METODE STATEMENT TOLL ROAD DEVELOPMENT OF SOLO KERTOSONO PHASE 1 OP GEMPOL (STA 152+331)
PT PP (Persero) Tbk. Jl. Letjend. TB. Simatupang No. 57, Pasar Rebo - Jakarta 13760 Phone : (021) 840 3910 / 3944 - Fax : (021) 840 3936
TOLL TO LL R OA OAD D DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
TABLE OF CONTENT
I.
GENERAL........................................... ................................................................. ............................................ ............................................. .................................. ........... 3 1.1. GENERAL DATA ......................................... ............................................................... ............................................ ...................................... ................ 3 1.2. TECHNICAL DATA........................................................ .............................................................................. ......................................... ...................3
II. FLOWCHART OVERPASS GEMPOL ........................ .............................................. ............................................. ........................... .... 4 2.1. FLOWCHART OVERPASS GEMPOL........................................... .................................................................. .......................4 III. METODE STATEMENT ............................................ .................................................................. ............................................ .............................. ........ 5 3.1. EXCAVATION STRUCTURE .......................................... ................................................................. ...................................... ............... 5 3.2. DRIVEN OF SPUN PILE ....................................................... .............................................................................. .................................. ........... 5 3.3. FORMWORK ............................................ ................................................................... ............................................. ....................................... .................17 3.4. CONCRETE WORK......................................... WORK............................................................... ............................................ ................................ ..........19 3.5. BEARING PAD WORK .......................................... ................................................................ ............................................ ......................... ... 21 3.6. ERECTION I-GIRDER ........................................... ................................................................. ............................................ ......................... ... 22 3.7. DIAFRAGMA AND RC PLATE WORK ........................................ ............................................................. .....................26 3.8. DECK SLAB WORK ............................................ .................................................................. ............................................ ............................ ...... 28 3.9. OPRIT WORK........................................... WORK.................................................................. ............................................. ....................................... .................30 3.10.MICHELENOUS WORK............................................................. .................................................................................... ......................... ..32 IV. SCHEDULE WORK.................................. WORK........................................................... ............................................... ................................. ........... 33 4.1. SCHEDULLE................................ SCHEDULLE...................................................... ............................................. ............................................. ............................. ....... 33 V. SITE INSTALLATION..................................... ........................................................... ............................................ ....................................... .................34 5.1. SITE INSTALLATION........ INSTALLATION.............................. ............................................ ............................................ ...................................... ................ 34 5.2. SAFETY.................................. SAFETY........................................................ ............................................ ............................................... ..................................... ............ 35
2
TOLL TO LL R OA OAD D DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
TABLE OF CONTENT
I.
GENERAL........................................... ................................................................. ............................................ ............................................. .................................. ........... 3 1.1. GENERAL DATA ......................................... ............................................................... ............................................ ...................................... ................ 3 1.2. TECHNICAL DATA........................................................ .............................................................................. ......................................... ...................3
