Larsen and Toubro Limited – ECC Division

New 132/33 kV Substation at Kalba

Contract No.: N-8033
External Cavity Wall
MS/N-8033/C13 Page 1 of 8
Method Statement

Larsen and Toubro Limited

New 132/33 kV Substation at Kalba
Title: External Cavity Wall Method Statement
Procedure No.: MS/N-8033/C13

Revision No. 0 A
Date 14-02-12 28-03-12
Revision History First submission O/E Comments Incorporated

Prepared by Reviewed by Approved by Approval By

(Section Head) (QA/QC In charge) (Project Manager)
Name CYN NKV NR
 Larsen and Toubro Limited – ECC Division
New 132/33 kV Substation at Kalba
Contract No.: N-8033
External Cavity Wall
MS/N-8033/C13 Page 2 of 8
Method Statement

Contents

1. Objective

2. Scope

3. Reference Documents

4. Tools, Tackles, Equipments and Materials

5. Responsibilities

6. Method / Procedure

7. Records

8. Attachments

Revision No. 0 A
Date 14-02-12 28-03-12
Approved by NR NR
 Larsen and Toubro Limited – ECC Division
New 132/33 kV Substation at Kalba
Contract No.: N-8033
External Cavity Wall
MS/N-8033/C13 Page 3 of 8
Method Statement

1. Objective:

The purpose of this method statement is to describe the logical sequence of activities
involved in external cavity wall, in order to maintain safety and quality.

2. Scope:

This method statement is applicable for all activities related to external cavity wall for
ADWEA / TRANSCO Project, N-8033, New 132/33 kV Substation by LARSEN and
TOUBRO at Kalba.

3. Reference Documents:

3.1 TRANSCO standard S-TR-CIVIL-MAS (Rev. 0-2009)

3.2 TRANSCO standard drawing for cavity walls and lintel (DWG TR CIV 05 02
01 & 05 02 02)

3.3 Material approval request for damp proof membrane Polyshield HD (N-
8033HM5100S509 Rev. A)

3.4 Material approval request for block work and plaster accessories, M/s
Metex and M/s Ancon (N-8033HM5100S524 Rev. A)

3.5 Material approval request for cement, M/s Emirates Cement, M/s National
Cement, M/s RAK Cement & M/s Sharjah Cement (N-8033HM5100S503 Rev.
A)

3.6 Material approval request for white cement, M/s RAK Cement (N-
8033HM5100S521 Rev. 0)

3.7 Material approval request for solid and hollow block work, M/s Bildco (N-
8033HM5100S522 Rev. B)

3.8 Material approval request for calcium silicate brick, M/s National building
Industries (N-8033HM5100S525 Rev. 0)

3.9 Material approval request for joint filler board, Speccell fibre (N-
8033HM5100S505 Rev. A)

3.10 Material approval request for special construction materials and chemicals
(N-8033HM5100S529 Rev. A)

3.11 Material approval request for 50 mm thick thermal insulation board for cavity
wall Roof master XPS-UHD (N-8033EL5100S562 Rev. 0)

3.12 Larsen and Toubro inspection and test plan

3.13 Relevant drawings for wall section (N-8033CM5100S1016 Rev. 0)

Revision No. 0 A
Date 14-02-12 28-03-12
Approved by NR NR
 Larsen and Toubro Limited – ECC Division
New 132/33 kV Substation at Kalba
Contract No.: N-8033
External Cavity Wall
MS/N-8033/C13 Page 4 of 8
Method Statement

4. Tools, Tackles, Equipments and Materials:

4.1 Masonry hand tools like plumb bob, aluminum straight edge, mason trowel,
shovel, PVC bucket, sponge, brush and rubber hammer.
4.2 Mobile concrete mixer, hand shovel, wheel barrow

4.3 Leveling instrument

4.4 Scaffolding / working platform with ladder

4.5 Safety cones, warning tapes, warning sign boards, proper PPE and first aid kit.

4.6 Damp proof membrane, cement, hollow and solid blocks, block work accessories,
joint filler board, thermal insulation board, external and internal joint sealant.

5. Responsibilities:

5.1 Job Performer (Site Engineer, Construction Manager and Project Manager) shall
be responsible for the Construction activities at site.

