PQ Document PDF

PRE -QUALIFICATION
Contents
01
10
Quality Policy
Company Profile
02
11
Certificates
HSE Policy
03
12
Plant & Equipments
Licences
04
Consultant Approvals
13
05
Appreciation Letters
14
Material Safety
Data Sheet
16
Method Statement
07
List of Projects
Organization
Structure
09
Test & Calibrations
15
06
Product List
08
Projects in Photos
Factory Layout
17
General Catalogue
Company Profile
About us
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 high
quality 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
Our Objective
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 Team
We have an experienced and a professionally
dedicated management team ensuring smooth
and efficient functioning of all our Precast
operations.
Certificates
Certificates
Licences
Product List
Range of Precast products

Apex Precast manufactures, delivers and erects
a wide variety of Precast concrete products.
The range covers
Building Systems
1.
2.
3.
Precast Villas
Labour Accommodation
Industrial structures
Cladding Panels
1.
2.
3.
Insulated panels
Solid grey panels
Exposed aggregate panels
Boundary wall
1. Type 1 low cost design without column
design
2. Type 2 medium range with column design
3. Type 3 exposed aggregate finish panel
design
Tanks
1. Holding and water tanks of 2.5/ 5/ 11/ 16
/ 24 cum
2. Septic tanks & Soak away of 5/ 11/ 16 cum
The sizes can be custom built to requirements
Building Elements
1.
2.
3.
4.
5.
6.
7.
8.
9.
Foundations
Columns
Beams
Slabs
Stair Cases
Parapet
Lintels & Sills
Copings
Pergolas
Range of Precast products

10.
11.
12.
Arches
Dome.
Hand rails
Retaining wall
1.
2.
Retaining wall
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.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Under ground Manholes

Road and Crash Barriers
Fencing Post
Wheel stoppers
Pole Light Foundations
Culverts & Protection slabs
Speed Humps
Counter weights
Feeder Pillars
Transformer Foundations
Earth Pits
Landscaping Elements
1.
2.
3.
4.
Benches
Planter Box
Steps
Decorative Bollards
Marine Protection Elements

1.
2.
3.
4.
Wave Breakers
Stabit Units
Mass Block
Quay Wall
List of Projects
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 Contracting
Precast boundary wall at

Al Warsan
Dubai
April 2010
M/s. Kaz Contracting
Precast Tanks for

Dubai
Al Ghurair Investments L.L.C
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. FNCT
Precast 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 Contracting
Precast Boundary Wall

at ICAD 1
Abu Dhabi February 2010
M/s. Future Scaffolding
Precast 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
Contractor
Project
Location
Completed Date
M/s. Amada Contracting
Precast Tanks
Dubai
November 2009
M/s. Al Hosnei Contracting L.L.C
Boundary Wall for 987 / DU

Dubai
Pop Exchange
October 2009
M/s. Water & Power Engineering

Co L.L.C
Precast Shoring Panels
Dubai
October 2009
M/s. Future Scaffolding
Boundary 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 Engineering
Precast Cover Slabs for

KB643- DWTC
Dubai
September 2009
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. Road and Infra structure

L.L.C
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
Contractor
Project
Location
Completed Date
M/s. Emirates Technical Associates
G 15 Substation in
Khorkhwair
Ras Al
Khaimah
April 2009
M/s. Condor Building Contracting
Du-Pop Exchange Building

and Villa
Dubai
March 2009
M/s. Al Huda Contracting

Company
Water Tank and Pump rooms

Dubai
for Jumeirah Park Villas
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 Construction
Cold Storage and G+2

offices at Ras Al Khor Ind
for Fresh Fruits
Dubai
December 2008
366 Villas for Phase One

M/s. Pauling Middle East Co. L.L.C Project within Falcon City of Dubai
Wonders
December 2008
AIMS, Ajman
Double sided road barrier
Ajman
November 2008
M/s. Tanqia
Wet well pump station at

Fujairah
Fujairah
November 2008
M/s. Tanqia
Wet well Pump station &

Service buildings
Fujairah
October 2008
M/s Sungwon Corporation
2 Nos G+1 Labour

Accommodation
Condor Building Contracting L.L.C
Work 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 Construct
Boundary Wall for Bahwan

Group
Dubai
May 2008
September 2008
List of Projects
Contractor
Project
Location
Completed Date
Ajman Police
General 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. 400/132 KV Grid Station at

L.L.C
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, Dubai
Planter Boxes for Jumeirahh

Dubai
Beach Residence Project
Novermber 2007
M/s. Globe Road Contracting L.L.C
Crash Barrier for the Sadi

Road
Ras Al
Khaimah
October 2007
M/s. Condor Contracting Company
Pop Teleport Exchange

Building
Dubai
September 2007
M/s Al Sahel Contracting Company
P-116 office park at Dubai

Internet City
Dubai
September 2007
M/s. National Contracting

& Transport Co
G+1 Villa at Sharqan
Sharjah
June 2007
M/s Construction Technology
3 Nos G+2 Labour

