n - Estidama

 Where preca
ast is ttaken to a h
higher r level
1 INTRODUCTION • Who is Xtramix? • Vision, Mission & Values • What We Can Do? Viision
Ourr vision is to
o exceed ou
ur customerrs’ expectattions, ensurring our pro
oducts are of the highest quality in accordance with nation
nal and inteernational sstandards.
M
Mission
n
Ourr mission is to be the b
best provideer for a wid
de range of precast pro
oducts and serv
on industry..
vices in the constructio
Vaalues
Xtramix Internation
nal Precast demonstrates full com
mmitment tto its core vvalues, ensu
uring a custome
er service‐o
orientated aapproach am
mongst all o
of its emplo
oyees. EX
XCEPTIONA
AL CUSTOMER SERVICEE Ou
ur commitm
ment is to maintain solid and long‐term business reelationships, not onlyy with our cliients, but also with our suppliers and consulltants. LEEADERSHIP Ou
ur highly professionall, experiencced and ou
utstandinglyy competen
nt management and employees e
arre continuously develo
oping new w
ways to imp
prove our quality of wo
ork and service. NTEGRITY IN
W are transparent, honest an
We nd innovative when it comes to being ethically unyielding co
orrespondin
ng our attitu
udes to ourr words. QU
UALITY CON
NTROL AND
D ASSURAN
NCE Th
he provided
d productss and services by us are of thee highest quality q
and we are co
onsistently measuring th
he results off our perforrmance. D SAFETY HEEALTH AND
Ou
ur aim is to
o ensure the
e health, saafety, securrity and weell‐being of our employyees, minim
mising risks an
nd observing zero incid
dent/accideent levels.
PR
RECISION W are driveen by a cu
We ulture of discipline an
nd superb attention a
to detail, which w
facilittates us to prrovide high‐‐quality pro
oducts and services consistently.
X
XTRAMIX IN
NTERNATIO
ONAL PRECAST IS PRO
OUD OF ITS CAPACITY TTO ACHIEV
VE THE SET TTARGETS AND CHALLENGIN
NG PROJECTS’ SCHEDU
ULES, WITH
HOUT COMPROMISING
G ON QUALLITY. 2 CAPABILITIES • Personnel • Equipment • Products Xttramixx Perssonnel Xtramix Internaational Precaast currentlyy has nearlyy 1000 perssonnel working in the Manaagement, Design, D
Prod
duction, Ereection, Cost‐‐control, Hu
uman Resou
urces & Adm
min, Health &
& Safety, Plaanning, and Sales & Marketing depaartments. Th
he workforce is highly m
multi‐cultural and is emp
ployed from many counttries around the world.
Key Perso
onnel Name Present Possition Mr. Abde
el Razzak Daajani Managing D
Director 22
2 Experience
e (years) Dr. Tomaasz Ciesielskki Operations Manager 22
2 Mr. Amggad Gomaa Planning Maanager 11
1 Mr. Yousssef Greige Design Man
nager 13
3 Mr. Ram
m Eskeif Production Manager 09
9 Mr. Mirzza Dobraca Health, Safeety, Security &
& Environmental Sr. Officer 12
2 Mr. Moaatasem M. Fo
oudeh Sr. HR & Admin. Manageer 12
2 Mr. Sohaaib Hamdieh
h Projects Maanager 25
5 Mr. Robe
ert Campbelll Commercial Manager 17
7 Mr. Jojim
mon Devasiaa Cost Contro
ol Manager 12
2 Maintenancce Manager 20
0 Mr. Taye
el Al Sehaim Support & SService Manager 09
9 Mr. Pravveen Kanoth QA/QC Man
nager 13
3 Mr. Shaikh Haque Sen
nior M
Managgemen
nt &
& Curre
ent Numbe
er of EEmplo
oyees
DEPARTM
MENT TOTAL MA
ANPOWER
Total for P
Precast Leadin
ng Team 4 Total for SSales & Marke
eting Dept 4 Total for Q
QA/QC Dept 19 Total for D
Design Dept 17 Total for EErection Dept
172 Total for P
Production Dept 527 Total for LLogistics Division 95 Total for P
Planning Dept
5 Total for SSupport & Servvices Operatio
on 23 Total IT O
Operation 2 Total for H
HR & Admin Dept 8 Total for H
House Keepingg Section Total for H
HSE and Security Operation
Total Costt Control Operration GRAND
D TOTAL 22 6 18 922
XTRAMIX INTERNATIONAL PRECAST LLC
OPERATIONS GROUPING STRUCTURE
MEMBER OF THE AL JABER GROUP OF COMPANIES
Organization Chart
LEGEND :
‐
‐
‐
‐
‐
TOP MANAGEMENT
SR. MANAGEMENT
‐
‐
UNIT LEADER
1st STAFF DOWNLINE
MANAGING DIRECTOR
MR. ABDEL RAZZAK DAJANI
2nd STAFF DOWNLINE
WORKERS DOWNLINE
MNGMT. & SALES
8
PLANNING
922
5
HUMAN RES.
DESIGN DEPT
17
PROD & LOGISTICS
622
5
HSSE DEPT
QA/QC DEPT
19
ERECTION
172
6
ADMIN
8
SERVICE & SUP.
25
HOUSE KEEPING
17
OTHERS
18
DEPARTMENT HEAD
OPERATIONS MANAGER
DR. TOMASZ CIESIELSKI
OM OFFICE TEAM
EXECUTIVE SECRETARY
TO THE OM ‐ XIP 1
CENTRAL DOCUMENTS CONTROLLER
2
PLANNING MANAGER
MR. AMGAD GOMAA
DIREECT TO OPERATIONS
1
1
QA/QC MANAGER (PRAVEEN KANOTH)
PRODUCTION MANAGER
MR. RAM ESKEIF
DESIGN MANAGER
MR. YOUSSEF GREIGE
1
PROJECTS MANAGER
MR. SOHAIB HAMDIEH
1
1
1
SR. QA/QC ENGINEER
(MOHD. YOONUS) 1
ASST. DESIGN MANAGER SR. PRODUCTION ENGINEER ‐ PRECAST
0
PLANNING ENGINEERS
1
STRUCTURAL / ARCHITECHTURAL 4
ENGINEERS
1
DRAUGHTSMANS
8
DETAILERS
DOC. CONTROLLER
1
SR. SALES MANAGER
0
0
PRODUCTION FOREMEN
CHARGE HANDS ‐
PRODUCTION
CHARGE HANDS ‐
PRODUCTION
CHARGE HANDS ‐
PRODUCTION
12
395
35
SR. MARKETING EXECUTIVE 0
MARKETING OFFICER 0
HR & ADMIN ‐ ASST. MGR / EXECUTIVE
1
DOCUMENTATION
INCHARGE
2
1
HOLLOW CORE PRODUCTION WORKERS
HR & ADMIN MGR
MR MOATASEM
MR. MOATASEM FOUDEH 1
COMMERCIAL MANAGER
MR. BOB CAMPBELL
1
PRODUCTION FOREMEN
4
QA/QC
ENGINEERS
1
0
PRODUCTION SUP / 20
FOREMEN
PRECAST PRODUCTION
WORKERS
4
SR. PRODUCTION ENGINEER ‐ GRC
SR. PRODUCTION ENG. ‐
HOLLOW CORE
3
SR. ESTIMATOR
SUPPORT TO OPERATIONS / XCS & XIP CO
OMBINED
1
TOTAL MP
SITE / ERECTION (CIVIL) ENGINEERS
5
3
ERECTION SUP / FOREMEN
1
CHARGE HANDS /
SURVEYOR
QC INSPECTORS
2
5
LAB TECHNICIANS / LAB HELPERS / CUBE DEMOULDERS
8
GRC
PRODUCTION WORKERS
35
146
COST CONTROL MGR
MR. JOJIMON DEVASIA
MR
JOJIMON DEVASIA
1
1
1
HSSE ENGINEERS / HSSE OFFICERS
FACILITIES / MAINTENANCE MANAGER
HSSE INSPECTORS / COMPANY NURSE
MAINTENANCE FOREMEN
1
7
ERECTION WORKERS
SSD MANAGER
MR. TAYEL AL SEHAIM
MR
TAYEL AL SEHAIM
1
14
SUPERINTENDENTS / SERVICE ADVISOR
0
LOGISTICS IN‐CHARGE
1
CHIEF ACCOUNTANT / PROCUREMENT EXEC
.
