Escolar Documentos
Profissional Documentos
Cultura Documentos
Licenses
Certificates
Quality Policy
Quality Assurance Plan
HSE Policy
Organization Chart
Method Statement
Technical Details
List of Projects
Projects Gallery
Photos of the Factory
Location Map
Company Profile
Exeed
d Precasst L.L.C
Vision
n:
The Prrecast parttner of chooice for acchieving thhe Abu Dhhabi Visio
on
Missioon:
Consisstently deeliver outtstanding shareholdder return
ns by prooviding suuperior
produccts and sollutions to customerss
Values:
Integriity & Respect, Com
mmitment & Couragge Empow
werment & Collabooration,
Discippline in Performancee
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Comp
pany Prod
ducts:
1) Precast Concrete
C
E
Elements
:
Few bbuilding materials
m
available today offer
o
the economy,, flexibiliity and
reliability of Preecast Conccrete.
c
ts have proven theemselves iin lowBoth aarchitecturral and sttructural componen
rise annd high-risse buildingg of all kiinds, as well
w as scho
ools, multtistory carr parks,
villas, boundaryy walls andd other struuctures.
Castinng concrette in a facctory allow
ws manuffacturer too exercisee precise control
over alll availablle that affeect its duraability, strrength and
d appearannce.
Exeed Precast produces
p
precast elements under
u
stricct Quality
y Assurannce and
Qualityy Control complyinng with thee Internatiional Standard for Quality.
Q
The caarefully qu
uality conttrolled con
nditions under
u
whicch the con
ncrete is moulded
m
and caast ensuress that the dense preecast conccrete comp
ponents will
w have smooth
s
surfacees that ressist moistuure penetraation, funggus and coorrosion.
Fast cconstructio
on meanss earlier completioon.
Thiss, in turn
n, means earlier
occupaancy or use
u of thee premisess, and redduces the high cosst of both onsite
labourr and interiim financiing.
The addvance an
nd automaated factoory producction methhods havee also perrmitted
Exeed Precast too vastly exxpand the design fleexibility possible wiith precastt.
Variatiion of san
nds, cemennt, aggregates, and tthe use off chemicall and mechhanical
treatm
ments, willl result inn striking rich andd varied difference
d
s in coloour and
texturee. Stone, tile or other
o
masoonry mateerials can also be cast
c
into Precast
P
Panelss while stilll at the faactory, enaabling dessigner to achieve
a
thee look of a much
more eexpensive material at
a a fractioon of cost..
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
3) Filigree Slabs:
S
Exeed filigree sllab (also called
c
plan
nks) is a reeinforced semi preccast concreete slab
m thicknesss of 56 cm with a single steel
s
reinfforced meesh and
with a minimum
lattice girder too give sttiffness once
o
instaalled. Deppending on
o the cooncrete
coverinng and reiinforcemeent, it can be
b up to 7 cm thick.
The slab is madde into a solid and monolithic
m
c reinforceed concrette floor byy using
cast-inn-situ concrete thatt is poureed at the constructtion site. The addittion of
insulattion layer for better thermal and
a sound results is possible. The thickkness of
the finnished flooor slab is between
b
1 and 30 cm, depending on the span and
12
a the
loadingg. The prrotruding truss reiinforcemennt and thhe concrette surfacee itself
providde the requuired anchhoring, ennsuring goood bondiing and addhesion between
the finnished partt and the cast-in-situ
c
u concretee.
Exeed
d Precasst L.L.C
It
is
economical,
fastt,
qualitty
superrior
and
d
time
saver.
F
m
method
is a processs for constructionn of conccrete deckks that
The Filigree
successsfully inteegrates "faactory precast" and field-consstruction technologi
t
ies.
Exeed filigree sllabs can be
b used as floor slabbs as well as a shutttering systtem for
m.
cast-inn-situ slabss with the use of poost-tensionning system
There are no lim
mitations in
i the use of Exeed filigree slab system
m. It can be
b used
in any constructtion projecct under anny conditiions.
4) Double Wall:
W
The ddouble waall system
m consists of two skins
s
of concrete
c
s
separated
by an
insulatted void. A typicaal 21 cm thick waall panel consists of
o two skkins of
reinforrced concrrete (eachh skin is 7 cm thickk). The tw
wo skins are
a held toogether
with stteel trussees. The walls
w
are produced
p
w smoo
with
oth surfaces on bothh sides
becausse of the unique manufactur
m
ring proceess which form finiishes bothh sides.
The walls
w
are simply paiinted or sttained on the exterior surfacce to achieeve the
desiredd color orr texturedd surface. When deesired, thee exteriorr surface can be
manuffactured too have a wide
w
variety of brickk, stone, wood
w
or other
o
form
med and
patternned appearrances.
The innsulated void in tthe doublle wall can
c
be aiir, insulattion layerr or a
combinnation off both airr and insuulation laayer for better
b
therrmal and sound
insulattion resultts. Windoow and door openiings are cast
c
into the walls at the
manuffacturing plant as part off the fabbrication process. Electricaal and
telecom
mmunicattions condduit and boxes
b
are flush mouunted andd cast direectly in
Exeed
d Precasst L.L.C
Licenses
Certificates
4-:-1
ADNOC
........... ,Ju, ...,.
l -;'
(Project N~84) ,
-r
7
Quality Policy
d Precasst L.L.C
Exeed
Assuraance Pla
Q
Quality
an
ntents:
Tablee of Con
1. Company Profile
1.1 Scope
1.2 Exclusiions
nsibility
3. Managemeent Respon
3.1
3.2
3.3
3.4
Managgement Com
mmitment
Custom
mer Focus
Quality
y Policy
Plannin
ng
3.4.1 Quality Objjectives
S
Planning
3.4.2 Quality Maanagement System
nsibility, Authority and Communication
3.5 Respon
3.5.1 Responsibillity and Autthority
3.5.2 Managemen
nt Represen
ntative
3.5.3 Internal Coommunicatioon
3.6 Managgement Review
3.6.1 General
3.6.2 Review Input
3.6.3 Review Outtput
3.6.4 Production Managemeent
3.6.5 Safety Man
nagement
M
nt
4. Resource Manageme
4.1 Provisiion of Resou
urces
4.2 Human
n Resource
4.2.1 General
ning
4.2.2 Competence, Awarenesss and Train
4.3 Infrastructure
4.4 Work Environmen
E
nt
5. Product Realization
5.1 Plannin
ng for Produ
uct Realizattion
5.2 Custom
mer Related Process
5.2.1 Determinattion of Requ
uirements Reelated to thee Process
R
ts Related too the Processs
5.2.2 Review of Requiremen
d Precasst L.L.C
Exeed
5.2.3 Customer Communicat
C
tion
5.3 Design and Develoopment
5.3.1 Design and Development Planningg
5.3.2 Design Inpu
uts
5.3.3 Design Outp
puts
5.3.4 Design Reviiew
5.3.5 Design Veriification
5.3.6 Design Valiidation
5.3.7 Control of Design
D
Chan
nges
5.3.8 Materials Submittals
S
5.3.9 Document Submittals
S
5.4 Purcha
ase
5.4.1 Purchasing Process
5.4.2 Purchasing Information
5.4.3 Verification
n of Purchassed Productts
5.5 Producction and Seervice Provission
and Servicee Provision
5.5.1 Control of Production
P
6. Measurem
ment Analyssis and Imp
provement
6.1 Generaal
6.2 Monito
oring and Measurement
M
t
6.2.1 Customer Satisfaction
S
6.2.2 Internal Au
udit
6.2.3 Monitoringg and Measu
urement of Process
P
6.2.4 Monitoringg and Measu
urement of Products
P
6.3 Controol of Non-Coonforming Products
P
6.4 Analysis of Data
vement
6.5 Improv
6.5.1 Continual Improvemen
I
nt
6.5.2 Corrective Action
A
and Preventive Action
A
7. Attachmen
nts
Processs Flow Charrts
d Precasst L.L.C
Exeed
1. Coompany Profile
P
o fulfill thhe demannd of a verity
v
of quality
Exeed Precast was estabblished to
g
hass added
industrrial produucts. To ennhance thee construcction induustry, the group
the preecast divission, whicch is set to
o become one of th
he biggest precast cooncrete
producction facilities in thee world with
w the moost advancced techno
ologies.