Accommodation
May 2007
M/s Construction Technology
G+2 Staff Accommodation
May 2007
List of Projects
Contractor
Project
Location
Completed Date
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 Accomodation
Al Quoz,
Dubai
April 2007
M/s SIEDCO General Contracting
Shore line Apartments, Palm

Jumeirah Al Nakeel
M/s. Al Hikma Building

Contracting L.L.C
Septic Tanks & Soak pits
Sharjah
November 2006
M/s. Bu Humaid Consultant
Farm House for Ruler of

Ajman
Ajman
October 2006
M/s. Seidco General Contracting
Slab covers at
Palm Jumeirah
Dubai
October 2006
M/s. Darwish Engineering
Al Batha Compound wall &

Guards rooms
Sharjah
September 2006
M/s. Omis Contracting
G + 1 School in
Al Quarryman
Sharjah
September 2006
Al Jazeera
Al 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 Contracting
G+13 Circular Tower Palm

Jumeirah
July 2006
M/s. Emirates Road contracting
Road and Crash Barriers for Umm Al

Umm Al-Quain racing club Quwain
July 2006
M/s. Al Ahamadiah Contractors
Hand Rails for Jumairah

Beach residences
May 2006
November 2006
Dubai
List of Projects
Contractor
Project
Location
Completed Date
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 Building
Copings 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 Steel
Hempel 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 Construction
G+5, and above for 5

buildings at Jumairah Beach Dubai
Residence
July 2005
M/s. AMB Building
Decorative Lintels and sills

at Endurance villa Lisalli
Dubai
June 2005
M/s. Al Sahel Contracting
Planter Boxes
Dubai
June 2005
List of Projects
Contractor
Project
Location
Completed Date
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. Engineers Office
Building for Ruler of Dubai
M/s. Essa Engineering & Marine

Services
Office Building
Ajman
March 2005
M/s. Ranya General Contracting
Precast Slabs
Sharjah
March 2005
Ajman
March 2005
M/s. Essa Engineering And Marine

Precast Slabs
Services
March 2005
M/s. Al Oroba Constructions
238 Villas at Arabian

Ranches for Emaar
Dubai
February 2005
M/s. Team Engineering Enterprises
Labour accommodation,
Sheds & Boundary Wall
Dubai
February 2005
Management of Private Properties
Womens 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 Berger
Fujairah Sewage Collection

Network
Fujairah
January 2005
M/s. Ginco Contracting
5000 Lit under ground

Water tank for 238 Villas at
Arabian Ranches
Dubai
January 2005
List of Projects
Contractor
Project
Location
Completed Date
M/s. Al Oroba Cont
Pergolas for 238 villas at

Arabian Ranches
Dubai
January 2005
M/s. Greenscape Contracting
Precast Steps
Dubai
January 2005
M/s Translite Interiors
St.Marys School & Church
Dubai
December 2004
H.H. Sheikh Mohammad Bin Zayed
Boundary Wall for Villa at Al

Dubai
Khawaneej
November 2004
M/s. Darwish Engineering
Stadium Steps for Choeifat

School
Sharjah
September 2004
M/s. C R C
240 Villas - Emaar

Properties
Dubai
July 2004
M/s. Al Eslah General Construction
66 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. Marys School
Dubai
January 2004
M/s. Ali Moosa & Sons
Mosque
Ras Al
Khaimah
January 2004
30 Villas for Private Dept.

for H H Sheikh Zayed Bin
Sultan Al Nahyan
Ras Al
Khaimah
January 2004
M/s. Ali Moosa & Sons Contracting
Youth centers @ Madam, Al

Thameed, Al Maleeha
Sharjah
December 2003
Compound Wall for Clinic in

Maleeha
Sharjah
December 2003
30 Villas for Private Dept.

for H H Sheikh Zayed Bin
Sultan Al Nahayan
Al Ain
December 2003
List of Projects
Contractor
Project
Location
Completed Date
M/s. Consultant Engineers Office
Villa at Al Manara for Higgs

& Hills
Dubai
November 2003
Low Cost Villas (276

Villas) for H.H. Sheik Zayed
Al Nahayan
Al Ain
September 2003
M/s. Amana Steel
Bus 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
Child 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 Zayed
Cladding panels for B+G+10

Sharjah
storied building at Al Tawun
M/s. Petron Emirates Construction

Mina Zayed Port
Co
M/s. Translite
Retaining wall and shoring

slabs for St. Marys church
September 2001
Abu Dhabi June 2001

Dubai
June 2001
Project Photographs
Project Photographs
G+12 Circular Tower
Shoreline Appartments
Palm Jumeirah
Nakheel, Dubai
Project Photographs
Project Photographs
G+12 Circular Tower, Shoreline Appartments, Palm Jumeirah

Nakeel, Dubai
Project Photographs
G+12 Circular Tower

Palm Jumeirah
Nakheel, Dubai
Project Photographs
G+12 Circular Tower
Palm Jumeirah
Nakheel, Dubai
Project Photographs
B+G+10 Insulated
Exposed Aggregate Panel
Cladding
Sharjah
Labour Accomodation
Project Photographs
Springs, Emaar
Dubai
Project Photographs
Boundary Wall
Sharjah
Boundary Wall
Dubai
Project Photographs
Boundary Wall, Hempel Paints