2
SR. SALES EXECUTIVE
1
SR. ESTIMATOR
ESTIMATOR
1
0
QUANTITY SURVEYOR
1
HR OFFICERS
3
ADMIN OFFICERS / RECEPTIONIST / PRO
3
TIME KEEPERS/ ADMIN DRIVERS
14
LOGISTICS FOREMEN
FACTORY OFFICER
[ HOUSE KEEPING ]
1
OFFICE BOYS AND FACTORY PREMISES CLEANERS 20
SECURITY GUARDS / SAFETY PATROLERS
3
4
3
MAINTENANCE WORKERS
PROJECTS FOREMEN / IT SUPPORT OFFICERS
2
SUPPORT AND SERVICE
WORKERS
25
0
7
CHARGE HANDS ‐
MAINTENANCE
2
HD DRIVERS ‐ TRAILER, TRANSIT MIXER / SHOVEL OPTR / HEAVY BUS DRIVER
68
PAYROLL OFFICERS / ACCOUNTANTS / STORE OFFICER/KEEPERS 7
STORE HELPERS / PURCHASE DRIVERS
8
FORM NO. XIP‐HR‐01‐003‐F01 ‐ MACRO ORGANIZATION CHART
Version Date :
29‐Sep‐11
Rev No: A/4
XTRAMIX INTERNATIONAL PRECAST LLC
GRC GROUPING STRUCTURE
MEMBER OF THE AL JABER GROUP OF COMPANIES
Organization Chart
LEGEND :
‐
‐
‐
‐
‐
TOP MANAGEMENT
SR. MANAGEMENT
‐
‐
‐
UNIT LEADER
1st STAFF DOWNLINE
DEPARTMENT HEAD
MANAGING DIRECTOR
MR. ABDEL RAZZAK DAJANI
1ST WORKERS DOWNLINE
2ND WORKERS DOWNLINE
1
3RD WORKERS DOWNLINE
OPERATIONS MANAGER
DR. TOMASZ CIESIELSKI
1
PRODUCTION MANAGER
MR. RAM ESKEIF
1
ERECTION MANAGER
MR. SOHAIB HAMDIEH
PRODUCTION ENGINEER GRC
MR. IDRIS AHMED
ERECTION FOREMAN
20
Team 1
Carpenter
3
Helper
1
Team 2
Carpenter
1
3
Helper
Team 3
Team 4
Carpenter
3
4
Team 1
Team 3
Team 2
Team 1
2
1
1
1
Erector
1
Team 3
Erector
Team 4
1
Erector
4
Team 5
1
Erector
1
Laminator
Carpenter
5
3
Helper
1
Team 2
Erector Team 4
Spray Man
3Spray Man
1
Helper
1
8
Helper
Mason
PRODUCTION PRODUCTION
FOREMAN
CARPENTRY FOREMAN
1
Helper
4
400
1
Mason
3
Mason
3
Mason
3
Mason
Mason
5
Helper
5
Helper
5
Helper
5
Helper
5
4
3
Summary of Manpower
Helper
2
Helper
2
Helper
2
Helper
2
*Note: Staff not included in the total manpower
Version Date :
15/08/2011
Production
1
1
1
0
0
12
20
13
5
4
0
Demoulding & Assembly Carpenter
8
Grand Total
65
Total MP
Production Engr.
Production Foreman
Carpentry Foreman
p
y
Erection Supervisor
Erection Foreman
Carpenter & Carving
Mason
Helper
Laminator
Sprayman
Erector
Erection
0
0
0
1
1
0
4
25
0
0
5
0
36
FORM NO. XIP‐HR‐01‐003‐F01R ‐ MACRO ORGANIZATION CHART
Rev No: A/1
Xtramix Equipm
ment
The factorry has producction facilities under 13,00
00 m2 and a weell equipped area for sttorage of fin
nished 2
elements equal to 18000 m . The prroduction hallls are o up to 16 tons equipped with overheead cranes of a the storaage area has 20 tons overhead capacity and cranes. The factory is fitted with w state‐of‐tthe‐art produ
uction equipmen
nt in the preccast industryy, available fo
or the first time in the Middlee East. This m
machinery inccludes 2
40 palletss (50m each), semi‐ rotattion system, a full scale mo
ould table plotter, nu
umeric controlled concrete distributors, an XY comp
pacting, advaanced mber for 30 m
mould vibration stations and a curing cham
1.5m3 tables. The batching plant for paneels has three 1
oncrete mixerrs. It is also equipped e
witth the hi‐tech co
latest tecchnology forr a controlled and acccurate concrete m
mixing. Automatic conccrete distributor
La
arge capacityy curing cham
mbers
Cen
ntrally locateed shifting ma
achines Xtrramixx Equip
pmen
nt
“Heliccopter” to alllow a super ssmooth finish
h
Fully a
automated pllotter Hollo
ow core slabss extruders Xtrramix Equip
pmentt
Solid W
Walls and Panels Pro
oduction Line WE, Germany) (EBAW
Pallet Produc
P
ction System
m for the Maanufacture o
of Wall Pane
els EBAWE Sr. No. 1 1.1 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 4.3 4.4 4.5 4.6 5 5.1 5.2 5.3 6 6.1 6.2 7 Item Description Pallets and Shuttering Pallet length gross approx: 12.5m Pallet width ggross approx: 4
4.0m Mould thickn
ness: 8mm Shuttering lim
mitations: 0 Admissible su
urface load: 40
00 kg/m2 Max. asym. LLoad 20 % Circulating Paallet system Central shifting unit with drriver Fixed rollers Fixed friction drivers Push‐pull me
echanism Rails Central shifting Fixed rollers Fixed friction drivers Push‐pull me
echanism Curing Curing racks w
with 2 x 5 tiress Curing chamb
ber shutters Rollers and FFriction Driverss Rollers fixed Rollers lowerrable Friction drive
ers fixed Friction drive
ers lowerable Pallet bufferss Safety equipm
ment ‐ fixed ro
oller line Side shifters,, rails, power Side shifters Rails Power supplyy chain for travvel Cleaning cleaning equiipment movab
ble with suck out compressorr oiling equipm
ment movable Concrete disttributor with 2 buckets, casting width 1,5m
m c/w Bucket‐ belt, casting span 1
1,5m Concrete disttributor with span 15.000mm
m Prepared for weighing facility and auto co
ontrol Pre‐selection
n control system
m Qty 45 1 12 4 1 370
1 12 4 1 3 30 450
28 14 4 21 1 3 200
50 1 1 1 1 1 1 Xtram
mix Eq
quipm
ment Paallet Producttion System for the Man
nufacture off Wall Panells EBAWE Sr. No. 8 9 10 11 12 13 14 15 16 Item Descriptiion Bucket weighing facility Workplace ligh
hting Central lubricaation facility Adjustable buccket height Track for the d
distributor draw
wing Compacting eq
quipment with
h high frequenccy vibrators sysstems Tilting equipm
ment Support Carrier to carryy out of the eleements 25t Rails Helicopter with 1 disc Plotter Centering mecchanism for pallets Kommunikatio
onsprogramm Circulation sysstem control w
with complete eelectrical installation maaterials and all software for ssystem manageement control system
m with pc and 17
7" monitor c/w
w software for
visualisation &
& monitoring of circulation syystem and curing chamber Pallet utilisatio
