Gratings Erection Procedure | Method Statement

1.0 PURPOSE
2.0 SCOPE
3.0 APPLICABLE DOCUMENTS
4.0 RESPONSIBILITY
5.0 MANPOWER
6.0 TOOLS AND EQUIPMENT
7.0 METHODS/PROCEDURE
8.0 QUALITY CONTROL
9.0 SAFETY PRECAUTION
10.0 ATTACHMENT

Gratings Erection Procedure | Method Statement

1.0 PURPOSE

1.1   This  method  statement shall  provide minimum guidelines  to carry out the Erection of Gratings activities and procedures for Plants and refineries to ensure that the work is carried out in accordance with Project Drawings and Project Specifications.

2.0 SCOPE

2.1    This method statement will cover the erection of all gratings of Plants and refineries.

3.0 APPLICABLE  DOCUMENTS

3.1   Project Specification and Standards

3.1.1    S-000-3130-002      Steel Structures – Site Erection

3.1.2   Construction Scope of Work.

3.1.3   Latest Approved For Construction  Drawings

3.2   ARAMCO  Project Specification and Standards

3.2.1	PIP STS05120	Fabrication of Structural and Miscellaneous Steel Specification
3.2.2	PIP STS05130	Erection of Structural and Miscellaneous Steel Specification
3.2.3	PIP STF05530	Grating Fabrication Details
3.2.4	SAEP-302	Instruction for Obtaining a Waiver of a Mandatory Saudi ARAMCO Engineering Requirements
3.2.5	SAES-M-001	Structural Design for Non-Building Structure
3.2.6	SAES-Q-010	Cement Based,  Non-Shrink Grout for Structural & Equipment Grouting
3.2.7	12-SAMSS-007	Fabrication of Structural and Miscellaneous Steel
3.2.8	12-SAMSS-008	Erection of Structural and Miscellaneous Steel
3.2.9	SCHEDULE Q	Saudi ARAMCO Project Quality Requirements
3.2.10	Saudi ARAMCO	Safety Requirement for Scaffolds
3.2.11	Saudi ARAMCO	Construction Safety Manual

 

3.3    Industry Codes and Standards

 

3.3.1	AISC	AISC  Code of Standard  Practice,  Specification  for Structural Joints Using ASTM A325 or A490 Bolts
3.3.2	AWS D1.1	Structural Welding Code
3.3.3	PIP STS05130	Erection    of   Structural    and   Miscellaneous   Steel Specification
3.3.4	Pl P STF05530	Grating Fabrication Details

3.4   Inspection and Test Plan/ Method Statement

3.4.1	SATIP-M-001-01	Structural   Steel   for   Piperack,   Steel   Supports  & Miscellaneous Steel Structures
3.4.2	SATIP-Q-010-01	Cement Based Non-Shrink Grouting
3.4.3	SATR-M-2002	Pre-Installation  Procedure Verification  Testing Using the Turn-of-Nut Method (ASTM A325 or ASTM A490 Bolts)
3.4.4	SAIC-M-2009	High Strength Bolts Tightening Inspection and Testing   (ASTM A325 or A490 Bolts)
3.4.5	SAIC-M-2006	Inspection  of Support Foundation Prior to Structural or Equipment Installation
3.4.6	SAIC-M-2007	Inspection of Structural Alignment During Erection
3.4. 7	1170-MS-3B00	Non-shrink Grout Installation

4.0 RESPONSIBILITY

4.1    Construction   Manager   is   responsible   for   implementation    of   all   HSE requirements;  he shall study, analyze and schedule all construction activities with  his department to include manpower and equipment line  up as well  as other possible  resources  required for the  successful  implementation  of the construction work activities. Study all aspects of work procedure as per DEC/JGC’s Technical  Scope of Work.

4.2   Structural Supervisor shall study and review all  necessary documents for the erection works in  his area to include,  technical  scope of work,  specification, bill  of  quantities,  planned  milestone  dates  and  construction  procedure  in support to his Structural  Foreman.  He shall monitor the availability of materials in  accordance  with  the  schedules  and  construction  analysis.  He shall  be directly reporting to the Construction Manager. He shall coordinate with other discipline  to  visualize  possible conflicts  in  the  drawings  as well  as  in  the schedules to provide other options in preventing unnecessary delays obstructions.