Exeed Precast recognizees its resp
ponsibilityy as a provider off quality precast
p
concreete produccts.
To thhis end, Exeed Precast
P
haas develooped andd documeented a quality
managgement syystem. Thhe qualityy system
m compliees with the internnational
standaard BS EN
N ISO90011:2000, Quality maanagementt systems Requireements.
This m
manual proovides com
mprehensiive evidennce to all customerrs, supplieers, and
employyees of what
w
speccific contrrols are im
mplementted to enssure the precast
p
concreete producct quality.
This manual
m
alsso governs the creaation of quuality relaated docum
ments. It w
will be
revisedd, as necessary, to reflect
r
thee quality syystem currrently in use.
u This will be
issued on a conttrolled coppy basis too all internnal functio
ons affecteed by the quality
system
m, and on an
a uncontrrolled cop
py basis too customerrs and suppliers.
1.1 Scope
The sccope of thiis system is:
i
1. Salles or tenddering for precast
p
cooncrete eleements,
2. Dessign and developme
d
ent fop reccast concrete elemennts,
3. Prooduction or
o manufaccturing of precast co
oncrete eleements,
4. Dellivery of precast
p
conncrete elem
ments andd
5. Ereection of precast
p
conncrete com
mponents.
6. Saffety
d Precasst L.L.C
Exeed
1.2 Exclusion
ns
The fi
financial and
a
admiinistration managem
ment is working
w
a a suppporting
as
functioon to the quality managemen
m
nt system, and also it is workking as a part of
the grooup manag
gement. Hence
H
it is excluded from this proceduree.
2. Qu
uality Maanagemen
nt System
2.1 General
The quuality systtems are established
e
d at Exeedd Precast to ensure that its prroducts
complyy with thee specifiedd requirem
ments. Theese system
ms are doccumented in this
qualityy assurancce manual..
Exeed Precast seenior mannagement, and their entire orgganization
n is committed to
develooping, impplementingg a qualityy manageement systtem that ensures
e
cuustomer
satisfaaction.
The toop manageement:
Ensures the
t
availaability off resources and infformation to suppoort the
operation and moniitoring of these proccesses,
2.2 Documen
ntation Reequiremeent
2.2.1 Gen
neral
Exeed quality managemen
m
nt system is documeented by:
d Precasst L.L.C
Exeed
Quality managemen
m
nt manuall
Records required
r
ennsuring th
he effective planningg, operatioon and conntrol of
processes.
2.2.2 Quaality Man
nual
m
is established
e
d to assistt the quallity managgement
A documented quality manual
m, which explains
e
thhe scope of
o the quallity managgement sy
ystem, exclusions
system
with juustificationns, referennces to thhe documeented proccedures established for the
qualityy managem
ment systeem and thee detailed descriptioon of interractions between
the proocesses off the qualitty manageement systtem.
2.2.3 Con
ntrol of Documentss
ments and
d data conntrol proccedures arre implem
mented to ensure thhat the
Docum
processses and prrocedures are perforrmed withh current in
nstruction
ns and dataa.
These documentted proceddures defin
ne the metthods usedd to:
Review, update
u
annd approvve documeents as neecessary for
f adequacy by
authorizess personneel.
ment of doocuments of
o externaal origin, such
s
as
Control thhe use andd amendm
international standaards and cuustomer drawings.
d
t currennt revision
n status off documennts to preclude the use of
Identify the
obsolete documents
d
s. Obsolette documeents that arre retained
d for legal and/or
future refe
ference purrpose are suitably iddentified.
d Precasst L.L.C
Exeed
Controol of docu
uments annd data related to thhe quality
y system is grouped in to
two:
System do
ocuments and
a
a. S
b. Project
P
documents
Proceddures for each
e
groupp are setup
p separateely. The Quality
Q
Con
ntrol Engiineer is
responnsible for the conttrol of thhe qualityy system documennt. The projects
p
docum
ments, duriing the exxecution of the projeects at diffferent stagges, will be
b kept
by eacch departm
ment and on complletion of the
t projecct the releevant docuuments
will be
b transferred to the
t
projecct file in the centtral archivve. The Project
Coordiinator is reesponsiblee for the control
c
of project
p
doocuments.
22.2.4 Conttrol of Reecords
Recordds are maiintained thhat providde evidencce of confo
ormity to the
t requirrements
and thhe effectivve operatioon of the quality managemen
m
nt system
m. Proceduures are
establiished to ensure records
r
arre legiblee, identifi
fiable, rettrievable, stored
approppriately, reetained foor appropriate time and dispo
osed off when
w
approopriate.
Wheree records are
a storedd as soft co
opies, thee integrity of the software sysstem is
approppriately asssured.
d Precasst L.L.C
Exeed
approppriately adddressed. The qualiity policy is undersstood and implemented at
all levvels of thee organizaation, quaality objecctives, andd plans arre establisshed as
necesssary, and that the responsib
r
ilities of all functiions affeccting quallity are
clearlyy defined. Senior M
Management will revview the system whenever
w
d
deemed
necesssary to determine
d
i meetinng the
its effeectiveness and effficiency in
objectiives. The Senior Managemen
nt will alsoo make prrovisions for
f the neccessary
resourcces and personnell to main
ntain the system, including a managgement
represeentative, who
w will ensure thhat the reqquirementss of this manual
m
arre met.
The SeniorMan
nagement is also coommitted to do an effective communnication
with cuustomer and
a within the comppany to fullfill the obbjectives.
3.2 Customer Focus
The quality
q
managemen
m
nt system
m is impplemented to meeet the cuustomer
requireements an
nd expectaations. On receipt off a job enqquiry, the sales depaartment
collectts all thee possiblle inform
mation froom the customer
c
regardingg their
expecttations andd requirem
ments andd describes it as a product
p
reequiremennt. This
will bee explained in detaill in relevaant proceduures.
3.3 Quality Policy
P
It is thhe policy and overrall busineess objecttive of Exxeed Precast to proovide a
producct and serrvice to thhe highestt quality and
a in com
mpliance with
w the clients
c
specifiied requireements.
It is also the objectivee of Exeed Precasst to enhhance its reputatioon and
capabiilities in orrder to gaiin wider recognitionn in its fieeld of expeertise.
The coompany reecognizes that genuine comm
mitment to understannding the present
p
and fuuture needss of its clients is esssential to the
t achiev
vement of these objeectives,
and thuus continu
ually strives to ensu
ure that thee needs annd reasonaable expecctations
of the clients aree realized in the quaality of thee product and
a servicce it providdes.
d Precasst L.L.C
Exeed
The quuality man
nagement system iss describeed in the quality
q
asssurance manual,
m
and deetailed in a quality procedurees manual. To furthher the quaality aimss of the
compaany we havve ensuredd that all employees
e
s fully undderstand and
a adheree to the
requireements off this policcy and the contents of
o the quaality assuraance manuual.
This quality
q
mannual and subsequen
s
nt proceduure manuaal are publlished as a direct
responnse to the requireme
r
ents defineed by BS EN
E ISO 90001: 20000.
The ccompany will connstantly monitor
m
its quality
y perform
mance annd will
implem
ment imprrovements where apppropriate..
3.4 Planning
g
3.4.1 Qu
uality Objectives
The m
managemen
nt of Exeeed Precaast establishes annuual key in
nitiatives, which
include quality objectivess. The objjectives are establisshed via the
t Managgement
Review
w Proceduure and coommunicatted to all levels
l
of the organizzation, forr use in
establiishing eacch functioon's and employeee's annuall key objectives. Quality
Q
objectiives are measurabl
m
le, includee businesss perform
mance indicators refflecting
requireements foor productts/servicess, and are consistennt with th
he quality policy
includiing the coommitmennt to continnuous impprovementt.
It is thhe respon
nsibility off the depaartment managers
m
t analyzee the objeectives,
to
providde necessaary resourrces needeed to fulfiill the objjectives annd commuunicate
the objjectives too concerneed people.
3.4.2 Qu
uality Man
nagementt System Planning
P
mented methods
m
arre implem
mented thaat controll how bussiness plaans are
Docum
review
wed, reviseed, updated, and com
mmunicateed throughhout the organizatio
o
on.
