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421/422-SBG-CCM-010-00
The Construction Manager: The Contractor:
King Abdulaziz International Airport Development Project(J-10-421-PF-00 and J-10-422-PF-00)
Compliance with CM Comments
Sl.No.
1
Contractor's Reply
Saudi Binladin Group
Facility Code:
Area of Appliacation:
4Rev.MST For Steel Structure Installation (421-DCS-MST-S-00850) F100
F100-PTB
Submittal Tittle:
Sub-Contractor :
A separate logistic plan for zone A&E will be submitted with coordination with the main contractor.
Please find section 13 Survey scheme.
CM Comments
Logistics of access to the working areas.
Method of lining and leveling required.2
THE ENGINEER:
King Abdulaziz International Airport Development Project
(Phase I) Jeddah, KSA
THE CONTRACTOR:
Contractor: Saudi Binladin Group Doc. Ref. No.: 421-DCS-MST-S-00850 Rev.04 Contract No.: J-10-421-PF-0 Date Issued: 31 Jan 2013
Method Statement for Installation of Steel Structure
Page 2 of 82
List of Contents 1 Preface ................................................................................................................... 4 2 Scope of Work ........................................................................................................ 5
2.1 Pier .................................................................................................................................................. 5 2.2 Terminal Processor ....................................................................................................................... 5 2.3 International Hub ........................................................................................................................... 8 2.4 Boarding Bridge ............................................................................................................................ 9 2.5 Reference Standards: ................................................................................................................ 10
3 Personnel Roles and Responsibilities ............................................................... 10 4 General Construction Introduction .................................................................... 10
4.1 Schedules .................................................................................................................................... 10 4.2 Site Plan ....................................................................................................................................... 10 4.3 Manpower plan .............................................................................................................................. 11 4.4Mechanical and Equipment............................................................................................................. 11 4.5 General Work Procedures .............................................................................................................. 12
5 AESS requirement ................................................................................................ 14 6 Site Welding ......................................................................................................... 15 7 Bolting Tightening ............................................................................................... 15 8 Touch Up Painting Procedure ............................................................................. 15 9 Installation Method for Pier ................................................................................. 17
9.1 Shipping Unit ............................................................................................................................... 17 9.2 Erection Units .............................................................................................................................. 18 9.3 Detailed Erection Unit and weight ............................................................................................ 18 9.4 Crane Analysis and Selection ................................................................................................... 20 9.5 Temporary Supports ................................................................................................................... 24 9.6 Detail erection method ............................................................................................................... 25
10 Erection Method for Terminal Processor ......................................................... 34 10.1 Shipping units ............................................................................................................................ 34 10.2 Erection Weight and Selection of Cranes ............................................................................. 35 10.3Temporary support ..................................................................................................................... 38 10.4 Detailed Erection Method for Terminal Processor ............................................................... 39
11 Erection Method for International Hub ............................................................. 44 11.1 Shipping Unit ............................................................................................................................. 44 11.2 Erection Units ............................................................................................................................ 45 11.3 Erection Weight and Crane Analysis ...................................................................................... 48
THE ENGINEER:
King Abdulaziz International Airport Development Project
(Phase I) Jeddah, KSA
THE CONTRACTOR:
Contractor: Saudi Binladin Group Doc. Ref. No.: 421-DCS-MST-S-00850 Rev.04 Contract No.: J-10-421-PF-0 Date Issued: 31 Jan 2013
Method Statement for Installation of Steel Structure
Page 3 of 82
11.4 Temporary supporting ............................................................................................................... 56 11.5 Detailed Erection Method for International Hub ................................................................... 57
12 Erection Method for Boarding Bridge .............................................................. 62 12.1 General Dimension ................................................................................................................... 62 12.2 Transportation Units ................................................................................................................. 63 12.3 Erection Units ............................................................................................................................ 64 12.4 Crane Selection ........................................................................................................................ 64 12.5 Erection Method ........................................................................................................................ 65
13 survey schemes ................................................................................................. 66 13.1 Analysis of difficulties ............................................................................................................... 66 13.2 Survey idea and control method ............................................................................................. 67 13.3 Accuracy control of anchor bolts ............................................................................................ 67 13.4 Accuracy control of Zone A Banana trusses ......................................................................... 68 13.5 Installation position for banana truss ..................................................................................... 69 13.6 Positioning accuracy of PIER ................................................................................................. 69 13.7 Assembly and installation surveying for boarding bridge ................................................... 78
14 Logistic Plan ....................................................................................................... 79 14.1 Storage Yard .............................................................................................................................. 79 14.2 Master Schedule ....................................................................................................................... 79 14.3 Manpower Plan ......................................................................................................................... 79 14.4 Equipment Plan ......................................................................................................................... 80
15 Health and Safety ............................................................................................... 82 16 Attachment: ........................................................................................................ 82
Appendix A Risk assessment
Appendix B Insert for temporary support layout
Appendix C Insert for temporary support detail
Appendix D Interface TC and processor
Concrete floor calculation see RFI
Site assembly yard plan dwg
Banana truss erect plan see attachment dwg
Page 4 of 82
1 Preface
PTB contains four main structural parts: Piers, Terminal Processor, International Hub, and Boarding
Bridge. The installation method for space frame roof in the terminal processor and international
hub is not stated in this document.
The total PTB covering area is about 220,000m2, with a length 1500m and width 1000m.
Piers contain columns and space truss roof. This statement applies to both of them.
Terminal processor contains support columns, space frame and shed framing, and this statement
only applies to the support columns and shed framing.
International hub contains support columns, gills truss, perimeter beams and space frame roof.
This statement only applies for the support columns, gills truss and perimeter beams.
Page 5 of 82
2 Scope of Work
According to project specs, drawings and contract, this statement describes the installation method
for the following steel parts:
2.1 Pier
Structure Introduction Pier is also named as concourse and could be described by single pier at zone B, C, E and double
pier at Zone F, G and D. The steel structure covering the 2nd civil floor is composed of cranes
(240PCS), H section roof, catwalk (only for double pier) and casting foot joint.
The supports columns composed of curved arch columns and the webs welding on it. Their
sections are CHS101.6X10~CHS475X14, UB127X76X13~UB838X292X14, CUB686X191X67,
UC254X254X132 and UC305X305X240.
2.2 Terminal Processor
Structure Introduction The terminal processor covers the 3rd civil floor and covering an area of approximately 66000m2. It
contains south facade, tree and tripod, north columns, space frame and shed framing.
JGS will erect all steel structures of terminal processor except space frame. The following
paragraphs give an introduction to each part of terminal processor
Double pier Single pier
Page 6 of 82
South facade
South façade is made up of 64 banana trusses and 826 transoms. Banana truss is connected with
space frame by bolts sphere joints, and welded with transom. There is a third segment between top
and bottom tusk. The length of the bottom segments is 11m, while the top segments range from
14m to 25m. The tusks range from 5.3ton to 19.5ton, and the total weight is about 1661 ton. Each
banana truss is constituted of front chord, rear chord and web member. The section of chord
ranges from CHS 219.1x10 to CHS244.5x25. The section of web ranges from CHS 168.3x12.5 to
CHS 193.7x16. The typical section dimension of transom is CHS 168x10, CHS 193.7x12.50.
Drawings below are for detail connection of tusk:
Top connection Interface with concrete +14.9m Base plate
Shed Framing
Detail at Level 3
South façade head
South facade
North Column
Tree and
tripod
Tree bottom 24pcs Detail at Level 1
Soffit
Page 7 of 82
88 trees and 6 tripods Tree columns with length ranging from 9.8m to 22.3m and weight ranging from 3.6 ton to 8.2 ton
for each tree. There are 6 tripod columns with length ranging from 26 to 30m, weight ranging from
9.6 to 10.9ton for each tripod.
The sections of tree and tripod column are CHS762x20.
North column There are 54 North columns. Their sections are CHS 457x16, and their lengths are 7.5m~14.1m
with their weight ranging from 1.6 ton to 2.5 ton. The whole weight is about 100 tons.
Tree support Tripods column
Page 8 of 82
Shed frame: Shed frame is made up of about 11800 beams, weighting total 1633 tons with length 3.3m to
28.3m, and typical section dimension CHS140x6.3,UB250*250*16, RHS203.2*203.6*7.2*11. The
weight of the heaviest beam is 0.7 ton.
2.3 International Hub
Structure Introduction International hub roof covers the 2nd civil floor and covering an area approximately 50000m2. It
contains arches, sloped columns, gill columns, gill trusses, perimeter beams and space frame.
JGS will do the installation of the steel structure except for the space frame.
North column
Page 9 of 82
There are 18 piece of Arches and 9 pieces of Sloped Columns in International Hub,Arches and
Sloped columns are on the second floor .Their length is 29 m and 16.5 m ; The section is RHS
600x40 (arches) and CHS 559x25 (sloped columns), and the weight is 20ton and 5.4 ton。
There are 54 pieces of Gill Columns distributed on Level 2 and Level 3 except GC20s that are on
Level 0, so their length are 10.6m, 14.9m, 25.9m respectively. Their section is different from CHS
406x16 to CHS508x50, and the weight is from 2.59 t to 6.08 t.
The gills trusses have a curved shape and are the key to make the project successful.
There are 15 pieces of Gills Trusses having 5 pieces of South Gills Trusses and 5 pieces of
Northwest Gills Trusses and 5 pieces of Northeast Gills. The weight of South Gills is from
12.6~70.38 ton and North Gills are from 14.5~63.8 ton. Both of their Height is from 4.5~7.7 m .The
section is as follow:
CHS193.1X10, CHS219.1X12.5~20, CHS273X20, CHS323.9X12.5~25CHS457X25, CHS457X40
2.4 Boarding Bridge
Totally 46 boarding bridges will be installed on site. The members are mainly H section and Box
section. Connections will be bolted on site and requires high erection accuracy.
Arch
Gills Truss
Gills Columns
Perimeter Beam
Sloped Column
GC20
Page 10 of 82
2.5 Reference Standards:
The reference of standards to be made in accordance with the following:
Project specification Section 051200 “Structural Steel Framing”
IBC2006 International Building Code
AISC "Manual of Steel Construction", 13th Edition.
AISC 303-05 "Code of Standard Practice for Steel Buildings and Bridges"
AICS/ RCSC-04 "Specifications for Structural Joints Using ASTM A 325 A490 Bolts"
AWS D1.1-08 "Structural Welding Code"
3 Personnel Roles and Responsibilities
The overall responsibility of KAIA PTB Steelwork as below:
SBG (Main Contractor) Saudi Binladin Group
RSS (Steel Subcontractor) Roots Steel
JGS (Steel Supplier & Erector) Jinggong Steel
4 General Construction Introduction
4.1 Schedules
The total schedule duration is 16 months, starting from the project commencement to the time of
steel structure erection completion.
Before the site erection, it requires at least 6 months for the following process:
Detailing drawing, procurement, fabrication, trail assembly, delivery.
1st Aug 2012 assumed as commence on site work, totally 10months for site installation
The main contractor is follow the submitted base line Schedule and meet the mentioned date for
the steel structure delivery to site and installation works.
4.2 Site Plan
Site assembly yard see attachment
storage yard shall be 610mx86m, 52460m2;
Page 11 of 82
4.3Manpowerplan
The maximum manpower on site shall be 292.
4.4MechanicalandEquipment
All tower cranes to be used by steel contractor shall complete the handover a month before
steel installation. During the installation, steel contractor shall have the priority to use the
cranes.
