Method Statement for Steel Structure & Erection

8/10/2019 Method Statement for Steel Structure & Erection

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INSPECTION Gr

FIELD INSPECTION REPORT ffi:-'-"INSPECTION TYPE

STEEL STRUCTURE INSTALLATION INSPECTIONWORK No.

ITEM NoAREA / LOCATION

ITEIM No. DESCRIPTION SIGNATUREINSPECTION NOTICE No OWNER CONSORTIUM CONTRACTOROWNER'S INSPECTOR

CONSORTI UM'S INSPECTOR

CONTRACTOR'S INSPECTOR

REFERENCE Drawing. No

I'IGHTENING METHOD

I Calibrated Wrench Method Twist-of-Type Tensron Control

INSPECTION

ffiTACC-T--REJ1 LOCATION2. VERTICALITY

3. HEIGHT

4 HORIZONTALITY5. FOUNDATION AND ANCHOR BOLT

6. SHIMMING

7 WELDINGB, BOLT I"ORQUI NG/I'IG HTEN'NG

9. GIlOUTING

1O PAINTING (TOUCH-UP)

OTHERS

1 TORQUE WRENCH CALIBRATION2 CRANE / HOIST RAIL INSTALLATION

COMMENTS

LEGEND ACC ACCEPI- N.A. Not Apptjcabte REJ REJECT

fjoRfi/ No. c-40


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FIELD INSPECTION REPORT

ITP NO- :INSPECTION Gr. :REPORT NO. :

INSPECTION TYPE:

STEEL STRUCTURE ALIGNMENT INSPECTION

LEGEND ACC ACCEPT N.A. : NotApplicable REJ: ttEJECT

FORMNO

C.41

ITEM No. :AREA / LOCATION

SIGNATURETEM No. DESCRIPTION:CONTRACTORNSPECTION NOTICE No

OWNER S INSPECTOR

CO lr SOniTVLY r'f .S P rCrO nCONTRACTOR'S I NSPECTOR

REFERENCE Drawing. No

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'['* rrunce ttl erc,(tiil rllr*r:tict l'rr tl*cl lrluilrling entJ Llrirlge*.)

COLUMN VERTICALITY

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TOP OF BEAM LEVEL


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TNSPEC ttoN Gr

FIELD INSPECTION REPORT ffi;:-,-"INSPECTION TYPE:

STEEL STRUCTURE ACCESSORIES INSPECTIONAREA / LOCATION :

WORK No.

ITEM No DESCRIPTION SIGNATUREINSPECTION NOTICE No OWNER CONSORTIUM CONTRACTOR

OWNER'S INSPECTOR

CONSORTI UM'S INSPECTOR

CONTRACTOR'S I NSPECTOR

REFERENCE Drawing. No.

VISUAL INSPECTION

o c0'=soqa

6.oIo

6coNoI

oc-6

o

oC

.ce0_

REMARKS

ACCESSORIES'l . Platform

2. Ladder

3. Grating

4. Checker Plate

5. Handrail

6. Stair

7

B

9

10

COMMENTS

LEGEND ACC: ACCEPT N.A. NotAppllcable REJ: REJECT

FORM NO. C-042


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Document Description METHOD OF STATEMENT FOR STEELSTRUCTURE & ERECTION

Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.S-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 2 of 13

TABLE OF CONTENTS

1.0 SCOPE ................................................................................................................ 3

2.0 REFERENCE DOCUMENTS .............................................................................. 3 2.1 A BBREVIATIONS ........................................................................................... 32.2 C ODES ........................................................................................................ 32.3 C ONTRACTOR 'S DOCUMENTS ....................................................................... 4

2.4 A SSOCIATED P ETROJET P ROCEDURES ......................................................... 43.0 RESPONSIBILITY .............................................................................................. 4

3.1 C ONSTRUCTION M ANAGER ........................................................................... 43.2 QA/QC M ANAGER ........................................................................................ 4

4.0 MATERIAL AND EQUIPMENT........................................................................... 4 4.1 S TEEL S TRUCTURES ................................................................................... 54.2 W ELDING FILLER METAL .............................................................................. 54.3 E QUIPMENT AND TOOLS .............................................................................. 5

5.0 PLANNING OF ACTIVITIES AND MONITORING OF PROGRESS ................. 5

6.0 ERECTION DRAWINGS .................................................................................... 5 7.0 RECEIVING, HANDLING AND STORING MATERIAL ..................................... 6

