Boundary wall panels and columns are cast into purpose built moulds. Prior to casting, all cast in parts fixed in position and the mould is treated with a mould release agent. Hereafter reinforcement is kept in position and mould sides are fixed. All reinforcement will normally be prepared and prefabricated in our own workshop and placed in the mould using adequate spacers to ensure correct position and cover.
The specially manufactured casting equipment is employed to pour concrete into the moulds. The concrete used in production of these elements is manufactured under controlled conditions in our own batching and mixer plants employed specifically for captive use only. The in house production of concrete ensures highest possible quality. From batching plants, the concrete is transported directly to the casting equipment.
During casting hand held vibrators and fixed table vibrators are used to achieve the best possible compaction. Type of vibration, duration and amplitude of vibration is skill fully fixed based on pre tests and type of element under casting
After elements are cast, they are covered with sheets to avoid vaporization and left as it is to develop the initial strength. The concrete strength is ensured before the panels are removed from their mould and transported to curing and finishing area.
The required finishing will be done after the curing is over. All the precast items below ground level will normally be painted using Bitumen Paint.
Quality control is performed according to BPC Group standard quality procedures in the well equipped laboratories. The testing equipment is calibrated and maintained at fixed intervals to ensure the test results are at par.
The material used in production of concrete goes under inspection and testing as per company inspection procedures and British Standards. The reinforcement steel used in the panels is as per British Standards.
Comprehensive strength of concrete is determined by standard test cubes from the green concrete and these are tested in accordance with BS 1881: Part 108:1983 and BS1881: Part 116:1983.
All moulds are individually checked before casting. The final product is checked and inspected to ensure it meets the required finish and is free from any snags.
All panels are cured as per British Standards and company procedures. During the curing period, the panels are regularly watered and kept covered with polythene sheets to retail the moisture around panel.
A full schedule of company standard quality control procedures can be requested from the Quality Department.
As a special service, we can offer a full Quality Control Report for the individual project consisting of casting dates, cube test and other quality checks for the particular project. This service shall be agreed with our sales department.
BPC Group Quality Control System and standard procedures have been certified to meet the requirements of ISO 9001:2000 standard covering design, manufacture and erection of the company's precast components. The ISO 9001:2000 certificate also ensures that the clients are guaranteed a good product and service throughout the entire project.
Quality Management System of Bahrain, Dubai and Abu Dhabi have been certified by DNV.
The excavation for the Boundary Wall is normally carried out by the client as is compaction of road base and access road.
After excavation, 200 mm road base should be placed and compacted well enough to achieve a load bearing capacity of minimum 120-150 kN/m2. Level tolerances for the road fill should not exceed + 10 mm.
In order to level the Boundary Wall panels, shims are placed on the footing. After placing the panel the final alignment is done using adjustable props.
When the panel is in level, the joints between the footing and the panel will be grouted. After the grouting is completed, all precast items below ground level will normally be painted using Bitumen paint (Bitumen paint could also be applied in the factory).
In cases where the Boundary Wall consist of (footing, column and panel) the column is placed in the footing and hereafter levelled and grouted before panel is slided in the pockets of the columns.
If the Bitumen paint is applied at the site, then the elements are left for the paint to dry. When the Bitumen paint has dried sufficiently the excavation in front and behind of the Boundary wall is ready to be filled and compacted. To avoid any overloading of the wall, it is important to fill up and compact both sides simultaneously.