1.0 PURPOSE.
2.0 SCOPE.
3.0 RESPONSIBILITIES.
4.0 EQUIPMENT & MATERIALS/ CONSUMABLES.
5.o MATERIAL HANDLING & STORAGE.
6.0 WORK PROCEDURE – FIRE PROOFING.
a. Steel structures.
b. Equipment Skirts or supports.
c. Topcoat application
7.0 INSPECTION.
8.0 RECORDS.
9.0 HEALTH AND SAFETY.
10.0 ATTACHMENTS
1.0 PURPOSE
The purpose of this Method Statement is to establish and describe the construction and control steps to be taken for achieving specified requirements for lightweight concrete fireproofing works for Structures and equipment skirt/ support at Refinery and Plants Projects.
2.0 SCOPE
The Method Statement covers general requirements for materials and workmanship for all structural and equipment skirt/support lightweight fireproofing works within scope of work for Jizan Refinery and Plants Projects.
References
• Saudi Aramco Engineering Standards SAES-B-006 Fireproofing for plants.
• Test design for fireproofing for structural steel UL-1709 XR 719.
• Datasheets of Promat Fendolite MIi fireproofing system.
• Promat (Cafco) Guideline specifications for application..
3.0 RESPONSIBILITY
SUPERVISOR DUTIES, RESPONSIBILITIES AND WORK
FOREMAN
• Reports to the Site Supervisor.
Scope
The function of the Supervisor is to co-ordinate the day to day activities of the Foreman and to provide support to the Site Manager.
Responsibilities
• Ensure all requirements of the specification are achieved.
• Coordinate with all Foremen in each work area.
• Notify JGC-DEC QC department of impending HOLD and WITNESS points.
• Control works to prevent non-conformances occurring.
• Verify, inspect, witness and monitor for conformance with the specification, those activities assigned on JGC-DEC Inspection and Test Plans and Checklists.
• Arrange inspection of goods on site ordered by JGC-DEC.
Authority
• Initiate action to prevent the occurrence of non-conformances relating to the work process and product.
• Identify and record any problems relating to the product and process.
• Direct corrective actions. This may involve stopping a work process until corrective action approved.
QC INSPECTOR DUTIES, RESPONSIBILITIES AND WORK
SITE HSE OFFICER
Reports to the Company Safety Manager, Liaise with the Site Manager.
Scope
Managing effective safety management system of company to ensure all activities affecting health, safety and environment of the workers at the workplace are conducted in safe manner. Promote recognition and enhancement of safety performance.
Responsibilities
• Ensure that Owner’s and Main Contractor safety policies and procedures are implemented on site.
• Ensure, check and monitor all activities on site are carried out in a safe manner.
• Ensure check and monitor, all personnel on site is adhering to safety procedures.
• Follow instruction concerning safety, hygiene and sanitation advised by Main Contractor.
• Carry out site safety induction of old and new workers.
• Weekly safety reports to Main Contractor.
• Advise all personnel on matters of safety and hygiene.
• Arrange safety signboards.
• Coordinate requirements for First Aid.
• Ensure all accident reports are sent to the Project Manager.
• Direct personnel to stop work on ground of safety.
4.0 EQUIPMENT & MATERIALS/ CONSUMABLES:
Equipment
• Fireproofing material spray machine
• SKVA Generator
• Electric Grinder
• Potable water tank
• Water jet pump (if required)
• CD Stud welding Machine
Material & Consumables
- Fendolite MII
- Poly Bond SBR
- Fendolite manufacturer recommendation based on SAES-B-006 clause 8.2.1.
1. For Equipment (vessel skirts) – Galvanised welded wire mesh 50mm x 50mm with a wire diameter of 1.6mm.
2. For Structural Steel members (Columns, Beams, Bracing etc.) – Galvanized welded wire mesh 50mm x 50mm with wire diameter of 1.2mm to 1.6mm - Galvanized tie wires 1.2 mm diameter.