Sharjah
Boundary Wall, Agility L.L.C

Dubai
Columns & Beams for Industrial / Indoor Sports Structures
Columns & Beams for Industrial / Indoor Sports Structures
Sharjah
Labour Accomodation
Project Photographs
Boundary Wall, DU, Sports City

Dubai
Project Photographs
Boundary Wall, RTA

Dubai
Project Photographs
Boundary Wall, Transco

RAK
Project Photographs
Precast steps for GECO school

Sharjah
Trenches for ADWEA
Project Photographs
Exposed Aggregate Finishes
Dubai
Ministry of Labour Building
RAK
Labour Accomodation, CTC
Project Photographs
Labour Accomodation
RAK
Staff Accomodation, Al Quoz

Dubai
RAK
Labour Accomodation, CTC
Sharjah
Labour Accomodation
Project Photographs
Labour Accomodation
Sharjah
Precast Cladding, Internet City

Dubai
Project Photographs
Boundary Wall, Falcon City of Wonders

Dubai
Dubai
Precast Building, Al Quoz
Project Photographs
Labour Accomodation, Conmix

Dubai
Project Photographs
Precast Stadium Steps, Goverment of Fujairah

Fujairah
Project Photographs
Precast Building
Al Quoz, Dubai
Project Photographs
Precast Dome, Golf Gardens, Sorouh

Abu Dhabi
Project Photographs
Precast Dome, Golf Gardens, Sorouh

Abu Dhabi
Dubai
GEMS World School
Dubai
GEMS World School
Project Photographs
GEMS World School

Dubai
Project Photographs
Precast Building, Al Quoz

Dubai
Royal Furniture Warehouse

Ajman
Project Photographs
Cladding, JBR
(Jumeirah Beach Residence)
Dubai
Dubai
Cladding JBR (Jumeirah Beach Residence)
Project Photographs
Boundary Wall, Arabian Ranches

Dubai
Organization Structure
Organization Structure
Departmental
Organization
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.
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
It is responsible for tasks such as preparing job referred to and ascertained as in the tender,
estimation, quotation and contracts based on the checked for accuracy and then handed over to the
current prices prevailing in the global and local Procurement department to initiate all the purchases.
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,
Technical Design
& Drawings Department
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.
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 industryOn commencement of a precast project, the standard practice. As soon as the steam cured
Estimation, Production & Projects department cubes attain the full strength as required in the
will prepare contributions on the varied services design, the Precast Elements will be stocked and
required to complete the overall shop drawings dispatched to the site.
required by clients.
Latest Windows Software: Design calculations
for Precast elements will be done by using the
Excel Spread Sheet.
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 production
and 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.
Planning Department
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.
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
This department also conducts regular in-house
duration for performance of certain activities,
training for the employees.
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 Program
Program Flow Chart
Labour 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.
Quality Assurance and
Quality Control Department
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.
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
On the commencement of every project, the certified invoices are forwarded to Sales
Department for payment follow up.
Project of Quality plan is prepared and regularly
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.
Finance Department
The Manager and personnel of this department
handle the
financing requirements for the
execution of the project. Financing is mainly
sourced 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.
Quality Policy
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.
Company has its own in-house Design team,

Production and Erection crew with necessary
machinery and equipment to carry out the work
complying with the Quality Standards.
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 clienteles requirements.
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.
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.
Purpose
Quality Control
Programme
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.
1.
2.
3.
4.
5.
6.
7.
Design and Drawings

Materials.
Casting Platforms and moulds.
Reinforcement
Concrete
Demoulding, Storage and Transport
Erection.
1. Design and Drawings
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.
Apex in-house Engineering team comprises of

Qualified, experienced Structural Engineers and f) Drawings
experienced Draughtsman who perform structural Layout plans, detailed production and erections
Design and detailing of all Precast elements.
drawings for each structural Pre-cast element are
prepared.
a) Loads
Dead loads, Live loads and the Erection loads are Shop drawings will feature following information.
considered as per BS 6399 and the Wind loads are
calculated in accordance with the provisions of BS a)
Size, grade, profile and dimensions.
CP3 Chapter V, Part 2 Basic data for the design of b)
Connection and anchorage details.
buildings wind loads.
c)
Lifting devices, locations and handling