II. FLOWCHART OVERPASS GEMPOL ........................ .............................................. ............................................. ........................... .... 4 2.1. FLOWCHART OVERPASS GEMPOL........................................... .................................................................. .......................4 III. METODE STATEMENT ............................................ .................................................................. ............................................ .............................. ........ 5 3.1. EXCAVATION STRUCTURE .......................................... ................................................................. ...................................... ............... 5 3.2. DRIVEN OF SPUN PILE ....................................................... .............................................................................. .................................. ........... 5 3.3. FORMWORK ............................................ ................................................................... ............................................. ....................................... .................17 3.4. CONCRETE WORK......................................... WORK............................................................... ............................................ ................................ ..........19 3.5. BEARING PAD WORK .......................................... ................................................................ ............................................ ......................... ... 21 3.6. ERECTION I-GIRDER ........................................... ................................................................. ............................................ ......................... ... 22 3.7. DIAFRAGMA AND RC PLATE WORK ........................................ ............................................................. .....................26 3.8. DECK SLAB WORK ............................................ .................................................................. ............................................ ............................ ...... 28 3.9. OPRIT WORK........................................... WORK.................................................................. ............................................. ....................................... .................30 3.10.MICHELENOUS WORK............................................................. .................................................................................... ......................... ..32 IV. SCHEDULE WORK.................................. WORK........................................................... ............................................... ................................. ........... 33 4.1. SCHEDULLE................................ SCHEDULLE...................................................... ............................................. ............................................. ............................. ....... 33 V. SITE INSTALLATION..................................... ........................................................... ............................................ ....................................... .................34 5.1. SITE INSTALLATION........ INSTALLATION.............................. ............................................ ............................................ ...................................... ................ 34 5.2. SAFETY.................................. SAFETY........................................................ ............................................ ............................................... ..................................... ............ 35
2
TOLL TO LL R OA OAD D DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
CHAPTER I GENERAL
1.1 General Data Name of Structure : Overppass Gempol STA : 152+331 Type of Spun Pile dia 50cm : - Abt 1 : Amount 40 point, depth 27m, 14m-13m Pier 1 : Amount 28 point, depth 25m, 14m-11m Pier 2 : Amount 28 titik, depth 25m, 14m-11m Pier 3 : Amount 28 titik, depth 25m, 14m-11m Abt 2 : Amount 40 titik, t itik, depth 27m, 14m-13m Concrete : - Class B-1-1 (Deckslab) : 228 m3 Class B-1-2 (Diafragma) : 57 m3 Class B-1-3 (Pier Head) : 114 m3 Class B-1-4 (Kolom Pier) : 141 m3 Class B (Barrier) : 124 m3 Class C-1 (Abt, Footing Pier, Retaining Wall, Wall, Aproach Slab) : 397 m3 Class C-4 (Precast Deck Slab) : 45 m3 Class E (Lean Concrete) : 29 m3 Bearing Pad : - Type : 300x350x41 (moved) = 20 unit Type : 300x350x54 (fix) = 20 unit Girder : - I Girder 25,6m hight 1,6m 10 unit I Girder 16,6m hight 0,9m 10 unit
1.2 Technical Data The display layout Overpass Gempol as shown below.
Layout OP Gempol
3
TOLL TO LL R OA OAD D DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Cross section Overpass Gempol
4
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
SECTION II FLOWCHART OVERPASS GEMPOL
2.1 Flowchart Overpass Gempol START
PREPARATION WORK
1.
SHOP DRAWING
2.
APPROVAL MATERIAL
3.
SAFETY PLAN
4.
SURVEY ELEVASI &
EXCAVATION WORK
FABRICATION OF PCI GIRDER
STAKE OUT
FURNISHED SPUN PILE
DRIVEN OF SPUN PILE
WELDING JOINT OF SPUN PILE
CALENDERING
NOT OK
OK PDA TEST
CUT OFF SPUN PILE
CONNECTION OF SPUN PILE
FOOTING: 1.
REINFORCEMENT BARS
2.
FORMWORK
3.
CONCRETE WORK
PIER: 1.
REINFORCEMENT BARS
2.
FORMWORK
3.
CONCRETE WORK
A
5
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
A
PIER HEAD: 1.
REINFORCEMENT BARS
2.
FORMWORK
3.
CONCRETE WORK
WINGS WALL: 1.
REINFORCEMENT BARS
2.
FORMWORK
3.
CONCRETE WORK
BEARING PAD
ERECTION I-GIRDER
DIAFRAGMA: 1.
REINFORCEMENT BARS
2.
FORMWORK
3.
CONCRETE WORK
INSTALL RC PLATE
DECKSLAB: 1.
REINFORCEMENT BARS
2.
FORMWORK
3.
CONCRETE WORK
PARAPET: 1.
REINFORCEMENT BARS
2.
FORMWORK
3.
CONCRETE WORK
OPRIT
MISCELLANEOUS: 1.
CHAILINK FENCE
2.
DRAINSE PIPE
FINISH
6
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
SECTION III METHODE STATEMENT
3.1 Excavation work Excavation depth structure done according to the needs of each pier to facilitate erection, excavation is performed only appropriate plan of diarea. The results of the excavation will be transported by DT that will go to disposal
.
