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    10 views61 pages

    Prefrab. Construction

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    Anandlal R

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    © All Rights Reserved
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    of 61
    en 2.1. GENERAL The design of precast concrete elements involves understanding the method of fabrication, the implicit constraints, as well as the various aspects that facitate the arection and assembly of these elements on site. Salient guidelines for the design of precast concrete elements can be found in the Singapore Code of Practices namely CP 68° and CP 81’. In addition to the design and detailing of pracast olaments, its important to carry out design checks on the overall building stability and robustness of the complete structure as recommended in these codes. The design should also consider the manufacture, transportation, hoisting and temporary stability of the element and of the structure during construction. To achieve good auality precast coner. design stage t© elements, itis important to consider the following aspects during the ‘+ Dimensions and Shape of Precast Elem + Mould Design + Concrete Constituents + Joints and Connections + Reinforcement + Lifting and Handing Devices 2.2. DIMENSIONS AND SHAPE OF PRECAST ELEMENTS ‘The optimal dimensions of tho precast elements largely depend on the -apacity ofthe lifting cranes at the fabrication yard and site as well as transportation limitations. It is however, a good practice to design for the largest possible size to minimise jointing and handing, Integration of different elements, such as the beam-wall system, mul dimensional units can be adopted to enhance dimensional controls ang construction auaiity 1 columns and three Where possible, plan fo appropriate repetition and standardisation in the dimensions and shape of the elements, which 's desirable for economic of scale and quality assurance, Fewer mould changes will facta the production schedule anc hence reduce construction time. Nevertheless, precast elements in particular the facade and wall panels, can be designed and mocifiet from the typical mould in profiles for greater variations as wel as to maximise mould usage. However, care should be taken in the design to consider some forms of strengthening for panels with significant openings or narrow segment at the side of the openings, to prevent cracking or spaling of the elements during installation Figure 2.2 Multtier columns Figure 2.1 in ed beam and wall panels siffere Refer to Singopore Code of Paste for St Use of Concrete P65; Part 1:19 "foter to: Singsoore Code a Practice for Preeas ote Sib ana Wal Panels CP 8: 190 2 PRECAST CONCR! IENTS | DESIGN 2.3. CONCRETE CONSTITUENTS Depending on the design requirements, a variety of concrete strangths and characteristics can be used to achieve ‘optimum performance required of the precast concrete elements. The relevant are listed in Table 2.1 dards for concrete constituents ‘Table 2.1 Relevant standards for concrete constituents Concrete Mix cP ss. cPat 88 288 gS ment. Concrete mix which is composed of portland cement and water together with fine and coarse aggregates, should be designed to achieve the desired workability during concreting, and the durability fand strength recuired of the final precast elements. In general, the mix should achieve a concrete strenath of minimum 10 Nimmo more at ealy stage for demoulding an higher production etficiency. Cement 3826 (Ordinary partiand cement and blended cement are commonly used in precast concrete production. High alumina cement should not be Used as it may cause substantial loss in concrete strength and durability in warm, humid concitions. Aggregates ss3i ‘Tho maximum size of the coarse aggragates should be established in th design. Tho size shouls be compatible with the minimum dimension and usage of the precast elements. As a general guide, the maximum agpragate size should not be greater than the speciied cover to reinforcement or tendons, For machine-extruded concrete such as hollow core slabs, whereby the concrete mix is forced through rotating augors and steel formers to create the voids, fine aggregates have to be carefully graded. To achieve quality product, the sizo of the coarse aygrogates should be loss than 18 or 20 mm, depending on the element dimension and machinery typ. Acmintures $8320 Chemical admixtures ray be acked io enhance the performance of ‘he concrete mix by redilcing the required water content of to accelerate the rate of early strength development. ts recommended teacarty out tral mixes to determine the optimum design propartion of admixtures to be added to concrete mix. Approptate methods of batching and concreting should be used to ensure correct dosage 50 35 to avoid any detrimental effects on precast concrete elements. PRECAST CONCRETE ELEMENTS | DESIGN 2.4, REINFORCEMENT Apart from concrate constituents, procast