limitations.
b) Design
d)
Steel reinforcement details.
Structural stability, analysis & design calculations e)
Locations of all openings, sleeves and
are done according to the BS : 8110. The design
inserts, identification marks.
documents along with drawing are submitted for
2. Materials
3. Casting Platforms and Moulds
a) Cement
Sulphate 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) Aggregates
All 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 Chemicals
Superplasticiser: Rheobuild 1100 are used in the
concrete as a water retardant. The same is then
procured from MBT and product catalogue are
provided.
d) Water
Potable water from Ajman Municipal supply is
used.
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.
e) Reinforcement
d) Tolerances:
Hot rolled deformed high yield stress It is ensured that deviations of formed surfaces do
bars that are conforming to BS 4449 with not exceed tolerances as per PCI standards.
specified characteristic strength of 460 N/sq.
mm are used. Manufacturers test certificates are
provided for the lot procured.
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.
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.
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 Mixes
Trial 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 checklist
All form work, reinforcement, inserts etc are
checked by QC Engineer as per prepour checklist.
c) Concrete Pour - Test/Records
For Days 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 Tests
For days concrete six cubes are casted and tested
after curing as detailed below.
i. 3 Days 3 cubes
ii. 7 Days 3 cubes
iii. 28 Days 3 cubes
Test results logbook are maintained for ready
reference.
7. De-moulding, Storage and Transport
8. Erection
The De-moulding, storage and the transportation Erection work is done under the supervision of
is done under the supervision of the site Erection Erection supervisor.
Engineer.
a) Precast erection is done according to erection
a) The pre-cast element is removed from the method statement.
moulds without damaging or over stressing and
stored at the storage yard for transportation. The b) All the erection crew wears PPEs like Hand
storage yard has storage racks to store the precast gloves and Safety shoes during erection work.
elements separately.
Temporary side bracings are also provided during
installation where required. A Crane with suitable
b) Each of the precast element is marked with an capacity is used for erection of pre-cast elements.
identification number and the date of casting.
c) Repairing work for any precast element that is
c) Pre-cast element is transported with sufficient damaged is done using repair mortars.
battens, bracing and supports so as not to over
stress by vibration or impact loadings.
d) Repair work with materials is carried out as per
manufacturers instructions given in the Technical
d) Transport, storage, handling of the structural data sheet.
precast units will be done carefully to avoid undue
strain, hair cracks, staining or other damages.
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.
Quality Control Plan

1. Scope
2. Receiving Material Inspection
3. Inspection/ Test of Concrete Mixes and Cubes
4. Inspection of mould fabrication
5. Pre-pour Inspection
6. Concrete
7. Post-pour inspection of finished precast
components
8. Final Inspection before delivery
9. Final inspection of erected precast components
1. Scope
This section provides the general performance
requirements specially needed for Precast concrete
products, which are continuously produced in
well-controlled factories. Standard requirements
related to construction including concrete work
at site using these products, are also laid down.
In-house testFM/QC/011- Report on cement

test on fortnightly basis.
Aggregate and Sand: All the aggregate and
sands are received with delivery note. Visual
checks will be conducted for each size of
aggregate and sands on receipt. All the
aggregates 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 and
Sands 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 aggregate
mass. On the other hand an aggregate having
particles of varying sizes will exhibit less voids.
1.1 Basic Requirements
Care shall be exercised in the choice of Principle of grading is that smaller size particles fill
materials used and in mix proportions, mixing, up the voids left in large size particles. The test will
layout of reinforcement, molding, casting, be carried out and record in the form Report on
curing,etc. To ensure that the manufactured sieve analysis FM/QC/006 for monthly 2 times.
concrete productsmeet the required quality and
performance. Also, concrete products shall be (ii) Specific gravity: Specific gravity implies the
manufactured in a manner that the quality and absolute weight per unit volume of aggregate.
performance are not impaired during handling, A low specific gravity may indicate high porosity
transportation, assembling and jointing, and shall and therefore, poor durability and low strength.
be settled and assembled to satisfy the required Specific gravity of aggregate is used in arriving at
mix design. It is also required in calculating the
function and performance of structure.
compaction factor in connection with workability.
Generally, the specific gravity of rock for
2. Receiving Materials Inspection
good aggregate is above 2.50. The test will be
The receiving inspection of all the materials used carried out and record in the form Report on
for the production of precast concrete elements as specific gravity FM/QC/007for monthly 2
times.
follows.
Cement: Cement shall be received with test
certificate and delivery order. Cement will be (iii) Bulk density: Bulk density is another value
visually inspected for color and quantity. The we make use of in mix design. It is measured by
cement received is stored in cement silos filling a container in a standard manner and
which are connected directly to the weighing it. It gives valuable information regarding
concrete mixer. Once a year, the cement will be the shape and grading of the aggregate. Higher
tested in an independent laboratory for physical the bulk density, the lower is the void content
to be filled by sand and cement. The test will be
and chemical parameters.
The cement test will be carried out through an carried out and record in the formReport on bulk
density FM/QC/010 for monthly 2 times.
Once in a year, the following tests will be

carried out through an independent Material testing
laboratory. Grading test including
(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 on
moisture content FM/QC/009 twice monthly.
passing 75 microns
Sulphate content.
Chloride condent.
Specific gravity.
Water absorption.
Flakiness index.
Elongation index.
RE M A RK S
SR
No.
1
2
3
4
5
6
7
8
DESCRIPTION
Grading
Mater ial Finer Than 0.075 mm
Natu r al, U ncru shed /Crushed
Crushed R ock
C lay L u mps And Fiber Particl es
Li ght weight pieces
O rganic Matter C ontent Bs 1377
Pa rt 3.M 3:1990
Water Absorptio n
Specific Gravity (appar ent)
Shell C ontent in Aggr egate
a. Coarser than 10 mm
b. Between 5 mm to 10 m m
c. Between 2.36 mm and 5 m m
d. Finer than 2.36 m m
Pa rticl e Shap e
a. Flakiness I ndex
b. E longation Index
10
BS 812
20
10
5
MM
MM
MM
AS PE R PART 103
STANDARD
0.3%
0.3%
DUNE
SAND
AS PE R STANDAR D
3.7%
1.5%
0.2%
-
0.2%
-
0.4%
-
0
-
0.8%
-
0.5%
-
1.6%
-
1.0%
-
12
20
19
23
0.01
%
0.03
%
0.01%
For m ass concr ete m ad e w ith

