SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT.
LTD
Method Statement August 2014
Page 1
METHOD STATEMENT FOR INSTALLATION OF
HOLLOW CORE SLABS
1.0 INTRODUCTION
This Method Statement accounts for the plan and procedure for the erection of “Precast
Hollow Core Slabs” for construction of 56 Villas at Alibaugh using Precast Technology for
Mahindra Lifespaces Developers Ltd.
.
2.0 SCOPE OF WORK
This statement describes the procedure, quality control and safety requirements related to
the erection of precast Hollow Core slabs under normal weather conditions. Wind speeds
upto 20 knots/hour will be under normal condition. Any live electrical wires or telephone
lines in line with the work will have to be disconnected before erection of slabs starts. The
client is responsible for getting these disconnected by the competitive authority.
3.0 LOCATION OF WORK
Proposed Premium Residential Development at Village Nagaon, Alibaug
4.0 REFERENCES
4.1 Erection Drawings.
4.2 Fabrication Drawings.
4.3 Project Specifications.
4.4 Test certificates for the Crane and other relevant lifting devices from the competent
authority as when requested at site.
5.0 RESOURCES
5.1 Manpower
5.1.1 Foreman
5.1.2 Erection Crew
5.1.3 Crane Operator
5.1.4 Mason
5.2 Machinery and Tools
5.2.1 Mobile Crane or Tower Crane (by others) with valid test certificate.
5.2.2 Hydra Crane for lift and shift of material
5.2.3 Flat bed Trailers
5.2.4 Lifting Gadgets (Chain sling, lifting sling, shackle, grinder, chisel& hammer)
5.2.5 Drilling Machine for making holes.
5.2.6 Grinder: a 220V portable 9” device with dead-man switch.
5.2.7 Crow Bars
5.2.8 Portable generator & Extension power cable
5.2.9 Scaffolding (if required)
5.2.10 Props
SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT. LTD
Method Statement August 2014
Page 2
FOR ERECTION OF HOLLOW CORE SLABS
5.3 Protective Equipment
5.3.1 Hard Hat
5.3.2 Safety Shoes
5.3.3 Safety Harness
5.4 Materials
5.4.1 PVC Shim Pad or other material as agreed with the client.
6.0 WORKS PROCEDURE
6.1 Erection Planning
Early planning starts in the design where precast slabs will be marked for
identification concerning its type and location as in erection wise.
Production is closely coordinated with site works to ensure availability of
precast slab at the exact period required.
Capacity of the crane depends on various factors but mainly on the weight of
the Hollow Core slabs, height of the building and location of the crane from the
building. Crane selected for the job will be sufficient to meet the requirement.
6.2 Erection Sequence
Sequence of erection will be as per suggested zoning or as reflected in the main
contractor’s in-situ works program.
6.3 Erection Method
a) Pre erection activity
(1) Request for an ideal place of momentary storage area for precast slabs at
project site shall be required from the contractor.
(2) Prior to erection schedule, check and setting-out will be conducted at site to
ensure efficiency of work.
(3) Precast slabs will be brought to site at the specified time of erection on a trailer
with a maximum numbers required per loading.
(4) The crane will be placed in such a way that it can reach the farthest place
within lifting capacity and without shifting the crane. After that the crane will
be shifted. This will be planned in advance as to decide how many slabs can be
erected from one crane position depending upon the capacity of mobile crane.
(5) In the ongoing course of erection, trailers will be positioned at an accessible
reach of either tower or mobile crane for easy maneuver (about1.5 m beside
the crane).
SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT. LTD
Method Statement August 2014
Page 3
FOR ERECTION OF HOLLOW CORE SLABS
(6) If the crane is not ready to receive the precast elements by the mobile crane,
Hydra will unload the elements and stock in the yard and will shift with Hydra
when required.
b) Carrying out the work.
(1) There will be two labors on the trailer to place the lifting belt under the slab.
The foreman will be on top of the building with the Drawings. The foreman
will be giving the signal to the crane operator for the movement of the crane.
Two erectors will be top of the beam. They will be wearing safety harness
which will be attached to the near by scaffolding if any on the outer periphery
of the building or on tower scaffolding which is provided by the main
contractor on the inner side of the room and is 1mt, below the beam where the
slab is to be placed.
(2) Before commencing the erection work the lifting slings will be checked for
safety latches, belt for any damage/cut to nylon sling belt.
(3) The lifting capacity of the belt will be checked as per the weight of the slab,
in advance before erection is planned.
