pq document.pdf

PRE -QUALIFICATION

Contents

01 10

04 13

16

17

07

02 11

1405

08

03 12

09

Company Profile

Consultant Approvals Factory Layout

Appreciation Letters

Certificates

Quality Policy

HSE Policy

Licences Plant & Equipments

Product List Material SafetyData Sheet

List of Projects Method Statement

Test & Calibrations

Projects in Photos

OrganizationStructure

General Catalogue

06 15

Company Profile

Apex Precast Products Industries LLC is an ISO 9001: 2008 certified company and a division of the multinational A&P group of companies. Operating from a 450,000 square feet plant, our superior and broad range of products includes precast building system with external insulated panels, hollow core slabs, internal solid panels, stairs and landings, claddings, boundary walls, underground holding tanks and septic tanks with soak ways, columns, beams, crash barriers, and other infrastructure elements.

With a computerized batching plant capacity of 600 cum/day, in house QC laboratory and a fleet of trailers, the company has the capacity to deliver quality products with shorter delivery cycles.

We have a strong reputation for supplying highquality precast products promptly & on competitive rates. Our list of prestigious clients includes major names in construction such as Emaar, Nakheel, Jumeirah Beach Residence(JBR), Municipalities, ADWEA, FEWA, SEWA, ADNOC, TRANSCO, JAFZA public works departments, Defence, various other general contractors and several other entities and names involved in the construction industry.

Our project portfolio includes supply and installation of the following:-

Precast District Cooling Plants for Zayed University•

48 nos. of G + 13 load bearing precast circular •

towers at Palm Jumeirah

11/0.4 KV Electrical Distribution Substations • for ADDC/ADWEA at Motorworld Development

73 KM of boundary wall within a span of 6 • months in Al Ain

Cladding at Jumeirah Beach Residence (JBR)•

Car parking buildings at Qusais•

Ministry of Labour building at Al Qusais•

7 nos (G + 2) precast residential accomodation • units in Sharjah

Precast Substations and Troughs for TRANSCO/• ADWEA

Labour and staff accommodations, claddings • and boundary walls.

G + 12 exposed aggregate cladding building • at Sharjah

Precast Tennis Stadium at Fujairah•

More than 1000 precast underground pump • rooms and water tanks for Jumeirah Park

Precast boundary walls for villas at Falcon city • of Wonders, Springs and Arabian Ranches

Grand Stadium for Emaar at Arabian Ranches•

250 nos. underground Precast tanks at Arabian • Ranches

GEMS World School at Dubai •

22 KV Electrical Substation for ADDC/ADWEA • at Al Falah Community

About us

Our aim is to be one of the premiere precast manufacturer and supplier to our valued clients. Earnestly geared towards being customer-centric, we take pride in maintaining our impeccable track record and commitment in meeting deadlines.We believe in ensuring professionalism combined with customer satisfaction, having to our credit unparalleled accomplishments and established

reputation as being identifiable with dependability and quality assurance.

Our TeamWe have an experienced and a professionally dedicated management team ensuring smooth and efficient functioning of all our Precast operations.

Our Objective

Certificates

Licences

Consultant Approvals

Appreciation Letters

Product List

Range of Precast productsApex Precast manufactures, delivers and erects a wide variety of Precast concrete products.

The range covers

Building Systems

1. Precast Villas2. Labour Accommodation3. Industrial structures

Cladding Panels

1. Insulated panels2. Solid grey panels3. Exposed aggregate panels

Boundary wall

Type 1 low cost design without column 1. designType 2 medium range with column design2. Type 3 exposed aggregate finish panel 3. design

Tanks

Holding and water tanks of 2.5/ 5/ 11/ 161. / 24 cumSeptic tanks & Soak away of 5/ 11/ 16 cum2.

The sizes can be custom built to requirements

Building Elements

1. Foundations2. Columns3. Beams4. Slabs5. Stair Cases6. Parapet7. Lintels & Sills8. Copings9. Pergolas

Range of Precast products10. Arches11. Dome.12. Hand rails

Retaining wall

1. Retaining wall2. Shoring Panels

Troughs & Cover Slabs

Cable trough & Cover slabs for all types of electrical cable distribution systems in substations for ADWEA, FEWA & DEWA

Infrastructure Elements

1. Under ground Manholes2. Road and Crash Barriers3. Fencing Post4. Wheel stoppers5. Pole Light Foundations6. Culverts & Protection slabs7. Speed Humps8. Counter weights9. Feeder Pillars10. Transformer Foundations11. Earth Pits

Landscaping Elements

1. Benches2. Planter Box3. Steps4. Decorative Bollards

Marine Protection Elements

1. Wave Breakers2. Stabit Units3. Mass Block4. Quay Wall

List of Projects

Contractor Project Location Completed Date

M/s. Al Bharat Contracting Precast Tanks Abu Dhabi May 2010

M/ s. Al Hikma Building Contracting L.L.C

Precast Slabs Dubai May 2010

M/s. Beaver Gulf ContractingPrecast boundary wall at Al Warsan

Dubai April 2010

M/s. Kaz ContractingPrecast Tanks for Al Ghurair Investments L.L.C

Dubai April 2010

M/s. New Valley Building Contracting

Precast Septic Tank Dubai April 2010

M/s. Geco Mechanical & Electrical LTD

Precast Concrete blocks for Sub Station

Dubai April 2010

M/s. Art Line Contracting Company L.L.C

Boundary Wall for Ware house at DIP

Dubai March 2010

M/s. New System Engineering L.L.C

Precast Tanks Dubai March 2010

M/s. FNCTPrecast Septic Tank & Soakaway

Fujairah March 2010

M/s. Innotech Construction Company L.L.C

Precast Slabs Dubai March 2010

M/s. Uhud Building Contracting L.L.C

Precast Wheel Stopper Dubai March 2010

M/s. Al Bharat ContractingPrecast Boundary Wall at ICAD – 1

Abu Dhabi February 2010

M/s. Future ScaffoldingPrecast Water Tanks and Pump room

Dubai January 2010

M/s. Nautical Engineering Precast Concrete Boxes Ajman January 2010

Building Contracting Beam at Zabeel Dubai December 2009

List of Projects


M/s. Amada Contracting Precast Tanks Dubai November 2009

M/s. Al Hosnei Contracting L.L.CBoundary Wall for 987 / DU Pop Exchange

Dubai October 2009

M/s. Water & Power Engineering Co L.L.C

Precast Shoring Panels Dubai October 2009

M/s. Future ScaffoldingBoundary Wall for Future Scaffolding

Dubai September 2009

M/s. Abdul Rehman Architectural Consultant

Precast Tanks Dubai September 2009

M/s. Water & Power Engineering Precast Shoring Slabs Dubai September 2009

M/s. Khansaheb Civil EngineeringPrecast Cover Slabs for KB643- DWTC


M/s. Al Huda Contracting Co. L.L.C Precast Tanks Dubai August 2009

M/s. Herald Contracting Precast Tanks Dubai August 2009

M/s. Gunal Construction Precast Tanks Dubai August 2009

M/s Ranya General Contracting Company

Boundary Wall at Al Ruwayah Phase – 1 for RTA

Dubai June 2009

M/s Emirates Road Contracting Co. L.L.C

Road and Infra structure works for RTA

Jebel Ali June 2009

M/s. Pivot Engineering and Contracting

Precast Dome for Golf Garden Projects

Abu Dhabi June 2009

M/s. Gayathi Construction Precast Tanks Dubai May 2009

M/s. Gayathi Construction Precast Tanks Sharjah May 2009

List of Projects


M/s. Emirates Technical AssociatesG 15 Substation in Khorkhwair

Ras Al Khaimah

April 2009

M/s. Condor Building ContractingDu-Pop Exchange Building and Villa

Dubai March 2009

M/s. Al Huda Contracting Company

Water Tank and Pump rooms for Jumeirah Park Villas

Dubai March 2009

M/s. Al Kitbi Contracting L.L.C Precast Tanks Dubai March 2009

M/s. Al Hamra Engineering Water Tanks Sharjah February 2009

M/s. Roshan ConstructionCold Storage and G+2 offices at Ras Al Khor Ind for Fresh Fruits

Dubai December 2008

M/s. Pauling Middle East Co. L.L.C366 Villas for Phase One Project within Falcon City of Wonders

Dubai December 2008

AIMS, Ajman Double sided road barrier Ajman November 2008

M/s. TanqiaWet well pump station at Fujairah

Fujairah November 2008

M/s. TanqiaWet well Pump station & Service buildings

Fujairah October 2008

M/s Sungwon Corporation2 Nos G+1 Labour Accommodation

September 2008

Condor Building Contracting L.L.CWork House, office & external works for M/s Lulu Hypermarket

Dubai August 2008

M/s Le Meridien Holding Tank Dubai June 2008

M/s. Arabian Construction Company

Single sided road barrier at Ibn Battuta

Dubai June 2008

M/s. System ConstructBoundary Wall for Bahwan Group

Dubai May 2008

List of Projects


Ajman PoliceGeneral Directorate of Ajman Police

Ajman May 2008

M/s. Delta Emirates Contracting Co. L.L.C

Boundary wall for Dubai Rehabilitation & Handicapped Centre

Dubai April 2008

M/s. Essa Engineering &Marine Services

Septic Tank & Soak away Ajman April 2008

M/s. Amana Contracting & Steel Building

Boundary Wall for RAK Investment Authority

Ras Al Khaimah

February 2008

M/s Actco General Contracting Co. L.L.C

400/132 KV Grid Station at Fujairah

Fujairah January 2008

M/s. Chicago Maintenance & Construction

G+3 World School at Al Barsha Dubai

Dubai December 2007

M/s. Al Wasit Roads Contracting, Dubai

Road Barrier Dubai December 2007

M/s. Herald Contracting Co. L.L.C Precast Tanks Dubai Novermber 2007

M/s. Proscape, DubaiPlanter Boxes for Jumeirahh Beach Residence Project

Dubai Novermber 2007

M/s. Globe Road Contracting L.L.CCrash Barrier for the Sadi Road

Ras Al Khaimah

October 2007

M/s. Condor Contracting CompanyPop Teleport Exchange Building


M/s Al Sahel Contracting CompanyP-116 office park at Dubai Internet City


M/s. National Contracting & Transport Co

G+1 Villa at Sharqan Sharjah June 2007

M/s Construction Technology3 Nos G+2 Labour Accommodation

May 2007

M/s Construction Technology G+2 Staff Accommodation May 2007

List of Projects


M/s Uhud Construction G+2 Staff Accommodation Sharjah May 2007

M/s. Amana Steel Buildings Precast Tanks Jebel Ali May 2007

M/s. Roshan Construction L.L.C G+3 Labour AccomodationAl Quoz,Dubai

April 2007

M/s SIEDCO General ContractingShore line Apartments, Palm Jumeirah Al Nakeel

November 2006

M/s. Al Hikma Building Contracting L.L.C

Septic Tanks & Soak pits Sharjah November 2006

M/s. Bu Humaid ConsultantFarm House for Ruler of Ajman

Ajman October 2006

M/s. Seidco General ContractingSlab covers at Palm Jumeirah

Dubai October 2006

M/s. Darwish EngineeringAl Batha Compound wall & Guards rooms

Sharjah September 2006

M/s. Omis ContractingG + 1 School in Al Quarryman


Al JazeeraAl Jazeera Paper Mill Factory

Umm Al Quwain

August 2006

M/s. Rigid construction Precast Tanks Jebel Ali August 2006

M/s. Khan Saheb Construction Co Deira City Center Dubai August 2006

M/s Seidco General ContractingG+13 Circular Tower Palm Jumeirah

July 2006

M/s. Emirates Road contractingRoad and Crash Barriers for Umm – Al-Quain racing club