on USV with USB connection Shutter screw titling side H=100mm, L=6.250mm Shutter screw titling side H=150mm, L=6.250mm Shutter screw titling side H=200mm, L=6.250mm Shutter with in
ntegrated maggnetic system with the follow
wing lengths peer pallets L=3700mm, H=
=100mm L=2500mm, H=
=100mm L=1000mm, H=
=100mm L=500mm, H=1
100mm L=3700mm, H=
=150mm Qty 1 1 1 1 1 2 1 1 2 100 2 1 1 1 1 1 1 30 30 30 60 30 60 30 60 Xttramixx Equiipmen
nt
Paallet Producction System
m for the Manufacture o
of Wall Pane
els EBAWE Sr. No. 17 18 19 20 21 Item Descriptiion L=2500mm, H=
=150mm L=1000mm, H=
=150mm L=500mm, H=1
150mm L=3700mm, H=
=200mm L=2500mm, H=
=200mm L=1000mm, H=
=200mm L=500mm, H=2
200mm Attachment sh
hutter L=3700 H=20mm H=30mm H=40mm H=60mm L=2500mm H=20mm H=30mm H=40mm H=60mm L=1000mm H=20mm H=30mm H=40mm H=60mm L=500mm H=20mm H=30mm H=40mm H=60mm Tilting table 15
5.0mX4.8m witth vibrating sysstem Stair ‐ straight version, 16 steeps width maxx. 3m Twin beam forrm 12000mm**600mm*600m
mm Battery mould
d 6.5m*3.5m w
with 2*8 pcs=16
6 walls per mo
ould Qty 30 60 30 60 30 60 30 60 60 60 60 30 30 30 30 60 60 60 60 30 30 30 30 3 1 1 1 Xtraamix EEquip
pmentt
Hollow Co
ore Slabs aand Walls Productio
on Line (Nordim
mpianti, Ittaly) Nordim
mpianti Equipment Hollow Core Sllabs Sr. No. Item Descriiption Qty 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 Element Cassting ‐ Extruderr System Motorized grroup and concrete feeding siilo Lifting arm Electric cable
e reeling drum Electric cable
e Forming inse
ert for h 150mm
m / 8 no. holess Wire guide fo
or h 150mm / 8 no. holes Pair of wire sspacers for h 150mm / 8 no. holes Start plate fo
or h 150mm / 8
8 no. holes Forming inse
ert for h 200mm
m / 6no. Holess Wire guide fo
or h 200m / 6 no. holes Pair of wire sspacers for h 200mm / 6 no. holes Start plate fo
or h 200mm / 6
6 no. holes Forming inse
ert for h 265mm
m / 5no. Holess Wire guide fo
or h 265m / 5 no. holes Pair of wire sspacers for h 265mm / 5 no. holes Start plate fo
or h 265mm / 5
5 no. holes Forming inse
ert from h 300m
mm up tp 500m
mm / 4no. Holes Set of changing height devices mm.300/4
4 Start plate fo
or h 300mm / 4
4 no. holes Set of changing height devices mm.400/4
4 Start plate fo
or h 400mm / 4
4 no. holes Wire guide from h 300mm up to 500mm / 4 no. holes
Pair of wire sspacers from h
h 300mm up to
o 500mm / 4 no
o. holes Service platform for castingg machine Element Cuttting Cutting saw 5
500 AM Electric cable
e reeling drum Electric cable
e Water hose rreeling drum Water hose Diamond blaade diam. 1.10 mm Element Lifting and Transp
port Equalizing arrm with lifting clamps 3.2 Telescopic eq
qualizing arm w
with lifting clam
mps 2 2 2 330m
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 165m
1 165m
1 1 1 Xtrramix Equip
pmentt
Nordim
mpianti Equip
pment Holllow Core Slaabs Sr. No. 3.3 3.4 3.5 3.6 3.7 3.8 4 4.1 4.2 4.3 5 5.1 6 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 7 7.1 7.2 7.3 7.4 7.5 7.6 7.7 8 8.1 8.2 8.3 8.4 Item D
Description Pulling device for transport wagon Steel wire for pulling device Radio control for pulling devvice Track for preccast unit transp
port wagon Fixing device ffor track Transport waggon Production Be
ed Cleaning Bed cleaner equipped with aa rotating brussh Electric cable reeling drum Electric cable Steel Wire Sto
orage Strand stackable decolier Steel Wire Strressing Wire stressingg machine Holding trolley for wire stresssing machine
Automatic single‐wire stresssing jack Automatic single‐wire stresssing jack Automatic single‐wire stresssing jack Reaction Beam
m Detensioning cylinder Detensioning pump unit Single wire an
nchor grips (typ
pe A45‐34‐3/8"") Single wire an
nchor grips (typ
pe A45‐34‐1/2"") Single wire an
nchor grips (typ
pe A45‐34‐6/10
0") Element Heatting and Coverring Heating Plant ‐ 750 / 6 Hot water pum
mping device Thermo ‐ regu
ulation system Coiler holdingg trolley Coiler Nylon sheet 2 m wide Nylon sheet 2.5m wide Production Be
ed Steel productiion bed Set of bed exttension Fixing device Set of pipes fo
or heating system Qty 1 230m 1 230m 460 10 1 1 165m 10 1 1 1 1 1 8 16 1 100 100 100 1 8 1 1 8 4 1 8 8 2560 8 Xtram
mix Eq
quipm
ment Stemaa Pedax (Gerrmany) Bendin
ng and Cutting Machinery (Reinforccement) Sr. No. Item Desscription Qty 1 2 3 4 5 Special 42
2S pin control ssingle benders
Simplex 45HV Hydraulic Shearing machine Mafix B30
00 Mesh bending machine 30
000mm Mafix 30V
V Mesh Shearin
ng machine 300
00mm Twinmastter 12 S Stirrup
p Bending Mach
hine 2 1 1 1 1 Xtram
mix Prrecastt Prod
ducts The diverse range of high
h quality prod
ducts that aree available is aassured throu
ugh compliance with internattional standarrds such as ASSTM, BS, BS EEN and DIN [X] Floor a
nd roof elem
ments [X] Internaal walls (load
d bearing & n
non‐load bearing) [X] Externaal walls (load
d bearing & non‐load beearing) [X] Claddin
ng (facade) w
walls [X] Stairs, p
parapets, ve
ertical shaftss [X] Foundaation units [X] Bathroo
om floor units [X] Boundaary wall elem
ments [X] Tanks, reservoirs and silos [X] Concrete poles for transmission lines [X] Road barriers [X] Balconiies [X] Ready‐mixed concrrete [X] Concrete pumping ded hollow ccore slabs / w
walls [X] Pre‐streessed extrud
[X] Glass fibre reinforcced concretee (GFRC) [X] Architeectural concrrete arches o
or decoratio
on designs [X] Custom
mized precasst elements There are more
m
than 65 shapes and colours
c
availa
able dependin
ng
on client req
quirements.