(4) When the slab will come at site it will be checked by the foreman for its
conformity. He will check the slab code and file number. The slabs will be
visually checked for any damage during transportation.
(5) The erection will start with the top slab on the trailer.
(6) Lifting of slabs is done with the belts.
(7) Slab will be lifted slowly from the trailer without giving jerk; it will be guided
slowly till it is clear of nearby slabs and then moved toward the building where
it has to be placed.
(8) The foreman will give signal to the crane operator and will guide the slab to
the top of the beam.
(9) As per the level required, Shims will be placed on the beam by the two erectors
on top of the beam. Two shims on each side about 100mm from each end.
SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT. LTD
Method Statement August 2014
Page 4
FOR ERECTION OF HOLLOWCORE SLABS
(10) The slab will be lowered in position slowly. The erectors on the beam or on the
scaffolding will hold and guide the slab to the top of the beam. When the slab in
the position and ready to be lowered in position, the erectors would inform the
foreman to lower the slab very slowly. The slab shall be placed slowly on the
top of the shims. Slab shall be checked for having required bearing on the
beam.
Slab placed in position must have enough length to have minimum bearing as
per the following (normal bearing is 60 mm):
Block work: 65mm
Concrete beams: 55mm
Steel beams 40mm
(11) The erectors will check for bearing and then they will instruct the foreman that
he can lower the beam completely and now the slab will be resting on top of
the beam. The belt will not be removed unless the minimum required bearing
is there for the slab. The slab will be moved / adjusted with the help of
crowbar.
(12) The erectors would then climb on top of the slab and remove the belt from the
sling hook.
(13) The foreman would direct the crane operator on to the trailer to lift the next
slab.
(14) By this time the two erectors on the slab will place the shims in position for the
next slab.
(15) The next slab will be placed in its position. The space between two adjacent
slabs which was left out for removal of belt will be closed after the belt is
removed. This will be done with the help of crow bar. The crow bar will be
placed in the space between the slab and the beam. The erector on top of the
slab will shift the slab to its correct position. All alignment work etc will be
done with the help of crow bar.
(16) Any cutting of slab required at site will be done with the help of grinder.
Hammer and chisel will be used to break the concrete where the grinder will
not work.
(17) Immediate action will be taken by the foreman in case of any accident. All
accidents will be reported to the safety officer.
SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT. LTD
Method Statement August 2014
Page 5
FOR ERECTION OF HOLLOW CORE SLABS
c) Leveling
(1) Once all slabs are placed in position, final alignment in all respects will be
carried on with the help of crow bar and leveling shims.
(2) Tools used for leveling are aluminum ladder, shuttering jack, crowbar,
hammer & shims.
(3) Leveling of slab will be done from inside of the room. The highest point on
the beam will be checked visually. If the beam looks leveled then the centre
slab will be taken as the base slab.
(4) The slab will be leveled on both ends.
(5) Considering that final alignment is completed, filling the gap at base
supports with grout should be done before placing any load on the slabs.
d) Grouting
1. End plugs are provided in the hollow Core slabs on the trailer before lifting it. End
plugs should be made of PVC, polystyrene or other sufficient material.
2. Hollow Core slabs are erected on shims leaving a gap of 0~20mm between the
soffit of the slab or the top of the in-situ beam as per requirement to achieve the
desired level.
3. Final leveling of the Hollow Core slabs by adjusting the shims, after lifting the slab
with props.
4. U-stirrups are placed in the joints between the slabs.
5. Joints and periphery beams are casted.
6. If the joints are left un grouted for a long period of time, then they will inevitably
collect dirt and dust, which will prevent proper grouting and most importantly,
will spoil the structural shear key between the slabs. To avoid such problems
tamp and grout immediately after erection and leveling. A cast joint is made by
pouring or pumping the concrete. All secondary reinforcement must be accurately
positioned according to the drawings.
SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT. LTD
Method Statement August 2014
Page 6
FOR ERECTION OF HOLLOW CORE SLABS
7. If the weather is very dry and hot, it is advisable that the floor be pre-soaked and
then kept moist for 2 days after joint casting to prevent the cast joint from drying
too fast and consequently shrinking and cracking, When curing, it is
recommended to cover the concrete with wet canvas and polythene sheets
instead of the continuous pouring of water. This procedure will give good curing
humidity and reduce the amount of water used for curing and at the same time
will not allow the Hollow Cores to be filled with water. In the event that the
Hollow Cores get filled with water, it is the responsibility of the customer to drill
the required hole to drain the cores.
7.0 SAFETY
Standard Safety Rules and Regulations are to be observed in the duration of
erection work. Safety shoes and hard hats are to be worn by all, all the time
while at site.
