1.

Method Statement Description:

Work Procedure for Erection of Hollow Core Slabs

2. Method Statement No.:

3. Discipline:
Civil Mechanical Electrical

4. Method Statement Releases/Revisions Control:

TABLE OF CONTENTS

Page 1
 S.L NO DESCRIPTION PAGE
1.0 TITLE PAGE NO. 3 TO PAGE NO. 3
2.0 SCOPE OF WORK
2.1 GENERAL DESCRIPTION & SCOPE PAGE NO. 3 TO PAGE NO. 3
2.2 DISCUSSION ON ERECTION REQUIREMENTS PAGE NO. 3 TO PAGE NO. 3
2.3 DISCUSSION ON SAFETY REQUIREMENTS PAGE NO. 3 TO PAGE NO. 3
2.4 PERSONNEL PAGE NO. 4 TO PAGE NO. 5
2.5 EQUIPMENT PAGE NO. 5 TO PAGE NO. 5
2.6 MATERIALS PAGE NO. 5 TO PAGE NO. 5
2.7 PREPARATION PAGE NO. 5 TO PAGE NO. 5
2.8 GENERAL METHOD STATEMENT FOR ERECTION OF HCS PAGE NO. 5 TO PAGE NO. 7
2.9 SAFETY PLAN & GUIDE LINE FOR ERECTION OF HCS PAGE NO. 7 TO PAGE NO. 11
3.0 QUALITY ASSURANCE
3.1 CONTRACTUAL REQUIREMENTS PAGE NO.11 TO PAGE NO.11
3.2 RESPONSIBILITY PAGE NO.11 TO PAGE NO.11
3.3 INSPECTION & TESTING PAGE NO.11 TO PAGE NO.12
4.0 SAFETY & HEALTH
4.1 PROTECTIVE SAFETY EQUIPMENT PAGE NO.12 TO PAGE NO.12
4.2 ENVIRONMENT SAFETY & HEALTH CONTRACTOR PAGE NO.12 TO PAGE NO.12
REQUIREMENTS
4.3 MSDS PAGE NO.12 TO PAGE NO.12
4.4 RISK ASSESSMENT PAGE NO.12 TO PAGE NO.12
5.0 REFERENCES PAGE NO.12 TO PAGE NO.12

kpc

1.0 TITLE

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 Work Procedure for Erection of Hollow Core Slabs

2.0 SCOPE OF WORK

2.1 GENERAL DESCRIPTION AND SCOPE

This document outlines the procedure for erecting hollow core slabs (HCS) and its safety
requirements. It is assumed that the bearing surface where the HCS will rest is in place, such as beams or
wall elements (cast-in-situ or precast). For erection of beams, wall panels and other precast elements,
please refer to their respective method statements.

This method statement does not include detailed procedure for design, planning and final works on
HCS e.g. screeding/grouting.

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, 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 HCS 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 DISCUSSION ON SAFETY REQUIREMENTS

OSHA Standard Part No. 1926 “Safety and Health Regulations for Construction” subpart M “Fall
Protection” provides non-mandatory guidelines for safe erection of precast units. Portions relating to
HCS erection is quoted in this method statement.

It is well established that the major hazards presented by erection of hollowcore slab is working at
height and handling of suspended HCS. These are the major consideration on the safety portion of this
method statement. The user of this method statement should refer to OHSE Risk/Impact Assessment
Register “Erection of Precast Units” prepared by Precast for further information especially on the
controls required to ensure safe erection of HCS.

2.4 PERSONNEL

1. Projects Manager

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 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 sufficient
number 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.

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

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 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 Plan. Safety requirements for Crane and Rigging Equipment are mentioned in
“Environment and Safety Handboo 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/Proprietary Scissor Clamps/Nylon Belt Slings/Spreader Bars - should be of the
type required particular to this project in reference to the Erection Plan. Selection, safety
requirements and other guidelines for lifting accessories are mentioned in “Environment
and Safety Handbook”

2.6 MATERIALS

PVC Shim Pads, various thickness

2.7 PREPARATION

Identify the area of erection as per Erection Plan and sequence of work. Verify site, equipment
and precast concrete units condition prior to erection, and they should satisfy all the relevant
requirements stated in

2.8 GENERAL METHOD STATEMENT FOR ERECTION OF HCS

(This procedure quoted from PCI-MNL-127 “Recommended Practice for Erection of Precast Concrete”,
pages 52-54)

1. 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.

