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8/10/2019 Method Statement for Steel Structure & Erection
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INSPECTION Gr
FIELD INSPECTION REPORT ffi:-'-"INSPECTION TYPE
STEEL STRUCTURE INSTALLATION INSPECTIONWORK No.
ITEM NoAREA / LOCATION
ITEIM No. DESCRIPTION SIGNATUREINSPECTION NOTICE No OWNER CONSORTIUM CONTRACTOROWNER'S INSPECTOR
CONSORTI UM'S INSPECTOR
CONTRACTOR'S INSPECTOR
REFERENCE Drawing. No
I'IGHTENING METHOD
I Calibrated Wrench Method Twist-of-Type Tensron Control
INSPECTION
ffiTACC-T--REJ1 LOCATION2. VERTICALITY
3. HEIGHT
4 HORIZONTALITY5. FOUNDATION AND ANCHOR BOLT
6. SHIMMING
7 WELDINGB, BOLT I"ORQUI NG/I'IG HTEN'NG
9. GIlOUTING
1O PAINTING (TOUCH-UP)
OTHERS
1 TORQUE WRENCH CALIBRATION2 CRANE / HOIST RAIL INSTALLATION
COMMENTS
LEGEND ACC ACCEPI- N.A. Not Apptjcabte REJ REJECT
fjoRfi/ No. c-40
8/10/2019 Method Statement for Steel Structure & Erection
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FIELD INSPECTION REPORT
ITP NO- :INSPECTION Gr. :REPORT NO. :
INSPECTION TYPE:
STEEL STRUCTURE ALIGNMENT INSPECTION
LEGEND ACC ACCEPT N.A. : NotApplicable REJ: ttEJECT
FORMNO
C.41
ITEM No. :AREA / LOCATION
SIGNATURETEM No. DESCRIPTION:CONTRACTORNSPECTION NOTICE No
OWNER S INSPECTOR
CO lr SOniTVLY r'f .S P rCrO nCONTRACTOR'S I NSPECTOR
REFERENCE Drawing. No
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COLUMN VERTICALITY
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8/10/2019 Method Statement for Steel Structure & Erection
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TNSPEC ttoN Gr
FIELD INSPECTION REPORT ffi;:-,-"INSPECTION TYPE:
STEEL STRUCTURE ACCESSORIES INSPECTIONAREA / LOCATION :
WORK No.
ITEM No DESCRIPTION SIGNATUREINSPECTION NOTICE No OWNER CONSORTIUM CONTRACTOR
OWNER'S INSPECTOR
CONSORTI UM'S INSPECTOR
CONTRACTOR'S I NSPECTOR
REFERENCE Drawing. No.
VISUAL INSPECTION
o c0'=soqa
6.oIo
6coNoI
oc-6
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.ce0_
REMARKS
ACCESSORIES'l . Platform
2. Ladder
3. Grating
4. Checker Plate
5. Handrail
6. Stair
7
B
9
10
COMMENTS
LEGEND ACC: ACCEPT N.A. NotAppllcable REJ: REJECT
FORM NO. C-042
8/10/2019 Method Statement for Steel Structure & Erection
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8/10/2019 Method Statement for Steel Structure & Erection
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.S-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 2 of 13
TABLE OF CONTENTS
1.0 SCOPE ................................................................................................................ 3
2.0 REFERENCE DOCUMENTS .............................................................................. 3 2.1 A BBREVIATIONS ........................................................................................... 32.2 C ODES ........................................................................................................ 32.3 C ONTRACTOR 'S DOCUMENTS ....................................................................... 4
2.4 A SSOCIATED P ETROJET P ROCEDURES ......................................................... 43.0 RESPONSIBILITY .............................................................................................. 4
3.1 C ONSTRUCTION M ANAGER ........................................................................... 43.2 QA/QC M ANAGER ........................................................................................ 4
4.0 MATERIAL AND EQUIPMENT........................................................................... 4 4.1 S TEEL S TRUCTURES ................................................................................... 54.2 W ELDING FILLER METAL .............................................................................. 54.3 E QUIPMENT AND TOOLS .............................................................................. 5
5.0 PLANNING OF ACTIVITIES AND MONITORING OF PROGRESS ................. 5
6.0 ERECTION DRAWINGS .................................................................................... 5 7.0 RECEIVING, HANDLING AND STORING MATERIAL ..................................... 6
8.0 CHECK FOR FOUNDATIONS........................................................................... 6
9.0 PRELIMINARY CHECKS .................................................................................. 6
10.0 MATERIAL WITHDRAWAL............................................................................... 7
11.0 ERECTION .......................................................................................................... 7 11.1 GENERAL ..................................................................................................... 711.2 M OUNTING GUIDELINES ................................................................................ 811.3 I NTERMEDIATE INSPECTION .......................................................................... 1011.4 F INAL INSPECTION ....................................................................................... 1011.5 T OLERANCES .............................................................................................. 1011.6 R EPAIR OF G ALVANIZED S TEEL .................................................................... 10
12.0 TESTING AND INSPECTION ............................................................................. 11
13.0 GROUTING ........................................................................................................ 12
14.0 QUALITY RECORDS......................................................................................... 12
15.0 APPENDIX ......................................................................................................... 12
8/10/2019 Method Statement for Steel Structure & Erection
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 3 of 13
1.0 SCOPE
This procedure describe the minimum requirements that shall be observed at site for handling and
storing materials, erection of hot dip galvanized primary and secondary steel structure to be installed .
