POSSIBUILD BUILDING TECHNOLOGIES

Plot No.135, Mythri Nagar – Phase -1, Madinaguda,

Miyapur, Hyderabad – 500045
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METHOD STATEMENT FOR PRODUCTION AND INSTALLATION OF PRECAST ELEMENTS

CLIENT TATA Projects Ltd. DOC REF. NO.: 033/D/001

STRUCTURAL CONSULTANT Possibuild Building Technologies REV 0

CONTRACTOR PSV Precast Pvt. Ltd. DATE: 07.03.2020

METHOD STATEMENT FOR PRODUCTION AND INSTALLATION OF PRECAST ELEMENTS

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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TABLE OF CONTENTS

1. Production of Wall panels

a. Assembly of mould
b. Mould cleaning and preparation
c. Fixing of Rebars/Cast-in-items
d. Final Inspection before casting
e. Concreting
f. Curing
g. Demoulding
h. Final Inspection and transfer to storage yard
2. Logistics

3. Handling

4. Storage

5. Installation

a. Setting out
b. Lifting and Installation
c. Grouting work
d. Joint casting and sealing
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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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1a. Assembly of mould:

• To check the level and flatness of the base mould before assembling the mould for panel
casting.
• Dimensions of the mould needs to be checked as per the drawings. Tolerances shall be
allowed within as specified by the code.
• Mould needs to be ensured as leak proof as this allows the chances of formation of honey
combs in the wall panels.
• Squareness of the mould forms to be checked.

Fig 1. Dimensional Check for moulds

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 2. Dimensional Check for moulds

1b. Mould cleaning and preparation:

• Mould should be made clean and free from debris and old mortars using remover or scaling
bars.
• Form oil or mould release agent should be applied evenly over the mould surfaces
• Check that the joints and edges of the mould, bolts, stoppers, tie rods, side props, Magnets
and rubber seal are intact and properly secured.
• Incase if any openings are present, the shutters or forms shall be ensured for proper angles
as per the drawing using proper bracing mechanism. 4
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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 3. Application of form release agent.

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Fig 4. Side braces of props.

1c. Fixing of Rebars/Cast-in-items:

• Check that the rebar size, spacing and lap length and location of precast inserts like corrugated
sleeve pipes, recess, lifting inserts as per the approved structural drawings.
• Ensure proper location of electrical and plumbing inserts if any present as per the production
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drawing.
 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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• Use of fabrication rig can help to ensure the accuracy of rebars fixing and spacing.
• Where needed, tack welding may be carried out to secure inserts.
• Sufficient number of spaces with the correct sizes should be properly placed and secured to
achieve the required concrete cover during casting

Fig 5. Checking of reinforcement and inserts as per fabrication drawing

Fig 6. Picture showing corrugated pipe sleeves and lifting inserts

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 7. Provision of recess

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 8. Picture showing electrical conduits (Inserts)

1d. Final Inspection before casting:

• Check and verify all the details as per drawings

• Check the mould fitting conditions including block out details
• The mould should be ensured free from dust, dirt, debri and any loose particles.

1e. Concreting:

• Check the specifications of the concrete like grade, slump etc., as per the fabrication drawings
before the concrete mix is placed in the mould.
• Ensure that the drop height of concrete shall not be more than 1m.
• Proper vibration and compaction should be carried out in particular, in more congested areas.
• Form vibrator can be used for slender and thin elements.
• Spreading and levelling of concrete surface level after initial set.
• Maintain the thickness required by use of screeder.
• Use of power trowel/ float is recommended for smoother finishes.
• Appropriate number of cubes may be collected for strength checking during the time of
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demoulding and 3 days, 14 and 28 days.

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 9. Picture showing the fixation of mould vibrator the wall palette

1f. Curing:

• Observe adequate curing time and desired environment. Curing compounds may also be
applied with reference to the details as approved by engineer – in – charge.
• Concrete cubes should be subjected to the same curing conditions as the precast concrete
elements.

1g. Demoulding:

• Depending on the anchor length of inserts and type of precast elements, minimum concrete
strength required may be higher to overcome the suction and frictional forces during
demoulding.
• Cube tests should be conducted to verify the concrete strength of elements before
demoulding.
• As a general guide, ensure that the concrete strengths attained for reinforced precast
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elements are 10 mPa.

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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• Loosen and remove all bolts and pins, side mould forms before lifting of wall panel.

1g. Final inspection and transfer to storage yard:

• Check the condition of the finished product. It shall be free from major defects likes honey
combs, cracks and breaking of edges etc.,
• Verification of critical dimensions to be made.
• Elements needs to be identified with markings and should be marked with the location,
member type, size, weight and orientation as per shop drawings.
• Check the elements have achieved 75% of their design concrete strength before delivery to
site for erection.

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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2. Logistics

Delivery of precast element should be planned according to the general erection sequence to minimise
unnecessary site storage and handling. Where possible, it is desirable to transport the precast
elements in to a manner which they can be lifted directly for erection or storage without much change
in orientation and sequence.

