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TATA PROJECTS LIMITED METHOD STATEMENT FOR STACKING, PRE-ASSEMBLY, EREC TION & INSPECTION. OF STRUCTURAL WORK.

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.)

1. INTRODUCTION

1. INTRODUCTION CONTENTS 1.1 OBJECTIVE 1.2 SCOPE 2. WORK CONDITION 2.1 WORK ENVIRONMENT 2.2

CONTENTS

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

1. INTRODUCTION     1.1 Objective:   The purpose of this work procedure is to

1.

INTRODUCTION

 
 

1.1

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.

WORK CONDITION:

 
 

2.1

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

 

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 .

Theodolite

-

1No. (for alignment & checking of verticality of structure)

2.4.2.

Torque Wrench

-

1No.

2.4.3.

Water level

-

1 No.

2.4.4.

Plumb

-

1 No.

 

2.5

Manpower & Equipment:

 

Manpower Utilization:

2.5.1.1.

Erection Engineer In-charge

-1

2.5.1.2

Erection supervisor

- Depending on the scope of work.

2.5.1.3.

Erection Foreman

- Depending on the scope of work.

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

-

2.5.1 Equipment Utilization: 2.5.2.1. Crane to suit site requirements - Nos. 2.5.2.2. Hydra Crane -

2.5.1 Equipment Utilization:

2.5.2.1. Crane to suit site requirements

-

Nos.

2.5.2.2. Hydra Crane

-

Nos.

2.5.2.3. Trailers

-

Nos

2.5.2.4. Welding M/c and other Tools & tackles

-

Nos.

3. WORK METHODOLOGY:

3.1 Construction Process Flow Chart:

Handing over of Foundation./Check Levels, & foundation bolt position (correction if Packing plate level -
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
Positioning of crane
and making lifting
arrangements.
 Selection of -Bolts
 Rectification of Damage if any.
 Check camber, Sag & etc.
Prepare the Tempary arrangement for changing the sling after erection. Arrg. of Temp. Platforms where

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
Sign. of Method
Statement by RCM,
Erection
Engineer & Safety
Officer
YES
NO

Further Process

Lifting the columns as per drawings

Statement by RCM, Erection Engineer & Safety Officer YES NO Further Process Lifting the columns as
3.2 Process Methodology : 3.2.1. General Procedure 3.2.1.1. Erection of structures such as column, beams,

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 the columns.

between

3.2.1.3

QA & QC shall ensure the acceptance and prepare necessary protocols for record purpose.

3.2.1.4.

Tightening of base plate bolt and release for grouting as per specification

3.2.1.5.

Structures required to be fitted in position shall be bolted / welded properly.

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.

3.2.3. Preparation for lifting 3.2.3.1 Crane of suitable capacity along with all the necessary accessories

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 The lifting zones to be clearly identified in the rigging plan.

3.2.3.4 Latest revision drawing for the structure that is to be erected shall be made available at site for ready references.

3.2.3.5 The tools and tackles will be checked for the availability of the required quantity as per checklist.

3.2.3.6 The valid test certificates for the rigging equipments, tools and tackles shall be ensured for the lifting requirements.

3.2.3.7 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.

3.2.3.8. 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.

3.2.4.2 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.

3.2.4.3 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.

3.2.4.4 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.

3.2.4.6 If any alterations are to be carried out, then prior approval to be sought from the Customer / Consultant before taking up the work.

3.2.4.7 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.

3.2.4.8 Ensure proper landing plat form is available and approachable safety.

3.2.4.9 Touch up painting shall be carried out for the damaged areas and also for

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.

temperature.

Calibrated thermometer shall be provided on each oven for monitoring

On opening a packet of electrodes, place the electrodes inside the compartment of

baking oven identified for the particular type and size of electrode. A log book shall

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.

SAFETY ASPECTS TO BE TAKEN UP WHILE EXECUTING THE JOB: Sl. JOB STEPS HAZARD/REACTIO N

SAFETY ASPECTS TO BE TAKEN UP WHILE EXECUTING THE JOB:

Sl.

JOB STEPS

HAZARD/REACTIO N TO FAILURE

CONTROL

&

CHECK

ACTION

No

REQUIRED

BY

01

Transportation

-Fabricated member loaded on trailer or transported by hydra may hit to person on road or at the time of loading.