Umm Al Quwain

July 2006

M/s. Al Ahamadiah ContractorsHand Rails for Jumairah Beach residences

Dubai May 2006

List of Projects


M/s. Fujairah National Const. and Transporters

Tennis Stadium Fujairah May 2006

M/s. Al Mostajed Technologies Precast Trenches for FEWA Dubai April 2006

M/s. Arabian Construction Company

Ahujan Soft Drink Factory Dubai March 2006

M/s. Arabtec Construction Deira City Center Dubai March 2006

M/s Hashim Al Dhabal Villa at Al Khawaneej Dubai February 2006

M/s. Ayoubco General Contracting G+1 Villa at Nad Al Sheeba Dubai February 2006

M/s. AMB BuildingCopings for Endurance villa at Al Lisalli

Dubai December 2005

M/s. E T A Troughs for ADWEA Abu Dhabi December 2005

M/s. Al Sahel Contracting Precast Wheel Stoppers Dubai December 2005

M/s. Amana SteelHempel Paints U.A.E Factory

Sharjah November 2005

M/s Holiday International Holiday International Hotel Sharjah August 2005

M/s. Greenland Company Precast Benches Sharjah August 2005

M/s. Arab Tech ConstructionG+5, and above for 5 buildings at Jumairah Beach Residence

Dubai July 2005

M/s. AMB BuildingDecorative Lintels and sills at Endurance villa Lisalli

Dubai June 2005

M/s. Al Sahel Contracting Planter Boxes Dubai June 2005

List of Projects


M/s. Al Khadim Building Contracting

Precast protection Slabs Sharjah May 2005

M/s. Essa Engineering and Marine services

Precast Trenches Ajman April 2005

M/s. Engineer’s Office Building for Ruler of Dubai March 2005

M/s. Essa Engineering & Marine Services

Office Building Ajman March 2005

M/s. Ranya General Contracting Precast Slabs Sharjah March 2005

M/s. Essa Engineering And Marine Services

Precast Slabs Ajman March 2005

M/s. Al Oroba Constructions238 Villas at Arabian Ranches for Emaar

Dubai February 2005

M/s. Team Engineering EnterprisesLabour accommodation, Sheds & Boundary Wall

Dubai February 2005

Management of Private PropertiesWomen’s Association – Umman-Al-Moumneen

Ajman February 2005

Management of Private Properties Ajman National School Ajman February 2005

M/s. Team Engineering Police station at Khalifa city Abu Dhabi February 2005

M/s. Apex Concrete Block Factory Precast Manholes Dubai February 2005

M/s. UNEC Dhaid Youth Center Sharjah January 2005

M/s. Bill Finger BergerFujairah Sewage Collection Network

Fujairah January 2005

M/s. Ginco Contracting5000 Lit under ground Water tank for 238 Villas at Arabian Ranches

Dubai January 2005

List of Projects


M/s. Al Oroba ContPergolas for 238 villas at Arabian Ranches

Dubai January 2005

M/s. Greenscape Contracting Precast Steps Dubai January 2005

M/s Translite Interiors St.Mary’s School & Church Dubai December 2004

H.H. Sheikh Mohammad Bin Zayed Boundary Wall for Villa at Al Khawaneej

Dubai November 2004

M/s. Darwish EngineeringStadium Steps for Choeifat School


M/s. C R C240 Villas - Emaar Properties

Dubai July 2004

M/s. Al Eslah General Construction66 Villas at Al Yahar North for Al Ain Municipality

Al Ain April 2004

M/s. Ecoplast Emirates Refinery Sharjah March 2004

M/s. China National Aero Tech Engg. Co

48 Villas at Al Yahar North for Al Ain Municipality

Al Ain March 2004

M/s. Translite Interiors St. Mary’s School Dubai January 2004

M/s. Ali Moosa & Sons MosqueRas Al Khaimah

January 2004

M/s. Ali Moosa & Sons30 Villas for Private Dept. for H H Sheikh Zayed Bin Sultan Al Nahyan

Ras Al Khaimah

January 2004

M/s. Ali Moosa & Sons ContractingYouth centers @ Madam, Al Thameed, Al Maleeha

Sharjah December 2003

M/s. Ali Moosa & Sons ContractingCompound Wall for Clinic in Maleeha

Sharjah December 2003

M/s. Ali Moosa & Sons30 Villas for Private Dept. for H H Sheikh Zayed Bin Sultan Al Nahayan

Al Ain December 2003

List of Projects


M/s. Consultant Engineers OfficeVilla at Al Manara for Higgs & Hills

Dubai November 2003

M/s. Ali Moosa & SonsLow Cost Villas (276 Villas) for H.H. Sheik Zayed Al Nahayan

Al Ain September 2003

M/s. Amana SteelBus Service Station for Dubai Municipality

Dubai August 2003

M/s. Ginco Day Care center at Emaar Dubai October 2002

M/s. Al Mansouri 3B Contracting LLC

Al Baharna Cemetery for Awqaf AlJafariayah

Dubai July 2002

M/s. Al Ghaith Building Construction Co

Precast Boundary Wall Works

Dubai May 2002

M/s. Al Ghaith Building Construction Co

Showroom and offices for H.H Saeed Khalfan Ahmad Al Ghaith

Dubai March 2002

M/s. Ali Moosa & Sons ContractingChild Care Center at Dibba Al Hesen

Sharjah March 2002

M/s. Al Mansouri 3B Contracting LLC

Al Baharna Cemetery for Awqaf AlJafariayah

Dubai January 2002

H.H. Sheikh Mohammed Bin ZayedCladding panels for B+G+10 storied building at Al Tawun


M/s. Petron Emirates Construction Co

Mina Zayed Port Abu Dhabi June 2001

M/s. TransliteRetaining wall and shoring slabs for St. Mary’s church

Dubai June 2001

List of Projects

Project Photographs

G+12 Circular TowerShoreline AppartmentsPalm JumeirahNakheel, Dubai

Project Photographs

Project Photographs

G+12 Circular Tower, Shoreline Appartments, Palm JumeirahNakeel, Dubai

Project Photographs

G+12 Circular TowerShoreline AppartmentsPalm JumeirahNakheel, Dubai

Project Photographs

B+G+10 Insulated Exposed Aggregate Panel Cladding

Project Photographs

Labo

ur A

ccom

odat

ion

Shar

jah

Project Photographs

Springs, Emaar Dubai

Project Photographs

Boundary WallDubai

Boundary WallSharjah

Boundary Wall, Hempel PaintsSharjah

Project Photographs

Boundary Wall, Agility L.L.CDubai

Colu

mns

& B

eam

s fo

r Ind

ustr

ial /

Indo

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port

s St

ruct

ures

Labo

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odat

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Shar

jah

Boundary Wall, DU, Sports CityDubai

Project Photographs

Boundary Wall, RTADubai

Project Photographs

Boundary Wall, TranscoRAK

Project Photographs

Trenches for ADWEA

Precast steps for GECO schoolSharjah

Project Photographs

Exposed Aggregate Finishes

Project Photographs

Min

istr

y of

Lab

our B

uild

ing

Dub

ai

Labo

ur A

ccom

odat

ion,

CTC

RA

K

Project Photographs

Staff Accomodation, Al QuozDubai

Labour AccomodationRAK

Labo

ur A

ccom

odat

ion,

CTC

RA

K

Labo

ur A

ccom

odat

ion

Shar

jah

Precast Cladding, Internet CityDubai

Labour AccomodationSharjah

Project Photographs

Boundary Wall, Falcon City of WondersDubai

Project Photographs

Prec

ast

Bui

ldin

g, A

l Quo

zD

ubai

Labour Accomodation, ConmixDubai

Project Photographs

Precast Stadium Steps, Goverment of FujairahFujairah

Project Photographs

Precast BuildingAl Quoz, Dubai

Project Photographs

Precast Dome, Golf Gardens, SorouhAbu Dhabi

Project Photographs

GEM

S W

orld

Sch

ool

Dub

ai

GEMS World SchoolDubai

Project Photographs

Project Photographs

Royal Furniture WarehouseAjman

Precast Building, Al QuozDubai

Project Photographs

Cladding, JBR (Jumeirah Beach Residence)Dubai

Clad

ding

JB

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Jum

eira

h B

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Res

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Dub

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Boundary Wall, Arabian RanchesDubai

Project Photographs

Organization Structure

Org

aniz

atio

n St

ruct

ure

Sales and Marketing Department

Being the front-runner of the organization, the primary function of this department is to garner revenue for the company, booking orders and servicing the client. It focuses on the needs and wants of the customer and constantly updates the management of the changing dynamics of the growing market.

It is responsible for tasks such as preparing job estimation, quotation and contracts based on the current prices prevailing in the global and local market and the agreed terms and conditions.

The Estimation and Contracts Department which reports to the Sales Manager, have duties which includes preparation of quotations for tenders or for current projects required by the client. Apex Precast has developed an in-house computer software application specifically designed to assist in preparation of estimates in an efficient and accurate way by calculating the necessary quantities.

Apex quantity surveyors inspect the tender drawings and estimate the combined weight of varied steel reinforcements, ranging from 8mm to 32mm, concrete, other material needed for shuttering areas, and other related activities.

A computerized bill of quantity developed by Apex to standardize quotation procedures is in use,

whereby making available a flexible format which can be adopted for various quantity requirement.

The quotations are finally adjusted taking into account the market conditions and client requirements by the Sales Manager for forward transmission to client. Upon final approval of the project by client, the contract is then subsequently awarded, the quantities are referred to and ascertained as in the tender, checked for accuracy and then handed over to the Procurement department to initiate all the purchases.

