Document

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Method Statement Revision No.: 0

Issue Date: 14 Dec. 2020

Design & Build Of External Works For Landscape, Irrigation Network,

Car Parking & Services At Lusail (Al-Daayan Area)
Project ID: P-16-26-DB-02

METHOD STATEMENT FOR PRECAST CONCRETE WORKS

DOCUMENT REFERENCE NUMBER:

00 15-12-2020

Initial Release
For Approval

REV. DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

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TABLE OF CONTENT
1.0 PURPOSE................................................................................................................................................4
1.0.2 SCOPE.................................................................................................................................................4
1.0.3 LOCATION MAP..................................................................................................................................4
2.0 References.............................................................................................................................................5
2.1 Terms and Definitions.........................................................................................................................5
3.0 Materials and Equipment......................................................................................................................6
3.1 Materials................................................................................................................................................6
3.2 Machinery and Equipment....................................................................................................................6
4.0 Duties and Responsibilities....................................................................................................................7
4.1 Project Manager....................................................................................................................................7
4.2 Construction Manager:..........................................................................................................................7
4.3 Lean Implementation Leads:.................................................................................................................7
4.4 HSE Manager:........................................................................................................................................7
4.5 Technical Manager:...............................................................................................................................7
4.6 QA/QC Manager:...................................................................................................................................8
4.7 Site Engineer:.........................................................................................................................................8
4.8 QA/QC Engineer, Inspector:...................................................................................................................8
4.9 Land Surveyor:.......................................................................................................................................8
4.10.2 Operators:........................................................................................................................................8
4.10 HSE Officer:..........................................................................................................................................8
4.10.1 Concrete foreman:............................................................................................................................8
5.0 LEAN implementation Plan....................................................................................................................8
5.0.1 SORT...................................................................................................................................................8
5.02 SET IN ORDER......................................................................................................................................9
5.03 SHINE...................................................................................................................................................9
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5.04 STANDARDIZE....................................................................................................................................10
5.05 SUSTAIN.............................................................................................................................................10
6.0 Methodology.......................................................................................................................................11
6.1 Fabrication of Precast Moulds.............................................................................................................11
6.2 Mould Preparation for Casting............................................................................................................11
6.3 Assembly of Reinforcement Cages......................................................................................................11
6.4 Placement of Reinforcement cages.....................................................................................................12
6.5 Embedded Items..................................................................................................................................13
6.6 Precast Concreting.............................................................................................................................13
6.7 Precast Curing......................................................................................................................................14
6.8 Precast De-moulding and stripping......................................................................................................14
6.9 Handling, Storage and Transportation of precast Elements................................................................14
6.10 Loading and Delivery.........................................................................................................................15
6.11 Quality Controls.................................................................................................................................15
6.12 Health, Safety and Environment........................................................................................................15
6.13 DOCUMENTATION / RECORDS...........................................................................................................17
6.14 Manpower.........................................................................................................................................17
10.1.1 Key Personnel.................................................................................................................................17
10.1.2 Survey Teams..................................................................................................................................17
10.1.3 Operators/Drivers...........................................................................................................................17
10.1.4 QA/QC Teams.................................................................................................................................17
10.1.5 Laboratory Technician....................................................................................................................17
10.1.6 Skilled & Unskilled Workers............................................................................................................17
10.1.7 Helpers...........................................................................................................................................17
6.15 Document References:...................................................................................................................17
6.16 Project Specification.......................................................................................................................17
6.17 QCS 2014..........................................................................................................................................17
6.18 IFC Drawing......................................................................................................................................17

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7.0 Attachments........................................................................................................................................18
7.1 Inspection & Test Plan (ITP).................................................................................................................18

1.0 PURPOSE
The Purpose of this method statement is to provide guidelines and to describe the procedure to
produce precast Concrete Items at the precast site yards of Design & Build of External Works for
Landscape, Irrigation Network, Car Parking & Services At Lusail (Al-Daayan Area)

This Method Statement covers the general procedures to be followed for Production of Precast
Concrete Item as described in QCS-2014.

1.0.2 SCOPE
The scope of this document is to lay down the systematic procedures for the Production and Delivery of
Precast Concrete Item and to ensure that all works are carried out in accordance with the approved
shop drawings, and to full compliance with the project specification.