Piers: 8 railed tower cranes
Terminal Processor: 9 fixed tower cranes
International Hub: 6 fixed tower cranes
Mobile crane 400t will be used for erection of piers in the cross zone between Zone B and
Zone D
Page 12 of 82
4.5GeneralWorkProcedures
The concrete works handover sequence is assumed in this statement. The handover shall
be 1 week prior to steel structure installation commencement. Accurate surveying report for
the concrete works to be provided to the erector prior starting erection, to ensure the entire
structure conformity. The above mentioned report shall be provided to the erector for action
and to CM for information. In case of any site modifications are required due to unconformity
between the concrete works and steel erection works a detailed report is to be submitted for
CM approval.
All tower cranes that are to used by steel contractor shall be taken over a week prior to steel
installation. During the steel installation, steel contractor has the priority to use the cranes.
The shed framing installation commences after the space frame execution is finished in
terminal processor, the temporary supports and scaffolding shall remain for JGS use.
4.5.1 Pier
The members will be transported to site as members in bulks.
Trial assembly will be executed to ensure the accuracy for fabrication.
The erection units named “crane” will be assembled on the ground in the pre-assembly area
and then lifted by the railed tower cranes to 2nd civil floor. Total nos. of “crane” for erection is
240.
The roof members will be installed after the “crane” is in its position.
The welding work will be done on the ground for the “cranes” to be assembled. All other
erection work is by bolt.
Totally 8 railed tower cranes are required, 4 of 8 have the capacity of 17.9t @ 27m and the
other four have the capacity of 12t @ 34m.
Page 13 of 82
4.5.2 Terminal Processor
All the columns, soffit steel, shed framing steel will be transported to site in bulks with
maximum a length of 17m, the south facade will be divided to 3 units as a truss segment.
A crawler crane will be used to lift the south facade units and then to be assembled as a
complete truss on the ground in the designated pre-assembly area.
Transom will be erected by tower cranes and the welding done with the brackets.
The tree columns, north façade columns will be erected by 9 fixed tower cranes, which have
the capacity 5.7t @ 50m.
The shed framing shall be installed with space frame erection unit prior to lifting
4.5.3 International Hub
All the columns, perimeter beams will be transported to site in bulks with maximum length of
17m. The gill trusses also will be in bulks and assembled on the civil floor to be a complete
erection unit.
Trial assembly will be done to ensure the accuracy for fabrication.
Total 6 fixed tower cranes will be used for lifting the steel having capacity of 8.8t @ 35m.
Any area inaccessible by tower cranes shall be managed by a 35T mobile crane.
Page 14 of 82
5 AESS requirement
For the architecturally exposed steel structure quality in the project should comply with the AESS
requirements:
≤2.4m first level
2.4~6m second level
≥6m third level
Level one and level two are the visible and the appearance on these levels is critical. A glossy
finish completed with grinding is required.
Page 15 of 82
6 Site Welding
Field welding shall be carried out as per the approved Welding procedure specification
(WPS)
Due to the significant number of site welding joints, an independent testing and
inspection agency will be engaged to perform site testes and inspection. The attendance
and numbers of the agency inspectors shall be according to the welding inspection
requirements and will not hinder the erection schedule.
Welding plan shall be prepared and updated daily by the assigned independent testing
and inspecting agency.
Welding shall be carried out in good climatic and environment condition. In case of
damp climatic condition, additional protection shall be provided to cover the weld area.
All joints are to be dried before welding in damp climatic condition.
In the case of multi layer welding, slag and spatters on each completed bead shall be
removed prior to weld the following layer.
7 Bolting Tightening
Bolt storage: All fastener set shall be delivered in a sealed box, it shall be stored into a
dry space, the sealed box shall be put away from ground. No such box is allowed to be
open before it to be fixed at site.
Bolt tightening shall be carried out after completion of alignment to the specified area. All
bolts / nuts and washers shall be used as per shop drawings and project specification.
Mobile Access Platform or scaffolding platform shall be used during Erection, Bolting
tightening and inspection.
Bolted connection shall be tested and inspection by the independent testing and
inspecting agency according to RSCC’S “Specification for structural joints Using ASTM
A325 or A490 Bolts”.
8 Touch Up Painting Procedure
Site Painting for site welding area. The welding shall be cleaned by using electrical sand disc or wire brush. Surface
profiles check shall be completed on the ST3 finish using testex tape.
Prior to the application, foreign material adhering to the surface shall be removed by
using hand / Mechanical clean by sand disc and dry cotton cloth to maintain SSPC-SP2
or SSPC-SP3 surface preparation.
Paint (Primer to top coat) shall be applied as per project specification by using hand
brush / roller. (As per below flow chart).
The following painting system shall be used.
Page 16 of 82
S/No Applicable Area Location Coating layer
Paint Type Painting DFT
1 Structural Steel painting system – As per the specification051200: Structural steel framing – clause 3.3.N. & 3.6 repairs and protection
Primer epoxy 125μm Intermediate Coat
epoxy 155μm
Final Coat polyurethane 80μm
Touch-up painting shall be carried where the paint surface is damaged during transit. Only approved paint shall be used for touch up painting work.
Prior to the application, foreign material adhering to the surface shall be removed by
SSPC-SP 2 hand-tool cleaning or SSPC-SP 3 power-tool cleaning.
Touch up painting (primer and top coat – for deep damage & top coat for small depth
scars & minor paint scars on top coat) shall be carried out by using hand brush / roller.
(see below flow chart for site painting)
Flow chart for Site Painting Touch-up (Repair) & Paint Work (Welds)
Identify the Location of Painting touch (Repair) work & Painting work (weld)
Check the Atmospheric Condition & Type of Painting System
Clean the painting damage area / Weld joint by: 1. Wire brush cleaning 2. Mechanically surface preparation to level ST3 (SSPC SP-3) by sanding disc for weld
joint area & major paint damaged area, the surface profile shall be test accordingly. 3. Hand sanding with 80 grade sand paper feathering back the existing coating to revel a
tight edge. The repair overlap distance on the existing coating shall be minimum 5mm 4. Solvent cleaning with approval Thinner with lint free cloth and allow to fully dry
before proceeding with the original coating system.
After check the cleaning surface – (Ref: Painting System table): 1. 1st Applied Strip coat paint at corner/holes/bolts/welds by brush. 2. All splice plate edges, fasteners edges shall be sealed with paint during strip coating. 3. After Strip coat all touch up area shall be paint by brush / roller uniformly as required paint thickness. 4. Top coat, before top coat paint application the first coat paint should dry minimum 2-3hours 5. Strip coating with top coat to sharp edges shall also be applied for the top coat. 6. Before applied top coat, the surface shall be clean by Cloth / brush 7. Applied top coat paint as required thickness
Check the Painting DFT / Visual Inspection
Page 17 of 82
9 Installation Method for Pier
9.1 Shipping Unit
The structure of pier shall be transported as illustrated considering the transportation, size
condition, connection type, appearance, etc.
For double Pier (Zone D, F & G), the shipping unit is as indicated below:
For Single Pier (Zone B, C, E), the shipping unit as indicated below:
For Roof Beams: Secondary Trusses are shipped in two pieces as shown in the picture while the
other beams are to be delivered in bulk.
Page 18 of 82
9.2 Erection Units
The erection unit shall consider the crane capacity, critical weight to minimize the installation work
mid-air.
The piers (green) could be erected by tower crane as complete unit. The piers (yellow) shall be
broken by one beam. The (red) one shall be installed by 400t mobile crane as a a complete set.
9.3 Detailed Erection Unit and weight
Conclusion:
Total Amount:240 PCS
Complete Units: 118 PCS, 50%
Part Assembly:102 PCS, 42%,by 25t mobile
crane on the floor and 8033.16
Mobile Crane:20 PCS, 8%, by 400t mobile
crane
Zone B, C 52 PCS(12.01t@29m<16.5t@29.5m)
Zone E 60 PCS (25t mobile crane)
THE ENGINEER:
King Abdulaziz International Airport Development Project
(Phase I) Jeddah, KSA
THE CONTRACTOR:
Contractor: Saudi Binladin Group Doc. Ref. No.: 421-DCS-MST-S-00002 Rev. 00
Contract No.: J-10-421-PF-0 Date Issued: 02 February 2012
Method Statement for Installation of Steel Structure
Page 19 of 82
Zone F, G 76PCS (15.9t@29m<16.5t@29.5m)
Zone D
32PCS (14.78t@31m<15.48t@31m)
Zone H
20 PCS (20.4t@27m<25.3t@27m)
Page 20 of 82
9.4 Crane Analysis and Selection
9.4.1 Crane selection and site position
Railed Tower Crane position: The railed tower crane shall be located at a distance from the concrete as detailed below:
Page 21 of 82
Page 22 of 82
Page 23 of 82
9.4.2 Crane Capacity Analysis
(Green) Denotes means erected by 16t tower crane.(see crane plan)
(Red) Means erected by 400t mobile crane of zone H, by 25t mobile crane on the floor of zone
B、C、E . Concrete floor calculation see attachment.
No. Zone AXES New Rev Weight
Radius for RTC
Crane Capaciy Burden
%
1
F、G
NE56 15.9 29m
WOLLF 8033.16
16.5 96%
2 NE54~NE26 15.54 29m 16.5 94%
3 NE24 15.7 29m 16.5 95%
4 NE20、22 16 29m 16.5 97%
5 NE18 19.7 29m 16.5 119%
6
D
N26~S33 14.9 29m 16.5 90%
7 S31~S29 15.7 29m 16.5 95%
8 S27 16.1 29m 16.5 98%
9
B、C
SE47 25.37 29m 16.5 154%
10 SE45、43 22.55 29m 16.5 137%
11 SE41~SE3 21.84 29m 16.5 132%
12 S1~S5 21.84 29m 16.5 132%
13
E
N24~N20 17.4 29m 16.5 105%
14 N18 19.7 29m 16.5 119%
15 N16、14 20.3 29m 16.5 123%
16 N12、10 23.9 29m 16.5 145%
17 N8~N2 24.4 29m 16.5 148%
18 NE2~NE10 24.4 29m 16.5 148%
19 NE12~NE18 20.4 29m 16.5 124%
20 NW2、4、6 24.4 29m 16.5 148%
21 NW8、10 24.1 29m 16.5 146%
22 NW12 20.48 29m 16.5 124%
23 NW14、16 20.3 29m 16.5 123%
24 NW18 19.7 29m 16.5 119%
25
H
S25~S21 18.45 35m
mobile crane 400t
30 62%
26 S19 24.1 35m 30 80%
27 S15~S17 25.2 35m 30 84%
28 S13~S7 21.84 35m 30 73%
Remark Contain Tool 0.5t。
Page 24 of 82
9.5 Temporary Supports
9.5.1 Temporary Supports layout
A. Assembly yard plan see attachment《KAIA zone pier assembly yard plan》: B. Setting temporary supporting using by expansion bolt.
Please ref to attachments appendix B embedded parts layout and appendix C embedded detail.
9.5.2 Ground Hardening Measurement
The floor under the assembly support should take the measurements as follow:
20dia expansion bolt to fix the support
Temporary supporting
Page 25 of 82
9.5.3 wind rope
Insert the embedded for fix wind rope during concrete pouring. All temporary support and completed steel structure should be using wind rope as safety
required.
9.6 Detail erection method 9.6.1 Pier Erection Sequence
The Pier Erection sequence is illustrated in the picture below. Procedure: crane assembly on the ground, crane erection, roof beam, side walk and some
other ancillary facilities Start from F, G, B, C, with the railed tower crane and move towards Zone D and Zone E. Eight railed tower cranes are required in total.
