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Modification Record

Version Date Section Page Modification and basis

00 02/02/2015 All All First issue

01 10/02/2016 All All Commented

02 12/02/2016 All All


NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

1/ Purpose

The aim of this document is to define the on-site manufacturing process of the pedestal support for
the heliostats in NOORIII solar field, undertaken by MMBS-ARTEPREF. The different steps and
actions conducing to the finishing of the pre-stressed concrete pedestal ready for delivery and
erection in its position. 7400 units are planned to be mass produced and erected distributed all over
NOOR3 solar field.
Basically, the pedestal is a pre-stressed reinforced concrete cylinder consisting on a reinforcement
steel frame bounded with concrete in a molding process under stress using steel cables, also some
inserts are fixed to the pedestal structure for further assembly of the heliostat mecanism.
The whole manufacturing process will take place on site within MMBS-ARTEPREF Workshop in the
NOOR3 complex. This document defines the different steps and procedures for the manufacturing
of the pedestals and also makes a description of the components, materials, machinery and tools
involved in the process.
The works are divided in eight stages, as follow:
- Stage I: Reinforcement
- Stage II: Cable laying
- Stage III: In-mould assembly, inserts and ferrules
- Stage IV: Tension application
- Stage V: Concrete pouring
- Stage VI: Curing
- Stage VII: Cable cutting and de-moulding
- Stage VIII: Storage and transport

2/ PROJECT OVERVIEW

The NOORIII Tower CSP Project consist in the erection of a solar thermoelectric generation Power
Plant, by means of a 150 MW water steam cycle which will use as primary energy source, solar
energy collected by a field of heliostats and a solar receiver located at the top of a tower. The Plant
includes as well a thermal storage system by means of molten salts which permits to extend
operation and electrical power generation during lack of solar radiation.

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

The Plant is located in the NOOR Ouarzazate Solar Complex of Morocco.

Main data of the participant Companies are pointed out here below:
Project Name: MASEN-NOORIII 150 MW TOWER CSP PLANT
Project Developer: ACWA Power
EPC Contractors: SENER Ingeniería y Sistemas S.A.
SEPCOIII Electric Power Construction Corporation.
Subcontractor: Management and Maintenance Building Services SARLAU

LOCATION
The NOORIII Solar Plant will be located 10 kilometers (km) east-northeast of Ouarzazate (Morocco)
and approximately 7.5 km north of the Mansour Eddahbi dam.
The average altitude of the site is around 1265 m.

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

PEDESTAL SUPPORT FOR HELIOSTATS

Pedestals are structural precast and prestressed concrete structures that accomplish foundation
and support functions for the Heliostats of the Concentrated Solar Plant.
The location of Pedestals is distributed all over NOORIII solar field as indicated in the below picture.

The location of MMBS-ARTEPREF Workshop where the pedestals are to be manufactured within
NOORIII complex limits is as described in the following picture.

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

The general arrangement of the workshop layout is as shown in the following picture.

COVER WORKSHOP

REINFORCING WORK AREA PRESTRESSED WORK AREA CONCRETE CASTING AREA

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

The general arrangement of the pedestal is as shown in the following picture.

I: REINFORCEMENT

1- Two cylinders of reinforcement bars of 6-12mm in diameter are delivered by the spiral rebar
bending machine conforming the outer (63cm diameter 845cm in length) and inner (45cm diameter
845cm in length) sections of the reinforcement cage. They will be handled separately until welded
assembly.
2- The vertical reinforcement bars are welded to the spiral conforming the cylinders generatrices
and giving longitudinal strength to rebar cages.
3- The inner rebar cage is inserted inside the outer one and both are welded together using radial
reinforcements conforming a solid reinforcement cage for the pedestal body.

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

4- A reinforcement outer cage for the pedestal truncated cone head is manufactured in an
analogous way, welding annular rebars with straight generatrices.

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

5- Body and head reinforcements outer cages are welded together.

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

6- A polystyrene cylinder is introduced inside the inner cage hollow through all the length of the
pedestals for lightening.

The necessary cover for rebar in presence of the polystyrene


cylinder is ensured by PVC circular concrete spacer
as showed in the picture.

7- Two circular grids are welded at the top and bottom of the pedestal finishing to enclose the full
reinforcement structure.

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

II: CABLE LAYING

1- 30 strands of cable 12.5mm in diameter are inserted through the cells of the
reinforcement cage running its full length.