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1.0.3 LOCATION MAP:

Zone 06 Zone 07
ZONE 05

Zone 03

Zone 01
Zone 02

Zone 04

2.0 References
● Approved Material Submittal

● Approved Mix Design

● Provided IFC Drawings

● All shop drawings relevant to the production works.

● Project Specification

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● QCS 2014

● BOQ Specifications

● HSE Plan

● Quality Plan

● Lean Implementation Plan

2.1 Terms and Definitions

Term Definitions

Client ASHGHAL

Consultant Arab Architects

Contractor UCC-INFRA JV

QCS 2014 Qatar Construction Specification 2014

MSDS Material Safety Data Sheets

RA Safety Risk Assessment

ITP Inspection and Test Plan

HSE Health, safety and Environment

PS Project Specifications

RSI Request For Site Inspection

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QA&QC Quality Assurance and Quality Control

TPL Third Party Laboratory

PE Project Engineer

3.0 Materials and Equipment

3.1 Materials
All materials required for the precast concrete works shall be in full compliance with QCS 2014
and Project specific specification.

● Approved Ready-Mix Concrete

● Approved Reinforced Steel Bars

● Approved Precast Formwork System

● Approved Miscellaneous Embedment

3.2 Machinery and Equipment

The following table lists the equipment to be used for the precast concrete works. All necessary
equipment calibration certificates and 3rd party certificates for the machinery shall be available
prior using the equipment.
EQUIPMENT Quantity

Air compressor 1no.

Generators 1no.

Slump Kit 1no.

Concrete Distributing buckets 1no.

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Concrete Truck Mixer 1no.

Boom Truck 1no.

Forklift 1no.

Wooden palette 1no.

4.0 Duties and Responsibilities

4.1 Project Manager:
To ensure that the responsible personals of the work are designated, and the work is planned to be
carried out by maintaining appropriate Design, LEAN, Quality, Environmental and Safety requirements.

4.2 Construction Manager:

To supervise the responsible construction team and shall ensure that all the works are carrying out in
line with design, lean, quality, environmental and safety requirements.

4.3 Lean Implementation Leads:

To ensure the Lean implantation plan is followed.

4.4 HSE Manager:

To ensures that all operation is carried out in a safe manner and in accordance with the minimum
requirement set out in the health and safety regulations and referred documents.

4.5 Technical Manager:

To ensure that the works are carried out as per the project IFC Drawings / Shop drawings and Technical
submittals as required.

4.6 QA/QC Manager:

To ensures all QA/QC requirements are fulfilled during the execution of the work.

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4.7 Site Engineer:

He has full control over the use of the labor, plant & equipment to carry out the construction activities
as per approved method statement, drawings and specifications.

4.8 QA/QC Engineer, Inspector:

To ensure the works are carried out as per approved method statement and QA/QC requirements.

4.9 Land Surveyor:

Responsible to provide survey points as per approved drawings.

4.10.2 Operators:
To operate equipment and machines in line with HSE & traffic rules and regulations.

4.10 HSE Officer:

Responsible to ensure works are carried out complying safety requirements.

4.10.1 Concrete foreman:

Responsible to carryout concrete works as per approved method statement and to comply with safety
and QA/QC requirements.

5.0 LEAN implementation Plan

The LEAN Implementation for the construction of Concrete works shall be as demonstrated in
below.

5.0.1 SORT
Goals:

● Reduce time loss looking for an item by reducing no. of items.

Reduce the chances of distraction by unnecessary items and increase safety.

Implementation:

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Refer Method Statement to plan requirements of equipment and materials prior to starting the work.
Avoid unnecessary equipment, materials not necessary for the work.
 All the Equipment’s should be checked before using if there is any Error.

Responsibilities:

● Construction Manager.
● Site Engineer
● Sr. Surveyor

5.02 SET IN ORDER

SORT

Goals:

Make the workflow smooth and easy.

Implementation:

● Arrange all necessary items in site so that they can be easily selected when required to use it.
● All the Equipment’s should be set in order and to be Calibrated.

Responsibilities:

● Sr. Surveyor
● Site Engineer.
● QAQC Engineer/ Inspector.
● Safety Officers

5.03 SHINE
GOAL:

To improve the construction process efficiency and safety, reduce waste, prev ent errors and
defects.

IMPLEMENTATION:
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● Housekeeping to be carried out at the work locations daily.

● Carry out safety inspections during construction to confirm the safety requirements

Responsibilities:

● Sr. Surveyor
● Site Engineer.
● QAQC Engineer/ Inspector.
● Safety Officers

5.04 STANDARDIZE
GOAL:

● Establish procedures and schedules to ensure the first three 5S are in place.