DepartmentalOrganization

Apex Precast Industries has been at the fore-front of the contracting and construction industry by utilizing computer technology. Our professional team of staff is always utilizing the most modern equipment and software available thus producing the highest quality of workshop drawings.

The following software is being used by our Technical Manager & Structural Engineer:-

STAAD/PRO: Structural Analysis, 2D, SD, • Framed Structural Analysis.

Finite Element Analysis will be carried out by • using 3 nodded & 4-nodded quadrilateral plate.

Latest Cad Software: • Design Drawing, Production & Erection Shop Drawings for all Precast Elements.

Latest Windows Software: Design calculations • for Precast elements will be done by using the Excel Spread Sheet.

On commencement of a precast project, the Estimation, Production & Projects department will prepare contributions on the varied services required to complete the overall shop drawings required by clients.

The Technical team co-ordinates with the Production & Projects to produce drawings that the construction team can adhere to. The feedback provided by the project consultant will then be incorporated into the drawings and re-submitted for approval before being distributed to productionand erection staff for implementation. At times alterations are made to suit conditions on the site itself, or to fulfill other requirements.

All changes made are noted on the shop drawings and at the end of the contract; they are cross matched with the original design to produce separate as built drawings. In the initial stages of the handing over of a project, the “As Built” drawings are given to the consultants, to be forwarded to the client for approval.

Production Department

The Production Department is responsible for the preparation of the moulds according to the true shape and sizes as provided in the approved shop drawings. Concreting and curing of the Precast Elements will be carried out as per the industry-standard practice. As soon as the steam cured cubes attain the full strength as required in the design, the Precast Elements will be stocked and dispatched to the site.

Technical Design & Drawings Department

Quality Assurance and Quality Control Department

The function of the Planning Department is to plan the execution of the projects, allocate necessary resources and to monitor the construction activities until handover to the clients. The department advises the project managers on the best ways to minimize the duration for performance of certain activities, whether they are on the right course of action or when an adjustment is required.

The following programs are developed at the onset of the project.

Bar Chart ProgramProgram Flow ChartLabour Histograms

They are monitored during the construction by the project manager as well as by the monitoring staff of the planning department. In the event of undue delays due to unforeseen circumstances during the construction period, a revised program is prepared taking into consideration the situation at hand as well as the completion date for the project. The revised program takes into consideration the extra labour and machinery that may be required at site not only to avoid further delays but also to fast track the delays that already exist at the time of preparation of the revised program.

updated as per the requirements of the clients. The QA/QC department has well trained auditors to perform internal audits at regular intervals at each site and in each departments to ensure that all the activities are carried out in accordance with the stipulated procedure, proper documentation.

This department also conducts regular in-house training for the employees.

The Management of Apex is committed to the task of implementing a quality system, which conforms to international standard requirements. The QA/QC department has also developed procedures in accordance with standard quality requirements for various activities within the company and also monitors to ensure that all the activities are carried out strictly in accordance with these procedures. The company has its own in-house quality policy and procedures which are constantly enhanced and upgraded to ensure that all the activities are well planned and executed to ensure complete customer satisfaction along with the smooth flow of the project.

On the commencement of every project, the Project of Quality plan is prepared and regularly

Planning Department

Projects Department

The Projects Department takes over the project after approval of drawings. The project is planned and schedule for the installation agreed upon with the client based on budget allocation. Approval for schedule is a mandatory requirement for start of a project. The projects department coordinates with design,production and store for the specifications and material deliveries.

The project department is responsible for quantity take-off for invoice preparation, certifications based on an agreed time period basis which is usually month end. The certified invoices are forwarded to Sales Department for payment follow up.

Finance Department

The Manager and personnel of this departmenthandle the financing requirements for theexecution of the project. Financing is mainlysourced through the established local and international banks, financial institutions that are operating in the UAE.

The Finance Manager is responsible for issuance of Performance Bond and down payment guarantees from the banks as well as financing of the projects in hand. He is also responsible for the issuance of Letters of Credit in favor of the many suppliers in accordance with the project contract agreements with them.

The accounting personnel handle the accounts of the projects in hand according to the procedures set by the manager of the department. This system is fully computerized to guarantee professional, speedy and accurate functioning. Auditing takes place on a regular basis by a reputed auditing firm. Their responsibility also includes preparation of the yearly budget and audit of the same.

Administration/Personnel Department

The Administration and Personnel Department is responsible for the allocation of the work force for various projects in accordance with the resource assignments done by the planning department.

This department also carries out regular follow-up procedures with the local authorities for the right allocation of required manpower from overseas in addition to handling the welfare of the employees.

Quality Policy

We endeavor to provide products in anticipation of the perceived needs of our clientele through our commitment to quality and service in accordance to British standards (unless specified otherwise by the client). Customer satisfaction is our greatest asset.

We establish, maintain and practice very effective systems, procedures and controls and keep them under review to achieve continuous improvement. Achieving consistency in our operations by strictly adhering to the laid down systems, we aim to satisfy the clientele’s requirements.

Developing and enhancing the awareness and skills of employees through training and motivation tops our list of priorities. By creating awareness of the commitment and responsibility of quality within each employee, it enables us to best serve towards achieving our goals. We constantly aim at enlisting employee participation to ensure total involvement of the human resources in achieving high work efficiency in our pursuit of excellence.

We relentlessly strive to surpass our performance by continuous improvement, to offer consistent and efficient quality and services.

Quality System

Apex Precast adheres to a highly effective Quality System since its inception to establish itself in the market as a quality producer of Pre-cast products.

Company has its own in-house Design team,Production and Erection crew with necessarymachinery and equipment to carry out the work complying with the Quality Standards.

Purpose

The purpose of this report is to ensure that the quality of the precast concrete elements produced by Apex Precast has been achieved using the materials and the methods that are in compliance with the requirements of the relevant ASTM, British Standards and in-house Quality Control System.

Quality Policy

Quality Control is monitored by Apex QA/QC department comprising of QA/QC Manager and QA/QC Engineers at different stage of execution of work. The Apex quality program will be covered under the following categories.

Design and Drawings1. Materials.2. Casting Platforms and moulds.3. Reinforcement4. Concrete5. Demoulding, Storage and Transport 6. Erection. 7.

1. Design and Drawings

Apex in-house Engineering team comprises of Qualified, experienced Structural Engineers and experienced Draughtsman who perform structural Design and detailing of all Precast elements.

a) LoadsDead loads, Live loads and the Erection loads are considered as per BS 6399 and the Wind loads are calculated in accordance with the provisions of BS CP3 Chapter V, Part 2 “Basic data for the design of buildings – wind loads.

b) DesignStructural stability, analysis & design calculations are done according to the BS : 8110. The design documents along with drawing are submitted for

the approval of the consultant.

c) Analytical as well as Standard Structural Analysis program STAAD/PRO is used for analysis wherever required. The Finite Element Analysis is done by using the 3-Noded triangular or 4-Noded Quadrilateral Plate /Shell elements of the STAAD/PRO.

d) Structural members are designed for the Ultimate Limit State: Moments, Shear forces and Service Limit State: Deflection, Cracking etc.

e) Nominal cover to the reinforcement including links is provided based on the durability and fire resistance requirements.

f) DrawingsLayout plans, detailed production and erections drawings for each structural Pre-cast element are prepared.

Shop drawings will feature following information.

a) Size, grade, profile and dimensions.b) Connection and anchorage details.c) Lifting devices, locations and handling limitations.d) Steel reinforcement details.e) Locations of all openings, sleeves and inserts, identification marks.

Quality Control Programme

2. Materials

a) CementSulphate Resistant Cement and Ordinary Portland Cement required for precast works are procured from specified Cement Industries conforming to BS 12. Test certificates are then provided for the procured lot.

b) AggregatesAll crushed stone aggregates complying to the contract specification requirements, required for concrete are procured from crushers at specified companies. Relevant test certificates are then submitted for these materials.

c) Construction ChemicalsSuperplasticiser: Rheobuild 1100 are used in the concrete as a water retardant. The same is then procured from MBT and product catalogue are provided.

d) WaterPotable water from Ajman Municipal supply is used.

e) ReinforcementHot rolled deformed high yield stress bars that are conforming to BS 4449 with specified characteristic strength of 460 N/sq. mm are used. Manufacturer’s test certificates are provided for the lot procured.

3. Casting Platforms and Moulds

Casting platforms, Moulds are fabricated and also maintained by the Apex formwork supervisor. The Pre-pouring inspection is then done by Apex QC Supervisor.

a) Steel moulds are fabricated as per standard Pre-casting techniques to the true size and shape for casting of wall panel as per dimensions and shape given in the approved drawings. Proper supporting system is provided to ensure rigidity and alignment.

b) Plywood formworks are used wherever required conforming to above requirements.

c) Before every concrete pour, integrity of mould / formwork is carefully examined and the form work is properly cleaned. Suitable mould release oil is also then applied to prevent adhesion of Concrete. Any mould/formwork joint gaps are sealed with paper tape or inserting foam tape between joints to avoid leakage of cement slurry.

d) Tolerances:It is ensured that deviations of formed surfaces do not exceed tolerances as per PCI standards.

4. Reinforcement

Cutting, bending of reinforcements done by Apex skilled tradesmen under the supervision of a well experienced Production and QC Supervisor.

a) Reinforcement is cut and bent to the shape and dimensions shown in the productions drawings in accordance with the requirements and tolerances of BS 4466.

b) Reinforcement is not heated before bending. Hot rolled high yield bars are not straightened or bent again once having been shaped to drawing requirements.

c) All the reinforcements are fixed rigidly in the position. At the intersections the bars are bound together with tying wire and the loose ends of the wire are turned towards the inside of the member.

d) Reinforcement is spliced according to the BS: 8110 requirements and the weld will be allowed for the welded mesh.

e) Reinforcement is fixed in the position shown on the drawings within a tolerance of 5 mm or 5 % of the lowest dimension of the cross-section of the member.

f) The concrete cover to the reinforcement bars is carefully maintained by using spacers as per the approved drawings.

g) Fabric reinforcement is used in standard sheets where possible. Adjoining sheets overlap by at least one rectangle or diameter of the bar at the lap, whichever is the greater.

During concreting operations, Apex steel fixer is in attendance to ensure that the reinforcement is maintained in position as pouring and compaction proceeds.

