WORK METHOD STATAMENT Document Number

Process/Discipline: PCM Revision: 0 Date:10/06/2024

Originator: AM Document: PLN Status: OFFICL Page 1 of 8

CONSTRUCTION PROCEDURE
FOR
PRECAST DRAIN ELEMENTS (PRODUCTION, HANDLING, TRANSPORTATION AND
ERECTION)

This document is the property of Kinetic Electromechanic Nig Ltd and shall not be disclosed to a third party or reproduced without the
written permission of the owner

0 10/06/2024 OFFICL Issued for Official use AM CS SM

Rev Rev. Date Status Revision Description Issued Checked Approved

XXX- XXX-KEM-PCM-PLN-01 Rev METHOD STATEMENT FOR PRECAST DRANE ELELMENTS MANUFACTURING, ERECTION
 WORK METHOD STATAMENT Document Number

Process/Discipline: PCM Revision: 0 Date: 10/06/2024

Originator: AM Document: PLN Status: OFFICL Page 2 of 8

Table of Contents

1 SCOPE................................................................................................................................3

2 OBJECTIVE......................................................................................................................3

3 REFERENCE DOCUMENTS.........................................................................................3

3.1 For Precast Concrete Manufacturing:................................................................................................. 3

3.2 For Precast Concrete Installation:...................................................................................................... 3

4 TOOLS AND EQUIPMENT............................................................................................3

5 METHODOLOGY............................................................................................................4

5.1 manufacturing in the precast yard:.................................................................................................... 4

5.2 Storage and Stacking:........................................................................................................................ 5

5.3 Transportation to the Installation Site................................................................................................ 5

5.3.1 Handling and transporting include:................................................................................................ 5

5.3.2 Key Hazards When Transporting Precast Concrete:.........................................................................6

5.3.3 Loading And Unloading:................................................................................................................. 6

5.3.4 Transporting.................................................................................................................................. 6

5.3.5 Unloading at the Installation Site:.................................................................................................. 7

5.3.6 Post-Transportation Inspection:..................................................................................................... 7

5.4 Installation Procedure........................................................................................................................ 7

5.4.1 Preparation of the Installation Site:................................................................................................ 7

5.4.2 Lifting............................................................................................................................................ 8

5.4.3 Placement of Precast Segments:..................................................................................................... 8

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Process/Discipline: PCM Revision: 0 Date: 10/06/2024

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1 SCOPE
The scope of work which will be covered by this procedure is:
 Production of the per casted elements for concrete drain with the sizes of:
 1.5mx1.5mx2.4m (836 no’s).
 1mx1mx2.4m (1083 no’s).
 The handling, stocking and storing.
 The transporting from the pre casting yard to the erection site.
 The erection procedure.
2 OBJECTIVE
The objective is to ensure that all the activities are carried out:
 In accordance with approved procedures, specifications and drawings,
 to give practical guidance for the handling, transportation and erection of precast
concrete elements. It covers the steps from manufacture through to final placement.
 Using special working and control process which have been previously qualified;
 Employing qualified and, when required, certified personnel;
 Performing all tests, measurements and inspection required by Contract responsibility.
3 REFERENCE DOCUMENTS
3.1 For Precast Concrete Manufacturing:
 ASTM International Standards:
 ASTM A36: Specification for Carbon Structural Steel1.
 ASTM A615: Specification for Deformed and Plain Billet-Steel Bars for Concrete
Reinforcement1.
 ASTM C33: Standard Specification for Concrete Aggregates1.
 ASTM C94: Specification for Ready-Mixed Concrete1.
 ASTM C150: Specification for Portland Cement1.
 ASTM C478: Specification for Precast Reinforced Concrete Manhole Sections1
3.2 For Precast Concrete Installation:
 American Concrete Institute (ACI) Codes:
 ACI 318: Building Code Requirements for Structural Concrete2.
 ACI 332: Code Requirements for Residential Concrete2.
 ACI 350: Code Requirements for Environmental Engineering Concrete Structures2.
 American Association of State Highway and Transportation Officials (AASHTO):
 AASHTO Standard Specifications for Highway Bridges3.
 National Precast Concrete Association (NPCA):
 NPCA Quality Control Manual for Precast Concrete Plants
4 TOOLS AND EQUIPMENT
 Batching plant.
 Transit mixers.
 Site Mixer.
 Excavators.
 JCB Backhoe.
 Tipper trucks.
 Lowbed/flat pad trailer trucks
 Mobile Crane’s (50 to 80) ton capacity.
 Frock lift (5 tons capacity).