a. SR PC
b. O PC and M SR PC cements
12
13
14
15
Sou nd ness , M gS04

Mechanic al Str ength
10% fine valu e
or impact value
Los Angles abrasion
D ry shr ink age
Potential R eactiv ity
Aggregates chemic al method
Cement aggregate combination
3%
7%
1%
0.5%
M ax 0.2%
M ax 2.3%
M in 2.6
M ax
M ax
M ax
M ax
-
1%
1%
1%
0.5%
Pa rt 103
M ax 2%
Mi n 2.6
M ax 5%
M ax 15%
Pa rt 106
M ax 25%
M ax 25%
Pa rt 105.1
Pa rt 105.2
Pa rt 117
0.01
%
11
M ax
M ax
M ax
M ax
Pa rt 103
M ax 10%
NR
A cid sol uble chlorides, C l

Fo r RCC made w ith
a. SR PC cement
b. O PC /MSR PC cem ents
For prestr essed concr ete and

steam cured concrete
A cid sol ub le su lp hates SO 3
FI NES
DM
C O A RS E
0.12
%
3%
.074%
0.06
%
0.06
%
0.08%
M ax
0.03%
M ax
0.03%
M ax
0.03%
M ax
0.05%
M ax
0.01%
M ax 0.3%
M ax 12%
M ax 0.01%
M ax 0.02%
M ax 0.02%
M ax 0.04%
M ax 0.01%
M ax 0.3%
Pa rt 118
M ax 12%
Mi n 100 k N Pa r t 111
M ax 30%
Pa rt 112
M ax 30%
M ax 0.05%
Pa rt 120
Innocu ous
Inn ocu ous
6 m onth expansio n
0.10% m ax
(According to BS 812 and BS 410)
Acceptance Limit For Raw Materials

SR
No.
Siev e
Size
37.5 mm
20.0 mm
14.0
mm
Percentage by mass p assing BS sieves for nom inal sizes

Aggregate
Aggregate
Crush
Sand
Dune
Remark s
(20mm )
(10mm )
Sand
(0-5m m )
Sand
0-5mm
----100
----90 to100
---40 to 80
100
--
--
--
10.0 mm
30 to 60
90 to 100
6.30 mm
--
--
100
100
--
5.00 mm
35 to 55
30 to 65
70 to 100
70 to 100
--
2.36 mm
5 to 30
60 to 100
25 to 100
1.18 mm
--
--
30 to 90
15 to 45
600 m
10 to35
10 to 30
5 to 54
5 to 25
10
300 m
--
5 to 15
3 to 20
11
150 m
0 to 82
0 to 82
0 to 15
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.
0 to 15
Incase of non-conformance, the steel yard

Foreman reports to Production supervisor
and 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.
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.
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 manufacturers test
certificate. Micro silica /GGBS received will be
In case of any non-conformity, action will be taken stored in silos and Apex storage area and covered
as follows:
with polythene sheet.
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.
Specications for Steel Bars
(a) cross sectional area and m ass
Mass per
SR Nominal
C ross
No. Size in
Sectional meter run kg
mm
Area mm 2
1
6
28..3
0.222
2
8
50.3
0.395
3
10
78.5
0.616
4
12
113.1
0.888
5
16
201.1
1.579
6
20
314.2
2.466
7
25
490.9
3.858
8
32
804.2
6.313
9
40
1256.6
9.864
10
50
1963.5
15.418
Tolerance on mass
Nominal size
T olerance on mass per
mm
meter run %
6
+9
8 and 10
+ 6.5
12 and over
+ 4.5
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
3. Inspection/ Test of Concrete Mixes and

Cubes
Slump 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.
(As p er BS 8110: Part 1:1985)
Strength of Concrete
SR Grade of Characteristic
No. Concrete
Strength
f cu
3 d ay s
1 y ear
U nit
N /mm
20.0
20.0
9.5
13.5
20
23
24
25
25.0
25.0
11.5
16.5
25
29
30
31
30.0
30.0
14
20
30
35
36
37
40.0
40
19.6
28
40
45.5
47.5
50
50.0
50.0
25.2
36
50
55.5
57.5
60
N/mm
Cube Strength at an Age of

7 d ay s 28 d ay s
3
6
months mon ths
N /mm 2 N/mm 2 N /mm 2 N/mm 2
3.1 Client/Consultant visit

