Project Title: Marriot Grand Ballroom

Contract Package No. Concrete Works

Document Title:

Method Statement for the Fabrication, Delivery, and Installation of precast

REVISION HISTORY

MARK DATE DESCRIPTION MEPF CIVIL / STRUCTURAL

A1 First Submission

GENERAL CONTRACTOR
Prepared By: NSC CQC

Checked By: QA/QC Head

NGCB DATE
PROJECT MANAGEMENT
Mechanical Engineer

Reviewed by: Electrical Engineer

EELHI Civil Engineer
Architect

Project Manager
Approved By:
Sr. Project Manager
EELHI

CONTRACTOR’S DOCUMENT No.: MGB-MS-001-CW-001 REVISION A1

 
SECTION

A. SCOPE

B. PRODUCTION PROCESS

C. MATERIAL SPECIFICATIONS

D. CONCRETE TESTING

E. QUALITY CONTROL REQUIREMENT

F. STANDARDS FOR MATERIALS AND PROCESSES

G. DELIVERY

H. INSTALLATION – ILLUSTRATION

SECTION A

SCOPE

This method statement describes the procedures that will be utilized in the fabrication
and installation of precast walls for in house general construction projects. Moreover, the scope also
includes the materials specifications, concrete testing processes and quality control requirements.

The configuration and dimensions of the structural and architectural members are
based on the approved shop drawings. The dimensions and cross sectional properties are customized to
the requirements of the project.

SECTION B

PRODUCTION PROCESS

The production of precast concrete panels is accomplished by the six basic processes listed
below.

B.1 Bed Preparation

B.2 Reinforcing Steel Fabrication and Assembly

B.3 Set – Up Details

B.4 Concreting
 B.5 Curing

B.6 Stripping / Stocking

B.1 BED PREPARATION

Horizontal casting will be used with phenolic, steel or concrete bed used as base,
aluminum tubing or channel will be used as sidings. If possible two side forms will be fixed to the bottom
of the bed and other side forms will be positioned by means of bolts, wedges, braces and magnet.

The forms shall be free from draft, rust and concrete waste from previous concrete
pouring. Grinding and brushing shall be completed as required. Application of release agent shall be
done after the cleaning of the of the bed. Preparation shall be carried out prior to placement of the
reinforcing bars.

B.2 REINFORCING STEEL FABRICATION

The approved shop drawings are thoroughly reviewed and the cutting and bending
schedules are prepared. The rebar comprising the main bars of the structural members are cut and bent
at the fabrication area.

After completing the assembly of the reinforcing bar matting, care shall be taken in
lifting the reinforcing bar matting and placing it into the formworks assembly. Rebars are positioned by
means of spacers.

B.3 SET-UP DETAILS

The position of the rebar is ensured that the proper cover requirements are satisfied.
Also, care should be taken on the installation of the dowels and plates since it would greatly affect the
erection procedure during construction at site.

For all cases, bolts and braces are installed to prevent movement of the side forms
during concrete pouring. The perpendicularity of the forms should always be checked to ensure the
squareness of the members.

Once the end forms are fixed, the lifting inserts are placed and fixed into position. Also, spacer
are placed to support the reinforcing steel bars at the bottom to provide a concrete cover

B.4 CONCRETING
 The concrete design mix is prepared beforehand conforming to the specification of the
structural designer with the help of ready mix concrete suppliers for this project. Typical compressive
strength is 3,000 to 4,000 PSI. Prior to concrete pouring, the following materials must be prepared:
shovels, vibrators, trowels, tarpaulin canvass and concrete cylinder molds for sampling. Also, a final
check should be made on the cleanliness of the forms as well as on the arrangement and positioning of
all the reinforcing bars, lifting hooks or inserts, dowels/ plates and MEPS inserts.

Upon arrival of the preordered ready mixed concrete, the delivered concrete is then
poured directly from the transit mixer into the forms. The concrete will be spread manually using
shovels and hand – held internal concrete vibrators. The use of the vibrators will ensure that there is
proper distribution as well as eradication of air bubbles. The vibrator should be probed vertically into
the concrete at an interval of 0.5m along the length and width of the panel and no longer than 15
seconds shall the vibrator be continuously placed inside the concrete due to possible segregation of the
materials.

During concreting, test samples representative of the batched concrete for several
members are taken for use in determining the compressive strength at different ages of the concrete.
The concrete will be poured into the test cylinder molds and will be prepared according to the proper
preparations of cylinders with tri layering and rodding . These samples would be tested for lifting at 16
hour compressive strengths . The concrete surface is then screeded and trowel-finished. After the
finishing, it is necessary to cover the product with tarpaulin canvass or plastic sheets to protect them
from premature dehydration

B.5 CURING

The concrete may be cured by either normal or steam curing. Normal curing is preferable. Steam
curing is adapted for cases wherein the project is pressed for time only.