- Sealant
- Poly Bond SBR shall be used as key coat application as deem appropriate to the condition of primed surface before fireproofing starts.
- CD weld pins, 3mm dia x 12°17mm mm (structural steel members).
5.0 MATERIAL HANDLING & STORAGE
Material handling and storage shall be according to the manufacturer’s recommendation. Fendolite MIi as per approval received against submitted material data sheet: Material shall be kept dry, covered and off the ground until ready to use. The materials shall be inspected while on receipt and recorded for the batch nos. and date of shipment. The material is usable for 12 months from the date of manufacturing. Each consignment shall be fully consumed before issuance of following consignment.
Mesh and other material: The material shall be kept packed under shade until the time of fabrication. While handling, extreme care shall be taken to avoid injuries with sharp edges. Usage of hand gloves, goggles, helmet and safety boots must be followed during material handling. Promaseal or its equivalent: Promat Promaseal or its equivalent is a silicon sealant material, shelf life is 12 months from the date of manufacturing. Top coat: Top coat shall be stored in cool and dry place. Shelf life is 12 months from the date of manufacturing.
6.0 WORK PROCEDURE – FIRE PROOFING
a. For Steel Structures
Surface preparation:
• Before application of fireproofing material, ensure that the surface shall be free from oil, grease, condensation, or other contamination.
• Contractor shall ensure that surface preparation prior to release for fireproofing is carried out as per SAES-B-006, para 8.4 and SAES-H-001 (APCS-1B) requirement by the main contractor.
• Make the marking points at appropriate centre subject to size of substrate member on staggered or diamond pitch on the surface of structural steel members.
• Prior to the application of Poly Bond SBR, the corrosion system must be reinstated to the original specification at the grinded area.
• Perform a 90° rotation test for Cafco Helical pins, at one test per square metre. Maximum allowable failure rate is 10%.
• Application of Sealer & Key coat “Poly Bond SBR”:
• Ensure that the surface to be coated must be free from loose mill, scale, oil, grease and visible moisture, dirt or other contamination.
• Stir content properly.
• No external curing is necessary as it is cured by air drying.
Mesh reinforcement/retention “G.I mesh”:
• The reinforcement mesh must be positioned so as to lie substantially within mid third of the total thickness. i.e. 11mm to 17mm away from the substrate.
• Mesh must be overlapped by at least 50mm at all joints and secured itself by twisting the cut ends together or using Galvanized wire ties at 150 mm centres. No more than 3 mesh apertures should overlap at any one point.
• Steel sections greater than 203mm X 203mm are protected by the profile method.
• Steel sections up to and including 203 mm x 203 mm between flanges are protected by solid fill method. In this case the web section may be filled with Fendolite MII prior to the installation of mesh to avoid any voids during the Fendolite MII application.
Mixing of fireproofing material FENDOLITE MII:
• Ensure that pump and mixing equipment shall be clean and operational.
• Fendolite MII shall be mixed with potable water in a suitable mixer. Use about 15-19 litres of water for every 20kg bag. Temperature of potable water shall be maximum of 35°C.
• Place most of the required mixing water in to the mixer.
• Add the bagged material steadily. Add the reminder of the mixing water slowly until a suitable consistency is obtained.
• Mixing time is 3 minutes to ensure correct properties of the mix. Avoid adding more water as explained above.
• It should be noted that sufficient material should be conveniently placed by the pump and mixing equipment to ensure continuity of supply.
Application of fireproofing material FEN DO LITE MII:
• Fendolite MIi may be applied when the substrate and air temperatures are within a minimum of 49 °C and a maximum of 50°C.
• During application, cover the application area by plastic tarpaulin to avoid spreading of fireproofing materials to nearby equipment/surroundings.
• Apply Fendolite MIi material on prepared surface by using sprayer machine. The thickness of the coat shall be maintained at 34 mm±3mm for 2-hour fire rating.
• The correct amount of air introduced at the nozzle is essential to ensure consistency of texture and approximate wet density of material in the range of 700 kg/m³ – 1300 kg/m³.
