Precast Yard Execution Engineer

1. Drawing Study & Technical Review

• Study and understand structural, architectural, precast shop drawings, reinforcement drawings, and approved construction drawings.
• Review drawings for dimensions, levels, reinforcement details, connections, openings, inserts, embedded items, lifting points, and finishes.
• Identify discrepancies or conflicts between architectural, structural, MEP, and precast drawings and raise them with the concerned design/project team for resolution.
• Ensure that only the latest approved drawings and revisions are being used for production.
• Prepare sketches and mark-ups wherever required for execution and production clarification.
• Maintain proper control of drawing revisions at the precast yard.
• AutoCAD proficiency is mandatory for reviewing drawings, checking dimensions, preparing details, and making necessary production-related mark-ups.

2. Quantity Take-Off & Material Planning

• Carry out detailed quantity take-offs from approved drawings for precast elements.
• Calculate quantities of concrete, reinforcement steel, structural steel, inserts, embedded items, lifting accessories, connection materials, grouting materials, and other consumables.
• Prepare element-wise and production-wise material requirements.
• Prepare Material Requisitions (MRs) sufficiently in advance to support the production schedule.
• Coordinate with stores and procurement teams to monitor availability of critical materials.
• Monitor material consumption and minimize avoidable wastage.
• Reconcile major material quantities against approved drawings and actual production.

3. Precast Production Planning

• Prepare daily and weekly production requirements in coordination with the Project Manager, Yard Manager, planning team, and erection/site team.
• Plan production sequences based on site erection priorities and availability of drawings, moulds, materials, reinforcement, inserts, and other resources.
• Coordinate mould utilization to achieve efficient production cycles.
• Ensure all technical information required for production is available before commencement of casting.
• Monitor production progress against the planned schedule.
• Identify constraints affecting precast production and escalate them for timely resolution.

4. Mould & Shuttering Inspection

• Check mould dimensions, line, level, squareness, alignment, and geometry before reinforcement placement and casting.
• Ensure moulds are adequately supported and suitable for the required precast element.
• Verify chamfers, grooves, rebates, block-outs, openings, sleeves, and other architectural/structural features against approved drawings.
• Ensure mould surfaces are properly cleaned and prepared prior to casting.
• Coordinate any necessary mould modifications required due to approved drawing changes.

5. Reinforcement & Pre-Pour Inspection

• Check reinforcement against approved bar bending schedules and reinforcement drawings.
• Verify bar diameter, spacing, quantity, lap length, anchorage, cover, chairs, spacers, and reinforcement positioning.
• Verify placement and fixing of inserts, sleeves, conduits, anchor plates, embedded plates, lifting anchors, dowels, and connection components.
• Ensure all embedded items are securely fixed so that their positions are maintained during concreting.
• Carry out pre-pour inspection jointly with QA/QC personnel where required.
• Ensure identified observations are closed before giving clearance for casting.

6. Concreting & Casting Supervision

• Supervise concrete placement for precast elements in accordance with approved requirements.
• Ensure correct concrete grade/mix is used for the designated element.
• Monitor placement and compaction to avoid segregation, honeycombing, voids, and other workmanship defects.
• Coordinate required concrete quality testing with the QA/QC and laboratory teams.
• Ensure exposed surfaces and finishes meet the specified requirements.
• Ensure proper identification of each precast element after casting for traceability.

7. Curing & Demoulding

• Ensure proper curing arrangements are implemented for precast elements.
• Monitor elements prior to demoulding and ensure demoulding is undertaken only after specified requirements are met.
• Supervise safe demoulding to prevent damage to edges, corners, inserts, lifting points, and finished surfaces.
• Arrange inspection of elements after demoulding.
• Record and coordinate rectification of any defects observed after demoulding.

