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TECHNICAL DOCUMENTS NUMBERING SYSTEM 

Originator Div Type Section Doc Number Ind

L 1 J O 0 0 Q 0 0 1 A

RGBS / ABDC Document review

Ref. letter number Date Name Date

CheckedDrawing number Approval sheet number

 ApprovedStatus of approval

 A ApprovedThe approval of the drawings will not exonerate the Contractor from anyresponsibility in connection with the works

 AN Approved except Noted

RR Returned for correction and Resubmission

2 2013-08-05 E. BLACHE N. KOENIG A. ROUSSIN ISSUED FOR OBSERVATION OBS

1 2013-05-25 E. BLACHE JL. PEREZ N. KOENIG ISSUED FOR OBSERVATION OBS

Ind Date Prepared Checked Reviewed Amendments Status

 ARAB REPUBLIC OF EGYPT 

Ministry of Water Resources and Irrigation 

Reservoirs and Grand Barrages Sector (RGBS) 

 ASSIUT BARRAGE DEVELOPMENT CONSULTANTS (ABDC)

NEW ASSIUT BARRAGE AND HYDROPOWER PLANT

LOT 1 – CIVIL WORKS 

EGYPTIAN – FRENCH NEW ASSIUT B ARRAGE 

JOINT VENTURE 

CONCRETE WORKS

PREFABRICATION ANALYSIS

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po:Koenig

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Table of Index

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List of Contents

1   Abbreviations ...................................................................................................................................................... 4 

2  Reference documents ........................................................................................................................................ 4 

3  Scope ................................................................................................................................................................... 5 

4  Precast slabs ....................................................................................................................................................... 6 

4.1  Precast slabs location ........................................................................................................................................ 6 

4.2 

Precast slabs characteristics ............................................................................................................................ 9 

4.3  Installat ion programme request and fabrication assumpt ions ...................................................................... 9 

4.4  fabrication storage ............................................................................................................................................ 10 

5  Technical galleries precast slabs .................................................................................................................... 11 

5.1 

Electrical galleries location.............................................................................................................................. 11 

5.2  Electrical galleries characterist ics .................................................................................................................. 12 

5.3  Installat ion programme request and fabrication assumpt ion ...................................................................... 12 

5.4  Fabrication and storage ................................................................................................................................... 12 

6  Technical gallery precast slab ......................................................................................................................... 13 

6.1  Location ............................................................................................................................................................. 13 

6.2  Characteristics .................................................................................................................................................. 13 

6.3  Installat ion programme request and fabrication assumpt ion ...................................................................... 13 

6.4  Fabrication and storage ................................................................................................................................... 13 

7  Precast channels .............................................................................................................................................. 14 

7.1  Precast channels location................................................................................................................................ 14 

7.2  Precast Channels Characteristics ................................................................................................................... 14 

7.3  Installat ion programme request and fabrication assumpt ions .................................................................... 14 

7.4 

Fabrication and storage ................................................................................................................................... 15 

8  Precast stairs .................................................................................................................................................... 16 

8.1  Precast stairs location ...................................................................................................................................... 16 

8.2  Precast stairs characteristics .......................................................................................................................... 17 

8.3 

Installat ion programme request and fabrication assumpt ion ...................................................................... 18 

8.4  Fabrication and storage ................................................................................................................................... 18 

9  Conclusion......................................................................................................................................................... 19 

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CONCRETE WORKS PREFABRICATION ANALYSIS

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1 ABBREVIATIONS 

NL DS Navigation Locks, Downstream HeadNL MP Navigation Locks, Middle PartNL US Navigation Locks, Upstream HeadPH EP Powerhouse, East pierPH WP Powerhouse, West pierSW EP Sluiceway, East pierSW WP Sluiceway, West pier

2 REFERENCE DOCUMENTS 

General:

(1) 1JN C00 0002-1: Concrete Works, Concrete blocks database

(2) 1JN C00 0003-2: Formwork surfaces analysis

(3) 1JR C03 1101-4: Construction joints, Powerhouse piers, Plan views & sections

(4) 1JR C03 3001-1: Construction joints – Powerhouse, central pier & units 1 to 4 – Plan views & sections

(5) 1JR C04 1001-2: Construction joints, Sluiceway pier axis 16, Plan views & sections

(6) 1JR C04 3001-1: Construction joints, Sluiceway pier axis 1, Plan views & sections

(7) 1JR C05 1001-4: Construction joints, Navigation locks – Downstream head, Plan views & sections

