FOR

PRECASTING OF
method statement CONCRETE
ELEMENTS
BASE GENERAL CONTRACTING L.L.C.
 CLIENT : Ministry of Energy and Infrastructure

ENGINEER : RTC Road & Traffic Engineering

CONTRACTOR : Base General Contracting LLC

PROJECT NO : 57/2023

PROJECT : Improvement of Al Khor St., UAQ

REVISION CONTROL

Revision Date of Details of Prepared by Reviewed by Authorized by Approved by

Status Issue Revision BGC BGC BGC RTC

First Issue for

00 13.06.2024 Mohamed Fadel Mohamed Fadel Shoukat Riaz
Approval
Office Civil Office Civil
Project Manager
Engineer Engineer

Second Issue
01 26.06.2024 Mohamed Fadel Mohamed Fadel Shoukat Riaz
for Approval
Office Civil Office Civil
Project Manager
Engineer Engineer

Doc. No: BGC-MS-014 Rev 01 Page 1 of 12 Method Statement for Precasting of Concrete Elements

Date of issue: 26.06.2024 BASE GENERAL CONTRACTING

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 INDEX

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 ABBREVIATIONS & DEFINITIONS

5.0 ROLES & RESPONSIBILITIES

6.0 ASSOCIATED REQUIREMENTS

7.0 PROCEDURE

8.0 RECORDS & DOCUMENTS

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1.0 PURPOSE
The purpose of this document is to provide the guidelines for precasting of concrete elements by
satisfying all the relevant specifications and requirements.

2.0 SCOPE

The scope of this procedure covers the steps to be followed for the Precasting of Concrete Elements
such as foundations, manholes, gullies, rings, and protection slabs to be used solely for project:
2023/57 Improvement of Al Khor St., Umm Al Quwain. The precast will be produced in the
Contractor Store.

3.0 REFERENCES

a) Tender specification- Volume 3

b) IFC drawings
c) Approved Pre-Qualification
d) Design Mix
e) Approved Material Submittal Ref. Nos. BGC-MT-UMQ-028, BGC-MT-UMQ-030
f) Approved Shop Drawing Ref. Nos. BGC/57-2023/SD/032, BGC/57-2023/SD/041

4.0 ABBREVIATIONS & DEFINITIONS

4.1 ABBREVIATIONS

IFC : Issued for Construction

PPE : Personnel Protective Equipment
BS : British standard
RFA : Request for Approval
ITP : Inspection and Test Plan
PQP : Project Quality Plan

4.2 DEFINITIONS

Client : This shall mean Ministry of Energy and Infrastructure

Engineer : This shall mean RTC Road & Traffic Engineering or its nominated
representative.
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 Contractor : This shall refer to Base General Contracting LLC
Project : This shall refer to the subject contract 57/2023 Improvement of Al Khor St., UAQ
Vendor : This shall refer to equipment and material suppliers for the Project.
Shall : This shall mean contractual requirement.
Should : This shall mean desired requirement.
May : This shall mean possible course of action.

5.0 ROLES & RESPONSIBILITIES

5.1 Project Manager

He shall be responsible for:

a) Responsible for overall execution, administration, monitoring and control of the project as per the
Contractual requirements, specifications & Project Quality Plan (PQP).
b) Coordinate with Office Civil Engineer for obtaining necessary resources for the project and deploy as
required.
c) Responsible for managing all interfaces with Client and Construction Manager - Projects.
d) Responsible for coordinating for all the procurement and subcontracting activities related to the project
e) Deal with all contractual matters to the project
f) Monitor the actual progress of the work against planned programme.
g) Ensure Quality Management System of the Contractor is effectively implemented in the Project.
h) Obtain subcontractors Procedures / Plans / Method Statements, where applicable and coordinate approval
of the same.
i) Assess manpower, equipment and other resources required to achieve targets set.
j) Coordinate with the Procurement Unit in carrying out procurement activities for the project.
k) Liaise with Construction Manager to ensure timely completion of civil activities pertaining to the project
l) Liaise with QHSE Manager for preparation and updating PQP.
m) Analyze deviation or change of contract scope in coordination with Construction Manager
n) Analyze deviations, change of contract scope or delays, if required, and reschedule to meet target dates in
coordination with the Construction Manager.
o) Ensure through the Office Civil Engineer that appropriate actions are taken on all NCRs and Audit Non-
Conformances raised in the Project.
p) Ensure through the QA/QC Engineer that all Corrective & Preventive Actions taken in the Project are
Effective.
q) Identify Training needs and Coordinate with appropriate function for fulfilling the Training Requirements.
r) Monitor & facilitate the implementation of HSE as per contract HSE plan, RAY procedure & requirement.

