o! 9%00er &en#er Tye : ($Lx>) W"r<$ +$ing a %e ? In$allai"n Fender /000L  6009 $ie )/2 +ni$- Fender @+nci"n$ a$ a ,+@@er :hen he $hi% d"c
&en#er Tye :

5. In&tallation Bit (# Ton Bollar* In$allai"n W"r< Bi Bi B"llard +$ing a %e "@ a ca%aci "@ 40 T"n$ "@ 1 +ni$* Bi @+nci"n a$ a eher $ra% B"llard 7e$$el i$ c+rrenl d"c
E+i%'en +$ed @"r he in$allai"nD (* L"c< Pa$ /* Sling $eel 2* 9a''er * A c"r<$cre:

"it "ollar# 5 Ton

MAINTENANCE PERIOD ). Period of Maintenance for  !ont/s 71%( ca$endar days co!!encing fro! t/e period of e
JA?A9TA+ $' ,etem0er $1 PT. EME9LA<= ,AMU69A ?