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

III: IN-MOULD ASSEMBLY, INSERTS AND FERRULES

1- Threaded ferrules are positioned on the inside faces of the mold top and bottom covers and
secured with bolts.
2- The reinforcement structure is introduced in the mold bottom half.
3- The 16 inserts are positioned on the head mould lid internal face and secured with bolts.

4- Cables are threaded through holes on the head and foot mould lids
5- Mold upper half is closed an secured with bolts

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

6- Mold head and foot lids are closed and secured with bolts
7- Tension wedges are inserted at the cable lid holes

IV: TENSION APPLICATION

1- Tension is applied one by one in sequence to all the cables using a n hydraulic jack
2- The amount of tension is controlled and checked via the hydraulic jack two manometers so it is in
margin with the design tension of 1420MPa.

V: CONCRETE POURING

1- The mold, rebar, cables and inserts ensemble is moved to the concrete pouring trench using the
overhead crane.
2- Mold concrete filling operation is organized by rounds of four molds in a simultaneous filling
operation two-by-two.
3- C45/55 concrete from the adjacent batching plant is poured in the mold through a ramp to its
trap door on the upper half cover. Concrete flow is adjusted in a coordinated manner between the
two molds simultaneously filled.

There is no vibration, Concrete for filling Pedestals Molds is Self-Leveling.

4- Molds have their filling trap doors closed and are taken to the curing area with the help of the
overhead crane.

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

VI: CURING

1- Mold is left to rest in the curing area (capacity for 50 molds) for 12-14 hours
2- If in need of heat assisted curing, molds are grouped in batches of five inside a curing casket
where heat is applied using hot air with a temperature never exceeding 35-40º.

VII: CABLE CUTTING AND DE-MOULDING

1- Prior to any maneuver the strength of the pedestals concrete is checked using an sclerometer
through the mold inspection window in order to check the quality of the curing process.
2- Cables are cut using a metal saw through the head and foot lids slots.

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

3- Bolts securing the inserts to the top lid and bottom and upper covers are unscrewed.
4- Upper half and head and foot lids of the mold are disassembled from the ensemble

5- Cable sprouts at the head and foot of the pedestal are shaved using a metal saw
6- Pedestal is hauled by its to lateral connectors and transferred to the storage area with an
overhead crane
7- Mold lids and two half covers are taken with an overhead crane for cleaning.

VIII: STORAGE AND TRANSPORT

1- Quality control is done to the pedestal checking geometry and surface.


2- After the 12-14 hours curing process the pedestal is ready for erection.
3- Pedestals are loaded into the automatic inloader vehicle by pairs using the inloader clamps.
4- Pedestals are delivered to their erection position by the automatic inloader vehicle.

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

PRODUCTION PLAN

Unit of Unit of Unit of


Week
PEDESTAL / PEDESTAL / PEDESTALES.

DAY WEEK Total Cumulated

1 5 28 28
2 10 56 83
3 20 111 194
4 30 167 361
5 40 222 583
6 50 278 860
7 50 278 1.138
8 50 278 1.415
9 50 278 1.693
10 50 278 1.970
11 50 278 2.248
12 50 278 2.525
13 50 278 2.803
14 50 278 3.080
15 50 278 3.358
16 50 278 3.635
17 50 278 3.913
18 0 0 3.913
19 0 0 3.913
20 50 278 4.190
21 50 278 4.468
22 50 278 4.745
23 50 278 5.023
24 50 278 5.300
25 50 278 5.578
26 50 278 5.855
27 50 278 6.133
28 50 278 6.410
29 50 278 6.688
30 50 278 6.965
31 50 278 7.243
32 50 278 7.400

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

3/ REFERENCES

 Eurocode 2 - EN 1992-1-1:2005 – Design of concrete structures – General Rules

 Eurocode 7 - EN 1997-1:2004 – Geotechnical design – General Rules

 Guidelines for Design of Wind Turbines – DNV/Riso

 FIB Bulletin 65

 FIB Bulletin 66

4/ OPERATION CONDITION

4.1 / DOCUMENTATION REQUIREMENTS

 OUA3-SRCA-PC-0102 Rev 3 Solar Field Pedestal


 160122-PROVISIONAL DRAWINGS FOR NOOR3 PEDESTALS SUPPORT FOR HELIOSTAT
 151123-Quality Assurance Program.Rev.01

4.2 / MANPOWER REQUIREMENTS

1/ Project manager - 1--> Responsible for the Project.


