1.0 PURPOSE
1.1 This method statement shall provide minimum guidelines to carry out the modification works for steel structure activities for commercial buildings, 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 modification works for steel structure of commercial buildings, plants and refineries.
3.0 APPLICABLE DOCUMENTS
3.1 ARAMCO Project Specification and Standards
3.1.1 SAEP-302 Instruction for Obtaining a Waiver of a Mandatory Saudi ARAMCO Engineering Requirements
3.1.2 SAES-M-001 Structural Design for Non-Building Structure
3.1.3 12-SAMSS-007 Fabrication of Structural and Miscellaneous Steel
3.1.4 12-SAMSS-008 Erection of Structural and Miscellaneous Steel
3.1.5 SAIC-M-2012 Inspection of Structural Welding (Per AWS 01.1)
3.1.6 SAIC-M-2008 Repair / Correction of Errors of Structural Alignment
3.1.7 SCHEDULE Q Saudi ARAMCO Project Quality Requirements
3.1.8 Saudi ARAMCO Safety Requirement for Scaffolds
3.1.9 Saudi ARAMCO Construction Safety Manual
3.2 Industry Codes and Project Standards
3.2.1 AISC AISC Code of Standard Practice, Specification for Structural Joints Using ASTM A325 or A490 Bolts
3.2.2 AWS 01.1 Structural Welding Code
3.2.3 PIP STS05130 Erection of Structural and Miscellaneous Steel Specification
3.2.4 S-000-3130-002 Construction specification for steel structures site erection
3.3 Inspection and Test Plan I Method Statement
3.3.1 SATIP-M-001-01 Structural Steel for Piperack, Steel Supports & Miscellaneous Steel Structures
4.0 RESPONSIBILITY
4.1 ARCC Construction Manager shall responsible for all HSE matters and to 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 Technical Scope of Work.
4.2 Structural Supervisor shall study and review all necessary documents for the modification 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 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 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 Safety Standard Procedure. He shall give reminders or advise to all workers to do the activity 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
• Welding Foreman
• Welders
• Crane Operator (ARAMCO Certified)
• Rigger (ARAMCO Certified)
• Manlift operator (ARAMCO Certified)
• Steelworkers
• Structural fitters
• Fire Watchers
• Safety Engineer/Supervisor
• QC Inspector
• 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:
• Clamps
• Cutting torch/gauging
• Grinder
• Welding machine
• Mobile Crane
• Manlift
• Forklift
• Chain puller/blocks
• Wrenches
• Nylon Slings
• Hand tools / jigs
• Hydraulic jack
• Annular cutter/magnetic drill
7.0 METHODS I PROCEDURES
7.1 Preparatory Works
7.1.1 QC to prepare Quality Control Inspection Report (QCIR).
7.1.2 Prepare Request for Information (RFI) regarding deficiency/field suit of pre- fabricated materials.
7.1.3 Secure Site Instruction regarding modification works to be done.
7.1.4 Prepare all tools and equipment needed.
7.1.5 Provide access scaffolding if required.
7.2 Modification Works
7.2.1 Cutting of Shear key
7.2.1.1 Remove shear key by gas cutting.
7.2.1.2 Flash grind excess material if it is undercut or build-up if it is over-cut.
7.2.1.3 After flashing/welding works touch-up paint as required.
7.2.2 Provision / Increasing of notch (beam’s flange, gratings etc.)”
7.2.2.1 Cutting by using grinder
7.2.2.1.1 Cut the member by grinding in accordance with the latest Approved for Construction (AFC) drawing / field suit dimension as per issued Request for Information (RFI).
7.2.2.1.2 Clean the edge of the cut portion as a surface preparation for touch-up painting of the affected area.
7.2.2.1.3 QC Inspection to verify dimensionally, acceptability of the cut portion.
7.2.2.2 Gas-cutting
7.2.2.2.1 Cut the member to the required dimension by oxy acetylene gas-cutting in accordance with the latest Approved for Construction (AFC) drawing / field suit dimension as per issued Request for Information (RFI). Flame cutting only on dimension changes, no flame cutting of bolt holes is allowed.
