Smart-Book SOP

SOP: Beam & Slab Construction (Site Execution)

A practical site workflow for GC teams: Formwork → Rebar → Inspection → Casting → Curing.

Purpose

Ensure safety, quality, and correct sequence for RC beam & slab works on site.

Scope

Formwork, rebar fixing, inspection, concrete casting, curing, stripping, QA & safety.

Responsible

Site Engineer • Foreman • Rebar Team • Formwork Team • Concrete Team • QA/QC • Structural Engineer (approval).

Easy Rule

Drawings → Formwork → Beam Rebar → Slab Rebar → Inspection → Concrete → Curing

1

Pre-Construction Preparation

Confirm drawings, materials, and site readiness before any formwork starts.

1.1 Drawing & Design Check

• Review structural drawings: beam sizes, slab thickness, rebar details, bar marks.
• Confirm span & support type (simply supported / continuous / cantilever).
• Verify concrete grade & steel grade per spec.
• Confirm standard/code used (ACI / BS / local project spec).

1.2 Material Check

• Rebar diameter, grade, and delivery certificates (if required).
• Formwork: plywood/steel panels, props, bracing, clamps.
• Concrete supply: mix design, slump requirement, truck access.
• Accessories: chairs, spacers, cover blocks, tie wire.

Site Tip: Prepare a “pour day plan” (truck route, pump location, vibrator quantity, manpower).

2

Setting Out & Level Control

Mark beam lines, slab boundaries, and control levels accurately.

• Mark beam centerlines and slab edges from grid/architectural reference.
• Check beam width & depth against drawings.
• Set slab top level (reference: ±0.00) and check tolerance.
• Confirm openings (stairs, ducts, sleeves) are located correctly.

QC Point: Fix any level error now—later it becomes expensive (finish thickness, drainage slope, etc.).

3

Formwork Installation

Install beam formwork first, then slab formwork with safe shoring.

3.1 Beam Formwork

• Install beam soffit (bottom) first, then sides.
• Ensure tight joints to prevent grout leakage.
• Provide strong bracing and correct beam dimensions.

3.2 Slab Formwork

• Install props/scaffolding, then main runners and secondary joists.
• Fix slab plywood; verify alignment and cleanliness.
• Apply release agent properly (not excessive).

Safety: Props must be on stable base + properly braced. No “loose” shoring allowed.

4

Rebar Installation (Beam → Slab)

Fix reinforcement in correct sequence with correct cover and anchorage.

4.1 Beam Reinforcement

• Install bottom main bars.
• Install stirrups (spacing as drawing) with proper hooks.
• Install top bars (negative moment bars) and extra bars at supports.
• Provide lap splice or couplers per design.

4.2 Slab Reinforcement

• Fix slab bottom mesh/bars.
• Add top mesh/bars (if required) and extra bars over beams/supports.
• Reinforce around openings (edge trimming bars) as per drawing.

Element	Typical Concrete Cover (site guidance)
Beam bottom & sides	25–40 mm (confirm with drawing/spec)
Slab bottom	20–25 mm (confirm with drawing/spec)
Roof slab top	30–40 mm (confirm with drawing/spec)

Important: Use chairs/spacers. Do not use broken bricks or stones as cover blocks.

5

Inspection Before Casting (Hold Point)

Engineer/QA approval required before any concrete pour.

5.1 Pre-Pour Checklist

• Formwork: alignment, dimensions, tight joints, stable bracing.
• Rebar: size, spacing, stirrup spacing, lap length/couplers.
• Concrete cover: spacers and chairs installed and correct.
• Openings/embeds: sleeves, conduits, anchor bolts in place.
• Cleanliness: remove debris, standing water, loose tie wire.

Site Rule: No pour without sign-off. Fix issues now, not after casting.

6

Concrete Casting (Beam + Slab)

Pour in the right order and compact properly to avoid honeycombing and cold joints.

6.1 Pouring Sequence

1. Start with beams (fill and vibrate).
2. Continue to slab; keep pour continuous.
3. Plan pour zones to avoid cold joints.

6.2 Compaction (Vibrator)

• Use mechanical vibrator with proper insertion spacing.
• Avoid over-vibration (segregation) and avoid hitting rebar/formwork aggressively.
• Vibrate beams carefully at congested zones (stirrups + bars).

6.3 Finishing

• Level slab to reference marks.
• Provide roof slope if required (drainage).
• Protect edges and openings immediately.

QC Point: Record slump, truck time, and cube/cylinder samples per project spec.

7

Curing

Start curing early to control cracking and gain strength.

• Start curing within 12 hours (earlier if hot/windy).
• Methods: water curing, wet burlap, plastic sheet, curing compound (if approved).
• Minimum curing:
  • Normal concrete: 7 days
  • High importance / hot weather: 10–14 days

Hot Weather Tip: Cure more frequently to reduce shrinkage cracks.

8

Formwork Removal (Stripping)

Remove formwork only when concrete strength is adequate and approved.

Element	Typical Minimum Time (Guidance)
Beam sides	24–48 hours
Slab soffit (props remain)	3–7 days
Beam soffit	14–21 days

Note: Actual stripping depends on concrete strength results + engineer approval.

9

Quality & Safety Control

Final checks, repairs, documentation, and safe site rules.

9.1 Quality

• Inspect honeycombing and repair immediately (as per method statement).
• Check cracks, deflection, and slab level.
• Record cube/cylinder results; keep pour log.

9.2 Safety

• PPE mandatory (helmet, safety shoes, gloves, eye protection).
• Edge protection on slab perimeter and openings.
• No overload on fresh slab (material stacking control).

Site Habit: Daily toolbox talk during beam/slab works (risk: falling, collapse, electrical, vibration).

Quick Copy: Site Sequence

Drawings → Formwork → Beam Rebar → Slab Rebar → Inspection → Concrete → Curing

Optional add-ons: printable pre-pour checklist, photo slots for your project, and a daily QC log template.

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