1. Foundation Construction

1.1 Purpose:
To ensure the safe, precise, and efficient construction of foundations for water and sewer treatment plants, ensuring structural stability and compliance with design specifications.

1.2 Scope:
This work instruction applies to all personnel involved in foundation construction, including site supervisors, laborers, engineers, and construction managers.

1.3 Responsibilities:

• Site Supervisor: Oversees foundation construction, ensuring adherence to plans and safety protocols.
• Laborers: Perform tasks related to excavation, formwork, reinforcement, and concrete pouring.
• Engineer: Verifies foundation dimensions, reinforcement placement, and ensures compliance with design specifications.
• Safety Officer: Monitors safety practices and ensures compliance with safety regulations.

1.4 Materials and Equipment:

• Excavators
• Concrete Mixers and Vibrators
• Formwork Panels and Supports
• Reinforcement Bars (Rebar)
• Binding Wire
• Concrete (Ready-mix or On-site Mix)
• Shovels, Spades, and Trowels
• Survey Equipment
• Personal Protective Equipment (PPE) - helmets, gloves, boots, high-visibility vests

1.5 Procedure:

1.6 Preparation:

• Review foundation design drawings and specifications.
• Conduct a site survey to identify and mark foundation locations.
• Obtain necessary permits and approvals from relevant authorities.
• Brief the foundation team on tasks, safety procedures, and emergency protocols.

1.7 Excavation:

• Marking and Layout:
  Mark the foundation layout on the ground using survey equipment.
• Excavation:
  Excavate soil to the required depth and dimensions specified in the design.
  Ensure the excavation is stable, with appropriate slopes or shoring to prevent collapse.
• Inspection:
  Inspect the excavation to ensure it meets design specifications.
  Verify the soil bearing capacity and make any necessary adjustments.

1.8 Formwork Installation:

• Formwork Construction:
  Assemble formwork panels and supports according to the foundation design.
  Ensure formwork is level, properly aligned, and securely braced to prevent movement during concrete pouring.
• Formwork Inspection:
  Inspect the formwork for correct dimensions, alignment, and stability.
  Apply release agent to the formwork surfaces to facilitate easy removal after concrete curing.

1.9 Reinforcement Placement:

• Cutting and Bending:
  Cut and bend reinforcement bars (rebar) to the required shapes and sizes as per design specifications.
• Reinforcement Installation:
  Place and tie rebar within the formwork according to the design layout.
  Ensure proper spacing and cover using spacers and chairs.
• Reinforcement Inspection:
  Inspect the reinforcement placement to ensure compliance with design specifications.
  Check for adequate clearance and correct positioning.

1.10 Concrete Pouring:

• Mixing and Transporting:
  Prepare concrete mix as per the specified mix design (use ready-mix concrete if available).
  Transport concrete from the mixer to the foundation area using wheelbarrows or pumps.
• Pouring:
  Pour concrete into the formwork in layers, ensuring even distribution.
  Use vibrators to compact the concrete and remove air pockets.
• Finishing:
  Level and smooth the concrete surface using trowels.
  Apply curing compound or cover the concrete with wet burlap/plastic sheets to retain moisture.
• Curing:
  Allow the concrete to cure for the specified period to achieve the required strength.
  Keep the concrete moist and protected from adverse weather during the curing process.

1.11 Formwork Removal:

• Striking Formwork:
  Carefully remove the formwork after the concrete has achieved sufficient strength.
  Avoid damaging the concrete surface during formwork removal.
• Finishing Touches:
  Repair any minor defects or surface imperfections.
  Clean and store formwork materials for future use.

1.12 Safety Considerations:

• Ensure all personnel wear appropriate PPE at all times.
• Maintain clear communication and follow site safety protocols.
• Keep a safe distance from operating machinery.
• Monitor weather conditions and cease work during adverse weather (e.g., heavy rain, lightning).

1.13Quality Control:

• Conduct regular inspections to ensure foundation dimensions, reinforcement placement, and concrete quality meet design specifications.
• Perform concrete tests (e.g., slump test, compressive strength test) to verify quality.
• Document all inspections, tests, and any deviations from the plan.

1.14 Reporting and Documentation:

• Maintain daily logs of foundation construction activities, including equipment used, volumes of concrete poured, and any incidents.
• Prepare and submit progress reports to the project manager.
• Keep records of all permits, test results, and inspections.

1.15 Approval:

• Prepared by: George Bunker
• Date: 07/02/2024
   

1.16 Note: This work instruction must be reviewed and updated regularly to reflect any changes in project requirements, equipment, or procedures.

 

2. Substructure Work

2.1 Purpose:
To ensure the accurate and methodical construction of substructures for water and sewer treatment plants, providing a stable foundation for superstructure elements and equipment.

