TATA PROJECTS LIMITED

METHOD STATEMENT FOR STACKING, PRE-ASSEMBLY, ERECTION & INSPECTION. OF STRUCTURAL WORK.

PREPARED BY : P.K.Mandhata

APPROVED BY : Mr.K.K.Rao( Sr.Project Dir.)

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CONTENTS

1.

INTRODUCTION 1.1 OBJECTIVE 1.2 SCOPE

2.

WORK CONDITION 2.1 WORK ENVIRONMENT 2.2 ESTIMATED QUANTITY 2.3 SCHEDULE 2.4 SPECIAL TOOLS/ INSTRUMENTS

2.5 MANPOWER / EQUIPMENT

3.

WORK METHODOLOGY 3.1 CONSTRUCTION PROCESS FLOW CHART 3.2 PROCESS METHODOLOGY

4.

QUALITY REQUIREMENTS

5.

SAFETY ANALYSIS

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1. 1.1

INTRODUCTION Objective: The purpose of this work procedure is to detail for the Erection of Structure, that shall be followed during the execution of the project.

1.2

Scope: The procedure covers all activities related to Erection of Structure that shall be carried out while the execution of the project.

2. 2.1

WORK CONDITION: Work Environment: To under stand the scope of work and decide in how many lifts the main columns are to be positioned. This will give us a fair under standing of the total height that is to be achieved while erecting the structure. 2.2 Estimated Quantity: 2.2.1. Steel structure consisting of Main Columns, Beams & Bracings, monorails, stairs, gratings, hand rails etc from +El 0 mtrs to + El _______ mtrs (top of the structure), consisting of approx. __________ MT. 2.3 Schedule: A tentative work execution schedule (L 2 schedule) needs to be prepared which shall give us the insight of the work involved. 2.4 Special Tools / Instruments: 2.4.1 . 2.4.2. 2.4.3. 2.4.4. Theodolite Torque Wrench Water level Plumb 1No. (for alignment & checking of verticality of structure) 1No. 1 No. 1 No.

2.5

Manpower & Equipment: Manpower Utilization: 2.5.1.1. Erection Engineer In-charge 2.5.1.2 Erection supervisor 2.5.1.3. Erection Foreman 2.5.1.4. Structural Fitter 2.5.1.5. Rigger 2.5.1.6. Khalasi 2.5.1.7. Welder 2.5.1.8. Helper 2.5.1.9. Gas cutter -1 - Depending on the scope of work. - Depending on the scope of work. -

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2.5.1 Equipment Utilization: 2.5.2.1. Crane to suit site requirements 2.5.2.2. Hydra Crane 2.5.2.3. Trailers 2.5.2.4. Welding M/c and other Tools & tackles __ Nos. __ Nos. __ Nos __ Nos.

3.

WORK METHODOLOGY:

3.1 Construction Process Flow Chart:

Handing over of Foundation./Check Levels, & foundation bolt position (correction if Packing plate level Calculation & arrangement Base plate level and diagonal checking

Transportation of column and fitment of temporary ladder.

Preparation of columns Centerline -marking Buffing Selection of -Bolts Rectification of Damage if any. Check camber, Sag & etc.

Positioning of crane and making lifting arrangements.

Prepare the Tempary arrangement for changing the sling after erection. Arrg. of Temp. Platforms where ever reqd.

Sign. of Method Statement by RCM, Erection Engineer & Safety Officer

YES

NO

Further Process

Lifting the columns as per drawings

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3.2 Process Methodology: 3.2.1. General Procedure 3.2.1.1. Erection of structures such as column, beams, ladders, grating and handrail shall be as per approved drawing. 3.2.1.2. Checking the verticality of column and center to center distance between the columns. 3.2.1.3 QA & QC shall ensure the acceptance and prepare necessary protocols for record purpose. Tightening of base plate bolt and release for grouting as per specification Structures required to be fitted in position shall be bolted / welded properly.

3.2.1.4. 3.2.1.5.

3.2.1.6. Temporary Erection loads or permanent loads shall not be placed on any incomplete portions of the structures being erected. 3.2.1.7. Temporary arrangements like providing jallis etc on the columns to facilitate guiding and positioning of the structures and for removing of the slings.

3.2.1.8. All erection activity shall be as per schedule. To maintain this, sequential material feeding to be ensured. 3.2.2. Foundation checking 3.2.2.1 All the structural erection activities shall be carried out after the approval / clearance of the foundations by the customer representatives.

3.2.1.2. Ensure the bench marking is transferred to the foundation. 3.2.2.3. The civil foundations for the structural shall be checked for any defects. If there is any defect the same shall be repaired before the erection of the structural into the foundation. The top of the concrete level shall be recorded. 3.2.2.4. The size of the bolts, no of nuts, height of the bolt and diagonal across the bolt holes shall be checked and shall be recorded ( Documentation through Protocol). 3.2.2.5. The dimension between consecutive foundations shall be checked and recorded including the diagonal across of footings as per Foundation plan. 3.2.2.6. The condition of the foundation bolt shall be checked before the commencement of the erection.