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 Surveyor total station

 Cutting / heating torch set.
 Chain blocks with different capacities.
 Carpentry formwork and mold tools.
 Iron bending tools
 Masonry and concrete finishing tools.
5 METHODOLOGY
5.1 manufacturing in the precast yard:
the manufacturing of precast concrete drain segments is a meticulous process that requires
precision and adherence to quality standards. Here’s a detailed breakdown of the manufacturing
steps:
 The Design and Mold Fabrication:
 Begin with precise engineering drawings and specifications for the drain segments.
Fabricate the steel/wood molds to match the design dimensions, incorporating
allowances for shrinkage and expansion1
 Concrete Mix Design:
 The concrete mix must achieve the necessary strength, durability, and workability.
 use of admixtures to enhance the concrete properties as required.
 Casting:
 Prepare the molds by applying release agents to facilitate easy demolding.
 Pour the concrete into the molds, ensuring even distribution and absence of air
pockets.
 Vibrate the concrete to achieve compaction and homogeneity
 Curing:
 Allow the concrete to cure in a controlled environment to attain the desired strength.
 Use steam curing or water curing as per the project requirements
 Demolding:
 Carefully remove the segments from the molds to prevent any damage
 Inspect the segments for any defects or imperfections
 Quality Control:
 Conduct strength tests such as compression tests to ensure the segments meet the
design requirements.
 Check for dimensional accuracy and surface finish.
 Storage and Curing:
 Store the segments in a designated area where they can undergo further curing if
necessary.
 Protect the segments from extreme weather conditions to prevent cracking
 Finishing:
 Apply any required surface treatments such as waterproofing coatings or sealants.
 Install lifting anchors and other embedded items before the concrete fully cures.
 Marking and Identification:
 Mark each segment with a unique identifier for traceability and installation
reference.
 Record the production details for quality assurance and project documentation.

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5.2 Storage and Stacking:

This section is about requirements for stacking and storing precast elements in the place of
manufacture and on the construction site.
 Precast elements should only be stacked and stored in the way the designer/client of
that particular element intended.
 Precast elements can become unusable through poor storage.
 Incorrect storage or support at the wrong points can cause damage that may not be
immediately obvious.
 Elements stacked on the ground must be supported at appropriate locations.
Prestressed elements in particular can be damaged if supported at inappropriate
locations.
 Precast elements must be stored in a manner to retain their correct shape. If they are
out of shape while stored, even for short periods, concrete creep can cause
permanent distortion. Even minor misalignment can make them unusable.
 Incorrect stacking can cause long term creep which is difficult to reverse. The younger
the age that precast elements twist, deflect or deform while incorrectly stored, the
greater the permanent creep deformation.
 Elements must not be stacked to a height that can result in instability, particularly if
uneven settlement could cause the stack to lean.
 Time in storage can increase cambers of eccentrically prestressed elements to
unacceptable levels.
 Differences in exposure during storage will cause differences to the shape of elements
and to their appearance. This can affect the outside panel in a stack against a frame,
and the top element when they are stacked on top of each other.
 Precast elements should be separated by suitable dunnage.
 Dunnage used to separate elements during storage can cause permanent or
temporary staining or discoloration.
 Normally elements in a stack should have all dunnage aligned vertically so that the
weight of all elements in the stack is transferred directly through the dunnage to the
ground, and no element is loaded by elements stacked above it.
 The dunnage below the bottom element should be capable of spreading the load to
the ground or whatever surface it is bearing on without overloading it or causing
undue settlement or deflection.
5.3 Transportation to the Installation Site
This section is about plant and equipment needed when handling and transporting precast
elements from the casting area to the construction site,
5.3.1 Handling and transporting include:
 lifting from the casting bed and moving to storage.
 moving from temporary storage to be loaded for transportation.
 loading onto means of transportation.
 moving from temporary site storage to final location (Installation location.)
5.3.2 Key Hazards When Transporting Precast Concrete:
 Hazards when transporting precast concrete elements include:
 poor maintenance of A-frames.
 bad storage of frames.
 poor design specifications.

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 overloading.
 poor use of ladders to access the load.
 falls from A-frames.
 crushing.
 non-compliant lifting systems.
 Control these hazards through:
 maintenance programs for equipment and frames.
 good planning.
 hazard assessment before starting a task.

