001-MS for Structural Steel Assembly and Erection.pdf

Pearl GTL Project

LINDE ENGINEERING

Contractor Project No : 5887 Shell Project No: HP-3000-QAT

Project Document Number: T- 4.250.896 Project Rev.: C Page 2 of 26

Purchase Order Number: 2MH127

N/A Tag/Item Number(s):

ASU Unit(s):

Z PCWBS:

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

F C 18.05.2008 Company Comments Incorporated AG EE AG CCI

E B 23.03.2008 Ready For Construction BR UA ZG RFC

D A 28.02.2008 Ready For Construction BR UA ZG RFC

C O 29.11.2007 Issued for Company Comments UA MC ZG ICC

B 22.11.2007 Issued for Review BR AU/MC ZG IFR

A 20.11.2007 Issued for Internal Review BR AU/MC ZG IIR

Approved By

GAMA Project Rev

Rev. Date Description Prepared

By Checked

By Status

No. No. ORIGINATOR

Document Title:

LINDE ENGINEERING AG

METHOD STATEMENT FOR STRUCTURAL STEEL ASSEMBLY AND ERECTION Document No.

GAM MTS MEC GTL 001 F LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T- 4.250.896 Rev No: C

Doc. Title : METHOD STATEMENT FOR STRUCTURAL STEEL ASSEMBLY & ERECTION

Doc No : GAM-MTS-MEC-GTL-001 Rev. F Date: 18.05.08

T-4.250.896 Rev. C Page 4 of 26

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TABLE OF CONTENTS

1. PURPOSE _____________________________________________________________________5 2. SCOPE ________________________________________________________________________5 3. HSSE _________________________________________________________________________5 4. REFERENCES _________________________________________________________________5 5. DEFINITIONS _________________________________________________________________6 6. RESPONSIBILITY ______________________________________________________________7

6.1. SITE MANAGER_________________________________________________________________ 7 6.2. CONSTRUCTION MANAGER _____________________________________________________ 7 6.3. EQUIPMENT MANAGER _________________________________________________________ 7 6.4. SITE ENGINEER_________________________________________________________________ 7 6.5. SITE SUPERVISOR/FOREMAN____________________________________________________ 7 6.6. QC ENGINEER __________________________________________________________________ 7 6.7. QC INSPECTOR _________________________________________________________________ 7 6.8. HSSE MANAGER ________________________________________________________________ 7 6.9. HSE OFFICER ___________________________________________________________________ 7

7. PROCEDURE __________________________________________________________________8 7.1. PLANT AND EQUIPMENT ________________________________________________________ 8 7.2. WORKFORCE ___________________________________________________________________ 8 7.3. MATERIALS ____________________________________________________________________ 9 7.4. SITE PLANNING AND PREPARATION_____________________________________________ 9 7.5. WORK METHODOLOGY _________________________________________________________ 9

8. QUALITY ASSURANCE_________________________________________________________12 9. ATTACHMENTS_______________________________________________________________13 TYPICAL ERECTION OF COLUMNS IN PIPE RACK PHASE 1 _________________________13 JSA______________________________________________________________________________13



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1. PURPOSE The purpose of this method statement is to outline the general requirements & precautionary measures which will be taken into consideration for the structural steel assembly & erection works for C2 ASU Pearl GTL Project by GAMA Qatar.

2. SCOPE This method statement identifies the general steps, arrangements & precautions for the structural steel assembly & erection works at the C2 ASU Pearl GTL Project site.

3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and International standards, codes, Linde Engineering AG and QSGTL and/or its PMC requirements and instructions. In addition all employees and Gama subcontractor employees on site will have through Linde Engineering AG Site Safety Induction and Gama Qatar Safety induction for site safety, health, environmental and security prior to work activities. Other training courses will be attended as required by Linde Engineering AG and QSGTL and/or its PMC as required. At a minimum a Risk Assessment will have been prepared by the Risk Assessment Team (RAT) ranking the hazards associated with project works and control measures to be taken to mitigate the hazards to an acceptable level. Each work scope or task will have a completed and approved Job Safety Analysis (JSA) identifying the potential hazards and control measures that will be implemented to protect people and environment. Supervisor as the basis of conducting his daily Pre-Task meeting and his weekly TSTI will use the JSA. In addition to the above, employees conducting survey works will wear required PPE and highly visible vest where traffic or other hazards may exist. For additional safety requirements for a particular or specific task please refer to the JSA prepared for that task.