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

2. On bearing wall (e.g. load-bearing wall panels), if required by design, the voids at ends of slabs
are generally blocked with HCS End Caps to prevent grout from flowing into the voids as the
end joints are grouted.
3. Full-width HCS (1200mm) must be lifted with scissor clamps or with spreader bar. Part slabs
(slabs that have reduced width therefore the HCS notch of one side used for lifting with scissor
clamp was cut) must be lifted using proprietary nylon belt slings.

Fig. 2: Scissor Clamps with proprietary spreader bars, if required. Note that the safety chains are engaged

Fig. 3: Use of choker for lifting and handling part HCS. These units will not be placed in its exact final position, and
needs to be adjusted afterwards.

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 4. Slabs installed using nylon belt slings cannot be set exactly in position and have to set into final
position after the slings are removed. This may be accomplished by setting the next slab down
and carefully nudging the HCS to be positioned against it, of by using come-a-longs to pull slabs
into position. Care should be taken to ensure that each HCS has at least the minimum bearing
shown on erection drawings.
5. After all the units are set, they can be adjusted, using a bar, so that the joints are uniform in
size and open or closed to properly cover the space allotted. If the final joint is 1/8” (3.5mm) or
more, it may be necessary to tape the joint or stuff a filler rod into the bottom of the gap to
keep grout from leaning though the deck.
6. Prior to grouting of the keyways, the sabs should be leveled while keeping the units tight and
at right angles to the bearing wall or support beam. Leveling should be done from the
underside, i.e. level the slabs while viewing the shear key relationships below. To attain the
desired position, several methods may be employed:
a. Blocking and a pole-mounted hydraulic jack (shores may be installed)
b. Pinch bars and hardwood wedges or steel shims driven into the shear key. The wood is
removed after the grout is set.
c. Plates top and bottom with bolt through joint.
7. Connections between slabs over bearing wall are accomplished by placing reinforcing bars ot
strands in the joints between slabs across the bearing walls. Additional bars may be placed into
the cores across the bearing wall and grouted. The amount of reinforcement depends on
design requirements and should be specified by the designer and shown on erection drawings.
8. In grouting operations, the grout key shout be pre-wetted. Approved grout shall be used. PCI-
MNL-127 recommends the use of grout with 1:3 cement to sand ratio and sufficient water to
spread easily. It should be spread with brooms and squeegees over the joints in the deck, and
all spaces between the HCS should be filled. Use of high-range water-reducing (HRWR)
admixtures provides fluidity while maintaining the necessary strength.
9. After grouting the joints, any material that may have seeped through the ceiling below should
be removed before it hardens.
10. Once the grout has attained strength, the wedges and/or jacking posts may be removed.
11. Bearings should be inspected to make sure the slab has full bearing.
12. If necessary, dry pack mortar can be tamped in any open spaces.
13. The deck can now be used for other trades, and as platform for erection subsequent precast
units.

2.9 SAFETY PLAN AND GUIDELINES FOR ERECTION OF HCS

Discussion

Standard safety requirements must be applied and all applicable provisions of “Environmental and
Safety Handbook” must be followed. The following topics are covered in the handbook and should be
referenced for erection of hollow core slabs:

 General Performance, Responsibilities and Objectives (Sec A, B);

 HSE Inspection, Reports and Records (Sec 3);
 HSE Organization and Responsibilities (Sec 4);
 HSE Practices and Procedures (Sec 5):
o Reporting of Incidents/Near-Misses (Sec 5.1);
o Reporting of Accidents (Sec 5.2);
o Toolbox Talks (Sec 5.3);
o HSE Training (Sec 5.4);
o HSE Committee Meetings (Sec 5.5);
o Housekeeping (Sec 5.6)
 Personal Protective Equipment (Sec 6);

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  Hazard Identification and Awareness (Sec 2);
 Emergency Response (Sec 8);
 HSE Instructions (Sec 9):
o Storing and Handing of Precast Units (Sec 9.1);
o Operation of Cranes (Sec 9.2);
o Site Operations Safety (Sec 9.9);
o Ladders (Sec 9.11);
o Cranes and Rigging Equipment (Sec 9.13);
o Mechanical Equipment (Sec 9.14);
o Transportation (Sec 9.15)
 Company Safety Provisions (Sec 11)
 Waste Management (Sec 12)
 Lock-Out and Tag-Out System (Sec 13)
 Heat Stress Prevention and Control (Sec 14)

Special consideration is discussed for fall protection during erection of hollow core slab on succeeding
section.