5.2 QA/QC Engineer shall be responsible for the QA/QC activities at site.

5.3 Safety Engineer shall be responsible for the HSE activities at site.

6. Method / Procedure:

6.1 General

6.1.1 Prior to the commencement of all construction activities, necessary work

permit if applicable shall be obtained.

6.1.2 All materials identified / used for the permanent works shall be complied
with the approved documents by owner / engineer, prior to procurement.

6.1.3 All HSE activities related to this activity shall be based on the owner /
engineer / contractor HSE management system guidelines.

6.1.4 All quality assurance and quality control activities shall be in line with
contractor civil quality management system and the specified
requirements of the contract and project quality plan.

6.1.5 The inner wall block work shall be constructed first and then the outer wall
brick work shall be constructed connecting both the leaves together by
250 mm SS cavity wall tie kept at 600 mm c/c horizontal and 400 mm c/c
vertical.

6.1.6 The insulation board roof master XPS also shall be kept close to the inner
wall using insulation retaining clips.

Revision No. 0 A
Date 14-02-12 28-03-12
Approved by NR NR
 Larsen and Toubro Limited – ECC Division
New 132/33 kV Substation at Kalba
Contract No.: N-8033
External Cavity Wall
MS/N-8033/C13 Page 5 of 8
Method Statement

6.2 Tests and Frequency

6.2.1 All concrete blocks shall comply with BS 6073 and its compressive
strength shall comply with the following:

Concrete hollow blocks:

Average of 10 blocks: 07.0 N/mm2
Lowest individual block: 05.5 N/mm2

Concrete solid blocks:

Average of 10 blocks: 13.0 N/mm2
Lowest individual block: 08.0 N/mm2

Sand lime bricks:

Average of 10 blocks: 10.0 N/mm2
Lowest individual block: 07.5 N/mm2

Tests shall be conducted for every 200 m2 of walls / each consignment of

block / brick brought to site.

6.2.2 Compressive strength of mortar (1:3 to 1:4 cement to sand) after 7 days
shall not be less than 10 N/mm2.

6.3 Procedure for Block Work

6.3.1 Prior to the commencement of block work, owner / engineer’s approval

shall be obtained by raising inspection request.

6.3.2 Blocks shall be stored and handled properly to prevent any damage by
cracks or broken edges.

6.3.3 All block work shall be done by the skilled manpower.

6.3.4 Before starting of block work, all loose particles shall be removed and the
surface cleaned with water.

6.3.5 All the blocks shall be adequately saturated with water before laid and the
top of walls left off from the previous day’s work shall be similarly wetted
before new works commences and only 1m height block / brick shall be
allowed per day.

6.3.6 Setting out of blocks shall be done to ensure the block work are done as
per the drawing, correct bonding achieved and minimum cutting is done.
Block cutting shall be done only by machines.

6.3.7 Openings related to building services / door / window / ventilator shall be

made as per approved drawings.

6.3.8 Reinforced concrete frames of at least 200 mm width and same thickness
shall be provided to strengthen all openings through the wall.

Revision No. 0 A
Date 14-02-12 28-03-12
Approved by NR NR
 Larsen and Toubro Limited – ECC Division
New 132/33 kV Substation at Kalba
Contract No.: N-8033
External Cavity Wall
MS/N-8033/C13 Page 6 of 8
Method Statement

6.3.9 Mortar for block work shall be cement mortar in the proportions 1: 3 to 1: 4
(cement to sand) by volume.

6.3.10 The material for mortar shall be accurately measured and a standard
container shall be used to measure cement and sand.

6.3.11 Mixing of cement mortar shall be carried out by a mixer machine only.

6.3.12 Block work which has not been thoroughly wetted and has developed a
thin crack between the block and mortar joint, shall be pulled down and
rebuilt.

6.3.13 All joints between blocks shall be filled to a thickness of 10mm and at no
point more than 15mm. The entire cross joints shall be filled by well
buttering the one side of the blocks and then pushing in to position
against its neighbor.

6.3.14 Mortar bed shall be laid in short lengths to limit any water loss.

6.3.15 Fixing of all block work accessories like, steel mesh, wall ties etc shall be
done strictly in accordance with manufacture instruction.

6.3.16 Sliding ties, lateral resistant ties etc shall provided at the locations as
mentioned in the approved drawings.

6.3.17 At every alternate joints horizontal (800 mm), at the top of the block work,
just below the soffit of ceiling / beams, ceiling wall strap 250 x 2.5 mm
(dove tail) shall be fixed and the gap filled with 20 mm thick joint filler
board.