Plan of Structure Excavation ELEVAtion Item
A1
P1
P2
P3
A2
Bottom Footing
50,874
50,688
51,956
50,688
50,113
Exis Ground
53,266
53,184
53,116
52,896
52,981
7
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
3.2 Driven Spun Pile START
PREPARATION WORK
TRIAL DRIVEN
MARKING POINT OF SPUN PILE COORDINATE BY SURVEYOR
MOVING SPUN PILE FROM STOCKPILE TO HAMMER MACHINE BY CRANE
DRIVEN
PDA TEST
CUT OFF SPUN PILE
CONNECTION SPUN PILE
JOINT INSPECTION
FINISH
3.2.1
Preparation Work
In this preparatory work prepared: 1. Shopdrawing Shopdrawing prepared to handle / reference work that has been signed by the consultant, so all the work is based on an existing image. 2. Request For Work Before performing the erection contractor filed a request that will be reviewed by the consultant as a starting material work. 3. Stockpile & Approval Material
8
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Stock pile Stock stake according to the image above, to shunt material stock piles pickets from location to location using a crane service stakes. Approval stake attached to the request for documents. 3.2.2 Trial Driven Trial erection done first to determine the depth stake, if the image is still undetermined for depth.
3.2.3
Marking Point of Spun Pile Coordinate
Coordinate stake in the attached drawing that has been approved and has been pegged by the survey team 9
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
3.2.4
Driven Process
Grove Stake OP Gempol
Working Location
Flow Stakes and Location of Survey Team
10
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Crane
surveyor position
Driven Driven process as follows: 1. The survey marks the location of pickets and gave information about the location servey consultant to stake 2. The contractor filed a request for a trial erection work to determine the depth of pile. 3. Move spun pile of stockpile using the service crane. 4. Once spun pile is ready, and the crane is mounted with a hammer, checking survey stakes angle (vertical and horizontal). 5. Piling spunpile using diesel hammer and survey follow the process of erection and check the straightness stakes (vertical and horizontal) 6. Connection stake using welding system between stakes. 7. Kalendering commences when the pile measured about 2 cm or decreased slightly, then put up a form / graph paper to process kalendering with the following formula: To calculate the carrying capacity by using the formula used kalendering Hiley, the following formulations
R = carrying capacity limits (ton) W = heavy hammer or ram (ton) P = heavy of spun pile (ton) H = hight falls ram 11
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
S = penetration of the pile at the time of last comminution (cm) K = avarage rebound to 10 final blow(cm) N = koefisien restitusi 0,4-0,5 for cast iron hammer, concrete pole without a helmet 0,3-0,4 for mallet (wooden base) 0,25-0,3 for a wooden pole
From the graph we take the 10 blows over. Obtained S 10 final blow is 2cm. so S = 2/10 = 0.2 cm. While the rebound (K) there are 10. The average taken from the graph reads K. K about: 0.9cm. 8. If calandering data has been entered, then PDA test will dont do, if data does not make it calendering ask consultant to do PDA test. Support tool erection as follows: 1. Crane Pancang
= 1 unit
2. Crane Service 50T
= 1 unit
3. Hammer 3,5T
= 1 unit
4. Waterpass
= 1 unit
5. Theodilit
= 2 unit
6. Genset 60Kva
= 1 unit
b. Tes Pile Through strain transducer will be the measured value of the Force that occurred near the head of the mast / sensor at the position after the impact of the collision hammer against the head of the pole. And through the accelerometer measured value of the acceleration to be calculated to get variable velocity. While the dynamic calculation of the carrying capacity of the axial PDA test method known dg CASE method. Of the average value of the signal measured force and velocity on the PDA data, measured directly from the PDA tool is as follows: 1. Voltage maximum prees in position sensor, know with initial (CSX, CSI0) 2. Displacement maxsimum (DMX) Witch can be calculated from the PDA tool are as follows : 1. Capacity pole mobilized, using the simplified method case (RMX) 12
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
2. The maximum tensile stress along the pole (TSX) 3. Maximum energy that is transfer to the pole during the collit ion (EMX)
when ; R
= total land
t1
= time impact from collision
t2
= t1 + 2L/c (when L is long pole)
Z
=
EA/c = A √(Er) (know with “impedance”)
Prisoners total land R is calculated using the above formula has two component: 1. A displacement-dependent component , Static Resistance (Rs) this will be calculated. 2. A velocity-dependent component, Dynamic Resitance (Rd), when Rd downgrade from R to get Rs. Variable Dynamic Resistance (Rd) it self will be calculated :
When : Jc
= value of damping factor, depending on the type of
Z
= pile impedance (Z=EA/c)
Vtoe
= velocity at the end of the pole, obtain from the force and velocity measure
near the head of the mast, based on the principle of the theory of wave mechanich. With the approach it obtained the equation to calculate the value Static Resistance (Rs),
13
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Implementation of the pile following: 1. Before starting PDA test, contractor make invitation to consultant and owner to see PDA test. 2. Prepare tool of PDA test and other supporting equipment 3. Dig the soil surface around the head of the mast head flush with the ground, so need excavation. 4. Drilling small hole on the pole for mounting strain transducer and accel ometer. 5. Installation of other Instrumen. 6. Prepare safety when testing PDA test, such as APD. 7. After preparation work, setting hammer with 1% - 2% capacit y from the pile 8. The hight of fall of the hammer of 0,25m – 1,5m from hole pile. 9. Reading of the screen followed by erection. 10. Do measurement decrease the stake to the base of the pile. 11. Then analyzed the result of the reading on the:
Data ultimated carrying capacity of the pole from the CPT/SPT compared with carrying capacity hole from result of PDA test. Analyze the data integrity of the test result PDA.
