009-CIVIL-MS CONCRETE WORKS.pdf

Pearl GTL Project

LINDE ENGINEERING

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

Project Document Number: T- 4.234.075 Project Rev.: D Page 2 of 23

Purchase Order Number:

2MH127

Tag/Item Number(s): N/A

Unit(s): ASU

PCWBS: Z

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

G D 19.01.09 Ready for Construction IU EO AG RFC

F C 03.12.08 As per Site Condition, Issued for Review SB EO AG RFC

E B 28.01.08 Ready For Construction SB UA/MC ZG RFC

D A 24.11.07 Company Comments Incorporated IU UA/IO MC CCI

C O 01.10.07 Issued For Company Comments IO MC ZG ICC

B 24.11.07 Issued for Review IO MC ZG IFR

A 01.10.2007 Issued for Internal Review MS MC ZG IIR

GAMA Rev.

Project Rev

Date Description Prepared

By Checked

By

Approved By

Status

No. No. ORIGINATOR

LINDE ENGINEERING AG

Document Title:

METHOD STATEMENT FOR CONCRETE WORKS

Contractor

Gama Qatar Co. W. L. L.

Document No. LOC470

GAM MTS CIV GTL 009 G

Org.

Code

Doc.

Type

Disc. Code

Geogr. Area

Seq.

No

Rev. No

Vendor Code

Project Document Number: T-4.234.075

Rev No: D

Doc. Title : GAM-MTS-CIV-GTL-009 Rev. G Method Statement for Concrete Works

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TABLE OF CONTENTS

1. PURPOSE _____________________________________________________________________ 5

2. SCOPE _______________________________________________________________________ 5

3. REFERENCES _________________________________________________________________ 5

4. DEFINITIONS _________________________________________________________________ 6

5. Responsibility __________________________________________________________________ 6

5.1. Site Manager _____________________________________________________________________ 6

5.2. Civil Works Manager ______________________________________________________________ 6

5.3. Site Engineer _____________________________________________________________________ 6

5.4. Work Supervisor __________________________________________________________________ 7

5.5. QA/QC Officer / Inspector __________________________________________________________ 7

6. Equipment & Manpower _________________________________________________________ 7

6.1. Equipment _______________________________________________________________________ 7

6.2. Manpower ________________________________________________________________________ 8

7. METHOD OF EXECUTION ______________________________________________________ 8

7.1. General __________________________________________________________________________ 8

7.2. Pre-Commencement Works _________________________________________________________ 9

7.3. PRE-CONCRETE _________________________________________________________________ 9

8. CONCRETE __________________________________________________________________ 13

9. Concrete Placement ____________________________________________________________ 14

10. Concrete Curing and Stripping of Formwork ______________________________________ 14

11. HSSE ______________________________________________________________________ 15

12. QUALITY ASSURANCE ______________________________________________________ 15

12.1. General _________________________________________________________________________ 15

12.2. Mass Concrete and Control of Heat of Hydration ______________________________________ 15

13. ATTACHMENTS ____________________________________________________________ 15

Job Safety Analysis ______________________________________________________________________ 15


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1. PURPOSE

This document describes the methods proposed to be used for the concreting operations that will be carried out as part of ASU Construction Works of Qatar Shell GTL Plant (Pearl) in Ras Laffan Industrial City of Qatar including similar works in TSF Area.

Concrete classification used in this document refers to Project Specification (see References).

2. SCOPE

Gama scope for Concreting Works will start upon the delivery of the concrete to the work area. Hence, all aspects of the works associated with the production and transportation of the concrete, including the precautions that should be taken to counter Heat of Hydration during the production phase, are beyond the scope covered in this document.

Subject works include the preparation and fixing of reinforcement bars (re-bars) and preparation and installation of formwork as well as pouring and curing of concrete.

The additional precautions for mass concrete, which is defined as any volume of concrete with dimensions large enough to require that measures be taken to cope with the generation of heat from hydration of the cement and attendant volume change to minimize cracking by the American Concrete Institute (ACI 207.1R-05), is excluded from this document. As stated in the Method Statement for Mass Concrete Works (T-4.234.079) any concrete volume having its least dimension equal or larger than 0.8 m will be considered as mass concrete for convenience.

3. REFERENCES

QCS Qatar Construction Standard

DEP 31.00.01.30-Gen Minimum Requirements for Structural Design and Engineering

DEP 34.19.20.31-Gen Reinforced Concrete Foundations and Structures

DEP 34.24.27.31-Gen Reinforced Concrete Stacks

T-13.376.358 Amendments and/or Supplements to Reinforced Concrete

Foundations And Structures.

