🧱 SOP • Reinforced Concrete
SOP for Beam & Slab (Site Construction)
A practical on-site workflow for RC beams and RC slabs: setting out → formwork → rebar → inspection → concrete pouring → curing → stripping → QA/QC.
For GC / Site Engineer
Blogger-ready
Checklists + Sign-off
Photos included
1) Scope & Standards
Scope: This SOP covers site construction works for reinforced concrete beams and slabs (typical residential / small commercial).
- Setting out & levels
- Formwork & shoring/props
- Rebar fabrication & fixing (beam + slab)
- MEP sleeves, inserts, openings
- Pre-pour inspection & approvals
- Concrete placement, vibration & finishing
- Curing, stripping formwork & repairs
- QA/QC documentation
Use project drawings, bar bending schedule (BBS), method statement, and local code/spec. If there is any conflict, follow the Engineer/Designer’s instruction.
2) Roles & Responsibilities
| Role | Main Responsibilities |
|---|---|
| Site Engineer / Supervisor | Check drawings, set out lines/levels, approve formwork/rebar, control pour sequence, keep QA records. |
| Foreman | Daily coordination, manpower, ensure checklists followed, request inspections before pour. |
| Formwork Team | Install formwork, shoring, bracing, ensure alignment, tight joints, safe access. |
| Steel Fixers | Cut/bend/tie steel, install stirrups, main bars, laps, chairs/spacers, maintain cover. |
| QA/QC (if available) | Inspection reports, slump/cube tests, NCR tracking, photo records. |
| Safety Officer | PPE, work-at-height controls, lifting plan, housekeeping, exclusion zones. |
3) Tools, Materials & Equipment
Survey / Setting Out
- Auto level or laser level, measuring tape, chalk line, marker paint
- Plumb bob / spirit level, straight edge
Formwork & Access
- Plywood/form panels, timber/steel joists, props/scaffolding, clamps, wedges
- Release agent, nails/screws, drills, saws
- Platforms, ladders, guardrails, toe boards
Rebar Works
- Rebar cutter, bender, tie wire, pliers
- Chairs/spacers/cover blocks, binding wire, rebar caps (safety)
Concrete Works
- Concrete pump (or buckets), vibrator (needle), screed/straight edge
- Trowels, floats, curing compound OR plastic sheet + water
- Slump cone set & cube molds (if testing)
4) Step-by-Step Procedure (Beam + Slab) — site sequence ▾
Step 1 — Review drawings & prepare
- Confirm: beam sizes, slab thickness, bar sizes, spacing, cover, laps, openings, drops, cantilever zones.
- Confirm concrete grade, pour volume, access, pump location, working hours, manpower.
- Prepare inspection forms and photo points.
Step 2 — Setting out (lines & levels)
- Mark beam centerlines, slab edges, openings, and control grids.
- Set reference level (benchmark) for slab top level and beam soffit.
- Check diagonals for squareness.
Tip: Keep one fixed benchmark point for the entire project (don’t change it).
Step 3 — Install formwork & shoring/props
- Beam soffit + side forms: align, plumb, and tighten joints (no leakage).
- Slab formwork: install joists, plywood/panels, and props with proper bracing.
- Install edge form, drop panels, slab openings, and pour strips if needed.
- Apply release agent (thin, even coat).
Critical: Props must sit on stable base plates and be braced to prevent buckling.
Step 4 — Beam reinforcement fixing
- Fix stirrups first, then main bars (bottom + top), add extra bars at supports/cantilevers per drawing.
- Maintain bar spacing using separators; keep bars clean (no thick mud/oil).
- Ensure lap length / anchorage length follows drawings/spec.
- Use cover blocks/spacers to maintain cover at soffit and sides.
Common mistake: Stirrup spacing becomes wider near the support. Always follow the drawing spacing zones.
Step 5 — Slab reinforcement fixing
- Place bottom mesh/bars → then chairs → then top bars (if two layers).
- Keep correct overlap (lap) and tie properly so steel doesn’t move during pouring.
- Provide extra top bars over beams and around openings (negative moment zones).
- Install cover blocks/chairs to maintain cover and prevent steel touching formwork.
Rule: No “floating steel”. If workers step on steel, it must stay at correct level using chairs.
Step 6 — Embedments, sleeves & openings (MEP)
- Install electrical conduits, sleeves, plumbing pipes, floor drains, and embedded plates.
- Secure everything firmly to avoid movement during vibration.