Analyze data maximum reduction of pole permanent c. Welding Treatment of Spun Pile Joint weld joint between piles munggunakan welding machine and using
welding wire LB 32 according to the drawings and instructions from supervisors consultants. Welding shall be in accordance with the provisions of JIS A 7201
14
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
d. Cut Off Spun Pile
LIST ELEVATION CUT OFF SPUN PILE Item Bottom Footing
A1
P1
P2
P3
A2
50,874
50,688
51,956
50,688
50,113
Jobs cut off the stakes are as follows: a. Once the process is complete, the erection process is then performed pieces of the stake according to the image using a cutter as elevation cut-off limit stakes. b. When cutting the pile rebar poles must be connected at least 60 cm to the structure footing. c. Next will be charging stake with iron, foundry contents piles and LC. 0 0 6 = M U MI IN M
Field detail of spun pile
15
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
3.3 Pekerjaan Bekisting MULAI
PEKERJAAN PERSIAPAN
LAYOUT RENCANA BEKISTING
PERHITUNGAN BEKISTING
SELESAI
3.3.1
Pekerjaan Persiapan Bekisting Sebelum memulai pekerjaan disiapkan terlebih dahulu gambar beksiting yang akan digunakan dan mendapat persetujuan dari pihak konsultan. Sehingga bisa dipakai saat proses pelaksanaan pekerjaan.
3.3.2
Layout Rencana Bekisting
Layout Bangunan Struktur
16
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Rencana bekisting Lebar dinding
= 9,5m
Jarak D
= 25cm
Material gelagar hollow = 5x5
Jarak C
= 55cm
Tebal plywood
Jarak B
= 60cm
= 1,5cm
Rencana panel bekisting footing
Rencana Bekisting Stage 1 9566 1200
1200
1200
1200
1200
1200
1200
Type 01
Type 01
Type 01
Type 01
Type 01
Type 01
Type 01
1166 Type 02
0 7 1 0 3 1
0 0 4
0 5 1
0 0 4
0 5 1
0 0 4
0 5 1
0 0 4
0 5 1 0 0 2 0 5 1 0 5 1
TAMPAK DEPAN
9566 1200
1200
1200
1200
1200
1200
1200
Type 01
Type 01
Type 01
Type 01
Type 01
Type 01
Type 01
1166 Type 02
TAMPAK ATAS
17
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
1200
1166
501 50 5 0 2 00 5 0 2 00 5 0 2 00 5 01 50 5 0
50
0 5
133 50 200 50 200 50 200 50 1 33
Hollow 50x50x2
0 0 0 3
50
0 5
Hollow 50x50x2
0 0 9 2
0 5
Hollow 50x50x2
0 0 0 3
Hollow 50x50x2
0 0 9 2
0 5
Hollow 50x50x2
TYPE 01
Hollow 50x50x2
TYPE 02
Phynol 15 mm Panel Bekisting
Tie Road
Hollow 50x50x2
Pipe Support Jarak 1200 mm
Pipe Support Jarak 1200 mm
Dasar TAMPAK SAMPING
Rencana Bekisting Stage 2
18
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
9566 1200 Type 01
1200 Type 01
1200
1200
Type 01
Type 01
1200
1200
1200
1166
Type 01
Type 01
Type 01
Type 02
0 7 1 0 3 1
0 0 4
0 5 1
0 0 4
0 5 1
0 0 4
0 5 1
0 0 4
0 5 1 0 0 2 0 5 1 0 5 1
TAMPAK DEPAN
Phynol 15 mm Panel Bekisting
Tie Road
Pipe Support Jarak 1200 mm
Hollow 50x50x2
Papan Triplek Pipe Support Jarak 1200 mm Balok 6/12
Lantai
Balok 6/12
Climbing Support
Rencana panel bekisting pier
19
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Rencana panel bekisting pier head
Klem
Besi Drat 10mm
Pipa