T-13.376.351 Amendments and/or Supplements to Minimum Requirements for

Structural Design and Engineering

T-13.376.365 Concrete General notes and Abbreviations

T-13.376.392 Selection of Structural Concrete Mix

T-4.234.079 Method Statement for Mass Concrete Works

T-4.234.541 QC Documents for Concrete Works

BS 4449 High Yield Hot Rolled Deformed Reinforcement Bars

BS 4461 High Yield Cold Rolled Deformed Reinforcement Bars

BS 4483 Specification for Steel Fabric or Wrapping Fabric

BS 8666(BS EN ISO-4066) Specification for steel cutting, bending and


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Dimensioning

ASTM-C494 Standard Specification for Chemical Admixtures for

Concrete

BS EN 934 Admixture for Concrete mortar and grout

BS EN 206 Concrete Works

BS 4027 Specification for Sulphate Resisting Portland cement

BS 6610 Specification for Pozzolanic Pulverized-Fly Ash Cement

4. DEFINITIONS

Company : QSGTL or its PMC

Contractor : LINDE Engineering AG

Subcontractor : Gama Qatar Co. W. L. L.

Contract : QSGTL Pearl Plant C2 ASU Construction Works

QCP : Quality Control Procedure

ITP : Inspection and Test Plan

QA/QC : Quality Assurance / Quality Control

JSA : Job Safety Analysis

5. RESPONSIBILITY

5.1. SITE MANAGER

The site manager will provide inputs to the project execution plan to ensure that Strategies &

philosophy are properly addressed.

5.2. CIVIL WORKS MANAGER

The Civil Works Manager is responsible for the overall management of the project

Construction team to ensure that safe and effective operations are conducted and

Properly documented.

5.3. SITE ENGINEER

He will be overall responsible for safe execution of the whole job including:

Confirming the installation location from schedule of approved construction drawings.

Organizing of equipments and tools needed for the job.

Assigning skilled personnel for the job.

Sequence of activities to be carried out for the work as per this method of statement.

Conduct inspection and surveillance.


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Notify to Contractor engineer for inspection as applicable.

Ensure all Contractor and Company regulations are followed.

Ensure all personnel involved are in safe working condition.

5.4. WORK SUPERVISOR

He will be responsible for safe execution of the following activities:

Conduct TSTI with the concerned work force prior to start the work.

Ensure that relevant work permits for the job are obtained prior to start the work.

Conduct daily toolbox talks for the entire work force prior to start day work.

Assigning a competent work crew for specific activities, details of activities and task information will be given to the work crew.

Organizing tools and equipment needed to the work site.

Inspection and supervision of work.

Ensure all Contractor and Company safety regulations are followed as applicable.

5.5. QA/QC OFFICER / INSPECTOR

He will be responsible for:

Assurance of approved methods and materials are being used and conformance of

the specifications.

Stage inspections and surveillance in accordance with ITP and assurance of quality of work as per specification and erection procedures.

Incoming material inspection and review of test certificates.

6. EQUIPMENT & MANPOWER

All equipment will be inspected and approved by the Contractor, when required, and all

Personnel will be inducted and trained before and during mobilization.

6.1. EQUIPMENT

Formwork material (plywood, ready or prefabricated plywood formworks, timbers; 5 cm * 10 cm and/or 10 cm * 10 cm cross-sectional area, shoring, supporting and bracing materials, etc.), deformed rebar(s),

Adequate working platforms, ordinary plastic sheets (nylon), special oil for the formworks,

Steel tie wire, steel nails, spacers (concrete spacers) for concrete cover,


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Concrete hand buggies,

Polyethylene Sheets and Hessian (for Curing)

Vibrators (Electrical, Diesel, Petrol; whichever is appropriate and/or feasible),

Surface finishing equipments

Steel fitter pliers, adzes or hammer for form-workers, saw, steel tape meters, rebar cutting and bending equipments

Shovels, rake and scratches, trowels, brushes, mechanical water levels,

Moulds for taking concrete samples and cones for slump measurement,

Water and/or water connection with a suitable length of hose,

Surveying equipment and instruments

6.2. MANPOWER

Site Engineer

Foreman (Work Supervisor)

HSSE Engineer

Surveyor & Helpers

Formwork workers with helpers

Rebar workers with helpers

Concrete casting workers with helpers

Concrete pump operator

Banks men / Flagmen

If the above-listed equipment or manpower proves not sufficient for the timely completion of the facilities and project; additional will be provided to complete the works on time and in line with rules, regulations and specifications of Contractor, Company and RLIC.

7. METHOD OF EXECUTION

7.1. GENERAL

This chapter explains the methods to be used for the execution of all type of concrete

Activities (blinding, reinforced concrete).