The m
managemennt of EXE
EED PREC
CAST ensuures that all
a the reso
ources neeeded to
achievve the quallity objecttives are iddentified and
a planneed. All quality planss are
d Precasst L.L.C
Exeed
docum
mented, inncluding the
t requirred resourrces; the processess of the quality
system
m, permissible excluusions; conntinuous im
mprovemeent of the quality syystem.
The geeneral mannager, mannagementt representtative, and
d the deparrtment maanagers
are ressponsible for qualiity manag
gement syystem plannning andd setting up the
qualityy objectivees.
By esttablishingg the quallity policyy, qualityy objectivees, qualityy manual, work
instrucctions, opeerational procedure
p
s, and proocesses mapping
m
the quality system
planninng is carrried out. Q
Quality obbjectives are
a set to enhance the
t efficieency of
the quaality manaagement system thaat leads to the impro
ovement prrocess.
The Senior Mannagement, based onn the releevant mannagement review annalysis,
identiffied the following obbjectives.
nts shall be
In settiing up theese objectiives, the foollowing requireme
r
b consideered:
Ressponsible function/ddepartmennt
Tim
me frame
Available ressource
and meassuring
Meethod of monitoring
m
Meethod of reeporting
Meethod of coommunicaation
Revview
d Precasst L.L.C
Exeed
Qualityy Control Engineerr will mak
ke sure thaat proper methods are
a implem
mented
and suufficient reesources arre allocateed to achieeve the quuality objeectives.
The efffectivenesss of impllementatioon of thesee quality objectives
o
s and the level
l
of
achievvement willl be revieewed in the managem
ment revieew meetin
ngs.
Once the objecctives are achievedd it may be
b re-set for new targets, or
o new
objectiives from a differennt area thaat shall bee set for continual improvem
i
ment. At
the sam
me time obbjectives once
o
achieeved will be
b maintaained.
uthority and
a Comm
municatioon
3.5 Responsiibility, Au
3.5.1 Ressponsibiliity and Authority
Managgement ennsures thaat the em
mployees understand
u
d their reesponsibiliity and
authorrity.
nt Represeentative
3.5.2 Maanagemen
e
In ordder to enssure the effective
implemenntation off the quality managgement
system
m the Seniior Managgement haas appointted a man
nagement representa
r
ative to
executte the activ
vities relatted to the system. His
H responsibilities are
a as folloows:
To com
mmunicatee to all the
t personnel regaarding thee importaance of
meetingg the custoomer requ
uirements
d Precasst L.L.C
Exeed
3.5.3 Intternal Com
mmunicaation
nternal coommunicaation systtem is esstablished
d by the senior
An efffective in
managgement within
w
the organizaation for the effectiveness of the quality
managgement sysstem.
3.6 Managem
ment Reviiew
3.6.1 General
Once in
i every six
s monthss a managgement revview meetting will be
b held too assess
the efffectivenesss, adequaccy, suitabiility, and opportunit
o
ties of impprovementt of the
qualityy system inncluding the
t qualityy policy annd objectives.
3.6.2 Revview Inpu
ut
nagementt review shhall includde the folloowing:
The innput to man
Follow
w-up actions from thhe manageement reviiew
Producct conform
mity/nonco
onformity analysis
Processses perforrmance an
nalysis
Recom
mmendatioons for thee continual improvement
The decisions,
d
actions taken
t
to improve the effecctiveness of the
quality
y managem
ment systeem, and itss processees
d Precasst L.L.C
Exeed
The suummary of the discuussions annd decisions taken during
d
thee meeting will be
recordded as minnutes of the
t managgement reeview meeeting by the
t managgement
represeentative.
3.6.4 Pro
oduction Managem
M
ment
Castinng of the prrecast com
mponents as per the design suubmitted.
Perform
m the in-hhouse quallity controol testing, and inspection.
Co-orddinate witth designn, projectss and ereection deppartments with reggard to
castingg schedulee, cast-in-pparts, and any otherr special reequiremennts.
3.6.5 Saffety Manaagement
Ensuree all the safety aspects thatt require at site during
d
erection of precast
p
compoonents Co-ordinatioon with coontractorss Safety Manager
M
or
o represeentative
at site..
4.
Resourcee Management
4.11 Provisiion of Ressources
d Precasst L.L.C
Exeed
of thee organizaation to minimize errors, ccontinuouus drive improvem
i
ment to
optimiize custom
mer and employee
e
satisfactiion, and maintain a safe working
w
environment.
4.2.2 Competencee, Awaren
ness and T
Training
The coompetencyy and the skills of personnell are assesssed, priorr to assignning of
work tto all perssonnel perrforming work affeecting prooduct quallity, and identify
their ttraining reequiremennts. Thesee training requirem
ments are consolidaated as
traininng is imparrted to thee employees throughh the follo
owing:
Recomm
mendationns given by
b the headd of deparrtments
By peerformancee improv
vement as
a assesseed throug
gh perforrmance
appraissal
d Precasst L.L.C
Exeed
nvironmen
nt
4.4 Work En
The Senior Mannagement has prov
vided suitaable workk environm
ment, suppporting
m
product
p
coonformity.. Staffs aree given addequate
facilitiies to achiieve, and maintain
workinng space, lighting, and perssonnel protective equipment
e
t as required to
perform
m their tassks.
n
5. Product Realization
g for Prod
duct Realiization
5.1 Planning
Exeed Precast have
h
establlished witth recordeed documeented proccedures to ensure
that thhe sequencce of proceesses is coonducted iin a controlled mannner. Plannning of
the reealization processees is consistent with othher requirrements oof the
organization's quality
q
s
system.
Plans
P
of product, and serrvice reallization
determ
mine the fo
ollowing:
d Precasst L.L.C
Exeed
5.2.2 Rev
view of Reequiremen
nts Relateed to the Process
P
ments are reviewed prior to thhe Exeeds commitm
ment to suupply a
Producct requirem
producct to the customer
c
mission of tender, acceptancce of conttract or
(e.g. subm
order, acceptancce of changes to conntract or orrder) and we ensuree that:
a) Producct requirem
ments are defined
b) We haave the cappacity to meet
m the reequiremennts.
Wheree the custoomers provvide no documentaary statemeent of reqquirementss, those
custom
mer requiirements are acceppted, andd regulariized as advised bby the
custom
mer. Records of thee results of
o the revview, andd actions arising
a
froom the
review
w are mainntained.
Wheree the prooduct reqquirements are chhanged, we
w ensure that reelevant
and that relevant
are awaree of the chhanged
docum
ments are amended
a
r
p
personnel
requireements.
5.2.3 Cusstomer Coommunication
Arranggements have
h
been determineed, and im
mplemented for com
mmunicatinng with
custom
mers in relations to:
a) Producct informaation,
b) Enquirries, contrracts or ordder handliing, includding amen
ndments annd
c) Custom
mer feedback, incluuding custoomer com
mplaints.
nd Develoopment
5.3 Design an
5.3.1 Dessign and Developm
D
ment Planning
Docum
mented pro
ocedures are
a established to coontrol, and
d verify thhe product design
and to ensure thhat the dessign meet the speciffied requirements of
o the cliennt. The
a develoopment
engineeering maanager is overall reesponsiblee for the design, and
planninng. The design
d
mannager is reesponsiblee for the input
i
and out verifiication,
and ennsures thatt sufficientt resourcees are available to peerform dessign activiity.
d Precasst L.L.C
Exeed
The deesign activvity starts when thee initial joob sheet iss distributeed; this inncluded
the preeparation for prograam and deesign planss. The dessign and developme
d
ent will
be carrried out baased on thhe customeer requirem
ments and
d internatio
onal standdards.
5.3.2 Dessign Inpu
uts
The design team
m perform
ms an oveerall revieew of thee availablee informaation to
ensuree that it is sufficientt to perforrm the dessign progrram. Consideration will be
given tto relevannt statutoryy, regulatoory and saffety requirrements.
5.3.3 Dessign Outp
puts
The drraftsman generates the draw
wing for production
p
n. These drawings
d
w be
will
checkeed and appproved beffore issuinng for prodduction.