Page 26 of 82
9.6.2 Erection Sequence For Double Pier
Step1: Loft & deploy supports Step 2: Erect the curve column
Step 3: Erect the “crane” Step 4: Erect the roof truss
Step 5: Completing the joint
Page 27 of 82
Step 6: Erect the other beams Step 7: Final Touches
9.6.3 Erection Sequence For Single Pier
Concrete floor calculation see attachment.
Step 1: Loft & deploy supports Step 2: Erect the curve column
Step 3: Erect the “crane” Step 4: Erect the sword and column
Page 28 of 82
Step 5: Erect the Curve part connection Step 6: Erect the Low span truss
Step 7: Web member assembly Step 8: Final touches
Step 9: Erection the roof truss Step 10: Erect other beams
Page 29 of 82
9.6.4 Erection Sequence For International Pier
Step 1: Casting& deploy supports Step 2: Erect the Dome
Step 3: Erect the High span Truss Step 4: Erect the web member
Step 5: Erect the sword Step 6: Erect the Curve part connection
Page 30 of 82
Step 7: Erect Low span Truss assembly Step 8: Erect the web member
Step 9: Erection the roof truss Step 10: Erect other beams
Workers are on the movable scaffolding platforms to erect the beams
Page 31 of 82
9.6.4 Assembly on the ground
Double pier assembly Step 1: Assembly the crane truss
Step 1: support setting assembly Step 2: Casting assembly
Step 3: Sword and Dome assembly Step 4: Middle Connection assembly
Page 32 of 82
Step 5: Curve part connection assembly Step 6: Crane truss assembly
Step 7: Web member assembly Step 6: Final Touches
Page 33 of 82
Single pier assembly
Step 1: Assembly support setting and truss Step 2: Assembly casting
Step 3: Dome assembly Step 4: High span Truss assembly
Step 6: A-frame and web member Step 6: Half crane finish
Page 34 of 82
10 Erection Method for Terminal Processor 10.1 Shipping units The structural elements of terminal processor building shall be transported as detailed below, considering transportation size condition, connection type, appearance, etc.
10.1.1 South facade
Length of element is 12m. Detail division method is as follow: lower segment 11.5m, middle segment 12m~16m, upper segment 5~13m. The lower segment and the middle segment is naturally separate. Drawing below is its detail method.
Upper and middle segment division
10.1.2 Tree and tripod
Shipping of Tree and tripod is classified to two kinds. Red one is erected by two pieces and black one is erected by one piece.
(Red) ones are divided into two units, (Black) ones are shipped as one unit
Type one: (>17.8m) T1、T2、T5、T6 and tripod (total 38 pieces) is divided to two segments to transport, T6 (16.8m) is divided for weight as it cannot be lifted up by fixed tower crane.
Upper segment Middle segment
Page 35 of 82
Type 2: (≤17.8m) T3,T4,T7,T8,T9,T10,T11 (total 56 pieces) shipped as one unit.
10.1.3 North column shipped as one unit
10.1.4 Shed frame shipped in bulk.
10.2 Erection Weight and Selection of Cranes
10.2.1 South Façade and Tripod
The weight of south façade tusk and tripod column is about 23 ton,so we consider to use 500ton crawler crane erect. analysis:loading capacity of 500t crawler crane at boom length 102m and working radius 75m is 47ton > 23 ton+0.4 ton(lifting hook and sling)
500t crawler crane
Banana truss erect plan see attachment dwg
Page 36 of 82
10.2.2 Lifting of tree columns on slabs
Tree columns of T1, T2, T6 as lifted by tower in two pieces after being shipped to site, other tree columns should be pre-assembled before lifting. Drawing below is about the location of tower cranes, each color and circle represents one tower. (Green):T36, T37 70m Wolf7532.12
(Red):T41 60m Wolf7532.12
(Blue):T40, T 42 70m Wolf7532.12
(Pink):T39, T43 60m Wolf7532.12
Location of tower cranes
Analysis of lift sequence for tree columns (same crane location above drawing)
Page 37 of 82
NO.
lgth(m) wt(T)wt*1.2(T
)cranenumber
liftingweight(t
)
lgth ofmainboom
radius(m)
cranecapactiy
(T)
burdenrate(T)
T1-1 22.3 8.2 9.8 T41 4.9 60 39.0 7.5 65.3%T1-2 21.5 7.9 9.4 T41 4.7 60 42.4 6.6 71.5%T1-3 21.1 7.7 9.3 T41 4.6 60 52.9 5.1 90.8%T1-4 21.9 8.0 9.6 T41 4.8 60 50.4 5.1 94.3%
T2-1 20.0 7.3 8.8 T36 4.4 70 58.3 4.2
104.6%[95.8%(10% saftyratio)]
T2-2 19.3 7.1 8.5 T36 4.2 70 49.3 5.3 80.0%T2-3 18.9 6.9 8.3 T36 4.2 70 53.4 4.7 88.3%T2-4 19.3 7.1 8.5 T36 4.2 70 54.5 4.7 90.2%T3-1 17.8 6.5 7.8 T36 2.9 70 32.3 8.0 35.8%T3-2 17.1 6.3 7.5 T36 2.7 70 27.0 9.6 28.6%T3-3 16.8 6.1 7.4 T36 2.7 70 18.5 11.8 22.9%T3-4 17.5 6.4 7.7 T36 2.8 70 23.0 11.8 23.8%T4-1 15.8 5.8 6.9 T36 2.5 70 27.7 9.6 26.5%T4-2 15.1 5.5 6.6 T36 2.4 70 31.0 8.0 30.3%T4-3 14.9 5.5 6.5 T36 2.4 70 24.5 11.8 20.3%T4-4 15.5 5.7 6.8 T36 2.5 70 20.0 11.8 21.1%T5-1 18.9 6.9 8.3 T42 3.0 70 24.0 11.8 25.7%T5-2 18.2 6.7 8.0 T42 2.9 70 28.7 9.6 30.5%T5-3 17.3 6.3 7.6 T42 2.8 70 30.6 8.0 34.8%T5-4 18.0 6.6 7.9 T42 2.9 70 26.2 9.6 30.1%T6-1 16.8 6.1 7.4 T42 3.7 70 55.5 4.2 87.8%T6-2 16.1 5.9 7.1 T42 3.5 70 61.0 3.8 93.0%T6-3 15.4 5.6 6.8 T42 3.4 70 61.8 3.8 89.0%T6-4 16.0 5.9 7.0 T42 3.5 70 56.4 4.2 83.7%T7-1 15.2 5.6 6.7 T36 2.4 70 39.8 6.9 35.4%T7-2 14.5 5.3 6.4 T36 2.3 70 37.3 6.9 33.8%T7-3 13.8 5.1 6.1 T36 2.2 70 48.2 5.3 41.8%T7-4 14.5 5.3 6.4 T36 2.3 70 39.8 6.9 33.8%T8-1 13.0 4.8 5.7 T36 2.1 70 37.3 6.9 30.3%T8-2 12.4 4.5 5.4 T36 2.0 70 39.8 6.9 28.9%T8-3 12.0 4.4 5.3 T36 1.9 70 47.5 5.3 36.4%T8-4 12.4 4.5 5.4 T36 2.0 70 45.6 5.3 37.6%T9-1 14.2 5.2 6.2 T43 2.3 60 22.6 12.0 19.0%T9-2 13.5 4.9 5.9 T43 2.2 60 25.0 12.0 18.1%T9-3 12.6 4.6 5.5 T43 2.0 60 19.5 12.0 16.9%T9-4 13.2 4.8 5.8 T43 2.1 60 16.3 12.0 17.7%T10-1 12.5 4.6 5.5 T43 6.6 60 52.6 5.1 39.4%T10-2 11.9 4.4 5.2 T43 1.9 60 47.0 5.8 33.0%T10-3 11.1 4.1 4.9 T43 1.8 60 48.2 5.8 30.8%T10-4 11.6 4.2 5.1 T43 1.9 60 53.7 5.1 36.6%T11-1 10.9 4.0 4.8 T35 1.8 60 19.7 12.0 14.6%T11-2 10.4 3.8 4.6 T35 1.7 60 14.6 12.0 13.9%T11-3 9.8 3.6 4.3 T35 1.6 60 17.8 12.0 13.1%T11-4 10.2 3.7 4.5 T35 1.6 60 22.2 12.0 13.7%
LIST OF ERECTION UNIT AND CRANE CAPACITY
characters crane
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10.3Temporary support
10.3.1 Temporary support layout
Insert plate during concrete pouring 300*300*16 Temporary support weld to the plate Please ref to attachments appendix B embedded parts layout and appendix C embedded
details
10.3.2 Head & Bottom Connection
Tack welding
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10.3.3 Wind rope
Insert the embedded for fix wind rope during concrete pouring. All temporary support and completed steel structure should be using wind rope as safety
required.
10.4 Detailed Erection Method for Terminal Processor
10.4.1Erection Sequence
Erection tree column start from center to both side. Space frame will installed follow the steel structure schedule. The roof frame will install after space frame completed. Remove the temporary support when work is completed, space frame and steel structure using separately.
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10.4.2 Erection process
South facade Step 1: Erect the lower segment of tusk of
south façade Step 2: Erect upper segment of south facade
Step 3: Erect transom between tusk for south facade
Step 4: Weld transom
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Tree
Shed frame Shed frame Installation in location after Space frame are installed.
Temporary catwalk will be installed on space frame to help installation of shed frame. See
picture below.
Soffit purlins installation use boom length 26m man lift . 26m man lift 2pcs.
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Step 1:Erect the first beam and short beam component
Step 2:
Step 3: Step 4:
Step 5: Erect from axis G0 to axis G11 Step 6: Erect from center to side
Step 7: Erect from axis NS to axis TW、TE Step 8: Erect from axis NS to axis TW、TE
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Page 44 of 82
11 Erection Method for International Hub 11.1 Shipping Unit Shipping Units should satisfy the capacity of transportation and easy to assembly. It’s better to being segmented at the different sections:
11.1.1 Arches and Sloped Columns
Arches: Total length is 29m and divided into 2 with 14.5m length(36units, 8.5t for each)
Sloped Columns: (9 units,5.4t per piece)
11.1.2 Gills Columns
Type 1: 10.6m~14.9m, delivered in one piece(50 units, From 2.28 to 6 t)
Type 2: 25.9m, deliver in two pieces(4 Units, 3 t per piece)
11.1.3 Arches Connection
Arches(Sloped Column) Space Connection and Base Connection(9 units,14tper Space Connection, 2.7 t per Base Connection): Both of them are delivered as single piece
11.1.4Gills Trusses
Gills trusses are delivered as single pieces, the length of web member is 4~7m. We should control the chord member in 9~15m as the following illustration:
14.5m 14.5m
25m
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11.1.5 Perimeter Beam
The perimeter beams are delivered as single units. If the length is shorter than 12.5m we deliver it as one unit, the others are delivered in two pieces. There are 84 straight pieces and 6 arc pieces in total:
11.2 Erection Units The tower crane type and position are unchangeable, the Erection Units should meet the followed principle: A. Under the capacity of tower crane 。
B. Easy to set temporary supporting。
C. Easy to transport and raise up。
D. Control the single pieces, improve the progress
11.2.1 Arches and Sloped columns
The arches shall be erected as two pieces, the sloped one shall be as one piece.