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7.2. PRE-COMMENCEMENT WORKS

7.2.1 Existing Underground Facilities

Prior to work commencement, the existing and possible underground structures and installations will be checked by means of As-Built Drawings issued by the Contractor or the Company. The locations of such installations will be marked at site and posted with signs. After the area has been barricaded, possible relocation or removal applications for the same will be studied. Same studies will be submitted to the Contractor and the Company for approval. Should any underground facility be encountered in spite that they have not been pointed out in the drawings, Contractor will be informed immediately; and approval of Contractor and Company will be waited before proceeding with the relocation or removal of the same. The barricades for such activities will be temporary.

7.2.2 Access Roads

The locations of access roads within the execution area will be pointed out by the Contractor. These access roads will be used for the planning of concrete activities within the area. However, the access roads may be diverted for some periods during the execution of the works in order to ensure smooth execution of the works in the area. Nevertheless, no such diversion will take place without prior written consent of the Contractor or the Company. After the locations of access roads have been excavated, they will be backfilled to allow traffic in and within the area.

7.2.3 Barricades, Safety Signboards & Night Activities

All work areas will be barricaded and posted with signs before any work starts. Barricades will be formed by black pipes (steel); and the signboards will be placed as needed. Barricades will be kept in place until the work done and the areas have been filled.

Since no night activities are foreseen for the time being, the site will be kept closed during the night preventing any pedestrian or vehicle traffic. The requirement for illumination will be reviewed by Contractor, when this condition is expected to change due to other works or a change in the work schedule. Or by the time, night-work activities are foreseen, the site will be illuminated for workers to execute relevant works.

7.3. PRE-CONCRETE

Earthwork will be carried as per Method Statement # T-4.234.074.

Leveling and grading will be done as per RFC Drawings.

Final level will be checked.

Lean concrete for a minimum of 50 mm will be done and level will be maintained.

Coating will be done as Method Statement # T-4.234.078.

Prior to concrete pouring, steel bars and shutters will be checked to make sure that:


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a. Re-bars are fixed properly.

b. Shutters are fixed and supported with a good dimensional stability.

c. At all surfaces concrete coverage of minimum 50mm depth shall be provided.

Especially in hot weather, care will be shown to keep the forms, embedment and reinforcing bars relatively cool.

All reinforcement spacers and supports, unless approved otherwise by Contractor and/or Company, will be made from concrete or mortar having the same or better specifications as described within the poured concrete specifications.

Rebar elements will be free of loose rust scale, oil or other coating that can have a negative effect on bonding with poured concrete. Loose rust scale if found present will be removed with the help of wire brush.

Prior to the actual pouring of the concrete all of the necessary approvals will be completed.

Foundation, Rebar, Concrete Foam Work will be blown with compressed air.

Setting time will be a minimum of 1 hour after pouring of concrete into the forms.

7.3.1 Reinforcement Bar

All reinforcement steel and welded wire fabric used in Qatar is supplied by Qatar Steel Company (QASCO), whose production capacity is adequate for supplying both local and export markets. In case, another supplier will be used and approval will be received from the Contractor. Accordingly, the reinforcement steel to be used for the Project will be procured from QASCO or its authorized dealers in Qatar. All reinforcement materials will conform to Section 4.3 of DEP 34.19.20.31.

Formwork materials will comply with Section 5 of DEP 34.19.20.31.

Before fixing steel reinforcement, the area will be cleaned by blowing.

7.3.2 Rebar Fixing

Prior to the start of the work, RFC drawing will be studied and a draft plan of the sequence of the works will be done. The quantities of the steel and concrete required will be determined as well as the equipment and number of the people that will work for that batch.

All working areas will be clearly defined and soft barricaded both to prevent accidental trespassing and to provide a good defined workspace.

For works at height, proper scaffolding will be provided and the workers will be specially trained for work at height.

Steel rebar material will conform to the ASTM A615 grade 60 standard.

RFC drawings dimensions are for finished concrete and will be strictly adhered to in the finished drawing.

Storage arrangements will ensure the material is prevented from any contamination or damage.

Reinforcement will be cut and bent to BS 8666 (BS EN ISO 4066)


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Reinforcement will be identified using clearly marked, securely fixed, durable tags.

Bending and subsequent straightening of reinforcing bars projecting from existing concrete will be carried out as follows:

a) Unless otherwise noted in the Project Specifications or RFC Drawings, the minimum

distance from an existing concrete surface to the beginning of a bend, and the minimum inside diameter of the bend will be:

Bar Size Min. Dist. from surface to beginning of bend

Min. Inside bend diameter

10 mm to 25 mm

3 Bar Diameters 6 Bar Diameters

25 mm to 32 mm

4 8

Over 32 mm 5 10

b) Bars of 10 mm to 32 mm diameter inclusive may be bent once without heating; heating

may be required for subsequent straightening or bending.