5. Concrete

Automated Concrete batching plant at the Apex factory premises is used to produce the required grade of concrete under the supervision of our production engineer.

a) Trial MixesTrial mixes are carried out with specified grade concrete mix with 20 mm down graded aggregates based on specification requirements and cubes taken from these mixes is tested. Suitable mix is then decided complying with the test requirements

b) Concrete Pre Pour checklistAll form work, reinforcement, inserts etc are checked by QC Engineer as per prepour checklist.

c) Concrete Pour - Test/RecordsFor Day’s concrete, slump, temperature etc is checked, recorded and it is ensured that slump, ambient temperature and concrete temperature complies with specification requirements.

6. Curing

Steam curing is started after initial setting period of 2 to 4 hours. Before starting steam curing, the precast element is covered with steam covers to avoid the leakage of steam. Spread of steam is maintained uniformly over the element.

The temperature of steam increase gradually with 4 0 C per hour up to maximum temperature level of 65 0 C. Steam curing is carried out for a period of 10 hours. The strength of the test cubes gives the actual strength attained by the steam curing.

a) Cube TestsFor day’s concrete six cubes are casted and tested after curing as detailed below.

i. 3 Days – 3 cubesii. 7 Days – 3 cubesiii. 28 Days – 3 cubes

Test results logbook are maintained for ready reference.

7. De-moulding, Storage and Transport

The De-moulding, storage and the transportation is done under the supervision of the site Erection Engineer.

a) The pre-cast element is removed from the moulds without damaging or over stressing and stored at the storage yard for transportation. The storage yard has storage racks to store the precast elements separately.

b) Each of the precast element is marked with anidentification number and the date of casting.

c) Pre-cast element is transported with sufficient battens, bracing and supports so as not to over stress by vibration or impact loadings.

d) Transport, storage, handling of the structural precast units will be done carefully to avoid undue strain, hair cracks, staining or other damages.

8. Erection

Erection work is done under the supervision of Erection supervisor.

a) Precast erection is done according to erection method statement.

b) All the erection crew wears PPE’s like Hand gloves and Safety shoes during erection work. Temporary side bracings are also provided during installation where required. A Crane with suitable capacity is used for erection of pre-cast elements.

c) Repairing work for any precast element that is damaged is done using repair mortars.

d) Repair work with materials is carried out as per manufacturer’s instructions given in the Technical data sheet.

e) Waterproofing membrane is applied to the boundary wall structure below ground level.

f) Workers use gloves, safety shoes and protective clothing while working with the repairing mortars and bitumen paint.

1. Scope2. Receiving Material Inspection3. Inspection/ Test of Concrete Mixes and Cubes4. Inspection of mould fabrication5. Pre-pour Inspection6. Concrete7. Post-pour inspection of finished precast

components8. Final Inspection before delivery9. Final inspection of erected precast components

1. Scope

This section provides the general performance requirements specially needed for Precast concreteproducts, which are continuously produced in well-controlled factories. Standard requirementsrelated to construction including concrete work at site using these products, are also laid down.

1.1 Basic RequirementsCare shall be exercised in the choice of materials used and in mix proportions, mixing, layout of reinforcement, molding, casting, curing,etc. To ensure that the manufactured concrete productsmeet the required quality and performance. Also, concrete products shall be manufactured in a manner that the quality and performance are not impaired during handling, transportation, assembling and jointing, and shall be settled and assembled to satisfy the required function and performance of structure.

2. Receiving Materials Inspection

The receiving inspection of all the materials used for the production of precast concrete elements as follows.Cement: Cement shall be received with test certificate and delivery order. Cement will bevisually inspected for color and quantity. The cement received is stored in cement siloswhich are connected directly to the concrete mixer. Once a year, the cement will betested in an independent laboratory for physical and chemical parameters.•The cement test will be carried out through an

In-house test”FM/QC/011- Report on cement test“ on fortnightly basis.Aggregate and Sand: All the aggregate and sands are received with delivery note. Visualchecks will be conducted for each size of aggregate and sands on receipt. All theaggregates and sands are stored in storage bins allotted for each size.

•The following test will be carried out through an In-house test on all aggregate andSands and will be recorded.

(i) Sieve analysis of aggregate.(ii) Specific gravity of aggregate.(iii) Bulk density of aggregate.(iv) Moisture content of aggregate.

(i) Sieve Analysis: Grading of aggregate means particle size distribution of the aggregate.If all the particles of an aggregate were of one size, more voids will be left in the aggregatemass. On the other hand an aggregate having particles of varying sizes will exhibit less voids. Principle of grading is that smaller size particles fill up the voids left in large size particles. The test will be carried out and record in the form “Report on sieve analysis FM/QC/006” for monthly 2 times.

(ii) Specific gravity: Specific gravity implies the absolute weight per unit volume of aggregate. A low specific gravity may indicate high porosity and therefore, poor durability and low strength. Specific gravity of aggregate is used in arriving at mix design. It is also required in calculating the compaction factor in connection with workability.Generally, the specific gravity of rock for good aggregate is above 2.50. The test will becarried out and record in the form “Report on specific gravity FM/QC/007”for monthly 2times.

(iii) Bulk density: Bulk density is another value we make use of in mix design. It is measured by filling a container in a standard manner and weighing it. It gives valuable information regarding the shape and grading of the aggregate. Higher the bulk density, the lower is the void content to be filled by sand and cement. The test will be carried out and record in the form”Report on bulk

Quality Control Plan

density FM/QC/010” for monthly 2 times.

(iv) Moisture content: determination of moisture content in the aggregate is of vital importance in the quality control of concrete particularly with respect to workability and strength. The measurement of the moisture content of aggregate is basically very simple operation. But it is complicated by several factors. The aggregate will absorb a certain quantity of water. The test will be carried out and record in the form “Report onmoisture content FM/QC/009“ twice monthly.

• Once in a year, the following tests will be carried out through an independent Material testing laboratory. Grading test including

” passing 75 microns“• Sulphate content.• Chloride condent.• Specific gravity.• Water absorption.• Flakiness index.• Elongation index.•

BS 812 D MSRNo.

DESCRIPTION

20M M

10MM

5M M

D U N ESAND

FI NES C OA RS E

REM A RK S

1 Grading AS PER PART 103STANDARD

AS PER STANDARD Pa rt 103

Mater ial Finer Than 0.075 mmNatur al, U ncrushed/Crushed 0.3% 0.3% 3.7% 1.5% M ax 3% M ax 1%2

Crushed Rock - M ax 7% M ax 1% Pa rt 103

3 C lay L umps And Fiber Particles 0.2% 0.2% 0.4% 0 M ax 1% M ax 1%

4 Li ght weight pieces - - - - M ax 0.5% M ax 0.5%

5 O rganic Matter C ontent Bs 1377Pa rt 3.M 3:1990

- - - -M ax 0.2%

-

6 Water Absorption 0.8% 0.5% 1.6% 1.0% M ax 2.3% M ax 2%

7 Specific Gravity (apparent) - - - - M in 2.6 Mi n 2.6

Shell C ontent in Aggregate

a. Coarser than 10 mm M ax 5%

b. Between 5 mm to 10 m m M ax 15%

c. Between 2.36 mm and 5 m m M ax 10%

8

d. Finer than 2.36 m m N R

Pa rt 106

Pa rticl e Shape

a. Flakiness Index 12 19 - - - M ax 25% Pa rt 105.1

9

b. E longation Index 20 23 - - - M ax 25% Pa rt 105.2

A cid soluble chlorides, C l Pa rt 117

M ax0.03%

M ax 0.01%Fo r RCC made w itha. SR PC cementb. OPC /MSR PC cem ents

M ax0.03%

M ax 0.02%

M ax0.03%

M ax 0.02%

10

For m ass concrete m ade w itha. SR PCb. OPC and M SR PC cements

M ax0.05%

M ax 0.04%

For prestressed concrete andsteam cured concrete

0.01%

0.01%

0.03%

0.01%

M ax0.01%

M ax 0.01%

11 A cid solub le su lphates SO 3 0.12%

0.06%

0.06%

0.08% M ax 0.3% M ax 0.3% Pa rt 118

12 Soundness , M gS04 3% M ax 12% M ax 12%

Mechanical Strength

10% fine value Mi n 100 kN Pa rt 111

or impact value M ax 30% Pa rt 112

13

Los Angles abrasion M ax 30%

14 D ry shr inkage .074% M ax 0.05% Pa rt 120

15 Potential Reactiv ity Innocuous Inn ocuous

Aggregates chemical method 6 m onth expansion

Cement aggregate combination 0.10% m ax

Water: The water used to prepare concrete will be conforming to BS 3148. The chemical analysis of water sample will be done through an independent laboratory once in a year.• The common water test will be carried out like PH value, TDS & Hardness test through an in-house test on each delivery. The test will be recorded in the form “FM/QC/005 Report on water analysis”.

Reinforcement: The reinforcement used in precast concrete elements will be conforming to the requirements of BS 4449 Grade 460B. Reinforcement will be received with delivery note. Visual inspection for rust, possible damages, verification of mill certificate etc. will be done on receipt. Reinforcement will be stored in the steel yard area.

Incase of non-conformance, the steel yard Foreman reports to Production supervisorand Quality Control Engineer for the necessary actions.

These would be• In case of rust: Reject the rusted part or the whole delivery.• In case of possible damage: Reject the damaged part or the whole delivery as applicable.• In case of Mill certificate not provided or Mill Certificate no. not mentioned on the DO: Hold the delivery till the requirements are fulfilled.• In case of non compliance of quality & quantity: By quality, reject the delivery. By quantity, note it on the delivery note and notify the Store Keeper.

Acceptance Limit For Raw Materials (According to BS 812 and BS 410)

Percentage by mass passing BS sieves for nom inal sizesSRNo.

SieveSize Aggregate

(20mm )Aggregate

(10mm )CrushSand

0-5mm

Sand(0-5m m )

DuneSand

Remark s

1 37.5 mm 100-- -- -- --

2 20.0 mm 90 to100-- -- -- --

3 14.0mm

40 to 80 100-- -- --

4 10.0 mm 30 to 60 90 to 100-- -- --

5 6.30 mm -- -- 100 100 --

6 5.00 mm 35 to 55 30 to 65 70 to 100 70 to 100 --

7 2.36 mm 5 to 30 60 to 100 25 to 100

8 1.18 mm -- -- 30 to 90 15 to 45

9 600 µ m 10 to35 10 to 30 5 to 54 5 to 25

10 300 µ m -- 5 to 15 3 to 20

11 150µ m 0 to 82 0 to 82 0 to 15 0 to 15

After inspection, the Quality supervisor/ Inspector signs the delivery note with QC passed seal and date. In case of any observations, the same will be mentioned on delivery note and handed over to Storekeeper. Mill certificate will be forwarded to Quality Control Engineer. The Store Keeper compares the delivery note with the purchasing order.