4. REFERENCES T.4.115-071 :Fabrication & Assembly of Steel Structure DEP 34.28.00.31 :Steel Structures (Amendment T-13.376.359) T-4.219.611 :HSSE Plan T-4.234.542 :Project Quality Plan SSPC-SP14/NACE No. 8:Industrial Blast Cleaning



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T-4.250.917 :ITP For Structural Steel 34-00-01-30 :Minimum Requirements For Structural Design & Engineering GZ00-C-SY2005.013 : Metal Works and Fencing. T-4.250.907 : Procedure for Structural Steel. T-13.376.369 Rev-K : Structural Steel Work General Notes and Abbreviations. T.4.250.545 : Procedure for Grouting T.4.129.859 : Lifting Procedure (General) T.4.129.868 : Work at height Scaffolding

5. DEFINITIONS COMPANY : QSGTL and/or its PMC

CONTRACTOR : Linde Engineering AG

SUB CONTRACTOR : Gama Qatar

PROJECT : QSGTL Pearl Plant C2 ASU Construction Works

QA/QC : QUALITY ASSURANCE/QUALITY CONTROL

QCE : QUALITY CONTROL ENGINEER

QCI : QUALITY CONTROL INSPECTOR

CM : CONSTRUCTION MANAGER



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6. RESPONSIBILITY

6.1. SITE MANAGER The site manager will provide inputs to the project execution plan to ensure that lifting strategies & philosophy are addressed.

6.2. CONSTRUCTION MANAGER The construction manager is responsible for the overall management of the project construction team to ensure that safe and effective operations are conducted and properly documented.

6.3. EQUIPMENT MANAGER The equipment manager will be responsible for the transporting equipments availability and good order.

6.4. SITE ENGINEER Shall report to Construction Manager. Shall be responsible for planning, execution and implementation of all site activities related to this procedure.

6.5. SITE SUPERVISOR/FOREMAN Shall report to Site Engineer. Shall be responsible for execution of construction activity. Shall also prepare daily site construction records.

6.6. QC ENGINEER Shall report to Manager (QA/QC) and shall be responsible for overall implementation, monitoring and control of QC activities.

6.7. QC INSPECTOR Shall report to QC Engineer Shall be responsible for attending all Inspection Stages as required by ITP. Shall be responsible of performing all checks and shall prepare necessary Inspection Reports.

6.8. HSSE MANAGER Shall report to Project Manager and shall be responsible for over all control and inspection of HSSE issues.

6.9. HSE OFFICER Shall report to HSE Manager. Shall be responsible for all safety aspects for this procedure.



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7. PROCEDURE

7.1. PLANT AND EQUIPMENT

Boom Truck or Hiab Min. capacity 3 ton. Fork Lift Articulated Man lift Trailer Crane Lifting studies for above 10 ton shall be presented, according to the

availability and size of the cranes. Gas cutting Torch Grinding Machine Welding Machine Diesel Generator Air Compressor Air actuated tools Hand tools Electrical tools

7.2. WORKFORCE Work force allocation shall be done based on quantum of job involved. So as to finish the job within stipulated period with the required quality and safety.

Site Engineer Rigger Survey Team Safety Officer Painter Supervisor/Foreman Operators Drivers Laborer a) Erection Crews

Crane operator Rigger Scaffolder Fitter Foreman Banks Man Helper



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b) Bolt Tightening Crews Bolt Tighteners

c) Material Handling Crew

crane operator rigger helper

7.3. MATERIALS

Structural-Steel Materials All Steel Material should confirm to;

EN 10025, ASTM A 36, JIS 3101 SS 400 BS 5950 Part 1, 2 Min Requirement Structural Steel

7.4. SITE PLANNING AND PREPARATION

Necessary work permit shall be taken before starting the job. The job will be carried out as per approved RFC drawing and specification.

7.5. WORK METHODOLOGY 7.5.1 STRUCTURAL STEEL FABRICATION AND ERECTION

A. Fabrication Structural steel will be fabricated according to the approved RFC drawings & Standard drawing if any.

1. Fabrication will be done with exposed surfaces smooth, square, and free of surface blemishes including pitting, rust, scale, sea, marks, roller marks, rolled trade names, and roughness.

2. Blemishes should be removed by filling or grinding or by welding and grinding, before cleaning, treating and shop priming.

3. Fabrication tolerances shall conforming to BS 5950-1 & 2. 4. Man Lock Hole (holes for fixing ladder support) shall be drilled as per Drawing

T.13.376.379 Rev G and the same to be used to tie off safety harness.

B. Thermal Cutting Heavy sections and thick plates will be preheated prior to cutting as required by Specification AWS code. The same will ground smooth to remove all serrations.