Bars having a diameter greater than 32 mm may be bent only in exceptional circumstances.

c) Heat will be applied as uniformly as possible over a length of bar equal to 10 bar

diameters. The centre of the heated length will be at the middle of the arc of the completed bend. The bar temperature will not exceed 350C. The temperature will be maintained constant during bending or straightening operations. Temperature-measuring crayons or a contact pyrometer will be used to determine the temperature. Care will be taken to prevent quenching of heated bars either by application of water or by a high volume of air.

d) Straightened bars will be visually inspected before and after straightening to determine whether they are cracked or otherwise damaged.

Bars not exceeding 32 mm in diameter not projecting from concrete may be bent without heating in accordance with this Section providing no local section is re-bent or straightened, and the area of the bend is inspected for cracks.

Tying wire will be 1.5 mm diameter black annealed mild steel wire for uncoated mild steel or high yield steel.

Galvanized or stainless steel tying wire is to be used for fixing reinforcing bars of the corresponding material.

Spacer blocks will be factory made type.


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Reinforcement will be fixed, supported and maintained in position by the adequate use of chairs, spacers and tie-wire.

Reinforcement will be free of all rust and scale or contamination of any kind.

Different types of reinforcements will not be intermixed unless indicated in the design.

For transportable rebar configurations, assemblies will be prepared in a nearby location and installed to the formwork by using mobile cranes with proper lifting gears as per Method of Lifting General (T-4.234.084). Tying will be carried out in accordance with project specifications, considering the inducible loads during transportation and concrete pouring. For non-transportable rebar configurations, assemblies will be prepared in-situ with manual handling. Tying will be provided considering the inducible loads during concrete pouring.

Prior to concrete pouring, fixed steel re-bars and shutters will be checked to make sure that a concrete cover of as RFC.

All reinforcement spacers and supports, unless approved otherwise by LINDE, will be made from concrete or mortar having the same or better specifications as described within the poured concrete specifications.

Rebar elements will be free of hardened concrete, loose rust scale, oil or other coating that can have a negative effect on bonding with poured concrete. Loose rust scale if found present will be removed with the help of wire brush.

Prior to concrete pouring, the re-bars will be cleaned by brushing.

7.3.3 Formwork erection

Inside surfaces of wooden forms and adjacent concrete surfaces will be soaked with clean water a half hour before the actual concrete pouring but standing water and puddles will not be allowed to form.

Coatings of forms and/or releasing agents will conform to the requirements of ACI 301 and ACI 347 and a MSDS will be provided where required.

The forms and shutters used on concrete surfaces that are 300 mm below the final grade will be of type giving an equally smooth concrete surface that is free from objectionable wrinkles, cracks, fins, projections or other deformities.

Timber used will be de-nailed and thoroughly cleaned of concrete residue and when need be repaired before storage or reuse.

Materials for formwork are timber, steel structures, plywood, modular panel form and uplift formwork.

Formwork will be properly supported by wood, steel tubes, tie rod, adjustable jacks and spans etc.


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Formwork will be maintained proper dimension as per last RFC drawings, plumb and tightness.

Formwork will be coated on the surface with wax oil mixture for easy removal.

Lifting of form work shutters :

a) Maximum size of form work made out of GTX wooden beams , 5000mm x 3000mm weighing approximately 300 Kg will be provided vertically and as well as horizontally.

b) Minimum three tie rods will be provided at each lifting points for ensuring safe lifting.

c) The double wrapped web sling shall be passed through the tie rods around the GTX beam and it shall be secured by shackles.

d) For further about lifting, please refer the Method Statement (T.4.234.084) for Lifting (General).

7.3.4 Form Removal

Forms will not be removed until concrete has attained sufficient hardness. The duration after which the forms will removed can be found in the below table (Table-1), which summarizes our past experience in similar works in the region, mainly in QCS Project. These values must be considered as guidelines and actual time of removal is subject to inspection and good judgement.

Wall/ Slab Thickness

Formwork Removal

Countermeasure Curing Plan C 1.0 d < 1.8m

Side wall forms 24 hours after concreting Bottom forms after concrete reaches 80% of 28-day strength

Countermeasure Curing Plan B 1.8 d 3.0m

Side forms 3 days after concreting. Bottom forms after 14 days or after getting 80% of the 28 day strength, whichever comes first.

8. CONCRETE

All permanent concrete will comply with the project specification. Concrete will be supplied by the Concrete Supply Subcontractor, which was appointed by the Contractor and the Company.

Provided that adequate information is given to the concrete supplier, Gama expects all the concrete supplied by the supplier to be in line with the project requirements. Hence, the temperature and slump of the concrete will be checked upon its arrival on site; and the concrete will be poured only if the said values are within the ranges specified on the Concrete Requisition Forms depending on the Concrete Mix. As a general principle, the concrete delivered to site should have a maximum temperature of 30C for lean and minor structural pours and 30C for major structural pours.