The 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 from
production one day prior to casting. Mould
inspection shall be done according to production
planning. The Quality Inspector inspects every
mould measurement according to shop drawing
and checked according toF/IMSP15/R1: Mould
Inspection to ensure mould measurements
before casting.
4.1 Actual Measurement:
The height, width & thickness of the mould should
be checked properly according to approved shop
N /mm
drawing. Actual measurement should be measured

and will be recorded in the formFM/QC/001Sample 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 reinforcement
The Quality Inspector will then identify the
reinforcing steel to be positioned as specified by
the 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 inch,
however concrete cover greater than 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 Cover
Cover is inspected as mentioned in the approved
shop drawing (after reinforcement is placed in the
mould).
5.5 Cast in parts
Preparation 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 nonconformance. 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 Insulation
Inspect the size & thickness according to shop
drawing. The placement & spacing of Anchor
pins & sleeve anchor to be placed according to the
shop drawing.
6. Concrete
6.1 Concrete mixing
The 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 Concrete
The 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 Finishing
The 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
sawlike 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 after
screeding is called floating. The process is
done with the help of wooded foat. Finishing is
performed by moving the wooden float
backward and forward. Bull float is used if the area of
concrete 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 component
In case of water curing
1) 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 20C per hour and the maximum temperature
shall not higher than 65C
5) 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
component
The 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 surface
After 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 exposed
surface 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 surface
After finishing work has been done for the first
precast component for fair faced surface, the
Production Supervisor and the Charge-hand
inspect to check whether the result complies
with 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-faced
surface of one panel complies with the surface of
another panel. In the event of nonconformance
chargehand informs the Production Supervisor
for further action.
7.4 Finishing on surface to be painted
After 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 nonconformance
the Charge-hand will inform the Production
supervisor for further action.

7.5 Painting
Before 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 Damages
In the event of damages, the Production
Supervisor shall bring this to the notice of

Production 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 for
final inspection before the precast components are
released for delivery. Precast components ready for
final inspection are placed in the finish area in the
stockyard, where following inspection to be
carried out and will be recorded informFM/
QC/002, FM/QC/003- Final inspection after
production
8.1 Final Inspection tolerances (Columns & Beams)

Main Measures
Max . Dim
Toleran ces
Length
< 3 me ter :
3 6 me ter :
> 6 me ter :
6 mm
12 mm
Width
< 500 mm :
500 700 mm :
Fo r each additio nal 200 mm :
15 m m
3 mm
6 mm
3 mm
Thickness
< 500 mm :
500 700 mm :
Fo r each additio nal 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
8.1.1 Final Inspection tolerances (Panels)

Main Measures
Max . Dim
Toleran ces
Height
6 mm
Width
6 mm
T hickness
< 500 mm :
>500 m m :
5 mm
9 mm
Squareness (d iffer ence
< 2 me ter :
2m 4 me ter :
6 me ter :
5 mm
6 mm
9 mm
in 2 d iagonals)
T hickness
< 500 mm :
>500 m m :
5 mm
9 mm
Squareness (d iffer ence
< 2 me ter :
2m 4 me ter :
6 me ter :
5 mm
6 mm
9 mm
in 2 d iagonals)
Cutout Si ze
Cutout lo catio n
5 mm
5 mm
Twist
< 600 mm (W ) & < 6 m (L ):

> 600 mm ( W ) & > 6m (L ):
6 mm
10 m m
Straightness
< 3 me ter :
3 6 me ter :
> 6 me ter :
Ma x. d ev iatio n fr om 1.5m
straight ed ge < 3 mm
3 mm
6 mm
9 mm
Flatness
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 Inspection
QC 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 removed
the 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 element
number 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 NonConformance Register.
9.1 Inspection of site ready for erection
Inspection 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 technical

manager for further action.
9.2 Final Inspection of Erected Precast
components
The 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
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 Project
HSE Plan is based on the applicable local
practice, Apex health and safety requirements/
standards, OHSAS 18001:2007 and customers
safety requirements. The Project HSE Plan covers
the Occupational Health & Safety aspects during
documentation of the Named Project.
2. HSE POLICY GOALS/ OBJECTIVES
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.
IMS Policy
HSE Goal
Deliver high quality Precast products and services
by proactively monitoring our business practices.
To achieve zero lost time incident throughout the
whole project.
Strive for continual improvement to setting and
achieving set objectives and targets.
Safety Principle
Identify risks and significant impacts to establish Deliver safely, on budget, on time and the right
best operational controls for environmental and quality
occupational health and safety related activities.
Lead our employees to communicate, participate
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
3. STANDARDS AND LAWS FOLLOWED
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.
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 Production / Factory In-Charge
Order No (32) 1982.
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
Ministry of Labour and social affairs Federal Law Production / Factory In-Charge ensures that the
No (8) 1980
health and safety plan is implemented monitored
and maintained.
Federal Environmental Law No (24) 1999
Dubai Municipality code of construction.
International Standards:
ISO 9001 : 2008 Quality Management System
ISO 14001 : 2004 Environmental Management
System
OHSAS 18001:2007 - Occupational Health and
safety Management System.
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
Low
Detailed working to
support conclusion
Tolerable
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
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.
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
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 / Factorys shall be followed strictly, which are
clearly marked on the layout shown in Appendix 9
Emergency Contact Numbers :
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
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.
List of safety equipment will be as follow.

