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Engineering Construction Methods Guidelines Cbs

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A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 1 of Civil Engineering Buildings Practice Construction Method Statements General Activities P Eng Suraj Singh Contents index For navigation please click these pasted hyperlinks Construction Method Statements for various activities within civil engineering for plants works Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 2 of Site Preparation & Earth Work PROTECTION SERVICES CONCRETING TO WALLS OF CENTRAL CONTROL BUILDING LABORATORY / OF EXISTING RE-ROUTING OF 33KV CABLES Concrete Pipe Culverts CONCRETE CULVERTS PIPE CULVERT CROSSINGS TO AVENUE E AND MAIN HIGHWAY. CONSTRUCTION RACK BASES OF CONSTRUCTION OF MAIN SUBSTATION MORTAR FOR BLOCKWORK REMOVAL MATERIALS HAZARDOUS STRUCTURAL STEEL-PIPERACKS COMPRESSORS’ STRUCTURES RCC COLUMN PLATE INSERTS ROAD CROSSING KV ROUTE NIGHT SHIFT EARTHWORKS EXCAVATION FOR 132KV CABLE INTERCONNECTION GROUTING TO PIPE RACK FOUNDATION BASES PLACING CONCRETE ON SERVICE WATER TANK 58-TK-205 FOUNDATIONS CONCRETE REPAIR EXCAVATION IN Operating Authority CONTROLLED AREAS CONSTRUCTION OF FLOOR SLAB CENTRAL CONTROL BUILDING FOR 132 CEMENTITIOUS GROUTING FOUNDATION BASES TO Top WORKING ETYLENE COMPRESSOR MASSIVE FOUNDATION POUR - (CONCRETE OF PIPE CONTROL OF CAMP SEWAGE SYSTEM PROPANE COMPRESSOR MASSIVE FOUNDATION (CONCRETE POUR) PROPANE COMPRESSOR MASSIVE FOUNDATION (CONCRETE POUR) PROPANE COMPRESSOR MASSIVE FOUNDATION (CONCRETE POUR SEAWATER BASIN (WATER TIGHTNESS BS 8007 : 1987 ) PROPANE COMPRESSOR MASSIVE FOUNDATION (CONCRETE POUR SEAWATER BASIN (WATER TIGHTNESS BS 8007 : 1987 ) PROPANE COMPRESSOR MASSIVE FOUNDATION (CONCRETE POUR ADMINISTRATION BUILDING STAIR LANDING EXTENSION AT GRID 4 J ADMINISTRATION BUILDING STAIR LANDING EXTENSION AT GRID 4 J ADMINISTRATION BUILDING STAIR LANDING EXTENSION AT GRID 4 J FENCING Top ADMINISTRATION BUILDING CERAPlant Operating Authority FLOORING SYSTEM ADMINISTRATION BUILDING CERAPlant Operating Authority TILES FLOORING SYSTEM ADMINISTRATION BUILDING PLASTERING AND RENDERING ADMINISTRATION BUILDING ROOFING SYSTEM ROOFING SYSTEM BUILDINGS ROOFING SYSTEM CRACKED GAS COMPRESSOR TABLE TOP CONCRETE POUR WATER TIGHTNESS TESTS FOR THE COLLECTION SUMPS ACCORDING TO BS 8007 : 1987 SECTION 9 WATER TIGHTNESS TESTS FOR THE COLLECTION SUMPS ACCORDING TO BS 8007 : 1987 SECTION 9 ADMINISTRATION BUILDING MARBLE FLOORING ETHYLENE GAS COMPRESSOR TABLE TOP POUR PROPANE GAS COMPRESSOR TABLE TOP POUR EXPANSION JOINTS IN DITCHES EXPANSION JOINTS IN DITCHES CONCRETE COATING USING MASTER SEAL 550 DEWATERING FOR THE 84” GRE LINE PARALLEL TO CORNICHE ROAD EAST WEST SEAWATER BASIN (WATER TIGHTNESS BS 8007 : 1987 ) TILES PAIR Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 3 of Top CERAPlant Operating Authority WALL TILES FIXING BEDDING AND GRAVEL FILLING BENEATH 60 “ DIA PIPE COOLING WATER PIPE EXTERNAL CONCRETE ADMINISTRATION BUILDING ABOVE GROUND CONCRETE PROTECTION USING MASTERSEAL 300 H ABOVE GROUND CONCRETE PROTECTION USING MASTERSEAL 300 H HAND EXCAVATION TO INSTALL TELEPHONE DUCTS BETWEEN