Cast, finish and cure wall panels WP-48 to WP-51

You are a leading hand in the Precast Yard at Bundamba.

Simulated workplaceIntermediate missionCAQA Apex Manufacturing

What is going on

Four wall panels for Sandstone Ridge Homes are scheduled to pour on Thursday on mould line 3. The drawings were revised last week to move two lifting inserts, and the reinforcement cages were fabricated on Monday to the earlier revision. The forecast is 33 degrees with a hot northerly. Concrete will be batched on site from the approved mix design, which sets a maximum concrete temperature of 30 degrees. Nathan Rudd is the batch plant operator and Grace Oduya from the laboratory will take cylinders. Last week panel WP-46 came out 9 mm over length and a concession had to be negotiated, so Tanya Whitlock has asked for the pre-pour inspection to be thorough.

Tanya Whitlock, Precast Yard Manager
Subject: Wall panels WP-48 to WP-51 pour on Thursday

Sandstone Ridge Homes wants the next four wall panels by the end of the month, so we pour WP-48 to WP-51 on Thursday. I want you to run the pre-pour inspection, batch the concrete to the approved mix design, cast, finish and cure the panels and keep the element records up to date. Grace will schedule the cylinders. Read the precast casting procedure first and be careful with the lifting inserts, we had a concession on WP-46 last week and I do not want another one.

Your brief

Run the pre-pour inspection against the current drawing revision, resolve the reinforcement and insert discrepancy, batch and place concrete within the mix design limits in hot conditions, finish and cure the panels, take the required records and record the pour and the post-strip inspection in the systems.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

Read the precast casting, finishing and curing procedure and compare the reinforcement cages and insert positions with the current drawing revision before ordering concrete.
Record the discrepancy between the cages and the revised drawing, hold the affected moulds and consult Tanya Whitlock on the correction before the pre-pour inspection is signed.
Complete the pre-pour checklist for all four moulds covering dimensions, release agent, cover, cast-in items and lifting inserts, and have the quality inspector countersign.
Plan the pour for the coolest practical time, confirm with Nathan Rudd how concrete temperature will be kept under 30 degrees and record slump and temperature for each batch.
Place and compact the concrete in the pattern in the work instruction, finish to the surface class on the drawing and mark the element identification.
Cover or steam cure the panels immediately and record curing temperature and duration at the required intervals on the element records.
Create the pour in the batch and production log and, after the laboratory confirms stripping strength, record the post-strip dimensional inspection in the quality test register.
Complete the fitness for work heat controls for the crew during the pour and record the rest breaks and water checks on the toolbox talk record.

My notes: what did I enjoy, and what surprised me?

What someone in this role would produce

Signed pre-pour checklists for four moulds with the discrepancy resolved
Batch and production log entry with slump and temperature results
Element records with curing log
Post-strip inspection entries in the quality test register
Toolbox talk record covering the heat controls

Printing this is a record of what you explored. It is not a certificate or a qualification.