-All lifting tools & tackles and crane or hydra should be in good condition & certified by competent person.

- Fleet I/C

of fabricated

member from

material Yard

to erection

site.

 

-Failure of crane or tool & tackles.

-Regular checking of moving vehicle

- Erection

-Fall of materials

-A transportation supervisor to be made responsible to guide the

Engineer

-

Hit injury.

trailer & alert people during transportation.

 

-

Rigging

-

Proper sling or belt

Foreman

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 PPE’s.

-

Proper stacking of

material should be done.

02

Crane

- Hit injury

- Proper crane to be selected as per the road

-Fleet I/C

placement

- Crane failure

condition & erection procedure.

- Collapse of road

-Area is to be cordoned off

03

Erection of column / tie beam / bracing / vertical bracing /

- Fall of person from

-

Fixed ladder should be

-

Erection

man basket( jhula) or fixed ladder

checked for soundness by rigger foreman before starting of work.

Engineer

-

Fall of material.

-

Person working on the

-

Rigging

 

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

 

man basket should anchor his safety belt on rigid material or lifeline.

Foreman

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

-

 

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

-

Fall of person or

-

Ensuring proper

-

Erection

material due to displacement of members or loose bolt or tack weld.

scaffolding / jallies before

Engineer

taking up any erection activity at height.

 

-

If working at height,

Fire & explosion hazard

-

make sure that the area below this is cordoned off.

   

-

Eye injury.

 

05 Guide rope

-

Fall of structure

-

Wire rope of atleast

-

Rigging

tying for

without proper tying with uniform load distribution.

16mm dia to be tied with column for proper anchoring of the column before releasing of crane upon erection.

Foreman

columns.

 

06 Area lighting

-

Improper area

-

Proper & adequate area

-

Safety

at erection

lighting

lighting to be provided

Engineer./

site.

- Fall hazard

before taking up any night activity.

Electrical

Engineer

-

Ensure that job at height

is taken up at the time of rain

 

07 GRINDING

- Breakage of wheels

-

To ensure that Grinding

-

Erection

AT HEIGHT

machine wheel guard is

Engineer

- Start the machine

Contact with wheel while in use.

-

in position while in use.

-

Grinding wheel ‘RPM’ to

- flying particles.

be checked & condition of grinding wheel is to be

- Dust hazard

checked

- Fire hazard

Face shield / Safety goggles to be used

-

- Scaffold collapse

Leather hand gloves to be ensured

-

Plug top is to be ensured

-

     

Ensure that the power connection is made through ‘ELCB’

-

 
 

08 WELDING

-Electrical shock

Ensure that the power connection is made

-

-

Erection

Engineer

- Fire hazard

through ‘ELCB’

-

Rigging

- Arc eye

-

Proper main earthling &

foreman

body earthling

are to be

- Unauthorized entry

ensured

-

Safety

-

Protection Shed/cover is

Engineer /

to be provided for welding machine. Position the welding machines at a elevated position to avoid coming in contact with water.

Electrical

engineer

-

Safety

Engineer.

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

 

- Leakage in the hose

-

Hose joints to be

-

Erection

CUTTING

checked by using soap solution & hose clamps are to be used

Engineer

-

Rigging

-Flash back

-Flash arrestor is to be ensured at both torch end

foreman

-Back fire

&

cylinder end

-

Safety

Engineer

-Falling of cylinders

-Correct size nozzle is to be ensured

-Fire hazard

-Proper clearance is to be

-

Unauthorized entry

maintained between job

 

&

nozzle

-Condition of regulator, hose & torch to be checked -Proper house keeping is to be
-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.
TATA Projects Limited COLOUMN PRE ‐ ASSAMBLY ( TYP ) FOUNDATION (TYP)
TATA Projects Limited COLOUMN PRE ‐ ASSAMBLY ( TYP ) FOUNDATION (TYP)

TATA Projects Limited

COLOUMN PRE ASSAMBLY ( TYP )

TATA Projects Limited COLOUMN PRE ‐ ASSAMBLY ( TYP ) FOUNDATION (TYP)

FOUNDATION

(TYP)

Lifting Plate Plumb Piano Wire Container with waste Oil. Guy Rope COLUMN VERTICALITY CHECKING (
Lifting Plate
Plumb
Piano Wire
Container with
waste Oil.
Guy
Rope
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