2.2 Scope:
This work procedure applies to all personnel involved in substructure construction, including site supervisors, concrete workers, masons, and construction managers.

2.3 Responsibilities:

• Site Supervisor: Oversees substructure construction, ensuring adherence to plans and safety protocols.
• Concrete Workers and Masons: Perform tasks related to concrete pouring, masonry work, and reinforcement placement.
• Engineer: Verifies substructure dimensions, reinforcement details, and ensures compliance with design specifications.
• Safety Officer: Monitors safety practices and ensures compliance with safety regulations.

2.4 Materials and Equipment:

• Excavators and Bulldozers
• Concrete Mixers and Vibrators
• Formwork Panels and Supports
• Reinforcement Bars (Rebar)
• Binding Wire
• Concrete (Ready-mix or On-site Mix)
• Masonry Blocks or Bricks
• Mortar and Cement
• Shovels, Spades, and Trowels
• Survey Equipment
• Personal Protective Equipment (PPE) - helmets, gloves, boots, high-visibility vests

2.5 Procedure:

2.6 Preparation:

• Review substructure design drawings and specifications.
• Conduct a site survey to confirm foundation dimensions and layout.
• Obtain necessary permits and approvals from relevant authorities.
• Brief the substructure team on tasks, safety procedures, and emergency protocols.

2.7 Excavation:

2.8 Marking and Layout:

• Mark the excavation boundaries and depths on the ground using survey equipment.

2.9 Excavation:

• Excavate soil to the specified depth and dimensions required for the substructure.
• Ensure proper slopes or shoring to prevent collapse and maintain stability.

2.10 Foundation Preparation:

2.11 Base Preparation:

• Grade and compact the excavated area to form a stable base for the substructure.
• Ensure adequate drainage measures are in place to prevent water accumulation.

2.12 Formwork Installation (if applicable):

2.13 Formwork Construction:

• Assemble formwork panels and supports according to the substructure design.
• Ensure formwork is securely braced and aligned to prevent movement during concrete pouring.

2.14 Formwork Inspection:

• Verify the dimensions, alignment, and stability of the formwork before concrete pouring.

2.15 Reinforcement Placement:

2.16 Cutting and Bending:

• Cut and bend reinforcement bars (rebar) to the required shapes and sizes as per design specifications.

2.17 Reinforcement Installation:

• Place and tie rebar within the formwork or directly into the excavated area.
  Ensure proper spacing, cover, and lap length as specified in the design.

2.18 Reinforcement Inspection:

• Inspect the placement of reinforcement to ensure compliance with design specifications.
• Check for proper clearance and positioning.

2.19 Concrete Pouring:

2.20 Mixing and Transporting:

• Prepare concrete mix as per the specified mix design (use ready-mix concrete if available).
• Transport concrete from the mixer to the substructure area using pumps or wheelbarrows.

2.21 Pouring:

• Pour concrete into the formwork or directly into the excavated area.
• Use vibrators to compact the concrete and ensure uniform distribution.

2.22 Finishing:

• Level and smooth the concrete surface using trowels.
• Apply curing compound or cover the concrete with wet burlap/plastic sheets to retain moisture.

Curing:

• Allow the concrete to cure for the specified period to achieve the required strength.
• Maintain moisture levels and protect from adverse weather conditions during curing.

2.23 Formwork Removal (if applicable):

2.24 Striking Formwork:

• Carefully remove the formwork after the concrete has achieved sufficient strength.
• Avoid damaging the concrete surface during formwork removal.

2.25 Finishing Touches:

• Repair any minor defects or surface imperfections on the concrete surface.
• Clean and store formwork materials for future use.

2.26 Masonry Work (if applicable):

2.27Block or Brick Installation:

• Lay masonry blocks or bricks using mortar as per the design specifications.
• Ensure proper alignment, level, and plumb of masonry walls.

2.27 Safety Considerations:

• Ensure all personnel wear appropriate PPE at all times.
• Maintain clear communication and follow site safety protocols.
• Keep a safe distance from operating machinery and excavation edges.
• Monitor weather conditions and adapt work plans as necessary for safety.

2.28 Quality Control:

• Conduct regular inspections to ensure substructure dimensions, reinforcement placement, and concrete quality meet design specifications.
• Perform concrete tests (e.g., slump test, compressive strength test) to verify quality.
• Document all inspections, tests, and any deviations from the plan.

2.29 Reporting and Documentation:

• Maintain daily logs of substructure construction activities, including equipment used, volumes of concrete poured, and any incidents.
• Prepare and submit progress reports to the project manager.
• Keep records of all permits, test results, and inspections.

2.30 Approval:

Prepared by: George Bunker
Date: 07/02/2024
 

2.31 Note: This work procedure must be reviewed and updated regularly to reflect any changes in project requirements, equipment, or procedures. Adjustments may be necessary based on specific project conditions or design variations.