6.3.18 Joints shall be provided in block work to allow for expansion and
contraction caused by temperature changes, shrinkage and moisture
movement by providing compressible joint filers, together with protective
sealers.

6.3.19 Approved galvanized steel mesh shall be laid horizontally over the block
work at every second layer (6 cm wide for 10 cm walls, 10 cm wide for 15
cm walls and 12 cm wide for 20 cm walls). All the joints shall be made
with minimum 300mm overlapping except at corners or junctions, where
the lap shall be equal to the width of the reinforcement in one wall bent
over that in the other.

6.3.20 For ground floors, damp-proof courses shall be laid on and bedded in a
bed of 1 : 4 cement mortar and shall extend to the full width on top of first
row of blocks. Where joints have to be made, they must be lapped at least
20 cm and sealed with black bituminous waterproofing paste. Exposed
DPC shall be protected from direct sun. The vertical damp proof course at
reveals shall extend the full width of the return.

6.3.21 Solid block work shall be provided wherever cables, service pipe etc are
penetrating.
Revision No. 0 A
Date 14-02-12 28-03-12
Approved by NR NR
 Larsen and Toubro Limited – ECC Division
New 132/33 kV Substation at Kalba
Contract No.: N-8033
External Cavity Wall
MS/N-8033/C13 Page 7 of 8
Method Statement

6.3.22 All the block work shall be cured by keeping the block work wet for
minimum 7 days.

6.4 Procedure for Brick Work

6.4.1 All the procedure applicable for block work is also applicable for calcium
silicate brick work.

6.4.2 Calcium silicate bricks shall be used only at the external walls as shown in
the approved drawings.

6.4.3 Bricks shall be dipped or sprayed with clean water before laying.

6.4.4 Mortar shall be prepared using a mixer machine with the following
proportions 1:3 or 1:4 (white cement is to white sand) by volume and shall
be used within 90 minutes from the time of adding the water.

6.4.5 The area where the bricks are laid shall be leveled using water level and
damp roof membrane laid as per specification at the ground floor.

6.4.6 The first and last bricks in the layer being constructed shall be fixed and
builder string attached between them to maintain the horizontal alignment.
The vertical alignment shall be maintained with the help of a builder
plumb.

6.4.7 Mortar joints of thickness 10 mm shall be maintained and it shall be made

sure that the joints are filled properly and does not contain any voids.

6.4.8 Brick work walls shall be constructed evenly and cavity walls shall be tied
with stainless steel cavity wall tie (butterfly) at 600 mm center to center
horizontal and 400 mm center to center vertical.

6.4.9 Pointing can be achieved by using recessed joints and filling the joints
with the pointing mortar and flushing the joints with a smooth 8 mm steel
bar.

6.4.10 If the brickwork gets stained with mortar during construction, stains can be
removed by scrubbing brickwork surface with a flat brick-chip of the same
colour.

6.4.11 Approved galvanized steel mesh shall be laid horizontally over the block
work at every second layer (6 cm wide for 10 cm walls, 10 cm wide for 15
cm walls and 12 cm wide for 20 cm walls). All the joints shall be made
with minimum 300mm overlapping except at corners or junctions, where
the lap shall be equal to the width of the reinforcement in one wall bent
over that in the other.

6.4.12 Brick work shall be cured by spraying with water twice a day for 7 days.

Revision No. 0 A
Date 14-02-12 28-03-12
Approved by NR NR
 Larsen and Toubro Limited – ECC Division
New 132/33 kV Substation at Kalba
Contract No.: N-8033
External Cavity Wall
MS/N-8033/C13 Page 8 of 8
Method Statement

7. Records:

7.1 Request for inspection

7.2 Checklist

8. Attachments

8.1 Inspection test plan for block and brick work

8.2 Checklist for block and brick work

8.3 Hazard Identification and risk assessment for block and brick work

8.4 TRANSCO standard drawing for cavity walls and lintel (DWG TR CIV 05 02 01 &
05 02 02)

8.5 Block work accessories application

8.6 DTS / MTS.

*******

Revision No. 0 A
Date 14-02-12 28-03-12
Approved by NR NR