2/ Construction Manager - 1--> Responsible for the Manufacturing Process
3/ Reinforcement activities foreman - 1--> Responsible for the Reinforcement Activities
4/ Cable laying activities foreman - 1--> Responsible for the Cable Laying Activities
5/ Mould assembly activities foreman - 1--> Responsible for the Mould assembly Activities
6/ Tension application activities foreman - 1--> Responsible for the Tension application activities
7/ Concrete pouring activities foreman - 1--> Responsible for the Concrete Activities
8/ De-moulding activities foreman - 1--> Responsible for the De-moulding Activities
5/ Helpers-Skilled, Unskilled - 30
6/ Quality control supervisor - 1--> Responsible for the enforcement of the Quality plan
7/ Crane Operator -3

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

4.3 / MACHINE&TOOLS REQUIREMENTS

1/ Hoverhead crane - 4
2/ Automatic rebar bending machine- 2
3/ Arc Welding Equipment - 1
4/ Concrete truck - 1
5/ Hydraulic Jack including all the necessary equipment and accessories
6/ Metal Power saw - several
7/ Pneumatic screwdriver - several

This document is Quality Certificate of New Overhead cranes purchased by Artepref For Pedestals
manufacturing in Noor3 Project, drawing and technical specification are included in annexed document.

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

4.4/ EQUIPMENTS&MATERIAL

- The Molds (two half covers + two lids) - 50 units


- The cable for pre-stress process 12.5mm in diameter
- Reinforcement bars in diameters from 6 to 12mm
- Polystyrene lightening rods
- Inserts
- Threaded Ferrules
- Concrete C45/55 for structural concrete

Materials Certificates are in Annexed Documents.

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

6/ QA/QC

All the equipment and components supplied, and all the works performed, shall comply with all
Moroccan and EU regulations, laws and requirements that apply to the Client/Constructor
(including any future modification to the regulations, laws and requirements during the period of
the contract).
Special attention shall also be paid to Moroccan regulation regarding Health and Safety.

Production quality control procedures described in 151123-QualityAssurance Program.Rev.01

Clean moulds and apply release agent.

The cleaning of the mould consists of removing the cement that remains stuck
to the mould after having taken out the parts and is done by scraping the
surface of the mould with spatulas, wire-haired brushes and sponges to
facilitate cleaning tasks.
During the cleaning tasks, the mould rests on the ground and is secured either
by its feet that support it or held fast by the lifting equipment hooked to the
gantry crane used to place the mould on the prestressing bed. Under no
circumstances should the worker cleaning the mould go underneath it, if the
mould is not hooked to the gantry crane or secured, it could break and fall on top of the worker.
Preventive measures
The use of gloves, anti-splatter spray glasses is obligatory when cleaning with hand-held tools and,
in the case of using hand-held electric tools, this protective clothing should also include a face visor
and antiparticle breathing mask.
Release agents are applied with a "matabi"-type hand pressure paint spray gun or knapsack.
When applying the release agent, avoid pointing the product into the air, spray it evenly over the
mould at an appropriate distance so as to avoid creating oil clouds.
The use of glasses, breathing masks, and gloves is obligatory.

Longitudinal distribution of cables for prestressing, wedge selection

The distribution of the cable in the mould is carried out with a high
strength steel strands designed for this purpose.
The worker threads the end of the cable through the corresponding
chopper holes paying special attention not to trap their hands when
activating the high strength steel strands.
The high strength steel strands are remote controlled and it is the
worker who guides the end of the cable who operates the remote
control to avoid any breakdown in coordination that could result in entrapment.
Since there is already some reinforcing steel in the mould, a blunt guide is fixed onto the end of the

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

cable so that the end of the cable does not get caught on the bulkheads of the said reinforcement
to prevent the worker using their hands to guide the cable.
Once the cable has reached the length required, it is cut using a rotaflex or radial and then another
cable is introduced. To cut the cables, the worker needs to use protective gloves, a face visor and
type-II or above breathing mask.
Ensure that no one is close before cutting to avoid any flying pieces hurting other people or
damaging materials, screening the area if necessary.