concrete elements are often reinforced using wolded wire meshes, bars or prostrossing tendons to achiove the required structural capacity. Thay are required to be designed to most the crack control, loading capacity and construction load requirements, The relevant standards for reinforcement and prestressing tendons are listed in Table 2.2, Table 2.2 Relevant standards for reinforcement and prestressing tendons tems. Sons Welded Wire Meshes $532 Stee! Reinforcement 382 ressing Tendons 88475, cP 65 In designing the reinforcement layout, itis important to also consi presence of other cast initems such as pipe sleeves or electrical fixtures. The layout design should be simplified wherever possible, to avoid congestion which may affect the conerate quality due to poor compaction and loss of conerote cover. Figure 2.3. Potential congestion at connection where there are reinforcement bars and cor When the projecting reinforcing bars that are requir ‘may pose storage and handling problem. In this respect, tis good practice to adopt mechanical counlers or spice system to provide for the structural continuity needed. for lap splicing PRECAST CONCRETE ELEMENTS | DESIGN Figure 2.4 Long projecting bars may pose storage and handling problems Figure 28 Use of splice sleeve system in place of long projecting reinforced bars PRECAST CONCRETE ELEMENTS | DESIGN 2.5. MOULD DESIGN Moulds ean be made of any suitable materials including steel, timberlplywoad, glass reinforced concrete (GRC) or a combination of these. The selection of the mould materials will dopend an the number of usage, required surface finish type and quality as well as the shape complexity ofthe pracast elements. Locally, stoe! mould is proferre the steal plate thickness adopted for mould dosign and fabrication varies from a minimum of 4.8mm to mm, which ean be used up to 50 ~100 times with proper cate and maintenance. Besicles, the mould should be designed to allow for anproprate placing and compaction of the concrete. Adequate numbor of braces, ties and struts should be provided for proper casting and hardening of the conerete. A minimal number of demountable parts will hp to ensure good maintenance of dimensional accuracy during reduction as ‘wall as to facilitate easy assombly and dismantling. To enhance cost competitivenass, adjustable mould should bo adopted where possible, for greater flexibility and variety in the production of precast concrete elements. ‘owning to its robustness and precision. In general Fig 2.6 Example of adjustle mould for the precast beam and colurmn production igure 2.7 Adequate bracing is required for better dimensional controls Figure 2.8 Examples of battery moulds anc mechanised vertical moulds used for wall elements PRECAST CONCRETE ELEMENTS | DESIGN moulds or mechan) roduction of standard elements such as refuse chutes and paray vertical moulds can be used for better quality and productivity, 2.6. JOINTS & CONNECTIONS Joints and connections must be designed to adequately transfor the loads from a precast concrete element to the supporting structure or to an acjacent element te form the structure, They have to meet the design and performance criteria such as strength, ductility, fre resistance, durabilty and stability. Apart from these structural requirements, siderations should be given to the production and erection process of the elements, To achieve a pra ion, the following items should be considered in the design due Standarcise tha joint and connection types and details Avoid congestion a joints Avoid penetration of farms Allow for production and erection tolerances Plan for easy assembly and accessibility Accompilation of conne Precast Concrete Hand or Landed Residential Development in Singapore ion and jointing details commonty used can be found in other BCA publications - “Structural 00k", “Bulldable Solutions for High-Rise Residential Development” and "Buildable Solutions Recommendations on watertightness details and workmanship standards for external wall can be obtained from CA's Good Industry Practices on Waterproofing for External Wall Figure 29 Examples of joints and connections between different precast elements PRECAST CONCRETE ELEMENTS | DESIGN 2.7. LIFTING AND HANDLING DEVICES In procast concrete construction, lting and hanaling devices are roquired and placed within the elements to facitate the demouling, handling and erection processes. The type, number and location of these temporary lifting and handling devices play an impartan: role, in ensuring that the precast elomants are not excessively stressed during Iting operation and befora jointing works commenced. The factors to be considered are as follows: Capacity ofthe lifting and handling devices. \Woight and shape of the procast elements, Strength of the concrete at the time of lifting Position of any opening or cut-out in the pracast elements. Rigging arrangomont Type of lifting clutch, hook or shackle used for handling and installation Figure 2.10 Lifting and