8. Quality Assurance & Quality Control

• Ensure precast works comply with approved drawings, project specifications, approved procedures, inspection requirements, and applicable quality requirements.
• Coordinate inspections with QA/QC engineers and other designated inspection authorities.
• Monitor dimensional tolerances, surface finish, alignment, inserts, openings, connections, and overall workmanship.
• Maintain element-wise traceability and relevant inspection/production records.
• Initiate or coordinate corrective actions for non-conforming work.
• Ensure repairs, where approved, are carried out using the specified repair methodology.

9. Lifting, Handling & Storage

• Ensure precast elements are lifted only from the designated/approved lifting points.
• Coordinate with the safety and lifting teams before handling heavy or critical precast components.
• Ensure appropriate lifting accessories and arrangements are used based on approved lifting requirements.
• Supervise safe transportation of elements within the precast yard.
• Plan proper stacking and storage locations to avoid damage, instability, distortion, or obstruction.
• Ensure suitable supports/dunnage are provided during stacking and storage.
• Maintain clear identification of precast elements in the storage yard for easy retrieval and dispatch.

10. Dispatch & Erection Readiness

• Coordinate with the site/erection team to understand the required sequence of precast elements.
• Ensure elements are inspected and cleared before dispatch.
• Verify element identification, dimensions, embedded items, connection details, and finish before dispatch.
• Prepare or coordinate dispatch priorities according to the erection sequence.
• Ensure loading arrangements minimize the risk of damage during transportation.
• Coordinate technical clarifications with the erection team whenever required.

11. Safety Responsibilities

• Ensure all precast yard activities are executed in accordance with approved HSE requirements and safe working practices.
• Conduct or participate in toolbox talks and pre-activity safety discussions as applicable.
• Ensure workers use the required PPE.
• Closely monitor high-risk activities such as lifting, shifting, loading, demoulding, working at height, and handling heavy precast elements.
• Coordinate with the Safety Engineer before critical lifting and handling operations.
• Stop unsafe work where there is an immediate risk and ensure necessary corrective measures are taken through the applicable site process.
• Promote good housekeeping and safe access throughout production and storage areas.

12. Coordination

• Coordinate with design, planning, QA/QC, safety, procurement, stores, batching plant, laboratory, lifting, logistics, and site erection teams.
• Attend daily/weekly production and coordination meetings as required.
• Communicate drawing changes and technical instructions to supervisors and production personnel.
• Resolve day-to-day execution issues affecting production while escalating matters requiring design or management approval.
• Coordinate material availability with production priorities to minimize interruptions.

13. Documentation & Reporting

• Maintain daily records of precast production activities.
• Prepare Daily Progress Reports (DPR) and production status reports as required.
• Maintain element-wise production and dispatch status.
• Maintain records of quantities produced, rejected, repaired, dispatched, and pending, as applicable to the project's reporting system.
• Maintain drawing registers and revision records.
• Maintain relevant inspection requests, checklists, test reports, and production documentation.
• Support preparation of look-ahead plans and material consumption/reconciliation statements.

14. Resource & Productivity Control

• Coordinate manpower, moulds, equipment, and materials according to planned production.
• Monitor productivity of reinforcement, shuttering/mould, casting, finishing, and handling activities.
• Identify causes of production delays and coordinate corrective measures.
• Optimize utilization of moulds and yard space.
• Minimize rework, material wastage, handling damage, and production losses.

Required Technical Competencies

The Precast Civil Engineer should have:

• AutoCAD knowledge: Mandatory
• Strong ability to read structural, architectural, reinforcement, and precast drawings.
• Good knowledge of quantity take-off and material estimation.
• Understanding of reinforcement detailing and bar bending schedules.
• Understanding of precast moulds, casting, curing, demoulding, handling, storage, and dispatch.
• Working knowledge of concrete and reinforcement quality requirements.
• Understanding of precast inserts, embedded items, lifting anchors, and connection details.
• Ability to prepare material requisitions and production-related documentation.
• Good coordination and site execution skills.
• Strong awareness of quality and HSE requirements, particularly for precast lifting and handling operations.