Baut Siku L 50.50.5
DETAIL 1
DETAIL KLEM
Jarak Plastikon & Tie Road
20
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
9566
1200
0 0 0 6
0 0 5 4
Lubang Tengah Pier
0 0 0 1
1200 9566
Bekisting Tengah yang Berlubang
4 3
2 1 Skema Bekisting Abt 1&2
Skema Beksiting Pier 1&3
21
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
4 3 2 1 Skema Bekisting Pier 2 Bekisting disini direncanakan untuk 3 kali pemakaian, rincian bekisting sebagai berikut: No
Item
Keterangan
1
Abutment
1 set (setelah abutment 1 maka bekisting akan dipakai untuk Abutment 2)
2
Pier
2 set (setelah pier 1 makan beksiting akan dipakai untuk pier 2 dan 3)
Kebutuhan bekisting antara lain : 1. Plywood t=1,5cm
: - Footing
= 14 lembar
- Stage 1 & 2 = 48 lembar - Pier Head 2. Hollow 5x5
: - Footing
= 20 Lembar = 10 btg
- Stage 1&2 = 36 btg - Pier Head 3. Plastikon & Tie Road
: - Footing
= 16 btg = 70 bh
- Stage 1&2 = 480 bh - Pier Head
= 100 bh
3.4 Pekerjaan Beton 3.4.1
Pekerjaan Persiapan Beton Pekerjaan beton dilakukan setelah pekerjaan pembesian dan bekisting selesai
di pasang dan mendapat persetujuan dari konsultan. Tahap pengecoran direncanakan 22
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
setelah pekerjaan pile cap selesai maka pekerjaan pier direncanakan 2 tahap setelah itu pekerjaan pier head 3.4.2
Skema pembetonan
No. 1
Item
Volume (m3)
Kelas Beton
Elevasi Stop Cor
Abutment 1 - Pile Cap
76,240
52,174
- Stage 1
63,295
55,174
- Stage 2
55,145
C-1
- Pier Head 2
3
4
5
59,597 61,54
- Wings Wall
43,320
- Pile Cap
77,190
- Stage 1
25,110
- Stage 2
26,900
- Pier Head
39,340
B-1-3
60,338
- Pile Cap
79,700
C-1
53,256
- Stage 1
20,330
- Stage 2
22,120
- Pier Head
35,030
B-1-3
61,606
- Pile Cap
77,190
C-1
51,988
- Stage 1
25,110
- Stage 2
26,900
- Pier Head
39,340
- Pile Cap
76,240
51,413
- Stage 1
63,295
54,413
- Stage 2
55,145
Pier 1 C-1 B-1-4
51,988 54,988 57,988
Pier 2
B-1-4
56,256 59,256
Pier 3
B-1-4 B-1-3
54,988 57,988 60,338
Abutment 2
C-1
- Pier Head - Wings Wall
Pengecoran Pile Cap
59,958 61,541
43,320
Pengecoran Pier
Pengecoran pile cap menggunakan truck mixer yang langsung dituang, sedangan untuk pengecoran pier akan dibantu dengan Concrete Pump.
23
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
3.4.3
Uji Tes Beton Sebelum dilakukan pengecoran maka akan dilakukan terlebih dahulu job mix formula, yang selanjutnya akan disetujui oleh konsultan sebagai acuan untuk melakukan pekerjaan pengecoran. Uji tes beton antara lain:
Setiap truck mixer yang datang akan dilakukan uji slump sesuai dengan spesifikasi yang ada. Tim QC akan mengecek setiap hasil slump sesuai dengan spesifikasi yang ada.
Benda uji slump sebanyak 8 pasang (16 buah) setiap 100m 3.
Setiap selesai pengecoran akan dilakukan curing beton sekaligus bongkar bekisting dan dipasang bekisting selanjutnya.
Uji slump Alat yang digunakan :
Truck mixer 8 m 3
= 8 unit/stage
Concrete Pump
= 1 unit
Electric Vibrator
= 3 unit
Genset 60Kva
= 1 unit
3.4.4
Durasi Pengecoran
No.