While generatin
ng the draawing thee draftsmaan may seeek help from the senior
detaileer, structurral engineer and dessign manaager.
5.3.4 Dessign Revieew
Designn review is a continuuous proccess duringg the progress of design activvity. An
overalll design review meeeting mayy be carrieed out if deemed
d
neecessary. Design
Project
progreess for all the runniing projeccts will be revieweed in the meeting.
m
orienteed design review wiill be cond
ducted as per
p the design plan.
5.3.5 Dessign Veriffication
Designn verificaation includes the verificattion of thhe structu
ural calcuulation,
drawinng, and othher specifi
fication.
d Precasst L.L.C
Exeed
5.3.6 Dessign Valid
dation
mponents will be completed
c
d only whhen the
Designn validatioon for prrecast com
erectioon is comppleted. Thhe final approval byy the clientt will be considered
c
d as the
designn validation
n.
The vaalidation of
o the conncrete mixx design iss done by meeting the
t strenggth, and
other rrequiremen
nts specifi
fied, and allso the appproval by the clientt.
5.3.7 Control of Design
D
Ch
hanges
Any changes too the desiggn and deevelopmennt other th
han the ap
pproved must
m
be
identiffied, and records are
a maintaained. Thhe changees are revviewed, veerified,
validatted, and ree-approved before th
he implem
mentation.
5.3.8 Maaterial Submittals
m
w be subbmitted to Contractoor/Consulttants apprroval
will
The foollowing materials
(a) Concreete Mix deesign, andd materialss used for concrete
(b) Reinfoorcement
S
s
5.3.9 Document Submittals
f
Documeents will be subm
mitted forr Contracctor/Consuultants
The following
approvval. Works will proceed withh approvall status A
A or B (A = Appproved,
B=Appproved wiith commeents)
(a) Designn drawings, and stru
uctural callculations..
(b) Projecct Quality Plan.
P
(c) Methood statemeent for Prooduction, Storage,
S
annd Deliverry.
(d) Methood statemeent for erecction.
(e) Inspecction and ttest plan.
(f) Quality
y Control Procedure for Inspeection, and testing.
(g) Projecct Safety Plan
P and Risk
R Assessment for erection.
d Precasst L.L.C
Exeed
5.4 Purchase
5.4.1 Purrchasing Process
is establisshed and maintaine
A docuumented procedure
p
m
d to ensurre that purrchased
producct confirm
ms to specific requireements off use.
Evaluaation selecction of suuppliers, suub-contracctors are on
o the basis of theirr ability
to meeet Exeedss quality reequiremennts, and anny other sppecific reqquirementts. This
will bee explained in detaill.
The peerformancce of supppliers will be evaluaated in tim
me-to-timee. If any suupplier
fails too meet thee requirem
ment continnuously, iit will be recorded
r
and
a that suupplier
will bee removed
d from the list.
Any puurchase will
w be donne only froom the appproved suuppliers lisst, which will be
updateed from tim
me-to-timee.
5.4.2 Purrchasing Informattion
The ppurchaser receives the inforrmation oon purchaasing eithher by puurchase
requisiition, or when
w
the stock conntrol systeem goes under
u
the minimum
m stock
level.
All puurchase reequisition must conntain the relevant material
m
i
informatio
on, and
approvved by thee concerneed person.
5.4.3 Verrification
n of Purch
hased Products
Activitties necessary for ensuring th
hat the purrchased prroduct meeets the sppecified
purchaase requirements arre establisshed, docuumented, and impleemented. Where
specifiied in the contract, the clien
nt or cliennts repressentative have
h
the right
r
to
verify that the pu
urchased material
m
c
confirm
the specifiedd requirem
ments.
d Precasst L.L.C
Exeed
ovision
5.5 Productioon and Seervice Pro
5.5.1 Control of Productio
P
vision
n and Serrvice Prov
Exeed controls all
a the proocesses wh
hich directtly affect the quality
y of the product,
and serrvice provvided.
6
d Precasst L.L.C
Exeed
6.2.3 Moonitoring and Measurementt of Proceesses
a
suuitable meethods forr measureement, and monitorring of
Exeed Precast applies
m
custo
omer requuirements. These
those realizationn processses necesssary to meet
methodds confirm
m the conntinuing abbility of eeach proceess to satiisfy the inntended
purposse.
6.2.4 Moonitoring and Measurementt of Produ
ucts
and monittors the chharacteristtics of thee product/service
m
Exeed precast measures,
p
ervice are met; thesse are carrried out
to veriify that reqquirementts for the product/se
at apppropriate stages
s
of the produuct/service realization proceess. Evideence of
conforrmity withh the accceptance criteria
c
is documennted; recoords incluude the
authorrity responnsible for release
r
of the produuct/servicee.
6.3 Control of
o Non-Coonforming Produccts
6.4 Analysis of Data
6.5 Improvem
ment
6.5.1 Continual Im
mprovem
ment
The coompany haas establisshed the fo
ollowing mechanism
m
m to achieeve the coontinual
improvvement off the system
m:
Managem
ment review
w meeting
g
p
andd quality objectives
o
.
Review of quality policy,
Control of non-connforming products
p
Internal auudits
Customerr satisfactiion
Employeee training program
Data analysis
Supplier performan
p
nce evaluaation
Corrective and prevventive acctions
d Precasst L.L.C
Exeed
6.5.2 Corrective Action
A
and Preventive Actio
on
mented prrocedures are imp
plemented to elimiinate the cause of nonDocum
conforrmities, inn order too prevent recurrence. The baasis of thee corrective and
prevenntive actioons are moonthly reccording off non-connformity, client
c
com
mplaint,
qualityy analysis report, innternal and externall quality audits,
a
staatistical annalysis,
processs controll, docum
ment contrrol, inspeection reeports, an
nd suppliier/subcontracctor evaluuation.
The Quality
Q
Coontrol Enngineer is responsibble to cooordinate with
w
depaartment
managgers in moonitoring, and identifying thhe potentiaal non-connformitiess. They
are allso responnsible forr assessinng the acctions takken to correct thee nonconforrmity, andd prevent thhe recurreence.
7 Attaachments::
1. Process Flow Ch
harts
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Q
Quality
A
Assura
nce Plaan
For
Precaast Man
nhole
Tablee of Con
ntents:
1. Inspection on
o Incomingg Raw Mateerials
1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
1.7.
Cemen
nt
Fine an
nd Coarse Aggregates
A
Water
Reinforcement
xture, Curing Compoun
nd and Form
m Releasing Agent
A
Admix
Strand
ds
Other Accessories
A
hed Produccts
4. Inspection and Finish
Exeed
d Precasst L.L.C
S
haas dividedd the Insppection annd Testing procedurres into
Exeed Quality System
five major
m
categgories (Zoones) in orrder to conntrol qualiity in our precast prroducts
as folloows
1) Inspectionn on Incom
ming Raw
w Materialss
2) Inspectionn on freshh and hardeened conccrete
3) Pre-produuction insppection
4) Post prodduction insspection
5) Inspectionn on Finished produucts
1. Inspecction on Incoming
I
Raw Matterials
QA/QC
C Engineeer to enssure that all incom
ming mateerials are from appproved
sourcees and in complianc
c
ce with ouur specificcations. QA
A & QC departmen
d
nt shall
collectt all relevaant mill ceertificates from supppliers as per the schhedule.
1.1.
Cement
Fine and
d Coarse Aggregattes
C Engineeer to ensuure that alll the agggregate recceived aree from appproved
QA/QC
sourcees only. Alll aggregaates shall be
b visuallyy inspecteed prior to
o acceptannce. All
the reqquired testts should be carried
d out on materials
m
internallyy or externnally to
ensuree its complliance withh specifications at the
t requireed frequen
ncies.
Exeed
d Precasst L.L.C
1.3.
Water
Reinforccement
QA/QC
C Departm
ment to ennsure thatt all reinfforcement bars shalll confirm
m to the
requireed specification of the job. The
T Mill certificatees from suuppliers shall be
receiveed for eveery consignnment andd checked its complliance withh BS 44499/ 97.
1.5.