Fall Protection Plan for Erection of Hollow Core Slabs

1. Planning:

a. All fall hazards in the work area must be identified. Pay special attention to work areas
with irregular shaped perimeters, floor openings, or locations near corners.
b. All fall protection equipment must be inspected for damage, wear, and obvious
defects by a competent worker before each use.
c. Any worker required to use fall protection must be trained in its safe use and proper
maintenance

2. Holes: all openings on HCS greater than 30 cm X 30 cm (12"xI2") will have covering. Before
succeeding HCS are erected, proper protection for the holes on previously installed HCS must
be provided to protect the erectors.

3. Perimeter guarding and covers, if required on cast-in-situ structure, will be the responsibility of
the main contractor

4. Fall arrest system strategy:

Guardrails or other perimeter-guarding devices or methods on the erecting floor will pose
problems to safe erection procedures. The perimeter of the floor and roof changes each time a
new member is placed into position. It is unreasonable and virtually impossible to erect
guardrails at the ever-changing leading edge of a floor or roof. See OSHA Standard Part No.
1926 “Safety and Health Regulations for Construction” subpart M “Fall Protection”. This is
especially true in precast concrete erection of HCS on load bearing wall panels, where there is
no vertical element to which the guardrail or perimeter lifeline will be attached; and the
installation of the guardrail itself poses the same or more fall risk.

The same OHSA Standard even went to say in Section IV.A that “…in this particular erection
sequence and procedure, personal fall arrest systems requiring body belt/harness systems,
lifelines and lanyards will not reduce possible hazards to workers and will create offsetting
hazards during their usage at the leading edge of precast/prestressed concrete construction.

…it is necessary that the employee be able to move freely without encumbrance in order to
guide the sections of precast concrete into their final position without having lifelines attached

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 which will restrict the employee's ability to move about at the point of erection. A typical
procedure requires 2 or more workers to maneuver around each other as a concrete member
is positioned to fit into the structure.

If they are each attached to a lifeline, part of their attention must be diverted from their main
task of positioning a member weighing several tons to the task of avoiding entanglements of
their lifelines or avoiding tripping over lanyards. Therefore, if these workers are attached to
lanyards, more fall potential would result than from not using such a device….

…Employees tied to a lifeline can be trapped and crushed by moving structural members if the
employee becomes restrained by the lanyard or retractable lifeline and cannot get out of the
path of the moving load…”

Conclusion:

The strategy to be used would require a ladder or scaffold to erect the initial one or two HCS
units. The erected HCS would then become the platform for the erector to erect the
succeeding HCS along the same row. Erection of HCS on different row must begin on the same
sequence.
The proposed strategy utilizes retractable fall arrest equipment, with its cable attached to wall
panel lifting anchor.

a. Placing the initial one or two HCS units shall be performed using ladders or scaffold
(see Ladder Safety on). A ladder or scaffold is to be utilized on each side to guide
these units into place. Working from the ladder will be the erector with a spotter to
stabilize the ladder. A fall-arrest system will be used when work is performed from a
ladder where a fall of 3 meters or more could occur.
b. To position a member safely, it is necessary to remove all obstructions extending
above the floor level near the point of erection, if there is any. Such a procedure
allows workers to swing a new member across the erected surface as necessary to
position it properly without worrying about knocking material off of this surface.
c. In floor or roof deck work, as in other precast concrete erection, others are not
typically on the work deck until the precast concrete erection is complete. The deck is
not complete until the leveling, aligning, and grouting of the joints are done. It is
normal practice to keep others off the deck until at least the next day after the
installation is complete to allow the grout to harden.
d. Placing subsequent precast units: the worker shall access the initial one or two units
placed, and immediately proceed to attach the retractable fall arrestor to anchorage
on bearing support1 for fall protection system.
e. Before attaching inspect the bearing support to determine there is no compromise in
the product, check for cracks or other signs of quality defects that would jeopardize
the security of the fall arrest system.
f. Once secured, the worker shall connect the equipment their lanyard/harness to the in
such a way to prevent falling over any edge.

1
Anchorages on bearing support includes lifting anchors/hooks on precast wall panels or beams which at all times designed to be stable and high-capacity,
and usually free during HCS erection. On cast-in-situ structure, it could be an exposed reinforcement. On masonry works, it might be required to install eye
socket.

