‘

METHOD STATEMENT
ERECTION OF PRECAST WALLPANELS
AND SLABS

TABLE OF CONTENTS
1.0 Title

2.0 Scope of Work

2.1 General Description and Scope
2.2 Discussion on Erection Requirements
2.3 Pre-Erection Planning
2.4 Personnel
2.5 Equipment
2.6 Materials
2.7 Preparation
2.8 General Method Statement for Erection of WP Cladding
2.9 General Method Statement for Erection of Slabs

3.0 Quality Assurance

3.1 Contractual Requirements
3.2 Responsibility
3.3 Inspection & Testing

4.0 Safety & Health

4.1 Protective Safety Equipment
4.2 MSDS
4.3 Risk Assessment

5.0 References

1.0 TITLE

Erection of precast wall panels and slabs

2.0 SCOPE OF WORK

2.1 GENERAL DESCRIPTION

This document outlines the procedure for erecting Precast Wall Panels, Slabs and its
safety requirements. Precast Wall panels which may either be plain (gray, troweled) or
architectural (pigmented, with special finishing such as sandblasted) and solid or
insulated. Regardless of type, the degree of care during handling and erection should be
as to avoid any damage to the unit, install the unit in correct (within tolerance)
location/position/fixation and overall safety at site.

2.2 DISCUSSION ON ERECTION REQUIREMENTS

A successful precast concrete project requires teamwork. This means close

cooperation and coordination of all participants including the Client, Consultant, Katerra
and the Main Contractor. The basic working relationship must be established in order to
achieve the desired results and schedule.

Quality erection is essential. In this end, the erection engineer and his crew should
assist the main contractor to help solve problems before they occur, by coordinating his
efforts with other participants. It is his foresight and planning that will help keep the
project moving on trouble free course. (PCI-MNL-127 “Recommended Practice for
Erection of Precast Concrete”).

Basic procedures and guidelines for erection of WP are presented in this method
statement. For more information about general erection practices, refer to PCI-MNL-127
“Recommended Practice for Erection of Precast Concrete”.

2.3 PRE-ERECTION PLANNING

The Katerra Projects Manager is overall responsible for the project schedule,
dimension and quantities, coordination with other Katerra Department Heads and other
trades, choice of construction means, methods, techniques, sequences and procedures
of construction, in addition to safety and quality precautions and programs in
connection to precast erection for the particular project. The following needs to be
considered in erection planning:

1. Completeness of details in precast concrete erection drawings; as well as

finality of its approval.
2. Precast handling, transporting and erecting schemes e.g. lift plans, risk
assessments, manpower and resources needed and lines of authority.
3. Sequencing is also of utmost importance; it should be agreed by the
planning team and factory and adhered to, unless severe unforeseen
problem dictate a sequence change. Consider the balance between
sequence and economy in manufacture, and should be flexible enough to
allow (a) close to full loads on delivery trailers (2) control of unit position
on trailer for safety and economy, (3) advance notice needs and (4)
assurance for prompt unloading. Special units which exceed normal
payloads/dimensions should be coordinated by the erection crew well in
 advance to the factory and dispatching crew.
4. Verification of dimensional interfacing of precast concrete with other
trades:
a. Cast-in-situ frames
b. MEP’s
c. Others (e.g. window, doors, architectural features, etc.)
5. Agreement on erection tolerances with other trades and the main
contractor.

2.4 PERSONNEL

1. Projects Manager
a. Overall, in-charge for project execution

2. Erection Manager, Engineer and/or Supervisor

a. Overall, in-charge for the erection processes in accordance to legal and
Client requirements, standard industry and best practices.
b. Directly responsible for monitoring the Health, Safety & Environment
activities in the sites. He shall work in close coordination with the HSE
Engineer to implement the Health, Safety & Environment Plan and any
addendum or modification as might be required. He will also supervise the
execution of remedial and emergency actions.
c. Shall perform/coordinate erection as per method statement.
d. Responsible to provide his workers with a safe working environment and to
promote HSE consciousness among all of them at every opportunity.
e. Provide safe construction equipment, Tools & Personnel Protective
Equipment in enough for the work to be performed.
f. To complete the work on schedule and without accidents.
g. Attend necessary HSE Meetings.

3. Site Foreman
a. Transmit, explain and enforce all HSE regulation requirements to be applied
during construction.
b. A site foreman has direct responsibility to provide and maintain a safe
working environment for the workforce under their control and promote
awareness at all opportunities.
c. Control emergency situations.
d. Attend necessary HSE meetings.