Admixtu
ures, Curiing Comp
pound and
d Form Releasing
R
A
Agent
QA/QC
C departm
ment shaall ensure that adm
mixtures to be ussed shall be in
Complliance BS
S EN 934--2:2001 and
a test ceertificates should be obtained from
the m
manufactures. Calciuum chloriide or addmixtures containinng chloridde salts
shall nnot be allowed used.
Curingg compounnds confirrming to ASTM
A
C- 309
3 can be used.
Approved type of
o Non staaining form
m oil shalll be used.
1.6.
Strands
QA/QC
C Departm
ment shalll obtain Mill certificates frrom manuufactures for all
consiggnment andd ensure thhat it conffirms to ASTM
A
A 416-98.
1.7.
Other Acccessoriess
Exeed
d Precasst L.L.C
2. Inspecctions on Fresh and
d Harden
ned Concrrete
2.1.
Slump Test
T
Concretee Temperrature
Exeed
d Precasst L.L.C
2) Form conndition andd cleanlineess adequaate
3) Joints pro
operly sealled
4) End and edge
e
details correct
5) Reinforcin
ng steel coorrectly pllaced and spacers innstalled
6) Insulation
n materialss are in plaace (If anyy)
7) Applicatioon of form
m release agent
8) Correct innstallationn of sleevees and pipees (If any))
3.1
Steel rreinforcem
ments shalll be one of the folloowing typees
1. Hot roolled mild,, medium or high yiield steel smooth
s
rouund
2. Deform
med bars complying
c
g with BS 4449 or similar
s
app
proved staandard.
In casee any otheer type of reinforcem
r
ment is reqquired, it shall
s
compply with thhe
requireements off the particcular speciification. E
Ensure all reinforcement shalll be
cut andd fabricateed in accoordance wiith the shaapes and dimensions
d
s
shownn on the shhop drawinngs. Thesee reinforceements shaall be freee of rust, mill
m
scale aand any cooating suchh as oil, cllay, paint etc., Bars shall be cut
c to lenggth
with a tolerance of 25mm
m and bent with a tolerance off 16mm foor the overrall
length except thhat 25mm bars
b and larger mayy be bent with
w a toleerance of 25mm.
2
3.2
Raw m
materials will
w be prooportionedd by weighht in a caliibrated weeight batchher and
thorouughly mixeed in the mixer
m
to produce
p
hhomogenouus concrete and disscharge
the conncrete witthout segrregation. Batching,
B
weighing, mixing of
o concrette shall
all striictly be carried in accordancce with thhe recomm
mendationns of PCI (MNL
117). The QA
A/QC Enggineer shoould deteermine thhe moistuure contennt and
ggregates on
o daily basis. Accoording to which
w
the weight
absorpption of ag
Exeed
d Precasst L.L.C
proporrtion of agggregates and quanntity of waater shall be adjustted to the design
mix. Inn any casee the waterr cement ratio
r
shall not exceeed its desiggned limitt.
The cooncrete shhall be connveyed thrrough fly buckets only.
o
Timee period between
mixingg and placcing shall be
b as shorrt as possibble in order to avoidd slump looss and
cold jooints.
Concreete shall not
n be droppped freelly from thhe height of
o more thhan 1m annd shall
be disstributed in
i uniform
m layers not to exxceed 600mm in height too avoid
inclineed layers and
a cold jooints.
4. Inspeection on F
Finished Products
P
QA/QC
C departm
ment shall thorough
hly check to
t ensure that the finished
f
prroducts
are of good quaality and comply
c
fullly to its requiremen
r
nts in all aspects. Inn order
to avoiid any disspute with consultan
nt regardinng surfacee finish, a mock up sample
shall bbe made by us and approved
a
by consulltant at the beginninng of prodduction
commencement.
HSE Policy
Organization Chart
SALES MANAGER
SALES EXECUTIVE
OPERATIONS MANAGER
DEVELOPMENT & SUPPORT
GENERAL MANAGER
SR. CUSTOMER SERVICE &
DOC CONTROLLER
PRODUCTION MANAGER
SEVP OFFICE
SALES COORDINATOR
SALES DEPARTMENT
PERSONAL ASSISTANT
ESTIMATION MANAGER
PROCUREMENT MANAGER
PLANNING MANAGER
CONTRACTS MANAGER
AND/OR SR. CONTRACTS
ADMINISTRATOR
(TBA)
HSE OFFICER
SR.PRODUCTION ENGINEER
SECRETARY/ ADMIN
STOCKMAN
WATCHMAN
PRODUCTION SUPERVISOR
TIMEKEEPER.
QC INSPECTOR
QA/ COMPLIANCE
TEAM
STRUCTURAL ENGINEER
SR. DETAILER
DETAILER/DRAUGHSTMAN
DETAILING ENGINEER
PLANNING OFFICER
JR ACCOUNTANT
PLANNING CLERK
PROCUREMENT OFFICER
HR EXECUTIVE
FOREMAN-HOUSEKEEPING
ASST. PROCUREMENT
OFFICERS
WORKERS
WORKERS
WORKERS
WORKERS
HR ASSISTANT
TIMEKEEPER
HELPER
PR OFFICERS
ADMIN EXECUTIVE
CAMP BOSS
RECEPTIONIST
HELPER
HELPER
HELPER
HELPER
CASTING
CARPENTRY
BACTHING PLANT
ACCOUNTANTS
JR ACCOUNTANTS
STORE MANAGER
TBA
FACTORY MANAGER
MAINTENANCE ENGINEER
PRODUCTION MANAGER
HEAVY EQUIPMENT
OPERATORS
FORKLIFT OPERATOR
LOADER & CRANE OPERATOR
SR. ACCOUNTANTS
OFFICE BOYS
FACTORY PREMISES
CLEANERS
WORKER
WORKERS
MAINTENANCE MANAGER
HELPER
HR OFFICER
PAYROLL OFFICER
HR ADMINISTRATOR
DOCUMENT CONTROLLER
WORKERS
FINANCIAL CONTROL
MANAGER
FINANCE MANAGER
ASST. FINANCE MANAGER
QUANTITY SURVEYORS
STORE SUPERVISOR
GRC MANAGER
QC MANAGER
GRC SUPERVISOR
SR. QC ENGINEER
PROJECTS DIRECTOR
LOGISTIC MANAGER
SR.MAINTENANCE
SUPERVISOR
SR. PRODUCTION ENGINEER/
PRODUCTION
SUPERINTENDENT
DOC. CONTROLLER
CHARGE HAND
MANTENANCE WORKER
GRC FOREMAN
PRODUCTION ENGINEER
(CIRCULATION PLANT)
PROCESS ENGINEER
PRODUCTION SUPERVISOR REINFORCEMENT FOREMAN
PRODUCTION SUPERVISOR
CHANGE HAND
PRODUCTION FOREMAN
PRODUCTION
WORKER
PRODUCTION SUPERVISOR
QC ENGINEERS/
QC SUPERVISOR
CHARGE HANDS
GRC WORKERS
CHARGE HAND
PRODUCTION
WORKER
QC INSPECTOR
CHANGE HAND
PRODUCTION
WORKER
LAB HELPER
LAB TECHNICIAN
SR. LOGISTIC
COORDINATOR
LOGISTIC
SUPERVISOR
LD DRIVER
BUS DRIVER
HD DRIVER
OPERATORS
ERECTION FOREMAN
LAND SURVEYOR
REPAIR FOREMAN
ASST. ERECTION
ENGINEER
ERECTION WORKERS
Senior Management
Head Of Department
Wokers
Unit Leaders
st
1 Staff Downline
Directly Reporting
Functional Reporting
Helper
Vacant/ Required/ TBA
Legend
SR. STORE
ADMNISTRATOR
SR. STORE
SUPERVISOR /
INCHARGE
SR. / STOREKEEPER
Method Statement
Exeed
d Precasst L.L.C
M
Method
d Statem
ment forr
Preccast Co
oncrete Producction
Tablee of Con
ntents:
1. Purpose
2. Responsibiilities/Scop
pe of Work
3. Equipment
4. Materials
5. Production
n
5.1. Manufaccture of Mou
ulds
5.22. Steel Reiinforcementt
5.33. Productiion
5.3.1. Preeparation off Moulds forr Concretingg
5.3.2. Cooncrete
5.3.3. Cooncreting in hot weatherr
5.3.4. Vib
bration
5.3.5. Cu
uring
5.3.6. Fin
nishing
5.3.7. Strripping, Iden
ntification and
a Storage
Exeed
d Precasst L.L.C
1.