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3.2.3. Preparation for lifting 3.2.3.1 Crane of suitable capacity along with all the necessary accessories shall be employed for the erection purpose. It shall be ensured that the crane used shall be in possession of all the safety requirements as emphasized. 3.2.3.2 To ensure having the valid crane load test certificate at site. The location of crane and trailer positioning shall be clearly marked, prior to receiving the structural material at site. 3.2.3.3 3.2.3.4 The lifting zones to be clearly identified in the rigging plan. Latest revision drawing for the structure that is to be erected shall be made available at site for ready references. The tools and tackles will be checked for the availability of the required quantity as per checklist. The valid test certificates for the rigging equipments, tools and tackles shall be ensured for the lifting requirements. It shall be ensured that the necessary permits from Safety Engineer, Customer and Consultant for erection are obtained prior to the commencement of the works.

3.2.3.5

3.2.3.6

3.2.3.7

3.2.3.8. Ensure the back filling is done and the area is workable as well as approachable for working. 3.2.4. Erection of the Steel Structure 3.2.4.1 All the transporting/maneuvering/lifting operation shall be carried out under the sole control of the designated TPL Execution Engineer / Foreman assisted by qualified crew of the erection contractor. Vertical columns shall be lowered on to the respective foundations, and the same shall be aligned and in next level the vertical columns should anchored with guy rope. Horizontal beams shall be erected in a single piece to an extent as much as possible. The beams shall be leveled and the top of structure elevation shall be checked and recorded.

3.2.4.2

3.2.4.3

3.2.4.4 Ensure horizontal bracings are erected to make frame in each level before next level of vertical column erection. 3.2.4.5 After the positioning of all the structural elements, including vertical and horizontal bracings, the final connection shall be carried out by Bolting / welding. If any alterations are to be carried out, then prior approval to be sought from the Customer / Consultant before taking up the work. After the final positioning, bolting and welding (if required) is completed, the Structure shall be offered for Inspection to TPL QA/QC department, Customer / Consultant representatives. Ensure proper landing plat form is available and approachable safety.

3.2.4.6

3.2.4.7

3.2.4.8

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3.2.4.9

Touch up painting shall be carried out for the damaged areas and also for the welded areas (if required).

4. QUALITY REQUIREMENTS Quality requirements are to be written down prior to the starting the job in the FQP. The same should get approved by all concerned. Ensuring that all the FQ requirements are adhered is the responsibility of the FQ Engineer. Work Procedure for Electrodes Baking / Issue Scope: Associated with the baking and issue of welding electrodes to be used on job, objective of this procedure is to set the guidelines for surveillance activities structural welds etc. as recommended by the manufacturer. Responsibility It is the responsibility of the Storekeeper /Welding engineer / QA & QC Engineer to ensure proper baking and documentations. Procedures Ensure correct size of electrodes are procured and put in the baking oven. Electrode packages (cartoons) shall be opened only when they are required for use. While handling the electrodes during opening of packages, baking, holding, issue and welding, avoid contact of oil, grease, dirt with electrodes. Do not use oily, dirty or wet gloves and do not lay the electrodes directly on ground or in any humid place. Ensure that not more than two days requirements of electrodes are baked at a time. Keep the issue indents and issue register updated. Baking and holding of electrodes Identify baking and holding ovens separately. Ovens shall have temperature control facility up to 350-400 deg C and 200 deg C for baking and holding ovens respectively. Calibrated thermometer shall be provided on each oven for monitoring temperature. On opening a packet of electrodes, place the electrodes inside the compartment of

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baking oven identified for the particular type and size of electrode. A log book shall be maintained to cover all relevant parameters like time of loading electrodes in oven,. temperatures achievement time, baking completion time etc involved in the baking of the electrodes Portable Ovens Each welder shall be provided with one portable drying oven, which shall also used to carry electrodes from stores to the place of work. Only one type of electrode shall kept in the portable oven. All portable ovens when in use shall be properly energized to maintain a uniform temperature of 100 deg C. While in use, only limited electrodes shall be permitted to be taken out of the portable oven. Unused cold electrode, if left at the site, shall be properly identified and moved to baking oven for re-drying. Unidentifiable / damaged / improperly maintained electrodes shall be removed from all working areas and disposed. All electrodes being issued to welders shall be through electrodes issue voucher only. This shall contain details like welder No., WPS No., electrodes specification, size and the issued quantity, and duly authorized by the welding supervisor. Welder Qualification Scope This procedure is meant to highlight the minimum requirement for qualification of welders. Reference ASME sec IX 1998 welding and brazing qualification / IS 816. Responsibility It is the responsibility QA & QC engineer for qualifying the welder and issue the identity card before deploying them on job. Procedure QA & QC engineer shall request to witness to client/ consultant 24 hours in advance indicating the welders name and location for testing. Before testing the welders, his present and past experience on similar nature of job shall be checked by scrutinizing his experience certificates. The necessary tools / Equipments shall be ensured for the inspection during testing. The root welding to be inspected by QA & QC engineer and upon finding acceptable the welder are allowed to complete the work piece. Client / Consultant may witness the test piece. The welder test piece is inspected for final weld visual quality and if satisfied, suitable identification / stamping shall be done prior to NDT / DPT. The record of all events / parameters of welders test shall be kept during the test, as per recommended format.

