Metal Works Installation Method Statement (Handrail, Cage Ladder, Gratings, Down spouts, & Aluminium Copping)

1. PURPOSE
2. SCOPE
3. REFERENCES
4. RESPONSIBILITIES
5. MATERIALS & TOOLS
6. WORK PROCEDURE
7. QUALITY CONTROL AND INSPECTION PLAN
8. SITE HEALTH & SAFETY
9. CONFLICTS & DEVIATIONS
10. DOCUMENTATION
11. JOB SAFETY ANALYSIS

Metal Works Installation Method Statement (Handrail, Cage Ladder, Gratings, Down spouts, & Aluminium Copping)

1. PURPOSE

1.1 This procedure is established to describe all activities related to installation of miscellaneous metal works (handrail, cage ladder, gratings, downspout & aluminium coping).

2. SCOPE

2.1 This method of statement covers erection procedure for miscellaneous metal work e.g. handrail, cage ladder, gratings, downspout & aluminium coping for buildings.

3. REFERENCES

a) International Standards

PIP STS0S130 Erection of structural & miscellaneous steel structure
PIP STS05120 Fabrication of structural & miscellaneous steel specification
PIP STF0SS30 Grating Fabrication Details

AISC Code of standard practice for steel buildings & bridges Steel construction manual

ASTM A36 Standard specification for carbon structural steel
ASTM A307 Carbon steel bolts & studs, 60000 PSI tensile strength
ASTM AS3 Standard Specification for pipe, steel, black & hot dipped, zinc coated, welded & seamless
ASTM AS00 Cold-formed welded & seamless carbon steel structure tubing in rounds and shapes
ASTM A385 Standard practice for providing high-quality zinc coating (hot-dip)
ANSI A1264.1   Safety requirements for workplace walking/working surfaces & their access; workplace floor, wall & roof openings; stairs & guardrail systems

b) SAUDI ARAMCO ENGINEERING STANDARDS (SAES)

SAES M-100 Saudi Aramco Building Code
SAES-H-100 Coating material & application requirement for industrial facilities
SAES-H-101 Approved protective coating system
SAES-Q-001 Criteria for design & construction of concrete structure

c)SAUDI ARAMCO MATERIAL SPECIFICATION SYSTEM (SAMSS)

12-SAMSS-007 Fabrication of structural & miscellaneous steel
12-SAMSS-008 Erection of structural & miscellaneous steel

12-SAMSS-014 Pre-Engineered Metal Buildings.

d) SATIP

SATIP-M-100-03 Structural steel for buildings

e) IFC & Shop drawings

Shop drawings for Handrail, Cage Ladder, Aluminium coping, Gratings & Down spout.

4. RESPONSIBILITES

4.1 Site Manager

The Site Manager ensures that the Site QHSE Sections are provided with the necessary facilities and cooperation from all Supervisor, Foreman and Labor to enable satisfactory inspection and verification of activities performed by the site civil section.

4.2 Site Engineer

The Site Engineer has the overall responsibility for the implementation of work as per approved drawings. He shall arrange the manpower, equipment and materials required for the implementation of the works, coordinate with HSE Officer and QA/QC Site Manager involved in the tasks in accordance to the method statement.

4.3 Safety Supervisor

The Safety Supervisor ensures that all safety management will be enforced in a ways to prevent injury to personnel, damage to Plant and/or equipment and fires.

4.4 Civil Supervisor and/or Erection Foremen

The Civil Supervisor and/or Erection Foremen are solely responsible for installation of miscellaneous metal work assuring all materials installed permanently and works being implemented are in conformance with specifications and approved drawings.

4.5 QC Manager

He will ensure all the material & method statement is approved prior to start of work. He will explain QC requirement for installation of Miscellaneous Metal Works to PM, site representative & QC supervisor/inspector by coordination with them. He will ensure that Miscellaneous Metal Works installers are trained and skilled & if required he will arrange training for them. He will ensure that all work is inspected and accepted as per Aramco requirement & SATIP. He will identify any potential nonconformance & suggest preventive action to eliminate occurrence of nonconformance.

4.6 QC Inspector

The QC Inspector is responsible to conduct daily surveillance and inspections as necessary in accordance with this procedure and project quality requirement. Prepare quality control records and documentation to secure completion of activity for final acceptance and handover.

5. MATERIALS & TOOLS

5.1 Material

o Handrails, cage ladder, gratings, downspout & aluminium copping should be as per approved shop drawing
o HILTI expansion bolts, A307 bolts with nut & washer and other fixtures should be as per approved MAR.
o Storage of all material shall be as per specification and manufacturer’s recommendation to avoid any damages.
o Steel Flat Bar (2X25) & Screw.(5 )

5.2 Equipment & Tools

All the below mentioned equipment and tools should be as per ARAMCO requirement
o Lifting Crane
o Welding Machine
o Drilling Machine.

6. WORK PROCEDURE FOR INSTALLATION OF MISCELLANEOUS METAL WORK:

6.1 Handrail Installation:

6.1.1 Concrete should be accepted prior to installation of handrail.
6.1.2 Concrete surface for handrail baseplate receiving area should be leveled, clean & aligned.
6.1.3 Lifting of fabricated handrail as per approved shop drawing should be done by proper lifting crane or manually as per lifting plan.
6.1.4 Lifted handrail should be aligned with temporary supports before fixing expansion bolts.
6.1.5 Expansion bolts should be fixed as per manufacturer’s recommendation & as shown in approved shop & IFC drawing
6.1.6 After fixing expansion bolts alignment of handrail for top profile & toe board should be checked and corrected. Also verify verticality of post for final acceptance.
6.1.7 Handrail joints should be welded with approved welders & welding procedure.
6.1.8 Damaged paint & welded joints should be repaired as per approved procedure.
6.1.9 Surrounding area of base plate concrete should be leveled and repaired.

