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II.

METHOD
STATEMENT
(WORK-PROCESSES FOR
THE FABRICATION OF
PRECAST COMPONENTS)

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
II. Method of Statement Normal Precast Components 08

2.1. BRIEF DESCRIPTION OF ACTIVITY

The construction consists of a combination of precast concrete elements and in


situ concrete.
The precast component shall be produced by the precaster at the designated
factory and transport them to site where it will be used entirely for the purpose as
stipulated in the contract. The types of components to be cast and the location of
casting are indicated in the list of precast components.
The production works shall be executed based on plans and specifications that
were approved by the client.
Project quality plan shall be prepared by the Precaster to ensure the products
compliance to quality and standard. The plan shall describe the procedures,
guidelines and reporting methods to be followed in the fabrication works.

2.2. FORMWORK

The formwork for the precast element shall be made purposely of steel moulds.
The moulds shall be rigid and even and shall comply with the clients
specification and sufficiently designed to withstand the concrete pressure.
Form release agent shall be applied to the moulds before casting for ease of de-
molding.

2.3. STEEL REINFORCEMENTS

Reinforcing bars shall be from approved supplier or as designated by the client.


All reinforcements and wire meshes shall comply with SS560 and SS561
standards respectively.
Test and Mill Certificates for all the types of reinforcements shall be provided by
the supplier.

2.4. INSPECTION

Joint inspection shall be conducted between the client representative and / or


consultant representative along with HLBM staff on the first casting.
Subsequent inspections will be as per clients and/or consultants representative
instructions.
Casting shall commence only upon inspection and/or approval by the clients
representative.

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
II. Method of Statement Normal Precast Components 09

2.5. CONCRETE

Only the client approved concrete mix design shall be used for casting.
Concrete are supplied by factory in-house batching plant / RMC certified supplier
using the approved mix design.
The concrete shall be compacted using poker and mould vibrators.
Test cubes preparation and sampling rate shall be in accordance with the
requirements set by the client.
Extra cubes shall be made to determine the strength before de-molding.

2.6. FINISHING

The products surface shall be finished according to the clients requirement.


Pinholes and minor chipped-offs shall be sealed/patch-up using approved
materials.
Major damage shall be repaired according to the method stated in the Project
Quality Plan.

2.7. PROTECTION, LIFTING AND TRANSPORTATION

Precast elements shall only be lifted, turned, and/or transported when the
concrete has reached its sufficient strength. Extra test cubes shall be made to
monitor the strength of the concrete prior to lifting, turning and /or transporting.
On the precast factory, overhead cranes shall be used to lift the units.
The precast units will be transported over the road to site by trailers or lorry
cranes.
For some precast units, special spreader beams or frames might be required for
de-molding and handling.

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
II. Method of Statement Normal Precast Components 10

2.8. EQUIPMENT
The following equipments shall be used for the fabrication of the Precast
concrete units:
Truck mixers and forklifts for transporting the concrete
Overhead cranes with lifting capacity that range from 10 20 tons
Poker Vibrators
Mould Vibrators
Low bed trailers and/or Lorry Cranes to transport the precast concrete panels

2.9. SAFETY
The company safety committee shall oversee and ensure that the workplace is
hazard free and safety regulations are being implemented.
All workers are to wear appropriate PPE:-
Safety Helmet
Safety Shoes
Dust Mask / Respirator
Ear Plug
Safety Glass
Safety Gloves

3.0. QUALITY CONTROL AND REPORTING


Quality control shall be according to the procedures stated in the Project Quality
Plan.
Inspections and tests shall be according to the Inspection Table.
During fabrication of the precast elements, the following documents shall be
maintained:
Inspection checklists according to the Inspection Table
Test cube results
Steel Bars Mill Certificates and test reports

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
II. Method of Statement Pictorial Guide 11

1. BASEMOULD PREPARATION &


SETTING UP

Control Point

a. Cleanliness

b. Level and Flatness

c. Provisions for Mould Oil

d. Joints and Edges

2. INSTALL REINFORCEMENTS
AND FIXING M&E FIXTURES

Control Point
a. Reinforcement size and
Spacing
b. Spacers and Concrete Covers
c. Starter Bars, Protruding
Reinforcements, SS Sleeve,
Corrugated Ducts, Spiral
Connectors, etc
d. Position of M&E Fixtures
3. CLOSING FORMWORKS
Control Point
a. Dimensions
b. Squareness
c. Diagonal, Plumb/Verticality
d. Locking Devices; Bolts, Pins,
Stoppers
Tie Rods, Propping, Rubber
sealants

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Method of Statement Pictorial Guide 12

4. FINAL INSPECTION

Control Point
a. Compliance with Drawings, codes
and Standards
b. Provisions for Lifting / De-molding
Hooks
c. Provisions for Cast in Inserts

d. Joints and Edges

5. CASTING

Control Point
a. Concrete Gade
b. RMC Slump and Temperature

c. Vibration and Compaction

d. Rubber Sealants and Grout Leaks

6. CURING
Control Point
a. Provisions for Ambient Curing
b. Application of Curing Compound
(Where Necessary or as per approval
from consultants)

