Panels are cast into purpose built moulds. Moulds are generally manufactured by our fabricators in our work shop as steel moulds with sufficient rigidity to ensure that the units are produced within the required tolerances.
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 panels 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.
All casting takes place in one continuous operation. However for insulated panels casting takes place in two steps. The concrete layer closest to steel moulds are cast first. Hereafter the insulation is placed in the mould and the top layer is cast.
After panels 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.
All precast panels are cured as per BS standard and company procedures. During the curing period, the panels are regularly watered and kept covered with polythene sheets to retail the moisture around panel.
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 undergoes 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 fresh 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
TRANSPORTATION AND INSTALLATION
Panels are transported to site on A- or U-frame trailers, depending on the size and shape of the panel. In cases where the panel is more than 5 m high, they are placed lying down on the trailer. Upright standing panels are lifted directly from the trailer into position in the cast-in lifting anchors.
Panels that have been tilted for transportation purposes are first unloaded from the trailer in that same position. Once unloaded from the trailer, a second crane will hook on to the lifting anchors in the panel’s vertical side, slowly turning the panel to an upright position. Once the panel is upright, the first crane will unhook its lifting device, and the second crane will lift the panel in place.
After the panel is installed it is supported with temporary jacks or other sufficient support, depending on the condition. The crane is released only when the temporary support is in place.
Each panel is then carefully levelled and aligned using shims.
After the final adjustments, the panels are now ready for grouting. In some cases the panels are fixed mechanically by bolts or securing devices. However the temporary support will only be released after securing the permanent support.
Safety is a key issue at BPC Group, and all lifting devices such as lifting beams, belts and chains are tested and certified at regular intervals by a calibrating agency.
All BPC Group’s site personnel wear a distinct red overall for easy identification, and needless to say that helmets and safety shoes are a must at any site.
Our experienced site supervisors and project managers are always at your service to assist and advise you in these matters.