12.5m
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11.2.2 Gills Columns
11.2.3 Connection units as shipping unit
11.2.4 Gills Truss
Gills 1 (8 Erection Units)
Gills 2 (6 Erection Units)
H: 14.85m
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Gills 3 (4 Erection Units)
Gills 4 (3 Erection Units)
Gills 5 (3 Erection Units)
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11.2.5 Perimeter Beam:
11.3 Erection Weight and Crane Analysis
11.3.1 Tower Crane Layout:
Some units’ weight is above the Tower Crane capacity. In such cases, we will use 35t mobile crane to raise them.
25m
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11.3.2 Tower Crane and Mobile Crane capacity analysis:
TW14
TW18
TW17
TW1
TW16
TW1
○M 35tmobile crane
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Crane capacity analysis of Sloped Columns and Arches
List of Erection Units & Crane Capacity
No. PCS Characters Wt*1.2 Crane
Light of
Radius (m)
Crane Capacity(t)
Burden Rate
Main Boom
Light Weight Kg/m (m)
SC1 1 16.5 5.4 327 6.48 TW15 60 40 7.5 86%
AR1a 1 14.4 8.5 590 10.2 MC 14.4 6 17.2 59%
AR1b 1 14.4 8.5 590 10.2 MC 15.6 6 15.6 65%
AR1c 1 14.4 8.5 590 10.2 TW15 60 30 10.4 98%
AR1d 1 14.4 8.5 590 10.2 TW15 60 19.4 12 85%
SC2 1 16.5 5.4 327 6.48 TW15 60 20 12 54%
AR2a 1 14.4 8.5 590 10.2 TW15 60 12 12 85%
AR2b 1 14.4 8.5 590 10.2 TW15 60 12 12 85%
AR2c 1 14.4 8.5 590 10.2 TW15 60 11 12 85%
AR2d 1 14.4 8.5 590 10.2 TW15 60 9 12 85%
SC3 1 16.5 5.4 327 6.48 TW15 60 35 8.8 74%
AR3a 1 14.4 8.5 590 10.2 TW15 60 17 12 85%
AR3b 1 14.4 8.5 590 10.2 TW15 60 25 12 85%
AR3c 1 14.4 8.5 590 10.2 TW15 60 30 10.4 98%
AR3d 1 14.4 8.5 590 10.2 MC 19.5 6 15.6 65%
SC4 1 16.5 5.4 327 6.48 MC 14.4 6 17.2 38%
AR4a 1 14.4 8.5 590 10.2 MC 19.5 6 15.6 65%
AR4b 1 14.4 8.5 590 10.2 MC 14.4 6 17.2 59%
AR4c 1 14.4 8.5 590 10.2 MC 14.4 6 17.2 59%
AR4d 1 14.4 8.5 590 10.2 MC 19.5 6 15.6 65%
SC5 1 16.5 5.4 327 6.48 TW16 60 19 12 54%
AR5a 1 14.4 8.5 590 10.2 TW16 60 25 12 85%
AR5b 1 14.4 8.5 590 10.2 TW16 60 17 12 85%
AR5c 1 14.4 8.5 590 10.2 TW16 60 12 12 85%
AR5d 1 14.4 8.5 590 10.2 TW16 60 12 12 85%
SC6 1 16.5 5.4 327 6.48 TW16 60 22 12 54%
AR6a 1 14.4 8.5 590 10.2 TW16 60 13 12 85%
AR6b 1 14.4 8.5 590 10.2 TW16 60 15 12 85%
AR6c 1 14.4 8.5 590 10.2 TW16 60 21 12 85%
AR6d 1 14.4 8.5 590 10.2 TW16 60 27 11.2 91%
SC7 1 16.5 5.4 327 6.48 MC 14.4 6 17.2 38%
AR7a 1 14.4 5.4 375 6.48 TW16 60 37 8.3 78%
AR7b 1 14.4 5.4 375 6.48 MC 14.4 6 17.2 38%
AR7c 1 14.4 5.4 375 6.48 TW17 60 43 7 93%
AR7d 1 14.4 5.4 375 6.48 TW17 60 35 8.8 74%
SC8 1 16.5 5.4 327 6.48 TW17 60 16 12 54%
AR8a 1 14.4 8.5 590 10.2 TW17 60 25 12 85%
AR8b 1 14.4 8.5 590 10.2 TW17 60 12 12 85%
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AR8c 1 14.4 8.5 590 10.2 TW17 60 10 12 85%
AR8d 1 14.4 8.5 590 10.2 TW17 60 15 12 85%
SC9 1 16.5 5.4 327 6.48 TW17 60 24 12 54%
AR9a 1 14.4 8.5 590 10.2 TW17 60 16 12 85%
AR9b 1 14.4 8.5 590 10.2 TW17 60 17 12 85%
AR9c 1 14.4 8.5 590 10.2 TW17 60 23 12 85%
AR9d 1 14.4 8.5 590 10.2 TW17 60 30 10.4 98% Crane capacity analysis of Gills Column
List of Erection Units & Crane Capacity
No. PCS Characters Wt*1.2 Crane
Light of Main
Boom(m)Radius (m)
Crane Capacity(t)
Burden Rate
Out-capacity
Light Weight Kg/m
GC1 2 10.6 3.15 297 3.78 TW18 70 35 8 47% 0
GC2 2 10.6 2.28 215 2.74 TW17 70 15 11.8 23% 0
GC3 2 10.6 3.97 375 4.76 TW17 70 22.5 11.8 40% 0
GC4 2 10.6 4.88 460 5.86 TW18 70 15 11.8 50% 0
GC5 2 10.6 3.97 375 4.76 TW18 70 30 9.6 50% 0
GC6 1 14.9 2.59 174 3.11 TW18 70 10 11.8 26% 0
GC7 2 10.6 5.97 563 7.16 TW18 70 12.5 11.8 61% 0
GC8 1 10.6 5.97 563 7.16 TW18 70 32.7 8.8 81% 0
GC9 2 14.9 2.59 174 3.11 TW18 70 35 8 39% 0
GC10 2 14.9 2.29 154 2.75 TW18 70 57 4.5 61% 0
GC11W 2 9.9 2.63 266 3.16 TW14 70 35 8 39% 0
GC11E 2 9.9 2.63 266 3.16 TW13 60 55 5.1 62% 0
GC12W 2 9.9 2.63 266 3.16 TW15 60 53 5.8 54% 0
GC12E 2 9.9 2.63 266 3.16 MC 22 10 7.9 40% 1
GC13W 2 14.9 4.43 297 5.32 MC 22 6 12.6 42% 1
GC13E 2 14.9 4.43 297 5.32 MC 22 6 12.6 42% 1
GC14W 2 9.9 3.71 375 4.45 TW14 70 20 11.8 38% 0
GC14E 2 9.9 3.71 375 4.45 TW13 60 35 8.8 51% 0
GC15W 2 9.9 3.71 375 4.45 TW14 70 34 9.6 46% 0
GC15E 2 9.9 3.71 375 4.45 TW13 60 58 4.8 93% 0
GC16W 1 9.9 4.56 461 5.47 TW14 70 10 11.8 46% 0
GC16E 1 9.9 4.56 461 5.47 TW13 60 20 12 46% 0
GC17W 2 9.9 5.57 563 6.68 TW14 70 17 11.8 57% 0
GC17E 2 9.9 5.57 563 6.68 TW13 60 32 9.6 70% 0
GC18W 1 9.9 4.56 461 5.47 TW14 70 33 8.8 62% 0
GC18E 1 9.9 4.56 461 5.47 TW13 60 21 12 46% 0
GC19W 2 9.9 5.57 563 6.68 TW14 70 32 8.8 76% 0
GC19E 2 9.9 5.57 563 6.68 TW13 60 27 11.2 60% 0
GC20W 2 25.9 6.08 235 7.3 MC 30.4 6 9 81% 2
GC20E 2 25.9 6.08 235 7.3 MC 30.4 6 9 81% 1
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11.3.3 Gills Trusses
Page 53 of 82
Crane capacity analysis of Gills Trusses: List of Erection Units & Crane Capacity
No. PCS Characters
Wt*1.2 CraneLight of Main
Boom(m) Radius
(m) Crane
Capacity(t) Burden Rate Light Weight Kg/m
SG1a 1 11.4 9.65 846 11.58 TW17 60 20 12 97%
SG1b 1 8 8.51 1064 10.21 TW17 60 14 12 85%
SG1c 1 16.4 8.68 529 10.42 TW17 60 17 12 87%
SG1d 1 16.3 8.83 542 10.6 TW17 60 29 10.7 99%
SG1e 1 16.3 6.89 423 8.27 MC 24.7 6 12.6 66%
SG1f 1 16.4 8.68 529 10.42 MC 24.7 6 12.6 83%
SG1g 1 8 8.51 1064 10.21 MC 24.7 6 12.6 81%
SG1h 1 11.4 9.65 846 11.58 MC 24.7 6 12.6 92%
SG2a 1 9.2 7 761 8.4 TW17 60 24 12 70%
SG2b 1 12.5 4.58 366 5.5 TW17 60 31 10.1 54%
SG2c 1 16.9 8.54 505 10.25 TW18 70 22 11.8 87%
SG2d 1 16.9 6.38 378 7.66 TW18 70 35 8 96%
SG2e 1 12.5 4.58 366 5.5 TW18 70 48 5.6 98%
SG2f 1 9.2 7 761 8.4 MC 24.7 8 10.2 82%
SG3a 1 12.5 7.14 571 8.57 TW18 70 32 9.2 93%
SG3b 1 15.2 6.85 451 8.22 TW18 70 2.6 11.8 70%
SG3c 1 15.2 4.76 313 5.71 TW18 70 18 11.8 48%
SG3d 1 12.5 7.14 571 8.57 TW18 70 32 9.2 93%
SG4a 1 9.4 6.83 727 8.2 TW18 70 16 11.8 69%
SG4b 1 13.9 4.9 353 5.88 TW18 70 13 11.8 50%
SG4c 1 9.4 6.83 727 8.2 TW18 70 16 11.8 69%
SG5a 1 7.7 3.7 481 4.44 TW18 70 30 9.6 46%
SG5b 1 8.2 4.86 593 5.83 TW18 70 34 8.3 70%
SG5a 1 7.7 3.7 481 4.44 TW18 70 30 9.6 46%
NWG1a 1 11.4 9.8 860 11.76 MC 24.7 6 12.6 93%
NWG1b 1 8 7 875 8.4 TW15 60 26 11.7 72%
NWG1c 1 16.4 8.78 535 10.54 TW15 60 25 12 88%
NWG1d 1 16.3 8.83 542 10.6 TW15 60 26.7 11.5 92%
NWG1e 1 16.3 6.66 409 7.99 TW15 60 35 8.8 91%
NWG1f 1 16.4 8.78 535 10.54 MC 24.7 6 12.6 84%
NWG1g 1 8 7 875 8.4 MC 24.7 6 12.6 67%
NWG1h 1 11.4 9.8 860 11.76 MC 24.7 6 12.6 93%
NWG2a 1 9.1 6.66 732 7.99 TW14 60 34 9.1 88%
NWG2b 1 15.8 4.29 272 5.15 TW15 60 40 7.5 69%
NWG2c 1 13.7 5.97 436 7.16 TW14 70 36 7.8 92%
NWG2d 1 13.7 4.5 328 5.4 TW14 70 34 8.3 65%
NWG2e 1 15.8 6.66 422 7.992 MC 24.7 8 10.2 78%
NWG2f 1 9.1 4.29 471 5.15 MC 24.7 10 7.9 65%
NWG3a 1 7.14 6.3 882 7.56 TW14 70 35 8 95%
NWG3b 1 7 6.6 943 7.92 TW14 70 17 11.8 67%
NWG3c 1 4.57 5.67 1241 6.8 TW14 70 17 11.8 58%
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NWG3d 1 7.14 6.3 882 7.56 TW14 70 29 10 76%
NWG4a 1 10.3 6.45 626 7.74 MC 24.7 10 7.9 98%
NWG4b 1 16.4 5 305 6 TW14 70 14 11.8 51%
NWG4c 1 10.3 6.45 626 7.74 TW14 70 37 7.6 102%
NWG5a 1 7.7 4.3 558 5.16 TW14 70 30 9.6 54%
NWG5b 1 8.2 4.9 598 5.88 TW14 70 33 8.6 68%
NWG5c 1 7.7 4.3 558 5.16 TW14 70 30 9.6 54%
NEG1a 1 11.4 9.8 860 11.76 TW16 60 20 12 98%
NEG1b 1 8 7 875 8.4 TW16 60 15 12 70%
NEG1c 1 16.4 8.78 535 10.54 TW16 60 20 12 88%
NEG1d 1 16.3 8.83 542 10.6 TW16 60 27 11.5 92%
NEG1e 1 16.3 6.66 409 7.99 MC 24.7 6 12.6 63%
NEG1f 1 16.4 8.78 535 10.54 MC 24.7 6 12.6 84%
NEG1g 1 8 7 875 8.4 MC 24.7 6 12.6 67%
NEG1h 1 11.4 9.8 860 11.76 MC 24.7 6 12.6 93%
NEG2a 1 9.1 6.66 732 7.99 TW16 60 25 12 67%
NEG2b 1 15.8 4.29 272 5.15 TW16 60 33 9.6 54%
NEG2c 1 13.7 5.97 436 7.16 TW16 60 35 8.8 81%
NEG2d 1 13.7 4.5 328 5.4 MC 24.7 10 7.9 68%
NEG2e 1 15.8 6.66 422 7.99 MC 24.7 8 10.2 78%
NEG2f 1 9.1 4.29 471 5.15 MC 24.7 10 7.9 65%
NEG3a 1 7.14 6.3 882 7.56 MC 24.7 10 7.9 96%
NEG3b 1 7 6.3 900 7.56 TW13 60 35 8.8 86%
NEG3c 1 4.57 5.67 1241 6.8 TW13 60 42 7.1 96%
NEG3d 1 7.14 6.3 882 7.56 MC 24.7 10 7.9 96%
NEG4a 1 10.3 6.45 626 7.74 TW13 60 19 12 65%
NEG4b 1 16.4 5 305 6 TW13 60 22 12 50%
NEG4c 1 10.3 6.45 626 7.74 TW13 60 35 8.8 88%
NEG5a 1 7.7 4.3 558 5.16 TW13 60 15 12 43%
NEG5b 1 8.2 4.9 598 5.88 TW13 60 23 12 49%
NEG5c 1 7.7 4.3 558 5.16 TW13 60 27 11.5 45%
11.3.4 Perimeter
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Crane capacity analysis of Perimeter:
List of Erection Units & Crane Capacity
No. PCSCharacters
Wt*1.2 CraneLight of MainBoom(m)
Radius (m)
Crane Capacity(t)
Burden Rate
Out-CapacityLight Weight Kg/m
S1 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2
S2 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2
S3 2 16.5 11.4 691 13.68 MC 19.5 4 18.4 74% 2
S4 2 13 3.9 300 4.68 TW18 70 47 5.6 84% 0
S5 2 10 5.36 536 6.43 TW18 70 37 7.5 86% 0
S6 2 25.3 9.1 360 10.92 TW18 70 25 11.8 93% 0
S7 2 33 5.9 179 7.08 TW18 70 25 11.8 60% 0
S8 2 36 2.24 62 2.69 TW18 70 45 6 45% 0
S9 1 40 2.47 62 2.96 TW18 70 50 5.3 56% 0
NM1 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2
NM2 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2
NM3 2 16.5 11.4 691 13.68 MC 19.5 4 18.4 74% 2
NM4 2 13 3.9 300 4.68 TW14 70 47 5.7 82% 0
NM5 2 10 5.36 536 6.43 TW14 70 40 6.9 93% 0
