FINAL EXAM

CE501 / CE51FB1 - Plant Visits and Seminars

SANTOS, JEFFRY L. October 10, 2016

1320055 Engr. Vibas

MEGAWIDE Pre-Cast Taytay Factory

DESCRIPTION

One of the assets of Megawide is its use of the Precast Construction System. This

provides easy standardization, faster construction, cost effectiveness, high quality finish and

enhanced faade design. Already among the largest and most advanced in Asia, with its top-of-

the-line features, our precast facility underwent an expansion to further facilitate production. A

second factory was constructed in late 2013 to accommodate the demands of a continuously

increasing workload. This factory is now fully operational.

As Megawide continues to expand, the precast system is its means to respond to an ever-growing

list of projects and developments. The aim is to diversify the companys project portfolio and to

consistently deliver quality engineering and construction solutions to Megawides varied

clientele.

ABOUT MEGAWIDE

Megawide is located at Barangay. Sanchon Taytay Rizal in which they started the

operation in September 2012. Megawide pre-cast factory has a production capacity of 72,000

cu.meter per year in which they could produce with a total of 6,000 cu.meter per month.

Megawide is known as the 2nd Largest Factory of Pre-cast in Asia in which it consists of Pre-cast

system and Sea based transport system. Below is their list of assets in Megawide Pre-cast

factory:

The Megawide has a total land area of 100,000 sq. meter which consists of the following:

Production area = 15,000 sq. meter

Pre-cast stock area = 17,000 sq.meter
Production Capacity and Facility
o Carousel Line = 80,000 sq. meter/month (two cycle/day)
o Battery Line = 15,600 sq.meter/month (two cycle/day) 18 cells
o Conventional Line = 8,300 sq.meter/month (two cycle/day)
 Flat Bed 20 beds
Tilting Table 3 beds
Batching Plant (FULLY AUTOMATED)
o Concrete Mixer (Pan Type) = 1.5 cu.meter x 2 sets (7m cu.meters/hour)
o Cement Silo = 20 tons x 4 silo
o Aggregate Silo = 1,000 sq.m with 10 bins
o Common Cement = 4 silos
o Fly Ash Cement = 1 silo
Office = 500 sq.m
Main Facility = 15,000 sq.m
2nd Facility = 1,600 sq.m
Warehouse = 1,580 sq.m
Stockyard = 32,400 sq.m
Laboratory = 50 sq.m
o for the laboratory, it consists of material testing section wherein this section is for

gathering of datas regarding about the products they just produced for its

durability and constructability. Most datas are for the concrete mix formulas and

its produced tensile strength.

o Compressive Testing Section this is where the compression test, flexure and

tensile stress testing takes place. Materials are tested after it was cured for 7, 14

and 21 days.
o Curing room consist of areas where the produced pre-cast and concrete mix

experiment is stored. Usually the concrete cylinder is cured in the pool for future

references and to avoid other variables of errors during the experiment and

testing. It is also airconditioned due to the temperature in which it should not be

lower or higher depending on its standards.

Load Base Transport This is where the pre-cast panels and materials are inserted to

the delivery machines such as trucks.

o Inloader Can carry 25 tons of pre-cast panels and has 6 sets
o Flat liner can also carry 25 tons of pre-cast panels and materials
o Mega Dumptruck a truck in which it is used to transfer the pre-cast to one place

to another. Known also as megatron due to its huge size and also could carry

almost 40 tons which has 4 sets.

o Low bed a place where pre-cast are held in which could carry 40 tons with 2

sets.

WHAT IS PRE-CAST?

Precast concrete is a construction product produced by casting concrete in a

reusable mold or "form" which is then cured in a controlled environment, transported to the
construction site and lifted into place. In contrast, standard concrete is poured into site-specific

forms and cured on site. Precast stone is distinguished from precast concrete by using a

fine aggregate in the mixture, so the final product approaches the appearance of naturally

occurring rock or stone.

PRE-CAST PRODUCTS PRODUCED BY MEGAWIDE PRE-CAST FACTORY

Exterior wall products

o Plain Flat
o Plain Flat with opening
o Plain Flat with ledge
o Complex walls
Interior wall products
o Plain flat
o Plain flat with openings
Half-Slab products
o Half slab
o Void slab
o Half slab with butterfly connection
o Light weight slab (with styro and topping)
Stairs products
o Without steel nosing
o With steel nosing
o Half landing
o Stair landing
Beam products
o U-beam
o Half-beam
Toilet products
o Type 1
o Type 2
o Type 3
Columns
o Warehouse column system
o Column with Corbel
o Column with fence
Other products
o Balconies
o Ledges
o Wheel stopper
o Curbs and Gutters
o Light weight concrete with styro and toppings

PRODUCTION OF PRE-CAST PANELS

 Cleaning

Mesh Welding
Machine

Concrete
Distribution

Concrete
Compaction

Surface Finishing

Curing Chamber

Shuttering/Demoul
ding

1) Cleaning This is where the first process starts for creating a pre-cast panels. The first

part is AutoCAD detailing. Using the I-laxx program, the computer itself automatically

plots the points and lines for the pre-cast lay-out and the information are passed thru the

robotic machine for creation. Then after which, assembly is the next process the machine

will do.
2) Mesh Welding Machine in this part, the robotic machine will automatically weld the

rebars for pre-cast reinforcements.

3) Concrete Distribution After the machine welded all the required points to be weld, the

next process will be concrete distribution. Using the formworks created by the machine in

the bed, the concrete will be poured according only to the plan.
4) Concrete Compaction since concrete has properties wherein voids cannot be removed,

the concrete compaction machine will do the job for compacting the concrete poured in

the pre-cast panels for it to have the most economical and governed quality products.
5) Surface Finishing after the compaction takes place, the machine will use skin coating

to produce a good quality and smooth surface concrete panels and materials
6) Curing Chamber A place where produced pre-cast materials are stored to maintain the

compressive and tensile stress. In addition, it is also used to avoid cracking of cement due

to temperature changes.
 7) Shuttering/Demoulding in this process, excess lines of concrete were produced.

Serujo is needed for it to produce a good quality with exact measurements of pre-cast

panels. Demoulding is to remove the excess concrete present in the pre-cast panels.

PROBLEMS ENCOUNTERED

According to the logistics head, the common problems that they encountered is the errors

of the laborers. Errors caused by the laborers are due to mishandling of pre-cast products

especially for the sensitive thin part of concrete pre-cast panels. Due to mishandling, crackings

and accidental detaching of concrete takes place. Therefore, the pre-cast panels that were

damaged were returned and the cost of production is affected due to these human errors

especially for the laborers.

SOLUTIONS

The solution of this matter based from the logistics head is the discipline of the laborers.

During the attachment of pre-cast panels, overseer or what we call supervision is advised in order

to eliminate accidents and mishandling of the pre-cast materials and panels.

ADVANTAGES OF PRE-CAST CONSTRUCTION

The advantages of pre-cast panels are to diminish the constructability or the duration of

building structure. Since the said panels were already made and ready to attach, it could lessen

the labor cost of the project in which it will require only a minimum of 3 laborers to attach the

pre-cast material compared to the conventional way of building walls in which it could take

roughly 3 days minimum to be finished in the construction site. Labor cost are almost eliminated

in the production.

DISADVANTAGES OF PRE-CAST CONSTRUCTION

The disadvantages of these pre-cast construction is that the production cost of each panel

compared to the conventional way is expensive wherein it requires automated machines to be

finished.