Installation - Overview

Please see below items that should be discussed/followed for the installation of concrete panels.

HB-SUPP-ITP 015 is to be read in conjunction with the below, as it contains a complete step by step process to be followed for installation:
• High Risk Checklist
– The high risk checklist HB-HSEQ-F-064 must be used to plan the works

• SWMS
– HB’s SWMS at a minimum must be used. Subcontractor SWMS can be used if it covers all items in HB’s SWMS.

• Lifting Procedure
– Ground Slope & Bearing capacity check
– Lifting Gear check
– Strongbacks
– Proximity to power lines/obstructions
– Lift plan in place
– Safety plan in place

• Connections/Fixings
– Verify brackets, and anchors are correct to current engineering design (size thickness, type etc) prior to install.

• Bracing Install
– Braces installed in accordance with engineer’s details and bracing layout plan.
– Adequately secure the braces to panel inserts and deadmen with the correct tension
– Manufacturer requirements complied with for installation of drill in type anchors.
– Ensure all silica dust prevention measures are utilized when drilling holes.

• Grouting
– Compare grout proposed to engineers requirements – have grout type approved by the engineer via technical submission
– Note grout manufacturers requirements for pre-wetting the substrates prior to grouting – to avoid rapid hydration of the grout into the porous substrates
– Wet bedding/setting – requires labour to lay a bed of grout under the full panel bearing area, and pack the grout tightly in once panel is complete to compress any voids. Measure area to check quality of grout required vs use (as you would a slab)
– Dry Packing – non shrink grout packed densely under panel – quality depends on many factors –suitable tools/equipment, and ensuring there is are no voids left by a lack of compaction by ramming/compacting grout under the panel and having a formed edge of some description to assist in the compaction.
– Grout extent testing - post installation testing/verification insitu for extent of grout depth/compaction to be completed with engineer present at locations nominated and inspected by the engineer

• Complete after 7 days grout strength achieved unless advised otherwise by engineer
• Drill min 12mm hole into the grout to check for full depth
• Where failed sections are identified, further drilling in the grout batch (lot plan) to be undertaken
• Failed sections identified and removed / replaced to achieve full depth (usually drypack method)
  – Witness filling of grout tubes - ensure grout is mixed correctly and fills ALL dowel castin elements entirely.
  – Grout Compaction Testing via Cube molds taken on the day of mixing to meet HB grout testing specification
  – Check 7 day strength. If grout is not achieving expected strengths, discuss any limits on further loading of the structure (loading the grout) with Engineer. It is critical lot plans (batches of works completed together) are accurate to understand the areas impacted to determine required steps.
  – Check 28 day strength. If grout does not achieve required strength, consult the engineer for advice on action to be taken. It is critical lot plans (batches of works completed together) are accurate to understand the areas impacted to determine required steps. Remove any areas of grout not accepted by the engineer

• Sealants
– Prototype sealant, check closed cell backing rods and joints primed prior to seal. Cut away samples of sealant to verify progressively

• Patching
– Undertake remedial patching of any damage, any fixings form ancillary connections like scaffold or the like using a structural patching product that’s been reviewed and approved by the engineer

• Records
– ITP–015 to be completed at each step of the process, including location of panels, grouting, grout test cubes, any failed/replaced sections of grout, connections, and photos of all as well as attaching engineer inspections, connection pullout test/welding test/verification, subcontractor ITP’s and sign offs for the works performed, grouting test reports to the ITP