BOX NO. 20 TO TELECOM CENTRE BACKFILLING OF THE WEST SIDE OF THE QUENCH TOWER FOUNDATION – (RIB) EXCAVATION COOLING WATER OUTFALL CHAMBER DRILLING OF HOLES ON PIPE RACK & STRUCTURES ON SITE SITE OFFICE ESTABLISHMENT Welding of Earthing Lugs on East West Piperack (SR0099A &B) FILLING AROUND ALL THE PIPES WITHIN THE Plant AREA PRECASTING MAN HOLES CATCH BASIN AND VALVE CHAMBERS TERMINATION DETAIL TO PROTECTIVE MEMBRANE AROUND RCC COLUMNS SUPPORTING THE STRUCTURAL STEEL COLUMNS FOR PIPE RACKS CASE (1) WITH ALUMINIUM BEAD CASE (2) WITH REBATE CASE (3) GRAVEL FILL CASE (4) PAVING TERMINATION DETAIL TO PROTECTIVE MEMBRANE AROUND RCC COLUMNS SUPPORTING THE STRUCTURAL STEEL COLUMNS FOR PIPE RACKS CASE (1) WITH ALUMINIUM BEAD CASE (2) WITH REBATE CASE (3) GRAVEL FILL CASE (4) PAVING Top ROAD CROSSING FOR LAYING 2 PIPES 1 FOR 20” RAW ETHANE & 1 FOR 6” PROPANE FIRST STREET Operating Authority ENTRY ROAD CROSSING FOR LAYING 2 PIPES 1 FOR 20” RAW ETHANE & 1 FOR 6” PROPANE FIRST STREET Operating Authority ENTRY DIRECTIONAL BORING FOR LAYING SLEEVES FOR 2 PIPES 1 # 20” RAW ETHANE & 1 # 6” PROPANE Operating Authority Plant REFINERY ENTRY 2 #s ROAD CROSSINGS FOR LAYING 1 FOR 14” DESALINATED WATER 1 FOR 8”POTABLE WATER & 1 FOR 20” RAW ETHANE 1 FOR 8” NATURAL GAS 1 FOR 6” PROPANE AVENUE ‘C’ AT FIRE STATION 2 #s ROAD CROSSINGS FOR LAYING 1 FOR 14” DESALINATED WATER 1 FOR 8”POTABLE WATER & 1 FOR 20” RAW ETHANE 1 FOR 8” NATURAL GAS 1 FOR 6” PROPANE AVENUE ‘C’ AT FIRE STATION ADMINISTRATION BUILDING GRC PANEL FIXING PAINTING ADMINISTRATION BUILDING PAINTING ADMINISTRATION BUILDING PROTECTION Top Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 4 of ROAD CROSSING FOR LAYING 2 PIPES 1 FOR 20” RAW ETHANE & 1 FOR 6”PROPANE AVENUE ‘C’ EARTHWORKS SYSTEM ROAD CROSSING FOR LAYING 84”G R E PAIR SEAWATER COOLING LINES AT AVENUE ‘D’ / CORNICHE JUNCTION TENNIS COURTS SURFACING LIGHTING FOUNDATIONS SEA WATER SURGE BASIN CONCRETE PROTECTION MASTER SEAL 550 CONCRETE COATING OF USING MASTERSEAL 550 ABOVE GROUND CONCRETE PROTECTION SEAWATER SURGE BASIN SEA WATER SURGE BASIN JOINT SEAL PAINTING SUB STATIONS PAINTING SUB STATIONS ELECTRICAL TRENCHES ELECTRICAL TRENCHES PULL PITS ROAD CROSSING TO MAKE GOOD WEARING COURSE OVER COMPLETED 1# FOR 14” DESALINATED WATER & 1# FOR 8”POTABLE WATER AVENUE ‘C’ PULL PITS ROAD CROSSING TO MAKE GOOD WEARING COURSE OVER COMPLETED 132 KV ELECTRIC CABLE AVENUE ‘C’ PULL PITS ROAD CROSSING TO MAKE GOOD (temporarily) WEARING COURSE OVER COMPLETED 132 KV ELECTRIC CABLE AVENUE ‘C’ DRINKING CONNECTION PROTECTION TO TRANSFORMER FOUNDATION SIDES IN SUB STATIONS WITH ALUMINIUM BEAD TERMINATION FOR BELOW GROUND AND MASTERSEAL 300H FOR ABOVE GROUND IN GRAVEL FILL AREA TIMBER DOORS FIXING ADMINISTRATION BUILDING GROUTING TO STEEL BEARINGS ON RING BEAMS EXCAVATION WATER TANK WATER Top EXCAVATION FOR UNDERGROUND WATER TANK ROAD CROSSING FOR LAYING 84”G R E PAIR SEAWATER COOLING LINES AT AVENUE ‘D’ / CORNICHE JUNCTION PRECASTING LIGHTING FOUNDATIONS POLES Top POLES GROUTING TO STEEL BEARINGS ON RING BEAMS SURVEY TANKS CCB & INSTRUMENTATION TANKS & FOR STRUCTURES INSTRUMENTATION CCB SOAKAWAY CHAMBERS EPOXY FLOORING BUILDINGS EPOXY FLOORING BUILDINGS EPOXY