Once the cable reel has been used up the worker changes it by bringing it close to the prestressing
bed with an automatic, self-propelled carrier taking special care so as not to bang it against the
frames or other objects.
Once positioned on the prestressing bed, the worker lifts the reel up with the gantry crane using a
fabric sling that can hold up to, or greater than, 3 tons placing both ends of the reel on the hook,
being careful not to leave it hanging since this type of hook greatly reduces the resistance of the
sling keeping it in a good condition and disposing of any deteriorated slings.
The reel is carefully inserted into the roll holder avoiding bangs. Before withdrawing the sling, some
of the straps are cut, keeping four that will stay with the roll until it is placed in the roll holder.
These cuts are made with special cutters made for this purpose using gloves and a face visor to
prevent the risk of cutting oneself when the strap becomes free.
Once all cables has been distributed, the restraining anchor wedges have to
be placed at the live and dead ends of the stress bench.
The wedges should be checked one by one before putting them into
position to ensure that no faulty parts make the anchorage unstable. As a
control measure, a procedure to clean and review the wedges should be

performed once a month by the prestressing yard assembly staff who have
to complete a maintenance record. If a defect is found, the entire wedge
should be disposed of. Before tensing, ensure that the anchor wedges of
the dead ends of the cables are the same and that the flaps are working in a
uniform way.

Prestress by tensioning the cables:

The prestress system consists of tightening the cable by pulling with an hydraulic piston equipped
with a draggable wedge and control manometers to ensure the stressing measurement is as
specified by the Technical Department, depending on the type of part to be tensioned.
The equipment used in prestress tensing operations is as follows:

Prestress tensing machine:

This equipment is made up of an hydraulic pump and hydraulic piston


equipped with a draggable wedge.
The hydraulic pump regulates the final tension of the cable whilst the
piston holds the cable in place, tensing it until it reaches the required

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NOOR II, NOOR III PROJECTS
DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

stress.
The team has safety systems in place to ensure that the tension is correct and prevent human error
or electrical faults so that the equipment does not tighten the cable until it breaks.
The device limits tightening to that set by the Technical Department, made up of a pressure control
that, once the tension has been regulated to that set by the Technical Department, automatically
blocks the traction movement of the hydraulic piston.
Connected to this device, the hydraulic pump has a manually-operated regulator for passing the oil
to the pump so that if a worker is careless and keeps pressing the tensioning remote, or the tension
switch is not regulated correctly, or the switch of the machine continues tensioning, this regulator
prevents the cable getting to the point that it will break.

The prestressing tension procedure.

The tension system begins once all cables are in the mould, the resistance
wedges are positioned on each cable, and the extended and blocked
hydraulic pistons are ready.
Advise all staff in adjacent areas..
Turn on the horizontal rotary axis line in the central warehouse of the factory that also has acoustic
signals spaced every few metres along it to advise that one of the manufacturing
prestressing beds is being tensioned.
Connect the rotary drums positioned on the tensioning bulkheads of the mould that is
being tensioned.

Block the access corridors to the prestressing yard with a bright-coloured chain and a sign that is
easily seen that should read: No entry to Tension Area.
Perform a visual inspection of the work area to make sure that no one is left
in the stressing area.
The stressing operation should be done by two people, the rest of the
prestressing yard staff must leave the risk zone, nearby thoroughfares, and
should be on the alert to make sure that no-one enters the risk zone by error.
If a worker who does not respect the safety distance or the instructions of the stressing staff or the
person controlling access to the risk area, shall be in breach of their labour contract, considered as
being serious misconduct and could result in a sanction that can be anything from suspension from
duties without pay, or disciplinary dismissal.
The risk zones can vary depending on the mould that is being stressed. The
model of the piece in question, is stressed with the reinforced steel section
assembled in the risk area, the distance from the areas behind the tensioning
bulkheads and the sides of the prestressing bed should be no less than 6
metres so that with this assembly configuration the cable can not come out
from the sides if it breaks.
The stressing operation begins when the cable is inserted in the hydraulic
piston or tensing cylinder, the pull action button is pressed until the control
measurement set by the Technical Department is reached, this measurement