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
IV. Method of Statement Pictorial Guide 13

7. DEMOULDING

Control Point
a. Next Day De-molding Strength (14-16
Hrs)
b. Loosening and removal of locking
devices
c. Stripping of Formworks

d. De-mould and Hoisting

8. HOISTING, OVERTURNING AND


TRANSFER TO STORAGE AREA

Control Point
a. Handling
b. Chip-offs
c. Propping and Safety supports /
paddings

9. STORAGE
Control Point
a. Methods of proper storage
b. Safety

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
II. Method of Statement Pictorial Guide 14

10. POST POUR INSPECTION

Control Point

a. Profile and features

b. Chip-offs/ concrete Cracks

c. Surface condition

d. Visual Checks

11. HOISTING, OVERTURNING AND TRANSFER


TO STORAGE AREA

Control Point
a. Handling
b. Chip-offs

c. Propping and Safety supports / paddings

12. LOADING AND DELIVERY


Control Point
a. Methods of proper storage
b. Safety

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
III.
QU A L I T Y
CONTROL
MANUAL

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Quality Control Manual 16
3.1. ORGANISATION CHART (PRODUCTION & OPERATION)

PROJECT MANAGER

PROFESSIONAL ENGINEER TECHNICAL CONTROLLER

PRODUCTION MANAGER QA QC MANAGER TECHNICAL MANAGER SAFETY & R&M

PLANT MANAGER QC ENGINEER PROJECT ENGINEER

PRODUCTION ENGINEER QC INSPECTOR DRAFSTMEN

PRODUCTION SUPERVISOR

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Quality Control Manual 17
3.2. LOCATION MAP

WE ARE HERE
HL BUILDING MATERIALS PTE LTD.
PRECAST CONCRETE DIVISION
7A TUAS AVENUE 13 S638979

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Quality Control Manual 18
3.3. FACTORY LAYOUT PLAN

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Quality Control Manual
3.4. MANUFACTURING FLOWCHART PRE PRODUCTION 19
PROCESS

From Production A1
Planning Process Preliminary
Mould
Planning
A3
Inspection No. 1-
Shop drawing
Check
A2
Shop
From Design drawing
Process Preparation
A4
Submission
of drawing
to Client

A6
A5
Amendment to NO
Approve?
Shop Drawings

YES

A7
Steel
Mould
Ordering

A8
Delivery &
Installing
Steel
Mould

A9
Incoming
Inspection No. 2

Return To A10 To Production


NO YES
Supplier Accept? Process

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Quality Control Manual
3.4. MANUFACTURING FLOWCHART - MATERIALS SUPPLY PROCESS 20

Delivery of
Precast
From Supplier Materials

Material
Receipt

Incoming
Inspection No. 3

NO
Return to Supplier
Accept?

YES

Fabrication &
Installation
(Use)

Storage

To Production
Material Issuance
Process

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Quality Control Manual
3.4. MANUFACTURING FLOWCHART RMC SUPPLY PROCESS 21

Delivery of
Concreting
Materials Material
From Supplier
Receipt
E1 E2

E3
Incoming
Inspection No. 4

E4
Return To
NO Accept?
Supplier

E5

Storage

E6

Concrete Return To
Batching Batching Plant

NO

E7 E8
To Production
From Readymixed Incoming
Accept? YES Process Point
Concrete supplier Inspection No. 5
B8

NO

Return to
Supplier

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Quality Control Manual
3.4. MANUFACTURING FLOWCHART - PRODUCTION 22
PROCESS

B1 B2 B3
From Pre- Preliminary
Cleaning / In-process
Production Alteration Assy. & Mould Inspection
Process A10 of Moulds Set-up No.6

B4 B5 B6
From Precast Steel In-process
M&E Embedded
Material Supply Reinforcement Services Assy. Inspection
Process D7 Assy. No.7

From Concrete B7
Batching Process Casting
E8

B8
Curing

B9
Inspection
No.8

B10
No To Finishing &
Passed Yes Demoulding
Delivery
&
Process C1
Turning

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674
PROJECT QUALITY PLAN
Document Title: Page No.
III. Quality Control Manual 23
3.8. MANUFACTURING FLOWCHART FINISHING & DELIVERY
PROCESS

C1 C2
From Production Storage Inspection
Process B12 Yard No.9

C3
Repair / Touchup

C4 C5
Inspection Waterproofing
No.10

C6
Testing
&
Inspection
No.11

C8
C7 Testing
Tilling Installation &
Inspection
No.12

C9
Loading of
Finished Products

C10
Final
&
Outgoing Inspection
No.13

Delivery To Customer

HL BUILDING MATERIALS PTE LTD


7A Tuas Ave 13, Singapore 638979
Tel: 6862 3501 Fax: 6861 0674