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SAFETY ASPECTS TO BE TAKEN UP WHILE EXECUTING THE JOB:

Sl. No 01 JOB STEPS Transportation of fabricated member from material Yard to erection site. HAZARD/REACTIO N TO FAILURE -Fabricated member loaded on trailer or transported by hydra may hit to person on road or at the time of loading. -Failure of crane or tool & tackles. -Fall of materials - Hit injury. CONTROL & CHECK REQUIRED -All lifting tools & tackles and crane or hydra should be in good condition & certified by competent person. -Regular checking of moving vehicle -A transportation supervisor to be made responsible to guide the trailer & alert people during transportation. - Proper sling or belt should be used while lifting and shifting the loads. -Tag line to be tied to the member being shifted and guided by two people with the help of guide rope. -Avoid lifting members in bunch. - Area should be barricaded. -Always use all the required PPEs. - Proper stacking of material should be done. 02 Crane placement - Hit injury - Crane failure - Collapse of road 03 Erection of column / tie beam / bracing / vertical bracing / - Fall of person from man basket( jhula) or fixed ladder - Proper crane to be selected as per the road condition & erection procedure. -Area is to be cordoned off - Fixed ladder should be checked for soundness by rigger foreman before starting of work. - Person working on the -Fleet I/C - Erection Engineer ACTION BY - Fleet I/C

- Rigging Foreman

- Erection Engineer

- Fall of material.

- Rigging

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platform / handrail by the use of crane & man basket (jhula).

man basket should anchor his safety belt on rigid material or lifeline. - No person allowed to work without safety belt/lifeline. - Only designated signal man should give the signals to the crane operator. - Always use required PPEs

Foreman

04

Other activity (bolt tightening / welding / gas cutting / grinding during erection.

- Fall of person or material due to displacement of members or loose bolt or tack weld. - Fire & explosion hazard - Eye injury.

- Ensuring proper scaffolding / jallies before taking up any erection activity at height. - If working at height, make sure that the area below this is cordoned off.

- Erection Engineer

05

Guide rope tying for columns.

- Fall of structure without proper tying with uniform load distribution.

- Wire rope of atleast 16mm dia to be tied with column for proper anchoring of the column before releasing of crane upon erection. - Proper & adequate area lighting to be provided before taking up any night activity. - Ensure that job at height is taken up at the time of rain - To ensure that Grinding machine wheel guard is in position while in use. - Grinding wheel RPM to be checked & condition of grinding wheel is to be checked - Face shield / Safety goggles to be used - Leather hand gloves to be ensured - Plug top is to be ensured

- Rigging Foreman

06

Area lighting at erection site.

- Improper area lighting - Fall hazard

- Safety Engineer./ Electrical Engineer

07

GRINDING AT HEIGHT - Start the machine

- Breakage of wheels - Contact with wheel while in use. - flying particles. - Dust hazard - Fire hazard - Scaffold collapse

- Erection Engineer

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- Ensure that the power connection is made through ELCB 08 WELDING -Electrical shock - Fire hazard - Arc eye - Unauthorized entry - Ensure that the power connection is made through ELCB - Proper main earthling & body earthling are to be ensured - Erection Engineer - Rigging foreman

- Protection Shed/cover is to be provided for welding machine. Position the welding machines at a elevated position to avoid coming in contact with water. - Welding job to be done on dry surface - Cable condition is to be checked &Leather hand gloves to be used -To ensure availability of Portable fire extinguisher (CO2 / DCP) -Proper housekeeping is to be maintained -welding shield is to be used -Area is to be cordoned off -Proper warning board is to be displayed 09 GAS CUTTING - Leakage in the hose - Hose joints to be checked by using soap solution & hose clamps are to be used -Flash arrestor is to be ensured at both torch end & cylinder end -Correct size nozzle is to be ensured -Proper clearance is to be maintained between job & nozzle

- Safety Engineer / Electrical engineer - Safety Engineer.

- Erection Engineer

-Flash back -Back fire -Falling of cylinders -Fire hazard - Unauthorized entry

- Rigging foreman - Safety Engineer

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-Condition of regulator, hose & torch to be checked -Proper house keeping is to be maintained -Stone lighter is to be used -Fire extinguisher is to be kept ready - Area to be cordoned off.

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TATA Projects Limited

COLOUMNPREASSAMBLY(TYP)

FOUNDATION (TYP)

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TATA Projects Limited

LiftingPlate Plumb PianoWire Containerwith wasteOil. Guy Rope

COLUMNVERTICALITYCHECKING(TYP)

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