handling devices are requited to facilitate the erection process PRECAST CONCRETE ELEMENTS | DESIGN Lifting anc handling devices can be prestressing strands or cable loops projecting from the elements, coll threaded inserts or proprietary lifting devices. Prostrossing strands or cable loops should be designed with adequate safety factors before use. Reinforcing bars unless specifically designed, should not be used as lifting loops as they are susceptible to breakage during hoisting operations in view oftheir low ductility. Where possible, these lifting and handling devices should be placed at locations thal requit little or ne patching after use. If they are required to be located on the fin'shed face of architectural component such as facade wall panels, it willbe good to provide recesses. These recesses can then be filled up with proper grout after instalation le achieve better wall finishes, Citing a eng Pos poe eres ee ee iting Hepat Figure 2.11. Differant types of deviens for lifting operation and temporary support Figure 2.12 Provision of iting anchor with recess former for bette finishes. Itis @ good practice to adopt proprietary lifting devices that come with specified design load capacity for safe and efficiont handling. These devices normally come with proper accessories to form recesses, which can be easily patched up after installation, rication Process 3.1, GENERAL Before fabrication, shop drawings of individual precast elem following information ‘are required to be prepared and detailed with the * Project location, reference number of elements, and their locations with respect tothe building layout and elevation + Dimensions of elements, centre of gravity, weight and concrete volume * Locations of all reinforcing steal, castin items for connection, Ifting and bracing ations of embedded items such as service conduits, blockouts and recesses as well as openings + Jointing and interfacing details between elements + Watertightness details at joints * Architectural details and treatments where applicable 1h requitements should be resolved before Any discrepancies among the architectural, structural and produ confirming these drawings for fabrication to minimise abortive works. Generally, there are two main types of precast concrete elements, namely precast reinforced concrete elements and precast prestress: concrete elements + Consist of reinforcement bars andjor ‘welded wire meshes within the elements to provide the tensile strength and resistance against cracks + Examples are facade walls, beams, columns, slats, refuse chutes, stircases ‘and parapet walls Deena crore Conere rgonents of @ bulking that are prefabricated in precast Yard ar site, They are tobe installed <0 the’ final postion in the buldng uring construction + Consist of prestressing tendons within the Reda) slements to provide a predetermined force Concrete Elements needed to resist external loadings and cracks ‘+ Common examples are hollow core slabs, beams and planks Figure 2.1. Types of precast concrete elements 0 "AST CONCRETE ELEMENTS | FABRICATION PROCESS " In fabrication, most ofthe precast concrate elements are produced using the normal wet casting method. However, for hollow core slabs and wals, dry casting process or extrusion method is ado 3.2. NORMAL CASTING PROCESS FOR PRECAST REINFORCED OR PRESTRESSED CONCRETE ELEMENTS Table 2.1 highlights some of the good practicas recommended for normal wet casting of precest concrete elements Table 3.1 Nor con 1. Assembly of mould “+ Check the level and flatness of the base mould bafore assembling the mould for panel casting, Ensure that the dimensions of mould ae within the specified tolerances. [ETE ELEMENTS | FABRICATION PROCESS. ie 2. Mould cleaning and preparation Form oil or mould release agent should be applied eveniy over the mould surfaces, Check that the joints and edges of the mould, belts, steppe de props and rubber seal are intact and properly secured! 3. Fixing of rebars/castin tems / prestressing strands Cheek thatthe rebar size, spacing and lap length are in accordance withthe drawings. CRETE ELEMENTS | FABRICATION PROCESS n process. Enno + Rebars, 3s, corrugated sleeve pipes, recesses, liting hooks land inserts must be correctly positioned and properly secured + Use of fabrication rig ean help to ensure the accuracy of rebars fixing and spacing CONCRETE ELEMENTS | FABRICATION PROCESS ie Eno of rebars /castiniterns / rossing stands conta) + Whore needed, tack welding nt number of spacers with the tnd secured to achieve the req cover duting ‘+ For precast prestressed concrete element such as planks, the sand hauling should only be carried out when the form release agent has. fed to a certain degree that will not contaminate the strands PRECAS! CONCRETE ELEMENTS | FABRICATION PROCESS. Fabr Seed 4. Final inspection before casting Cerin Check an verify that all details comoly with drawings. It is good to check the base mould level again before casting, in paricular for site