For normal curing (ASTM C31), the concrete is allowed to cure while being covered with
canvass until the concrete attains the required strength for lifting.

B.6 STRIPPING AND STOCKING

The stripping of the form and lifting of the product shall be done when concrete
strength is at least 60% of the 28-day compressive strength. In some case, we use high-early strength
concrete to maximize the cycle use of the moulds. The concrete strength can be determined using the
field-cured test cylinder. Stripping could be done once the precast concrete member is ready to be
lifted.
 Stocking area should be clean, plain surface, stable ground and no obstruction above for
free movement of lifting equipment. With big space enough to store precast horizontal or vertical also
provided access to delivery truck, fork lift and mobile crane for loading process.

Stocking of precast panels is mostly done horizontally. However, there are few cases
wherein panels will be stored vertically. Precast can store horizontal or vertical, for precast stack
horizontally should be provided with bolster place on top of lifting socket. Vertical piling of precast
should be provided with rack to place precast on standing position or a support to hold precast
perpendicular to the ground.

Dunnage or Bolster are important for stack and piling of precast. You can use any
material like wood, concrete, steel, rubber or any related materials that can hold heavy load. Bolster is
place religiously on top of the lifting socket or as indicated on the plan.

EXAMPLE OF HORIZONTAL PILING FOR LONG SPAN PRECAST

EXAMPLE OF HORIZONTAL PILING FOR SHORT SPAN PRECAST

EXAMPLE OF VERTICAL PILING OF PRECAST PROVIDED WITH RACK

PANEL PLACED ON PRECAST RACK AT THE STAGING AREA

SECTION C

MATERIAL SPECIFICATIONS

1. Reinforcing Steel

All reinforcing bars shall comply with ASTM A615. Grade 60 bars shall be used for bars greater
than diameter of 12mm and smaller diameter bars shall be done according to ASTM A370.

2. Cement

Cement shall be Portland cement type and shall comply with ASTM C150. Chemical and physical
analysis shall be performed to include compressive strengths of the cement. The cement should have a
compressive strength of at least 12.4(optional). Testing shall be done in accordance with ASTM C 109.

3. Aggregates

Fine aggregates or sand shall be composed of Porac sand. They should conform to ASTM C33
with a maximum nominal size of 19.0 mm. Sieve analysis for both the fine and coarse aggregates shall
also be performed in accordance with ASTM C136. Important properties that need to be determined
include unit weights (ASTM C29) and specific gravity and absorption (ASTM C127 and 128).

4. Water
 All water used for the mixing of concrete shall be clean should not contain dissolved or
undissolved impurities likely to be harmful to the cement, aggregates or the steel reinforcement. The
water used for the concrete mix shall conform with AASHTO T-26.

5. Admixtures

The concrete admixture is a high performance superplasticing admixture (Type F).The usual
dosage ranges from 7 ml./kg. of cementitious material. The concrete admixture shall conform with
ASTM C494.These materials are subject to the approved design mix and trial mixes done prior to actual
batching.

SECTION D

CONCRETE TESTING

1. Slump Test

A sample of fresh mixed concrete is placed and compacted by rodding in a mold shaped
as the frustum of a cone. The mold is raised and the concrete allowed to subside. The distance between
the original and displaced position of the top surface of the concrete is measured and reported as the
slump of the concrete. Slump readings between 150mm and 200mm are considered acceptable.

Slump tests are carried out in accordance with ASTM C143

2. Compressive Strength Samples

Samples for compressive strength tests are mould in 150mm diameter by 300mm high
cylinders. A sample set consists of 12 cylinders taken from the bed. Three cylinders are used to establish
the rate or gain in strength of the concrete before lifting.

Three cylinders are used for the 7 – day compressive strength and three cylinders for
the 28 – day compressive strength. The remaining three cylinders are extra.

All samples are taken, mould and cured in accordance with the procedures in ASTM
C172 and ASTM C31. All samples are marked with the sampling date and an appropriate identification
mark

3. Comprehensive Strength Test

This test method consists of applying a comprehensive axial load to molded cylinders at
the rate which is within a prescribed range until failure occurs. The comprehensive strength of the
specimen is calculated by dividing the maximum load attained during the test by the cross sectional area
of the specimen.

 
 Testing of the comprehensive strength samples are carried out in accordance with the
procedures in ASTM 39.

4. Acceptance Criteria for Compressive Strength

A minimum of three test cylinders shall be made to verify strength of concrete during
lifting and a minimum of three test cylinders shall be made to verify the 28-day strength. The strength of
concrete at any given age shall be determined as the average of three cylinders.

For the verification of the 28-day compressive strength requirement, the concrete is
considered acceptable if no value of the test strength is less that the 28-day compressive strength
design.