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C. Bolt Holes

Standard bolt holes will be drilled, or punched perpendicular to metal surfaces.

Holes will be provided required for securing other work to structural steel and for passage of other work through steel framing members.

All holes for high strength bolts shall be drilled. Holes shall be clear of burrs or rough edges and countersunk when required. The diameter of all holes shall not exceed the diameter of bolts by more than

1mm for bolts 12mm, 2mm for bolts 16 to 24mm and 3mm for bolts 27mm and larger.

All threaded portion each bolt shall project beyond the nut by at least 3 threads.

D. Finishing

Ends of members and any other supports will be accurately finished.

E. Welding

Welding procedure Specification, Welder Qualification, Quality of welders, tolerances etc. shall be complied with AWS D1.1 / ASME Section IX.

Weld size, fabrication sequence, and equipment used for exposed structural steel will be verified to limit distortions within allowable tolerances.

Defects that would be visible in the finished work shall be ground out, filled with welding material, and ground flush prior to finishing. Grind welds smooth where indicated. Welds shall be neat, complete and free of voids, flush finish, and not ground. NDE requirements if applicable shall be performed.

All welding shall be performed in an area protected from adverse weather conditions, rain, wind dust and sand with tents.

Welding procedures shall identify material, weld geometry, tolerances, and Welding process, and preheat temperature, welding position to be used and welding consumable.

All welders and welding operators shall be qualified by tests for welding structural shapes, pipe and plates to meet to the requirement of welding codes.

Spills of zinc based paint on structural steel causes the material to disintegrate during welding. Have the welding areas be cleaned properly and free from paint spills. (FSI Ref. # Q3b-13.0)

F. Surface Preparation

Surface preparation will be done as per MS for Painting and Repair Works T.4.250.900



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G. Galvanizing

Spray galvanize paint shall be applied on damaged areas using Paint System as per the Painting and coating of new equipment. (DEP 30.48.00.31)

H. Grouting

Grouting shall be done on equipment and steel structure foundation with approved materials as per specifications and MS for Grouting T.4.234.076.All structural steel frame will be aligned/plumb accepted by contractor before start of Grouting Works.

I. Pre Assembly:

Work permit will be taken for pre assembly works. Pre assembly will be done at site/yard on leveled ground surface. Pre assembly size will be determined based on transportation and capacity

of crane, the lifting procedure T.4.129.859 will be followed strictly. All the preassembled structure will be tightened as per MS for bolt

tightening T.4.250.857 and torqued with calibrated Torque wrench and recorded in GAM-QCR-QAC-GTL-041

Over all safety precautions will be taken care for assembly activities.

J. Handling and Storage

All materials shall be stored well clear of the ground with erection marks are clearly visible on skids or timbers. These supports shall be spaced so that no damage results from deflection. Stacking of components more than three pieces high is not permitted.

Steel work components shall be handled and stored in such a manner as to minimize the risk of surface abrasion and damage.

Fasteners and small fittings shall be stored in dry conditions. Steel work shall be stored so that erection marks are clearly visible.

7.5.2 Execution

Elevation of concrete and masonry-bearing surfaces and location of anchor rods, bearing plates, and other embedment will be verified with steel erector present, for compliance with requirements. Temporary shores, guys, braces, and other supports will be provided during erection to keep structural steel secure, plumb, and in alignment against temporary construction loads. Temporary supports will be removed when permanent structural steel, connections, and bracing are in place, unless otherwise indicated. Temporary shoring supporting composite deck construction will not be removed until cast-in-place concrete has attained its design compressive strength.



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7.5.3 Erection

Work permit will be taken before commencement of the Structural steel erection activities.

Training for all personnel for working at height will be provided. All personnel shall use Man Lock Hole to tie off safety harness.

All plant and equipment shall be suitable, and of sufficient capacity to complete erection of steel work.

All plant and equipment shall conform to the statutory regulations and requirements applicable to construction, plant and lifting devices. Test certificates for such items as slings and D shackles etc. shall be available for inspection.

Gama shall ensure that no part of the structure permanently distorted by stacking of materials or temporary erection loads during the erection process.

No equipment shall be supported from the frame until correct position and alignment has been obtained and the structure is securely connected and grouted to its foundations.

Column base plates shall be set and shimmed to the correct positions and elevations as shown on the drawings.

The erection of structural steel shall not commence until shims and anchors have obtained sufficient strength to adequately support all the loads imposed upon them including any due to the erection operation.

All steel shall be plumb and level. During erection, temporary bracing and guys shall be used to maintain structural

stability as necessary. (Ref. Attachment) Concrete and masonry-bearing surfaces of bond reducing material will clean and

roughened surfaces prior to setting base and bearing plates. Bottom surface of base and bearing plates will be clean.