4.3    Structural Foreman shall be responsible for the direct work supervision at site and ensure that the work is performed in accordance with DEC/JGC Technical Scope  of  Work  and  latest  approved  for  construction  drawings.   He  shall monitor the availability of materials in line with  his required schedule.

4.4    Surveyor shall study and analyze if the location where the structure should be installed satisfies the condition or restriction  of erection works on site.  He shall coordinate with  other discipline to visualize possible conflicts in  the drawings as well  as in the schedules to provide other options in preventing  unnecessary delays obstructions.

4.5    QC Inspector  shall  be responsible  in  monitoring and inspection  of the work and ensure that the work is performed in accordance with DEC/JGC Technical Scope of Work and Standards.

4.6    Safety Engineer/Supervisor  shall be responsible  in  monitoring safety  aspects and  ensuring  that  the  work  is  done  in  accordance  with  DEC/JGC  Safety Standard  Procedure.  He shall  discuss to the workers the- characteristics  of related materials and status of work area giving reminders as an additional point to work safely.

5.0 MANPOWER

5.1     Manpower will consist of the following,  but not limited to as listed to as below:

• Structural Supervisor
• Structural Foreman
• Surveyor
• Crane operators (ARAMCO Certified)
• Manlift operator (Qualified/ ARAMCO Certified)
• Truck drivers
• Steelworkers
• Structural fitters
• Riggers (ARAMCO Certified)
• Plate welders (Qualified)
• Scaffolders (ARAMCO Certified)
• Safety Engineer/Supervisor
• QC Inspector/Welding Inspector (AWS-CWI)
• Helpers

6.0 TOOLS AND EQUIPMENT

6.1 Tools and equipment needed should be in good condition and must be checked by Structural Supervisor/ Safety Officer prior to use in the good condition area.
These includes but not limited as below:

• Mobile crane, capacity as required
• Manlift

• Trailer/tractor
• Boom truck
• Welding machines
• Air compressor
• Tower lights
• Manbasket
• Bolt Tension Calibrator
• Manual Wrench/ Spud Wrench/ Hand Tools
• Impact Wrench/ Torque Wrench
• Magnetic drill
• Surveying instrument
• Rigging tackles
• Cable wires /turnbuckles/ chain block
• Nylon Ropes for Taglines

7.0METHODS / PROCEDURES

7.1 Preparation Works

7.1.1 Secure work permit from DEC/JGC Arabian Ltd. Representative prior to start of work/activity.
7.1.2 Prepare all materials, tools and equipment needed for the job.
7.1.3 Deliver all materials intended for gratings or floor plates.
7.1.4 Position mobile crane (capacity as required) on the assembly area.

7.1.5 General. Gratings or floor plates to be erected in structure shall be installed after erection, alignment and bolt tightening of the main structural members with scaffolding platform (by others).
7.1.6 Gratings & Floor Plates. Prior to installation of gratings or floor plates, provide the required number of lifelines spaced at 3 meters apart across the areas to be grated or plated. Using a crane at the initial stage, install grating or plates, one panel at a time, until such time that a sufficient area for staging one or more grating bundles is covered. Make sure that each grating panel is secured with four pieces fully tightened grating clips before lifting and installing the next panel. During manual installation of grating panels or floor plates, provide retaining sling (see illustration for fall protection) on grating panel tied to the scaffold mid-rail while being carried and installed to respective location. This is to prevent grating panel from falling down directly to the ground in case of accidental slips. A minimum of four persons will do the manual installation of grating and floor plates. Check final alignment and bolt tightness after completing the installation of all gratings or floor plates in the area. Weld floor plates if required in the drawings.

7.1.6.1     Prior to erect the structure,  scaffold access and platform should be  installed.  Scaffold  will  be  use  as  life  line,  access,  and platform.  See picture below:

• Pre-assemble structure at ground
• At ground install scaffold to steel structure prior to erect.
• Scaffold  will    serve   as   access,    working   platform    and anchorage  point for full  body harness if  permanent rails, access and platform are not installed.
• If structure  is   already  erected  without   scaffold,   scaffold installation shall  commence immediately.