(8) 1JR C05 1002-4: Construction joints, Navigation locks – Upstream head, Plan views & sections(9) 1JR C05 2001-1: Construction joints, Navigation locks – Middle part, Plan views & sections

Concrete works:

(10) 1JR C00 5002-1: Concrete works, precast slabs forming table

(11) 1JR C05 5003-2: Navigation Locks, precast fill-empty channels mould (standard)

(12) 1JR C05 9101-1: Navigation Locks, precast slabs, fill/empty gallery, layout and principles

(13) 1JR C05 9102-1: Navigation Locks, precast slabs, ballast room, layout and principles

(14) 1JR C05 9201-1: Navigation Locks, precast slabs, fill/empty gallery, schedule

Electrical galleries:

(15) 1JD K05 0109-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis F to axis K

(16) 1JD K05 0110-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis K to axis O

(17) 1JD K05 0111-C: Guide drawing, Navigation Locks, plan view level +54.00, from axis O to axis S

Precast stairs:

(18) 1JD K03 0167-A: Preliminary guide drawing, Powerhouse, stair cases, axes 6-7A, 12-13A

(19) 1JD K03 0168-A: Preliminary guide drawing, Powerhouse, stair cases, axes 6-7R, 12-13R

(20) 1JD K03 0171-A: Preliminary guide drawing, Powerhouse, precast stairs, details

(21) 1JD K05 0170-B: Guide drawing, Navigation Locks, stair cases G17, G20

(22) 1JD K05 0171-B: Guide drawing, Navigation Locks, stair cases G18, G19

(23) 1JD K05 0172-B: Guide drawing, Navigation Locks, stair cases O17, O20

(24) 1JD K05 0173-B: Guide drawing, Navigation Locks, precast stairs, details

Planning:

(25) 1JP J00 0003-A: Working programme, revision (A) dated on 15th July 2013 

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3 SCOPE 

This document describes the quantities of workshop prefabricated elements:- Precast slab for:

o  the fill/empty galleries (NL)o  the high rooms, mainly ballast rooms (NL and PH)o  the technical galleries (NL and PH)

- Precast channels (NL)- Precast stairs (NL and PH)

- Public road bridge deck precast slab (not yet defined)- Ibrahimia head regulator precast walls (not yet defined)

for following structures:- Navigation locks (NL-DS / NL-MP / NL-US)- Powerhouse: intermediate pier axis 7 (PH-WP) & intermediate pier axis 12 (PH-EP)- Powerhouse: main structure (PH)- Sluiceway: abutment pier axis 1 (SW-WP) & abutment pier axis 16 (SW-EP)

There are no workshop prefabricated elements in Sluiceway bays and standards piers.

This document doesn’t describe in situ prefabrication which includes:- Sluiceway gantry crane beams- Sluiceway service gallery- Public road bridge deck precast beams

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4 PRECAST SLABS 

4.1 PRECAST SLABS LOCATION 

Precast slabs for the fill/empty galleries (NL-DS):

Precast slabs for the fill/empty galleries (NL-MP):

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Precast slabs for the fill/empty galleries (NL-US):

Precast slabs for the rooms (NL-US):

Precast slabs for the rooms (NL-DS):

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Precast slabs for the rooms (PW):

Precast slabs for the rooms (PW-WP):

Precast slabs for the rooms (PW-EP):

Precast slabs for the rooms (SW-Pier axis 16):

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Precast slabs for the rooms (SW-Pier axis 1):

4.2 PRECAST SLABS CHARACTERISTICS 

Precast slab thickness: 0.07m for the Navigation locks fill/empty galleries top slab0.12m for the Navigation locks and Powerhouse ballast rooms top slab

 Above element: Wall (mainly gallery)Slab (shoring height superior to 5m)

Distribution of precast slab quantities:

Workshop p refabrication elements

Precast slabs Th: 7cm Th: 12cm Total

Navigation Locks

Upstream 552 m²  650 m²  1202 m² 

Downstream 533 m²  305 m²  838 m² 

Middle part 1291 m²  0 m²  1291 m² 

Powerhouse

Intermediate piers 0 m²  1854 m²  1854 m² 

Main structure 0 m²  305 m²  305 m² 

Sluiceway

 Abutment pier axis 0 m²  1967 m²  1967 m² 

Standard piers and bays 0 m²  0 m²  0 m² 

Total 0 m²  5082 m²  7458 m² 

4.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTIONS 

Installation programme request:If first concrete structures start on the 21

th  August 2013 as per working programme, first installation of precast slabs

will be on the middle of December 2013.