It also covers the tests and inspections that are to be carried out during the execution of the
assembly works.
And this procedure covers Steel Structures, Steel from Building, Supporting Steel, Steel Pipe Rack,
and Miscellaneous Structure Steel.
The objective is to ensure that all the activities are carried out:
In accordance with approved procedures, specifications and drawings,
Using special working and control process which have been previously qualified;
employing qualified and, when required, certified personnel;
using material which are kept under control from receiving throughout entireworking cycle;
Performing all tests, measurements and inspection required by Contract.
2.0 REFERENCE DOCUMENTS
2.1 ABBREVIATIONS
ITP = Inspection & Testing PlanQC = Quality Control
2.2 CODES (BRITISH STANDARDS )
AISC (9 th edition) The American Institute of Steel Construction.AWS D1.1 Structural Steel Welding Code.
(B S) British Standard.
(ISO) International Standard Organization.
ANSI American National Standard Institute.
ASTM American Society for Testing and Materials.
2
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 4 of 13
2.3 CONTRACTOR'S DOCUMENS
Minimum Quality Requirements for Site Activity.Steel Structural Works Technical Specification.Steel Structure Standard Drawings and Details.
ED-9999-STR-SPEC-000-JB611 Specification Of Steel Structure.
CD-9999-FQC-PRC-000-001 QC Procedure.
ED-9999-PJM-PEP-000-006[1] Project Quality Plan.
ITP NO: 2001 : 2011 Inspection & Test Plan for Mechanical Works.ITP NO:20 Structural Steel (Erection).
2.4 ASSOCIATED PETROJET PROCEDUR
PJ-EEP2-MRI-PRO-0001 Method of Statement of Material Handling , Storage Procedure
PJ-EEP2-NR-PRO-0001 Non Conformance Management Procedure.
PJ-EEP2-NDT-PRO-0001 Visual Inspection Procedure.
3.0 RESPONSIBILITY
3.1 CONSTRUCTION MANAGER
The Construction Manager is responsible for the implementation of this procedure for
the over all direction and coordination with the QA/QC Manager for monitoring,
coordinating
and control of all the erection activities.
3.2 QA/QC MANAGER
The Site QA/QC Manager is responsible to verify the proper implementation of the quality
systems and to implement quality control activities related to erection.
4.0 MATERIAL AND EQUIPMENT
4.1 STEEL STRUCTURES
The Steel Structures shall mainly consist of the following: Steel Building and Shelter Pipe Racks / Steel Structure Equipment Platform, Stair and Walkways / Handrails/Cross over /Shetters. Minor Steel Structure / Supports / Ladders / Grouting /Beams, etc.
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 5 of 13
4.2 WELDING FILLER METAL
When required for any modificat ion Welding filler metal shall conform now to BS 5135,
BS 639 and ISO 5182 /E7018 welders and welding WPS as per BS4871 & BS 4872
4.3 EQUIPMENT AND TOOLS
All tools and equipments to be used for erection shall be standard (not allow any
fabricated or hand made fouls) in good order, safe condition and sufficient quantity.Examples of tools and equipment are:
Cranes
Lifting gear including sling wires,belts,chackles,ect.
Plastic Ropes to be used as guide only during lifiting not for any lift.
Standard tools such as spanners, Transportation Trucks
Torque Wrenches5.0 PLANNING OF ACTIVITIES AND MONITORING OF PROGRESS
The Project Planner is responsible to plan the sequence of erection of steel structure
according to the Construction Master Schedule.
He is also responsible to monitor the progress of the work and to keep informed the
Construction Manager and Project Manager for any deviation from the original schedule.
Planning of steel structure erection shall be made according to erections priority
and material availability.6.0 ERECTION DRAWINGS
The Technical Office (TO) receive the steel structures drawings from engineering department.