NM6 2 25.3 9.1 360 10.92 TW14 70 25 11.8 93% 0
NM7 2 33 5.9 179 7.08 TW14 70 27 10.7 66% 0
NM8 2 36 2.24 62 2.69 TW14 70 41 6.7 40% 0
NM9 1 40 2.47 62 2.96 TW14 70 45 6 49% 0
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NE1 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2
NE2 2 8 8.7 1088 10.44 MC 19.5 4 18.4 57% 2
NE3 2 16.5 11.4 691 13.68 MC 19.5 4 18.4 74% 2
NE4 2 13 3.9 300 4.68 TW16/MC
60 35 8.8 53% 1
NE5 2 10 5.36 536 6.43 TW16/MC
60 45 6.6 97% 1
NE6 2 25.3 9.1 360 10.92 MC 19.5 4 18.4 59% 2
NE7 2 33 5.9 179 7.08 TW13 60 30 10.4 68% 0
NE8 2 36 2.24 62 2.69 TW13 60 25 12 22% 0
NE9 1 40 2.47 62 2.96 TW13 60 38 7.2 41% 0
(Red) stands for 35t mobile crane in the illustration. It means that the unit are lifted by mobile crane. The other colors stand for different tower cranes in the illustration and forms. As shown in the form, there are 264 units (including 57 single pieces in Gills Trusses). Mobile crane erects 68 of them. A tower crane erects 74.2% of the unit which makes full use of tower crane. 11.4 Temporary supporting
11.4.1 The temporary supporting layout
Arches and Sloped Columns are inclined and they need temporary supports to resist the horizontal forces. Arches are divided into two pieces as shipping unit and Gills Trusses are divided into many units as the erection units shown before. The break position needs temporary support to resist self weight and horizontal force. Based on the erection units.
11.4.2 Temporary Supporting
Insert plate during concrete pouring Temporary support welding to the plate Please ref to attachments appendix B embedded parts layout and appendix C embedded
details
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11.4.3 Head & Bottom Connection
11.4.4 Wind rope
Insert the embedded for fix wind rope during concrete pouring. All temporary support and completed steel structure should be using wind rope as safety
required.
11.5 Detailed Erection Method for International Hub
11.5.1 General
International Hub is erected from inside to outside. While erecting the inner part, the outside place can be used for assembly. The Gills Trusses is erected from middle to side outwards. The single part is erected after both side units have been erected and fixed. The man lift is used to reach and weld the single piece into position.
The space frame install will follow the steel structure erection schedule. Using temporary support is separately and removed when work is completed. The erection sequence show as following:
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11.5.2 Erection of Lens
Step 1: Position Fix and Base Connection erection
Step 2: Temporary support fixing
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Step 3: Lens arches erection
Step 4: Space Connection erection
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11.5.3 Erection of Gills column
Gill Columns are upright which can be fixed on the floor without temporary supporting directly.But every steel column needs four cables to improve the stability.
11.5.4 Gills trusses erection
Step 1: Loft & deploy supports Step 2: Erect the middle unit
Step 3: Erect the other middle unit Step 4: Adding the single units
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Step 5: Erect from middle to side Step 6: The second Gills Trusses erection
Step 7: Erect piermeter beam Step 8: Permeter beam butt joint
Step 9: From inside to outside Step10: Final touches
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11.5.5 Gills trusses assembly
Step 1: Chord fixing
Step 2: Adding the web member
12 Erection Method for Boarding Bridge
12.1 General Dimension Boarding Bridge: 46 PCS Weight: 46 ton for each Size: H*B*L=3275mmx5000mmx37000mm Height: 6m~10m Section: UB for chords, Box for webs
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12.2 Transportation Units
The transportation method of boarding bridge shall be as side truss, other members in bulk.
Width: 5000
Height: 3275
level:10m
level:6m
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12.3 Erection Units The erection weight of bridge shall be less than 23ton.
12.4 Crane Selection Apply: 150 t mobile crane, 25.2m (boom)@11m, 35 ton >23 ton + 0.4 ton (hook)
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150t mobile crane
12.5 Erection Method Step 1: Assemble on ground
Step 2: Erect the first unit
Step 3: Erect the second unit
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Step 5: Adding the single piece on the manlift
13 survey schemes
The structure of this project is complicated, with large construction and so much bolt connection joints. And high accuracy requirement make survey work of KAIA PTB Steel structure work very difficult. Installation accuracy control is an important and difficult work on site. So we need to solve many problems in survey work.
13.1 Analysis of difficulties (1) Survey process is more; high elevation locating is difficult.
According to the construction scheme we should first assemble most of components on the ground, then hoist them integrally. In construction process the survey work and process would be increased, so that the accuracy control became very difficult.
(2) The weather is bad; the view condition is very poor. In Jeddah, the weather is very hot and the sunshine is too strong. BetweenAM9:00 toPM4:00 the air temperature is above 40℃,the air current is very uneven and the target is too fuzzy. We can′t view the aim directly by the Total station, because the construction area is too large with a cover of about 1312m×941m, None of the tall building to be used as the survey location, this cause the aims and control points can't be view directly one another. Lots of extra work has to be done to grantee the survey accuracy.
(3) To control the accurate of curve members is difficult. In structure system the sword in Piers and the gill truss in Hub are belongs to the curved tubes. Controlling the curve is a technical difficulty. As the gill truss had lots of joints connect with it, the components can′t be installed successfully if the installation dimensions
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exist any mistake. (4) To control the welding deformation is difficult.
There are great deals of welding works in this project; control of the welding deformation is an arduous work. The deviation of deformation dimension will impaired the dimension accuracy directly. So we should control the deviation of deformation dimension both in assembly and installation process. How to solve these difficulties, and ensure the project quality are two vital points the survey work must take into consideration.
13.2 Survey idea and control method We adopt the survey principle that “first whole then part, use high accuracy control point and instrument to make sure small allowance” to measure these survey work difficulties in this project. First we should measure and lay the “First class survey control network”according to the control points provided by special surveying Institute, then measure the local placement, that is to say first the whole engineering were controlled by the high accurate measurement and advanced technology, then every parts and local were controlled . In whole measurement work, we should keep to the principle that is "to control installation accuracy from entirety to part, fabrication precision is small than installation accuracy” and eliminate the error in the every survey process, ensure the installation precision to meet the standard. In measurement process the coordinate system should be set up and adjust according to the design and position principle. All measurement data is based on the design drawing and sections. Site positioning drawing as below:
In observation time, we adopt the method of direction observation in round to measure; we usually using 2 direction observations to measure them. To the place of high precision, we adopt the method of more direction observations to raise the accuracy, the same Total station, survey station and the measurement data are used as the calculate basis, and then the adjustment program is used for ensuring the precision. We main adopt the method of measuring the truss open-location and terminal point to control the whole dimension during the course of assembly and installation. To strictly control the error of every measurement, to prevent the error is accumulating reached the maximum value.
13.3 Accuracy control of anchor bolts To position the anchor bolts, the axis and elevation should be setting-out on reinforcing steel or template by the Total station, and then adopt the method of supporting-wire and bracing wire to position them. The leveling would be used for measure the elevation of anchor bolts; first the leveling points must be measured and marked on the template or reinforcing steel from the nearest elevation control point as the leveling basis. The Total station was used for checking the top of anchor bolts location when the anchor bolts were installed. Finally, all measurement data should be controlled within allowable deviation.