• The spray head must not be held stationary. Even coats are obtained with steady sweeps of the spray head which is held, wherever possible, at 90° to the work surface. As a general rule, do not apply a single coat less than 8mm.
• Where the materials are applied in more than one coat, the preceding coat should be left with a spray texture finish or well scratched to ensure good bonding of subsequent coats.
• Coating thickness may be conveniently checked by the use of a needle penetration gauge with ruled indicator.
• If the surface has become very dry, it should be well dampened with clean water before applying further coats.
• Carryout finishing work using trowel once the specified thickness has been applied and allowed to stiffen slightly.
• The setting time required to achieve the maximum thickness is 24 hours. During this time the applied surface shall be protected from rain and running water.
• For minor repair, apply manually by using trowel.
• Over work to achieve smoother finish may lead to surface cracking in future. Hence the finishing will be done just to maintain a level and not to smoothen too much for cosmetic purposes.
b. For equipment skirts or support:
Surface preparation:
• Before application of fireproofing material, ensure that the surface shall be free from oil, grease, condensation, or other contamination.
• JGC-DEC shall ensure that surface preparation prior to release for fireproofing is carried out as per SAES-B-006, para 8.4 and SAES-H-001 (APCS-1B) requirement by the main contractor.
• A good weld can only be achieved by good metal-to-metal contact, so remove existing corrosion protection system/paint at the marked place by using electric or air driven wire brush cleaning until a bright metal surface is obtained.
• Prior to the application of Poly Bond SBR, the corrosion system must be reinstated to the original specification at the grinded area.
• Application of Sealer & Key coat “Poly Bond SBR”:
• Ensure that the surface to be coated must be free from loose mill, scale, oil, grease and visible moisture, dirt or other contamination.
• Stir content properly.
• No external curing is necessary as it is cured by air drying.
Mesh reinforcement/retention “G.I mesh”:
• The reinforcement mesh must be positioned so as to lie substantially within mid third of the total thickness. i.e. 11mm to 17mm away from the substrate.
• Mesh must be overlapped by at least 50mm at all joints and secured itself by twisting the cut ends together or using Galvanized wire ties at 150 mm centres. No more than 3 mesh apertures should overlap at any one point.
Mixing of fireproofing material FENDOLITE MIi:
• Ensure that pump and mixing equipment shall be clean and operational.
• Fendolite MIi shall be mixed with potable water in a suitable mixer. Use about 15-19 litres of water for every 20kg bag. Temperature of potable water shall be maximum of 35C.
• Place most of the required mixing water in to the mixer.
• Add the bagged material steadily. Add the reminder of the mixing water slowly until a suitable consistency is obtained.
• Mixing time is 3 minutes to ensure correct properties of the mix. Avoid adding more water as explained above.
• It should be noted that sufficient material should be conveniently placed by the pump and mixing equipment to ensure continuity of supply.
Application of fireproofing material FENDOLITE MII on Equipment and Saddle Support:
• Fendolite MII may be applied when the substrate and air temperatures are within a minimum of 49 °C and a maximum of 50 °C.
• During application, cover the application area by plastic tarpaulin to avoid spreading of fireproofing materials to nearby equipment/surroundings.
• Apply Fendolite MII /material on prepared surface by using sprayer machine. The thickness of the coat shall be maintained at 34 mm±3mm for 2-hour fire rating.
• The correct amount of air introduced at the nozzle is essential to ensure consistency of texture and approximate wet density of material in the range of 700 kg/m³- 1300 kg/m³.
• The spray head must not be held stationary. Even coats are obtained with steady sweeps of the spray head which is held, wherever possible, at 90° to the work surface. As a general rule, do not apply a single coat less than 8mm.
• Where the materials are applied in more than one coat, the preceding coat should be left with a spray texture finish or well scratched to ensure good bonding of subsequent coats.
• Coating thickness may be conveniently checked by the use of a needle penetration gauge with ruled indicator.
• If the surface has become very dry, it should be well dampened with clean water before applying further coats.