- Confirm opening sizes + positions; add trimming bars around openings if required.
Step 7 — Pre-pour inspection & approval
- Inspect formwork (alignment, tightness, support/bracing, cleanliness).
- Inspect rebar (size, count, spacing, cover, lap length, hooks, stirrups).
- Inspect embedments and openings.
- Get approval/sign-off before pouring.
Step 8 — Concrete placement & vibration
- Check slump (if required) and record delivery ticket/time.
- Pour beams first (or per pour plan), then slab. Avoid segregation (don’t drop too high).
- Vibrate in layers; do not over-vibrate; keep vibrator vertical and move systematically.
- Maintain cold-joint control: continuous pour where possible.
Good practice: Assign one person to vibration only (focus job).
Step 9 — Leveling & finishing
- Control slab level using level markers/screed guides.
- Screed → float → trowel (as specified). Keep slope for drainage where needed.
- Finish edges and around openings carefully.
Step 10 — Curing
- Start curing as soon as finishing allows (do not wait too long).
- Method options: water curing + wet covering, plastic sheet, or curing compound.
- Protect slab from sun/wind/rain and early loading.
Minimum: Keep concrete moist and protected during early-age strength gain (follow your project spec).
Step 11 — Formwork stripping (remove)
- Remove side forms first (after concrete is stable), then soffit props later per engineer/spec.
- Do not remove props early. Keep back-propping if required.
- Inspect surfaces: honeycomb, voids, cracks, misalignment.
Step 12 — Repairs & handover
- Repair honeycombs/voids with approved method (chip loose concrete, clean, repair mortar/grout).
- Record cube test results (if any), slump records, pour photos, approvals.
- Handover to next trade only after curing/protection plan is in place.
5) Inspection Checklists (Beam + Slab) — tick before pour ▾
✅ Beam Checklist (Pre-Pour)
✅ Slab Checklist (Pre-Pour)
After ticking, the site engineer/supervisor signs the Sign-Off Form.
6) QA/QC + Common Defects — how to prevent ▾
| Issue | Main Cause | Prevention |
|---|---|---|
| Honeycomb / voids | Poor vibration, congested steel, leaking formwork | Proper vibration pattern; tighter formwork joints; smaller aggregate if spec allows; re-check steel congestion zones |
| Cracks (plastic shrinkage) | Hot sun/wind; delayed curing | Start curing early; use wind breaks; keep surface moist; avoid finishing water on top |
| Slab out of level | No level control points; rushed screed | Set level markers; assign leveling crew; check with laser regularly |
| Exposed rebar | Insufficient cover; bars moved during pour | Use correct spacers/chairs; re-tie steel; protect cover blocks |
| Cold joint | Pour interruption; slow supply | Plan concrete supply; pour continuously; follow joint treatment method if unavoidable |
Documentation to keep: pour date/time, concrete grade, delivery tickets, slump & cube results (if any), inspection checklist, and photo log.
7) Safety Rules (Critical) — non-negotiable ▾
- PPE: helmet, safety shoes, gloves, eye protection. Use harness for work at height when required.
- Work at height: guardrails + toe boards, safe access ladders, no jumping over beams.
- Rebar impalement protection: use rebar caps and keep housekeeping clean.
- Formwork safety: never remove props without approval; keep exclusion zone under slab during stripping.
- Electric safety: safe cables, waterproof connections, vibrator with proper earthing.
- Concrete pouring zone: keep pump hose controlled; one signalman; no standing under suspended loads.
Stop work if: formwork movement, prop settlement, abnormal cracking sounds, or unsafe access is observed.
8) Photo Section (Included in Post)
These images are embedded for reference and training. Each caption includes a source link (for attribution).
9) Site Sign-Off Form (Copy & Use)
Fill this before pouring. You can copy this section to your daily report.
| Project | ________________________ |
|---|---|
| Location / Block | ________________________ |
| Element | ☐ Beam ☐ Slab ☐ Beam + Slab |
| Concrete Grade | ________________________ |
| Pour Date / Time | ________________________ |
| Inspected Items | ☐ Formwork ☐ Rebar ☐ Cover ☐ Embedments ☐ Openings ☐ Access/Safety |
| Remarks / NCR | ________________________ |
| Approved by (Engineer/Supervisor) | ________________________ |
| Foreman | ________________________ |
| QA/QC (if any) | ________________________ |
Tags:
RC _ Site SOP