Fabrication assumptions:Equipment: 3 prefabrication tables of 36m² (4.90*7.40m) used currently for about half of capacity

Slab areaTable area

 Average ratio table/slab: ~ 0.6Equipment capacity: 325 m² (table) / week

Production assumption: 1 batch of precast elements / table / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~2 weeks between casting and installation in situ)

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Storage assumption:

4.4 FABRICATION STORAGE 

0

1000

2000

3000

4000

5000

6000

7000

8000

   P  r  e  c  a  s   t  s   l  a   b  s  q  u  a  n   t   i   t   i  e  s   (  m   ²   )

Progress (in week)

Sluiceway

Powerhouse

Navigation locks

 

Prefabrication rate: to minimise storage ( )145 m²/week from November 2013 up to July 201430 m²/week from July 2014 up to July 2015

Storage:Storage period: 2 months from November 2013 up to July 2014

6.5 months from July 2014 up to July 2015Needed storage area: 800 m²

If first concrete structures start on the 21th

  August 2013 as per working programme, prefabrication should start middleof November 2013 and first installation of precast slabs will be on the middle of December 2013. 

Precast slabs

Thickness DimensionStorage

superpositionPrecast slab

storedStorage area

Ratio(m²/m²)

7 cm 3×5m 7 elements 105 m² 35 m² 3

12 cm 1.5×6m 6 elements 54 m² 28 m² 1.9

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5 TECHNICAL GALLERIES PRECAST SLABS 

5.1 ELECTRICAL GALLERIES LOCATION 

Two electrical galleries are present in Navigation locks.

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5.2 ELECTRICAL GALLERIES CHARACTERISTICS 

Location: G17-Q17 G20-Q20Level: + 53.45 +53.45Span: 1.35m 1.35mGallery length 215m 17.55m (span: 0.50m) and 173m (span: 1.35m)Gallery height 1.90m 1.90mPrecast slab surface 294m²  245m² 

Total precast slab surface: 539m² 

5.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION 

Installation programme request: at the end of NL concrete works: February 2015

Fabrication assumptions:Equipment: same equipment as precast slabs

3 prefabrication tables of 36m² (4.90*7.40m) used currently for about half of capacity

Slab areaTable area

 Average ratio table/slab: ~ 0.6Equipment capacity: 325 m² (table) / week

Production assumption: 1 batch of precast elements / table / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~ 2 weeks between casting and installation in situ)

Storage assumption:

5.4 F ABRICATION AND STORAGE 

Prefabrication rate: 145 m² / week

Storage:Storage period: 6 weeksNeeded storage area: 200 m² 

Precast slabs

Thickness DimensionStorage

superpositionPrecast slab

storedStorage area

Ratio(m²/m²)

7 cm 3×5m 7 elements 105 m² 35 m² 3

12 cm 1.5×6m 6 elements 54 m² 28 m² 1.9

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6 TECHNICAL GALLERY PRECAST SLAB

6.1 LOCATION 

One technical gallery is present in Power House.

6.2 CHARACTERISTICS 

Location: C8-C9 and C10-C11Precast slab level: + 27.30Span: 1.40mGallery length 22.10m (C8-C9) and 21.2m (C10-C11)Gallery height 1.10mPrecast slab surface 61m² 

6.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION 

Installation programme: at the beginning of PH concrete works: August 2014

Equipment: same equipment as precast slabs3 prefabrication tables of 36m² (4.90*7.40m) used currently for about half of capacity

Slab areaTable area

 Average ratio table/slab: ~ 0.6

Equipment capacity: 325 m² (table) / week

Production assumption: 1 batch of precast elements / table / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~ 2 weeks between casting and installation in situ)

Storage assumption:

6.4 F ABRICATION AND

STORAGE 

Prefabrication rate: 145 m² / week

Storage:Storage period: 2 weeksNeeded storage area: 25 m² 

Precast slabs

Thickness Dimension

Storage

superposition

Precast slab

stored Storage area

Ratio

(m²/m²)7 cm 3×5m 7 elements 105 m² 35 m² 3

12 cm 1.5×6m 6 elements 54 m² 28 m² 1.9

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7 PRECAST CHANNELS 

7.1 PRECAST CHANNELS LOCATION 

The precast channels are located in Navigation locks Middle part.