In case of any non-conformity, action will be taken as follows:

· In case of Mill certificate not complying: Reject the delivery and mark the Steel reinforcement with “MAY NOT BE USED” and inform the supplier to collect the rejected reinforcement.• In case of quality not complying; but good enough to use, note it on the purchasing order and notify the Accounts Department. If the quality cannot be used, reject the delivery and mark the delivery with “REJECTED” and inform the supplier to collect the consignment back.

• Steel will be tested as per BS 4449 grade 460B.In-house test to determine the area of steel &mass/meter for all the dia of steel. The test results will be recorded in form no. “FM/QC/013-Report on Area of steel and mass”.Admixture: Admixture shall be used in concrete products only after appropriately considering the special method used for mix

proportion, compaction, accelerated curing, as well as the effect on the products and improvement of the production efficiency. Mixer plant operator / storekeeper receives the test Certificate & Delivery order. Test certificate is sent to the Quality Control Engineer for verification.Micro silica / GGBS: Every delivery of micro silica/ GGBS is received with manufacturer’s test certificate. Micro silica /GGBS received will be stored in silos and Apex storage area and covered with polythene sheet.

3. Inspection/ Test of Concrete Mixes and CubesSlump Test: The test is indented for determining the consistency of freshly mixed concrete and for defining ranges of consistency of concrete based on the slump values. Slump test will be done on the first batch of every concrete mix design produced on that day. Sample will be collected from the mix before it is used for casting.Cube Test Sample: The sampling of Fresh concrete samples for precast concrete elements, cube making are taken as follows:

· 1 test sample per day for each design for concrete consumption up to 50 m3· 2 test samples per day for each design for concrete consumption more than 50 m3

Cubes will be tested as per BS 1881, to determine the strength of the concrete. The test results will be recorded in form no. “F/IMSP15/R3 Concrete pours chart and FM/QC/012 Compressive strength of cubes” and shall be filed with Quality Control Engineer for a period of at least 3 years.All the test records form no. “F/IMSP15/R3 Concrete pour chart and FM/QC/012 Compressive strength of cubes” shall be filed with Quality Control Engineer for a period of at least 3 years.

Specifications for Steel Bars(a) cross sectional area and massSRNo.

NominalSize in

mm

C rossSectionalArea mm2

Mass permeter run kg

1 6 28..3 0.2222 8 50.3 0.3953 10 78.5 0.6164 12 113.1 0.8885 16 201.1 1.5796 20 314.2 2.4667 25 490.9 3.8588 32 804.2 6.3139 40 1256.6 9.864

10 50 1963.5 15.418Tolerance on mass

Nominal sizemm

Tolerance on mass permeter run %

6 + 98 and 10 + 6.5

12 and over + 4.5

Strength of Concrete (As per BS 8110: Part 1:1985)

Cube Strength at an Age ofSRNo.

Grade ofConcrete

CharacteristicStrength

f cu

3 days 7 days 28 days 3months

6months

1 year

U nit N /mm 2 N/mm 2 N /mm 2 N/mm 2 N /mm 2 N/mm 2 N /mm 2

1 20.0 20.0 9.5 13.5 20 23 24 25

2 25.0 25.0 11.5 16.5 25 29 30 31

3 30.0 30.0 14 20 30 35 36 37

4 40.0 40 19.6 28 40 45.5 47.5 50

5 50.0 50.0 25.2 36 50 55.5 57.5 60

3.1 Client/Consultant visitThe client/consultant visits and carries out the inspection to ensure their comments are complied with and same shall be recorded in the form” FM/QC/008 - Client/Consultant Inspection Report “for the quality of product.

4. Inspection of Mould fabrication

Inspection will be carried out on all new moulds or when a mould is altered or when the mould has been used for 20 castings or on projects with special requirements. For fixed moulds, the inspection frequency can be reduced with special permission from Technical Manager. Twisting will be inspected separately for each mould table whenever it is replaced/moved or at least once a month. The Quality supervisor/inspector is responsible for inspection of the twist.As a daily routine, the Quality Inspector should receive casting planning – program fromproduction one day prior to casting. Mould inspection shall be done according to productionplanning. The Quality Inspector inspects every mould measurement according to shop drawing and checked according to”F/IMSP15/R1: Mould Inspection” to ensure mould measurementsbefore casting.4.1 Actual Measurement:The height, width & thickness of the mould should be checked properly according to approved shop

drawing. Actual measurement should be measured and will be recorded in the form“FM/QC/001-Sample mould inspection” and should be verified as per specification.4.2 Diagonal Measures:Both diagonals are inspected and the differences are checked as per shop drawing.4.3 Twist:Mould tables to be inspected for twist by using proper leveling Machine at least once in a Month.

5. Pre-Pour Inspection

5.1 Cleaning of Forms.Form shall be cleaned after each use. Concrete, tape, polystyrene, and other materials adhering to the forms shall be removed.5.2 Application of Form Release Agent.Form release agent shall be applied after the forms are cleaned and if necessary, the seams sealed. Reinforcement and other items to be embedded in concrete shall be free from release agent. Care shall be taken to avoid over application of forms release agent, which may lead to pudding. If pudding does occur, the puddle shall be removed prior to casting.5.3 Positioning of reinforcementThe Quality Inspector will then identify the reinforcing steel to be positioned as specified bythe approved shop drawing, and the concrete cover must conform to product requirements.

Unless otherwise required, the tolerance on concrete cover shall not be less than ½ inch, however concrete cover greater than ½ inch may be used depending upon specification requirements. Positive means shall be taken to assure that reinforcement does not move significantly during the casting operations. The QC Engineer will verify the reinforcement according to shop drawing. Inspection will be carried out when the reinforcement placed in the mould. Observations will be recorded in form “F/IMSP15/R2 - pre pour check list “.Inspection is carried out as follows:Shape is inspected visually.Bar diameter is inspected visually.Quantity counted.Spacing inspected visually and measured where required.Reinforcement checked as per the approved drawings visually.Geometry is inspected visually.5.4 CoverCover is inspected as mentioned in the approved shop drawing (after reinforcement is placed in the mould).5.5 Cast in partsPreparation for embedded items shall be positioned at location specified in the shop drawing. Inserts, plates, lifting devices and other items to be imbedded in precast concrete products shall be held rigidly in place so that they do not move significantly during the casting operations. In case of any non-conformance observed by the QC Engineer , the Production Supervisor is advised to correct the non-conformance. After correction, a new inspection will be carried out. All the observations to be entered properly in “F/IMSP15/R2- pre-pour check list” and signed by concerned dept QC Engineer maintains all the inspection records for a minimum period of three years.5.6 InsulationInspect the size & thickness according to shop drawing. The placement & spacing of Anchorpins & sleeve anchor to be placed according to the shop drawing.

6. Concrete

6.1 Concrete mixingThe Grade of concrete as per the clients

requirement shall be produced in batch to batch uniformity of strength. The slump and consistency of the concrete shall be suitable for the specific pre cast element.6.2 Placing ConcreteThe production supervisor monitors the casting to ensure proper placing, distribution and vibration. The slump and consistency of the concrete shall be suitable for the specific precast element. Concrete shall be consolidated in such manner that segregation of the concrete is minimized and honey-combed areas are kept to a minimum. Vibrator used to consolidate concrete shall have frequencies and amplitude sufficient to produce well consolidated concrete.6.3 Surface FinishingThe operation adopted for obtaining a true, uniform concrete surface is called surface finishing operation.The methods adopted are finishing are:

(i) Screeding(ii) Floating(iii) Troweling

(i) Screeding: The leveling operation that removes humps and hollows and gives a true, uniform concrete surface is called screeding. Straight edge is used for this purpose. The surface is struck off by moving the straight edge back and forth with a ‘saw‘like motion across the forms. The process of screeding is also known as striking off.(ii) Floating: The process of removing the irregulation from the surface of concrete left afterscreeding is called floating. The process is done with the help of wooded foat. Finishing isperformed by moving the wooden float backward and forward. Bull float is used if the area ofconcrete surface is large.(iii) Trowelling: The final operation of finishing is called trowelling. It is performed where a smooth and dense surface is desired. Trowelling should be done after the surface water has evaporated from the concrete surface. Power trowels are also being widely used to finish concrete but it should be delayed till the concrete becomes firm.6.4 Curing of Precast componentIn case of water curing1) After de-molding, the pre cast components will be taken to the stockyard and covered with

Hessian cloth.2) At least twice a day, water shall be poured on the pre cast element until the surfaces are completely wet. 3) Quality Inspector and Foreman have to ensure that the elements are covered well.4) The curing shall be done normally for 7 days but not less than 3 days.

In case of steam curing:1) Steam curing at atmospheric pressure is widely used for high productivity; therefore, there are many examples of steam curing application stipulated as follows.2) After casting and finishing of pre cast components, it will be covered with steam covers, and the curing temperature is raised uniformly.3) Steam curing shall be started 2-3 hours or more after mixing.4) The rate of temperature rise shall be no more than 20ºC per hour and the maximum temperature shall not higher than 65ºC5) After 8 to 10 hr. steam curing, the element is allowed to cool for at least 1.5 hours.6) Details of steam will be recorded in the format “F/IMSP15/R5 curing chart”. All details will be recorded by boiler operator and QC supervisor will be checking on daily basis.

In case of curing compound:1) After casting and finishing of pre cast components, curing compound will be applied uniformly with sprayer gun.2) Apply curing compound in thin layer, even coats barely wetting the surface with sprayer gun. Immediately after the first coat dried, apply a second coat uniformly.3) Drying time will be varying from 10 to 30 minutes depending on temperature/environment.4) Curing compound assures that, the specified design strengths will be achieved along with the development of improved surface durability.