precasting where other concur have shited the mould level Site activites may PRECAST CONCRETE ELE! ENTS | FABRICATION PROCESS i Sr 5. Conereting + Conduct slump test in compliance with SS 78 to assess the workability lof the concrete mix before placing the canerete to the mau + The drop height of concrete mix should nat exceed more than Im, + Proper vibration and compaction should be cari rote congestion areas. ¢ out in particular, in + Form viorator ean be used for slender and thin elements ‘+ Maintain the required thickness by use of screed. PRECAST CONCRETE ELEMENTS | FABRICATION PROCESS ie ery 5. Conereting (cont'd) + Use of power trowel j float is recommended for smoath surface ‘+ Observe adequate curing time and desired environment. ‘+ Concrete cubes should be subjected tothe same curing conditions as et | — 7, Demoulding + Depending on the anchor length of inserts and type of preva for e.g, thin flor slabs, the mnimum conerete strength requred may higher to overcome the suction and frictional forces during ddemoulding, ‘+ Cube tests should be conducted to verify the concrete strength of clements before demoulding + As 2 general guide, ensure that the concrete strengths attained for reinforced precast elements and presivessed precast elements are minimum 10 Nimm* or 25 Ninm* respectively. + Loosen and remove all bolts & pins and end and side mould forms before iting. + For prestressed elements, cut strands before lifting INCRETE ELEMENTS | FABRICATION PROCESS Fabrication process Enno 8. Final inspection / Transfe yard to storage, Finishing works before delivery to site + Check the concition of the finished product, + Verity the ertical dimensions. ~_ + Proper identification markings should be placed on elements showing the location, mamber type, size, weight and erientation a per shop drawing. + Chea elements have achieved 75% of thelr design concrete strength before delivery to site for erection, 1" PRECAST CONCRETE FLEMENTS | FABRICATION PROCESS 1° 1g Process (Extrusion Method) for Precast Hollow Core Elements to produce hollow core slab of wall panels. Table 3.2 highlights rusion method of precast hallow core panels. 3.3. Dry Cast The dy casting or extrusion method is mainly use: some of the good practices recommended for dry casting o: ‘Table 3.2 Dry Casting Fabrication Process Fabrication process ron 1. Base mould cleaning and ‘+ Check that the base mould is clean and free from debris and old preparation mortars the extrusion machine including the vibrator are in good ‘+ Form release agent used should have ant-rust properties and be relatively ary after application so that the strands will not be contarnin hould be applied eveniy over the mould surfaces PRECAST CONCRETE ELEMENTS | FABRICATION PROCESS Fabrication process Enno 2. Prostressing strand hauling and tensioning + Check the strand size, spacing an: + Strand hauling shouldbe carried out only when the release agent hes dried toa degree that it will nat contaminate the strands, “+ Before concreting, check machine setting for concrete cover and panel thickness. Check that concrete grade used is according to design specications. ‘+ Conduct slump test to ensure adequate workabilly ofthe concrete Check that the elams-on vibrate provide good compact 20 PRECAST CONCRETE FLEMENTS | FABRICATION PROCESS Fabrication process Enno 3. Conereting cont'al + Cory out visual inspection ofthe surface finish to ensure there is serious defect like honeycomb, dimensional changes, cracks etc + Stop operation to investigate if serious defect detected 4, Curing + Protect the hollow core panels with rapid moisture loss and shrinkage cracks, paulin oF canvas to prevent + Observe adequate curing time and desired environment + Concrete cubes should be subjacted tothe samo curing conditions as the elements " a PRECAST CONCRETE ELEMENTS | FABRICATION PROCESS Fabrication process Enno 5. Detensioning of strands 6 Final inspection / Transfer to storage yard + Cube tests should be conducted to verity the conerete strength ‘+ Check that the concrete has attined the designed transter stength fof minimum 35 Nimm’ or as sporified before detorsioning led water holes at the bottom of panels should be between 10 ram to S00 mm fromm the end of the panels. ‘+ Ensure that dimensions of the hollow core panels mest the design that proper identi and tracing. jon markings are in place for easy retrieval ‘+ Check for possible slippage of strands at both endl of hollow core panels. The values of allowable slippage should meet the design + Check if there are any major cracks along the element section, + Plugging of holow coro openings with plastic caps before transfering tw storage yar. “+ Check tnat the elements have loved 75% of their design strength before delivery to site for erection, 4.1. DELIVERY Delivery of precast elements should be planned according to the general erection sequence to minimise unnecessary site ge and handling. Where possible, its des transport the precast elements into a manner