Vertical Panel Installation


To be read in conjunction with ACP Concrete Installation Drawings

IF IN DOUBT THEN ASK

It is recommended at all persons involved in the off loading and installation of any concrete panels should have training and hold current certificates in all relevant areas such as crainage, forklift truck operation, use off access hoists and carry current CSCS cards.
All persons must be equipped with safety clothing including boots, gloves, high visibility clothing hard hats & safety glasses. Where concrete cutting or grinding is to be carried out, dust masks must be used.

THESE NOTES ARE ONLY ISSUED AS GUIDANCE. ALL SPECIFIC SAFETY INSTRUCTIONS REGARDING WORKS WITHIN THE SPECIFIC SITE MUST BE FOLLOWED AT TIMES.


Hazards

Main hazards include working with mobile plant & machinery, working with suspended precast units, working within a construction site and damage to structure and third parties. Working at heights and falls.


Risks

Main risks associated include: death, crushing, dust inhalation & falls


Environmental

There are no specific risks to the environment other than dust and noise during cutting operations.


Manual Handling

There should not be any manual handling of items over 15kg required.
Any manual handling tasks must be executed in accordance of Manual Handling Regulations by persons trained in manual handling.


Temporary Works

Temporary works calculations to determine a suitable propping method must be completed prior to unit erection. Appropriate props must be available prior to any start. Checks of prop suitability, serviceability, quantity and anchorage to units and ground must be made.


Plant Required

Telehandler – Specification to suit unit weight.
Crane  - suitable to unit weight and radius
Temporary props
Simple 2 leg lifting chains
Hand tools


Typical Installation Method

1)  EXCAVATE FOUNDATION TRENCHES AS DRAWINGS
     Get the layout correct before starting and ensure that the thickness of the panels has been allowed for at the corners.
Suggest 600mm wide bucket to allow room to work in base, Peg out level for concrete strip using survey level.

2)  POUR FOUNDATION STRIP OF CONCRETE AS DRAWING
     Tamp to level of pegs, ensure that strip is level both along foundation and across. Do not allow concrete to rise on edges of strip.

3) SET OUT STRING LINES
     Set up approx. 10mm away from outside of wall to avoid being pushed
out during installation. Set up approx. 600mm above base. Survey foundation strip with level and identify highest point.

4)  UNLOAD PANELS
      Unload panels using suitable loader or crane and stack on firm level ground as shown in drawings (no more than 6 panels high)

5)  CHECK TYPE OF PANELS USED
Most vertical panels are designed to have the smoothest face inside the store. This is not always the case. Slotted panels should have the narrow slot inside. CHECK WITH THIS OFFICE IF THERE IS ANY DOUBT.

6)  SET OUT CRADLES
     Start at a corner nearest to the highest point on the foundation. Position cradles on joints between panels.

7)  POSTION FIRST PANELS
     Lift panels using suitable loader or crane and approved lifting gear (available from ACP Concrete Ltd) located in lifting holes of loops cast in panels. Check rated lifting capacity of machine, lifters, chains or slings against weights of panels before handling and ensure lifters and chains are fully secured. Position reinforcing bars in holes as drawing before panels are lowered into position. Ensure correct arrangement of reinforcing bars.
     Ensure first panel is in correct position and is vertical in all planes. Secure propping system. A suitable propping system may be RMD’s raking “push / pull” props fixing to concrete panels using anchor bolts. Additional support can be provided by placing a substantial dead weight (such as a stack of panels) and roping installed panels back to weight. This can be used when there is limited access to one side of walls.

8)  INSTALL REMAINING PANELS
 Ensure all panels are true and level and pack under panels to achieve level top line. Set packers to ENSURE that at the highest point on the foundation strip no packers will be required. Square sections (40mm x 40mm) of asbestos free cement board are suitable packers.
 Corners can be propped at corner point. Panels should be propped in accordance with the temporary works calculations (typically every 3 to 6 metres).


9) ENSURE ALL PANELS ARE LEVEL
 Check top height as work goes on. There may be a slight variation in the length of panels (+/- 3mm) so check top height in centre of each panel with survey level and by eye. It is essential that the leading edge of each panel is vertical and this should be achieved even if joints are uneven. In some cases expanding water stops are to be placed on the panel surface just above the reinforcing bars.

10)  POUR FOUNDATION CONCRETE
 Before placing concrete seal inside vertical joints of panels with sealant. Please see the “Health and Safety Data Sheet” for joint sealants. If joints are “open” then fill out with joint backing strip or foam. Seal approx. 50mm above finished floor level.
 Pour concrete into foundations and work to remove air and ensure filling beneath panels. Concrete should be placed as soon as one load can be used and panels should be left propped for the minimum amount of time. Do not pour too much concrete on one side at a time as the panels can be displaced. Fill trenches to just below top of cradle hoops. Before concrete cures, check panels have not been displaced.

11) POUR FLOOR SLAB CONCRETE
 Fix reinforcing bars to floor fabric and position bars to be in the centre of floor slab. Finish outside concrete to form required channel, kerb or floor.


12)  SEAL JOINTS
 Back out wide joints as stated above and gun in sealant. Work into joint and ensure that there are no air bubbles and good contact is made to joint sides. Cut out to form joint between floor and panels and seal as above. In some cases joints should be primed before sealing.

13)  FILL HOLES
 Fill lifting holes, and any areas damaged during installation with a bonding mortar using a suitable SBR (i.e. Unibond, Sika Latex etc). Apply surface protection where necessary.


14)  BACK FILL IF REQUIRED
 The backfilling of panels must be carried out strictly in accordance with ACP Concrete Ltd notes on “Earth Retaining Walls”. The backfilling must be closely supervised by competent persons to ensure the panels are not overloaded and we advise that a qualified engineer is consulted before the operation commences.


15) MAINTENANCE
An annual maintenance check should be carried out by a responsible person. Also check all surfaces for any signs cracks or impact damage. A qualified engineer must be contacted if any corrosion or cracks are noted.

Safe Storage & Disposal of Materials


Sika  Sealant          No special consideration for storage other than avoidance of frost. Store in dry when not required

                               No special requirement for disposal of packaging. Avoid litter and use skips on site. Remove unused packs from site for later use on other projects.

                               Avoid watercourses with material and packaging.

Concrete Panels    No special consideration for storage

                              No special requirement for disposal


 


ACP CONCRETE LTD

EARTH RETAINING WALLS

The characteristics of backfill vary enormously. These can be compounded by moisture content, compaction, top profile and expected trafficking.

ACP Concrete earth retaining vertical panels have the following service load capacities:

145mm thick panels  33KNm
180mm thick panels  45KNm

It is the responsibility of the contractor to ensure that these capacities are not exceeded specifically during backfilling.

We would advise that an engineer be consulted to ensure site conditions will not exceed these capacities. We also recommend that panel props be installed during the backfilling operation to guard against accidental surge loads.


 

 
 

Enquiries

Floors / Stairs:

01900 814659

Walls, Agriculture and Bespoke:

01889 598660
 
 
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