Alignment and adjustment of various members forming part of complete frame of structure will be done before permanently fastening. Before assembly, bearing surfaces and other surfaces that will be in permanent contact with members will be properly cleaned. All steel members will be cleaned before start of erection.

Individual members of structure will be leveled and plumbed. Erection bolts on welded, architecturally exposed structural steel will be removed;

holes should be filled with plug welds and ground smooth at exposed surfaces. For all Lifts above 10 MT single unit ,prior approval will be taken for Rigging plans. Bolt Tightening Shall be done as per Method statement T.4.250.897

8. QUALITY ASSURANCE A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented through relevant T-4.250.907(QCP), T-4.250.917(ITP) and QCRs.



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9. ATTACHMENTS

TYPICAL ERECTION OF COLUMNS IN PIPE RACK PHASE 1

JSA



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JOB SAFETY ANALYSIS FORM

JSA Number: T.4.250.896 Page No: 15 of 26

Job being analysed: METHOD STATEMENT FOR STRUCTURAL STEEL ASSEMBLY AND ERECTION

Department/Section doing JSA: HSSE & Construction JSA Members: Mr. Syd Osborne, Mr. Atila GunJob Performers: Mr. Aitla Gun Normal Approvals: Name Signature Date General job requirements / Common Personnal Protective

Equipment.JSA by: Mr. Atila GUN 18.05.08

Job Supervisor: Mr. Ihsan POLAT 18.05.081. The following Personal Protective Equipment shall be worn while erecting structural steel at C2 ASU PEARL GTL PROJECT: Approved coveralls, safety glasses, safety helmet, safety steel toe shoes, gloves and safety harness.

Additional Approvals (Determined by Job Supervisor in correlation with LINDE HSSE Manager).Name Signature Date

Discipline Superindent LINDE

HSSE Representative LINDE

OTHERS (List Below): 2. Permit To Work.

Approval required for hazardous work detailed in the LINDE work permit procedure.Changing conditions and emergency procedures: -Stop work. Switch of equipment.Supervisor directs personnel to nearest and safest muster point considering wind direction. Supervisor counts all employees. Missing employees are reported to LINDE HSSE Dept. When all clear is given check with LINDE HSSE before returning to work.

EMERGENCY TELEPHONE NO. RLIC: 474 88 88LINDE HSSE MANAGER: 583 40 72

Note: 1) If any of the tasks involves biological, physical or chemical hazards, then The LINDE Industrial Hygienist must also approve the work. 2) Use additional sheets as necessary. 3) Details on safety (PPE,Hazard etc) and environmental requirements can be found in LINDE and Shell Safety and Environment Procedures.

NEW REVISED

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RISKRANK

1 1.1 1.1.1 Work area shall be properly maintained, all equipment and materials must be properly stored.

1.1.1.1 Remove any unecessary materials.

1.1.2 Housekeeping shall be done daily at the end of the days work.

1.1.1.2

1.1.3 Material storage areas shall be identified, stored properly, barricaded & secured.

1.2 1.2.1 Ensure employee has appropriate hand protection.

1.2.1.1

1.2.2 Do not use wrenches if the jaws are sprung.

1.2.3 Operate tools according to manufacturers instruction.

1.2.1.2

1.2.4 Perform mechanical tools maintenance regularly.

1.2.5 Cheater bar are not allowed to be uses as an extension for tightening bolts.

1.3 1.3.1 Ensure correct cribbing of dunnage.1.3.2 Ensure support can withstand

maximum intended weight/load.1.4 1.4.1 Ensure workers hand shall be away

from the connecting pieces of materials.

1.4.2 Ensure employee has appropriate hand protection.

Pre-Assembly of Frames at ground level.

Fall of materials from dunnage or support. B 3

Hand injury.

C 2

CCONTROLS

A

JOB SAFETY ANALYSIS / RISK ASSESSMENTT.4.250.896

SCOPE : Steel Structure Assembly and Erection

Initial Risk Residual Risk

ACTIVITY P RITEM C PHAZARD / POTENTIAL ADDITIONALCURRENTCONSEQUENCES

MED2

ALOWKeep the structural steel as low as possible to the ground.

LOW3

3 LOW

LOWA 2

1.4.1.1

1.3.1.1

LOW

EThe weight, size and type of tool should be selected to fit the job at hand.

All tools shall be inspected prior to use. Use the right tool for the job.

Discuss in TSTI.