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 Fig. 4: Recommended set-up for HCS erection. Refer to appendix for the direction of erection. Note that the
retractable fall arrestor is attached then detached to a new location as the leading edge changes by
erection of succeeding HCS. A lookout person is assigned to ensure that the cables of the arrestor would not
get tangled. Taglines can be installed on HCS for guidance if the HCS is still above waist – note that the
erector is only allowed to approach the HCS if it is waist high

g. Designated erectors, while waiting for the next floor or roof member are directed to
stay a minimum of two meters from any leading edge. Use taglines to guide HCS if
above the waist height.
h. Whenever possible the designated erectors will approach the incoming member at
the leading edge only after it is at waist height so that the member itself provides
protection against falls.
i. When the arriving floor or roof member is within 5-10 cm of its final position, the
designated erectors can then proceed to their position of erection at each end of the
member being placed.
j. As subsequent precast units are placed the worker detach the retractable fall arrestor
and re-attach to the nearest anchorage, especially if the length of cable is no longer
enough to cover the row of HCS. NOTE: AT NO TIME SHALL A WORKER PERMIT THEIR
CABLE TO BE OF A LENGTH THAT WOULD ALLOW THE WORKER TO FALL OFF ANY
EDGE.

5. For work of other trades which requires access to the HCS recently erected, such as grouting
and installation of accessories, and no vertical elements erected yet to mitigate fall hazard, a
"CONTROL ZONE" shall be developed as follows:

a. CONTROL ZONE means an area in which certain work may take place without the use
of guardrail systems, travel restraints, personal fall arrest systems, or safety net
systems and the access to the zone is controlled.
b. Warning line systems shall be erected around all sides of the roof work area, not less
than two meters from the edge, on all perimeter units, at each edge.
c. Points of access, materials handling areas, storage areas, and hoisting areas shall be
connected to the work area by an access path formed by two (2) warning lines.
d. When the path to a point of access is not in use, a rope, wire, chair, or other
barricade, equivalent in strength and height to the warning line, shall be placed across

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 the path at the point where the path shall be offset, such that a person cannot walk
directly into the work area.
e. Warning lines shall consist of rope, wire, or chains flagged with high-visibility material.
f. The rope, wire, or chain shall be rigged and supported in such a way that its lowest
point (including sag) is no less than 34” (850mm) from the walking/working surface,
and its highest point is no more than 39” (975mm) from the walking/working surface.
g. The line shall be attached at each stanchion in such a way that pulling on one section
of the line between the stanchions will not result in slack being taken up in the
adjacent sections before the stanchion tips over.
h. No employee shall be allowed in the area between the roof edge and a warning line,
unless the employee is performing leading edge work and is using a fall arrest system.
i. The control line shall extend along the entire length of the unprotected or leading
edge and shall be approximately parallel to the unprotected or leading edge. NOTE: IN
THE AREA OUTSIDE THE CONTROL ZONE, WORKERS MUST USE A FALL-ARREST
SYSTEM.
j. Before starting work inside the CONTROL ZONE you must make sure the contractor
covers all openings and penetrations in the slabs.

6. For the erection of subsequent vertical elements, e.g. load bearing wall panels or columns, the
control zone demarcation is removed and the erector is required to use fall arrest system using
retractable fall arrest equipment.

3.0 QUALITY ASSURANCE

3.1 CONTRACTUAL REQUIREMENTS

1. Satisfy general acceptability of erection of hollowcore 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 of hollow core slab: Erection Engineer

2. Inspection of completed erection works: Main Contractor representative

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 / CAPA NC Report and NC/CAPA Log Sheet

Records shall be kept in QC Department and kept for minimum of two (2) years.

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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

4.2 RISK ASSESSMENT

Follow all applicable HSE detailed nature of controls of this activity from
 “Erection of Precast Units” and “Transportation of Precast Units”

5.0 REFERENCES

OSHA Standard Part No. 1926 “Safety and Health Regulations for Construction” subpart M “Fall Protection”
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=standards&p_id=10927
Occupational Safety and Health Administration
United States Department of Labor

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

PCI-MNL-132 “PCI Erection Safety for Precast and Pre-stressed Concrete”
Precast/Pre-stressed Concrete Institute (PCI)
175 West Jackson Blvd., Chicago, Illinois 60604

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