Waalls We prroduce the fo
ollowing typess of walls: Solid walls ‐ both lload‐bearing and non‐load
d‐bearing, h are used in apartment buildings, b
villas, hotels which
and siimilar structures. Sandw
wich panels cconsist of two
o concrete leeaves with an inssulation layer in between. The external e
leaf is normally made of arcchitectural concreete, i.e. of a a material inttended to ad
dd to the architectural effecct of the façaade, while the internal leaf iss in grey concrete. L
Load‐bearing wall Solid wall pa
anel Pa
anels in the sttockyard In
nsulated wall l panel We maanufacture precast p
stairrcases to su
uit a majorityy of combinaations of arcchitectural deesign, includingg: 9 Straight 9 Spiral / elliptical 9 Freestandingg a
The method of production we use allows components, to be b tailored to suit sp
pecial ments. requirem
Since, moulds m
are used, u
the maajor advantagge of using precast p
elem
ments is th
hat during mass production of the same elem
ment, precisio
on is ensured. Staaircases Colu
umns & Beams
We manufacture m
precast reinforced beaams and column
ns. Precasst beams havve a rectangu
ular cross‐secction and are mostly used horizontally h
for the stru
ucture of ngs. multi‐sstorey buildin
Precasst columns haave a rectanggular or roun
nd cross‐
section
n and are mo
ostly used veertically for sttructures and su
upports of multi‐storey m
b
buildings and
d parking facilitiees. R
Road B
Barrie
ers Man
nholess We manufactture a wide
W
e range of precast road
d barriers, m
manholes, wa
ter tanks and
d foundationss: W r Tankks Water
Road barrierss are generally used to red
R
duce the risk of an out‐
o
of‐control veehicle crossiing the cen
ntral reservaation and c
colliding with opposing trafffic or roadway workers.
F
Found
dation
ns Manholes aree used as catcch basins for storm waterr drainage, M
p
providing acce
ess to buried pipelines and junction ch
hambers at the intersection of sewer lines. The use of precast concrete m
manhole strucctures will re
educe constru
uction time and a labour c
costs, when co
ompared to ccast‐in‐situ orr masonry stru
uctures. Water tanks aare manufacttured of vario
W
ous types and
d sizes and a usually used as comp
are ponents for wastewater treatment p
plants, indust
rial wastewater treatmen
nt systems or amenities fo
or the treatm
ment of agricu
ultural waste. Precast found
P
dations can be used as lamp post foundation f
u
units, where the t lamp possts are fasten
ned to the fo
oundations b
by anchor bolt
ts. Hollow C
Core Slabs
Hollow core slabs are among the most advanced a
productts in the preecast industryy, particularlyy due to their higgh quality. Pre‐stre
essed hollow
w core slabs are a pre‐stresssed floor elementts with eitther round or shaped
d voids, depending on the loccal conditionss. Hollow core slabs have h
longitud
dinal cores, the t main purposee of which is tto reduce thee weight of the floor. Such prrecast elemeents are main
nly used in buildings with larrge spans, forr example villas, schools, h
hospitals, office buildings, b
industrial buildings and shopping s
centres.. We prod
duce hollow ccore slabs of the followingg thicknessses: 9 150
0 mm 9 200
0 mm 9 265 mm 9 32
20 mm 9 40
00 mm 9 50
00 mm Boundaryy Wallls Our boun
ndary walls and fences are manufaactured on table mo
oulds or batttery moulds.. The moulded side is smooth as a cast, the top face levvelled and floated and various su
urface finishees are possiblee. Boundaryy walls and feences are norrmally used to separate areas from
m each otherr, e.g. residen
ntial plots, aiirports and so on. Claaddingg A clad
dding panel iss the concrete leaf that fo
orms the outermost layer of o a façade and a
thereforre fulfils only aan enclosing aand decorativve function. With our factory eequipment, w
we offer high‐‐level of manship requ
uired to make cladding paanels of workm
the finest textu
ures and profiles. p
Alsso, we dding panelss that creaate the manufacture clad
impreession of matterials such as a marble, graanite or brickw
work. It is normally ussed for preestigious buildings, commeercial buildings and officces and refurb
bishment. The units u
can bee used for the t
facing of walls, colum
mns and spand
drel panels. The units can be b attached separately to the structture or they ccan be self‐beearing and in general their aarchitectural design is veryy flexible. Archittectural cladd
ding panels can c be supplied with a divverse varietyy of self an
nd applied surface finishees, such as exposed e
aggregate, acid treated and saand blasted ssurfaces. Alteernatively, paatterned liners can be used to imitate natural finishess. Glass FFibre R
Reinfo
orced Conccrete
W
What is Gla
ass Fibre Reinforced Concrete?? Glass Fibre Reinforced R
Concrete (G
GRC) is not a single m
material but a range off high strength special concrete w
which can be
e engineered
d to suit parrticular prod
ducts and ap
pplication, such as cladd
ding and deccorative com
mponents, reestoration of old strructures, sp
pecial finishes and scculptured sh
hapes. How are Gllass Fibre Reinforced Concrete Products H
m
manufacture
d? Glass Fibree Reinforced Concreete produ
ucts are m
manufactured
d using various v
tech
hniques, th
he most po
opular are: Sp
pray: Manufactured
M
d by spraaying a micro concreete mix, prrepared in a a high shear mixer, through a speccial spray gu
un which inccorporates tthe AR glasss fibre reinfo
orcement att the nozzle; the materrials are spraayed onto moulds m
to fo
orm thin sectioned, lighttweight prod
ducts. Prre‐mix: Manufactured
M
d by mixingg micro con
ncrete with AR glass fibre reinforcement in a sspecial two‐‐stage mixerr, the pre‐
m material is poured into mouldss and comp
mix pacted by viibration. Sp
prayed Pre‐m
mix: A form pre‐m
mix is prepaared with th
he pre‐cut glass g
fibre reeinforcemen
nt in a speciaal mixer, and
d then sprayed. Xtrramixx Prod
ducts Glasss Fibrre Reiinforcced Co
oncrette What are the prope
erties of Gllass Fibre R
Reinforced
d Concrete
e? Like steel reiinforced conccrete, GRC's p
properties vaary according to cement content, wateer/cement rattio, Alkali Resistant Glaass Fibre type
e, content and
d orientation. Traditional spray can produce the high
hest strength
h due to the h
high AR Glasss Fibre conten
nt, low waterr/cement bre length an
nd plane fibre orientation.