Man Lock Holes are provided to tie off Lan Yards while working at heights.

Slip,trip and fall hazards.

Improper use of hand tools during assembly of frame.

B 3 LOW

CONTROLS

LOW2C

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ACTIVITY P RITEM C PHAZARD / POTENTIAL ADDITIONALCURRENTCONSEQUENCES CONTROLS

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2 Lifting of assembled structural frame.

2.1 2.1.1 Ensure that crane operator is certified by Third party, valid certificates and driver's licenses.

2.1.1.1 All equipment, slinging, hooks, pin, shackles shall be Third party certified.

2.1.2 Ensure that all lifting gear/lifting tackle is properly inspected and color coded as per color code chart.

2.1.1.2 Rigger shall be 100% visible & clearly relay the information to the crane operator.

2.1.3 Third party crane inspections. 2.1.1.32.1.4 Competent Riggers.2.1.5 Daily crane inspections.2.1.6 Tag lines are to be used to control

loads.2.1.7 Barricade the working area with sign

boards indicating crane lifting is in progress to prevent unauthorized entry.

2.1.8 Ensure that no materials are on the assembled materials.

2.1.9 Ensure pre lift check to be conducted prior to lift.

2.2 2.2.1 Only work on level solid ground use out riggers with adequate support pads.

2.2.1.1

2.2.2 Ensure all lifts will be controlled and supervised by supervisor/competent person.

2.2.3 Safe Working Load displayed.2.3 Attempting to lift

unknown weigth2.3.1 Load chart should be available in the

operators cabin at all times.2.3.1.1 Provision of lifting plan if

there are critical.2.3.2 Display of SWL, radius of working

indication.2.3.3 Ensure automatic safe load indicator is

working.2.3.3.1 Test before use.

4 LOWB

3 LOW

4 MED A

Ensure the machine shall be traveled to the most suitable position for the job to be carried out before any slewing takes place.

B

Overturning machines

Dropped loads.

Ensure all lifts will be controlled and supervised by a supervisor/competent person. LOW

3 LOW

4

A

AC 4 MED

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B 4 MED2.3.4 Use of out riggers and/or counter

weights. A 4 LOW

2.4 2.4.1 Ensure to have a valid certificates for drivers/operators.

2.4.1.1

2.4.2 Competence checks for drivers / operators.

2.5 2.5.1 Use only cranes less than 10 years old.

2.5.1.1

2.5.2 Ensure to have Third Party Inspection.2.5.3 Ensure to have a valid certificates

checks.2.6 2.6.1 Competence checks registered riggers

clearly identified.2.6.2 Ensure to have a list of competent

persons maintained.2.6.3 Contractor supervisor to constantly

monitor rigger performance.

2.7 2.7.1 Ensure to know the weight of load. 2.7.1.1.2.7.2 Ensure all lifting equipment shall be

inspected and approved by third party and certified prior to use on site.

2.7.3 Safe Work Load should be display.

2.8 2.8.1 Keep away personnel from lifting /moving area.

2.8.2 Rigger and crane operator must be certified by third party as being competent.

2.8.3 Tag lines shall be attached to control the loads.

2.8.4 Personnel shall not work directly below suspended load.

LOW

Underrated slings/hooks/shackles.

LOW

Improper rigging method

C

People/material struck by swinging loads/crane in motion.

B

C

4 MED

4

A

A 4

A

A

4

MED

Sub-standard cranes

B

4 MED

Unqualified crane drivers/operators.

B A

MED

Ensure competent rigger oversees all lifting operations.Rigger shall be 100% visible to the crane operator & clearly relay the information to the crane operator and Refer MS for Lifting, Ref T-4.234.084

2.6.1.1

2.6.1.2

MED

Crane shall be inspected and approved by third party and certified prior to use on respective site.

Ensure that nobody on the way of the crane.Barricade and secure the working area with high visibility warning signs.Assign competent banks man to control passerby.

4

2.8.1.1

2.8.1.2

2.8.1.3

4

LOW

LOW

4

4 LOW

4

Ensure all lifting gear brought into the site shall be clearly identified by means of a name plate, supplied by a manufacturer, as to SWL & serial no.

Only drivers/operator with Qatar license & certified operator inducted and trained personnel are allowed to work on site.

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2.9 2.9.1 Ensure to have inspection of all equipment prior to use on site.

2.9.1.1

2.9.2 Inspection shall be carried out by a competent person who has detailed knowledge of the type of machine he is to examine.

2.10 2.10.1 Ensure permanent bracings are installed and bolt tightened.