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However, for large monolithic pours (i.e. Mass Concrete) the threshold should be lower; and such cases will be addressed on a case-by-case basis on site.

Moreover, upon delivery cube (and if applicable Cylinder) samples will be taken from the concrete for strength tests (7 and 28 days, and others if required). Should any of these tests prove not within project requirements, the subject concrete will be broken and removed from the worksite. However, Gama will not assume any responsibility for defects due to low-quality concrete (other than those associated with the placement and curing); and all costs associated with the same will be assumed by the responsible party.

Such tests will be carried out by a third party, or under the supervision of an independent specialist

9. CONCRETE PLACEMENT

Placement will be carried out either directly from trans-mixer or by using concrete pump depending upon the physical conditions on site in accordance with DEP 34.19.20.31 (Section 8) and T-13.376.358 (3.22).

Actual conditions or rebar arrangement and member size (in accordance with Section 6 of DEP 34.19.20.31) for each structure will be evaluated on site and free fall height of concrete will be adjusted so as to avoid segregation of the concrete poured.

Free fall, in excess of 1.5-m, of concrete will be prevented by using chutes or troughs in placing concrete.

Concrete works will be a continuous operation through to completion. During the placement of concrete in shutters concrete vibrators will be used for the homogeneity of the concrete. Slab surface will be finished by wooden trowel or equipments to reach a smooth surface for the upper covers (i.e. tile flooring, screed, etc.)

10. CONCRETE CURING AND STRIPPING OF FORMWORK

After pouring fresh concrete within half an hour, the concrete will be protected with polythene sheet to avoid direct contact with air for a max of 12 hours.

All concrete will be moist cured by covering concrete with wet Hessian below the polythene sheet and keeping the Hessian wet by sprinkling water. Curing will be done in accordance with DEP 34.19.20.31 (Section 9) and T-13.376.358 (3.26).

Forms will not be removed until concrete has attained sufficient hardness so as not to be thereby injured.

Concrete curing and stripping of formwork will strictly be in accordance with the requirements set forth in project specifications Section 9 of DEP 34.19.20.31 and Article 3.26 of T-13.376.358.

Unless otherwise instructed by the Company and/or the Contractor, no curing compound will be used. If it proves to be necessary, the material to be used will be submitted to the Contractor and/or the Company for approval; and its application will be carried out as per manufacturers recommendations in line with project requirements.

The details for coating and finishing are discussed in the Method Statement for Concrete Coating; however, as a general principal the tasks will be carried out in line with Article 8.23 of T-13.376.358 (please note that this replaces the corresponding section in DEP 34.19.20.31)


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11. HSSE

All works shall be in compliance with the State of Qatar laws and regulations, Ras Laffan Industrial City and international standards/codes, and Company and Contractor requirements and instructions.

All personnel will go through Gama, Linde and Company Safety Induction courses as well as other trainings as identified by their supervisor. Please see Document Number GTL-GM-001-A-5635 for details.

A Job Safety Analysis (JSA) specific for this work including a Risk Assessment is prepared as per Gama procedure GTL-GM-001-A-5626 and is attached herein. Such JSA addresses the hazards associated with each task within the scope of this Method Statement and introduces the controls that will be implemented to reduce the associated risks to acceptable levels. The JSA will be used by the Site Supervisor as the basis of his TSTI / TSTO and Toolbox Talks.

All personnel will have PPE required for their specific tasks in addition to the minimum PPE (coveralls, safety goggles, safety shoes, high-visibility vests, gloves) at site at all times as required.

In the event of a release, fire or explosion, employees will secure their area and evacuate to the nearest muster point. Once all employees are evacuated the supervisor will conduct a headcount to verify all employees are out of harms way. The supervision will report this to Contractor. Emergency Contact numbers for Company, Contractor and Gama will be posted onsite.

All vehicles and equipment used for the subject work will be inspected and certified as required.

Drivers and operators will be competent and will have attended all required trainings set forth in project procedures and specifications.

All rebar ends will be protected by capping.

12. QUALITY ASSURANCE

12.1. GENERAL

A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented through relevant GAM-PRO-QAC-GTL-023 (QCP), GAM-ITP-QAC-GTL-023 (ITP), and QCRs.

12.2. MASS CONCRETE AND CONTROL OF HEAT OF HYDRATION

Precautions to control the heat of hydration (the difference between the concrete core and the ambient should not be more than 15C) is discussed in the Method Statement for Mass Concrete Works (Project Document No: T-4.234.079).

As stated in the Method Statement for Mass Concrete Works (T-4.234.079) for foundations

And slabs over 3.0-m thick, the method will be decided on a case-by-case basis.