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DESCRIPTION PEDESTAL SUPPORT FOR HELIOSTATS MANUFACTURING

differs depending on the diameter of the cable being used, the cable is marked and the pulling
action continues until the final tension is reached before going on to the next cable.
Begin by stressing the cable with a system that is similar to that of tightening the lug nuts on a tyre
working in a star-shape pattern. That is, one by one working with opposite cables to avoid
overloading the stress bench if the cables are only tensed from one side. In the same way, tense the
lowest cable and then the highest.
On a periodic basis, the measurement as a result of stretching the cable is controlled; the mark
indicating the first tension and the elongation of the cable after the last stretch are compared to
ensure that the resultant measurement corresponds to that calculated by the Technical Department
to check the correct tension.
Once the tension is completed, the workers of the tensing machine deactivate the acoustic and light
warnings and inform the workers in adjacent places that the operation has concluded and withdraw
the chains that cornered-off the area.
Preventive measures
During the tensing operation, the workers of the equipment should never go behind the cylinder in
tension mode, and no one is allowed to get close or pass behind the workers of the equipment
without prior authorisation.
The machine operators should be positioned on either side of the the cylinder, to be handled by
only one of them holding it with outstretched arms and with their hands on top of the handle of the
cylinder, so that if anything untoward happens, (if a cable becomes loose, etc.) the handle of the
cylinder does not trap their hands. In the same way , never position your head on top of the cylinder
because in the event of a sharp movement, the cylinder could hit it.

Assemble steel reinforcing steel.

The pieces come pre-assembled from the steel workshop and the prestressing
yard workers have to position the steel reinforcement of the bulkheads as
well as the anchoring and installation components (guides, tubes, etc.) as
specified by the Technical Department.
Assembly is performed in an ordered way, taking care not to bang the cables.
The braces should be placed in order of size with their feet always faced
towards the ground to avoid upward turned spikes that could cause injury if
stepped on.
It is strictly prohibited cut with a radial-arm saw or use a blow torch, solder, bang or perform any
other activity that could put at risk or weaken the structure of the cable whether a cable is being
tensioned, or not.
To anchor the different components that make up the pieces, use either wire or steel staples paying
attention so as not to prick oneself which means that the use of gloves is obligatory as well as long
sleeves and trousers for the entire assembly process since the braces often have sharp edges.
When assembling the prestressing bed it is quite normal that at some point the worker will place his
knee or both knees on the floor or on the bed so it is important that staples or pieces of wire that
fall to the ground are picked up immediately because they are sharp and could cause injury to
people or damage vehicles when stepped on or run over.
Preventive measures

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The workers should have available at all times glasses and face visors, gloves, protective footwear,
acoustic protection and breathing masks as well as suitable clothing. This protective equipment
should be used correctly depending on the task to perform. Long sleeves are preferable to avoid
cuts and scratches.
The most efficient preventative measures during assembly of the piece is order and proper cleaning
and needs to done continuously by the workers who have different containers to classify and clean-
up the residue generated.

Moulding and demoulding operation.

Once the prestressing bed has been assembled the upper part of the
mould can be placed into position. These components are very heavy and
vary in length and weight depending on the size of the piece to be
prepared.
From an at-rest position, on the floor parallel to the prestressing bed, you
can begin the hooking phase using one or two cranes, one on each end,
with two tools prepared for this purpose, each one of the cranes are to be
driven by an operator with a wireless remote that facilitates movement
within the work area and communication with the operator of the other
crane, by staff who are fully trained and with proven experience.
Before lifting the mould, the crane operators verify that there is no one in the moulding area and
either in a loud voice or using a signal shall advise of the lifting in a coordinated manner. The
operators should not allow other people to be present whilst they are handling the mould and the
wireless remote controls gives the two operators the option to be together which means that a
third party is not required to coordinate the manoeuvres.
Once the mould has been lifted, it is to be brought over to and positioned on the base mould taking
care not to bang any element of the same with smooth manoeuvres.
Once the mould is in position, the support elements are put into place and the crane lifting tools are
unhooked.
The joining of one mould to another is done using threaded fixtures.
Once the upper part of the mould is in position, it is tightened slightly with a key or pneumatic
screwdriver.
If the tasks to be carried out on the upper part of the mould are too high up then they are
performed from footbridges, ladders, etc. under no circumstances do the workers climb the mould
without the necessary safety measures in place.

Preventive measures

- Moulding and demoulding tasks should performed by fully-trained staff with proven experience
only.
- Access to the moulding area is not permitted to any person and the moulding staff are to ensure
that this prohibition is respected.
- Never go underneath the hanging moulds.

- Keep a safe distance away from the mould being handled until it is at rest in the work area.

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Demoulding.

Once the concrete has set, the mould can be removed beginning
with releasing the bolts that are holding the covers and then
hooking the mould using the lifting tools to the crane and
withdrawing the upper part of the mould. When the mould is
disengaged, the mould is laid to rest, these manoeuvres should be
performed under the same conditions and procedures set for
moulding.
The staff who perform this task must be fully-trained with proven experience, not allowing any
person without sufficient training or experience handle heavy loads with overhead, gantry or semi-
gantry cranes.