4. Individual
a. Each worker or employee is responsible for observing all HSE rules applicable
to his work area.
b. They should report to the person concerned of any hazards, injuries,
accidents and / or any other unsafe working condition so the same can be
rectified in the best possible manner.
c. Erectors – should be experienced erectors for the precast unit being erected;
attestation on attendance to safety orientation specific to erection and
construction site safety required.
d. Lifting Equipment Operators – should be experienced operators with valid
certification/license from local government agency and third-party training
specific to the equipment being operated.
e. Riggers – should be experienced riggers with valid third-party training
certification.
f. Labors, other trades – attestation on attendance to safety orientation on
construction site safety required.
 5. HSE Engineer/Officer
a. Responsible to oversee HSE activities at the factory and site.
b. Responsible for organizing HSE inspections / audits.
c. Along with the site in charge, he shall also represent the company at Site
HSE Meetings.
d. Will represent the company, on HSE matters, to the government officials.
e. Will maintain & develop HSE Handbooks, Instructions and Procedures in the
company.
f. Ensure that the company’s HSE Procedures are complying with local safety
laws and norms.
g. Coordinate with client & client’s representatives in matters regarding safety.
h. Conduct regular HSE inspection on Sites and Factory.
i. Assess the risk factors by monitoring factory and site activities and take
necessary measures to prevent the occurrence of any untoward incidents.
j. Conduct training for staff and workers concerning safety, emergency
response to accidents and appropriate use of Personal Protective Equipment
(PPE).
k. Train workers to promote the awareness of injury prevention and control of
damage to equipment.
l. Ensure that there are necessary PPE’s for performing the various works in
the plant.
m. Investigate accidents at site and factory, fix responsibilities and adopt
procedures for non-recurrences of accidents.
n. The HSE Engineer is responsible to enforce the implementation of the
Occupational Health and HSE Plan, to upgrade safety where possible, inspect
working areas to detect and correct unsafe or unhealthy situation and
organize education and awareness of the workforce and all other staff.
o. Oversee the toolbox meetings being conducted; organize training sessions
on HSE with different levels of supervision.
p. Report unsafe situations and monitor implementation of remedial actions
represented.
q. Make sure that safe working procedures for any hazardous work have been
established.
r. Maintain all HSE records.

2.5 EQUIPMENT

List of Equipment:

a) Mobile Crane – should be of the type required particular to this project in

reference to the Erection/Lift Plan and additional client specifications apply
whichever is stricter. The Erection Engineer must ensure compliance to be
verified by HSE Engineer/Officer and/or Client/Main Contractor representatives.

b) Chain Slings/Nylon Belt Slings/Spreader Bars/Hooks - should be of the type

required particular to this project in reference to the Erection/Lift Plan.

2.6 MATERIALS

 PVC Shim Pads, various thickness – used as temporary base support for
alignment
 Proprietary Push-Pull Props as Temporary Support; to be fixed using
 stud/expandable anchors
 Depending on connection design, the following may be used:
o Proprietary Steel Angular Plates and Bolts (usually on bolted
connections);
o Proprietary Dowel Bars (usually on corbelled WP to Beam
connections);
o Proprietary Steel Plates (if welded connections are designed); if
welded connections are designed, the welder, welding equipment and
materials should comply the design requirements and approved
Welding Procedure Specification (WPS);
o Proprietary Chemical Anchors (if required);
o Proprietary Non-Shrink Grout (for filling dowel holes);
o Proprietary Load-Bearing Grout.
 Approved Joint Sealant and backing rod

2.7 PREPARATION

Identify the area of erection as per Erection Plan and sequence of work. Verify
site access, equipment and precast concrete unit’s condition prior to erection, and they
should satisfy all the relevant requirements. An important aspect of site readiness is the
cast-in-situ structure to receive the panels. The Erection Manager/Engineer/Supervisor
should thoroughly field check the CIS structure especially in terms of dimension (by
surveying and layout) and access and, whenever possible, to inspect the Wall Panels &
Slabs in the factory (in concert with Katerra QC Department) in advance to ensure smooth
erection process. The objective of the survey is to ensure that the areas to receive
elements are ready, accessible and that the elements will fit.

They should also coordinate with the main contractor to halt or limit any other
activities in the erection area and/or apply guidelines indicated in OHSE Risk/Impact
Assessment Register to mitigate safety risks involved. Any discrepancies between site
conditions and approved erection drawings, which may cause problems during erection
such as costly delays and errors, should be noted in writing by the Erection
Engineer/Supervisor and sent to the Katerra Projects Manager, who will review the
discrepancy and notifies the relevant party/s for required actions. Erection should not
proceed until all erection requirements are fulfilled and discrepancies modified

2.8 GENERAL METHOD STATEMENT FOR ERECTION OF WALLPANEL

(This procedure quoted from PCI-MNL-127 “Recommended Practice for Erection of
Precast Concrete”, pages 44, 56-58)

