WORK METHOD STATEMENT – PRECAST WORKS

For

IM009/2021_UPGRADING AND CONSTRUCTION OF AN

EXTENSION TO PINTO QUAYS 4 & 5 INCLUDING
RECONSTRUCTION OF LASCARIS WHARF, PORT OF
VALLETTA, GRAND HARBOUR, MALTA

REVISION SCHEDULE
REV. DATE DETAILS PREPARED BY REVIEWED BY
Solidbase
01 11.10.2022 New Main Contractor-GP
Laboratory

Page 1 of 8
Contents
1. Title ....................................................................................................................................................... 3
2. Scope of work........................................................................................................................................ 3
2.1 General Description ............................................................................................................................ 3
2.2 Plant and Equipment..................................................................................................................... 3
2.2.1 Plant and Equipment.................................................................................................................... 3
2.2.2 Tools and equipment ................................................................................................................... 3
2.3 Material ............................................................................................................................................... 3
2.3.1 Material to be used ...................................................................................................................... 3
2.3.2 Handling, Inspection and Testing of Material .............................................................................. 4
2.4 Site Planning and Preparation ............................................................................................................ 4
2.5 Work Methodology ............................................................................................................................. 5
2.5.1 Shuttering..................................................................................................................................... 5
2.5.2 Reinforcement ............................................................................................................................. 5
2.5.3 Concrete works ............................................................................................................................ 5
2.5.4 De-shuttering or striking of shuttering ........................................................................................ 6
2.5.5 Transportation ............................................................................................................................. 6
2.5.6 Delivery to site ...................................................................................................................... 6
2.5.7 Placement ............................................................................................................................. 6
4. Organisation, Responsibility & Supervision .......................................................................................... 6
5. Submittals ............................................................................................................................................. 7

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 1. Title
Work Method Statement (WMS) for precast works including Shuttering, Reinforcement, Concrete, Curing,
Lifting, Transportation and placing of precast elements.

2. Scope of work
2.1 General Description
This document describes the method of preparation, transportation and placement of precast elements.
This WMS is simplified and doesn’t include analysis or descriptions of all works, stages, Material and
equipment.

2.2 Plant and Equipment

2.2.1 Plant and Equipment
1. Batching Plant
2. Concrete distributor – Bianchi Speedy
3. Gantry crane
4. Mobile lifting crane
5. Low loader
6. Crane barge

2.2.2 Tools and equipment

1. Handheld vibrator
2. Table vibrator
3. Trowel
4. Wood/rubber fenders

2.3 Material
2.3.1 Material to be used
1. Concrete – C45

2. Reinforcement steel

3. Tying wires

4. Spacers (Concrete/PVC)

5. Mould releasing agent

6. Steel shuttering

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2.3.2 Handling, Inspection and Testing of Material
1. Concrete – Concrete would be inspected against the approved mix design and checked for
temperature and workability. The concrete would further be sampled for compressive strength
testing with age. Inspection is carried out by the QAQC engineer as per the approved checklist.
2. Reinforcement – The reinforcement steel will be checked for mill certificate and heat numbers
will be verified. Subsequent checks are required for new consignment deliveries. Random spot
checks can also be done to verify continual compliance. Installed reinforcement is then inspected
by the QAQC engineer against approved drawings.

Installed reinforcement is then inspected by the QAQC engineer against approved drawings which is
added below:

• Spacing
• Number of bars
• Dia of the bar
• Lapping lengths
• Stirrups
• Cover zone to not have the binding wire protruding.

3. Steel Shuttering – Steel shuttering has been adopted for all mass-produced precast elements. 9-
11 such moulds will be fabricated based on the trail casting. The shuttering is inspected for
dimension, shape and installation by the QAQC engineer before allowing for concrete works.
4. Conventional shuttering – For special precast units to be used around the corners, custom
shuttering will be prepared using conventional methods.

2.4 Site Planning and Preparation

to be part of this MS and Quality Plan
1. Batching plant certificate – To be submitted

2. Batching plant audit – Being Planned

3. Coordination of works

A. Batching plant – The Plant Manager will coordinate with the Project Management and Independent
QAQC for all inspection and testing after each stage of work like shuttering, reinforcement, concrete, de-
shuttering, and transportation.

B. Site – The Site Manager will coordinate with the Project Management and Independent QAQC for all
inspection and testing for the stages of lifting and placing of precast elements.

4. Communication

Sl. No. Designation Profile Company Phone number

1 Project Manager Supervising / Project management team CTP
2 Project Manager Contractor GP Borg
3 QAQC Manager Independent QAQC SBL
4 QAQC Engineer Independent QAQC SBL
5 QC Lab Manager Independent QAQC SBL

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 If role belongs to Plant
Manager, we believe the
personnel should be from
Bonnici's side.

6 Site Manager Contractor GP Borg

7 Site Engineer / Contractor GP Borg
Supervisor
8 Surveyor Contractor GP Borg
release agent should be compatible to the admixtures being used in
the concrete mix. We note that Mix Designs have admixtures from
2.5 Work Methodology another brand.

2.5.1 Shuttering
1. Shuttering is cleaned and erected over the base on the shop floor using the gantry crane as per
approved drawings and shop drawings.
2. Mould releasing agent (Masterfinish RL216) is applied to the surfaces which would be in contact
with the concrete.
3. After placing reinforcement, shuttering is sealed for any gaps and braces, struts and tie rods are
fastened to adequately hold the concrete pressure.
4. Inspections/checks are done as mentioned in ‘2.3.2 Handling, Inspection and Testing of Material’.