which they can be lifted directly for erection or storage without much change in orientation and sequence. For example, wall panels can be ‘ransported using A-Frame type taller in upright pos'ton Precast elements should be loaded and delivered with proper supports, frames, cushioning and tie-downs to prevent in transit damage. Adequate pecking or protection to the edges of precast elements should also be provided to minimise tisk of damages during ta Figure 4.1. The manner of delivery will depend on the type, dimension and weight of the precast elements 24 PRECAST CONCRETE ELEMENTS | DELIVERY, HANDLING AND STORAGE Fa Pera rae a ret eioet peeing cua Lae) perro) Berita Cushion packing should be provided to prevent damage to the edges of precast Epis eA Damages can be commonly found at the ‘contact areas between the precast ei antate Figure 42 Pro damages to precast concrete elements reer packer to secul the precast tac Petia ety PSS Perea eres pepe eerie ion measures such as the use of cushion packing or polythene wrapping can be used to minimise PRECAST CONCRETE ELEMENTS | DELIVERY, HANDLING AND STORAGE Figure 4.2 Precast elements should be adequately fixed and secured ta pre-emat mevernent or accidental spillage during transit 4.2. HANDLING The handling process mainty involves the removal of the precast elements from the mould, transportation to the storage yard, loading and unloading operation and erection of thase elements at the job site. Different sets of lifting points and castin devices will have to be used for various handing stages. ‘Tyically, precast concrete elements are demoulded and lifted from their casting position to storage yard and delivery to site once they reach the expected concrete strength reauired. As these elements have not gained their full designed strength, they are generally more susceptible to damages during handling. Its therefore important to fensure that they are handled in a way that is consistent with their shapes and sizes, to avoid excessive stresses or damages. For elements with large openings, temporary bracing, ties or strongoacks should be provided handling as shown in Figure 4.4 ‘The handling requirements depends on th lowing factors + Position of the casting mould {e vertical casting vs horizontal casting) ‘+ Minimum conerate strength of the precast elements for demoulding, delivery and erection * Adequacy of the design reinforcement to resist handling stresses + Size and weight of the precast sloma! + Number, size and location o iting points and type of inserts/de + Method of iting, type af lifting equipment and crane capacity * Support points for storage and transportation 2% PRECAST CONCRETE ELEMENTS | DELIVERY, HANDLING AND STORAGE Figure 4.4 Temporary strengthening of panels with openings Basically, the elements when handled must be balanced and inline with their centre of gravity. The general hoisting methods used for different precast conerete elements are llustrated inthe following Figute 4.5 - Figure 48 Precast Beam Note : The lifting points should be designed and located to limit the bending moments within the bear element. ‘As a general guide, they should be located at about one fifth of the beam length measured from the edge. Figure hoisting method for beam 2 PRECAST CONCRETE ELEMENTS | DELIVERY, HANDLING AND STORAGE Precast Wall For wall panels itis recommended tolft the panel in vertical position for installation so that turning is not required joisting mothod adopted for demoulaing of wall panels that are cast horizontally Figure 4.6 General hoisting method for wal Precast Plank / Slab Note : Where necessary, multiple iting points can be designed and located to minimise undue stresses within the slab elements, in particular for slender panels such as precast planks. Figure 4.7 General hoisting method ‘or plankslab Ey 2 PRECAST CONCRETE ELEMENTS | DELIVERY, HANDLING AND STORAGE Precast Column gd LV Note : Columns are usually frst handled in horizontal position Slings are attached to the inserts at the top 0 facilitate the rotation of the elements to vertical position, before hoisting and placing to their designated Figure 4.8 General hoisting methos for column 4.3. STORAGE The storage area provided in the yard and job site should be adequate to permit easy access and handling of the ast elements. The area should be relatively level, firm and well drained to avoid any differential ground s re which may damage the stored elements iate stacking method shoul be used to store the precast concrete elements to prevent any undue stresses and damages (see Fig 4.9 and 4.10}. Horizontal precast conerete elements such as precast slabs, planks, beams and hollowcore panels, can be stacked and supported separately using strips of woods or battens across the full ‘width of the designated bearing points. Precast walls and tacade panels are usually stored in vertical position supporting their own weight using racks with stabilising wall, Storage conditions can be an important