8.0 CHECK FOR FOUNDATIONS........................................................................... 6

9.0 PRELIMINARY CHECKS .................................................................................. 6

10.0 MATERIAL WITHDRAWAL............................................................................... 7

11.0 ERECTION .......................................................................................................... 7 11.1 GENERAL ..................................................................................................... 711.2 M OUNTING GUIDELINES ................................................................................ 811.3 I NTERMEDIATE INSPECTION .......................................................................... 1011.4 F INAL INSPECTION ....................................................................................... 1011.5 T OLERANCES .............................................................................................. 1011.6 R EPAIR OF G ALVANIZED S TEEL .................................................................... 10

12.0 TESTING AND INSPECTION ............................................................................. 11

13.0 GROUTING ........................................................................................................ 12

14.0 QUALITY RECORDS......................................................................................... 12

15.0 APPENDIX ......................................................................................................... 12


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Client The Egyptian Ethylene and Derivatives Company(ETHYDCO)On Shore JV TOYO and ENPPI Document No. PJ-EEP2-ST.ST-PRO-0001 Rev. SheetJob Location Ameriya Alexandria, Egypt 2 3 of 13

1.0 SCOPE

This procedure describe the minimum requirements that shall be observed at site for handling and

storing materials, erection of hot dip galvanized primary and secondary steel structure to be installed .

It also covers the tests and inspections that are to be carried out during the execution of the

assembly works.

And this procedure covers Steel Structures, Steel from Building, Supporting Steel, Steel Pipe Rack,

and Miscellaneous Structure Steel.

The objective is to ensure that all the activities are carried out:

In accordance with approved procedures, specifications and drawings,

Using special working and control process which have been previously qualified;

employing qualified and, when required, certified personnel;

using material which are kept under control from receiving throughout entireworking cycle;

Performing all tests, measurements and inspection required by Contract.

2.0 REFERENCE DOCUMENTS

2.1 ABBREVIATIONS

ITP = Inspection & Testing PlanQC = Quality Control

2.2 CODES (BRITISH STANDARDS )

AISC (9 th edition) The American Institute of Steel Construction.AWS D1.1 Structural Steel Welding Code.

(B S) British Standard.

(ISO) International Standard Organization.

ANSI American National Standard Institute.

ASTM American Society for Testing and Materials.

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2.3 CONTRACTOR'S DOCUMENS

Minimum Quality Requirements for Site Activity.Steel Structural Works Technical Specification.Steel Structure Standard Drawings and Details.

ED-9999-STR-SPEC-000-JB611 Specification Of Steel Structure.

CD-9999-FQC-PRC-000-001 QC Procedure.

ED-9999-PJM-PEP-000-006[1] Project Quality Plan.

ITP NO: 2001 : 2011 Inspection & Test Plan for Mechanical Works.ITP NO:20 Structural Steel (Erection).

2.4 ASSOCIATED PETROJET PROCEDUR

PJ-EEP2-MRI-PRO-0001 Method of Statement of Material Handling , Storage Procedure

PJ-EEP2-NR-PRO-0001 Non Conformance Management Procedure.

PJ-EEP2-NDT-PRO-0001 Visual Inspection Procedure.

3.0 RESPONSIBILITY

3.1 CONSTRUCTION MANAGER

The Construction Manager is responsible for the implementation of this procedure for

the over all direction and coordination with the QA/QC Manager for monitoring,

coordinating

and control of all the erection activities.

3.2 QA/QC MANAGER

The Site QA/QC Manager is responsible to verify the proper implementation of the quality

systems and to implement quality control activities related to erection.

4.0 MATERIAL AND EQUIPMENT

4.1 STEEL STRUCTURES

The Steel Structures shall mainly consist of the following: Steel Building and Shelter Pipe Racks / Steel Structure Equipment Platform, Stair and Walkways / Handrails/Cross over /Shetters. Minor Steel Structure / Supports / Ladders / Grouting /Beams, etc.

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4.2 WELDING FILLER METAL

When required for any modificat ion Welding filler metal shall conform now to BS 5135,

BS 639 and ISO 5182 /E7018 welders and welding WPS as per BS4871 & BS 4872

4.3 EQUIPMENT AND TOOLS

All tools and equipments to be used for erection shall be standard (not allow any

fabricated or hand made fouls) in good order, safe condition and sufficient quantity.Examples of tools and equipment are:

Cranes

Lifting gear including sling wires,belts,chackles,ect.

Plastic Ropes to be used as guide only during lifiting not for any lift.

Standard tools such as spanners, Transportation Trucks

Torque Wrenches5.0 PLANNING OF ACTIVITIES AND MONITORING OF PROGRESS

The Project Planner is responsible to plan the sequence of erection of steel structure

according to the Construction Master Schedule.