1. Layout: Vertical and horizontal control should be maintained. Elevations should

be clearly marked on the face of supporting structure. On steel or CIS
structures, offset lines may be set on floor slabs or marked on steel to give
control for the exposed face. Panel joint centerlines should also be located both
vertically and horizontally. As erection proceeds, a check should be made on
overall elevation and plumbness of the precast units already placed. The
erector should be aware that the deformation on supporting structure may
induce unintended loading on the wall panel, and should report promptly. Be
cautious when cladding is supported at the ends of cantilevers, which make
alignment difficult.
2. Wall Panels should be shipped to the jobsite in vertical position, whenever
possible, so that turning is not required. It should be brought close to the area
under reachable crane radius where erection is being carried out.
3. Panels should be installed in floor-by-floor basis, where feasible, to keep
loading equal on the structure. It is also an important and efficient practice to
have the claddings erected right after it is lifted from the delivery trailer truck to
avoid double handling. However, if stacking at site cannot be avoided, the
storage should be on A-Frames placed on a level, stable surface. The area
should be properly barricaded and identified. Keep minimal amount of panels
stored at site at a time, preferably only a day’s worth of erection.

Lifting of Delivered Wall Panel Cladding from Trailer Truck A-Frame

4. Lifting area is cordoned and barricaded by warning tape with a safety

signboards precaution.
5. Precast wall panel will be lifted directly from the trailer using mobile crane with
the aid of 2-leg chain sling. Lifting anchor will be embedded in all precast
elements in which to be used as a lifting point. Center of gravity is determined
from the design department to have accurate and balance lifting execution. The
movement of precast elements is controlled by using taglines (rope).

Hoisting and Positioning of Wall Panel Cladding closer to the Structure

6. In case of any blind lift, additional certified rigger/banksman should be provided

to pass rigging to the crane operator.
7. Precast panel will be erected or placed directly atop of PVC shims which rest on
the top of foundation/slab.

Shim Pads used to achieve exact cladding alignment

8. Each panel will be temporarily braced by 2 (or more) adjustable push-pull

props. First, the erection crew drills a hole 12mmϕ x 65mm depth on the
slab/foundation. The lower end of props will be fixed using M12 x 100mm stud
anchor which inserted on the drilled hole. Same procedure is made on the
panel (interior portion) to fix the upper end of push pull props. Drive the stud
anchor through by hammering and tighten using a spanner before fully
releasing the load from the crane.

Installation of Push-Pull Props as Temporary Support

9. No additional live loads should be allowed to be imposed on the claddings while

on temporary supports.
10. Verify and adjust, if needed, the alignment and plumbness of wall panel
cladding using spirit level and plumb tools. It should be within the tolerance
specified in the contract documents or PCI-MNL-135. If required (and
recommended practice), a Request for Inspection (RFI) is raised by the Erection
Engineer to the Client or Main Contractor QC Personnel, for every completed
elevation, in order to gain approval to proceed to final fixation.
11. After the verification of alignment, plumbness and final position, permanent
fixing is installed:
 a. Welded Steel Connection – embed Steel Plates (conforming to ASTM
A36) is welded to adjacent panel’s embed steel plates. Additional steel
conforming to ASTM A36 may be required to connect the embed steel
plates, depending on design. Follow the approved Welding Procedure
Specification (WPS) for any welded connection and should not proceed
until the RFI is approved.

Sample Wall Panel – CIS Structure Welded Fixing Set-Up; verify approved Erection
Drawings

b. Doweled Connection – at this stage, usually the dowel hole is not

grouted until the panel alignment is approved by the Client or Main
Contractor QC. The dowel bar may be threaded or non-threaded
deformed reinforcing bar conforming to ASTM A615, uncoated, and
should be free from rust, contamination, oil and dirt.

12. After acceptance/approval of alignment and permanent fixing, grout holes (for
dowelled connection) is grouted. In case of welded connection, the assembly is
coated with galvanic or red oxide primer and grouted for corrosion protection.
13. The gap between top of foundation or slab and corbel bottom of precast
cladding will be grouted using approved non-shrink grout. Temporary push pull
props will be removed 3 days after grouting.
14. Same procedures apply for erection of succeeding panels.
15. After completion of erection, backing rod and approved external joint sealant is
applied to panel-to-panel joints in accordance to its corresponding technical
data sheets. Work of other trades (block work, insulation, MEP) usually starts at
this stage.
 Typical Joint Sealing Detail
.