Pengecoran
Lokasi
1
Pengecoran ke-1
Abt 1 (Pile Cap)
2
Pengecoran ke-2
3
Pengecoran ke-3
Volume (m3)
Durasi (hr)
76,240
1
Abt 1 (stage 1)+ P1 (Pile Cap)
140,485
1
Abt 1 (stage 2) + P1 (Stage 1) + P2 (Pile Cap)
159,955
1
24
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
4
Pengecoran ke-4
Abt 1 (Wings Wall) + P1 (Stage 2) + P2 (Stage 1) + P3 (Pile Cap)
167,74
1
5
Pengecoran ke-5
P1 (Pier Head) + P2 (Stage 2) + P3 (Stage 1) + A2 (Pile Cap)
162,81
1
6
Pengecoran ke-6
P2 (Pier Head) + P3 (Stage 2) + A2 (Stage 1)
125,225
1
7
Pengecoran ke-7
P3 (Pier Head) + A2 (Stage 2)
94,485
1
8
Pengecoran ke-8
A2 (Wings Wall)
43,32
1
3.5 Pekerjaan Bearing Pad Bearing adalah satu alat mekanikal yang dipasang antara girder dengan pilar atau abutment. Fungsi bearing sebagai dudukan girder untuk meneruskan gaya dari girder ke pilar atau abutment.
Dudukan bearing pad dapat segera dikerjakan setelah pekerjaan pilar. Yang harus diperhatikan adalah kerataannya agar tidak diperlukan grouting yang banyak dan untuk menghindari rusaknya dudukan atau bearing pad / pot bearing akibat beban yang tidak merata.
25
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
3.6 Pekerjaan Girder
3.6.1
Pekerjaan Persiapan Girder
Pemasangan wedge plate
Wadges Plate dan Wadges/Baji
Lokasi stock yard girder
26
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
a. Safety Plan
Dalam pekerjaan erection girder ada beberapa hal yan perlu diperhatikan antara lain: a. Pemasangan rambu wajib APD di seluruh area pekerjaan b. Pemasangan tolo-tolo di area tepi workzone untuk penanda angkutan yang loading dan unloading disekitar area workzone c. Work at Height wajib menggunakan Full Body Harness dengan pemasangan safety line sebagai cantola full body harness d. Sebelum bekerja pekerja diinduction terlebih dahulu untuk pekerja baru dan diberikan toolbox meeting sebelum memulai pekerjaan setiap harinya e. Mandor/Subkon wajib mengisi From Surat Izin Bekerja dan melaporkan kepada petugas safety untuk dicek lokasi bekerja f. Dilarang merokok diseluruh area kerja kecuali shelter/tempat merokok yang sudah di tentukan g. Memperhatikan
jarak
aman
bekerja
terutama
saat
erection
denganpesawat alat angkat dan angkut
Perlengkapan APD lengkap (full body harness)
27
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
3.6.2
Mobilisasi Girder Girder dari lokasi workshop akan dimobilisasi kelokasi stock yard untuk
selanjutnya akan di laksanakan proses stressing. No
Item
Amount
Waktu (hr)
1
bentang 16,6m
10
2
2
bentang 25,6m
10
2
Total waktu pengiriman selama 4 hari 3.6.3
Stressing Girder Proses stressing girder akan dilakukan dilokasi stockyard dengan urutan sebagai berikut:
Mengatur posisi ketinggian girder
Memasukkan kabel strand baja
Pemasangan angkur bolt dan wedges
Tendon 1 dilakukan terlibih dahulu dengan kekuatan tarikan 40%, kemudian tendon 3 kekuatan tarikan 40%, kemudian tendon 2 kekuatan tarikan 40%. Mempersiapkan form pencatatan hasil penarikan, alat tulis dan kalkulator kemudian menghubungkan hydraulic pump dengan power listrik untuk pelaksanaan stressing . Setelah pekerjaan stressing selesai maka dilakukan grouting. 3.6.4
Setting Lokasi Sebelum dilakukan erection girder, maka perlu untuk melihat dan menyiapkan lokasi erection girder apakah sudah siap atau belum, maka perlu disiapkan craine untuk proses erection 50ton 2 unit
3.6.5
Erection Girder Dari lokasi stock material ke lokasi perletakan girder akan di angkat dengan crane 50 ton 2 unit. 28
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Urutan proses erection girder sesuai urutan dibawah
Analisa pekerjaan girder dengan craine Amount girder span 16,6 m
: 10 unit/3 hari
Amount girder span 25,6 m
: 10 unit/3 hari
Waktu pelaksanaan
: 6 hari
3.7 Pekerjaan Diafragma & RC Plate
3.7.1
Pekerjaan Persiapan Setelah pekerjaa erection girder selesai maka akan dilanjutkan dengan pekerjaan cor in situ diafragma dan precast RC Plate. Disiapkan untuk bekisting diafragma dan perlengkapan pendukung lainnya. Pekerjaan RC Plate diperlukan crane untuk install.