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5.2 Office Civil Engineer

He shall be responsible for:

a) Responsible for overall execution, administration, monitoring and control of the project as per the
Contractual requirements, specifications & PQP.
b) Coordinate with Project Manager for obtaining necessary resources for the project and deploy as required.
c) Responsible for managing all interfaces with Client and Project Manager.
d) Responsible for actual progress of the work against planned program.
e) Obtain subcontractors Procedures / Plans / Method Statements, where applicable and coordinate approval
of the same.
f) Coordinate with the Procurement Unit in carrying out procurement activities for the project through Project
manager.
g) Liaise with Site Engineers to ensure timely completion of civil activities pertaining to the project
h) Analyze deviations, change of contract scope or delays, if required, and reschedule to meet target dates in
coordination with the Project Manager.
i) Appropriate actions shall be taken on all NCRs and Audit Non-Conformances raised in the Project.
j) Ensure through the QA/QC Engineer that all Corrective & Preventive Actions taken in the Project are
Effective.
k) Identify Training needs and Coordinate with appropriate function for fulfilling the Training Requirements.
l) Reports to the Project Manager.

5.3 Project Engineer

He shall be overall responsible for safe execution of the complete activity including, but not limited to:
a) Organizing tools and equipment required to the work site.
b) Assigning work crew.
c) Sequence of activities to be carried out for the work as per this work procedure.
d) Stage Inspection & Surveillance.
e) Ensure all safety Regulations are followed as applicable.
f) Contract specific requirements for excavations, if any specified shall be identified and the requirements of
such specification shall prevail in addition to the non-conflicting requirements of this procedure.
g) Ensure & study the approved drawings & statements before starting the activity.
h) Communicate all HSE requirements to the entire working crew and ensure that they understand.
i) Thoroughly familiar with all MODES/RAY contract and general HSE requirements and understand it to
maintain a healthy and safe environment for employees and contract staff.

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5.4 NOC Officer
He shall be responsible for the following activities:
a) Ensure that all relevant permits are applied for and obtained prior to the commencement of work.
b) Executing monitoring and updating the Authority Approvals (NOCs) and works with regulatory authorities
to ensure that the required approvals are in place in a timely manner.
c) Developing relationships with key stakeholders to ensure all necessary permits are in place as required.
d) Tracking the status of approvals and ensuring government compliance.
e) Support in resolving authority approval and permit interface issues as necessary together with the wider
project team, develop systems to ensure that permits are current and valid for the activity being
undertaken.
f) Advising and informing appropriate staff and department of document and plan submittal requirements

5.5 General Foreman / Supervisor:

He shall be responsible for the following activities:

a) Execution of work as per contract specifications, QC procedure, approved method statement and work
instructions.
b) Toolbox talks shall give by the Site Engineer & Supervisor with the concerned work force prior to start
of the work is a mandatory requirement.
c) Organizing tools and equipment required for the work site.
d) Ensure all PPEs are available to all the workers involved in the work.
e) Inspection of all works at every stage.
f) Ensuring the sufficient First Aiders and fire wardens are available with the crew.
g) Ensure all Safety Regulations are followed as applicable.