2.9 GENERAL METHOD STATEMENT FOR ERECTION OF SLABS

Fig. 1: Checking of bearing surfaces. Note the use of retractable fall arrest equipment during this process

Fig. 2: Chain Slings with proprietary spreader bars, if required

2.9.1 Safe System of Work Preparation

a. Before erecting any slabs, the supporting structure should be checked to

determine if all pertinent dimensions correspond with those shown on the
approved erection drawings. Prior to placing the slabs, the bearing surfaces
should be checked to ensure that they are smooth and level. Bearing material
should be placed as required by the erection drawings.
b. Upon delivery of Slab to site by the trailer, it shall be erected immediately
based on the lifting plan arrangement.
c. The area for erection activities shall be cordoned to isolate the area plus 10
meters from the radius extra distance as safety zone.
d. The area where the slabs to be erected shall be completely installed
with scaffold pipe railings as the hooking point for the riggers and
 erectors. Shear Connector Reinforcement and lifting hooks also aid as
a hooking point. Retractable fall arrestor device can also be used and
hooked on the same hooking point.
e. Pre-Task Briefing shall be done for the involve workers conducted by
the Erection Supervisor and Safety Manager.

2.9.2 Safe System of Work During Erection

a) All workers involved in the erection activities on the structure (Rigger,

Foreman, Erectors) shall wear full body harness with a double lanyard.
They should connect their lanyard to the scaffold pipe railings or shear
connector reinforcement. If pipe railings are not installed, the lanyard
must be attached to a retractable fall arrestor which in turn is
adequately hooked to slab lifting hook.
b) Two riggers at the ground level will prepare the rigging and execute to
give signal to lift and travel the load. One rigger assigned in the ground
level to give signal and one rigger assigned at the top receives and
transmits the signal.

c) When the first slab is to be erected, foreman will stand at the area
near the rigger position and the two erectors will position at the
opposite side. All of them must connect the lanyard all the time to the
scaffold railings as designed and prepared, or use retractable fall
arrestors as described in (a).

d) For erection of second slab, the two erectors, foreman and rigger shall
position at the same side connected to the same hooking point of the
lanyard.

e) Erection of succeeding slabs shall follow the same procedure in (c) and
so on.

2.9.3 Typical Erection Cycle

a) Arrival of trailer to Site. Delivery note shall be duly noted by Erection

Foreman/Supervisor/Engineer upon checking the load quantity,
element code and damages during delivery.
b) Trailer to wait outside the building site until called in by the flag man.
c) The driver will go down and loosen all straps or chains used to secure
the precast load on the trailer.
d) One rigger will go up the trailer and connect the element with the
lifting device which is connecting to the crane sling.
e) Rigger will give instruction to crane operator and erection crew to start
the lifting and installation step.
f) From the same position the crane will erect all elements in its range
capacity

2.9.4 Erecting of slabs to Final Position

a) Position the crane as per Erection Layout.

b) Arrange and ensure workers and rigger are with complete safety
accessories.
c) Mark and layout the slab on final position as per drawing.
 d) Ensure two (2) tag lines are connected to lifted slabs for safe
maneuvering.
e) Place the slab in final position.
f) Level the slabs using steel bearing plates or shim pads.

2.9.5 Fixing of Connection Details

a) For erection, connections must be installed as per approved detail

drawing. If welding is required, ensure that the welder is certified as
per AWS D1.1 and/or D1.4
b) Reinforcement shall be installed as per approved detail drawing.
c) Screeding and grouting (by other sub-contractor) shall commence after
approval of levels and connections by the Client.

3.0 QUALITY ASSURANCE

3.1 CONTRACTUAL REQUIREMENTS

1. Satisfy general acceptability of erection of wall panels and slabs in

accordance to this method statement and safety practices.

3.2 RESPONSIBILITY

The following personnel are responsible for the conduct of this Operational
Procedure:

1. Erection procedure:Erection Engineer

2. Inspection and confirmation of compliance: QC Engineer

3.3 INSPECTION & TESTING

1. Frequency:
Per completed floor

2. Records
The following Forms must be used on each specified Quality
Control Points:

Quality Control Point Form

Reporting of Non-Conformance / NC Report and NC/CAPA Log
CAPA Sheet

Records shall be kept in Katerra QC Department and kept for

minimum of two (2) years.

4.0 HEALTH & SAFETY

4.1 PROTECTIVE & SAFETY EQUIPMENT

The following are the list of Personal Protective Equipment to be used by personnel
 conducting this activity:
1. Protective Overalls
2. Proprietary Hard Hat with Suspension Strap
3. Safety Shoes
4. Good Quality Gloves, Goggles and Dust Mask
5. Fall Protection PPE’s

4.2 MSDS (MANUFACTURER SAFETY DATA SHEET)

Not applicable
.

4.3 RISK ASSESSMENT

5.0 REFERENCES

PCI-MNL-127 “Recommended Practice for Erection of Precast Concrete”

PCI-MNL-132 “PCI Erection Safety for Precast and Prestressed Concrete”
PCI-MNL-135 “Tolerances for Precast and Prestressed Concrete Construction”