SECTION E

QUALITY CONTROL REQUIREMENT

Quality control requirement shall be done according to MNL-116 as detailed below.

Acceptability criteria are also written for various aspects on the following sections in the manual.

1. Concrete

MNL-116 Sections 3.1 Concrete Mixture

3.2 Batching and Mixing

3.3 Placing Concrete

3.4 Curing Concrete

3.5 Finishing

2. Production Practices

MNL-116 Sections 5.1 Plant Practices

5.2 Reinforcing Steel

5.3 Plant Safety

3. Quality Control Operation

MNL-116 Sections 6.1 Testing

 6.2 Record Keeping

6.3 Product Evaluation

6.4 Product Dimensional

6.5 Tolerances

SECTION F

STANDARDS FOR MATERIALS AND PROCESSES

The following manuals, specifications, test methods, practices, codes and standard shall apply in
the production of precast concrete.

1. Precast Prestressed Concrete Institute (PCI) MNL -116- Manual for Quality control for Plants and
Production of Precast Prestressed Concrete Products.

2. Precast Prestressed Concrete Institute (PCI) MNL-120- PCI Design Handbook.

3. American Concrete Institute (ACI ) 318-95 – Building Code Requirements Reinforced Concrete

4. AASTHO T-26 – Quality of water to be used in concrete.

5. ASTM A370 – Standard Test Methods and Definitions for Mechanical Testing of Steel Products.

6. ASTM A615 Standard Specifications for Deformed and Plain Billet Steel Bars for Concrete
Reinforcement.

7. ASTM C29 – Standard Test Method for Unit Weight and Voids in Aggregate.

8. ASTM C31 – Standard Practice for Making and Curing Concrete.

9. ASTM C33 – Standard Specifications for Concrete Aggregates.

10. ASTM C39 – Standard Test Method for Compressive Strength of Cylinder Specimen.

11. ASTM C109 – Standard Test Method for Compressive Strength of Hydraulic Cement Mortars.

12. ASTM C127 – Standard Test Method for Specific Gravity of Coarse Aggregates.

13. ASTM C128 – Standard Test Method for Specific Gravity of Fine Aggregates.

14. ASTM C136 – Standard Test for Sieve Analysis of Fine and Coarse Aggregates.

15. ASTM C143 – Standard Test Method for Slump of Hydraulic Cement Concrete.

16. ASTM C150 – Standard Specifications for Portland Cement.

17. ASTM C172 – Standard Practice for Sampling Freshly Mixed Concrete.
18. ASTM C311 – Standard Test Method for Sampling and Testing Fly Ash or Natural Pozzolans for Use as
a Mineral Admixture in Portland Cement Concrete.

SECTION G

Precast panels are delivered on site by means of high bed and low bed trucks.

The units are stocked horizontally in 3 or 4 layers with concrete dunnages directly below the
lifting points.

(see figure 1)

Panels which are relatively wider and longer are transported to the project by truck
fitted with frame at both sides.( see figure 2)

Equipment

For hauling of precast from fabrication to job site may use:

a. Ten Wheeler Truck

b. Tractor and High Bed Trailer

c. Tractor and Low Bed Trailer

d. Truck fitted with Frame

Loading

Loading should done with care to avoid damage on finish product. Proper handling and
correct location of dunnage should be observed. Supervision of an engineer is also necessary to avoid
some problem.

Unloading

Prior to unloading of precast site must be prepared to accept delivery. Rerouting should
be plan to avoid traffic during unloading. Delivery trucks should be accessible to tower crane for pick up.
Storage area and rack are ready for precast placement.

TRACTOR AND HIGH BED TRAILER FITTED WITH FRAME

LOADING OF PRECAST BY MOBILE CRANE

UNLOADING OF PRECAST BY TOWER CRANE

SECTION H
INSTALLATION

1. Using tower crane, position the panel to designated location.

2. Place two (2) units chain block for panel horizontal alignment.

3. Install frame or steel support to hold precast to its vertical position.

4. After concreting of beams and slabs allow concrete to cure until it reaches desired strength then
remove temporary support.

5. Repeat procedure 1 to 4 until all panels are positioned and installed.

ILLUSTRATION SHOWING PROCESS OF INSTALLATION

SOME PICTURE AND FIGURE FOR REFERENCE

CASTING BED LAYOUT AT BUILDING 1 & 2

CASTING BED LAYOUT AT BUILDING 3

PREPARATION OF BED FOR ON SITE CASTING

PRECAST PREPARATION AT CASTING PLANT

ANOTHER SHOWING PRECAST PREPARATION

PRECAST CONRETE POURING

VERTICAL STOCKING OF PRECAST SUPPORTED WITH FRAME

STOCKING OF PRECAST WITH FABRICATED RACK

ANOTHER VERTICAL STOCKING OF PRECAST