29
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
3.7.2
Pekerjaan Diafragma Diafragma dipasang dengan tujuan agar kedudukan/posisi balok girder menjadi Fixed/kaku. Pekerjaan diafragma ini akan dikerjakan dengan metode in situ. A1
3.7.3
P1
P2
P3
A2
Pekerjaan RC Plat Pada lantai jembatan menggunakan tebal 7 cm. Pemasangan RC Plate
dilakukan terlebih dahulu untuk akses pekerja lebih mudah install diafragma, install RC Plate tidak dipasang pada posisi diafragma. Untuk pemasangan RC Plate menggunakan crane dengan urutan sebagai berikut :
30
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Posisi Erection Precast RC Plate Proses erection RC Plate menggunakan bantuan crane untuk membantu pekerjaan ini. 3.8 Pekerjaan Plat Lantai
3.8.1
Pekerjaan Persiapan Pekerjaan plat lantai perlu disiapkan alat pendukung seperti truk mixer,
concrete pump, electric vibrator, genset 60 Kva, lampu penerangan(saat kondisi malam hari), serta pendukung lainnya.
Truck Mixer & Batching Plan
Concrete Vibrator
31
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Electric Vibrator 3.8.2
Pengecoran Stelah pekerjaan diatas selesai kemudian dikerjakan pembesian untuk
pengecoran top plat. Pengecoran dilakukan setelah pekerjaan pembesian selesai. Pengecoran dilakukan 4 bagian, penghentian cor dilakukan pada posisi expansion joint per pilar.
Gambar Pembesian top plat dan stop cor per pilar
Rencana Bekisting Pekerjaan Pengecoran Plat Lantai
Gambar posisi stop cor untuk expansion joint 32
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Posisi stop cor untuk expansion joint berjarak 5 m. Waktu yang dibutuhkan untuk proses bekisting+pembesian selama4 hari/bentang dan pengecoran 1 hari, jadi untuk 4 bentang membutuhkan waktu selama 20 hari. Alat yang digunakan :
Bar bender 42 mm
: 1 unit
Bar cutter 42 mm
: 1 unit
Concrete pump
: 1 unit
Concrete vibrator electrik : 2 unit
dan alat bantu lainnya
3.9 Pekerjaan Oprit Saat akan memulai pekerjaan oprit dilakukan terlebih dahulu d-tour tahap 2. Setelah d-tour dikerjakan maka dilakukan step pekerjaan oprit, pelaksanaan akan dilakukan per layer (20 cm) sampai terpenuhi nilai CBR 6%.
Gambar pekerjaan oprit 3.10 Pekerjaan Lain-Lain 3.10.1 Lapisan Struktur Aspal Lapisan struktur terdiri dari:
Beton Setelah dilakukan pekerjaan beton dan ketika akan memulai pekerjaan aspal makan bet on dibersihkan dari kotoran denga n compressor.
Take Coat Pekerjaan ini dilaksanakan dengan langkah-langkah sebagai berikut :
- Sub base sudah dibersihkan dari kotoran dengan menggunakan
compressor dan sudah di prime coat - Membuat guideline di sisi dan di centerline dari rencana jalan untuk arah
finisher. - Laston Lapis Pondasi (AC-Base) diangkut denga n truck dengan ditutupi 33
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
terpal, Amount dump truck harus sesuai dengan kapasitas finisher. - Laston Lapis Pondasi (AC-Base) di atas truck sebelum didrop harus dicek
temperaturnya. Campuran Laston Lapis Pondasi (AC-Base) dituangkan ke asphalt finisher. Ada tiga tahapan pemadatan yaitu break down, intermediate dan finishing rolling dengan tandem roller dan tire roller.