fact achieving and maintaining panel bowing and warping tolerances, More lateral support should be given to slender panels, which are more likely to bow or warp. To minimise handling, the elements should also be stored based on Ann the erection sequence. PRECAST CONCRETE ELEMENTS | DELIVERY, HANDLING AND STORAGE J Stacking method and packers for support spacers] vary | Do not use mote than two support points in partic, socercing to the tynes of precast elements, Horizontal | for prestressed element such as hollow core slab stacking of slabsbeam of column units can be done with Suitable packers or support spacers shown above. AS 2 guide, the storage support position for beams and planks should be within 200mm from the lifting points. x x v ‘Tho packers or supaor spacers should pot be misaligned | Wal panels should be stored vertically and braced in as shown, position by Aframes or a racking system. Figure 4.9 General guidelines on stacking method of precast elements Fr eet oes 31 Figure 410 Different storage and stacking requirements for diferent precast elements PRECAST CONCRETE MENTS | DELIVERY, HANDLING AND STORAGE Figure 4.11 Examples af improper storage and stacking methods ‘The storage area atthe jo site should areferably be close to the locations where the precast elements are to be installed to minimise the risk of damage by handing Figure 4.12 Procast concvot should profe near ther final position for easy handling ments be stored 2 5. Installatio 5.1, GENERAL Proper planning and preparatory works are required before the actual erection of precast concrete elements to ensure efficiant and qualty instalation. The following items should be carefull planned . 1d and sequence of assembly and erection . 1d of providing temporary supports + Provision for final steuctural connections and joint details Erection tolerances Handling and rigging requirements Prior to the instllati checks isted in Table 6.1 of the precast concrete elements, itis important to consider the following work items and Table 5.1 Pray ratory works items and checklists = Check for site accessibllty for the delivery of precast elements * Check delivery checklist for corroct type, quantity and panel identiicatic * Check for adequate crane capacity and working clearance for hoisting of precast concrete elements ‘Conduct samole measurement to confirm the accuracy ofthe critical dimensions st concrete elements and openings '* Conduct visual inspection on concrete finishes and check for any major defects PRECAST CONCRETE ELEMENTS | INSTALLATION ‘+ Check the locations and conditions of iting inserts before hoisting + Check on the accessibility of unloading point and storage area’ * Check that the storage area is of hard, level, clean and well drained ground * Store the precast elements where required using "First In First Out” principle according to the delivery schedule and erection sequence ™ ONCRETE ELEMENTS | INSTALLATION 5.2. INSTALLATION OF VERTICAL PRECAST COMPONENT The method a Cf installing the precast wall panels (which is also applicable to other vertical components) tlined in Table 6.2 Peer cers nee line and offset tine | + Check the accuracy of the offset lines. mine the position of the precast elements to be instaled. | + Chack the shim plate level and stability + For vertical precast component, check the positions and aignmen: lof the starter bars before hoisting for installation. 1.2. Provide level pads (or shim plates) for setting the level of the elements. Set the level pads in position using non-shrink mortar. b 1.3.For precast external wall column, fix the compressiole form or backer rod on the outer perimeters of wall PRECAST CONCRETE ELEMENTS | INSTALLATION 2.1. Lift and ig the panel to its location with the Use of wire ropes. 2.2. Adjust the panel to position and ‘secure it with diagonal props. SS + Check the hoisting condition of the precast oloment. + Check alignment and verticalty of the panel. If necessary, aust the temporary propaing to achieve the level and position of the precast + Check the staiity of the. cable leasing the hoisting =< 36 PRECAST CONCRETE ELEMENTS | INSTALLATION 2 Pe 3a 32, 33, routing work Prepare and apply non-shrink ‘mortar to seal the gaps along the boattom edge othe inner sie of the panel For corrugated pine sleeve or splice sleeve connection, prepare fand pour non-shrink grout or proprietary grout into the sine inlets provided. Keep the installed panels Lnsisturved for atleast 24 hours, Good + Check that the joint width between panels are within design allowances before grouting i + Non-shrink grout used atthe interface with the precast elements should preferably be free flowing and self comoacting in nature so {2 fo ensure good compaction at the joint and to minimise the risk of cracking. ‘+ Non-shrink grout should be prepared in accordance with the specifications. + Check that all horizontal joints are properly sealed. + Collect sample test cubes ofthe grout mix used fr critical elements such loading bearing walls or testing PRECAST CONCRETE ELEMENTS | INSTALLATION Installation sequ 4, Joint casting and sealing 4.1. For panels with cast in-situ joints, install the jon rebars as required. 