FLOORING BUILDINGS VINYL WALL COVERING BUILDINGS DRY WALL LININGS BUILDINGS RUBBER FLOORING (BUILDINGS) RUBBER FLOORING (BUILDINGS) RUBBER FLOORING (BUILDINGS) RUBBER FLOORING (BUILDINGS) RUBBER FLOORING (BUILDINGS) UNDERGROUND Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements 5 of SUSPENDED CEILINGS ALL BUILDINGS PIT 21 WATER CONNECTION CEMENT BASED NON SHRINK GROUTING TO FOUNDATION BASES USING MASTERFLOW 928 T Top REPAIR OF SCREEDS CONCRETE Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page FLOOR REPAIR OF SCREEDS CONCRETE FLOOR Top EPOXY GROUTING TO VIBRATING INSTALLATION BASES USING MASTERFLOW 648 CP GENERAL FOUNDATIONS KERBS & INTERLOCKING BLOCKS PAVING AROUND BUILDINGS ERECTION OF STEEL STRUCTURES (FOR HIGHER LEVELS) VINYL FLOORING BUILDINGS CONCRETE PAVING CONCRETE PLACEMENT PRECAST RCC COVERS CABLE & INSTRUMENTATION TRENCHES CENTRAL CONTROL BUILDING CERAPlant Operating Authority TILES FLOORING SYSTEM BLACK TOP REPAIR IST STREET BETWEEN AVENUE C & B REPAIR TO FLOOR SCREED LEVELS RESIN INJECTION TO LEAKING JOINT SEA WATER SURGE BASIN RESIN INJECTION TO LEAKING JOINT SEA WATER SURGE BASIN RESIN INJECTION TO LEAKING JOINT SEA WATER SURGE BASIN FIRE WATER LINE EXCAVATION AROUND CONSUMER RECEIPT STATION ROAD CROSSING FOR LAYING 1 FOR 20” RAW ETHANE 1 FOR 6” PROPANE FIRST STREET ROAD CROSSING FOR LAYING 1 FOR 20” RAW ETHANE 1 FOR 6” PROPANE FIRST STREET 2 #s ROAD CROSSINGS FOR LAYING 1 FOR 20” RAW ETHANE 1 FOR 8” NATURAL GAS 1 FOR 6” PROPANE & 1 FOR 14”DESALINATED WATER 1FOR 8” POTABLE WATER AVENUE -D TREATMENT TO MOVED EXPANSION JOINTS SEA WATER SURGE BASIN TESTING OF FRESH CONCRETE ON SITE ROAD CROSSING TO INSTALL CULVERT FOR 1# 14” DESALINATED WATER CORNICHE ROAD / ROAD C AT GUP GATE NOTH ROAD CROSSING TO INSTALL CULVERT FOR 1 # 14” DESALINATED WATER AVENUE ‘C’ ROAD GUP GATE EAST MAIN ENTRANCE Top REPAIR OF SINGLE LEAF SWING GATES Top Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 6 of ROAD CROSSING TO INSTALL CULVERT FOR 1 # 14” DESALINATED WATER AVENUE ‘C’ ROAD GUP GATE EAST MAIN ENTRANCE ROAD CROSSING TO INSTALL CULVERT FOR 1 # 14” DESALINATED WATER AVENUE ‘C’ ROAD GUP GATE EAST MAIN ENTRANCE REPLACEMENT OF MISALIGNED ANCHOR BOLTS IN FOUNDATION 55-VV-906 USING RENDEROC LAX TRA REPLACEMENT OF MISALIGNED ANCHOR BOLTS IN FOUNDATION 55-VV-906 USING RENDEROC LAX TRA BUILDINGS SCREEDS FOR VINYL AND EPOXY FLOOR FINISHES BUILDINGS SCREEDS FOR VINYL AND EPOXY FLOOR FINISHES BUILDINGS SCREEDS FOR VINYL AND EPOXY FLOOR FINISHES DIRECTIONAL BORING AT 3# LOCATIONS FOR 14”DESALINATED WATER PIPE CORNICHE ROAD NORTH OF Operating Authority DIRECTIONAL BORING AT 3# LOCATIONS FOR 14”DESALINATED WATER PIPE CORNICHE ROAD NORTH OF Operating Authority DIRECTIONAL BORING AT 3# LOCATIONS FOR 14”DESALINATED WATER PIPE CORNICHE ROAD NORTH OF GUP EPOXY SKIRTING ON DRY LINING DIRECTIONAL BORING AT 3# LOCATIONS FOR 14”DESALINATED WATER PIPE CORNICHE ROAD NORTH OF GUP EPOXY SKIRTING ON DRY LINING EPOXY SKIRTING IN CENTRAL CONTROL BUILDING & SUB STATIONS ON DRY LINING Top REPAIR TO LIFT CLADDING PANEL ADMINISTRATION BUILDING FIXING SHEETING PANELS WALL & ROOF CLADDING ROAD CROSSING AT FIRE STATION- FIRST STREET FOR LAYING 2 # 100 mm SLEEVES FOR