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The tolerances see AISC 303-5 section7.The location of measurement points as below:
13.4 Accuracy control of Zone A Banana trusses
Banana trusses are cut into pieces in shop, and assemble on site at the assembly yard, and then lift up integrally. In construction process, we should consider how to control the assembly accuracy on the ground firstly. We adopt the method of mould bed to control the assembly accuracy that is according 1:1 scale to stake out the axis and control line on assembly yard, and make the control lines, joints and position line. The leveling is used for measuring the elevation of adjustable plate.
To control the accuracy of assembly dimension, we mainly adopt the method of supporting
wire to do it, just ensure the whole dimension and every joints relative position, the diagram as below:
Setting-out the axis and elevation
Position
Measurement point
After concrete placement, location of every bolt should be check by the Total station
The leveling was used for measure the elevation of corresponding location
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Lastly, the Total station is used for checking the whole dimension and relative position
of every joint. The accurate must be controlled within allowable deviation. The detail tolerances see AISC 303-5 section7.
13.5 Installation position for banana truss To position the banana truss, we usually adopt the method of measure the 3D coordinate to control them that are tube center or forth point of open-location.
Just to ensure the measurement points in consistent with work points in design drawing. The
measure diagram as below:
In installation process, the measure data must be satisfied with allowable deviation,
every point should be controlled within tolerance value. We need stake-out the line and elevation on the temporary support before lifting, then wending the limiting plate. The components need to connect the ropes when lifting, and alignment the axis on the temporary supports. After that, we use the wind ropes and hydraulic jack to correct the axis and elevation reached to the allowable deviation. At last, we use the Total station to check the coordinated of control points, if all dates are OK, fix the rope and limiting plate. The detail tolerances see the AISC303-5 section7.
13.6 Positioning accuracy of PIER Pier can be divided into 3 types: double pier, Single pier and International pier. Most of components adopt the bolts connection; to install Pier we should assemble truss, and then hoisting them integrally. So the assembly accuracy must be controlled. During the course of installation, the steel standard and code should be execute and check whole dimension before welding the truss. The truss must be corrected when we found the
We main adopt the method of supporting wire to control it
Measure point)
Measure point (the fourth point of pipe open-l ti )
Measuring points not less than 2)
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dimension accuracy overstep the allowable deviation. The principle and base of survey position
To control the Crane accuracy is the key of Pier ′accuracy control, the accuracy of assembly and installation control were base on 3D model and situation plan. The critical is to control the key joint and location. The model position drawing as below:
During the course of installation, the open location and terminal location should be controlled.
The Total station is used for measure the 3D coordinates of truss open-location; all measurement value is base on design value.
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(1)Temporary supports To design the temporary supports first the assembly yard should be considered, whether the temporary support can satisfy the geometry linear and concrete height of truss. (Assembly yard must be hardening before installing temporary support) the diagram as below:
The allowable deviation table of temporary support (mm)
Item Allowable deviation Check method axis ≤3 Using the steel ruler
elevation (0, +10) Using the Total station
(2)Positioning the casting
The axis and control lines should be staked-out on the assembly yard by the Total station, and the casting base plate should be positioned before assembling the Crane. To position the casting we usually measuring the pipe orifice centre or fourth points by the Total station. The rope and hydraulic jack were used for moving the casting to control the Tolerance.The diagram as below:
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During the course of assembly, we need considered the wending shrinkage and settlement. So
we usually let the position value more than or less than design value 5mm.Lastly, the dimension accuracy can reached the allowable deviation.The requirement and accuracy see the AISC303-5 section7.
(3)Positioning accuracy of the curved pipe
To position curved pipe, we adopt the method of combined of supporting wire and plane right angle coordinates to accurate position, first one point should be moved as the survey station from the nearest place, and then the Total station is set up on this point and we adopt the method of measuring the curved pipe center or fourth point 3d coordinate to accurate position. All survey points must be controlled less than tolerance. The detail allowable deviations see the AISC303-5 section7.The diagram as below:
(4) Assembling main truss of double pier on the ground Main truss is first assembled on the ground, and then lift up integrally. To control the
dimension accuracy we should set up a new coordinate system according the truss dimension and linear, and then staking-out the axis, elevation and contour lines. During the
Survey point (the pipe center or fourth point) Survey point
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course of assembly, the dimension accuracy should be controlled by the method of supporting wire and measuring steel ruler. The whole dimension and every key joint position must be checked when truss assembly finished by the Total station.
The allowable deviation see the AISC 303-5 section7 7.13.
(5) Assembly accuracy control of double pier To position the main truss, we adopt the method of measuring the Flange plate center point of
H section steel 3D coordinates to accurate position by the Total station. First the main truss were controlled within the 20mm, and then fixed the rope and wending the limited plate on the support. After control the accuracy within the allowable deviation. We can use the ropes to correct the error. The survey control points diagram as below:
During the course of survey, the coordinates should be translated in the light of actual conditions.
(6) To control the whole dimension of double pier
The whole dimension and key location of double pier must be checked; all error was strictly observed according the standard and code of steel structure. The measuring diagram as below:
Measurement point
Measurement point
Measurement point
Measurement point
Measurement point
Measure point (The center point of H section)
Measure point (The center
i t)
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All control accuracy seeing the Code of Standard Practice for Steel Building and Bridge (AISC303-5)
Assembly surveying for Single pier
(1) Temporary supports
Survey method of temporary supports layout and installation the same to double pier. The diagram as below:
(2)Single pier assembly surveying process and method
Step1: To position the casting
Measurement point (The flange plate center point of H section)
Survey point
To measure the key location
Measurement point (center point)
Measurement point (roof hanger)
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Step2: Assembly positioning for curved pipes
Step3: Assembly positioning for section 1
Step4: To position the joint
measurement point1(pipe center or fourth point)
measurement point2(pipe center or fourth point)
measurement point(pipe center or fourth point)
Survey point A (Flange plate center of Cantilever beam
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Step5: Assembly positioning for section 2
Step6: To install the joints
Step8: To check the whole dimension
(Flange plate center of cantilever
To couple
Control
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The whole dimension must be checked and measured when all components have finished, the detail requirement and allowable deviation see AISC303-5 section7 Erection. The unqualified location must be corrected again. We can weld them when the error of every survey location should be controlled within allowable deviation.
Installation surveying for Pier.
To loft the location of web member before installing
The key location must be checked
Measure point (open Location)
measure point (cantilever beam of
truss )
Survey point (cantilever
beam of truss )
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13.7 Assembly and installation surveying for boarding bridge Totally 46 boarding bridge will be installed on site. The members are mainly H section and Box section. Connection will be bolted on site and requires high erection accuracy.
For boarding bridge, we adopt the method of assemble them in sections to install them lying on the ground. To control the assembly accuracy we adopt projection method to do it, in other words, the axis and contour lines of boarding bridge should be lofted on the ground, according to the design drawing and model, and then adopt the method of supporting wire to accurate position. To install the boarding bridge, the axis and elevation of boarding bridge should be lofted on the temporary support before hoisting; lastly, the every dimension and key joints coordinate must be checked by Total station.
■Quality accuracy assurance measure for truss (1) To strict execute the request of assembly technology, and ensured the accuracy of
assembly dimension Many components would be pre-assembling in the factory; the problem should be found and solved before leaving the factory that is maybe happening in site. That ensured the dimension accuracy, section, beveled edges, and making the clearly mark on components. The assembly quality and progress can be raised by this method. So the key measures of ensured quality accuracy are adopting the method of Pre-assembly in factory.
(2) To ensure the assembly accuracy of support on site, and ensured the assembly quality Temporary supports quality will impaired the component of assembly quality, to design the temporary support we must strict according the technology to do it. The temporary support must have the enough strength, and can′t be rock clearly. The temporary support must have the web member connection. We should check the position dimension and elevation, to ensure the temporary support accuracy.
(3)Reinforce the quality management During the course of assembly, the quality scout and check should be executed strictly; the
disqualification components can′t be passed the next process to construct. Insist on prevention first, wall up the quality accident be happened. Define the inspection item,
Installing for second
Installation finished
The assembly di
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inspection standard and method, to demure keep record, date condition and operation staff etc. The disqualification components should be mark and correct timely.
Construction monitoring ■ Deformation survey
To monitor the deformation, we adopt the polar coordinates method to do them in this engineering, to measure the settlement observation we according the observation request and point to do it. The observation point must be installing securely and be using long time. When the steel roof have finished, we must set the observation point, the observation cycle is two months, and the detail plan according the actual conditions to do it. We must call the project department if found have the big displace.
■ Uninstall survey The reflector plates must be stick on the cantilever beam and bottom chord location when the
steel roof structure have finished. During the process of uninstall, all points should be measured by total station. The construction department must be stopped when we found the measure data have a big displace of truss and till make a solving scheme. All support points have uninstalled, we should continue to observation the key points 2 weeks till the data became stability, and then collecting the survey data.
14 Logistic Plan
14.1 Storage Yard
The storage yard must be as close as possible to the site, and it should be as small as possible in accordance with the peak necessity. The peak is expected in July and August as marked in the following table:
The area of the storage yard is 610*86*2=52460㎡ which contains 2 assembly area and 1 check point before unloading, so the remaining area is about 280*86*2=48160㎡. Deducting the road area ,the pure area is about 31360㎡(>23234 ㎡)
14.2 Master Schedule
The total schedule is planned for 16 months, starting from the project commencing date to the completion of steel structure. Before the site erection, it requires 6 months minimum for the following processes: Detailing drawing, procurement, fabrication, trail assembly, delivery. 1st Aug 2012 is assumed as start date and a total of 10months for site installation. 14.3 Manpower Plan
The maximum manpower required is 292 and the welders shall be 60.
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14.4 Equipment Plan
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14.5WaterandElectricity
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15 Health and Safety
Site HSE manager will be response to the site safety issues and as a key manager to this
project.
The workers will be made aware of the safety requirements related to this activity through
daily toolbox meeting and safety talk.
Every effort shall be made to assure that employees can accomplish their assigned scope
of work safely.
Carry out provision of the warning sign and isolation requirements on site
Splice joints will be supported by temporary supports and the work platform will also be set.
The movable scaffolding will be the majority facilities for moving.
For the workers, overall equipment will be supplied such as hammer, work suit, safety
harness, safety glass, etc. to guarantee the safety of workers.
Scaffold inspector and erector certifications submit prior start the job.
Fully comply with approved SBG’s safety plan.
16 Attachment:
Appendix A
RISK ASSESSMENT
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
FACILITY
421-F100 RISK ASSESSMENT NO: Steel structure Installation-001
Pages: 16
ACTIVITY
Top coating at site ASSESSMENT TEAM: JGS GEOFFREY RSS JAYAKUMAR
ASSESSMENT DATE: 7 Nov 2012 REVIEW DATE: 7 Nov 2012 ASSESSMENT APPROVAL:
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
Inadequate knowledge of
Project Requirement
s
Personal injury Injury to others
Ignorant to site regulations
5 4 20
Attend NDIA Safety Induction for New Employees Attend SGW Safety Induction for New Employees A qualified person should be assigned the responsibilities to ensure all personnel comply with ES&H Requirements include hygiene and health sanitation in safety induction All areas shall be kept free of nuisance & safety hazards
3 1 3 YES
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
Moving traffic in and out of the lay down area North
West
Hit by moving vehicle Hit by moving truck
Heat stroke
Wear proper high visibility vest Use adequate PPE Provide shed / covering Provide cool drinking water Provide adequate lighting at work area Provide signalman Provide moving equipment with flasher lights and audible back up alarm
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
Personnel on ground
Hit by moving vehicle Hit by moving truck
Heat stroke
5 4 20
3 1 3 YES Wear proper high visibility vest Use adequate PPE Provide shed / covering Provide cool drinking water
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
CRANE TO BE LOCATED ON LEVELLED
SURFACE & OUTRIGGERS TO BE FULLY
EXTENDED & PLACED ON PACKING.