He is also responsible to monitor the progress of the work and to keep informed the

Construction Manager and Project Manager for any deviation from the original schedule.

Planning of steel structure erection shall be made according to erections priority

and material availability.6.0 ERECTION DRAWINGS

The Technical Office (TO) receive the steel structures drawings from engineering department.

Based on the availability of drawings, material after fabrication, specifications and in

congruence with planning, TO shall issue detailed drawings for erection and copy to all the

concerned departments (AFC DWGS & Last Rev).

The following information shall be provided in the detailed drawings:

Identification of each item, part or assembly number with match mark and otherinformation as necessary for easy identification and erection;

Specific instruction, as necessary for erection;

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7.0 RECEIVING, HANDLING AND STORING MATERIAL

The Material Control Manager (MCM) shall receive all steel structures in accordance with the

procedure and shall be responsible for checking quantity and type of materials indicated in

the packing list and QC inspector checks for quality. The damages shall be immediately

notified to take the required measures.

The materials shall be stored, handled and preserved in accordance with the procedure.

8.0 CHECK FOR FOUNDATIONSBefore commencing work, center lines, locations, orientation, chipping and

elevations of foundations shall be checked for prescribed tolerances.

Support shims shall be located after marking the centre lines on the plinths.

At least 3/4 shims packs with levelling mortar shall be provided for the base plates of each

column. Centre lines marked on plinths shall have a tolerance of 1 mm and elevation

of 1 mm.

The foundation bolt surface that will come in contact with concrete shall be free fromdirty and oily matters or points. Foundation surface shall be chipped prior to erection activity.

9.0 PRELIMINARY CHECKS

According to the sequence and schedule of erection, the following preliminary checks

shall be carried out before erection activities begin, in order to verify:

The availability of experienced, qualified personnel and equipment necessary to

carry out the works;

The availability of fabricated steel structure and its status of acceptance.

The status and availability o f approved for Construction drawings and

/or specifications.

All tools and equipments used for erection are calibrated as per Calibration of

Inspection and Testing Equipment procedure

The status of torque wrench calibration the above preliminary checks shall be

jointly made by all the concerned as i n responsibility matrix.


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The contact surfaces of bolted elements shall be free from rust, mill scale, grease, etc. Bolts

already used and previously tightened shall not be re-used.

All site bolted connections shall be assembled and torque tightened in accordance with Appendix

A. After the torque tightening of bolts shall be identified by the paint on the bolt head.

All material, plant and equipment used shall be of sound construction and free from flaws.

Bolts designed for transmitting forces in structural member connections, shall have a minimum

diameter as follows :

Minimum diameter For main members, bracings and struts 20mm

For secondary, i.e. bracings, purlins, 16mm

Ladders, handrails, etc.

( Unless noted otherwise on standard drawings).

Except otherwise noted on design drawing, hole diameter for bolts shall be as followsDiameter bolt, plus:

For steel-to steel connections : 2mm For steel-to-concrete connections (anchor bolts):

o Up to 24 mm bolt diameter : 4mm

o 24 to 32 mm bolt diameter : 6mm

o 32 mm bolt diameter and over : 8mm

The spacing of bolts in the direction in which the force is applied shall be at least three bolt

diameters (measured in the direction of the force).

The minimum distance from center of bolt edge of plate measured in the direction of force shall be two bolt diameters, and measured at r ight angles to the direction o f force, one and a half bolt

diameters.

Slotted hole connections are to be executed in such away, that these connections may perform

their design function, as indicated on the design drawings, and shall be provided with washers.

High-strength bolts shall be used for structural steel-to-steel connections.

High-strength bolts shall be used for in bearing-type connections and not as friction grip bolts

11.2 MOUNTING GUIDELINESIf required, additional drilling of beams, columns or other components shall be made to

remedy fabrication mismatch / faults. Magnetic base drills shall be used for such work.


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Checking at a pre-erection stage for correct distance of the connected column

Flanges to beam.

Handrails and toe plates shall be not welded to the columns; however they shall be

Adequately jointed in the vicinity of the columns.

When not provided in the design drawings, the tube passage through grating shall

be admissible only in case grating is adequately reinforced at the pass hole.

A toe plate shall be provided around the pass hole.

11.3 INTERMEDIATE INSPECTION

Each framework floor shall be checked for verticality and diagonals before and after tightening of

bolts.

Survey instrument shall be used for checking of verticality. When executing the tests, proper

consideration shall be given to the deformation changes occurring in the steel structure during a day

on account of exposure to the sunlight.

Verticality:

Verticality and levelness shall be checked by means of a Survey instrument.