6.2 Cage Ladder Installation:

6.2.1. Concrete should be accepted prior to installation of cage ladder.
6.2.2. Concrete surface for cage ladder baseplate fixing area should be leveled, cleaned & aligned.
6.2.3. Lifting of fabricated cage ladder as per approved shop drawing should be done by proper lifting crane as per lifting plan.

6.2.4. Lifted cage ladder should be aligned with temporary supports before fixing expansion bolts.
6.2.5. Expansion bolts should be fixed as per manufacturer’s recommendation & as shown in approved shop & IFC drawing. Expansion bolts in wall should be fixed first and then expansion bolts for concrete pedestal should be fixed. Mismatched holes should be rectified as per specifications.
6.2.6. After fixing expansion bolts alignment & verticality of cage ladder should be checked and corrected.
6.2.7. Joints should be welded by approved welders & welding procedure.
6.2.8. Damaged paint & welded joints should be repaired as per approved procedure.
6.2.9. Surrounding area of base plate concrete should be leveled and repaired.
6.2.10. Functioning of safety drop bars & position of rungs should be checked and repaired if found any damage.

6.3 Grating Installation:

6.3.1 Concrete should be accepted prior to installation of grating.
6.3.2 Concrete surface for angle fixing area should be leveled, aligned & cleaned.
6.3.3 Steel angle locations & level as per approved IFC drawing should be marked on concrete walls.
6.3.4 Steel angles & plates to support steel channels shall be fixed with set anchors as mentioned in approved shop drawing & IFC drawing.
6.3.5 Steel channels shall be fixed with supporting steel angles & plates as shown in approved IFC & shop drawing either by bolts or welding.
6.3.6 Level & alignment of all supporting steel channels & angles should be checked & rectified. Any damage coating or damage member shall be repaired as per specification.
6.3.7 Any mismatch of holes or damaged member should be repaired as per specification.
6.3.8 Grating will be laid as per approved grating plan & location.
6.3.9 After checking final level and alignment, gratings shall be securely fastened to the supporting members with use of approved grating clips as mentioned in IFC/shop drawing.
6.3.10 300 mm thick – 30 mm gravel filling shall be done on gratings after release from all relevant disciplines.

6.4 Downspout Installation:

6.4.1 Pre cast scupper and cast iron drain installation should be approved prior to downspout installation.
6.4.2 Area surrounding cast iron drain outlet should be clean & free from any unwanted foreign particles.
6.4.3 Approved quality galvanized steel pipe (downspout) should be inserted on cast iron drain outlet as shown in attached approved shop drawing.

6.4.4 Straight length of downspout should be extended up to 200 mm above top EL of splash block installed at designed elevation as shown in approved IFC and shop drawing.
6.4.5 Bottom 212 mm portion of downspout should be bend as shown in attached approved shop drawing.
6.4.6 Downspout should be fixed with concrete/CMU wall with 2X25 STL Flat Bar & 5 CD screws at every 1200 mm C/C distance as shown in attached shop drawing. Starting & End points of flat bars must be as per approved shop drawing.
6.4. 7 Contractor will ensure that alignment and verticality of installed downspouts are with in tolerance limit.
6.4.8 All surface area between downspout and precast scupper should be sealed with approved quality caulking material with back filler to avoid any leakage or seepage of water.
6.4.9 Water leak test (only for precast scupper & downspout contact area) shall be conducted after completion of work to ensure effectiveness of sealant used between downspout and scupper.

6.5 Aluminium Coping Installation:

6.5.1 Concrete should be accepted prior to installation of aluminium coping.
6.5.2 All construction & expansion joints shall be prepared and accepted prior to installation of aluminium coping.
6.5.3 Parapet top concrete surface for aluminium coping assembly should be leveled, aligned & cleaned.
6.5.4 Steel angles 30 X 30 X 3 shall be fixed at 625 mm C/C on top of parapet wall by expansion bolt.
6.5.5 Assembly made from 30 X 30 X 2.3 steel square pipe shall be fixed with angles by spot welding as shown in IFC/shop drawing.
6.5.6 During fixing of this assembly, slope and alignment shall be maintained as shown in I FC drawing.
6.5.7 Damaged coating, welding spots & damaged members should be repaired as per specification prior to installation of aluminum coping.
6.5.8 Approved aluminium coping shall be fixed on this assembly by screw nails as shown in approved shop drawing. Vertical ends of coping shall be supported on wall by fixing of FB SOX 2.3 at every 600 mm C/C.
6.5.9 10 X 10 approved sealant with backstop shall be fixed as shown in approved shop drawing.

7. QUALITY CONTROL & INSPECTION PLAN

All materials, workmanship and inspection shall conform to relevant Saudi Aramco Typical Inspection Plan, Saudi Aramco Inspection Checklist, Construction Specification, Standard Drawings, shop drawings and IFC Drawings.

8. SITE HEALTH & SAFETY

The work shall be executed in accordance with the approved safety plan. Work permit shall be obtained prior to any commencement of the work when required.

10. DOCUMENTATION

1. Approved MAR for handrail, cage ladder, gratings, Downspout & aluminium coping.
2. Approved MAR for expansion bolts, FB & Screws.
3. Approved shop drawings.
4. Approved IFC drawings.