ratio, long fib
Pre‐mixed sttrength is gen
nerally lowerr than that off the traditional spray meethod due to lower AR Glass Fibre content , higgher water/ce
ement ratio, sshort fibre len
ngth and 3 – d
dimensional ffibre orientation. The final pro
operties of particular p
type of GRC maaterials will depend d
on th
he mix design
n and the method of manufacturee. Typical propeerties for GRC
C materials m
made using the spray up an
nd pre‐mixed processes: Property Glass Fibre (Weight %) Bending Ultimate Sttrength MPa ((MOR) Elastic Limitt (LOR)MPa Shear Interlaminaar Strength M
MPa In‐Planar Sttrength MPa Compressivve Strength M
MPa Impact Streength KJ/m2 Elastic Mod
dulus GPa Strain to Faailure % Dry Densityy T/m3 Hand or Machine Sprray 5% 20‐30 7‐11 3 – 5 8 – 11 5
50 – 80 1
10 – 25 1
10 – 20 0
0.6 – 1.2 1
1.9 – 2.1 Vibraation Cast 3% 1
10‐14 5 ‐ 8 N/A 4 – 7 4
40 – 60 10 – 15 10 – 20 0.1 – 0.2 1.8 – 2.0 Xtramixx Prod
ducts Glasss Fibre Reiinforcced Co
oncrette Advanttages of GFRC Lightweiight structure
e, reduced traansport and iinstallation costs Due to itts reduced th
hickness, a GRC G cladding panel can weeight 7 timess less than a similar precaast concretee panel. GRC
C lightweightt panels can
n be transpo
orted in ligh
ht pick‐up with w
no weigght restrictio
on, and can be erected eassily without n
need for heavy cranes or sp
pecial erectio
on tools. Excellentt Edge and Co
orners Strenggth Due to heavy h
fiber concentration
c
n in the GRC
C mix, GRC edges, e
chamfeers, decorative reliefs have strong im
mpact resistaance and it doesn't d
spall or break du
uring transpo
ort and installation like the normal cconcrete edge
es. Improved Surface De
etails and Quaality of Finish
h With GRC
C the quality of finish is so
o outstandingg that it allows much greatter freedom aand creativityy in the desiggn of intricate
e moldings an
nd patterns.
Easy to m
mould into co
omplex shape
es With thee exceptional strength and
d impact resisstance, GRC allows for all ssorts of comp
plex shapes and details, offering o
an infinite array of possibilities, from araabesques to moushrabiass to sculptured columns to decorative
e open screen
ns. Mainten
nance Free GRC is an a inert mate
erial, unaffeccted by salt, freeze/thaw cycles, or co
orrosive atmo
osphere, unliike concretee, as it has no
o steel compo
onents, and iit is not weakkened or cracked by steel corrosion and can live w
without main
ntenance for long years. Ideal forr Restoration Work All the above a
characcteristics poin
nt to GRC ass the ideal material m
for restoration off old buildinggs, facades aand decorativve features, aas GRC can replicate exactlly, or improvee upon, any o
original featurre. Environm
ment Friendlyy GRC neitther uses norr emits any vo
olatile materiial and is a low energy pro
oduct, therefo
ore contributtes to a safe and clean en
nvironment. Xttramixx Prod
ducts Glaass Fib
bre Re
einforcced Co
oncre
ete Products A
Availab
ble and
d Typiical Ap
pplicattion [X] Clad
dding Pane
els [X] Architectural Moulding work [X] Resstoration w
[X] Dom
mes [X] Corrnices [X] Deccorative Sccreens [X] Ligh
htweight B
Buildings w
with Steel Structure Frames [X] Columns pitals [X] Cap
[X] Arches ping [X] Cop
There are
a 3 basic finishing tech
hniques coatting
finish, faces
f
mix an
nd pigmented
d finish
3 HSE & QUALITY • Health, Safety & Environment • Quality Control • Licenses & Certification Heallth, Saafety &
& Envvironm
ment
Xtramix Intternational Precast hass established a comprehensive Environmentt, Health an
nd Safety Management M
HSMS) in System (EH
compliance w
with the requ
uirements of ZZonescorp, b
being the Enviironment, Health and Safety (EHS)) Regulatory Authority fo
or Industrial Sector in Abu Dhabi. Emirate of A
XIP believees that im
mplementation
n of appro
opriate (nattional & internationaal) Design, En
ngineering and HSE Codes & Standaards shall ensure the ssafe operatio
on and eliminate incidentss arising due to design deficiency or lack in Opeerations & HSSE Controls. ISSO Certificatiion in the 01), Environm
ment (ISO1400
01), Health and Safety areas of Quaality (ISO 900
(OHSAS 180
001) is the way w forward to achieve the t excellencce in EHS managemen
nt within the o
organization. XIP’s HSE team looks forrward to consstantly strivin
ng for excelleence in all aspects of health, h
safetyy and environmental relaated issues. The T team recognises the t impact that its activiities can havve on peoplee and the environmentt. At XIP, we believe that we live in thee environmen
nt that we create. Heallth, Safety, Environment E
protection and a Risk Man
nagement are the integral part of our o planning and decision
n‐making. Wee manage our businesss in an ethicaal way that sttrikes for an appropriate and well‐
reasoned baalance betweeen economicc, social, and environmental needs through effeective assessm
ment of the risks associated in condu
ucting our business. Quality Po
olicy Indusstrial LLicensse Cham
C mber o
of Com
mmercce Memb
M bership Cerrtificaate (Arrabic)) Cham
mber o
of Com
mmerrce Mem
mbersh
hip Ce
ertificaate (EEnglish
h) Abu Dh
habi C
Chamb
ber Ce
ertificaate ISO Ce
ertificcation ISO C
Certifiication
n ISO Certifficatio
on Residential
The dessign, manu
ufacture, delivery and
d erection of precast villas Project: ntractor: Main Con
Project Duration: Scope: Location: Al Falah Community Deveelopment
Al Jaber Building 33 months
pes and 3 styless 2018 precast villas ‐ 3 typ
bu Dhabi Al Falah, Ab
As part of the Abu Dhabi 2030
0 directive, Al Falah community developm
ment project is a master planned community for UAE naationals. As part off Abu Dhabi G
Government H
Housing Initiaative, the package includes i
consstruction of 5,000 5
homes for UAE families. The estim
mated duratiion of the project p
is fro
om third quarter of 2009 to thirrd quarter 2012. Residentia
al
The design, manu
ufacture an
nd deliveryy of undergground waater tanks Project: ntractor: Main Con
Project Duration: Scope: Location: Al Falah Community Deveelopment
Al Jaber Building 33 months
nd water tanks
2018 precast undergroun
bu Dhabi Al Falah, Ab
As part of the Abu Dhabi 2030
0 directive, Al Falah ment project is a master planned community developm
community for UAE naationals. As part off Abu Dhabi G
Government H
Housing Initiaative, the package includes i
consstruction of 5,000 5
homes for UAE families. The estim
mated duratiion of the project p
is fro
om third quarter of 2009 to thirrd quarter 2012. Res
sidential
The d
design, maanufacture, delivery aand instaallation of ffootings an
nd hollow core slabss Projectt: Main C
Contractor: Projectt Duration: Scope:: Locatio
on: Presiden
ntial Sea Palacee
Al Jaber Building 02 montths Precast ffootings and hollow core slab
bs Abu Dhaabi The Presidential Sea Palacee (Qasr Al Bahr) incorrporates the developmentt of entertain
nment pavilion and trelliis link in the palace, where XIP ootings and h