Piece cementing:

Once the moulds are in position and secured, the concrete is ordered from the cement mix floor
and poured directly from the floor into the mould.

Preventive measures

The cementing operator is the only person allowed in the area.


When using precast, self-levelling concrete, there are no splashes when the ready-mixed concrete is
poured into the moulds, however, despite this, the use of eye protection during pouring is
recommended, being obligatory the use of glasses if the concrete mix is different.
Nitrex gloves should be used at all times if there is any possibility of coming into contact with wet
concrete.
If there are any special circumstances for preparing the pedestal that involve manoeuvres that are
not normally performed or are not covered in this document, the prestressing yard operators
should advise their Structure Manager and at the same time the Safety Department to assess the
situation and decide the best way to resolve it.

Radial cutting and removal of pieces.

To perform radial cutting, the Operator should be appropriately protected and is


obliged to use all the equipment available for this purpose by the Company; eye
and face protection, breathing masks, gloves, safety footwear, anti-spark leather
apron, paper caps and suitable work clothes. Before beginning to cut the cables, the
worker should check that there are no other people in the work area that could be
hit by the sparks that the radial cutter generates as well as any products that could
be damaged by flying sparks, and if any, move them or protect them with fireproof
blankets, protection screens, etc. The cables are cut one by one letting the weight
of the tool make the cut.
Pay special attention to the possibility that the disk could break and get caught by
the cable avoiding leverage during the cutting process as well as applying pressure

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forcing the cable to be cut.

Cutting cables.

Due to the length of time of the cutting process and the posture that is held "slightly inclined
forwards", it is advisable that the workers rotate when handling the radial or that the cut is
performed by two people at the same time, one on each side, to shorten the process and be less
time in an uncomfortable position.
Once the cables have been cut, the pieces are taken out of the prestressing bed.
It is intended that a pneumatic cutter for cutting cables is used to facilitate the task and reduce
flying sparks and particle risks.

Removal of pieces.

Choosing lifting equipment; the equipment used to hook the pieces securely is selected depending
on the weight and size of the pieces from the equipment available varying
from 2.5 -15 T resistance with the finally equipment to be used always having a
resistance greater than the weight to be lifted.
The hooking method depends on the number of anchors that the piece has,
the size of the pieces that we manufacture normally come with four anchors in
twos on both ends of the piece as specified by the Technical Department and
are to be handled with two gantry cranes. The chains need to be of an
appropriate length form the distance between the hooking points and must
not exceed under any circumstances a 90º angle formed by the chains in the two-strand octopus.
Depending on the length of the piece, it shall be lifted with one crane or two if the piece is longer.

If two gantry cranes are used, the approach of the cranes to the piece is done with two half-gantry
cranes as close together as possible to be able to visually control the path of the same anticipating
any circumstance that could occur. The path the load and the crane need to follow is controlled by
the Operator who follows the crane a few metres behind.. The Operator of the crane should never
loose sight of the gantry crane or the load being handled.

If synchronised bridges are used, the crane operation positions one of the
cranes over the piece to lift right over the hook points of the piece and, without
hooking the FRIMEDA lifting anchor system approaches the other crane. Under
no circumstance does the crane operator hook any anchor of the piece without
having checked that the gantry cranes are in the correct position.
To hook the pieces, select the appropriate FRIMEDA lifting anchor system for
the hook specified by the Technical Department, with this hooking system it is
impossible to make a mistake with regards to the which FRIMEDA to use since
the hole of the hook adjusts to the size of the FRIMEDA.
Before lifting the piece, tense the lifting equipment slightly and carry out a visual inspection
checking that the hook is correct, the FRIMEDA lifting anchors are closed, and that there are no
kinks in the chain, when verified, the lifting can proceed in a coordinated fashion between two

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crane operators.

No one except the crane operators are allowed into the work area where the lifting operation of the
piece is in process. Neither of the crane operators should go into the operational radius of the
moving piece.