2.10.1.1

2.10.2 Ensure center of gravity of the frame being lifted.

3.1 3.1.1 Ensure that all hand tools are in good condition.

3.1.1.1

3.1.2 Ensure qualified/ competent employee to carry out the task.

3.2 3.2.1 Ensure employee use proper lifting techniques i.e. lift with their legs not their back.

3.2.1.1

3.2.2 Use the "Buddy System" get help.3.2.3 Break the job down into manageable

portions.3.3 3.3.1 Only authorized & skilled worker for

the task.3.3.1.1

3.3.2 Ensure workers not to hold base plate.

3.3.3 Supervisor shall ensure that work will be supervised as per work Method Statement. Ref.T-4.250.896

4.1 4.1.1 Ensure that all hand tools are in good condition.

4.1.1.1

4.1.2 Ensure qualified/ competent employee to carry out the task.

4.1.3 Ensure not to use extentsion handles.

LOW3A

LOW

3

2 LOW

3 LOW

LOW

Equipment failure due to mechanical problem.

B

4 Initial bolts tightening.

Pinch point .

B

4

Tools to be checked and certified and colour coded prior to use. A

Discuss in TSTI.

A

Discuss in TSTI.

2

3

3

Ensure two tag lines are controlling the load.

4

Discuss in TSTI.

A

A

3 LOW

MED

Possible collapse of assembled frame due to severe twisting. B

3 Setting up of lifted frames at anchor bolts foundation.

Pinch point injuries tightening of nuts to the anchor bolts. B

Muscle strain or sprain while positioning of frames into anchor bolts.

B

Caught in between column base plate & foundation.

B

MED A

Ensure after inspection to generate report specifying any repairs, renewals which he considers are necessary if the equipment is to continue to be used with safety.

LOW

LOW

LOW

4 LOW4

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5 5.1 5.1.1 Ensure employee has appropriate hand protection.

5.1.1.1

5.2 5.2.1 Warn employees of pinch or crush points.

5.2.1.1

5.2.2 Two tag lines shall be attached to control the loads.

6.1 6.1.1 Discuss in TSTI.6.1.2 Ensure employee has appropriate

hand protection.6.2 6.2.1 Ensure employee use proper lifting

techniques i.e. lift with their legs not their back.

6.2.1.1

6.2.2 Use the "Buddy System" get help.6.2.3 Provisions for mechanical equipment

i.e. trolley, fork lift etc..7 Assembling

purloins between columns & diagonals prior for tirfors, sling removal.

7.1 Fall of personnel. 7.1.1 All employees shall wear inspected full body harness fitted with twin lanyards with shock absorbers, each lanyard shall be fitted with dual action self-locking safety hook to allow for 100% Tie-off.

7.1.1.1 Discuss working at height hazards at daily TSTI. Provided Man Lock hole for tie off Land Yard.

7.1.2 Ensure that all employees working at height are properly trained.

7.2 7.2.1 Ensure bolts/nuts are contained in bolts bags.

7.2.1.1

7.2.2 Tools shall be tied with retaining rope attached to the body harness.

7.3 7.3.1 Ensure lifeline has a design calculation/Engineering design.

7.3.1.1

7.3.2 Ensure lifeline can withstand load impact.

A

LOWA 4

LOW

MED

LOW

Hook-up of temporary support stability concrete blocks.

A 3

Discuss in TSTI.

2 LOW 2

LOW

LOW

B

Back injury due to manual handling.

Hand injury.B

3

3

4

Personnel injury from poor body position.

B 3

2Installation of temporary support for frame stability.

Hand injury.

Break the job down into manageable portions.

B

6

LOW A

LOW

A

B

Lifeline failure.

MED

3

B 4

B 3

Lifeline should be inspected prior to its use by a competent personnel.

Barricade and secure the working area with signboard.

A

A

Tools/materials fall hazard.

LOW

LOW

4 LOW

LOW

3

Discuss in TSTI.

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8 Removal of slings. 8.1 Fall of personnel, while working on slings.

8.1.1 All employees shall wear inspected full body harness fitted with twin lanyards with shock absorbers, each lanyard shall be fitted with dual action self-locking safety hook to allow for 100% Tie-off.

8.1.2 Ensure that all employees working at height are properly trained.

9 9.1 Possible fall down of frame.

9.1.1 Tie-back to prevent frame from any deflection and fall.

9.1.2 Supervisor shall ensure that work will be supervised at all times as per work Method Statement.

9.1.3 Method statement detailing the proposed erection schemes will be produced. These method statements will identify hazardous site features and other aspects likely to impair safe erection. These proposed methods for ensuring the stability of the framework and its component will also be addressed.