7.Post- Pour Inspection of finished Precast Component

7.1 Inspection of wet finished precast componentThe foreman / charge hand ensures:That leveling and/or brushing is carried out

immediately after casting.Trowelling carried out before the concrete is settled.In the event that the concrete is too stiff to trowel, this has to be brought to the notice of the Production Supervisor for further action.7.2 Finished on Retarded surfaceAfter the first precast component of a new project has been retarded the Production Supervisor and the Quality Control Engineer checks whether the results comply with the specifications and the approved samples in the following aspects:

Stones exposed as per sample specification.• Uniformity of the pattern of the stones.• Absence of areas without stones.•

For the following precast components the charge-hand inspects whether the exposedsurface of one panel comply with the surface of another panel. In the event of non-conformance the Production Supervisor informs the Production Manager/Quality control Engineer for further action.7.3 Finish on fair faced surfaceAfter finishing work has been done for the first precast component for fair faced surface, theProduction Supervisor and the Charge-hand inspect to check whether the result complieswith the specifications and the approved samples in the following aspects:

Chamfering, blowholes, etc• Color.•

For the following precast components, the charge-hand inspects whether the fair-facedsurface of one panel complies with the surface of another panel. In the event of nonconformance charge–hand informs the Production Supervisor for further action.7.4 Finishing on surface to be paintedAfter finishing work has been done on the first precast component for surface to be painted, the Production Supervisor and the QC will check whether the results comply with the specifications and the samples in the following aspects:

Chipping, blow holes, burrs etc: repaired/• removed

For other precast components, the charge-hand inspects whether the surface of one panel to be painted matches with the surface of another panel. In the event of nonconformancethe Charge-hand will inform the Production

supervisor for further action.7.5 PaintingBefore commencement of painting the Production Supervisor ensures that description of paint and painting method are available. The Production Supervisor instructs the Charge hand on the method for painting and inspects the painting of at least the first precast component.For the following precast components the charge hand inspects whether one painted element matches with another painted element. In the event of nonconformance the Stockyard Foreman inform the Production Supervisor/ Quality control Engineer for further action.7.6 Repair of DamagesIn the event of damages, the Production

Supervisor shall bring this to the notice ofProduction Manager,who in turn should discuss with QC Engineer for further repair instructions.

8. Final Inspection before Delivery

Final inspection is carried out on all precast elements. The QC Engineer is responsible forfinal inspection before the precast components are released for delivery. Precast components ready for final inspection are placed in the finish area in thestockyard, where following inspection to be carried out and will be recorded inform“FM/QC/002, FM/QC/003- Final inspection after production”

8.1 Final Inspection tolerances (Columns & Beams)

8.1.1 Final Inspection tolerances (Panels)

Main Measures Max . Dim Tolerances

Length < 3 me ter :3– 6 me ter :> 6 me ter :

± 6 mm

± 12 mm

± 15 m m

Width < 500 mm :500 – 700 mm :Fo r each additional 200 mm :

± 3 mm± 6 mm± 3 mm

Thickness < 500 mm :500 – 700 mm :Fo r each additional 200 mm :

± 3 mm± 6 mm± 3 mm

Straightness < 3 me ter :3m– 6 me ter :6m - 9 me ter :Fo r each additional 6m:

± 6 mm± 9 mm± 12 m m± 6 mm


Height ± 6 mm

Width ± 6 mm

Thickness < 500 mm :>500 m m :

± 5 mm± 9 mm

Squareness (d ifference

in 2 d iagonals)

< 2 me ter :2m– 4 me ter :6 me ter :

5 mm6 mm9 mm

Cutout Si zeCutout location

± 5 mm± 5 mm

Twist < 600 mm (W ) & < 6 m (L ):> 600 mm ( W ) & > 6m (L ):

6 m m10 m m

Straightness < 3 me ter :3– 6 me ter :> 6 me ter :

3 m m6 m m9 m m

Flatness Max. dev iation from 1.5mstraight edge < 3 mm


Height ± 6 mm

Width ± 6 mm

Thickness < 500 mm :>500 m m :

± 5 mm± 9 mm

Squareness (d ifference

in 2 d iagonals)

< 2 me ter :2m– 4 me ter :6 me ter :

5 mm6 mm9 mm

Cutout Si zeCutout location

± 5 mm± 5 mm

Twist < 600 mm (W ) & < 6 m (L ):> 600 mm ( W ) & > 6m (L ):

6 m m10 m m

Straightness < 3 me ter :3– 6 me ter :> 6 me ter :

3 m m6 m m9 m m

Flatness Max. dev iation from 1.5mstraight edge < 3 mm

8.1.2 Visual Inspection•The precast components surface is checked for structure, discolor, exposure, stoniest, blowholes and flakes etc.•In the event that the precast component has discrepancies to a degree, which cannot fulfill the requirements, it is registered as a non-conforming product.8.1.3 Surface Treatment•Corners/edges and cutouts are checked and if necessary grinded/filled to fulfill the requirements.•If necessary the surface is treated suitably/grinded until a plane surface is obtained.•Exposed surface is checked for “right” stone pattern and if necessary stones are Removed /replaced until conformance is obtained.•Painted surface is checked for discoloring and if necessary repainted.•Toweled surface is checked and if necessary grinded until conformance is obtained.8.1.4 Cast in parts•Fittings, inserts, sockets, conduits etc. are cleaned and if necessary greased.•Electrical boxes, pipes etc. are checked for passages.•Exposed reinforcement for fixing etc. are cleaned/straightened.8.1.5 Loose Parts•Steel angles, threaded bars etc. are fixed in accordance with the production drawings. After finish work is carried out, the QC inspector tick marks () the element and informs to QC Engineer for final inspection.

8.2 InspectionQC Engineer inspects the precast component as follows:•Whether the precast component is marked correct.•Whether the precast component is registered as a nonconforming precast•Component (marked rejected if the component is rejected).

All the precast elements will be inspected and the inspection will be registered on format. F/IMSP15/R4 POST POUR CHECK LISTS, to the following extent: If any non-conformance is found, it will be recorded. After the non-conformity is removedthe element will be re-inspected. If major non-conformance is noticed e.g. dimensional variations, missing components in an element etc then it will be dealt as a non-conforming precast component. And it will be recorded in FORM F/IMS P4/R2 Product Non-Conformance Register.

In case of major non-conformance, all the elements produced under the same elementnumber will be inspected. After the QC Engineer is satisfied with the element, he marks the precast component OK and signs it.

9.Inspection of precast component at site before Erection

The site supervisor verifies and ensures that all the site arrangements are made to receive the

elements i.e.,•Crane placed at predetermined position•Area around is unobstructed for crane operation•That all site fixing parts and necessary erection tools/ equipment are available•That lifting slings, belts, shackles, trolleys, spreader beams etc. are of right capacity and in good working condition. In the event of any non-conformance in either of the above, the site foreman contacts the site supervisor for further action. Before off loading and erection, the site foreman check the Precast components to ensure all elements are present according to delivery note.• Ensure that the Precast components are loaded / placed in accordance with loading list i.e. right element number and sequence.•Ensure that there is no damage occurred during handling or transportation•Ensure that all inserts for temporary fixing are cleaned and clear from any blockage.In case of any non-compliance of the above, the Site Foreman tries to rectify them at site if possible, otherwise return them to the factory for correction. The Site Supervisor will be informed who will register the Precast component as a non conforming product and handle it in accordance with procedure F/IMS P4/R2 Product Non- Conformance Register.

9.1 Inspection of site ready for erectionInspection of site will be carried out well in advance to ensure that the site is ready to receive the elements. Site setting out will be carried out as per the program. Following main aspects will always be checked.•planned crane position and access•access and parking for lorries within crane operation range.•Main building construction ready for erection.•Availability of water and electricity if required.In case, the site is not ready for erection, site supervisor contact the Project manager to discuss the matter with client for further actions. If the erection needs to be postponed, site supervisor informs the Transport supervisor in order to hold / cancel the loading and delivery. If the main construction does not comply with the drawing / specification, then the site supervisor note down the deviation

and inform the project manager and technicalmanager for further action.9.2 Final Inspection of Erected Precast componentsThe Site Supervisor is responsible for carrying out of the final inspection of the erected precast elements. The inspection will take place after the erection is completed or on daily basis.•Precast components are checked for alignment, level, adjustment and plumb.•Mechanical fixings are done.•All grout joints are filled.•All mastic joints are intact.•Lifting and temporary bracing holes are grouted / filled.•Surface appearance is even.•Color appearance is even.•Damages if any are suitably repaired.•Repairing of damage has acceptable appearance.If any non-conformance is noted in the precast element, feedback will be given to the QC Engineer/Production Manager for rectification and the Project Manager will be informed. If any non-conformance occurred during erection, Site Supervisor shall resolve the problem. After correction is done, a further final inspection will be carried out. The observations are recorded on form “F/IMSP10/R6 IN PROCESS INSPECTION REPORT.” The Site Supervisor will keep all the inspection records for at least 3 years after the completion of the project.

HSE Plan

1. GENERAL PRINCIPLES

This document, called hereafter as HSE Plan, is prepared in order to demonstrate how safety and environmental management systems are handled by Apex Precast Industries (L.L.C.) at Site / Factory during execution of works. The Project HSE Plan will be reviewed, updated throughout the period of execution of project. The ProjectHSE Plan is based on the applicable local practice, Apex health and safety requirements/standards, OHSAS 18001:2007 and customer’ssafety requirements. The Project HSE Plan covers the Occupational Health & Safety aspects duringdocumentation of the Named Project. 2. HSE POLICY GOALS/ OBJECTIVES

IMS Policy

Deliver high quality Precast products and services by proactively monitoring our business practices.

Strive for continual improvement to setting and achieving set objectives and targets.

Identify risks and significant impacts to establish best operational controls for environmental and occupational health and safety related activities.Lead our employees to communicate, participate

and work as a team to develop a good working environment & achieve excellent business results.

Comply with applicable statutory, regulatory and legal requirements related to products and services rendered by us.

Ensure all our customers are satisfied with our products and services as part of strategy for continual business improvement.

Serve internal and external parties by creating an environmental friendly atmosphere with an emphasis on health and safety aspects.

Committed to implement an effective system to prevent pollution, ill health & depletion of natural resources resulting from our work activities.

HSE Goal

To achieve zero lost time incident throughout the whole project.

Safety Principle

Deliver safely, on budget, on time and the right quality

HSE Plan

3. STANDARDS AND LAWS FOLLOWED

The rules and regulations outlined in this plan comply with the safety regulations as per OSHAS 18001 stands for Occupational Health & Safety Management systems, ISO 14001 stands for the Environmental Management System and Customer Health & Safety and Environmental Manual.

General part

List of the laws that must be followed

Ministry of Labour and social affairs “ Ministerial Order No (32) 1982.

Dubai Municipality code of construction.

Ministry of Labour and social affairs “ Federal Law No (8) 1980

Federal Environmental Law No (24) –1999

International Standards:

ISO 9001 : 2008 – Quality Management System

ISO 14001 : 2004 – Environmental Management System

OHSAS 18001:2007 - Occupational Health and safety Management System.

Safety Objective

To ensure the safety for all the works that are to be carried out at the Site /Factory with assistance of Personal Protective Equipments, adherence to this is compulsory to all the safety regulations, and the guidelines, best practices.

4. ORGANISATION, ROLES & RESPONSIBILITIES

The General Manager of Apex Precast has the overall responsibility for Apex health and safety management for the project. For matters of health and safety, the Apex Project In-Charge will interact with the designated Customer representative. The Site / Factory Supervisor is the nominated safety officer responsible for ensuring the Site/Factory activities occur in accordance with the safe work method statements.