The piece is lifted to the extent that it clears any obstacles on the floor on the path to the collection
point, either with a carrier or directly on the floor, in either case the piece should be moved as close
to the floor as possible.
All repairs to the piece should be done at ground level and before being lifted so as not to perform
tasks from ladders, stools, or climbing onto the piece itself.
Once the pieces have been deposited at the collection point to be subsequently taken from the
warehouse, the stability of the same needs to be checked using wedges, supports, ratchet slings or
any other support system to secure them.
The shape of the pedestals make it difficult for them to be stored high up.
To store them high up, supports made for this purpose need to be used and stored in a suitable way
that does not compromise the stability of the pieces.
Removal of carriers:
Once the pieces have been placed on the transport carriers, to get the pieces out of the warehouse,
the Structure Manager or the designated member of staff shall advise the vehicle that is pulling the
carriers, make sure that no one comes near while the pieces are being transferred to the
warehouse, assuring that the path of the carriers remains clear until they are left in the allocated
area of the warehouse guiding continually the manoeuvres of the moving vehicle.
The vehicles that move the carriers to the warehouse keep their headlights dipped at all times, turn
on any rotating lights and ensure that the reverse warning sounds.

Repair and parts' finish.


Sometimes the pieces are chipped or slightly damaged and have to be
repaired by mortar repairers.
Repairs involve covering with mortar any imperfection, crack, or chip from
when the mould is removed.
It is important that the setting time of the mould is correct to avoid
imperfections from chips, as well as monitor the state of the mix to decide
on whether it is necessary to shake it slightly to improve the finish of the piece and prevent repairs
that are easy to avoid.
The tools that are normally used are hand-held: small shovel, spatula, trowel, brush, and the bucket
where the mortar is mixed, using each tool according to the type of repair or finish that is required.
Mixing is done in a bucket and the mix amounts are usually small.
Different mortars are chosen depending on the type of imperfection and the required finish.

Preventive measures

Follow the manufacturers instructions with regards to the dose, use nitrile gloves, a breathing mask
and eye protection if the type of mortar to mix requires them, in all cases refer to the safety

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instructions for products that are going to be used and available to all members of staff on the
concrete floor. Should you have any doubts, go to the Safety Department or your Area Manager.
.
General maintenance, order and cleaning in the work area.

Maintenance tasks, repairs as well as preventative maintenance is performed by Artepref staff, or


specialised companies depending on what needs to be done.
The staff of the different areas, should be constantly monitoring the correct operation of the
equipment used daily, communicating any incident or fault the moment it is detected to their Area
Manager, or Safety and Health Department.
Periodic controls of the more volatile and high risk equipment are set by the Safety Managers as
well as for the lifting equipment, gantry cranes, tensing machines, and emergency stop devices. All
workers handling this equipment are also trained and instructed on how to detect any possible
defects in the same, being an additional monitoring level for preventing possible incidents.

Order and Cleaning.

Order and cleaning when carrying out any task is, without doubt, the best of the preventative
measures that a worker can adopt in their work area, it is a proven fact, that a high percentage of
accidents occur due to the lack of order in organising the tasks, no order when positioning the
elements and the tools to be used in the tasks, as well as the lack of cleaning.
This situation generates a multitude of small incidents over the course of the day due to slips,
bangs, etc.
The amount of hours or days to perform these cleaning tasks is not covered in this document but
must be an integral part of the day, being ordered and disciplined when handling residues to
prevent them building up.
General cleaning of the warehouse is to be carried out by the workers when the residues are
generated avoiding that dust is unsettled during the cleaning process. The prestressing yard staff
will remove any residues from inaccessible places for collection.

Places that are cleaned by hand with brushes shall be hosed with water to avoid the dust unsettling
and the workers will wear a FPP1 or higher type mask when cleaning.

The residues are managed in a suitable way in compliance with the instructions of the
Environmental Area