9.2 9.2.1 Area shall be properly maintained with all equipment and materials to be properly stored and picked up.

9.2.1.1

9.2.2 Housekeeping shall be on going and picked up at the end of the day.

9.2.3 Material storage areas shall be identified and properly barricaded.

LOW4

2

A

LOW

LOW4A

B

Alignment of structural columns.

Slip, trip and fall hazards.

C

MED4B

4

2 LOW

Remove any unnecessary materials.

A

MED

8.1.1.1

9.1.1.1

9.1.1.2

Discuss working at height hazards daily in TSTI.

Barricade and secure the area to prevent unauthorized entry.Provide competent banks man to control passerby.

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10 10.1 10.1.1 Insulate yourself from work and ground.

10.1.2 Ensure tools/equipment are of correct type, size and they are in good condition and inspected and color coded.

10.1.3 Ensure good electrical connection.

10.2 10.2.1 Ensure employee wear suitable gloves when using mechanical torque wrench.

10.2.2 Only qualified & trained employee will carry out the task.

10.3 10.3.1 Housekeeping shall be a priority, walk and work areas shall be kept free of materials.

10.3.2 Remove any unnecessary materials.11 Roof installation. 11.1 11.1.1 Install barricades "exclusion zone" with

sign boards indicating roofing works in progress to prevent unauthorized entry.

11.1.1.1 Remove any unnecessary materials.

11.1.2 All materials shall be safety lowered from one level to the next either by hand-to-hand or by securely attaching a rope and hauling.

11.1.1.2 Provision of Watchman with whistle & vest to control people from barricaded area.

11.1.3 Tools shall be tied by a retaining rope attached to the harness.

LOW

LOW

Electric shock.

B 4 MED

Ensure all electrical equipment were properly grounded and built with ELCB at their source.Dont touch electrically live parts with skin or wet clothing.

Final tightening of bolts using electric & mechanical wrench.

Hand & Finger injuries.

C 1

Slip, Trip & Fall from same level due to cluttered area. C 2 LOW 2

4

LOW

A

10.3.1.1

10.1.1.1

10.1.1.2

A

C HIGH 5 MEDA

Dropped materials.

5

Keep cables, materials, tools neatly organized.

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11.2 11.2.1 100 % fall protection system.

11.2.2 Monitor wind speed using Anemometer. Crane operations should be stopped at greater than 25 knots.

11.2.3 Lifting work must be stopped during strong wind as per crane manufacturers recommendations.

11.2.4 Ensure all roofing sheets to be secured on the ground and on the roof.

11.3 11.3.1 Full body harness and lanyards shall be inspected & color code or tagged.

11.3.1.1

11.3.2 Harness and safety line when work is greater than 1.5 meters.

11.4 11.4.1 Ensure lifeline has a design calculation/Engineering design.

11.4.1.1

12 Sliding installation. 12.1 12.1.1 Install barricades "exclusion zone" with sign boards indicating sliding works in progress to prevent unauthorized entry.

12.1.2 All materials shall be safety lowered from one level to the next either by hand-to-hand or by securely attaching a rope and hauling.

12.1.3 Tools shall be tied by a retaining rope attached to the harness.

LOW

A 4

C

4B

5

12.1.1.1

12.1.1.2

MED

Remove any unnecessary materials.Discuss in daily TSTI.

A 5

Dropped materials.

C 5 HIGH

Unprotected edges or openings. C

Lifeline failure.MED

Lifeline should be inspected prior to its use and erected by a competent person.

2

HIGH

11.2.1.1 Employees should be aware of the affect of weather conditions on the operation.

Wind hazard.

BLOW2

Ensure that all employees working at height are properly trained with proper TSTI.

A

LOW

5 MED

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12.2 12.2.1 100 % personal fall protection system.

12.2.2 Monitor wind speed using Anemometer. Crane operations should be stopped at greater than 25 knots.

12.2.3 Lifting work must be stopped during strong wind as per crane manufacturers recommendations.

12.2.4 Ensure all roofing sheets to be secured on the ground and on the roof.

12.3 Poor illumination/ No lights

12.3.1 Provide suitable area flood lighting to ensure the workers have sufficient light to allow accurate depth perception with elimination of shadows.

12.3.2 Employees shall wear clear lens safety glasses.

12.3.3 All access should be cleared of all materials.

12.3.4 Lighting shall be set up to prevent shadows.

12.3.5 Lighting shall be set up in such a way that it does not blind employees.

12.3.6 Provide adequate lighting ( Light Towers or Flood Lights) around the work fronts, access roads and welfare facilities.