Precast elements should be loaded and delivered with proper supports, frames, cushioning and tie
downs to prevent in-transit damage. Adequate packing or protection to the edges of precast elements
should also be provided to minimise risk of damages during transit.

Normally “A” frames are used for transportation.

Fig 10. Picture showing transportation of wall panels

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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3. Handling

It mainly involves the removal of precast elements from the mould, transportation to the storage yard,
loading and unloading operation and erection of these elements at the job site.

Different sets of lifting points and cast-in-devices will have to be used for various handling stages.

Typically, 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 required. As these elements
have not gained their full designed strength, they are generally more susceptible to damage during
handling. It is therefore important to ensure 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 strongbacks should be provided for safe
handlings.

The handling requirements depends on the following factors:

• Position of the casting mould (ie., Vertical casting vs horizontal casting)

• Minimum concrete 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 element
• Number, size and location of lifting points and type of inserts/devices
• Method of lifting, type of lifting equipment and crane capacity
• Support points for storage and transportation
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Fig 11. Bracing of elements for wall panels with larger openings
 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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4. Storage

The storage area provided in the yard and job site should be adequate to permit easy access and
handling of the precast elements. The area should be relatively level, firm and well drained to avoid
any differential ground settlements which may damage the stored elements.

Appropriate stacking method be used to store the precast elements to prevent any undue stressed
and damages.

Precast wall and façade panels are usually stored in vertical position supporting their own weight using
racks with staibilising wall. Storage condition can be an important factor in 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 be stored based on the
erection sequence.

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 12. Stacking of wall panels in storage yard in self stabilised storage rack.

The storage area at the job site should preferably be close to the location where the precast elements
are to be installed to minimise the risk of damage by handling.

5. Installation

Proper planning and preparatory works are required before the actual erection of precast concrete
elements to ensure efficient and quality installation.

The following items should be carefully planned:

• Method and sequence of assembly and erection

• Method of providing temporary supports
• Provision for final structural connections and joint details
• Erection tolerances
• Handling and rigging requirements

Prior to installation the following points may be checked.

• Check for site accessibility for the delivery of precast elements

• Check delivery checklist for correct type, quantity and panel identification
• Check for adequate crane capacity and working clearance for hoisting of precast elements
• Conduct sample measurement to confirm on the accuracy of the critical dimensions of
precast concrete elements and openings
• Conduct visual inspection on concrete finishes and check for any major defects
• Check the location and conditions of lifting inserts before hoisting
• Check on the accessibility of unloading point and storage out
• Check 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

5a. Setting out

• Set reference line and offset line to determine the position of the precast elements to be
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installed. This may be checked for its accuracy.

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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• Provide level pads or shim plates for setting the level of the elements. Set the level pads in
position using non-shrink mortar.
• For precast external walls, fix the compressible foam or backer rod on the outer perimeters
of wall.
• Before installation of the panel, the shim plate level and stability may be checked.
• For vertical precast component, check the positions and alignment for the starter bars before
hoisting for installation.

5b. Lifting and installation

• Check the hoisting condition of the precast elements

• Lift and rig the panel to its designated location with the use of wire ropes or belts.
• Adjust the panel to position and secure it with diagonal props.
• Stability of erected props be checked before releasing the hoisting cable.
• Check alignment and verticality of the panel. If necessary, adjust the temporary propping to
achieve the level and position of the precast elements.

Fig 13. Picture showing shim pads

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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 14. Checking of alignment of walls

5c. Grouting

• Prepare and apply non-shrink mortar to sear the gaps along the bottom edged of the inner
side of the panel.
• Check the joint width between panels are within design allowances before grouting.
• Non-shrink grout used at the interface with the precast elements should preferably be free
flowing and self compacting in nature so as to ensure good compaction at the joint and to
minimise the risk of cracking.
• Check that all the horizontal joints are properly sealed.
• For corrugated pipe sleeve or splice sleeve connection, prepare and pour non-shrink grout or
proprietary grout in to the pipe inlets provided.
• Non-shrink grout should be prepared in accordance with the specification.
• Keep the installed panels undisturbed for atleast 24 hours.
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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 15. Grout packing at the bottom of the wall

5d. Joint casting and sealing

• For panels with cast-in-situ joints, install the joint rebars as required. Joint rebars should be
correctly placed in accordance with the design specifications.
• Set up forms for the casting of vertical joint. It should be secured properly against plumb outs
and blug outs.
• Carry out concreting casting
• Remove forms after sufficient concrete strength has been achieved.
• For joints between façade walls or between external columns with beams or walls elements,
approved sealant and grout will be installed at later stage.
• The joint gaps should be consistent to allow for proper installation of sealant or grout for
better watertightness.
• For panel with welded connection, place the connecting plate between the panels and carry
out welding as per design requirement.
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 POSSIBUILD BUILDING TECHNOLOGIES
Plot No.135, Mythri Nagar – Phase -1, Madinaguda,
Miyapur, Hyderabad – 500045
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Fig 16. Supports to Form work for jointing

Fig 17. Picture showing backer rod and caulking

Prepared by
Pavan Patchigolla, MTech, AMIE,
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Sr. Structural Engineer,

PossiBuild Building Technologies, Hyderabad.
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