hollow had cconstructed tthe precast fo
core slabs. Resid
dential
The design, m
manufacture, deliverry and insstallation o
of undergro
ound wate
er tanks Projject: Maiin Contractor: Projject Duration: Scope: Locaation: Wateer tanks for Saaadiyat Island
Al Jab
ber Building 04 months nd water tankss Precaast undergroun
Saadiiyat Island, Abu
u Dhabi Devveloped byy Tourism Developmeent and Inve
estment Com
mpany (TDIC),, Saadiyat Beeach is an elite residential community offering a wide w
range m
and sophisticated
d facilities, to achieve of modern the
e island’s prom
mise of first‐cclass living. The
e primary phaase of the deevelopment cconsists of 3‐bedroom to 6‐bedroom villas with
h varying uriously deesigned layyouts in Arabian, luxu
Mediterranean and Contemp
porary styles. All villas are designed to exude elegance and com
mfort, with som
me of the top
p‐end luxury vvillas having their own gym
mnasium, eleevator, swimm
ming pool and movie the
eatre. Saaadiyat Island will also havve Saadiyat bridge and exp
pressway, thee Gary Playyer designed Saadiyat Beaach Golf Cou
urse and thee Saadiyat Experience Cen
ntre (Manaratt Al Saadiyat)), which will p
provide an ove
erview of the island’s distin
nctive projectts. Industrial / Oil & Gas
s
The design and m
manufacturre of cable trenches
and foo
otings Project: ntractor: Main Con
Project Du
uration: Scope: Location: SE Full Field
d Developmentt
Al Jaber Eneergy Services
12 months
nches and man
nholes Precast tren
ASAB, Abu Dhabi ASAB EP
PC was award
ded to Petrofac Sharjah in January 2009 and will be com
mpleted at thee end of 2012. The projject scope in
ncludes additional wells, flow f
lines, replacem
ment and modification of o existing faacilities as well as building new
w surface facilities that will w sustain productiion targets fro
om 2011 thro
ough 2045. Such pro
ojects demon
nstrate UAE’ss commitmen
nt to play an active
e role in secu
uring future eenergy suppliees despite the curre
ently availablle space capacity. Ind
dustria
al / Oil & Gas
s
The design and
d manufaccture of maanholes, vaalve boxe
es and junction boxe
es Projecct: Main Contractor: Projecct Duration: Scope
e: Locatiion: Integratted Gas Develo
opment Consolidated Contraccting Engineerin
ng nths 03 mon
Precast manholes/valve boxes/ juncction boxes Habshan, Abu Dhabi
The pu
urpose of thee Abu Dhabi Gas Industriies (GASCO) Integrated Gas Develo
opment (IGD
D) project is to add new onshore and
d offshore gas processsing facilities at Habshan
n and Ruwais in Abu Dhaabi. These IG
GD projecct’s new facilities will enab
ble for gas to be received ffrom the Umm Shaif ffield and proccessed at Hab
bshan and Ruw
wais. The purpose p
of the t
project is to provid
de natural gas g
supply to consumers in Abu Dhabi and to
o meet their increasing reequirement for f
nnect the onsshore and offfshore facilities energyy. The projectt will also con
of com
mpanies which are opeerating under Abu Dhab
bi National Oil O
Compaany (ADNOC). A new
w complex, known as Habshan 5 is one of the projectt’s compo
onents, which
h will includee a gas proceessing facilityy, a natural gas liquidss (NGL) recovvery unit, fou
ur sulphur reccovery units and utilities in additio
on to other onsite facilities. In Ruw
wais, new faacilities will also a
be addeed to the GA
ASCO’s alread
dy existin
ng plant inclu
uding a new N
NGL train and
d six cryogenic NGL storagge tanks. Once ffully operatio
onal, the com
mplex will havve a capacity of 900mmsccfd of nattural gas, 12,,000t/d of NGL and 5,000t/d of liquid
d sulphur. Th
he propane, butane, paraffinic naphtha and su
ulphur produ
uced in Ruwaais b exported.. The ethan
ne will be supplied s
as raw materiial will be (feedsstock) to the B
Borouge Petrochemical Co
omplex. Indus
strial / Oil & Gas
The
e design an
nd producttion of pre
ecast pipe sup
pports, fou
undations,, junction boxes and
d grade beaams Projject: Maiin Contractor: Projject Duration: Scop
pe:
Locaation: Bu Haasa Water Injecction Enhancement
Sicon Oil & Gas S.P.A. (Member off CCIC p) Group
04 mo
onths Precaast pipe supporrts, foundation
ns, junctiion boxes and grade beams Abu D
Dhabi e purpose of tthe Bu Hasa Water Injectiion Enhancem
ment Project is to The
provide addition
nal water injection capacity in Shuaiba Unit "H" nortth, in n this area. Itt will also pro
ovide order to remedyy the pressuree depletion in
ort to the in
nactive wellss and help to maintain the pressure suppo
duction capaccity. susttainable prod
The
e completion of the projeect is expectted to be by the end of year 201
11. Co
ommerrcial
The dessign, produ
uction, deliivery and eerection off beams aand hollow
w core slab
bs Project: Main Conttractor: Project Du
uration: Scope: Location: Lifecare Hosspital
Internationaal Construction
n and Contractingg Company 04 months
Precast beams, hollow corre slabs Abu Dhabi Mussafah, A
The Lifeccare hospital is being builtt in Worker’s Village, Mussafaah. This pro
oject involvess the constru
uction of a 160 1 bed hospital comprising of a basemeent level, a ground d 4 additional floors. floor and
Thereforre, the build
ding is 5 sttories in strructural combinaation of casst‐in‐situ columns and precast beams and hollow co
ore slabs. Com
mmerc
cial
The
e design, production,, delivery aand erectio
on of b
beams and
d hollow co
ore slabs fo
or Sewage Treatment Factory Project: Main Contractor: Project Duration: pe: Scop
Locaation: Sewagge Treatment FFactory
4 Dim
mensions 01 month hollow core slaabs Precast beams and h
u Dhabi Saadiyyat Island, Abu
Sew
wage Treatmeent Factory comprises of o two storiees buildings. The structure iss a combinaation betweeen cast‐in‐sittu colu
umns and preecast beams aand hollow co
ore slabs. Gov
vernm
ment
Th
he design, production
n, and erecction of ho
ollow co
ore slabs and walls Pro
oject: Maain Contractorr: Pro
oject Duration
n: Sco
ope: Loccation: National Security B
Building
Starss General Conttracting Co. 01 m
month Preccast hollow corre slabs and waalls Abu Dhabi The T National Security Building is a onee storey build
ding, th
he structure of which is full precast system including lo
oad‐bearing w
walls and holllow core slabs. Priva
ate
The design
n, production, and errection of boundaryy walls for p
private villa, Abu Dhaabi Project: Main Contractor: Project Duration: Scope: Location: Precast boundaary walls for Am
mena Al D
Dhahery A
Al Jaber Buildin
g 01 month Precast boundaary walls A
Al Barsha, Duba
ai XIP’s scope of work for tthis project in
ncluded constructio
on of boundarry walls for prrivate villas in
n Dubai. The boundaary wall includ
ded precast ffootings, columns, walls and decorative GRC elements. *Pho
otos – com
ming soon
Privatte
The design, produ
uction, and erection o
of boundary walls fo
or private p
plots, Abu Dhabi Project: Main Contractor:
Project Duration: Scope: Location: Precast boun
ndary walls forr Plot 105 & Plo