TELEPHONE CABLES ROAD CROSSINGS TO CONSTRUCT BOX CULVERTS OFH 2&3 CORNICHE ROAD ETHYLENE EXPORT SEA WATER SURGE BASIN CLOSING THE STRUCTURAL GAP ON THE ROOF, WALL & BASE SLAB MDPE DRINKING WATER LINE – NY LINES ROOF & SIDE CLADDING – Plant AREA REINSTATEMENT TO ‘DAMAGE CAUSED FLARE PIPE RACK COLUMN MEMBER 01537’ AT GRID 19A REINSTATEMENT TO ‘DAMAGE CAUSED FLARE PIPE RACK COLUMN MEMBER 01537’ AT GRID 19A FOUNDATIONS ALONG FENCE BELOW ‘FERTIL OVER HEAD CONVEYOR’ FOR PIPE RACK LEADING TO SEA Maintenance Warehouse Overcoating To Epoxy Painted Surface With Mastertop Top Coat 44P Access to Corridors & Walkway Roads Bituminous Concrete Surfacing Roads Bituminous Concrete Surfacing Excavation for 200 pair Telecom Route (Direct Buried) parallel to Avenue D & 3rd street Hand Excavation for 200 pair Telecom Route (Direct Buried) parallel to Avenue C 200 pair Telecom Road Crossing at Avenue D / 3rd Street Intersection along E 676976 Manual Excavation 200 pair Telecom Road Crossing @ Access road to GASCO camp @ C / L, co-ordinate N 2666305 / avenue C HDPE PIPES BUTT FUSION ROAD SURFACE REINSTATEMENT OVER BOX CULVERT CROSSINGS FIXING SHEETING PANELS WALL & ROOF CLADDING ROAD CROSSINGS TO INSTALL CULVERTS OFH 4 & 5 CORNICHE ROAD ETHYLENE EXPORT Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 7 of Manual Excavation 200 pair Telecom Road Crossing @ Access road to Operating Authority camp @ C / L, co-ordinate N 2666940 / avenue C REINFORCEMENT RECEIVAL & FABRICATION REMOVAL OF CONTAMINATED SOIL BLINDING CONCRETE REINFORCEMENT PLACEMENT FORMWORK ERECTION CONCRETE TO PAVED AREAS EXCAVATION STRUCTURES TELEPHONE CABLE TO SITE OFFICE ELECTRIC CABLE FROM RLIP SUBSTATION TO Civil Contractor CAMP WATER SUPPLY TO Civil Contractor CAMP ADMINISTRATION BUILDING SUBSTRUCTURE WASTE MANAGEMENT SEA WATER BASIN EXCAVATION FOR ETHANE & PROPANE GAS PIPELINE INTERCONNECTION & BACKFILL TO Top GENERAL #1 Site Preparation & Earth Work Top Index Scope - Reference documents – Definitions – Responsibilities – Safety – Method – Equipment - Attachment Scope The purpose of this method statement is to define the sequence of activities for the site preparation works related to the Company Petrochemical project. The extent of these activities are defined upon the attached site plan (Not included with this statement). Refer to indicative google photos. Reference documents Specifications for: Site preparation,Excavation & backfill for underground installations,Fill, Grading and Paving,Testing Laboratory,Geotechnical Investigation Definitions GE PSM SE SO QM/QE IS ST PPE Geotechnical Engineer Project Site Manager Site Engineer Safety Officer Quaity Manager/Quality Engineer Infrastructure Superintendent Survey Team Personal Protective Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 8 of Responsibilities It is an overall responsibility of the PSM to ensure that the site preparation activities are conducted according to the project specifications. PSM shall arrange all required resources. The IS shall ensure that the site preparation activities are conducted according to this method statement as well complying with all specifications. The GE shall ensure that the activities are conducted