Project In-Charge

The Project In-Charge is responsible for all aspects of project safety management on assigned projects and accountable to Lead Project In-Charge. The Project In-Charge must ensure that all significant health and safety risk are identified, eliminated or minimized.

Production / Factory In-Charge

The Production / Factory In-Charge is responsible for all aspects of health and safety on Site/ Factory and accountable to the Production In-Charge. The Production / Factory In-Charge ensures that the health and safety plan is implemented monitored and maintained.

6. COMMUNICATION

All workers will undergo Site / Factory and project specific safety training and inductions. This also ensures commonality of customer and the Apex requirements through periodical meetings, communications in case of an incident, notice

5. RISKS ASSESMENT

The project team will be utilizing the Apex UAE Risk Assessment procedure (9AEZ-05-034) to proactively identify and control the hazards and risks from Apex site/factory activities. General risk analysis includes working environment (Factory/Site conditions), each phase of the site/ factory life cycle and tools/equipment.

Risk Rating = Severity x Likelihood of occurrence

High

Immediate requirement & investigate the case for removing/ reducing the risk or improving the control measures

Immediate actions

Medium

Risks not broadly acceptable. Need investigation to consider reasonably practicable improvements

Actions within 45 days

LowDetailed working to support conclusion

Tolerable

Risk assessment must be repeated in case of an accident or upon any change in the scope of work and/or at pre-determined intervals during any long-term projects that are carried out over a period exceeding 12 months.

boards on sites/ factory, coordination and control of activities throughout the duration of work.

The location of Fire Extinguisher/ First Aid facilities / Assembly point / Emergency contact numbers like nearest hospitals, immediate contact point at Site / Factory’s shall be followed strictly, which are clearly marked on the layout shown in Appendix 9

General

Police 999

Ambulance 999 or 998

Fire 997

Hospitals

Nearest Hospital

GMC, Ajman 06 746 3333

Apex

PRO 055 221 1302

Factory In-Charge 050 462 4977

Site Incharge 055 939 9490

HSE Officer 055 221 1302 / 050 875 9782

First Aider

Taxi Services (Ajman) 06 740 8000

Emergency Contact Numbers :

7. RESOURCES

Apex Precast will provide all the necessary safety resources like, factory lay out, information posters, safety signs, fire extinguishers, first aid kit, PPE etc for our worker through out the project.

The use, quality, suitability of all the protective equipment will be controlled during routine Site/ Factory safety observation tours.

8. TRAINING AND COMPETENCE

Competences in each task is to be executed on the Site / Factory will be determined and documented also taking into account the risk assessments and results. Factory induction for the subcontractors and visitors will be done according to the checklist. All operators of Crane / Shovel / E.O.T crane, Load shifting equipment, Pressure equipment ( boilers and turbines), Scaffolding, Rigging, and any other machinery, tools or equipment for which a license or a certificate of competence is legally required will be property trained and certified.

9. EMERGENCY PREPAREDNESS

Emergency Evacuation Procedure at the time of an emergency, alarm will be initiated (either automat-ically/manually). On hearing the alarm every one is expected to respond to it by moving safely to the predetermined assembly point. Before coming out from the work place, ensure all

10. INCIDENT REPORTING AND INVESTIGATION

All incidents and near misses should be reported as soon as possible after their occurrence. Not only is this is legal requirement in some cases, but factual information must be gathered as soon as practicable after the incident in order to prevent a reoccurrence by accurately determining the cause and contributory factors.

All incidents, near misses should be investigated and an investigation team should be formed which includes a senior level manager, HSE Officer, Site/Factory Incharge and Engineers. Detailed reports should be submitted to the GM with corrective actions to prevent the reoccurrences. Investigation forms should be complying with local regulations.

11. HSE AUDITS

Audit – A systematic, independent, documented process for obtaining “audit evidence” and by -

are moving out and electrical equipments are OFF(If Possible). Evacuation shall be as fast as possible through Normal/ Emergency exits, and then assemble at the assembly point.

Responsibilities of Team Leader:

To maintain an updated POB (Person on Board) • list all the timeTo check muster rolls for any missing persons• Report missing persons to management/ civil • defenseTo record the time taken for evacuation• To be equipped with emergency contact • numbersTo give further instructions to the gathering in • moving them to a safe place.

Fire Drill

A Mock-up Drill shall be conducted as agreed with the customer and records of the same shall be maintained to ensure the effectiveness of above procedure in case of a real emergency. A mock-up drill is conducted every 6 months to ensure effectiveness.

Safety Equipment Needs to be used

Helmet Throughout the Factory/ Site

Safety Shoes Throughout the Factory/ Site

Safety harnesses Working at heights

Safety Gloves Working with sharp tools (all kinds of cutting tools) & sharp materials

Eye/ Face protectiveequipment

Working with grinder, welding

Fire proof clothes ( when necessary )

Where necessary

Fire Blanket While welding

List of safety equipment will be as follow.

evaluating it objectively to determine the extent to which “audit criteria” are fulfilled. HSE audits are held at least once every month, unless customerdetermines otherwise.

Safety Inspection Check List

Safety inspection – full-scale examination of all or part of the workplace using a checklist, carried out at least monthly.

Safety Observation Tour

SOT – Monitoring of workplace, employees and the subcontractors behavior. The internal Safety Observation Tours are for Controlling/ Monitoring Apex employees and subcontractors for adherence to the agreed health and safety rules.

12. EQUIPMENT / WORK ACTIVITIES SAFETY

Factory Security system

The entire Factory shall be fenced and protected to avoid unauthorized entry.

Rules of Conduct

Personnel must conform to all rules of conduct re-lating to safety while on the job-site/factory and while absent from the job-site / factory in the per-formance of their duties.

No smoking areas

Smoking is prohibited within areas posted with NO SMOKING signs.

Housekeeping

House keeping shall be carried out at all areas of the Factory/site. Supervisor/foreman shall make sure the same has done before leaving the, Factory / site, after every shift.

Off-the job Safety and Health

Off-the-job safety is the extension of a company’s on-the-job safety culture. Off-the job safety also includes programs to educate and help employees who are “off-the clock.” Apex provides numerous training programs for employees and safe culture is expected from employees at all times.

Heat stress at work

Heat related illness is common during the hot and dry summer months. Heat related illness can develop over several days or can strike during a single burst of strenuous physical activity. Guidelines are provided to prevent heat stress and first aid trainings are given in case of any medical help.

Equipment operation

Unauthorized operation of all mobile powered equipment is prohibited. Every operator shall have successfully demonstrated that he is fully able to competently operate the equipment and have the license where law requires it.

Cords, leads, and hoses

Electrical cords, welding leads, water, air and the welding hoses shall be placed where they cannot be damaged or cause damage or injury.

Mechanical Safeguards

Starting and Operating Machines: Employees shall not start or operate any mechanical equipment unless qualified and authorized to do so.

Machinery and Tool Guards

Machinery and tool guards shall be provided for protection against revolving or reciprocating parts. These guards shall be in place before the machine or tool is used and shall not be removed or made inoperative except during repairs.

Ladders

Ladders should be secured so that they cannot move from their top or bottom points of rest. If the ladder cannot be secured at the top, it should be securely fastened at the base. If fastening at the base is not practical, personnel should be stationed at the foot of the ladder to prevent it from slipping.

Hand and Power Tools

It is the employee’s responsibility to check prior to and after use, all tools assigned to him. The right tool for the job shall be selected. Unsafe tools include wrenches with cracked or worn jaws, all screw drivers with broken tips, or split - broken handleshammers with chipped, mushroomed or loose heads, broken or split handles; mushroomed head on chisels; dull saws; and extension cords or the electrical tools with broken plugs, improper or any removed grounding systems, and any worn out installations.

Handling and use of compressed gases

Compressed gas cylinders must be upright at all times, secured to prevent it from falling, protected from extreme heat, from being struck by any moving equipment or falling objects. If transported by crane, hoist, or derrick, compressed gas cylinders shall be handled in a suitable cradle, net, never by wire or the fiber rope, web or chain sling, nor by dragging. Regulators shall be removed and caps, where required, shall be in place. Caps should be replaced on empty cylinders that are designed for such caps, and such cylinders shall be marked `Empty´. Where Contractors bring their own equipment into the Project, such equipment must comply with approved standards.

Portable Fire Extinguishers

Portable fire extinguishers are designed only to extinguish or suppress small fires. All fire extinguishers are classified according to the type of fire they can extinguish. Some fire extinguishers have multiple ratings and can be used on more than one type of fire.

Fueling Equipment

No gasoline or diesel engine shall be re-fuelled while running. If fuel cans are used for refueling, they shall be approved metal safety fuel cans with a flash arresting screen, spring closing lid, and spout cover that will then safely relieve internalpressure if the can is exposed to fire. The can shall have a sign on the side identifying the contents. There shall be no smoking or open flame within 15.24 m (50 ft.) of fuel storage tanks, fuel pumps, or the refueling operations. All fuel storage tanks shall be anti-static earthed in an approved manner; such electrical grounds shall not be removed without authorization. Leads for vehicle attachment to anti static earthing shall be provided (and so designated) at suitable locations near the refueling tanks.

Crane safety

Detailed guidelines for the usage of crane in the factory / site are provided by the Apex Precast in Apex safety manual.

Spray Painting

A detailed guide line for spray painting in the factory / site is provided in the Apex HSE policy manual.

Shot Blasting

Detailed guidelines for shot blasting in the fac-tory / site are provided by the Apex HSE policy manual.

Welding

Detailed guidelines for welding in the factory / site are provided in the Apex HSE policymanual.

Confined Space

Control Measures: Risk Assessment prior to any entry, suitable training, including for those on standby duties.Check if adequate level of ventilation continues in air replacement systems, the extractor fan airline respirator or self contained breathing apparatus by directing gases to the open air.

Construction Equipment

All multi- directional earth moving, haulage and or compacting equipment, and all trucks with a body capacity of 2.2 cubic yards (1.7 cubic meters) or more used to haul dirt, rock and concrete or other material shall be equipped with an automatically operated reverse signal alarm (such as a buzzer, horn or bell). It shall be the duty of the project contractor to inform his suppliers of requirements. No person shall be allowed to ride in or on any equipment or vehicle, except in seats, which are provided by the manufacturer. All loaders, backhoes, bulldozers, and all other similar equipment shall have their blades, buckets fully lowered and the engines shut-off when left unattended. No persons shall be allowed to stand or pass under elevated portion of the equipment whether loaded or empty. Pile driving lofts men will use safety belts when working at elevations outside loft platforms. When the leads are to be rotated or moved, the lofts man will descend from the leads.All exhaust pipes, steam lines and hot surfaces, located where employees could contact them, shall be effectively guarded or insulated.