ot 106 4 Dimensions 02 months ndary walls Precast boun
Khalifa City A
A, Abu Dhabi XIP’s sco
ope of work in
ncludes the co
onstruction o
of boundary walls for prrivate villas in Khalifa City A
A, Abu Dhabi. The boun
ndary wall inccludes precasst footings, co
olumns and deco
orative walls. *Photo
os – comin
ng soon Private
The design, productio
on, and ereection of
boundary w
b
walls for m
multiple pro
ojects/villa Project: P
Main Contracto
M
or: Project Duratio
P
on: Scope: Location: Boundary walls vvarious villas
Em
mirates Canadiaan Contracting
03 months Preecast boundaryy walls Abu Dhabi XIP’s X
scope of work for f
this pro
oject in
ncluded the constructio
on of bound
dary walls w
for 3 private viillas in sevveral lo
ocations. The T
boundaary wall in
ncludes preecast footings, colu
umns, walls and decoraative GRC elements
G
s. 5 BRIEF METHOD STATEMENT • Short Description of the Production and Erection of Precast Concrete Elements Short Desscriptiion off the uction
n and Erectiion off Produ
Precaast Concrete
e Elem
mentss D
Design
Design Deepartment XIIP’s Design Department D
p
prepares stru
uctural design calculation
ns and all drrawings need
ded for the prroduction and
d erection of the precast eelements. Th
he drawings include: layo
out drawings,, elevation drawings, draw
wings for errection details and detailed shop draw
wings. The shop drawinggs include reebar arrangem
ment, position of lifting ho
ooks, cast‐in parts, the weeight and qu
uantities of each e
type of panel. All off these draw
wings are subm
mitted to th
he client, the client’s reprresentative, the t consultan
nt, the contraactor, the m
municipality and the projeect managem
ment agent fo
or approval, using the latest softwaree specific to p
precast. F
Factory
an
nd Equipm
ment Th
he production takes placee in XIP’s neew factory located in ICAD III. The faactory has prroduction faccilities underr 20,000 m2 and a well equipped sttorage area for finished
d elements equivalent to 26,000 m2. The prroduction halls are equipped with oveerhead cranees of up to 16 1 tons in caapacity and th
he storage areea has 25 ton
ns overhead ccranes. Stockyard a
and Factory Th
he factory iss fitted with state‐of‐the‐‐art production equipment in the prrecast industtry, availablee for the firsst time in the Middle East. E
This 2
m
machinery includes 40 palllets (50m each), e
semi‐ro
otation systeem, a full sccale mould taable plotter, n
numeric conttrolled concreete distributo
ors, an XY co
ompacting, advanced a
vib
bration statio
ons and curiing chamberrs for 30 m
mould tables. The batchin
ng plants for panels havee three 1.5m
m3 hi‐tech co
oncrete mixeers. It is alsso equipped with the latest techno
ology for co
omputer conttrolled and acccurate concrrete mixing. P
Production
n Productio
on Halls Th
he production
n is planned tto follow the schedule for erection laid
d down by th
he company to t fulfill the desired delivvery rate. Mo
oreover, we have the latest softwarre from Germany for planning of production p
off precast p analysis elements, costt estimation, ffacilitating work preparatiion, follow‐up
an
nd invoicing ffor structural prefab elemeents. Sh
hort Descrip
ption o
of the
e Prod
ductio
on and
d Erecction o
of Preccast C
Concre
ete Ele
ements Mould Manufacturing Moulds fo
or panels are fabricated on
n the rolling m
mould tables. Before any mould building takes t
place, the table is rolled throu
ugh the cleaning sstation and a rotating brussh cleans it frrom all the dirt, dust and possible rust. After cleaaning the mou
uld table, thee table is plottted to the sh
hapes of the panells to be casteed. The plotting can only take place after the shape of the panels iss loaded direcctly from thee Design Depaartment mputer. into the controlling com
Fully auto
omated plottter From thee plotting station the mould tablee is moved to the designateed area in the production
n hall, where the mould building takes placce. The prep
paring of shu
uttering (mou
uld sides) and other mould parts can begin
n. Advanced p
professional sshuttering syystem of newest technology combined witth integrated
d magnets is used. Additionaal materials used for mo
ould buildingg are basically steel plates and steel profiiles. Plywood
d is used in limited partss of the mould. The steel shu
uttering for individual moulds m
is welded as separate parts compleete with 10x1
10 chamfer lissts and then fixed to h strong maggnets. Windo
ow openings require the mould table with
special in
nside shutteering. Therefore, special manufactu
uring is performed on three diimension elements like paanels with L, U and Z shaped seections. When thee mould is fin
nished it is ch
hecked by thee Quality Con
ntrol for all measurements, including thee diagonals having thee same ment in both directions. TThe correct lo
ocation of reiinforced measurem
steel, em
mbedded piecces and liftin
ng anchors are checked and a
the shutteringg is controlled for stabilityy and straigh
htness. The ch
hamfers must be straight s
and have close contact c
to the table surfaace. The finished aand controlled
d mould is sp
prayed with aa thin layer of slip oil on all inside parts of th
he mould. It iis important tthat a very th
hin layer p oil is applieed. Areas of the mould with w excessivee slip oil of the slip
layer are cleaned with
h a dry cloth. The type of sslip oil used m
must be d for hamperiing painting o
of the panels after finishing. controlled
Sh
hort D
Description of the Pro
oductiion an
nd Ere
ection
n of Pre
ecast C
Concrrete Elemen
nts Steel Reinforcem
R
ment and Cast-in Parts
P
Reinforceement is bou
und in a sep
parate zone of o the produ
uction hall an
nd brought aas units to the mould. Befo
ore placing th
he reinforcem
ment spacers, it is ensureed that the correct c
concreete cover is fixed to the reinforcement units. Lifting hooks and cast‐in paarts are placed and fixed
d in the mould together with the rein
nforcement. TTo hold the rreinforcement and the casst‐
in parts in
n position, weelding in a lim
mited degree could be used. Stteel reinforcem
ment and casst‐in parts When all reinforcemeent and the cast‐in partss are placed in the mould, quality co
ontrol takes place. The reeinforcement shall be con
ntrolled for th
he correct dimension, d
co
orrect bendin
ng radius, co
orrect positio
on and correect cover to all surfaces. TThe cast‐in paarts are checked to be thee correct item
ms and in acccurate position. The contrrol includes eensuring that all parts in th
he mould arre firmly fixed
d, so they wiill not move d
during casting, shaking an
nd vibration. Concre
eting the Mould
M
Concretiing the mould
d “Helicopter”” used for smo
oothing The finish
hed mould reeady for conccreting is rolled by central shifter to th
he concretin
ng station and a
placed on the shaking and viibrator frame. Concretin
ng must be planned p
so that t
it can taake place in one operatio