IMPLEMENTATION

● Review the implementation of above three 5S in the weekly lean construction meetings for
compliance.
● Ensure everyone knows their responsibilities and they are doing it.

RESPONSIBILITIES:

 Lean Implementation Leads

5.05 SUSTAIN
● Ensure 5S approach is followed

IMPLEMENTATION:

● Perform audits to ensure LEAN implementation plan is followed.

● Encourage team members for identifying improvements.
● Implement improvements whenever possible.
● When issues arise, identify the cause and implement the changes necessary to avoid recurrence.

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RESPONSIBILITIES:

● Lean Implementation Leads

6.0 Methodology
6.1 Fabrication of Precast Moulds

● The precast moulds shall be fabricated at UIV Workshop located at the laydown area of UIV Site
offices.

● All precast moulds shall be fabricated as per approved shop drawing.

● The prepared items will be set up on the ground by suitable fixing elements.
● If there are openings like hole for pipe use the same procedure like for main shutter.
● Provisions for lifting will be fixed on the upper part of the mould without damaging the surface of the
elements by using lifting devices or any other suitable measures

● Upon completion of set up, the mould shall be checked for accordance with workshop drawing and
fabrication drawing regarding dimensional requirements and provisions of other accessories.

● The QC, PE and the Foreman are responsible to check the conformity of the mould to the approved
workshop drawing and fabrication drawing.

6.2 Mould Preparation for Casting

● Clean the mould from dust and dirt by using appropriate method.

● Apply the approved form oil by using high pressure pump.

● Make sure pump has the right pressure and produce a fine mist.

● Avoid any excess of form oil especially in corners etc.

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6.3 Assembly of Reinforcement Cages

● Mock-up for each precast element shall be carried out prior to start production.

● All the reinforced steel bar shall be factory cut and bend from an approved manufacturer through an
approved supplier.

● UIV shall submit a material delivery inspection request to ARAB ARCHITECTS for approval for all
deliver of steel bars.

● Testing of samples of rebars shall be carried out with TPL as per the frequency stated in QCS 2014.

● The diameter, length, and bending shall be as per approved shop drawing.

● The reinforcement cage shall be constructed at the fabrication yards of laydown area.

● A foremen/ gang leader shall supervise the installation of the rebars.

● The rebars shall be tied with approved tie wire and spacing of rebars shall be carried out as per
approved shop drawing.

● After completion of reinforcement installation, QC and Site Engineer shall verify the completeness of
the fabrication and shall verify the correctness of installation as per approved shop drawing.

6.4 Placement of Reinforcement cages

● Transfer the reinforced cage from storage area into the mould by using suitable provision.

● Avoid distortion, bending, stretching etc. of the cage.

● Reinforcement cage Inspection shall be carried out prior to placing into mould.

● Place cage into the mould.

● Make sure the spacers are in the right position, maybe add some spacers to fix the cage properly in
the mould to prevent dislocation.

● Upon completion of installation the whole set up shall be checked for accordance with approved
workshop drawing regarding dimensional requirements and provisions of inserts.
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● The QC, PE and the Foreman are responsible to check the conformity of the set up to the approved
workshop drawing

● Make sure no debris, tie wire cut offs etc. are left in the set up.

6.5 Embedded Items

● All inserts fixing items to be used to the elements as per approved shop drawing.

6.6 Precast Concreting

● Inspection request shall be submitted for consultant Inspection prior to concrete pouring.

● Only Approved mix designs are to be used for production of precast elements.

● The Production Engineer is responsible to order the right mix design in accordance with approved
mix design list and workshop drawings.

● Concreting must be planned as complete operation without any breaks to avoid the occurrence of
cold joints.

● The concrete will be delivered via the concrete hopper from batch plant to a designated position.

● Concrete will be discharged into the bucket of the pouring bridge or a pouring bucket.

● During pouring make sure the outlet of the pouring bridge or pouring bucket is as close as

● possible to the mould set up to avoid segregation or splashing of the concrete.

● Pouring height shall not exceed more than 1.5m.

● The QC and 3rd party Laboratory Technician shall check the type of mix design, slump, and
temperature and take sample cubes in accordance with approved concrete design mix.

● For compacting the concrete use provision of fix installed vibrators, temporary installed vibrators or
poker vibrators.