PRE LIFT PLAN TO BE FILLED OUT PRIOR OF
EVERY LIFT
LIFTING AREA TO BE BARRICADED AS TO
AND SIGNED (KEEP OUT)
TRAINED, COMPETENT RIGGER SHALL BE
APPOINTED AND MUST BE AWARE OF THE
LIFTING PROCEDURE
TAGLINES WILL BE USED
LOADS SHALL NOT BE LIFTED/SLEWED OVER
PEOPLE - AREA WILL BE ISOLATED.
LIFTING AREA TO BE BARRICADED AS TO
PROHIBIT UNAUTHORIZED PERSONNEL .
OPERATOR SHALL FOLLOW RIGGER
DIRECTIONS - ORDERS
HOT WORKS ELECTRICITY ELECTROCUTION, FIRE 4 4 16 HOT WORK PERMIT SHOULD BE OBTAINED
PRIOR TO WORK. 3 1 3 YES
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
WELDING UNIT SHOULD BE WELL
MAINTAINED & SHOULD BE CHECKED BY
COMPETENT PERSON BEFORE USING.
COMPETENT & EXPERIENCED OPERATORS
SHOULD HANDLE IT.
THE AREA SHALL BE CLEARED OF ANY
COMBUSTIBLE AND FLAMMABLE MATERIALS
PRIOR TO HOT WORKS COMMENCING. -
GOOD HOUSEKEEPING
A FIRE EXTINGUISHER OF A SUITABLE TYPE
SHALL BE LOCATED NEARBY.
A FIRE WATCH SHALL BE IN ATTENDANCE AT
THE LOCATION DURING HOT WORK ACTIVITY
AND ALSO 1 HR AFTER THE WORK.
ALL WASTE ELECTRODES SHALL BE
COLLECTED FROM THE FLOOR IN AREAS
WERE WELDING IS TAKING PLACE AND SHALL
BE STORED IN A SUITABLE METAL
CONTAINER.
DCP FIRE EXTINGUISHERS & FIRE BLANKETS
SHOULD BE AVAILABLE ON SITE
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
APPROPRIATE PPE SHOULD BE WORN
WHICH INCLUDE WELDING HOOD, WELDERS
GLOVES ,COTTON COVERALLS ETC
HAND TOOLS/
POWER TOOL
OPERATION
HAND TOOLS AND
POWER TOOLS
INJURY TO PERSONNEL, ,
DAMAGE TO MATERIAL. 3 3 9
BEFORE HANDING OUT TOOLS, VISUAL
INSPECTION WILL BE CARRIED OUT, BY
COMPETENT PERSON.
2 1 2 YES
HEARING PROTECTION SHALL BE USED IF
EXPOSED TO NOISE LEVELS OF 85 DB(A) OR
ABOVE
COMPETENT OPERATORS SHALL HANDLE
THE TOOLS & COMPETENT SUPERVISION
WILL BE ENSURED.
ALL TOOLS USED WILL BE WELL MAINTAINED
AND DEFECT FREE.
ELECTRICALLY OPERATED TOOLS SHALL
COMPLY WITH OBI / ADCC
REQUIREMENTS-DOUBLE INSULATED /
COLOUR CODED / PROPERLY GROUNDED
APPROPRIATE PPE
GENERAL SITE
CONDITIONS
SLIPS TRIPS FALLS 3 3 9
GOOD HOUSEKEEPING, STARRT TALK FOR
TEAM. 2 1 2 YES
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
USE OF APPROPRIATE PPE ALL TIMES.
WORK ACCESS AREA SHALL BE MAINTAINED
IN A SAFE CONDITION, FREE OF DEBRIS &
MATERIAL THAT WILL POSE A HAZARD.
MATERIALS SHALL BE STORED PROPERLY
ADEQUATE LIGHTING SHALL BE MAINTAINED
AT WORK / ACCESS AREAS WHILE WORKING
AT NIGHT
GRINDING GRINDER
FLYING PARTICLES , EYE
INJURY, OTHER INJURIES
2 3 6
BARRICADE THE AREA & PLACE WARNING
SIGNS
3 1 3 YES
GRINDING WHEEL MUST BE DRESSED
REGULARLY
GRINDER SHOULD HAVE ITS GUARD
SECURED IN PLACE.
FLAME PROOF SCREENS SHOULD BE USED
TO PREVENT SPARKS FALLING ON
PERSONNEL & OBJECTS.
PROPER PPE FACE SHIELD/GOGGLES
SHOULD BE WORN
WELDING ELECTRICITY = ELECTROCUTION, FIRE 5 4 20 BEFORE WORK STARTS THE MACHINE WILL
BE CHECKED BY COMPETENT PERSON . 3 1 3 YES
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
THESE MACHINES SHOULD BE HANDLED BY
EXPERIENCED OPERATORS ONLY
COMPETENT SUPERVISION WILL BE
ENSURED.
THE MACHINES SHALL BE WELL
MAINTAINED AND COLOUR CODED. ENSURE
PROPER GROUNDING
THE MACHINES SHALL BE DOUBLE
INSULATED AND THEIR CABLES AND PLUGS
SHALL NOT BE MODIFIED OR CHANGED.
WELDING FUMES INHALATION OF FUMES 3 4 12
THE WELDING AREA SHALL BE WELL
VENTILATED.
2 1 2 YES
STRICT ADHERENCE TO WELDING PPE
TOOL BOX TALKS WOULD BE CARRIED OUT
AND RISK ASSESSMENT TO BE DISCUSSED
APPROPRIATE PPES TO BE USED
MINIMUM PERSON TO BE IMPLEMENTED ON
WORK
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
WORK ON
SCAFFOLDS
STRUCTURAL
COLLAPSE
SCAFFOLDING
(COLLAPSE OF SCAFFOLD,
FALL OF MATERIAL FROM
HEIGHT ETC. FALL OF MEN
FROM HEIGHT, ACCIDENTAL
MOVEMENT OF MOBILE
TOWER, TUMBLING OF
SCAFFOLD DURING
MOVEMENT)
5 4 20
VEHICLES NOT TO BE ALLOWED TO DRIVE
NEXT TO THE SCAFFOLD. AREA TO BE
BARRICADED.
3 1 3 YES
ERECTION & DISMANTLLING SCAFFOLD TO
BE DONE BY A CERTIFIED AND COMPETENT
SCAFFOLDER ONLY.
PROPER ACCESS TO WORKING PLATFORM
AND WORKING AREA
POLES, LEGS, OR UPRIGHTS OF SCAFFOLDS
SHALL BE PLUMB & SECURELY & RIGIDLY
BRACED TO PREVENT SWAYING AND
DISPLACEMENT
BASE TO RATIO TO BE ADHIRED TO
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
ACCESS/EGRESS LADDER TO BE PROVIDED
ACCESS AND EGRESS THROUGH SCAFFOLD
SHOULD BE THROUGH THE INNER SIDE OF
MOPBILE SCAFFOLD
AREA UNDERNEATH SHALL BE BARRICADED,
WHILE SIGNS INDICATING THAT "MEN
WORKING OVERHEAD" SHALL BE PLACED
LATERAL SUPPORTS REQUIRED TO SECURE
LATERAL MOVEMENT OF THE SCAFFOLDING
SCAFFOLDS SHOULD BE CHECKED
REGULARLY BY COMPETENT SCAFFOLDER
AND SCAFFTAG SYSTEM FOLLOWED.
FALL ARRESTERS SHOULD BE USED AND
SHOULD BE FIRMLY ANCHORED.
MOBILE TOWERS SHALL NOT BE MOVED
WITH PEOPLE ON IT.
CASTOR WHEELS WOULD BE LOCKED TO
AVOID ACCIDENTAL MOVEMENT ON MOBILE
SCAFFOLD.
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
GROUND TO BE FREE OF OBSTRUCTION FOR
LATERAL MOVEMENT OF MOBILE SCAFFOLD.
HANDRAILS, MIDRAILS & TOE BOARD TO BE
INSTALLED AND IF DISMANTELLED FOR
ACCESS OR EGRESS TO BE REPLACED
IMMIDIATELY
MANUAL
LIFTING
MANUAL LIFTING /
MATERIAL HANDLING MINOR INJURY 2 3 6
SAFE METHODS OF MANUAL LIFTING
SHOULD BE BRIEFED BEFORE THE WORK
STARTS THROUGH STARRT TALK.
1 1 1 YES
MANDATORY PPE SHOULD BE WORN ALONG
WITH THICK GLOVES TO PROTECT FROM THE
EDGES OF CORRUGATED SHEET AND NAILS .
CHEMICAL
HANDLING /
STORAGE
PAINT PRIMER
HANDLING / STORAGE POISONING, IRRITATION , FIRE 3 4
12
MSDS TO BE AVAILABLE ONSITE. SAFE
HANDLING PRACTICES SHOULD BE BRIEFED
TO HANDLERS
1 1 1 YES GOGGLES ,MASK & GLOVES WILL BE USED
ALONG WITH OTHER PPE
EYE / HAND WASH FACILITY & FIRST-AID
FACILITY WILL BE PROVIDED ONSITE.
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
POISONING, IRRITATION , FIRE 2 3 6
PRIMER SHOULD BE STORED IN
MANUFACTURER SUPPLIED CONTAINER
ONLY IN WELL VENTILATED AREA AWAY
FROM ANY SOURCE OF IGNITION 1 2 2 YES
DRY CHEMICAL / CO 2 / ALCOHOL RESISTANT
FOAM EXTINGUISHERS SHOULD BE
AVAILABLE ONSITE.
ENVIRONMENT
WASTE CONTAINERS
OF
PAINTS / THINNER
ENVIRONMENT 3 3 9
WASTE CONTAINERS SHALL BE COLLECTED
SEPARATELY AND PROPERLY DISPOSED OFF
BY LICENSED AGENT.