5.6 Surveyor
He shall be responsible for:
a) The surveyor along with his team members shall carry out the survey work in a systematic manner within
the stipulated time.
b) Ensure that all the levels / positions / alignments marked are properly secured and their location identified
accordingly.
c) Ensure that based on the latest Approved for construction drawings levels and benchmark has given.
d) Time to time preparing and submitting the survey report for the client review & approval.
e) Ensure before commencing of the activity all instruments are having valid calibration.
f) Ensure the permanent benchmark and cross verification in intervals.

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5.7 QA/QC Officer

He shall be responsible for:

a) Stage Inspections and Surveillance in accordance with QCP and assurance of quality of work as per
specification and approved procedures.
b) Ensure all the testing equipment are calibrated and calibration certificate is available at site.
c) Ensure availability of latest Approved for construction drawings/Specifications and reference documents.
d) Coordinate with approved Third party laboratory for Material testing as per Client specifications and
International standards.
e) Ensure all incoming site materials are as per approved Material submittal.
f) Review and Maintain records of all material test reports as per client requirement.

5.8 HSE Officer

He shall be responsible for:

a) Be familiar with the Client general safety, contractual requirements.
b) Advising site persons of any problems relating to the implementation of the HSE plan.
c) Permanent member of the HSE committee compiles and presents HSE site specific reports.
d) Maintain records of HSE meetings and ensure that routine HSE meetings and toolbox talks are carried out,
actions recorded, as stipulated in the HSE procedures.
e) Carryout safety audits and inspections, record proceedings and follow up recommendations.
f) Arrange for the distribution and display of safety posters and other safety promotional material.
g) Provide relevant advice on health, safety and environmental issues to all employees.
h) Assist with investigations of all accidents or incidents.
i) Maintain copies of all accident/incident reports and provide a monthly report and accident statistics to the
HSE professional.
j) Provide technical support in the preparation of departmental HSE action plans.
k) Demonstrate active involvement in HSE training programs.
l) Carryout assessment of sub-contractor activities and HSE systems.
m) Generally, monitor Occupational health risk assessments, performance monitoring and surveillance.

5.9 Direct Staffs

He shall be responsible for:
a) Carrying out all works as per standard and specifications.

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 5.10 Quantity Surveyor
She shall be responsible for:
a) Continually analyzing outcomes and write budget reports.
b) Advising on contractual claims and disputes.
c) Undertaking cost analysis for repair and maintenance project work.
d) Valuing completed work and arranging for payments.
e) Raising of Request For Approval (RFA) to substantiate claims.
f) Tracking changes to the design and/or construction work, and adjusting budget projections accordingly.
g) Coordinating with all concerned personnel to ensure quality of work, precision of work done and to meet
the requirements of the Client and Consultant.

5.11 Material Engineer

He shall be responsible for:
a) Implements all aspects of the ITP.
b) Review all material submittals for compliance with the contract documents.
c) Supervise laboratory and all testing activities.
d) Supervise site inspectors and all inspection activities.
e) Review all method statements for quality compliance.
f) Ensure that Material Inspection Requests for all designated activities are presented to the Engineer.

5.12 Site Laboratory Technicians

a) Maintains site laboratory and equipment in suitable condition.
b) Monitor sampling and conduct testing to appropriate standards.
c) Maintain all records in suitable fashion

6.0 ASSOCIATED REQUIREMENTS

6.1 HSE Requirements

a) Ensure all P & M Equipment being used for the activity are in good working condition.
b) Ensure P & M Operators are qualified & authorized to operate the relevant equipment.
c) Ensure the work area shall be barricaded.
d) The toolbox talk shall be carried out before starting the work.
e) Ensure all necessary PPEs are worn by workers involved in the work.
f) Work shall be carried out in the daytime and if authorized, night work is permitted.

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 g) All sub-contractor men, material, machinery details to be collected and checked against insurance.
h) No work shall be allowed if temperature is more than 50 degree Celsius / high wind / more than 80%
humidity / inclement weather due to rain, lighting storm, fog or dark condition.

