Precast Pre-stressed Girders

OBJECTIVE
The objective of this method statement is to provide guidelines for production and placing of Precast Pre-stressed girders

Scope
This method statement covers production of pre-cast pre-stressed, girders their handling, transportation and placing.

Production Methodology
Precast Pre-stressed concrete structure i.e. girders will be produced in yard as per specifications with the approval of engineer. Materials to produce girders i.e. cement; aggregates (course and fine), reinforcement steel, strands and anchors will be stored properly in secured places. Concrete mix design trials will be carried out to produce the pre-cast concrete structures of required strength prior to starting of production of girders. The girders will be cast on level platform having adequately firm foundations to prevent settlement during casting and curing operations. Forms will be arranged to provide ample working room and ease for carrying out all operations required for the proper placing, consolidating and finishing of the concrete. Wires and strands will be placed as per drawings and pre stresses will be induced through pressure jacks by the competent person as per design requirements. Reinforcement of the girder will be carried out as per design. Each structure will be thoroughly worked into the corners of the forms and compacted by internal vibrating, spading and rodding as required during the concrete placing operation. Pre-cast members will remain undisturbed after casting until completion of a 3-day initial curing period, for storage purposes.

Quality control tests such as slump test and temperature record will be taken during the placing of concrete and compressive strength will be conducted to ensure that the structure satisfy the strength requirements mentioned in the specifications. Strands and wires will be cut down after testing concrete cubes to transfer the stresses to concrete. Great care will be taken to make sure that the entire pre-cast member matches the finishing standards of approved sample by the Engineer.

Delivery, Handling and Storage

Precast concrete members will be lifted and supported during manufacturing, transporting and erection operations only at the lifting or supporting points and with suitable lifting devices such as gantry crane, mobile crane). All members will be separately stacked size wise so that lifting devices can easily access the member without damaging the structure.

Transportation
Transportation, site handling, and erection will be performed with acceptable equipment and methods, and by skilled & experienced personnel. For the purpose of safe transportation of girders two lifting points on the both ends will be provided. Heavy lifting cranes capable to lift the load of girders will be available at the time of loading of girders on trailers. Rigging expert will be available during loading activity to ensure the proper lifting and placing of girders as special care is required to avoid un-equal lifting. After loading on trailers, girders will be transported to site and will be placed directly at their point of placement, where our site team will launch them according to the instructions of the engineers representative.

Erection and Placing Methodology

Clear, well-drained strong enough unloading areas and road access around and in the structure will be provided and maintained to facilitate the movement of cranes and trucks used in process of erection. To complete the erection activity a crane of suitable capacity will be made available with skilled riggers.

Handling and placing of the girders will be accomplished through experienced and competent staff, by using suitable bridles, slings or other approved means to avoid damage to pre- cast members. Members will be properly aligned and leveled as per the approved shop drawings. Adequate barricades, warning lights and signs will be erected to safeguard traffic in the immediate area of hoisting and handling operations. Precast concrete structures will be repaired (if damaged) during erection and will be cleaned upon completion of erection.