according to the project specifications and this method statement. Safety Prior to the commencement of any activities, the workforce shall receive a toolbox talk on the project site as well as on general safety requirements. SO shall ensure that the persons being inducted on site are well aware of the safety procedure to be implemented on site for the activity concerned.All persons upon the site shall wear PPE issued to them. Where possible hazards may arise from excavation activities, the necessary safety measures shall be taken to prevent accident or injury at all times. This may include provision of signage, barriers, watchman and lighting.Where work upon existing services is required, the necessary authority, permits and safety equipment shall be attained prior to the activity commencing. Scanning of existing services shall be conducted by suitable methods. Method The survey team shall locate and mark all services that are present upon the site (This includes above ground services as well as buried services). These services, (Electric, telephone, gas, oil, chemical, water etc), shall be clearly marked using stakes and warning tapes, reflected upon a site drawing and the issues raised with the client. The survey team shall also mark upon the site plan all obstructions, structures and developments. Any obstruction encountered during excavation activities shall be plotted and recorded. Where hazardous material is encountered, it shall be identified and isolatedin compliance with the safety procedures under SO supervision. The client shall be informed & hazardous material be collected and removed to a licensed tipping place. The details of the material and tipping arrangements shall be documented for review by the client as appropriate. Refer to Method statement Removal of hazardous materials. Existing structures, fences and developments shall be demolished in a safe manner as sitestripping activities proceed. The necessary permits, approvals and permission shall be obtained from the concerned authorities prior to the commencement of the activity. The method of removal of these existing elements shall usually be conducted by dozer or breaker. Where necessary otherwise, discussions on site shall be made concerning alternate methods of removal when the full extent of these structures are exposed. The removal of the topsoil shall include all vegetation and rubbish material from the work site. Prior to the start of topsoil removal, the surveyor shall peg out the haul roads to be used by the construction equipment to execute all the site preparation activities. These roads shall be constructed by leveling of the existing terrain. Grade pegs shall be set to an agreed grid to Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 9 of indicate existing grade and reduced grade. Dependant upon the quality of the existing soil where the roads is to be built, suitable compactable fill may be imported or re-located from other parts of the site. The material shall be approved by the GE & QM/QE jointly. These roads shall be maintained as the work proceeds. Where required, water shall be spayed for dust control. For general removal of the topsoil activities