Purpose
Responsiibilities/Sccope of Work
W
Design deppartment to
t perform
m design calculations, quantiity, Calcuulations
D
annd the prepparation oof shop draawings.
Pllanning Department
D
t to preparre the Metthod Stateement.
Faactories too prepare moulds,
m
annd castingg of precasst elementts.
Q
Quality Dep
partment to
t Inspectt, and Quaality Contrrol of all works.
w
3.
Equipmeent
Materialss
Exeed
d Precasst L.L.C
Prre-stressinng Strandss Approved Seven Wire low
w relaxatiion to AS
STM A
416 std. com
mplying with
w projecct specificcations.
Productioon
5.
Manufactu
ure of Mou
ulds
5.1. M
To proovide / fabbricate all necessaryy number of steel foorms based on dimeensions
shownn in the appproved shop drawin
ngs, and prroject speccificationss.
5.2. Stteel Reinfforcementt
Prre-stressedd strands of
o 9.53mm
m or 12.7m
mm nomin
nal diametter as per ASTM
A 416 sttandards, and reinnforcemennt steel complyinng with project
sppecificatioons shall be
b obtained
d from an approvedd source.
Stteel mill certificatees shall be
b kept along withh the deliivery notees in a
seeparate file for checcking, and easy referrence.
Sttorage of reinforcem
r
ments, andd strands:
Stteel Rebaar shall bee covered
d, and storred on pllatforms, 20cm
2
aboove the
grround leveel or on cooncrete plaatform.
Stteel rebar shall be properly
p
p
protected
f
from
dust, humidityy, salts, and other
agggressive materials..
B
Bending off reinforceement:
Stteel rebar shall be cut from bars free from bennds or othher damagges and
beent cold by mechannical bendiing machinne or man
nual meanss.
A
All bendin
ng dimensions shaall be in accordan
nce with approvedd shop
drrawings, and
a specifi
fications.
5.3. Prroduction
n
A dailly producction forecast shalll be prepared by the
t factorry based on the
approvved workks program
m, and according
a
to the weekly delivery/e
d
erection
forecast issued by
b the projjects depaartment.
Exeed
d Precasst L.L.C
5.3.1 Prepa
aration of Moulds for
f Concrreting
The forms shall be cleaned, assembleed and co
oated withh mould release
aggent.
R
Reinforcing
g steel asssemblies shall be put in place
p
on the mouldds and
chhecked forr spacing, and coverred to makke them reeady for concreting..
The mouldd side form
ms/shutterrs shall be assemblled on thee casting tables,
w
where the elements
e
dimensio
ons are maarked withh respect to the appproved
drrawings by
b weldinng and/orr magnetic shutter systems and/or nut/bolt
n
syystems. Whichever
W
is conven
nient for thhe production activvity, considering
thhe numberr of elemennts to be cast
c and lifting posittion.
The mould joints shaall be sealeed water tiight with a sealant (silicon).
(
The re-asseembled mooulds shalll be checkked for diaagonal meeasuremennts, and
right anglees on the corners to
t ensure the correectness off the mouuld for
caasting.
5.3.2 Concrrete
C
Concrete shhall be preepared as per
p projecct specificaations.
M
Mix designn shall be as
a approveed by the Consultan
C
nt.
A
As soon ass concretee is readyy in the factory,
f
itts time ex
xplants, ambient
a
teemperaturee and conccrete tempperature shhall be obsserved.
Im
mmediatelly, a slum
mp test shall be carriied out. All
A these obbservationns shall
bee recordedd by Materrial Testinng Techniccians.
Iff the tempeerature annd slumpag
ge are fouund withinn the limitss, concretee cubes
(ttotal 9 Nos. from daaily produuctions) shhall be preepared byy lab technnicians,
w
where eachh cube shalll be mark
ked with a serial num
mber, and date.
A record off all the cuubes and correspon
c
ding elem
ments prod
duced, on the
t day
shhall be kep
pt in a sepparate file.
Exeed
d Precasst L.L.C
O
Out of six test
t cubes,, three shaall be cureed for seveen days, annd the rem
maining
thhree for 288 days.
The cubes shall be crushed in the laboraatory, in which
w
threee cubes shall
s
be
keept spare in
i factory laboratorry. The cruushing ressults shall be loggedd into a
cuube file fo
or record.
5.3.3 Concrreting in hot
h weath
her
The tem
mperaturee of the cooncrete at the
t time of
o placing shall not Exeed
E
32C, and
speciall measures shall be taken to control
c
the temperaature of the concretee. Such
measuures shall include buut not be liimited to the
t following:
A
All forms shall
s
be protected froom direct sunlight.
C
Cement andd aggregaate stockpiiles of reaady mix supplier
s
shhall be prootected
frrom directt sunlight.
C
Cooled watter shall be
b used foor mixingg concrete. If necesssary, crusshed or
flaked ice shall be added.
a
This proceduure shall be
b perform
med undeer strict
a
of water added
a
rem
mains undder the
coontrol to ensure thhe total amount
prrescribed limits.
l
R
Reinforcem
ments shalll be proteccted from direct sunnlight.
5.3.4 Vibration
Vibrattion of thee poured cconcrete shhall be doone with care
c
to avooid displaccement
of the reinforcement andd accessoriies and too ensure satisfactory
s
y compacction of
the conncrete. Thhis is norm
mally donee in two waays:
H
Horizontal vibration:: By plate vibrators fixed to th
he castingg table.
V
Vertical vibbration: By
B vibratiing pokers handled
d manuallyy. The viibrators
shhall be innserted annd removeed slowlyy but shalll not rem
main idle in the
C
Concrete.
Exeed
d Precasst L.L.C
t abovee combinaation of viibration, cconcrete reaches
r
alll corners of the
With the
mouldd.
Also eexcess waater, air poockets wiill be elim
minated an
nd honeyccombing will
w be
prevennted. The top
t surfacces shall be
b toweledd manually
y to achieeve a smoooth fair
face.
5.3.5 Curin
ng
All curring proceedures shaall complyy with ACII 517 requuirements.
N
Normal Cu
uring invoolves covering the exposed surfaces with a Hessian
H
clloth, and wetting
w
thhe membeer with muunicipalityy water annd keepinng it so
foor a minim
mum of:
a)) 3 days for
f 15cm & 20cm thhickness
b)) 4 days for
f 26cm & 32cm thhickness
c)) 5 days for
f 40cm & 50cm thhickness
Additionally, thhe precast elements shall be ccovered with
w polyetthylene shheets to
mize loss off water froom the Heessian clotth.
minim
Exeed
d Precasst L.L.C
d)) The cast elemennt shall be coverred overnnight afteer the steeaming
operatio
on is compplete.
Total ttime of stteam appliication sh
hall be for 7 hours. Holding period
p
forr steam
curingg shall be adjusted
a
soo as to attaain the reqquired streength at reelease.
5.3.66 Finishiing
The toop surfacee of the slabs shall be finisheed rough in
i order to
o facilitatte good
bondinng betweeen Filigreee Slab, annd Cast inn Situ parrt of slabss. The am
mplitude
(depthh) of rough
hness on deck
d
surfacces shall be
b around 5 mm (2-44 mm for HC).
The prrecast eleements shaall have trowel
t
finnish on onne side, and
a mouldd stuck
finish on the othher sides.
5.3.77 Strippiing, Identtification and Storaage
After streength veriffication, th
he forms shall
s
be sttripped annd every element
e
shall be inndelibly marked
m
wiith a speciific name as per shhop drawinng, and
the date of
o casting.
The elements shall then be shifted to the
t storagee area whhere they shall
s
be
stored unttil they reaach the deesired strenngth.
A separatte area will
w be arrranged as storage for
f each project, and
a the
elements shall be stored with
w
propper care to
t avoid damage during
handling.
Vertically
y stored elements shhall be givven speciall support.
In case off horizontaal storage on groundd, packingg materialss like woood shall
be used below the element
e
too avoid dam
mage.