13. ATTACHMENTS

JOB SAFETY ANALYSIS

RISKRANK

1.1 Falling or dropped loads.C 5 HIGH

1.1.11.1.21.1.3

Third party crane inspections.Daily crane checks.Competent riggers.

1.1.1.1 Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards

B 3 LOW

1.2 Overturning of machine.

B 5 MED

1.2.11.2.2

1.2.3

SWL properly displayed.Qualified and 3rd party certified operators.Set up crane on solid level ground

1.2.1.1

1.2.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Ensure daily check is performed prior to each use.

B 3 LOW

1.3 Improper rigging.

C 5 HIGH

1.3.11.3.2

1.3.3

Competency check for all riggers.Rigging supervisor to monitor rigger performance.Ensure that the riggers are competent and Third Party certified.

1.3.1.1

1.3.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Rigging operations shall be performed by competent and qualified riggers.

B 3 LOW

1.4 Damaged, worn or unusable rigging equipment and/or gears.

C 5 HIGH

1.4.1

1.4.2

1.4.3

Quarterly inspection of lifting gear by Third party and color coded.Removal and isolation of all worn or damaged lifting equipment.Rigging gear shall be color coded as per Contractor procedure.

1.4.1.1

1.4.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Ensure that all rigging gear are has 3rd party certificates.

B 3 LOW

1.5 People struck by suspended or swinging load. B 5 MED

1.5.1

1.5.21.5.31.5.4

Barricade and secured area and install safety sign boards.Use tag lines to control load.DO NOT lift load over people.Do not allow people to walk under the load.

1.5.1.1 Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed. B 2 LOW

2 Manually transferring of stock rebars, to rebar cutting machine.

2.1 Manual handling.

C 2 LOW

2.1.12.1.2

2.1.32.1.42.1.5

Worker to wear appropriate gloves.Break the load into manageable portions.Lift with your legs not your back.Use the buddy system, Get help.Provide pictorial sign boards with correct lifting position.

2.1.1.1 Provision for lifting aids when practical.

B 1 LOW

1 Unloading rebar from delivery truck with crane to rebar stock area.

JOB SAFETY ANALYSIS / RISK ASSESSMENTFOR T-4.234.075

SCOPE : CONCRETE WORKS

Residual RiskInitial Risk

RP CADDITIONALCONTROLSMAIN

CONTROLSITEM ACTIVITY CPCONSEQUENCESHAZARDS / POTENTIAL

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RISKRANK






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2.2 Debris and materials causing slip, trips and falls. B 2 LOW

2.2.12.2.2

2.2.3

Adequate stacking of materials.Regular housekeeping practices and removal of trash and unnecessary items.Maintain access and walk paths.

B 1 LOW

3.1 Hand and finger injuries.B 2 LOW

3.1.1 Wear approved PPE, safety goggles, safety helmet, safety shoes, gloves, high-vis vests

B 1 LOW

3.2 Manual handling of rebar.

B 2 LOW

3.2.1 Approved quality hand gloves, available in a full range of sizes to ensure proper fit to maintain dexterity.

B 1 LOW

3.3 Rebar cutting machine.

B 3 LOW

3.3.1

3.3.2

3.3.3

Competent operators, trained on the machine they operate.Ensure that the guards are properly installed and are being used.Post near machine the manufacturers safe operating procedures in different languages.

3.3.1.1

3.3.1.2

3.3.1.3

Post the manufacturer safe operating manual near the machine and HSSE office.Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Minimum 4 persons-Team leader with 3 helpers.

B 1 LOW

3.4 Defective equipment.

B 3 LOW

3.4.1

3.4.2

3.4.3

Daily inspection of equipment by operator prior to use according to manufacturers recommendations.Current Contractor inspection certificate.Monthly equipment inspection and color code.

3.4.1.1 Proper maintenance performed by maintenance department according to manufacturers recommendations. B 1 LOW

4.1 Manual handling.

C 2 LOW

4.1.14.1.2

4.1.34.1.4

Worker to wear appropriate gloves.Break the load into manageable portions.Lift with your legs not your back.Use the buddy system, Get help.

4.1.1.1 Provision for lifting aids when practical.

B 1 LOW

4.2 Debris causing slip trips and falls. B 2 LOW

4.2.14.2.2

Adequate stacking of materials.Regular housekeeping practices and removal of trash and unnecessary items.

B 1 LOW

Measuring and cutting rebar to length.

4 Transferring cut rebars from cutting machine to rebar bending machine.

3

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5 Setting up rebar bending machine to perform desired bend.

5.1 Hand and finger injuries.

B 3 LOW

5.1.1

5.1.2

5.1.3

Follow manufacturers recommendations for properly and safely setting up rebar bending machine.Control of hazardous energy, LO/TO. de-energize equipment" before making adjustments to moving parts.Wear approved hand gloves for the task.