• Carryout finishing work using trowel once the specified thickness has been applied and allowed to stiffen slightly.
• The setting time required to achieve the maximum thickness is 24 hours. During this time the applied surface shall be protected from rain and running water.
• For minor repair, apply manually by using trowel.
• Over work to achieve smoother finish may lead to surface cracking in future. Hence the finishing will be done just to maintain a level and not to smoothen too much for cosmetic purposes.
Water shedding for steel structures and equipment skirts/ supports:
• Where there is risk of water accumulating on a Fendolite MIi protected surface it should be sloped to allow the water to run away. This is particularly important on beams where the top flange is protected and the top surface of the bottom flange when following the profile of a beam.
Hot Weather conditions for steel structures and equipment skirts/ supports:
• In hot, dry conditions, it is necessary to protect the Fendolite MIi coating from too rapid evaporation of its moisture content. Over rapid evaporation causes insufficient water to be left for full hydration of cement.
• Wrapping the exposed members with polyethylene sheeting to retain moisture OR wrapping with wet hessian sacking which require periodic wetting. During hot weather it is recommended to do this protection for a minimum of 3 days.
Joints for steel structures and equipment skirts/ supports:
• Cut a”U” shaped groove at all Fendolite MIi steel junctions and shall be filled with elastolar or silicone sealant.
c. Top Coat Application on fireproofing of steel structures and equipment skirts/ supports:
Surface Preparation:
All concrete surfaces should be treated to achieve a sound, clean surface free from laitance, oil, grease, dust or other contaminants. Substrate temperature should be above 5C and at least 3€ above dew point.
Application
• Sigmacover 410 is two component high solids, high build, polyamide cured epoxy coating which can be applied by airless spray, brush or rolled.
• Mixing ratio by volume: base to hardener 80:20. Stir well before use.
• Paint temperature shall preferably be above 15C, otherwise extra thinner may be required to obtain application viscosity. Too much solvent results in reduced sag resistance. Thinner (as per manufacturer’s recommendations) shall be added after mixing the components.
• Sigmacover 410 shall be applied as a top coat in two layers as per manufacturer’s recommendations. The recommended dry film thickness shall be 75 to 150 microns.
Repair procedure for steel structures and equipment skirts/ supports:
• Cut away any loose fireproofing material by chamfering by any sharp edges. Where mesh reinforcement is exposed, clear the fireproofing material away from the mesh and ensure that it will remain in the mid-third of repair.
• If damage has resulted in mesh failure, totally remove the affected mesh and reinstate with new mesh ensuring that minimum 50mm overlap onto the original mesh is achieved and that is secured by the use of wire ties or twisting cut ends together.
• Re move loose dust.
• If the existing fireproofing material has become very dry, dampen the surface adjacent to the repair site with potable water.
• Mix and apply the fireproofing material and finish level with existing material.
7.0 INSPECTION
The Site supervisor shall inspect each activity to verify that it has been correctly applied, and record it in the Fireproofing Checklist prior to final inspection. Checks shall include but not limited to:
• Preparation of surface.
• Installation of attachments.
• Reinforcement mesh installation.
• Thickness of fireproofing materials, keycoat.
• Wet density and slump of Fireproofing material.
• Temperature (ambient, water and substrate) during application.
• Application of fireproofing material.
• Proper curing.
• Batch number & Expiry date.
8.0 RECORDS
• Checklist for Fireproofing work
• Material Data Sheet/Test Certificate.
• Material Safety Data Sheet.
• Surface preparation.
• Density and temperature monitoring sheet Form
9.0 HEAL TH AND SAFETY:
• All work permits (as applicable) shall be obtained prior to commencing any work.
• All the persons involved shall be briefed for the health hazard and shall be provided with required PPE.
10.0 ATTACHMENTS:
❖ Job Safety Analysis (JSA).
❖ Typical Inspection Plan (SATIP).
❖ Product Data Sheet.
❖ Letter for thickness calculation for CAFCO FENDOLITE MII from PROMAT.