Based on the availability of drawings, material after fabrication, specifications and in
congruence with planning, TO shall issue detailed drawings for erection and copy to all the
concerned departments (AFC DWGS & Last Rev).
The following information shall be provided in the detailed drawings:
Identification of each item, part or assembly number with match mark and otherinformation as necessary for easy identification and erection;
Specific instruction, as necessary for erection;
1
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 6 of 13
7.0 RECEIVING, HANDLING AND STORING MATERIAL
The Material Control Manager (MCM) shall receive all steel structures in accordance with the
procedure and shall be responsible for checking quantity and type of materials indicated in
the packing list and QC inspector checks for quality. The damages shall be immediately
notified to take the required measures.
The materials shall be stored, handled and preserved in accordance with the procedure.
8.0 CHECK FOR FOUNDATIONSBefore commencing work, center lines, locations, orientation, chipping and
elevations of foundations shall be checked for prescribed tolerances.
Support shims shall be located after marking the centre lines on the plinths.
At least 3/4 shims packs with levelling mortar shall be provided for the base plates of each
column. Centre lines marked on plinths shall have a tolerance of 1 mm and elevation
of 1 mm.
The foundation bolt surface that will come in contact with concrete shall be free fromdirty and oily matters or points. Foundation surface shall be chipped prior to erection activity.
9.0 PRELIMINARY CHECKS
According to the sequence and schedule of erection, the following preliminary checks
shall be carried out before erection activities begin, in order to verify:
The availability of experienced, qualified personnel and equipment necessary to
carry out the works;
The availability of fabricated steel structure and its status of acceptance.
The status and availability o f approved for Construction drawings and
/or specifications.
All tools and equipments used for erection are calibrated as per Calibration of
Inspection and Testing Equipment procedure
The status of torque wrench calibration the above preliminary checks shall be
jointly made by all the concerned as i n responsibility matrix.
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8/10/2019 Method Statement for Steel Structure & Erection
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 8 of 13
The contact surfaces of bolted elements shall be free from rust, mill scale, grease, etc. Bolts
already used and previously tightened shall not be re-used.
All site bolted connections shall be assembled and torque tightened in accordance with Appendix
A. After the torque tightening of bolts shall be identified by the paint on the bolt head.
All material, plant and equipment used shall be of sound construction and free from flaws.
Bolts designed for transmitting forces in structural member connections, shall have a minimum
diameter as follows :
Minimum diameter For main members, bracings and struts 20mm
For secondary, i.e. bracings, purlins, 16mm
Ladders, handrails, etc.
( Unless noted otherwise on standard drawings).
Except otherwise noted on design drawing, hole diameter for bolts shall be as followsDiameter bolt, plus:
For steel-to steel connections : 2mm For steel-to-concrete connections (anchor bolts):
o Up to 24 mm bolt diameter : 4mm
o 24 to 32 mm bolt diameter : 6mm
o 32 mm bolt diameter and over : 8mm
The spacing of bolts in the direction in which the force is applied shall be at least three bolt
diameters (measured in the direction of the force).
The minimum distance from center of bolt edge of plate measured in the direction of force shall be two bolt diameters, and measured at r ight angles to the direction o f force, one and a half bolt
diameters.
Slotted hole connections are to be executed in such away, that these connections may perform
their design function, as indicated on the design drawings, and shall be provided with washers.
High-strength bolts shall be used for structural steel-to-steel connections.
High-strength bolts shall be used for in bearing-type connections and not as friction grip bolts
11.2 MOUNTING GUIDELINESIf required, additional drilling of beams, columns or other components shall be made to
remedy fabrication mismatch / faults. Magnetic base drills shall be used for such work.
8/10/2019 Method Statement for Steel Structure & Erection
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8/10/2019 Method Statement for Steel Structure & Erection
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 10 of 13
Checking at a pre-erection stage for correct distance of the connected column
Flanges to beam.
Handrails and toe plates shall be not welded to the columns; however they shall be
Adequately jointed in the vicinity of the columns.
When not provided in the design drawings, the tube passage through grating shall
be admissible only in case grating is adequately reinforced at the pass hole.
A toe plate shall be provided around the pass hole.
11.3 INTERMEDIATE INSPECTION
Each framework floor shall be checked for verticality and diagonals before and after tightening of
bolts.
Survey instrument shall be used for checking of verticality. When executing the tests, proper
consideration shall be given to the deformation changes occurring in the steel structure during a day
on account of exposure to the sunlight.
Verticality:
Verticality and levelness shall be checked by means of a Survey instrument.