6.2 Materials, Tools, Equipment and Machineries

a) Vibrator
b) Concrete Mixer
c) Water Tanker
d) Ready-mixed concrete
e) Steel reinforcement (whenever applicable)
f) Concrete spacers
g) Tie wires
h) Formwork release agent
i) Waterproofing (whenever applicable)
j) Damp proofing (whenever applicable)
k) Bonding agent
l) Sealant
m) Epoxy
n) Formworks
o) Hessian cloth

7.0 PROCEDURE

7.1 General
The following documents as a minimum shall be readily available for ready reference at work site.
 Client specifications
 Approved Method statement
 Issued for Construction drawing &
 Approved Material approval sheet

7.2 Procedure
A. Production of Precast Elements
Approved ready mixed concrete is being used in the production of precast elements from the approved
supplier.
B. Testing of Concrete

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 The testing procedures and frequency of concrete constituents testing shall be as per the Project
Specifications as mentioned in Volume 3.2 Part I, Particular Specifications 4/31, Minimum Test
Requirements for Concrete.
C. Sequence of Work for Precast Element
 Mold Fabrication & preparation
 Fabrication and assembly of steel reinforcement
 Placement of steel reinforcement into the mold
 Embedded parts (if any)
 Pre-stressing of wire strands (if required)
 Concreting works
 Curing
 De-molding
 Stripping
D. Embedded Parts/Items
 Place the embedded items as per approved drawings and approved submittals (if required)

 Embedded items must be checked by the production engineer/supervisor prior to casting of the
element before concrete. All embedded items, insulation grouts; sealants, backing rods, and
other materials to be used shall be as per the approved Material Submittal. All cast-in parts
shall be fixed in position as per approved shop drawings.

 Prior to the casting of precast elements, it will ensure that all MEP inserts & points i.e.
Electrical boxes, conduits, etc. are provided based on approved drawing locations. QC will
ensure that it is properly fixed based on approved drawings.

E. Concreting
 Precast casting is planned in such a way that concreting work is done in one complete
operation without breaks. Concrete is brought by either the concrete transport shuttle from the
batch plant or through the transit mixer discharged via mixer chute or extended chute, to the
casting mold.

 Time interval is observed to avoid the occurrence of the cold joint, QC Inspector will ensure
the batching with the approved mix design & its batching record at the checkpoint of the lab at
the checkpoint material engineer will conduct all fresh concrete tests according to Inspection
& test plan. QC Engineer will ensure the concrete temperature at the time of concrete placing
should not exceed 25°C. Concrete casting in hot weather shall be according to Project
Specifications.

 Lay the concrete up to the mold in such a manner that the entire mold surface is covered
evenly. Air concrete thermometers shall be kept on the Site. Temperature monitoring shall
continue until the interior temperature is within 20°C of the lowest ambient temperature of two
weeks.

 Vibration: For casting on table base mold with built-in high-frequency vibrators: Switch on the
vibrator at the pre-determined period of time as instructed by the Production in charge or QC
inspector.
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  For casting on table base mold without built-in vibrators: Compact the concrete by using poker
vibrators, immersion type. Vibration is applied continuously for a predetermined time during
the placement of each concrete batch. Special attention is given to difficult areas where heavy
reinforcement occurs to prevent the presence of void or honeycomb in the concrete. Level the
top surface and remove excess concrete after concreting. After the initial setting of the concrete
surface, apply the required surface finish as per the requirement of the Specification.

F. Curing

Panel/elements are covered with a Polythene sheet and hessian cloth to avoid dehydration. All
produced panels/elements will be cured by water continuously for 7 days after tilting and stacking.
Alternatively, an approved curing compound may also be applied after 24 hours of water curing as per
the Engineer’s approval.

G. De-molding and Stripping

 De-mold and strip the precast units off the mold once they have attained the required
compressive strength or as per the approved design.

 Curing to Attain Specified compressive strength as follows. A sample consists of 6 cubes, 3 to

be taken 7 days and 3 at 28 days.

 Once the precast unit is stripped off the mold, mark the precast element taking into account the
identification number and casting date as per the approved unique numbering style. The
marking is placed in such a way that it is visible.

7.3 Records & Documents.

RFA
Laboratory Test Results

 END OF PROCEDURE 

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