● When using poker vibrators make sure the correct diameter related to mould set up will be used.

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● Special attention shall be given to difficult areas like heavy reinforcement areas, difficult mould
geometry etc. to honeycombing, voids etc.

6.7 Precast Curing

● For standard curing after concreting and finishing, the open concrete surface shall be water cured
and covered by wet hessian cloth and polyethylene sheet or other suitable measures to avoid fast
drying.

● In some cases, after consultant approval, an approved curing compound can be sprayed onto the
surface of the concrete in accordance with specification of supplier.

6.8 Precast De-moulding and stripping

● De-moulding and Stripping of formwork shall be following requirements of QCS 2014, Section-5,
Part-9, Subsection- 9.5.2.

● During de-moulding and lifting the element shall be checked visually for any defects or damages.

● The element shall be directly marked / labelled with casting dates as specified in the workshop
drawing.

● In case of defects or damages the QC shall be informed immediately prior transferring to the stock
yard.

● Post pour Inspection shall be carried out to check the surface damages and repairing shall be done as
per approved Method Statement.

6.9 Handling, Storage and Transportation of precast Elements

● Precast elements shall have provisions for stripping, lifting and all purposes during production and
erection.

● All provisions shall be made by approved materials only.

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● Positions and type of provisions shall be identified in the workshop drawings ensure lifting forces are
equally distributed.

● Lifting of precast elements are not allowed until the achieved strength and age are notified to the
consultants.

● Lift the precast elements only on their designated lifting positions and with suitable approved lifting
equipment.

● Precast elements shall be preferably stored in erection position to avoid over handling.

● Precast elements shall be preferably transport in proper position and used suitable lifting devices to
avoid any damage and rejection of the transport elements in the erection.

6.10 Loading and Delivery

● Precast concrete items will be loaded once 28 days required strength achieved, at flatbed trailer by
using a forklift.

● Wooden palette will be provided for the proper seating of the precast concrete item on the trailer
and precast concrete item directly to the flat bed.

● All the precast concrete item in the trailer are secured with the belt slings tightened to the trailer
hooks.

● The tightened belt meeting precast concrete item will be protected to avoid damages.

● QC inspector visually confirms on site the condition of the goods received is on well condition or not,
before releasing for installation.

6.11 Quality Controls

Only approved materials will be used. Inspection and testing will be done in compliance with the
approved Test Plan. Control of the material will be in full adherence and compliance with project specific
specifications and conditions of the contract.

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6.12 Health, Safety and Environment

The Safety Officer shall be responsible to monitor the implementation and effectiveness of Health,
Safety and Environmental requirements as necessary, but not be limited to the followings.

a) All workers in the factory will be instructed to wear Personal Protective Equipment (PPE).
● Safety Hard Hats

● Safety Steel Toe Capped and Soled Footwear

● Safety Gloves

● Dust Mask

● Safety Glass

● Hi-visibility jackets

● Tension Belts

● Ensure Valid Permits, Licenses and Certificates

● All workers in the factory must have inducted properly, received the required
training / competencies prior to proceed the works. All safety equipment must
be inspected and approved by the factory supervisor or safety officer.
● All workers in the factory must have inducted properly, received the required
training / competencies prior to proceed the works. All safety equipment must
be inspected and approved by the factory supervisor or safety officer.

● All activity would always be supervised by a competent staff.

● All lifting and binding tools are to be mark with a valid safety seal to ensure
their safe workability and use.

● Use adequate and visible signage, posters and board to promote awareness.

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● Ensure adequate resting areas, toilet and drinking water are accessible to all.

● Ensure enough lightings are provided when working at night times. In addition
to fixed lightings, portable lights must be kept on standby.

● Any accident or near miss must be reported to Safety Officer immediately and
with a written report to UIV Head Office within 24 hours.

6.13 DOCUMENTATION / RECORDS

● MIR

● Inspection records & Test records

6.14 Manpower

10.1.1 Key Personnel

10.1.2 Survey Teams

10.1.3 Operators/Drivers

10.1.4 QA/QC Teams

10.1.5 Laboratory Technician

10.1.6 Skilled & Unskilled Workers

10.1.7 Helpers

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6.15 Document References:

6.16 Project Specification

6.17 QCS 2014

6.18 IFC Drawing

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7.0 Attachments
7.1 Inspection & Test Plan (ITP)

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8.0 RISK ASSESSMENT

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