For verticality reference shall be made to points (flags) marked on columns;
Diagonals (in plan):
Diagonals shall be checked using a metric roller;
All structural framework / floors shall be checked;
11.4 FINAL INSPECTION
Check for steel structure framework verticality, horizontal alignment and height shall be carried
out after mounting.
Splicing shall be executed in accordance with prescriptions listed para 9.4. Bolt torque
tightening shall be as mentioned in the Appendix Completeness check as per approved for
construction drawings.
After checking of connection, the erecion drawing shall be marked to indicate acceptance.
11.5 TOLERANCES
The deviation in overall dimensions, positions, alignments, plumpness and
elevations shall not exceed the limits specified in specification.
1
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 11 of 13
11.6 REPAIR OF GALVANIZED STEEL
Any damage to galvanized steel shall be repaired in accordance with ASTM A780.
Before repairing the damaged galvanized coating, the exposed substrate metal shall be cleaned to bright
metal
and free of all visual rust, oil or grease. Any none adhering galvanizing shall be removed to the
extent that the surrounding galvanizing is integral and adher ent.
12.0 TESTING AND INSPECTION
Inspection and test shall be carried out by qualified personnel, coordinated by SQM, according to
the Inspection & Testing Plan (ITP).
All structural steel material and fabrication shall be subject to inspection by client
Welds shall be inspected by contractor according to the previsions of regulatory requirements with
respect to technique, equipment, and acceptance criteria and personnel qualifications. All welds
shall be subject to random visual inspection by client .in addition, the following specialrequirements shall apply to welding inspection.
Grating shall be tagged with metal plate having raised letters so that the mark shall be seal welded
to the grating prior to galvanizing.
Contractor may submit alternate proposal for marking galvanized members, subject to clients
written approval.
SQM shall manage all Witness and Hold Points shown on the ITP, including convocation to
Contractor.The form worked out toyo shall be used for issue of the certificates listed in the Inspection and
Test Plan The Inspection mentioned in the Inspection and Test Plan shall be carried out using the
following calibrated instruments:
Optical levels, steel metric rollers, water levels, manual dial type torque wrench for torque read-out.
10% of all connections for each bolt size shall be randomly selected and inspected, of each
joint shall show the tightening value of high strength bolts. Such test shall be conducted on
minimum 2 bolts per each joint.
Tested bolts shall be clearly marked with paint.
Each high strength bolts assembly shall consists of one heavy semi-finished hexagon structure
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 12 of 13
bolts one heavy semi-finished hexagon nuts and one hardened washer to be used the nut
In presence offload indication Washers ,turn-of nut tightening follow-up; one nut sample per each
size of bolts shall be unscrewed by at least 1/6 turn and then to check whether the prescribed torque
brings the nut back to its original position.
Galvanized bolts shall not be reused after unscrewed; bolts may be reused after repaint
by galvanize spray.
13.0 GROUTING
All bearing plates, loose lintels, beams and columns shall be shimmed to proper grade and
level before grouting.
Grout material as specified in the technical specification or on drawing shall be used.
The sand-cements mixture shall be combined with the least amount of water to produce a low
slump, place able grout.
Prior to setting structure, the concrete surface to receive grout shall be chipped to a depth of
6 mm to obtain a roughened surface.
After the structure is a place, positioned and shimmed immediately before grouting, the surface to
receive grout shall be cleaned and wetted. Excess water shall be removed.
Grout shall be placed and thoroughly worked to eliminate voids and provide a uniform bearing
surface under the base plate.
When specified on drawings, epoxy grout shall be used for grouting under heavy equipment
where large bearing and /or vibration stresses occur. Epoxy grout shall be mixed by mechanical
mixer and placed in accordance with manufacturer instruction.
14.0 QUALITY RECORDS
The following records shall be provided:
ITP and Procedure
Certificates of materials supplied
Dimensional reports
Bolt torque tightening reports
Surface treatment reports
Grouting reports
Final dossier containing the report of the test carried out
8/10/2019 Method Statement for Steel Structure & Erection
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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION
Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 13 of 13
15.0 APPENDIXB
1- Torque Tightening of Steel Structure Table 001.
2- Steel structure installation inspection C-40.
3- Steel Structure Alignment Inspection C-41.
4- Steel Structure Accessories Inspection C-42.
TORQE TIGHTENING OF STEEL STRUCTURE
Bolts Classes 8.8 and 10.9
The tightening torque shall be in accordance with the following Table 001.
Nominal Diameter of Bolt in mm Tightening Torque in NM
12 94
14 148
16 234
18 320
20 456
22 616
24 787
27 1150
30 1562
33 2125
36 2729 39 3532
Form No. Table :001
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