7.2 PRECAST CHANNELS CHARACTERISTICS  

Quantity of elements: 96 elements with:  80 elements done with standard mould ( )  16 elements done with mould and extension ( )

7.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTIONS 

Installation programme request:Starting of Middle Part casting: 23

th October 2013

Installation period: March / September 2014 (6 months)

Installation period assumption: Installation of pier axis 20 24 units Beginning of MarchInstallation of pier axis 18-19 48 units Beginning of May

Installation of pier axis 17 24 units Middle of July

Fabrication assumptions:Equipment: 1 mould & extensions setProduction assumption: 1 precast channel / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~ 2 weeks between casting and installation in situ)

Storage assumption: 3 elements stored on 3*3m area

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7.4 F ABRICATION AND STORAGE 

0

10

20

30

40

50

60

70

80

90

100

Oct-13 Nov-13 Jan-14 Mar-14 Apr-14 Jun-14 Jul-14 Sep-14 Nov-14

   C   h  a  n  n  e   l  q  u  a  n   t   i   t   i  e  s   (  u  n   i   t   )

Programme of installation

Channels installation

 

Prefabrication:Prefabrication rate: 3 channels / weekPrefabrication period: 32 weeks ~ 7monthsStarting of prefabrication: Mid of November

45 elements have to be produce before the beginning of period installation(14 weeks before)

Storage:Maximum storage period: 6 monthsMaximum precast channels stored: 45 elementsNeeded storage area: 200 m²

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8 PRECAST STAIRS 

8.1 PRECAST STAIRS LOCATION 

Precast stairs (NL-DS, axis O17/O20):

Precast stairs (NL-DS, axis G17/G18/G19/G20):

Precast stairs (PH-EP, axis 12-13R):

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Precast stairs (PH-EP, axis 12-13A):

Precast stairs (PH-WP, axis 6-7R):

Precast stairs (PH-WP, axis 6-7A):

8.2 PRECAST STAIRS CHARACTERISTICS 

Quantities: 34 units with:o  16 units in Navigation Locks

  Precast stair type PCS 9: 2  Precast stair type PCS 10: 4  Precast stair type PCS 10A: 2  Precast stair type PCS 11: 5  Precast stair type PCS 11A: 3

o  18 units in Power house

  First flight of stairs: 2  Precast stair type PCS 7: 4  Precast stair type PCS 7A: 2  Precast stair type PCS 8: 2  Precast stair type PCS 10: 4  Precast stair type PCS 12: 4

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8.3 INSTALLATION PROGRAMME REQUEST AND FABRICATION ASSUMPTION 

Installation programme request:NL precast stairs: October 2013 to March 2014PW precast stairs: November 2013 to December 2015

Fabrication assumptions:Equipment: 1 mould & extensions set

Production assumption: 1 precast channel / 18h (curing)Lifting assumption: f cj ≥ 12 MPA minimum for the precast slab liftingInstallation assumption: f cj ≥ 90% f c28 (~ 2 weeks between casting and installation in situ) 

Storage assumption: 3 elements stored on 3*3m area

8.4 F ABRICATION AND STORAGE 

Fabrication:Prefabrication rate: 1 precast stairs a weekPrefabrication period: 34 weeks ~ 7.5 months

Storage:Maximum storage period: 15 monthsMaximum precast stairs stored: 16 unitsNeeded storage area: 150 m²

0

5

10

15

20

25

30

35

40

   P  r  e  c  a  s   t  s   t  a   i  r  s   (  u  n   i   t   )

Programme of installation

Precast stairs installation

 

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9 CONCLUSION 

Precast slabs

Prefabrication 145 & 30 m²/week

Storage (×) peak : 800m²

Ins tallation in s itu continuous

Electrical galleries (NL)

Prefabrication 145 m²/week

Storage (×) peak : 100m² ×

Ins tallation in s itu continuousTechnical gallery (PW)

Prefabrication 145 m²/week

Storage (×) peak : 100m² ×

Ins tallation in s itu continuous

Channels

Prefabrication 3 channels /week

Storage (×) peak : 100m² ×

Insta llation in s itu d iscontinuous

Precast stairs

Prefabrication 3 stairs/week

Storage (×) peak : 150m²

Insta llation in s itu d iscontinuous

×

×

2013

9

2014

9 10 11 12 4321 10 10 11 12

2015

6 7 81 2 3 4 51211Prefabrication programme

98765

 

Recommendations:- Storage area peak: 1000m² (January to April 2014)

- To be considered: Mould fabricationPrecast slabs design (done by JV)Precast stairs design (done by designer)Concrete formula ad hoc which authorizes 12 MPA for theprecast lifting