on without being interru
upted by breeaks or any other o
reasons. The Castin
ng or orders thee concrete frrom the Batcch Plant Operator. The m
mix Superviso
design an
nd the amou
unt needed are a always given g
on the element sho
op drawing. It is the Castting Superviso
or’s responsib
bility to ensure that correct concrete mix design iss ordered. The conccreting is exeecuted mechaanically by th
he concrete distributor d
that can be operated either manually or by compu
uter. After fillling the mould c
the concrete is ready fo
or with thee correct amount of concrete, compactiing. The com
mpacting is done by first shaking the frame in X, Y angle. Th
hen the vibrattor frame staarts operatingg on which th
he mould tab
ble is fixed. The vibratorr frame vibraates and shakkes the moulld at the sam
me time. Aftter compactin
ng the panelss, the surfacee of the paneels are eveneed with a straight alumin
num beam an
nd finally made smooth m
mortarboard b
by “helicoptter” (see photto). SShort Descrription
n of th
he Producttion and Ere
ection
n of ents Precast Concrete EEleme
Concrete ccube sampless Conttrolling the Concrette Con
ncrete cube ttesting equipment Every concrete mixx design used
d requires to
o have nine teest cubes to be taken out once a d
day. Three cu
ubes are storred and cured
d together with the element, later to be used to control th
he strength by b de‐mouldin
ng. he laboratoryy and cured under standard conditions. Six arre sent to th
Three are crushed tested afterr seven days and three are crush testted after twenty t
eight days for thee final test. The T Laboratorry Supervisorr is responsible for con
ntrolling the cconcrete. He works out th
he concrete m
mix design
ns and supervvises the com
mpany’s laboratory for testting of concreete and agggregates. Curing Centra
al shifter The mould m
table with the casst panels reaady for curing is moved by centraal shifter to the curing chaamber. The ccuring is closed and isolatted to enssure 100% hu
umidity and avoid a
heat lo
oss. The curin
ng is finished in aboutt eight to twelve hours. One teest cube is crrushed at thee time of expected sufficieent strength ffor de‐mo
oulding. Wheen the strenggth has reacched 70% of specified fin
nal strenggth the mould
d table with the panel eleements can b
be taken out of the cu
uring chamber and moved to the place for de‐mould
ding. La
arge capacityy curing cham
mbers Short D
Descriiption
n of th
he oduction an
nd Ere
ection
n of Pro
Pre
ecast Concrrete EElements De-m
moulding, Re-touching and Storage
S
Fully automa
ated tilting ta
ables De‐moulding takes place by takin
ng off the panel’s top shuttering o the panels. Then the mould and the outer sidee shuttering of om the table iss tilted 80 deegrees (10 degrees from vertical). Fro
tilted position, p
the panels are moved m
one by one with a a crane and plaaced in vertiical position on railed waagons. The wagons w
transpo
ort the paneels to the sttockyard wheere the paneels are placed in vertical po
osition in rackks. Sto
ockyard Sto
ockyard On thee stockyard, the Stockyard Supervisor m
monitors the panels for bein
ng correctly m
marked, whilee making a viisual quality ccontrol of the element to match the shop drawin
ng. The sto
ockyard a he supervisor also cheecks if the paanels needs re‐touching and t
stockyard re‐touching team. It is i normal th
hat the leads the panels need more o
or less retouching (smooth
hening and reepair of c
smallerr damages). Re‐touching or minor reepairs must comply with th
he written procedures an
nd only the approved a
maaterials must be used. The Sto
ockyard Supeervisor is also
o responsiblee for keepingg order on the stockyard an
nd has to kno
ow the locatio
on of the pan
nels on the sto
ockyard (prefeerably by plo
otting their nu
umbers on th
he plan of the sstockyard). Sto
ockyard Sho
ort Descripttion of the Production
n and Erecttion of Precaast Co
oncrette Elem
mentss Transportation and Erecttion Transportation of claadding panelss from stockyyard to the building b
site takes t
place o
on trucks, w
which are sup
pplied with A‐frames placeed on the tru
uck load plan.. The A‐framees carry thee panels in upright positio
on ‐10 degreees from verticcal. The paneels are secureed with nylon straps or cchains. On th
he site the panels are off lo
oaded to a teemporary storre or preferably taken d
directly by thee crane for insstallation and
d erection in tthe building. Erection
n and installaation of cladd
ding panels in high rise buildings is executed e
witth Precast, bitumen coated water tan
nks cranes h
hoisting the p
panels to the place for permanent fixingg. The metho
od in which th
he panels are a fixed is accurately a
deescribed on the project drawings delivered to th
he erection
n teams, which are prio
or approved by the consultant. The method an
nd procedu
ure for the ereection and can briefly be d
described as ffollows: The panels are fixed in the upperr edge with aa so called “w
wet fixing”. Th
his means thaat cast in place p
concrette is placed around protrruding reinfo
orcement at the t top of th
he panel at the edge and
d over the existing concrette floor. At the lower l
panel edge stainless steel partts cast in thee panel previously erecteed underneeath and staiinless steel parts p
in the panel being erected is connecting c
th
he panels in a way thatt there is allo
owance for a a vertical mo
ovement, but no horizontal or temperatu
ure movemen
nts, yet holdin
ng the panel in movemeent. Thereforre, allowing fo
correct p
position horizzontally. The erecction takes place by hoisting the panell and placing it on leveled
d shim pads o
on top of th
he panel prevviously erecteed underneath. To do that, it is necessaary to hoist th
he Erection
n of precast elements on site panel to
o a level sligh
htly over the final level, th
hen pulling in
n the panel w
with ropes an
nd loweringg it until the stainless partts connect th
he panels. Thee top of the p
panel is pulleed closer to
o the floor’s edge and especially desiggned holder secures the panel p
allowin
ng the cran
ne to be loadeed. The final positioning of the panel can be done without the ccrane. The sp
pecial holder aat the top o
of the panel ccan pull the p
panel to correect vertical po
osition and a specific devicce for lifting and adjusting height is u
used under th
he panel. P
Precast manh
holes When th
he panel is finally f
adjusteed and contrrolled the gaap between the t top of th
he panel an
nd the concreete floor is clo
osed. The castting can take place at the ffixing. 6 IN THE NEWS • Construction Week Articles In
n the N
News “Consstructtion W
Week” ” Maga
azine
In
n the N
News “Con
nstructtion W
Week”” Mag
gazinee In
n the N
News “
“Const
tructio
on Weeek” M
Maga
azine In the Newss “Con
nstrucction W
Weekk” Mag
gazinee Location M
Map
Xttramix IInternaational P
Precastt W
Where p
recast iis taken
n to a higher le
evel.