5.1.1.1

5.1.1.2

5.1.1.3

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Minimize number of people at work area of bending/cutting machine.Mark the work area.

B 1 LOW

6 Measuring and bending rebar.

6.1 Hand, finger and foot injuries.

D 3 MED

6.1.1

6.1.2

6.1.3

6.1.4

6.1.5

Install stops on the edge of workbench.Approved hand gloves, available in a full range of sizes to ensure proper fit to maintain dexterity.Follow manufacturers recommendations for operating and adjusting machine for rebar size.Competent and properly trained operator.Keep away hand & finger from moving parts.

6.1.1.1

6.1.1.2

6.1.1.3

6.1.1.4

6.1.1.5

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Ensure that equipment manual is available near the machine.Post names of authorized operators near the machine.Minimum 3 persons-Team leader with 2 helpers.Post the rebar bending machine safe operating procedures and safety precautions at the job site.

B 2 LOW

6.2 Dropped rebar from height. D 2 MED

6.2.1

6.2.2

Install appropriate stops on the edge of workbench.Ensure adequate number of workers to control the operation.

6.2.1.1 Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.

B 2 LOW

6.3 Unauthorized people in rebar bending area or radius.

B 2 LOW6.3.1 Barricade and secure area and post

safety sign boards Authorized Employees Only.

B 1 LOW

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6.4 Improper use of rebar bending machine.

B 3 LOW

6.4.1

6.4.2

6.4.3

Competent and properly trained operator.Follow manufacturers recommendations for operating and adjusting machine for rebar size.Post near machine the manufacturers safe operating procedures in the appropriate languages

6.4.1.1

6.4.2.1

6.4.3.1

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Ensure that equipment manual is available near the machine.Post names of authorized operators near the machine.

B 1 LOW

7.1 Use of tie-wire causing hand, face or eye injury.

C 3 MED

7.1.17.1.2

7.1.37.1.4

Use proper tie wire techniques.Wear approved PPE, safety glasses, safety helmet and safety foot wear.Appropriate hand tools.Appropriate hand gloves.

7.1.1.1

7.1.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Ensure that workers carrying the task is properly trained and competent.

B 2 LOW

7.2 Dropped or collapse of bar structure or stand.

C 2 LOW

7.2.1

7.2.2

Use approved stands to support rebar load.Visually inspect daily support stands.

7.2.1.1

7.2.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Ensure that workers performing the task is properly trained and competent.

B 1 LOW

8.1 Potential hazard gas

C 1 LOW

8.1.1 Check the potential hazardous gas inside the space / Gas test.

8.1.1.1 Supervisior/foreman shall ensure that the TSTI is proberly executed at the work front and hazards discussed

B 1 LOW

8.2 Skin injury.C 1 LOW

8.1.2 Proper access-egress. 8.1.1.2 Ensure that works performing the task is properly trained and competent

B 1 LOW

8.3 Foot injury. C 1 LOW 8.1.3 Walkways in the space to be performed8.1.1.3 Deciding the authorised workers

yet to work inside. B 1 LOW

9.1.1

9.1.2

Ensure that guards are kept in place and not removed.Do not wear loose clothing or jewelry. Long hair shall be pulled back and kept from dangling.

9.1.3 PPE ( hearing protection as appropriate).

9.1 Use of hand held power tool, grinding buffing and air compressor.

B 2

7 Assembly of reinforcement bars.

9 Surface preparation for construction joints.

8 Rebar fixing in confined spaces

B 1 LOWLOW

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9.2 Electrocution and burns.

B 2 LOW

9.2.1

9.2.29.2.3

GFCI and using the correct operating voltage.Competent personnel.Equipment inspections performed by competent personnel and has valid inspection sticker with color coding.

B 1 LOW

9.3 Sub-standard equipment.

B 5 MED

9.3.1

9.3.2

Distribution panel inspected by Contractor before being energized.Inspection and color-coding of power tools monthly with a visual inspection prior to each use.

9.3.1.1 Ensure all sub-standard equipment should be remove from site and tag as unsafe. B 2 LOW

10.1 Use of hand and power tools.

B 3 LOW

10.1.1 All work is to be completed with approved PPE, including safety glasses with side shields, safety helmet, coveralls and steel toe footwear and gloves.

10.1.1.1

10.1.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Post the table saw and combination saw machine safe operating procedures and safety precautions at the job site.

B 1 LOW

10.2 Handling shutters (Back injury).

B 3 LOW

10.2.1

10.2.2

10.2.310.2.410.2.5

Provision for lifting aids when practical.Break the load into manageable portions.Lift with your legs not your back.Use the buddy system, Get help.Provide pictorial sign boards with correct lifting position.