7.2.2.2.2 Proper care should be taken to avoid unnecessary damage and deformation of the member.
7.2.2.2.3 Flush surface and if necessary, build-up deep marks and notches caused by torch cutting.
7.2.2.2.4 QC Inspection to verify dimensionally, acceptability of the cut portion.
7.2.2.2.5 Touch-up painting of the affected area.
7.2.3 Bolt hole distance discrepancy
7.2.3.1 Plug-weld the existing bolt hole in accordance with AWS D1.1.
7.2.3.2 Conduct PT as required.
7.2.3.3 Lay-out and drill required/corrected bolt hole.
7.2.3.4 QC Inspection verifying/checking the lay-out dimension.
7.2.3.5 Drill bolt holes using magnetic drill or annular cutter.
7.2.3.6 Touch-up painting of the affected area.
7.2.4 Bolt hole enlargement
7.2.4.1 Re-drill bolt holes as per fabrication drawing and/or enlarge using pencil grinder.
7.2.4.2 Touch-up painting of the affected area.
7.2.5 Additional Bolt holes
7.2.5.1 Lay-out and mark the additional bolt hole location as per latest Approved for Construction (AFC) fabrication drawing.
7.2.5.2 QC Inspection verifying/checking the lay-out dimension.
7.2.5.3 Drill the required bolt holes using magnetic drill or annular cutter.
7.2.5.4 Touch-up painting of the affected area.
7.2.6 Additional gusset / connector plate / base plate / etc.
7.2.6.1 Lay-out and mark the location of the additional gusset/connector plate/base plate as per latest Approved for Construction (AFC) fabrication drawing.
7.2.6.2 Prepare the surface by grinding to remove the paint of the particular location where the additional will be welded.
7.2.6.3 Proper care should be taken to avoid unnecessary damage and deformation of the members.
7.2.6.4 Flush surface and if necessary, build-up deep marks and notches caused by torch cutting or gauging to both members.
7.2.6.5 Conduct PT as required.
7.2.6.6 Fit-up gusset plate to corrected location.
7.2.6.7 QC Inspection checking dimensionally, alignment and acceptability of the fit-up.
7.2.6.8 Upon acceptance, full welding shall commence and to be completed as per approved project WPS / PQR.
7.2.6.9 Conduct NDE as required.
7.2.6.10 Clean and prepare surfaces of affected area.
7.2.6.11 Touch-up painting of the affected area.
7.3 Painting
7.3.1 Clean and prepare surfaces to be painted using power brush.
7.3.2 Apply necessary coats as per required paint system and let dry. Painting shall be in accordance with Saudi Aramco Standard.
7.3.3 Painting shall match with the existing painting color.
8. 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 to ensure that all applicable requirements, codes and standards are complied with.
8.3 QC Inspector will produce all the documents attesting to the acceptability
of the works and submits.
8.4 QC Inspector has to utilize the applicable SATIP’s & SAIC’s for every activity.
9 SAFETY PRECAUTION
9.1 Approved work permit should be obtained prior to the start any repair works.
9.2 Work execution shall be carried out in accordance with this method of statement.
9.3 Erection crew must carry out a safety risk assessment prior to the start of any new activities.
9.4 The necessary manpower inclusive of supervisory staff, tools, equipment, materials, and other resources required must be made available and ready to use.
9.5 Workers should wear their PPE’s needed for work.
9.6 Certified permit receiver, traffic/flagman and work-in-charge should be at work site during the execution of the work.
9.7 Personnel who will be working form a suspended workbasket should secure Suspended Personnel Work Basket Authorization / Permit prior to start work.
9.8 Manlift equipment shall be tested and certified by the Saudi ARAMCO Equipment Inspection Division.
9.9 Only certified manlift operator(s) shall be allowed to operate the manlift equipment.
9.10 Sufficient lightings shall be provided if work is done at night time. Work at night shall be approved by client.
9.11 Full body harness with double lanyards shall be at all times when working at elevated platforms 1.8 meters high and above.
9.12 Good housekeeping must be maintained in the duration of works.
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 all shall be incident and injury free.
9.15 The area shall blocked by physical barricade or warning tapes during activitieS is to be done to ensure safety.
10 ATTACHMENTS
Attachment A – Job Hazard and Risk Assessment (JHRA)