Safety Equipment
Needs to be used
Helmet
Throughout the Factory/ Site
Safety Shoes
Throughout the Factory/ Site
Safety harnesses
Working at heights
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 time
To check muster rolls for any missing persons
Eye/ Face protective Working with grinder, welding
Report missing persons to management/ civil
equipment
defense
Fire proof clothes
Where necessary
To record the time taken for evacuation
( when necessary )
To be equipped with emergency contact
Fire Blanket
While welding
numbers
To give further instructions to the gathering in
The use, quality, suitability of all the protective
moving them to a safe place.
equipment will be controlled during routine Site/
Factory safety observation tours.
Fire Drill
Safety Gloves
Working with sharp tools

(all kinds of cutting tools)
& sharp materials
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.
10. INCIDENT REPORTING AND
INVESTIGATION
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.
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
9. EMERGENCY PREPAREDNESS
Emergency Evacuation Procedure at the time forms should be complying with local regulations.
of an emergency, alarm will be initiated (either
automat-ically/manually). On hearing the 11. HSE AUDITS
alarm every one is expected to respond to it by
moving safely to the predetermined assembly point. Audit A systematic, independent, documented
Before coming out from the work place, ensure all process for obtaining audit evidence and by -
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 companys
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
evaluating it objectively to determine the extent to training programs for employees and safe culture is
which audit criteria are fulfilled. HSE audits are expected from employees at all times.
held at least once every month, unless customer
determines otherwise.
Heat stress at work
Safety Inspection Check List
Heat related illness is common during the hot

and dry summer months. Heat related illness can
Safety inspection full-scale examination of all or develop over several days or can strike during a
part of the workplace using a checklist, carried out single burst of strenuous physical activity.
at least monthly.
Guidelines are provided to prevent heat stress and
first aid trainings are given in case of any medical
Safety Observation Tour
help.
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.
Equipment operation
12. EQUIPMENT / WORK ACTIVITIES SAFETY
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.
Factory Security system
Cords, leads, and hoses
The entire Factory shall be fenced and protected to Electrical cords, welding leads, water, air and the
avoid unauthorized entry.
welding hoses shall be placed where they cannot
be damaged or cause damage or injury.
Rules of Conduct
Mechanical Safeguards
Personnel must conform to all rules of conduct relating to safety while on the job-site/factory and Starting and Operating Machines: Employees shall
while absent from the job-site / factory in the per- not start or operate any mechanical equipment
formance of their duties.
unless qualified and authorized to do so.
No smoking areas
Machinery and Tool Guards
Smoking is prohibited within areas posted with NO Machinery and tool guards shall be provided for
SMOKING signs.
protection against revolving or reciprocating parts.
These guards shall be in place before the machine
Housekeeping
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 employees 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 internal
pressure 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 factory / site are provided by the Apex HSE policy
manual.
Check the installation is dead

Carry out earthing and short circuiting
Detailed guidelines for welding in the factory Issue a permit to work
/ site are provided in the Apex HSE policy
manual.
Chemicals and Hazardous Substances
Welding
Apex Precast will do the COSHH assessment and

hazard identification in the use of chemicals and
Control Measures: Risk Assessment prior to any hazardous substances, MSDS of all substance will
entry, suitable training, including for those on be displayed and explained, proper training and
standby duties.
appropriate PPES should be provided.
Check if adequate level of ventilation continues in
air replacement systems, the extractor fan airline 13. FIRE PREVENTION
respirator or self contained breathing apparatus by Each employee shall be advised of and
directing gases to the open air.
therefore shall comply with the fire prevention,
detection, and control requirements as applicable:
Construction Equipment
Fire risk assessment should be done in Apex sites/
factory and control measures to be done to prevent
All multi- directional earth moving, haulage and or fire. Major areas that are vulnerable to fire are Diesel
compacting equipment, and all trucks with a body storage area, Generator room, Office and store
capacity of 2.2 cubic yards (1.7 cubic meters) or area, Cylinder storage area and main activities are
more used to haul dirt, rock and concrete or other welding, cutting, grinding. Fuel storage tanks
material shall be equipped with an automatically area shall be properly grounded, vented and
operated reverse signal alarm (such as a buzzer, provided with drip trays. Adequate number
horn or bell). It shall be the duty of the project of fire extinguishers should be procontractor to inform his suppliers of requirements. vided.
Smoking
is
strictly
prohibited
No person shall be allowed to ride in or on any in
Apex
Factory/sites.
Certified
fire
equipment or vehicle, except in seats, which are fighters are available at Apex Factory/site
provided by the manufacturer.
and all employees are trained in fire fighting.
All loaders, backhoes, bulldozers, and all other
similar equipment shall have their blades, buckets 14. ENVIRONMENTAL MANAGEMENT
fully lowered and the engines shut-off when left The Environmental Management & the
unattended. No persons shall be allowed to stand Safety Management systems are integrated
or pass under elevated portion of the equipment on the Site/ Factory. Before works start, the
whether loaded or empty. Pile driving lofts men environmental plan for the Site / Factory
will use safety belts when working at elevations Waste Management, Chemical Management, and
outside loft platforms. When the leads are to be Control Measures etc will be done according to
rotated or moved, the lofts man will descend from Apex policy. The Environmental Planning process
the leads.All exhaust pipes, steam lines and hot involves identifying and then maintaining upsurfaces, located where employees could contact to-date information concerning environmentally
them, shall be effectively guarded or insulated.
relevant
aspects, including legal & other
Confined Space
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
requirements for the Site/ Factorys 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 & Equipment