2.5.2 Reinforcement
1. The reinforcement is erected and tied as per the approved drawing.
2. Covers are provided as per the approved drawing which is 60mm.
3. Inspections/checks are done as mentioned in ‘2.3.2 Handling, Inspection and Testing of Material’.
Concrete pour should be done in a way so that it does
2.5.3 Concrete Works not affect neither the rebar placement nor the mould
alighment. pouring should consider distribution and
velocity.
1. The precast plant is equipped with a concrete batching facility. Once the reinforcement and
shuttering are ready, concrete is produced as per requirement.
2. Concrete is delivered through a concrete distributor (Bianchi Speedy) and poured into the mould.
3. Performance (Workability, temperature) tests are done on fresh concrete.
4. Inspections/checks are conducted as mentioned in ‘2.3.2 Handling, Inspection and Testing of
Material’
5. Sampling will be carried out to test for 1st, 2nd and 3rd day of casting to be extra sure and monitor
the strength achieved apart from the specified samples in the PQP/Technical specs.
6. The precast element is tagged with the type ID (Type-B at the moment) and placement sequence
number CTP provided ID number for
each PC block. ID Number to
2.5.4 Curing be adhered too.
1. The Precast moulds would be left covered in the mould for curing under a shaded place for 3 days.
2. Curing- Curing period will be as per the specification, as soon as the concrete reaches its initial
setting time, it will be covered with a polythene sheets, upon final setting, the element will be
covered with wet hessian cloth and covered with the polythene sheet on top, this process will
continue for a period of 5-7 days for all the precast elements or if the strength achieved is as per
the requirements.
3. Application of white-pigmented resin based curing compound will be carried out in accordance
with the manufacturer's instructions. Specification to be provided.

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we note that the Halfen pins rely on
tension between the pin and the
concrete. We believe that units Based on point 1,
should not be lifted from there place transportation cannot be
carried out since PC units will
before the 7th day and before the
still be in respective mould.
concrete reaches C45.

2.5.5 De-shuttering or striking of shuttering

1. The striking of shutters is only done after 3-day test results are satisfactory, achieving at least 60%
of the target strength.
2. On 5th to 7th day of casting the element will be transported to storage area or after achieving 50%-
70% of the required strength.

Ctr to provide 3. The surface of the precast element is inspected for cracks and chips. If chips >50mm are found,
curing regime they are repaired with an approved grout.
between 7 and
14th day. Ctr to 4. If cracks are observed over the precast surface, an NCR is recorded and the precast element is
refer to notes
we issued in
marked with a red cross () on all exposed surfaces and deemed rejected for use. Depends on the location.
Exposed surfaces should
MS comments have a maintained cover of
dated 7th 2.5.5 Lifting and Transportation 60mm.
October. 1. A statement based on the compressive strength achieved on 3rd day of casting will be obtained
from the structural engineer to be on safer side for lifting and transporting the element.
2. The precast is only lifted using the designated lifting points / studs.
3. The precast element is loaded on a low loader with necessary fenders and transported to the site
with care. ctr to assure that the PC unit will not be affected by
shock loads during the lifting, delivery or placement
2.5.6 Delivery to site process
1. The precast elements are placed on-site at designed areas using a mobile crane.
2. Wooden or rubber fenders are provided to avoid damage during placement
3. The elements are then inspected for any visual damages like cracks/chips
4. If chips >50mm are found, they are repaired with an approved grout (SikaRep).
5. If cracks are observed over the precast surface, an NCR is recorded and the precast element is
marked with a red cross () on all exposed surfaces and deemed rejected for use.

2.5.7 Placement
1. The 28 days concrete strength result is checked. If the results are found unsatisfactory (less than
desired strength), the precast element is marked with a red cross () on all exposed surfaces
and deemed rejected for use.
2. If satisfactory strength results are achieved, the precast element is placed using a mobile crane or
crane barge as per the placing sequence.
3. Divers ensure that the elements are placed correctly.
Should be Solid base

4. Organisation, Responsibility & Supervision

Contractor's

1. The Project Manager has the overall responsibility for the implementation of this WMS.
2. The Project Manager is responsible for internal coordination and obtaining necessary works
permits and approvals from the local bodies and the Supervising / Project Management team.
3. The Plant manager and the Site Manager are responsible to ensure the availability of resources
to carry out work as scheduled.
4. The Plant Manager is responsible to carry out the works as per approved Shop Drawings, Method

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 Statements.
5. The Site Engineer/Supervisor is responsible to ensure that the work has been carried out as per
specifications & drawings and inspections are done as per contract.
6. The Surveyor/Site Engineer/Supervisor is responsible for Setting out the area and measuring,
monitoring and controlling the lines and levels.
7. The QA/QC Engineer/ QC inspector is responsible to ensure that the work performed follows the
approved method statement & other applicable requirements.
Not correct.
5. Submittals

Sl. Submittal Submission Reference Approval Status

No. status
1 Drawings Yes Yes
2 Project Quality Plan Yes Yes
3 Shop drawing No
4 Material Submittal No
5 Inspection checklist No
6 Batching Plant commissioning No
certificate
7 Equipment manuals No
8 Material Data Sheets No
9 Lifting diagram No

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