QC engin
neer shall check thhe fully cured
c
and ready eleements foor size,
shape, craacks, spallling, generral defectss, and veriify loadingg procedurres.
After QC
C approvall, the desiignated prrecast mem
mbers shaall be allowed to
be loaded
d on trailerr, and disppatched.
Exeed
d Precasst L.L.C
6.
Delivery to Site
Adequate care shaall be takeen in handling, and
d transporrting the precast
p
elements, so as to ensure that theyy reach their desttination without
w
damage.
The projeects depaartment / Site Mannagement shall prrepare a weekly
w
forecast for
f the dellivery, in order to ensure thee delivery
y of the reequired
element on
o the scheeduled ereection datee.
Daily cooordination between the factorry and Prooject engiineer will ensure
the deliveery, and errection sch
hedules match with the approved progrram.
Elements shall be transportted on flaat bed traiilers or AA frame trailers
dependingg upon thee element size, and type.
t
Elements shall be well
w proppped againnst any moovement during
d
traansport,
with special stands shall be used
u
for deelivering large
l
elem
ments.
The Main
n Contracttor shall provide
p
proper access for ouur trailers to the
sites
Necessaryy cranes with
w suffiicient capacity shalll be arran
nged on site
s for
offloadingg, and erecction workks as per the
t approvved prograams.
The area of
o erectionn and the range of the
t crane boom
b
shalll be checkked for
before unloading thhe precast elements at the sitee.
Followingg measurees shall bee taken to ensure deelivery off elementss at site
without damage.
d
Final insppection forrms shall be
b provideed with evvery deliveery.
Wooden or
o polystyyrene suppports shall be proviided to ennsure stability of
the precasst elementts.
The precaast elemennts shall be
b braced, by speciial belts (Ties)
(
to pprevent
the precasst elementts from tiltting over w
when the trailer
t
takees a turn.
Exeed
d Precasst L.L.C
Wooden planks
p
shaall be placced betweeen verticaal elementts to avoidd direct
contact.
The traileers shall bee loaded in
i accordaance with the trafficc regulatioons and
limitationns.
Site forem
man shall supervise the unloaading of prrecast elem
ments at thhe site.
Precast ellements shhall be eithher storedd on site att designateed area prrovided
by the Main
M
Conntractor annd/or be installed directly into theiir final
position depending
d
on the sitte conditioon.
On unload
ding at sitte, the num
mber of prrecast elem
ments shalll be verifiied and
recorded in
i the erecction schedule.
Care shalll be exerccised whille placingg the precaast elemennts on groound to
avoid dam
mage to addjacent eleements.
7.
Quality Assurance
A
e
7.1. General
To ennsure the best standdards for productioon, storagge, supplyy of the precast
p
elemennts, follow
wing qualiity assuran
nce prograam shall be
b implem
mented, annd daily
recordds maintainned.
7.2. Quality Coontrol Proocedures during
d
M
Manufactu
ring
Qualityy Controol shouldd be recorded iin an inndividual identity sheet
correspponding to
t each ellement, duuly signedd by the Quality
Q
Control Enngineer,
and keept in the quality
q
conntrol file for
f future reference..
7.3. Prrecast Mooulds
Beforee each castting, the precast
p
mooulds shalll be checkked for thee followingg:
a) Dimensioon, and dettails accorrding to thhe approveed shop drrawings
Exeed
d Precasst L.L.C
b) Mould asssembly
c) Reinforcin
ng steel accordin
ng to thee approved shop drawings, and
specificattions
Qualityy Controll Engineeer shall tiick mark, commen
nt on all the itemss to be
checkeed and sign the checck list slipp with datee to clear the
t mould for castinng.
7.4. Cooncrete Batching
B
Follow
wing shall be checkeed for eachh batch:
a) Mix desiggn: Whethher it is acccording too project sppecificatio
ons
b) Slump
c) Concrete temperatuure: Wheether chillled water is addedd to batchhing, if
concrete temperatur
t
re is abov
ve 32C
d) Cube castting: Wheether miniimum of 9 cubes haave been taken from
m each
day's prodduction cooncrete. Whether
W
thhese cubees have beeen markeed with
serial num
mber and dated,
d
cureed and cruushed for de-moldin
d
ng, 7 days and 28
days.
e) Water curring: Typee and periood shall bee monitoreed.
7.5. Reepair Pro
ocedures
Repairr categoriees shall bee used to define
d
the repair, off non-strucctural blem
mishes,
and reinstatemen
nt of cornners or edgges resultiing from stripping,
s
lifting, haandling
to storrage areas or during erection works
w
on site.
s
After placing
p
off precast concrete
c
m
members
i stock yard the QC engineeer shall
in
to the
inspect the work, and any
a
repairring workk shall be done according
a
approvved repair proceduree.
Exeed
d Precasst L.L.C
n & Erectiion Tolerrances
7.6. Prroduction
PCI Manual
M
12
20-99 chaapter 8, PCI
P
manuual 135-000 shall bee referredd to as
internaational staandards to accommo
odate any tolerancess in produ
uction & eerection
of pre--stressed elements.
e
Exeed
d Precasst L.L.C
Metthod Sta
atemen
nt for Prroductioon, Storrage & Deliverry of
Hollow
w Coree Slabs
Tablee of Contents:
1. Introductioon
1.1.
1.2.
1.3.
1.4.
1.5.
Com
mpany Profiile
Purrpose
Scop
pe of Work
Refeerence
2. Personnels Responsiible
3. Receiving Inspection
I
3.1.
3.2.
4. Production
n
4.1.
4.2.
4.3.
4.4.
Production Proocedure
Casting Commeences
Pre--stressing Foorces
Exeeed Precast Scope
S
of Wo
ork
5. Quality Coontrol/Assu
urance
5.1.
5.2.
5.3.
Insp
pections Beffore Casting
g (Pre-stressing of Stran
nds)
Insp
pection duriing Casting
Fina
al Inspection
n after Castting
6. Curing
7. Repairing of Elementts
8. Loading an
nd Deliveryy
9. Process Floow Chart
Exeed
d Precasst L.L.C
1. Introducttion
1.1.
Compan
ny Profile
L
is sppecializedd in designn, productiion, deliveery, and eerection
Exeedd Precast L.L.C
of preccast concrrete compoonents to meet
m high level of customer
c
satisfaction
s
n
1.2.
Purpose
Referencce
Approval
Implem
mentation
3. Receivingg Inspectiion
3.1.
Receivin
ng Inspecttion of Maaterials
Exeed
d Precasst L.L.C
Agggregate andd Sand:
All the aggreg
gates and sands aree received along witth a deliveery note. Visual
o for eacch size of aggregated when reeceived.
checcks will bee carried out
Sievve analysiss will be carried
c
outt at regulaar intervalss.
Reqquired testts will bee conductted througgh approvved indeppendent material
m
testiing laboratories
Watter:
The water useed to makee concretee, will be conformin
c
ng to UAE
E Standardds
The chemicaal analysis of watter samplle, is donne througgh an appproved
indeependent laboratory
Straands:
The strands used
u
for pre-stressi
p
ing, are received
r
w
with
mill certificatees, and
delivvery notess
Miccro Silica:
Miccro Silica is receiveed along with
w deliveery notes,, required certificatees, and
test results approved byy independdent laboratory.
3.2.
Inspectiion/Test of
o Concrete Mixes and Cubees
Productiion Proceedure
Exeed
d Precasst L.L.C
ment usedd in Holllow Coree slabs are
a pre-stressing strands
The rreinforcem
complyying with ASTM A416.
A
The sttrands are stressed to
t approximately 70% of theeir breakinng load ovver the
full lenngth of casting bed before.
4.2
Casting Commen
nces
Pre-stresssing Forrces
When the conccrete achieves the required strength, distressinng is donne with
t slab will
w be theen cut as per
p the
diamonnd tipped water coooled cuttiing saw, the
cuttingg list and removed
r
f
from
bed. After cuttting the sllabs the sllab is lifteed from
bed, annd is inspected for cracks, slippage off strands annd any oth
her irreguularities
before transferriing to stocck yard.
mall cutoutts, core
Speciaal slabs (leesser widtth) are maade in thee area assiigned. Sm
drillingg etc. willl be done in
i the cutting yard if it is speccified.