10.3 Debris and materials causing slip, trips and falls. B 2 LOW

10.3.110.3.2

10.3.3

Adequate stacking of materials.Regular housekeeping practices and removal of trash and unnecessary items.Maintain access and walk paths.

B 1 LOW

10.4 Fall hazards.

B 3 LOW

10.4.1

10.4.2

Use approved ladder i.e. scaffold material to gain height advantage.Work from ground level or use approved platform.

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

B 1 LOW

Install formworks.10

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11 Install rebar re-enforcement steel into form works with gantry crane.

11.1 Falling or dropped loads.

C 5 HIGH

11.1.111.1.211.1.311.1.4

11.1.5

Third party crane inspections.Daily crane checks.Competent riggers.Quarterly and Daily inspection of rigging gear and equipment (color coding).Third party crane operator.

11.1.1.1

11.1.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Ensure the area is properly barricaded and secured.

B 2 LOW

11.2 Improper rigging.

C 5 HIGH

11.2.111.2.2

11.2.3

Competency check for all riggers.Rigging supervisor to monitor rigger performance.Third party certified and competent riggers.

11.2.1.1

11.2.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Rigging operations shall be performed by competent and qualified riggers.

B 3 LOW

11.3 Damaged, worn or unusable rigging equipment.

C 5 HIGH

11.3.1

11.3.2

11.3.3

Quarterly inspection of lifting gear by Third party and color coded.Removal and isolation of all worn or damaged lifting equipment.Rigging gears shall be color coded as per project procedure.

11.3.1.1

11.3.1.2

Supervisor/foreman shall ensure that the TSTI is properly executed at the work front and hazards discussed.Ensure that all rigging gears are has 3rd party certificates.

B 3 LOW

11.4 People struck by suspended or swinging load. B 5 MED

11.4.1

11.4.211.4.311.4.4

Barricade and secured area and install safety sign boards.Use tag lines to control load."DO NOT" lift load over people.Do not allow people to walk under the load.


12.1 Fall hazards.

B 3 LOW

12.1.1

12.1.2

Use approved ladder i.e. scaffold material to gain height advantage.Work from ground level or use approved platform.

12.1.1.2 Ensure that all employees working at height are properly trained. B 2 LOW

12.2 Use of hand held power tools, vibrator.

B 3 LOW

12.2.1 All work is to be completed with approved PPE, including safety glasses with side shields, safety helmet, coveralls and steel toe footwear and gloves.

12.2.1.1 Ensure that all employees are properly trained to use the assigned tools. B 2 LOW

12 Pour concrete.

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12.3 Electrocution and burns.

B 2 LOW

12.3.1

12.3.212.3.3

12.3.4

GFCI and using the correct operating voltage.Competent personnel.Dont touch electrically live parts with skin or wet clothing. Ensure good electrical connection.

B 1 LOW

12.4 Sub-standard equipment.

B 5 MED

12.4.1

12.4.2

Distribution panel inspected by Contractor before being energized.Inspection and color-coding of power tools monthly with a visual inspection prior to each use.

12.4.1.1 Ensure all sub-standard equipment is removed from site and tagged as unsafe. B 2 LOW

12.5 Concrete pump truck boom malfunctioning.

B 5 MED

12.5.112.5.2

12.5.3

12.5.4

12.5.5

Contractor inspections.Daily operator inspection of vehicle and associate pump equipment.Competent operator trained on the equipment in which he operates.Visual inspection of boom prior to each use.Ensure whip check is nstalled.


12.6.1 Approved PPE( including face shield by employees working is close proximity of concrete pour).

12.6.212.6.3

Competent personnel.Eye wash available.

12.7 Skin injury.C 1 LOW

12.7.1 Wearing of approved coveralls and gloves, with the hose man wearing additional non-permeable suit.

B 1 LOW

12.7 Foot injury. C 1 LOW 12.7.1 Appropriate footwear B 1 LOW

12.8.1 Use of plastic, spread on the ground to contain waste.

12.8.2 Operator to properly control pump boom movement.

12.8.3 Workout set approved area.

LOW B 1 LOW

12.8 Concrete waste.

B 2

12.6 Concrete splash. (Eye injury).

B 1 LOWLOW1C

MS For concrete works-28.01.2008.pdfMS For concrete works-28.01.2008.pdfMTS for CONCRETE 28.01.08.doc009 Concrete Works Rev.O JSA X 1.pdfCover

009 Concrete Works Rev.O JSA X 2.pdf

009 Concrete Works Rev.O JSA X.pdfCover

Concrete Works Rev.O JSA X.pdfMTS for CONCRETE.pdf009 Concrete Works Rev.O JSA.pdfCover

METHOD STATEMENT CONCRETE WORKS.pdf009 Concrete Works Rev.O JSA.pdfCover