1 1 1 YES
OIL SPILLS
FLUID SPILLS
FROM VEHICLES &
EQUIPMENT
ENVIRONMENT 3 3 9
DAILY INSPECTION OF EQUIPMENT FOR
LEAKS
2 1 2 YES
PLANT & EQUIPMENT WILL BE CHECKED &
MAINTAINED IN A SAFE CONDITION
MAINTENANCE PERFORMED BY COMPETENT
PERSONS
DRIP PANS AND SHEETS USED DURING
SERVICE
SPILL KIT WILL BE AVAILABLE ONSITE IN
ADDITION TO MOP UP ANY ACCIDENTAL
SPILLS TO GROUND
SPILLS TO BE REPORTED IMMEDIATELY
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
DIP TRAYS TO BE PROVIDED AS TO HANDLE
ANTICIPATED SPILLAGE OR CONTAINMENT
REQUIREMENTS
IMPERVIOUS MATERIAL UNDER FUEL TANKS
WORKING ON
MEWPS
CHERRY PICKER
("BASKET CRANE'') -
PERSONNEL AND OR CHERRY
PICKER STRUCK BY VEHICLE
OR THE EXTENDED BOOM,
MATERIALS AND PERSONNEL
FALL FROM HEIGHT
4 3 12
TRAINED, COMPETENT OPERATOR AND
RIGGER (FOR HELPING OPERATOR WITH
BLIND SPOTS) TO CONTROL HIM SHALL BE
APPOINTED
2 1 2 YES
LIFTING AREA TO BE BARRICADED AS TO
AND SIGNED (KEEP OUT AND LIFTING IN
PROGRESS)
SAFETY OFFICER IN SITE TO ENSURE DAILY
INSPECTION OF EQUIPMENT, PERIODIC
MAINTENANCE AS REQUIRED
SAFETY HARNESS/FALL ARRESTORS TO BE
USED BY PERSONNEL ON AERIAL PLATFORM
(BASKET)
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
OPERATOR TO FOLLOW THE EQUIPMENT
LIFTING CHART RESTRICTIONS, MAX. BOOM
RADIUS, PERSONNEL NUMBER AND WEIGHT
TO BE LIMITED ON BASKET ACCORDING TO
EQUIPMENT SPEC. - LIFTING PLAN TO BE
AVAILABLE PRIOR USE
LIFTING AREA TO BE BARRICADED AS TO
PROHIBIT UNAUTHORIZED PERSONNEL .
CHERRY PICKER TO BE LOCATED ON
LEVELLED SURFACE & OUTRIGGERS TO BE
FULLY EXTENDED & PLACED ON PACKING.
HANDRAILS, MIDRAILS & TOE BOARD ON
BASKET (MINIMUM REQUIREMENT FOR
EQUIPMENT USE)
DAILY INSPECTION TO BE CARRIED OUT BY
COMPETENT MECHANIC/OPERATOR
LIGHTING OF 30LUX AND 3.0 FOOT CANDLE
TO BE PROVIDED
TUNGSTEN HALOGEN LIGHTING TO BE USED
WHEREVER POSSIBLE TO MINIMISE FIRE
HAZARDS CAUSED BY TUNGSTEN LIGHTING
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Task Hazard Hazard effect(consequence) C L Risk Proposed Control Measures C LReduced
Risk ALARP
BULB TO BE PROTECTED FROM BREAKAGE
AND ANY BROKEN OR DEFECTIVE BULBS TO
BE IMMEDIATELY REPLACED
LIGHTING FIXTURES TO BE POSITIONED TO
MINIMISE WORKER CONTACT WITH FIXTURES
DURING WORK OPERATIONS
LIGHTING SUPPLY CORDS AND CABLES TO
BE INSTALLED IN CONSISTENCY WITH GOOD
ELECTRIC WIRING PRACTICES.
ALL POINTS OF ACCESS AND EGRESS SHALL
BE CLEARLY ILLUMINATED AND MARKED
PORTABLE GENERATOR TO BE GROUNDED
AT OVER 3.0M DEPTH, METAL CASE SOCKETS
OF BULBS TO BE GROUNDED
Risk Assessment Sheet
Form Issue 01 Date: 7 Nov 2012 Author REN
Criteria ( C ) Consequence: Negligible- immediate return to work
Minor - first aid and return to work.
Moderate- medical treatment/ lost time
Major- multiple injuries and
RIDDOR reportable
Fatal/Catastrophic- Death, loss of
installation
Criteria ( L ) Likelihood:
Improbable- so unlikely that it would not
happen.
Unlikely- remote chance of event Possible- inattention may cause an
event to happen.
Probable- highly likely without control.
Certain- will happen without
Intervention / control.
Risk Calculator, Risk level R= C X L 1-4 Acceptable 5-8 Tolerable 9-10 Moderate 12-15 Substantial >15 Intolerable
Conclusions: Overall risk - Low/Medium Are risks reduced to ALARP (as low as reasonably practicable), Yes
Likelihood→ Consequence↓
Improbable 1
Unlikely 2
Possible 3
Probable 4
Certain 5
Negligible 1 1 2 3 4 5 Minor 2 2 4 6 8 10 Moderate 3 3 6 9 12 15 Major 4 4 8 12 16 20
Fatal/catastrophic 5 5 10 15 20 25 Overall risk. 1-4 =Low; 5-10 = Medium; 12-25=High
Appendix B
Insert for temporary support layout
Appendix C
Insert for temporary support detail
Appendix D
INTERFACE TC AND PROCESSOR
Construction InterfaceBetween
Transportation Center 422and
Processor (PTB) 421
7 August 2012
OBJECTIVE
Installation of Structural Steel Elements (Banana Trusses) at the Façade of the Processor of PTB Opposite Transportation Centre Without Compromising Completion Dates of Either Facility.
Outline Construction Schedule of Affected Facilities / Element
Aug Sept Oct Nov Dec Jan 13 Feb 13 Mar 13
Apr 13
Processor Concrete Level 2
XX XXX
Processor Concrete Level 3
XXXX
Transport Centre Roof XXXXX
Pedestrian Bridges XXXXX XXXXX
Automatic Walkway Bridges from MSCP
XXXXX XXXXX XXXXX
Structural Steel (Middle) XXXXX
Via Duct Decks Zones 2 & 4
XXXXX XXXXX XXXXX XXXXX XXXXX
Considered and Discarded Schemes for Installation of Banana Trusses
• Scheme 1: Crawling along the Façade
• Scheme 2: Two additional Heavy‐duty Tower Cranes
Outside the TC
• Scheme 3: Factory Cutting of Banana Trusses into 2‐3 ton
Segments
Scheme 1Crawler Crane along the Periphery
150 ton Crawler Crane lifts assembled upper two parts of banana Trusses (16 to 23 ton approx) and crawl with them along the periphery of the Façade to where they will be finally installed .
ProblemPostponing most activities on Curbside VD, TC and Bridges till after Façade works. Not acceptable phasing
Crawling along the Periphery
Scheme 2Two Additional Tower Cranes
• Two heavy‐duty tower cranes on either side of TC to install
banana trusses opposite to it.
Problem• Clash with Tower Cranes in Processor
Scheme 2 Operational Clash Diagram
Scheme 3Factory Cut into Shorter Segments
• Cutting Trusses into 2‐3 ton segments at factory and reassemble at final location (welding)
Problem• Result in 8 pieces and 7 Joints. Each will need to be supported
individually resulting in massive volume of temporary support. Involves multiple handling and on‐hook holding for longer time.
• More time and efforts as well as being esthetically inferior.
Load Contours of Tower Cranes at Processor
Proposed Scheme
Install Two All‐Terrain 500 ‐750 ton Telescopic Crane on either side of
Transportation Centre
– Transport assembled Truss from assembly yard on specially adapted flat bed trailer (26m long) to be lifted by 500‐750ton telescopic crane to its final location at the middle façade.
OR
– Transport the two parts separately and assemble on adjacent deck of Kerbside Via Duct. Lift to location as before (require shorter trailer)
NOTE: Added Advantage: Dismantle TC Tower cranes by
the All Terrain Telescopic Crane
Operational Radii for One Side of Middle Banana Trusses (East)
Typical All TerrainTelescopic Crane
Access and Space Details
Overhead Installations and Headroom Verifications above Access Route
East
Overhead Installations and Headroom Verifications above Access Route
East
Needed Scheduling Adjustments
Aug Sept Oct Nov Dec Jan 13 Feb 13 Mar 13 Apr 13
cessor crete Level 2
XX XXX
cessor crete Level 3
Remove Garbage Sorting Area and Concrete Delivery Stations
XXXX
nsport Centre Roof XXXXX
estrian Bridges and kways from MSCP Execute Piles and Footings ONLY
XXXXX XXXXX
omatic Walkway ges from MSCP
XXXXXXXXXXXXXXXSuper Structure (Decking)
ctural Steel (Middle sses)
‐Prepare Lifting Plan‐Prepare Access Road Layers
XXXXX
Duct Decks es 2 & 4
XXXXX XXXXX XXXXX XXXXX XXXXX XXXXXXXXXXXExecute Decks
General Layout around Processor
STAGE 4 ROOF and FAÇADE STRUCTURES _ REV 01_ WBS
• STAGE 4 ROOF and FAÇADE STRUCTURES _ REV 01_ PROPOSAL
EXTRACT FROM MST_ rev 02 STEEL ROOTS
EXTRACT FROM MST_ rev 02 STEEL ROOTS
EXTRACT FROM MST_ rev 02 STEEL ROOTS
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310
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9100
10123
10066
10069
8968
9039
10083
10083
10083
8041
4606
10083
8041
9039
10083
8041
9039
10083
8041
9039
10083
8042
266612333
6120 15880
7479
1452
1
7479
1452
1
N
1
6
N
1
4
N
1
2
N
1
0
N
8
N
6
N
4
N
2
N
1
8
N
2
0
N22
N24
56404250
61201588056404250
61201588056404250
KAIA PROJECT ASSEMBLY YARD PLAN
A
:
1
~
3
S27
S2
9S
31
S33
S35
S37
S39
S41
N40
N3
8N
36
N34
N32
N30
N2
8N
26
3588
3867
1876
8326
8319
9643
3588
6298
2137
4259
5882
6462
4818
8017
9386
8264
36645650
6512
3097
4894
9095
1060
4
15009
15001
15003
15001
22000
15001
15000
15000
15001
1500
1
2200
0
6474
8017
8614
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Water
tank
Remark: Zone F、G、D each need four water tank, Zone B、C、E、H each need two water tank
5548
70
65
88
75 1
73
08
11
20
9
25
63
0
36000 3600035514
1105555466
54
97
9
10946
16
42
59
25
9
21
09
6
23
66
0
46
29
382652
R
1
5
0
0
0
7
3
8
4
4
6
8
6
6
8
5
1
8
8
0
Assembly Yard
52
41
0
24945
7
1
5
2
9
52
41
0
500t Crawler crane
Scope of work
50t Crawler
crane 2 PCS
Temporary road
Temporary road
Temporary road
80
00
8149 8000 8796
80
00
R
1
5
0
0
0
4
5
5
9
1
500t Crawler crane
Scope of work
Assembly Yard
50000
25
00
0
50t Crawler crane 2 PCS
45
83
R
1
5
0
0
0
7
3
8
4
4
6
8
6
6
8
5
1
8
8
0
Assembly Yard
52
41
0
24945
7
1
5
2
9
50t Crawler
crane 2 PCS
Temporary road
Temporary road
Temporary road
80
00
814980008796
80
00
R
1
5
0
0
0
4
5
5
9
1
500t Crawler crane
Scope of work
Assembly Yard
50000
25
00
0
50t Crawler crane 2 PCS
45
83
10.1t
16.8t
16.72t
16.6t 22.3t
22.8t
22.2t
16.5t
16t
15.4t
15.5t
9.0t
15.3t
15t
17.6t
17.7t
17.9t
13.6t
13.3t
12.7t
12.5t
6.7t
11.6t
11.3t
14.3t
13.9t
13.2t
9.6t
9.3t
2.5t
16.8t
16.72t
16.6t22.3t
22.8t
22.2t
16.5t
16t
15.4t
15.5t
9.0t
15.3t
15t
17.6t
17.7t
17.9t
13.6t
13.3t
12.7t
12.5t
6.7t
11.6t
11.3t
14.3t
13.9t
13.2t
9.6t
9.3t
2.5t
500t Crawler crane500t Mobile crane
Autodesk Autodesk
Autodesk
Autodesk
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