  

7.1.6.2    Installation  of grating will be done by manual  (min.  of 4 people) using grating hook.  See picture below

• Install physical  barricade at area covered of grating installation (below level of activity) with signage “danger on-going grating installation”.
• No simultaneous   activity   (working   at  same   location   and different level),  it is strictly prohibited.
• Use grating hook only on installation of gratings
• If the steel structure does have a stair access,  starting point of grating installation will be on stair up to end point of structure.
• If the steel  structure don’t have a stair access,  starting point will be on any end side of structure.

Fall  Protection for grating installation  (“wire  rope with  hook  should be provided”)

7.1.7  Valve Access  Platforms &  Other Related Access ways.  Assemble all platform parts and accessories at the ground level as follows:  Connect posts,  beams  and bracings as shown in  the drawings (normally  four- legged   platform  in  upright position)  and  install  complete bolts  on  all connections.   Install   ladder,   handrails   and   gratings   with   complete connection bolts and grating clips. Erect the assembly on concrete pedestals or on top of structural beam with predrilled connection holes. Check   plumbness   and  alignment   and  tighten   bolts  to  snug   tight condition.

7.1.8   Repair or replace members which are damaged during erection.  Do not secure damaged members in position.

7.2    Touch-up Application

7.2.1   As   mentioned   in   Specs.   No.   S-000-3130-002    para.   5.6.3,   when damaged painting or galvanized surface  on steel  structure  is  observed, and the unpainted  area by masking  at connection  is exposed,  surface shall be touch-up.

7.2.1.1     All  repaired,  reworked,  damage  galvanized  steel  supports and gratings will be coated as per applicable coating system.

8.0 QUALITY CONTROL

8.1 ARCC QC Inspector will be assigned to attend to the quality control and assurance of this work.

8.2 ARCC QC Inspector shall be responsible to conduct all required inspection as detailed in S-000-3130-002 sec. 9.0 to ensure that all applicable requirements, codes and standards are complied with.

8.3 ARCC QC Inspector will produce all the documents attesting to the acceptability of the works and submits to DEC/JGC.

8.4 ARCC QC Inspector has to utilize the applicable SATIP’s & SAIC’s for every activity.

9.0 SAFETY PRECAUTION

9.1 Approved work permit should be obtained prior to the start any structural works.
9.2 Work execution shall be carried out in accordance with this method of statement.
9.3 Erection crew must carry out a TSTI prior to the start of any new activities.
9.4 During any lifting works, signalman must be assigned full-time.
9.5 The necessary manpower inclusive of supervisory staff, tools, equipment, materials, and other resources required must be made available and ready to use.

9.6     Workers should wear their PPE’s needed for work.

9.7    Certified  permit receiver,  traffic/flagman  and work-in-charge should be at work site during the execution of the work.

9.8    Sufficient lightings shall be provided if work is done at night time. Work at night shall  be approved by client.

9.9    Full body harness with double lanyards shall  be at all  times when working at elevated platforms 1.8 meters high and above.

9.10  A 1/2  diameter wire rope must be provided for safety lifeline.

9.11   Good housekeeping must be maintained in the duration of works.

9.12  Field Supervisor  shall  monitor the work  activities  to  help and to  protect  all assigned workers  against exposure to  safety  hazards.  He shall ensure  that Personal  Protective equipment  (PPE’s)  are supplied,  used and  comply with JGC/DAEWOO applicable standards.

9.13  Safety Supervisor/Engineer shall monitor compliance of entire working crew to safety procedure until the work is fully completed.

9.14  ARCC shall make sure that the structural  installation  and erection  of  platform and access-way shall be incident and injury free.

10.0   ATTACHMENTS

Attachment A       SATIP-M-001-01  (Structural Steel-Piperack,  Steel Supports& Miscellaneous Steel Structures

Attachment B      Job Hazard and Risk Assessment (JHRA)