5.3.3 Loading And Unloading:

 Pre-loading Inspection:
Conduct a thorough inspection of the precast elements to ensure they are free from
damage and defects.
 Verify that all lifting and handling inserts are securely in place.
 Loading at the Precast Yard:
 Use appropriate lifting equipment such as cranes or forklifts with the capacity to
handle the weight of the precast elements.
 Attach the lifting equipment to the embedded lifting anchors in the precast elements.
 Ensure the elements are properly supported and balanced during lifting to prevent
stress and cracking.
 Each concrete element should be individually restrained from the sides and ends to
prevent movement in any direction.
 Each concrete element should be individually secured as the unloading sequence can
lead to instability of loads.
 Concrete elements should be loaded in a sequence compatible with the required
unloading sequence at their destination.
 Concrete elements should be loaded so that identification marks are visible for
unloading.
5.3.4 Transporting
 Securing for Transport:
 Load the precast elements onto the transport vehicle (flat pad trailer), which should
be equipped with a flatbed and adequate tie-down points
 Secure the elements using straps, chains, or other approved tie-down methods to
prevent movement during transit.
 Use padding or edge protectors to prevent damage to the elements from tie-down
equipment.
 Transportation Route Planning:
 Plan the transportation route carefully, considering factors such as road conditions,
clearance heights, and weight restrictions.
 Obtain necessary permits for oversized or heavy loads, if required.
 Coordinate with local authorities for any traffic management that may be needed
along the route.
 Transportation to the Site:
 Transport the precast elements using a heavy haul trucking service with experience in
handling oversized loads.

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 Ensure the driver is aware of the handling requirements and the planned route.
 Monitor the transportation process to respond quickly to any issues that may arise
during transit.
5.3.5 Unloading at the Installation Site:
 Prepare the installation site for unloading, ensuring there is adequate space and the
ground is stable.
 Use the same lifting equipment as in the precast yard to unload the elements.
 Position the elements close to the installation area to minimize handling and
movement on site.
5.3.6 Post-Transportation Inspection:
 Inspect the precast elements upon arrival at the installation site for any damage that
may have occurred during transportation.
 Document the condition of the elements and report any issues to the project
manager.
5.4 Installation Procedure
This section is about specific requirements for installation and placing precast elements,
handling and erecting precast elements is potentially hazardous, all parties involved have a
responsibility to ensure the work is carried out safely.
Personnel involved with handling and erecting should be adequately trained and supervised.
Personnel not directly involved should be excluded from any area where they might be at risk
if an element fell or a support failed.
5.4.1 Preparation of the Installation Site:
 Excavate the trench to the specified dimensions, ensuring that the sides are stable and
the base is level.
 Crane & rigging:
 Suitable ground conditions for transporters, cranes, crane outriggers or other
equipment.
 Adequate concrete strengths for loads that may be applied by transporters, cranes or
other equipment.
 Clearance for lifting and manoeuvring precast elements.
 Clearance for crane outriggers and counterweights.
 Clearance between all crane operations and any braces, props or components that
will be in place to avoid accidental damage.
 It is desirable for the crane operator to be able to retain visual contact with the loads
throughout the erection process.
 Clearance of power lines and other services.
 Clearance from public spaces.
 the rigging arrangements for which inserts have been provided in the elements –
confirm that suitable rigging systems are available (this is particularly important
where load equalisation is required or elements require turning while suspended).
 the rigging arrangement results in suitable sling angles that don’t increase loads
above the safe capacity of any insert, sling or part of the system – in some cases
spreader bars or longer slings may be required.

 Setting the Foundation:

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 Lay a bedding of compacted granular material or lean concrete to create a stable

foundation for the precast segments.
 Ensure the bedding is level and at the correct grade to facilitate proper drainage.
5.4.2 Lifting
Lifting operations must be under control of a competent person.
 Lifting inserts:
Prior to lifting an element, ensure the drop zone is clear.
Check lifting inserts are not damaged and lifting clutches or other attachments are
not damaged and are able to connect properly.
 Missing Or Unusable Lifting Inserts:
If any inserts are in the wrong place, faulty, missing or cannot be used, the element must not
be lifted until a competent person has designed a suitable and safe solution. Solutions may
involve:
 Attaching a plate with undercut anchors.
 Attaching a plate with expansion anchors
 Attaching a plate with chemical anchors. Chemical anchors can only be used for lifting
after each one has been individually proof tested.
 Drilling through the element and bolting on a lifting plate.
5.4.3 Placement of Precast Segments:
 Laying and alignment of the drain elements:
 Use a crane or excavator with the appropriate lifting capacity to lower the precast
segments into place.
 Position each segment carefully, checking for alignment and levelness with the
adjacent segments.
 Jointing and Sealing:
Apply a suitable joint sealant to the mating surfaces of the segments to ensure a
watertight seal.
 Connect the segments together, using mechanical connectors if specified in the
design.
 Backfilling and Compaction:
 Backfill the trench around the precast segments with suitable material, such as sand
or gravel.
 Compact the backfill in layers to provide lateral support to the segments and prevent
settlement.
 Finishing Touches:
Install any additional components such as grates, frames, or access covers as per the
project specifications.
 Clean the area and remove any installation equipment or materials.
 Quality Assurance and Testing:
Conduct visual inspections to ensure the segments are installed as per the design
requirements.
 Perform water testing to verify the integrity of the joints and the overall functionality
of the drainage system.
 Documentation and Handover:

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 Document the installation process, including any deviations from the original plan
and measures taken to address them.
 Hand over the completed drainage system to the client or project manager, along
with all relevant documentation.

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