 

3. Superstructure Work

3.1 Purpose:
To ensure the systematic and accurate construction of superstructures for water and sewer treatment plants, meeting design specifications and ensuring structural integrity.

3.2 Scope:
This work instruction applies to all personnel involved in superstructure construction, including site supervisors, carpenters, steelworkers, concrete workers, and construction managers.

3.3 Responsibilities:

• Site Supervisor: Oversees superstructure construction, ensuring adherence to plans, safety protocols, and quality standards.
• Carpenters, Steelworkers, and Concrete Workers: Perform tasks related to formwork, reinforcement, concrete pouring, and installation of structural elements.
• Engineer: Verifies superstructure dimensions, reinforcement details, and ensures compliance with design specifications.
• Safety Officer: Monitors safety practices and ensures compliance with safety regulations.

3.4 Materials and Equipment:

• Formwork Panels and Supports
• Reinforcement Bars (Rebar)
• Binding Wire
• Concrete (Ready-mix or On-site Mix)
• Structural Steel Beams, Columns, and Plates
• Masonry Blocks or Bricks
• Mortar and Cement
• Shovels, Spades, and Trowels
• Survey Equipment
• Personal Protective Equipment (PPE) - helmets, gloves, boots, high-visibility vests

3.5 Procedure:

3.6 Preparation:

• Review superstructure design drawings, plans, and specifications.
• Conduct a site survey to confirm layout and dimensions.
• Obtain necessary permits and approvals from relevant authorities.
• Brief the superstructure team on tasks, safety procedures, and emergency protocols.

3.7 Formwork Installation:

3.8 Formwork Construction:

• Assemble formwork panels, supports, and shoring according to the superstructure design.
• Ensure formwork is securely braced and aligned to accommodate concrete pouring and structural elements.

3.9 Formwork Inspection:

• Verify the dimensions, alignment, and stability of the formwork before concrete pouring.

3.10 Reinforcement Placement:

3.11 Cutting and Bending:

• Cut and bend reinforcement bars (rebar) to the required shapes and sizes as per design specifications.

3.12 Reinforcement Installation:

• Place and tie rebar within the formwork or directly into masonry walls or concrete elements.
• Ensure proper spacing, cover, and lap length as specified in the design.

3.13 Reinforcement Inspection:

• Inspect the placement of reinforcement to ensure compliance with design specifications.
• Check for proper clearance and positioning.

3.14 Concrete Pouring:

3.15 Mixing and Transporting:

• Prepare concrete mix as per the specified mix design (use ready-mix concrete if available).
• Transport concrete from the mixer to the superstructure area using pumps or wheelbarrows.

3.16 Pouring:

• Pour concrete into the formwork or directly into masonry walls and structural elements.
• Use vibrators to compact the concrete and ensure uniform distribution.

3.17 Finishing:

• Level and smooth the concrete surface using trowels.
• Apply curing compound or cover the concrete with wet burlap/plastic sheets to retain moisture.

3.18 Curing:

• Allow the concrete to cure for the specified period to achieve the required strength.
• Maintain moisture levels and protect from adverse weather conditions during curing.

3.19 Structural Steel Installation (if applicable):

3.20 Placement and Alignment:

• Install structural steel beams, columns, and plates as per the design drawings.
• Ensure proper alignment and connection of steel components.

3.21 Welding and Bolting:

• Weld or bolt structural steel connections as per industry standards and design requirements.
• Conduct inspections to verify weld quality and bolt torque.

3.22 Masonry Work (if applicable):

3.23 Block or Brick Installation:

• Lay masonry blocks or bricks using mortar as per the design specifications.
• Ensure proper alignment, level, and plumb of masonry walls.

3.24 Safety Considerations:

• Ensure all personnel wear appropriate PPE at all times.
• Maintain clear communication and follow site safety protocols.
• Keep a safe distance from operating machinery and structural elements under construction.
• Monitor weather conditions and adapt work plans as necessary for safety.

3.25 Quality Control:

• Conduct regular inspections to ensure superstructure dimensions, reinforcement placement, and concrete quality meet design specifications.
• Perform concrete tests (e.g., slump test, compressive strength test) to verify quality.
• Document all inspections, tests, and any deviations from the plan.

3.26 Reporting and Documentation:

• Maintain daily logs of superstructure construction activities, including equipment used, volumes of concrete poured, and any incidents.
• Prepare and submit progress reports to the project manager.
• Keep records of all permits, test results, and inspections.

3.27 Approval:

Prepared by: [Name/Title]
Date: [Date]

3.28 Note: This work instruction must be reviewed and updated regularly to reflect any changes in project requirements, equipment, or procedures. Adjustments may be necessary based on specific project conditions or design variations.