12.4 12.4.1 Warn employees of pinch or crush points.

12.4.1.1

12.4.2 Two tag lines shall be attached to control the loads.

12.5 12.5.1 All employees shall wear inspected full body harness fitted with twin lanyards with shock absorbers, each lanyard shall be fitted with dual action self-locking safety hook for 100% Tie-off.

12.5.1.1

12.5.2 Ensure 100% fall protection.

LOW

LOW

A

A

LOW

12.2.1.1

4

Refer to Lighting Plan.Obtained Extended Work Hours/Night Work Request with prior approval.

LOW

Employees should be aware of the affect of weather conditions on the operation.

3

2B

Discuss working at height hazards at daily TSTI. Provided Man Lock hole, to tie off Land yard.B MED4

Personnel injury from poor body position.

B

B

Fall of personnel, while working at heights.

3

Wind hazard

C 2

3

LOW

12.3.1.112.3.1.2

LOW

LOW A 3

Discuss in daily TSTI.

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13 Using of Manlift. 13.1 Mechanical breakdown. 13.1.1 Equipment shall be serviced, maintained and inspected as per set maintenance and inspection program.

13.1.2

13.1.3

13.1.4

Ensure E-Stop is in place through the control system. Perform equipment daily check prior to use.Supervisor shall ensure that work will be properly supervised as per Work Method statement.

13.1.5 Ensure an emergency stop should be provided on the platform control panel.

13.2 Improper use of equipment.

13.2.1 Manlift shall not be used as cranes or jacks unless they have specifically been designed for this purpose by their manufacturers.

13.2.1.1 Ensure all equipments are inspected / approved & color coded.

13.2.2 Leaning out of the platform shall be avoided.

13.2.3 Color coded inspected sticker should be available on the equipment.

13.3 Untrained personnel. 13.3.1 Ensure platforms must only be used by authorized personnel who have been trained in the operation of the type of platform in use.

13.3.2 Initial training should cover operating principles, machine controls and environmental conditions, which are likely to be encountered.

13.3.3 Training and practice in the type of work to be undertaken is essential.

13.3.4 Ensure that equipment operator is certified by Third party, valid certificates.

LOW3A

LOW3ALOWB 3

LOW3B

B

13.1.1.1

3

13.3.1.1

LOW

Ensure equipment to be provided with controls of the Dead man type, which only allow movement of the machine to take place whilst they are actually being operated. Dead man controls automatically return to the neutral position.

Ensure supervisor who will using manlift should be particularly aware of the hazards which may be encountered while using these machines and of the precautions which may be taken to eliminate or minimize there hazards.

LOW3A

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13.4 Fall of personnel. 13.4.1 Safety harness shall be provided for the use of all personnel working from mobile work platforms so that in the event of any advertent movement of the platform they are working from, they will not be thrown from it.

13.4.2 Boxes, hop-ups or ladders shall never be used to gain additional height or reach from the platform of manlift machine/ work platform.

13.5 Overturning of machines.

13.5.1 Ensure no excessive force is used by the operator on the platform, by introducing an element or side load.

13.5.1.1 When a manlift needs to work in confined area, an approval for the operation shall be obtained.

13.5.2 The outriggers or stabilizers, when fitted, shall be fully extended and in position, before the platform or boom is raised.

13.5.1.2 Considered the effects of acceleration and deceleration.

13.5.3 The platform shall not be overloaded exceeding the regulated Safe Working Load.

13.5.4 Ensure the machine shall be placed to the most suitable position for the job to be carried out before any slewing takes place. Slewing the boom to the extent that causes the machine to overturned shall be avoided.

13.5.4.1 Ensure the boom to be well within the limits of control.

13.6 Vehicle movement. 13.6.1 Ensure all vehicle movement to be guided by competent banks men with High visibility vests.

13.6.2 Ensure that each piece of equipment is fitted with an automatic reverse alarm and beacon or strobe light.

MED

LOW4A

LOW3A

5A

MED

3B

B 4

5B

13.6.1.1

13.4.1.1

13.4.1.2

MED

LOW

Barricade and secure the working area with sign boards to prevent unauthorized entry.

Discuss working at height hazards at daily TSTI.Supervisor shall ensure that work will be properly supervised at all times as per work Method Statement. Provided Man Lock hole/live wire to tie off Land yard.

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MS STRUCTURAL Rev F 18.05.08.pdfJSA-Erection of Steel Structure 18.05.08_1.pdfcover

JSA-Erection of Steel Structure 18.05.08_2.pdf

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001-MS for Structural Steel Assembly and Erection.pdf

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