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QUALITY OF WORK PROGRAMME

The residues coming from chips and loose materials will be collected
Order and
in the iron containers.
Cleaning
Order and Keep the areas and paths clear and clean.
Cleaning
If the Operator of the chute remains in the cementing area, the rest
Collective
of the Operators should be outside the operational radius of the
Protection
work team.
Before using lifting tools, make absolutely sure that they are in good
condition for use, disposing of those that do not conform to safety
Collective
conditions. Inform members of the prevention service of said
Protection
condition. The prevention service shall perform monthly controls on
the state of the slings in all work areas.
Before moulding the pieces, check that they are in optimal
Collective
conditions for setting to avoid pieces breaking off and falling onto
Protection
the workers in the prestressing yard.
Collective Only fully-trained and authorised operators can use the gantry
Protection cranes.
The pieces are to be stored on timber mats that do not exceed the
Collective
height specified by the Technical Department to avoid that the load
Protection
overturns when being moved or temporarily stored on the pedestal.
The use of appropriate work clothes, nitrile gloves and anti-splash
Individual glasses is obligatory when cementing the prestressing bed. For
Protection applying cement release agents; appropriate work clothes, FPP1
mask and face visor rather than safety glasses.
MLM (Manual Maximum manual load weight is 25 kg. If the recommended weight
Loading is exceeded, and is greater, another operator should help.
Movement)
individual
protection
Individual Avoid prolonged contact with the skin of either cement or release
Protection agent as they could cause an allergic reaction.
Individual At the end of the day when you leave the factory or for breaks, the
Protection workers should wash their hands and face correctly especially
Hygiene around the corners of their mouths.
When applying release agents, the workers carrying out this task
Individual
should take special care not to create clouds that could upset the
Protection
workers in adjacent areas and should wear masks so as not to inhale
Hygiene
clouds regardless of their concentration.
Safety with Hand-held or electric tools should never be left in thoroughfares.
hand-held and When they are not being used they are to be kept in their drawer.

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electric tools Faulty or broken equipment should be given to the maintenance


staff for repair.
Unplug the machine before fixing disks or drill bits.
Use each tool for the purpose it has been designed for. The cutting
disk to cut and the plane to smooth.
When the perishable component is worn out or gone blunt, replace
it immediately with a new one (cutting disk).
To disconnect the tool from the mains, pull the plug out never the
wire.
Under 18 year olds are prohibited from using electronic equipment,
gantry cranes, or motorised traction vehicles.

Obligatory use of suitable work clothes that is not too loose.


A face visor is obligatory when using the radial cutter rather than
safety glasses.
FPP1 mask when using the radial cutter.
Individual Safety gloves at all times.
Protection It is obligatory the use of safety glasses or a face visor when working
with hammers and chisels.
Hearing protection is obligatory in all those areas and tasks where
the level of the noise could be harmful and it is recommended that
hearing protection is worn in the entire manufacturing area.

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7/ HSE

Hazard Prevention and protective measures

When the worker is in place, it must properly wearing a helmet, gloves, glasses,
shoes and reflective vest.

It is forbidden that worker work in ill.

Once a week workers have to receive tool box , explaining the risks of use,
environmental and hygiene for example use of PPE, management of cutting
machines, do not throw garbage anywhere.

Monthly course how to use hand tools, how to use each machine and hand tool
to prevent strokes fools.

General regulate In the working, worker should wears safety belt correctly, and hangs the belt
above where is firm. Walkway board should be bound firm.

It should take reliable shielded measure to avoid damage when do the work at
the different height in the same site.

In any job should at least two workers, in case emergency you can call for help.

Always secure the area before we can pour the concrete, always using glasses,
avoiding enter the eyes.

Monthly courses would be taught to all skilled workers how use and risk cutting
machines.

Power supply cable should be flexible rubber-insulated wire in good quality, it’s
Electrical safety forbidden that use naked wire. The cable should be overhead or buried to
prevent rolled by vehicle. The light should be hanged above 2.5m, if the height is

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lower than 2.5m, the shield should be fixed on the light, it is forbidden to use
hot-light source in sit for illuminating.

Professional electrician in charge of construction power, switchboard need be


locked generally, electro-facility should be checked and maintained regularity,
it’s forbidden that other person connects power by himself.

Fire safety Keep enough fire fighting facility in the work site.

Always use the harness in case of height,and have it tied to a fixed location, to
avoid a fall which could cause a serious accident
Material fall prevention

If lower or raise a pit should use a ladder, for easy access to workplaces.

Which will use the machines to cut wood, iron are people authorized by the
company and has to be written and submit it to Sepco III.
Cutting tools
Prohibited use cloth around the neck when one uses a slicer, because it is
possible that you will roll and can create a disastrous situation.

Everyone is obliged to select waste before disposal, for proper recycling.

Provide appropriate information to workers and people working on behalf of the


company to encourage their active participation and sense of responsibility in
the impact on the environment during the performance of their activities, both
Environment protection industrial and private.

Stop the car, light generator e and machinery if not being used in the work.

Using water and power in reason, waste is not allowable.

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After the work is finish, the material and tools should store together, deal with
the sundries in time.

Surplus material stack together, waste material should be sent to scrap yard in
time.

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