Serial No
1
Equipment
Batching Plant
Total No
1
Chiller Plant
Compressor 475
Compressor L75
Air Dryer B.W
GH Crane
Demag Crane
Boiler 1
Boiler 2
10
Welding Machine (H)
11
Welding Machine (L)
12
Bar Bending Machine
13
Bar Cutting Machine
14
Sand Blasting Plot
15
45 Ton Crane
16
25 Ton Crane
17
Showel
18
Mack Trailer
19
Mercedes Benz Trailer
20
Transist Mixture
23
Mack Trailer
24
Mercedes Benz Trailer
25
Transist Mixture
29
Power Plot Machine
30
Hilti Machine
31
Drilling Machine
33
Plate Compactor
34
Air Blower
35
Generator
37
Grouting Machine
38
Mixer Machine
39
Gantry Crane
40
Water Plant
41
Needle Vibrator
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 system
Boilers 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
Factory Layout
Test & Calibration
Test & Calibration
Test & Calibration
Material Safety
Data Sheet
Material Safety Data Sheet

1. Product / Company Identification
Manufactures Name & Address
Apex Precast Products Industries L.L.C
P.O. BOX: 6530
Ajman U.A.E.
Tel: 06 7436138
Fax: 06 7436858
Products: Precast Concrete
2. Composition of Ingredients
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
1. Eye contact (fresh concrete) immediately
rinse under running water.
2. Skin contact (fresh concrete) immediately
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.
Precast Concrete is a mixture of various natural

aggregates; cement & water, admixtures may be
added to modify the properties of the finished 5. Fire Fighting Measures Not applicable
product.
6. Accidental Release Measures
3. Hazard Identification
Avoid Contact with skin
Prevent entry of wet concrete into watercourses,
Fresh Concrete
Fresh concrete contains cement and water with the drains or other areas where hardened material can
create problems. Remove product using the most
result that an alkaline solution is produced.
appropriate equipment.
Repeated skin contact with fresh cement over a
7. Handling
period may cause irritant contact dermatitis.
The abrasiveness of the constituents can Avoid contact with skin and eyes. Always follow
aggravate the effect on some skin type which are safe lifting and manual handling procedures.
more sensitive to fresh concrete and can develop
allergic contact dermatitis. However this is a rare 8. Exposure Control/Personal
Protection Equipment
occurence.
Prolonged skin contact with cement can result in Hand protection wear suitable protective
gloves.
burns.
Skin protection avoid contact with skin. Coverall
should be worn.
Hardened Concrete
Eye protection wear goggles to prevent any eye
Cutting, Drilling or Hammering of fully hardened contact from splashing of fresh concrete, flying
concrete can create dust. If inhaled in excessive particles when hammering concrete.
quantities over extended periods, respired dust Safety Shoes wear knee high rubber boots or
similar with protective toecaps.
may constitute long term hazards.
Kneepads wear kneepads when kneeling on
Cutting drilling or hammering of fully hardened fresh concrete
concrete unless adequately controlled can project
Material Safety Data Sheet

9. Physical & Chemical Properties
12. Disposal Considerations
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.
Hardened concrete may be recycled or placed in

approved landfill.
10. Stability & Reactivity

Not applicable
11. Toxicology Information
No risk upon observance of safety instructions.
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 projects
main contractor.
B. Site Mobilization
Lay 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.
components required for the project.

F. Project Execution
Production 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 Apexs 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 Control
On 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. Safety
All 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 Apexs employees; which
include safety, in regards to machinery equipment,
D. Material Procurement
All required materials will be identifiable in detail safe load handling, PPE, Fire, Transport / Driving,
with sources / technical details. Submissions will be Chemicals, and safety against all types of hazards
prepared and submitted for clients approval along / Accidents.
with Pre-Qualification document. On approval,
all materials will be procured well in advance in I. Handing Over of the Project
phases as per the requirement of the work All snag points will be attended to and works
will be presented for final approval. All cleanup
program.
work will be carried out. After the final approval,
handing over will be carried out as directed by the
E. Machinery and Equipments
All machinery / equipments i.e. Mobile Cranes, client.
C. Shop Drawings
Approvals for the shop drawings will be obtained
from the Consultant / client before commencing
the work.
Trailers etc. required for execution of the project

will be made available from Apexs source or by J. As Built Drawings
hiring if required. Apex has a well equipped As built drawings will be prepared and submitted
precast factory at Ajman to produce the precast on completion of the work
P.O.Box 6530, Ajman, United Arab Emirates

T : +971 6 743 6138 F : +971 6 743 6858
E : sales@apexprecast.com
www.apexprecast.com

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