Exeed
d Precasst L.L.C
Exeed Precast
P
Sccope of Work
W
4.4
Inspectiion durin
ng Castingg
Exeed
d Precasst L.L.C
5.3.
Final In
nspection after Cassting
Exeed
d Precasst L.L.C
b kept in the stockyyard in
stockyyard, as iniitial curingg have staarted. Slabbs are to be
a firm ground too avoid anyy cracks resulting
r
ddue to unevven stackiing.
Slabs is
i then covvered withh hessian cloth
c
and polythene
p
e sheet
The hoollow coree slabs aree water cuured for 3 days exclluding thee date of ccasting,
and deelivery.
7. Repairing of Elem
ments
Hollow
w core slabbs is repaiired for minor
m
defeccts only
All cosmetic reppairs is doone in the stockyardd using appproved reepair mateerials &
proceddures
8. Loading and Delivvery
All loaadings to be
b done affter complleting the stipulated
d curing tim
me.
Once the curingg is comppleted, as per the sequence of load provided
p
by the
ment, the loadings arre made.
erectioon departm
Slabs are
a loaded
d into the flat
f bed traailer usingg overheadd cranes, and
a with sslings.
Properr wooden support iss providedd for seatinng of the elements
e
o the trailler.
on
All eleements in the trailer are secuured with chain slin
ngs tighten
ned to thee trailer
hooks..
The coontact poinnt between the elem
ments and slings aree to be pro
otected wiith soft
materials to avoid damagees.
Loadinng foremaan ensuress that the elements loaded arre in accoordance with
w the
erectioon sequencce and alsoo in a safee manner.
The trrailer driveer checks the load for safetyy conditions and fo
ollows the traffic
rules aand regulaations.
The drriver will be
b provideed with sitte route map
m and thee deliveryy notes.
Exeed
d Precasst L.L.C
ge, and theereafter
When the driverr reaches tthe site hee will conttact the sitte in charg
the sitee in charge should take
t
care of
o the loadds for off-lloading an
nd erectionn.
It is tthe respon
nsibility of
o the maain contraactor/clientt to provide propeer, safe
access for the traailer to thee site prem
mises.
9. Process Flow
F
charrt
Bed Cleanning
Applyin
ng Mould Release
R
Agennt
Pulling Strrands
Stressinng
Casting Bed
B
Cutting Strrands
Exeed
d Precasst L.L.C
Marking Slabs
S
Cutting Sllabs
D
De-moulding
g Slabs
QC Inspecction
De-moulding
D
gSlabs
QC Inspecction
Final Inspeection
Stacking Slabs
S
Remov
ving Cover & Inspectionn
R
Ready
for Deelivery
METHOD STATEMENT
Erection of Precast Concrete Elements
Table of Contents:
1. Scope of Work
2. Resources
2.1 Description of Equipment & Tools Required
2.2 Description of Materials to be Used
General Preparation
Installation of Beam
Hollow Core Slab
4.3.1 Transportation of Hollow core Slabs
4.3.2 Hoisting of Hollow Core Slabs
4.3.3 Site Storage of Hollow Core Slabs
4.3.4 Installation of Hollow Core Slabs
4.3.5 Preparation and Casting for Structural Topping on the Hollow Core Slabs
4.3.6 Field Cut Openings of Hollow Core Slabs
4.3.7 Field Repair and Modification of Hollow Core Slabs
5. Supervision
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Construction Manager
Site Engineer
Site Surveyor
Foreman
Quality Control Engineer
Safety Officer
Sustainability and Environmental Engineer
4.
b.
Always handle hollow core slabs in the flat horizontal position. Never
turn Slab on edge or end unless approved by design engineer.
4.3.4 Installation of Hollow core Slabs
Hollow core slabs are installed on proper location on the precast beam,
which is loaded on the Formwork designed for its purpose.
Hollow core slabs are to be located as per design drawings in conjunction
with architectural and structural drawing s for connection details of other
building components and/ or structural system interacting with hollow core
slabs.
Minimum bearing distance should not be less than 100 mm as recommended
by designer and mentioned on the drawing.
All slabs with differential camber should not be leveled, adjusted, etc. to
within allowable tolerances prior to grouting.
Sequence of erection of hollow core slabs should be reviewed designer prior
to starting the work.
Technical Details
List of Projects
Sr.
Project Name
Client
Consultant
Main Contractor
Scope Of Work
Pal Technology
Sorouh
Sorouh
Sorouh
Arabtec/CCC/ Tav
Al Dar Properties
Fluor Mideast/Atkins
Al Jaber Group
Pioneer
Ghantoot Group
10
11
ADNOC
12
Meydan Heights
AK Design
Sr.
Project Name
Client
Consultant
Main Contractor
Scope Of Work
13
OTAK International
Al Habtoor Engineering
14
15
16
17
Musanada
Precast Substations
18
Various Constructions for Border Guard Group General Head Quarter's Command
H.Q ( 4 Sites)
of MilitaryWorks
19
20
CMW-11003-C001
21
N/A
22
23
Venus Contracting
24
Woods Bagot
Precast Stairs
25
Siemens
Sr.
Project Name
Client
Consultant
Main Contractor
Scope Of Work
26
Bloom Gardens
Bloom Properties
World Planners
27
Brighton College
Bloom Properties
AEC
28
Bloom Academy
Bloom Properties
Broadway Malyan
29
30
AECOM /
BWGulf Engineers, Planners &
Managers
31
32
ADNOC
33
ADNOC
34
ADNOC
ASCON
35
Al Dar Properties
36
37
Al Naser Industries
ARENCO
38
Al Fahim
Precast Planks
Sr.
Project Name
Client
Consultant
Main Contractor
Scope Of Work
39
40
41
Al Hamra Project
42
Precast Footings
43
Private office
Private office
Private office
44
ELID
45
Minal
IMECO
46
JACOBS
47
Syrex
48
UHDE
49
ADNOC
N/A
50
Apartment Hotel
Almansouri 3B
51
Al Bakhet Resort
Sr.
Project Name
Client
Consultant
Main Contractor
Scope Of Work
52
Bloom Properties
53
54
Mosque
55
Majles
56
Private Majlis
City Plan
57
58
Exeed Precast
59
Exeed Precast
Exeed Aswar
60
Sr.
Project Name
Client
Consultant
Main Contractor
Scope Of Work
61
Technicians Construction
62
Mr. AL Mansoor
63
64
TDIC
Arabtec Precast
65
NIC
Dewan Architect
Arabtec Precast
66
Al Maya Resort
67
68
69
GASCO
70
71
Al Bateen Camp
Presidential Guard
Presidential Guard
72
73
72
Jindal Mcwane-ICAD I
Mcwane
Gulf Erectrion
73
Pal Technology
74
ADNOC
ADNOC
73
74
Al Bateen Camp
Presidential Guard
Presidential Guard
Precast Elements
75
CMW-11121-C001
Arabtec Precast
Projects Gallery
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Ruw
wais Housiing Compplex Expannsion Phasse (III), Deesign & C
Constructioon of
Ruwaiis Shoppinng Mall
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Abu Dhabi Centre for Technical & Vocational Education & Training
Exeed
d Precasst L.L.C
Ruw
wais Housiing Compplex Expannsion Phasse (III), Deesign & C
Constructioon of
Ruwaiis Shoppinng Mall
Exeed
d Precasst L.L.C
Bloom
m Gardens Project
Exeed
d Precasst L.L.C
Bloom
m Gardens Project
Exeed
d Precasst L.L.C
Ritz-Carlton H
Hotel
Exeed
d Precasst L.L.C
Ritz-Carlton H
Hotel
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Al Falaah Commu
unity Devvelopment Project
Exeed
d Precasst L.L.C
Labbor Accom
mmodationn at Al Maafraq
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Brig
ghton College
Exeed
d Precasst L.L.C
Abbu Dhabi P
Police GH
HQ in Al A
Ain
Exeed
d Precasst L.L.C
Baakhet Resoort
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Arkan Cement F
Factory
Exeed
d Precasst L.L.C
Ceemix Factoory
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Exeed
d Precasst L.L.C
Location Map
..
..-
To Tartf, AI AI"
~
To Abudhabl
Dubal