Workers are fully equipped with protective equipments such as safety shoes,
helmets, vest and many others as required.
Aside from physical check performed for lifting gadgets, test certificates are to
be verified true and validated.
The main contractor to ensure that erection area is better segregated from
other operations to prevent the risk of unauthorized access that may result to
injury.
Safety harness is to be provided specially to workers maneuvering the edge of
the structure at high level for fall arrest.
Simplex Prefab’s Safety Officer’s presence is to be available whenever required.
SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT. LTD
Method Statement August 2014
Page 7
FOR ERECTION OF WALL PANELS/BEAMS/COLUMNS/STAIRS
1.0 INTRODUCTION
This Method Statement accounts for the plan and procedure of Simplex Prefab for the
erection of Precast panels /beams/columns/stairs for construction of 56 Villas and
compound wall at Alibaugh using Precast Technology for Mahindra Lifespaces Developers
Ltd.
2.0 SCOPE OF WORK
This statement describes the procedure, quality control and safety requirements related to
the erection of Describes the procedure and quality control related to the erection of
precast wall panels and similar elements under normal weather conditions.
3.0 LOCATION OF WORK
Proposed Premium Residential Development at Village Nagaon, Alibaug
4.0 REFERENCES
4.1 Erection Drawings
4.2 Fabrication Drawings
4.3 Project Specifications
5.0 RESOURCES
5.1 Manpower
5.1.1 Foreman
5.1.2 Erectors
5.1.3 Crane Operator
5.1.4 Mason
5.2 Machinery and Tools
5.2.1 Mobile Crane
5.2.2 Flat bed Trailers
5.2.3 Lifting Gadgets (Chain sling, lifting sling, shackle, grinder, chisel& hammer)
5.2.4 Drilling Machine
5.2.5 Grinder: a 220V portable 9” device with dead-man switch.
5.2.6 Crow Bars
5.2.7 Portable generator & Extension power cable
5.2.8 Props
SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT. LTD
Method Statement August 2014
Page 8
METHOD STATEMENT
FOR ERECTION OF CLADDING PANELS
5.3 Protective Equipment
5.3.1 Hard Hat
5.3.2 Safety Shoes
5.3.3 Safety Harness
5.4 Materials
5.4.1 PVC Shim Pad
5.4.2 Dowel Bar
5.4.3 Concrete Grout
6.0 WORKS PROCEDURE
Axis and reference gridlines are marked on the foundations or slabs.
Levels of foundations or floors are checked, and then correspondingly PVC shims will be
provided whenever required.
Location of dowel to be checked or marked as per approved drawings.
Whenever possible, element codes are marked on the foundation or slabs.
Sequence of erection to be as per site priorities depending on crane positioning.
Panels will arrive on ‘A’ frame trailers. Proper access for our trailers and mobile cranes to
be provided by the client
Panels will be lifted from the trailer directly into position using mobile crane using the
lifters casted with the precast panel. Tested chain sling is used to connect to mobile crane
hook.
No personnel are allowed below the lifted panels. Tag line will be provided in the element
for control.
The panels will be erected on the shims and braced using adjustable props fixed to bracing
inserts in the panels and in the floor slabs.
After completing erection of panels, alignment will be done using plumb bob and sprit
level to checked the verticality of panels.
Vertical joints between precast panels will be grouted with non-shrink flow able
cementation grout from approved supplier. Shuttering will be used to close inside and
outside joints.
All dowel holes will be grouted using non-shrink cementations flow able grout.
Bracing of the panels will be kept until the stability of the panel is secured. The props will
be removed after erecting of hollow core slabs.
Erection of panels, stairs, columns, beams, etc. on the next floor, meaning repeating step 1
to 13.
SIMPLEX PREFAB INFRASTRUCTURE (INDIA) PVT. LTD
Method Statement August 2014
Page 9
METHOD STATEMENT
FOR ERECTION OF CLADDING PANELS
7.0 SAFETY
Standard Safety Rules and Regulations are to be observed in the duration of erection work.
Workers are fully equipped with protective equipments such as safety shoes, helmets, vest
and many others as required.
Aside from physical check performed for lifting gadgets, test certificates are to be verified
true and validated.
Simplex Prefab and customer to ensure that erection area is better segregated from other
operations to prevent the risk of unauthorized access that may result to injury.
Safety harness is to be provided specially to workers maneuvering the edge of the
structure at high level for fall arrest.
Simplex Prefab’s Safety Officer’s presence is to be available whenever required.