Electrical Safety

Apex requirements “Seven steps” for electrical works must be applied

Clearly identify the work location• Disconnect and secure against reconnection• Protect against other live parts• Take special precautions when close to bare •

conductors

Check the installation is dead• Carry out earthing and short circuiting• Issue a permit to work•

Chemicals and Hazardous Substances

Apex Precast will do the COSHH assessment and hazard identification in the use of chemicals and hazardous substances, MSDS of all substance will be displayed and explained, proper training and appropriate PPE’S should be provided.

13. FIRE PREVENTION

Each employee shall be advised of and therefore shall comply with the fire prevention, detection, and control requirements as applicable: Fire risk assessment should be done in Apex sites/factory and control measures to be done to prevent fire. Major areas that are vulnerable to fire are Diesel storage area, Generator room, Office and store area, Cylinder storage area and main activities arewelding, cutting, grinding. Fuel storage tanks area shall be properly grounded, vented and provided with drip trays. Adequate number of fire extinguishers should be pro-vided. Smoking is strictly prohibitedin Apex Factory/sites. Certified fire fighters are available at Apex Factory/site and all employees are trained in fire fighting.

14. ENVIRONMENTAL MANAGEMENT

The Environmental Management & the Safety Management systems are integrated on the Site/ Factory. Before works start, the environmental plan for the Site / Factory Waste Management, Chemical Management, and Control Measures etc will be done according to Apex policy. The Environmental Planning process involves identifying and then maintaining up-to-date information concerning environmentally relevant aspects, including legal & other requirements for the Site/ Factory’s location

15. REFERENCES

• Code of Construction – Dubai Municipality• DCA Safety Manual- 2005.• Construction Safety Regulation Trakhees

(regulation no: CS 001, fourth edition 2010).• OHASAS 18001: 2007.

Plant & Equipments

Plant & EquipmentSerial No Equipment Total No

1 Batching Plant 1

2 Chiller Plant 1

3 Compressor 475 1

4 Compressor L75 1

5 Air Dryer B.W 1

6 GH Crane 1

7 Demag Crane 1

8 Boiler 1 1

9 Boiler 2 1

10 Welding Machine (H) 9

11 Welding Machine (L) 1

12 Bar Bending Machine 2

13 Bar Cutting Machine 2

14 Sand Blasting Plot 1

15 45 Ton Crane 1

16 25 Ton Crane 1

17 Showel 1

18 Mack Trailer 1

19 Mercedes Benz Trailer 1

20 Transist Mixture 1

23 Mack Trailer 1

24 Mercedes Benz Trailer 1

25 Transist Mixture 1

29 Power Plot Machine 5

30 Hilti Machine 9

31 Drilling Machine 3

33 Plate Compactor 1

34 Air Blower 3

35 Generator 1

37 Grouting Machine 5

38 Mixer Machine 1

39 Gantry Crane 1

40 Water Plant 1

41 Needle Vibrator 3

Plant & Equipment

Production Feasibility

Factory

Apex Precast Concrete Products Factory located at Ajman, United Arab Emirates, has a concrete pouring capacity of 500 cum per day. The factory is equipped with the following facilities:

Concrete Ready mix plant• Overhead EOT Cranes• Compressor with compressed air distribution • piping systemBoilers with steam distribution-piping system• Power floats, beam vibrators, pneumatic • vibrators, poker vibrators, rebar cutting/ bending machines etc.Electric power and Water supply.• Well-equipped office with Production and • Erection department, Technical department (comprising of Design & drawings, QA/AC and Estimation), Sales and administrative departments.

Production Technology

Production of precast components is done on 12 m x 4m flat steel tables, which are supported on bases having rubber pads underneath and vibrated by attached pneumatic vibrators below. Sequence of production is given as follows.

Prefabricated steel moulds / forms as per shop • drawings of project/job are assembled and fixed on steel tables.Prefabricated re-bar mesh / steel is placed • / tied in the moulds as per project/job shop drawing. Plastic spaces as per drawing are fixed to steel reinforcement as per shop

drawing requirement.Ready mix concrete is batched in our •

batching plant as per approved mix design for the project.

Ready mix concrete is transported by skip with •

the help of overhead cranes/ loaders to the individual table locations.Concrete is poured in the moulds, leveled and • vibrated by switching on pneumatic vibrators attached underneath of the steel tables until maximum air is taken out and concrete gets properly consolidated. In addition to this poker vibrators are used to ensure good vibration.Then concrete is trimmed off and leveled • using custom made beam vibrator, which provides high standard of surface compaction and aids in achieving smooth finish.Remains of spilt over concrete are removed • and area around mould is cleaned properly.After the concrete sets hard enough to • receive final finish, hard and smooth finishing is done by use of power trowel. In cases of any small pre-cast component, finishing is done manually.Pre-cast components are steam cured for 8 to • 10 hours to achieve early strength for quick delivery.On the following day, moulds / forms are • stripped off and components are shifted to stacking yard for minor touch up and cosmetic works and the elements will be water cured until delivery.Moulds are released ever day for daily • production.Finished components are ready for dispatch • on daily basis to achieve the required work progress target.

Factory Layout

Test & Calibration

Material SafetyData Sheet

Material Safety Data Sheet1. Product / Company Identification

Manufacture’s Name & Address

Apex Precast Products Industries L.L.CP.O. BOX: 6530Ajman – U.A.E.Tel: 06 7436138Fax: 06 7436858

Products: Precast Concrete

2. Composition of Ingredients

Precast Concrete is a mixture of various natural aggregates; cement & water, admixtures may be added to modify the properties of the finished product.

3. Hazard Identification

Fresh ConcreteFresh concrete contains cement and water with the result that an alkaline solution is produced.

Repeated skin contact with fresh cement over a period may cause irritant contact dermatitis.

The abrasiveness of the constituents can aggravate the effect on some skin type which are more sensitive to fresh concrete and can develop allergic contact dermatitis. However this is a rare occurence.

Prolonged skin contact with cement can result in burns.

Hardened Concrete

Cutting, Drilling or Hammering of fully hardened concrete can create dust. If inhaled in excessive quantities over extended periods, respired dust may constitute long term hazards.

Cutting drilling or hammering of fully hardened concrete unless adequately controlled can project

particles at high velocity with consequent risk of impact damage and / or injury particularly to the exposed areas of the body.

4. First Aid Measures

Eye contact (fresh concrete) – immediately 1. rinse under running water. Skin contact (fresh concrete) – immediately 2. rinse affected areas under running water. Cuts / abrasion – should be cleaned and treated using normal first aid measures. Wounds must receive proper medical attention.In all cases if in doubt or where symptoms persists, medical advice must be obtained.

5. Fire Fighting Measures Not applicable

6. Accidental Release Measures

Avoid Contact with skinPrevent entry of wet concrete into watercourses, drains or other areas where hardened material can create problems. Remove product using the most appropriate equipment.

7. Handling

Avoid contact with skin and eyes. Always follow safe lifting and manual handling procedures.

8. Exposure Control/Personal Protection Equipment

Hand protection – wear suitable protective gloves.Skin protection – avoid contact with skin. Coverall should be worn.Eye protection – wear goggles to prevent any eye contact from splashing of fresh concrete, flying particles when hammering concrete.Safety Shoes – wear knee high rubber boots or similar with protective toecaps.Kneepads – wear kneepads when kneeling onfresh concrete

Material Safety Data Sheet

9. Physical & Chemical Properties

Density of fresh concrete is typically @2.6 tons • per cubic meter.Ph of fresh concrete is typically 12.• Fresh concrete is usually grey in color.• Ready mix concrete hardens through a -• chemical reaction between cement and water.

10. Stability & Reactivity

Not applicable

11. Toxicology Information

No risk upon observance of safety instructions.

12. Disposal Considerations

Hardened concrete may be recycled or placed in approved landfill.

13. Disclaimer

Every care has been taken to further ensure that the information contained herein is correct and also accurate at the time of issue. However, Apex Precast will not accept any responsibility or liability for any errors, inaccuracies or omissions, which may have occurred inadvertently.

Method Statement

Method Statement

Work - Plan

Plan of work will be implemented exactly as per work program given herewith.

A. Documentation (On Award of Contract)All documentation required will be completed within the stipulated time period for signing of any Contract Agreement. Notice; before starting the productions and erections of elements, will be given to main contractor for providing necessary access, scaffolding etc.

Any permission, approvals required from the local authorities will be first obtained by the project’s main contractor.

B. Site MobilizationLay down area will be taken over immediately in co-ordination with the main contractor. Offices, stores, sanitary facilities, first aid etc. allocated by the main contractor will be used as per the written agreement.

C. Shop DrawingsApprovals for the shop drawings will be obtained from the Consultant / client before commencing the work.

D. Material ProcurementAll required materials will be identifiable in detail with sources / technical details. Submissions will be prepared and submitted for client’s approval along with Pre-Qualification document. On approval, all materials will be procured well in advance in phases as per the requirement of the work program.

E. Machinery and EquipmentsAll machinery / equipments i.e. Mobile Cranes, Trailers etc. required for execution of the project will be made available from Apex’s source or by hiring if required. Apex has a well equipped precast factory at Ajman to produce the precast

components required for the project.F. Project ExecutionProduction of precast components required for the job will be carried out at Apex factory under strict Quality Control as per IMS procedures.All site work items will be carried out at project site as per work program and complying with project specifications.Precast Components will be transported to site on flat beds, supporting / securing them on purpose made strong steel frames.Installation of precast components will be carried out by Apex’s experienced trademen, supervisors, and engineers at project site, using tower cranes and proper lifting / handling devices. Joint sealant and painting work will be carried out by the main contractor.

G. Quality ControlOn site, off site quality control required for the project will be carried out as per Quality Control PLAN for production and erection submitted by the Technical Department.

H. SafetyAll safety regulations will be strictly adhered to while carrying out all items of work and particularly all safety regulations applicable to precast industry will be strictly followed by Apex’s employees; which include safety, in regards to machinery equipment, safe load handling, PPE, Fire, Transport / Driving, Chemicals, and safety against all types of hazards / Accidents.

I. Handing Over of the ProjectAll snag points will be attended to and works will be presented for final approval. All cleanup work will be carried out. After the final approval, handing over will be carried out as directed by the client.

J. As Built DrawingsAs built drawings will be prepared and submitted on completion of the work

P.O.Box 6530, Ajman, United Arab Emirates T : +971 6 743 6138 F : +971 6 743 6858 E : [email protected]

www.apexprecast.com

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