4.2. Sot up forms for the casting of the vertical joint. 43, Carty out concrete casting 44, Remove forms atter sufficient concrete strength has beon achieved, 45, For joints between facade walls or between external columns ‘with beams or walls elements, approved sealant and grout will be installed at later stage, cy 46. For panel with welded connecton, place the connecting plate between the panels and carry out welding as per design requirement. + Tho joint rebars should be correcty placed in accordance with the dosign specifications. +The formwork shouldbe propery secured duting the casting operation of the joint + The joint gaps should be consistent to alow for proper installation of sealant or grout for better watertightness. Consistent joint 1989 to for proper sealant or grout instalation Sealent application Backer rod 38 PRECAST CONCRETE ELEMENTS | INSTALLATION 5.3. INSTALLATION OF HORIZONTAL PRECAST COMPONENT ‘The method and sequence of installing the precast slabs and beams {which is also af omponents} are outlined in Table 5.3. ‘able to other horizontal Table 5.3 Horizontal component installation Installation sequenet ens Setting out 1. Set reference ine and ofset line | * Check the accuracy ofthe offeet lines. fo determine the required ‘ignment andlevel tthe precast | * Chock the level and stability ofthe shim pat slab/beam elements during instalation. + Before hoisting, check that the dimensions and alignment of the protruding bars are within the speci prevent any obstruction during the erec fied toleranc to + Beam elements shouldbe supported at minimum two leations during hoisting, PRECAST CONCRETE ELEMENTS | INSTALLATION 2.2. Lift and rig the slemants to designated location with the use of wire ropes. 2.3. Align and check I the required seting out before placement of precast members to final position + Balcony, planter lodge and slab should be supported at more than tions, depending on the dimensions of the elements and + Itisimportant to check on the levelness of the precast elements as ‘well as between the elements bofore proceeding to do the jointing works. 40 PRECAST CONCRETE ELEMENTS | INSTALLATION a 2.1. For components with cast in-situ Joints, place and lap the rebars as required. 3.2. Set up the formwork for the casting of the joint. 33.Carry out concrete casti 2.4, Remove forms after sufficient fe strength hes been ear actices + The joint rebars should be corre design specifications. ly placed in accordance with the + The formwork should be properly secured during casting ofthe in- + Supporting beams can be designed to form part of the formwork for the casting of joint. uality In 6.1. GENERAL iis important to have quality inspections as part of the integral process in managing quality of precast concrete elements. Close supervision should be provided for both critical in-process and finished works so as to achieve high ‘workmanship quality. Quality assurance and control stats with good planning and management. Itis @ good practice to prepare an Inspection and Test Pian, ITP (see Appendix A) whicn summarises the projects’ inspection, acceptance criteria and frequency of inspections. Checklists for the in-process and final inspection of precast concrete elements should also be prepared {as in Appendix B} to detail the checks required at critical stages. Quality inspections for the in-process works are highlighted in Chapter 3 ~ Fabrication Process. This section will only cover quality inspections for the finished precast concrote elomants delivered and erected on site, 6.2. INSPECTION OF PRECAST CONCRETE ELEMENTS The finished precast concrete elements and works should be inspected to ensure they meet the client's requirement and standards. Table 6.1 shows the recommended checklist fo final inspection of the precast conerete elements based ‘on CONQUAS 21 quality assessment criteria, Table 6.1 Checkli {or final inspection of precast concrete elements ears PEON CUE ea oc Re 1.1. Tolerance of cross sectional dimensions of precast elements : +10mm /-Smm [Note : It is common to have the actual dimensions of a precast Maximum dimension concrete element to be slightly different from its designed A, +10mm OR A, +10mm dimensions, However, the variation n cross sections should be within acceptable tolerances “Minium gimension A 5mm OR A, 5mm 4“ PRECAST CONCRETE ELEMENTS | QUALITY INSPECTION. Note: It is important to ensure that the penetration / opening for services are within tolerances for proper connection and linkages of the M & E services. 1.3, Tolarance for langth of precast members (major dimension of unit + Upto 3m: + 6mm + 3m t0.4.5m : 4 9mm {8m + 12mm. tion for every subsequent 6m : + 6mm po, t members Dimensional length of pre L& 6mm for L<3m LL 9mm for am

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