AC-WC Lapis
Pengikat
mengandung
aspalt
dengan
kerosin
yang
dipergunakan sebagai coating dengan kekentalan tertentu sesuai spesifikasi, dan dihampar di atas permukaan yang beraspal. Sebelum di-coating / dihampar dengan aspalt sprayer, agregat atau lapis permukaan yang beraspal harus dibersihkan dengan kompressor dari kotoran dan material lepas.Pekerjaan pembersihan menggunakan alat air compressor. 3.10.2 Pekerjaan Expansion Joint Dalam pekerjaan expansion joint menggunakan type C-1 (Asphaltic Plug Joint), seperti gambar dibawah :
Urutan pekerjaan sebaai berikut :
Marking posisi expansion joint terlebih dahulu, kemudian dilakukan cutter & chipping setelah pekerjaan slab selesai.
34
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
Leveling aspal
Dilakukan pemasangan acuan untuk ekspansion joint
Tuang material pengisi dan ratakan serta finish permukaan
3.10.3 Pekerjaan Barrier
Stek besi paraped disetting untuk persiapan pengecoran insitu. Analisa pekerjaan barrier :
Volume rencana
: 124 m3
Panjang Barrier
: 170 m
Kapasitas mixer/hari : 35 m 3
Lama pekerjaan
: 124/35 = 4 hari
35
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
3.10.4 Pekerjaan Chailink Fence
Pemasangan kolom dilakukan saat pekerjaan pembesian barrier. Analisa pekerjaan chailink fence :
Panjang
: 170 m
Tinggi rencana
:3m
Rencana jarak tiang: 2,5 m
Lama pekerjaan
: 11 tiang/hari
170/(11*2,5) = 6 hari
36
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
SECTION IV SCHEDULE PELAKSANAAN 4.1 Schedule Pelaksanaan
SECTION V FASILITAS SEMENTARA
5.1 Site Installation
Posisi pagar dan rambu yang lain sesuai dengan gambar diatas untuk menjaga posisi kendaraan yang lewat untuk tetap aman.
37
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
5.2 Safety Untuk setiap aktifitas membutuhkan perhatian dari pihak safety, diantaranya adalah sebagai berikut untuk setiap pekerjaan: No
IMITIGASI
1
RTL
Pekerjaan Pemancangan
Memberi garis pembatas area lintas pekerja
mengenai pekerja
Menggunakan APD lengkap
Terjadinya gangguan pendengaran
Pengecekan kondisi alat pancang & kondisi
Terjatuhnya
tiang
pancang
&
akibat kebisingan alat pancang
tiang pancang
Kerusakan alat pancang & tiang
pancang
Bekerja
Kapasitas dan tipe crane ditentukan terlebih dahulu oleh site manajement dan coordinator
di
dekat
mesin
yang
bergerak
Penggunaan Mobile crawler cranes
Penggunaan Trailer
pengangkutan crane
Seluruh pekerjaan diselesaikan dibawah arahan dan kontrol dari koordinator operasi crane
Kondisi tanah sebaiknya dinilai oleh operator crane dan koordinator crane dan ditandatangani oleh koordinator crane untuk menetapkan
Jangan pernah berdiri diantara traktor dan mesin lain atau dibelakang mereka kecuali traktor diam dan pengemudi menyadari kehadiran anda
2
Pekerjaan Pengecoran
Terjatuh saat melakukan pekerjaan
pengecoran & install precast
Terjadi kebocoran/tidak kuatnya
Menggunakan APD lengkap terutama di tempat ketinggian wajib menggunakan full bodyharnest
Mengecek kondisi bekisting
bekisting saat pengecoran 3
Pekerjaan Install PCI Girder
Alat install mengalami standby
Mengecek secara rutin alat install
Terjatuhnya PCI Girder saat
Mengecek kondisi saat akan erection
Menggunakan APD lengkap
Mengikuti toolbox meeting sebelum bekerja
erection
4
Bekerja diketinggian Pekerjaan Galian
Tanah longsor
Pemasangan rambu-rambu di area galian
Terkena swing excavator/ bucket
Pengawasan rutin pekerjaan galian
38
TOLL R OAD DE VELOPMENT OF SOL O KE R TOSON O PH AS E 2
excavator
Pemasangan railing/baricade
Tertimbun tanah longsor
Pemasangan penahan longsor
Pemasangan terpal agar tanah tidak mudah tergerus air
Pengecekan alat sebelum digunakan
39