For verticality reference shall be made to points (flags) marked on columns;

Diagonals (in plan):

Diagonals shall be checked using a metric roller;

All structural framework / floors shall be checked;

11.4 FINAL INSPECTION

Check for steel structure framework verticality, horizontal alignment and height shall be carried

out after mounting.

Splicing shall be executed in accordance with prescriptions listed para 9.4. Bolt torque

tightening shall be as mentioned in the Appendix Completeness check as per approved for

construction drawings.

After checking of connection, the erecion drawing shall be marked to indicate acceptance.

11.5 TOLERANCES

The deviation in overall dimensions, positions, alignments, plumpness and

elevations shall not exceed the limits specified in specification.

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11.6 REPAIR OF GALVANIZED STEEL

Any damage to galvanized steel shall be repaired in accordance with ASTM A780.

Before repairing the damaged galvanized coating, the exposed substrate metal shall be cleaned to bright

metal

and free of all visual rust, oil or grease. Any none adhering galvanizing shall be removed to the

extent that the surrounding galvanizing is integral and adher ent.

12.0 TESTING AND INSPECTION

Inspection and test shall be carried out by qualified personnel, coordinated by SQM, according to

the Inspection & Testing Plan (ITP).

All structural steel material and fabrication shall be subject to inspection by client

Welds shall be inspected by contractor according to the previsions of regulatory requirements with

respect to technique, equipment, and acceptance criteria and personnel qualifications. All welds

shall be subject to random visual inspection by client .in addition, the following specialrequirements shall apply to welding inspection.

Grating shall be tagged with metal plate having raised letters so that the mark shall be seal welded

to the grating prior to galvanizing.

Contractor may submit alternate proposal for marking galvanized members, subject to clients

written approval.

SQM shall manage all Witness and Hold Points shown on the ITP, including convocation to

Contractor.The form worked out toyo shall be used for issue of the certificates listed in the Inspection and

Test Plan The Inspection mentioned in the Inspection and Test Plan shall be carried out using the

following calibrated instruments:

Optical levels, steel metric rollers, water levels, manual dial type torque wrench for torque read-out.

10% of all connections for each bolt size shall be randomly selected and inspected, of each

joint shall show the tightening value of high strength bolts. Such test shall be conducted on

minimum 2 bolts per each joint.

Tested bolts shall be clearly marked with paint.

Each high strength bolts assembly shall consists of one heavy semi-finished hexagon structure


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bolts one heavy semi-finished hexagon nuts and one hardened washer to be used the nut

In presence offload indication Washers ,turn-of nut tightening follow-up; one nut sample per each

size of bolts shall be unscrewed by at least 1/6 turn and then to check whether the prescribed torque

brings the nut back to its original position.

Galvanized bolts shall not be reused after unscrewed; bolts may be reused after repaint

by galvanize spray.

13.0 GROUTING

All bearing plates, loose lintels, beams and columns shall be shimmed to proper grade and

level before grouting.

Grout material as specified in the technical specification or on drawing shall be used.

The sand-cements mixture shall be combined with the least amount of water to produce a low

slump, place able grout.

Prior to setting structure, the concrete surface to receive grout shall be chipped to a depth of

6 mm to obtain a roughened surface.

After the structure is a place, positioned and shimmed immediately before grouting, the surface to

receive grout shall be cleaned and wetted. Excess water shall be removed.

Grout shall be placed and thoroughly worked to eliminate voids and provide a uniform bearing

surface under the base plate.

When specified on drawings, epoxy grout shall be used for grouting under heavy equipment

where large bearing and /or vibration stresses occur. Epoxy grout shall be mixed by mechanical

mixer and placed in accordance with manufacturer instruction.

14.0 QUALITY RECORDS

The following records shall be provided:

ITP and Procedure

Certificates of materials supplied

Dimensional reports

Bolt torque tightening reports

Surface treatment reports

Grouting reports

Final dossier containing the report of the test carried out


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15.0 APPENDIXB

1- Torque Tightening of Steel Structure Table 001.

2- Steel structure installation inspection C-40.

3- Steel Structure Alignment Inspection C-41.

4- Steel Structure Accessories Inspection C-42.

TORQE TIGHTENING OF STEEL STRUCTURE

Bolts Classes 8.8 and 10.9

The tightening torque shall be in accordance with the following Table 001.

Nominal Diameter of Bolt in mm Tightening Torque in NM

12 94

14 148

16 234

18 320

20 456

22 616

24 787

27 1150

30 1562

33 2125

36 2729 39 3532

Form No. Table :001

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Method Statement for Steel Structure & Erection