using appropriate equipment, the areas concerned shall be excavated and graded to levels that ensure adequate surface water drainage. The GE/QM/QE shall monitor the activity to ensure that the topsoil material is removed. Sampling and testing of the resultant material shall be conducted for specification compliance & proper compaction. Upon completion of the topsoil removal activities where appropriate, the exposed surface shall be scarified, moistened and compacted to achieve the required density criteria. The areas shall be divided into manageable sections that be defined upon sketches. The GE shall monitor and test all sections. The results of the tests shall be recorded upon the relevant QC format. The number of tests conducted shall reflect the specification requirement. In excavation areas, the GE shall review the material to be excavated to ascertain its suitability for re-use as fill material. This excavated material shall be transported to areas that require filling. The material shall be deposited onto the areas to receive filling, leveled, moisture conditioned and compacted. If necessary, stockpiling may be required. The excavated areas shall be divided into manageable sections, which be defined upon sketches. The excavated areas shall be monitored by the GE to ensure that any unsuitable material does not appear. Where unsuitable material appears, it shall be removed. The excavated formation surface shall be treated by scarification, moistened and compacted according to the specification criteria. All areas shall be tested and the results recorded. Where areas are to receive fill, the material that has been excavated shall be transported to the fill area, tipped, leveled, moisture conditioned and compacted. The material shall be spread and leveled in 200mm layers. The areas to be filled shall be divided into manageable sections that be defined upon a sketch. The fill layer shall be moistened and compacted to achieve the required specification criteria. No further fill activity shall be conducted upon an area that has not been approved and released by the GE. Attention shall be observed at edges and slopes, to ensure that compaction criteria are achieved. Additional layers of fill material shall be placed similarly as described above until the desired elevation has been achieved. Production procedure. Verification exercise for fill activity had been conducted to establish the economical and effective method for the fill activity. Import and place fill to controlled areas of approximately 25m wide by 100 - 150m long. Spread and level the imported fill. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 10 of Add water to the fill layer by passing the water tanker over the fill layer. The water tanker should pass over the layer twice. A time gap of approximately two hours is allowed for the water to soak into the fill material. The layer is now mixed with the grader until a uniform blend of moist material is achieved. Additional water is added by passing the water tanker over the layer in a uniform sequence. A time period of approximately one-hour is allowed for this water to soak into the fill layer. The fill layer is mixed again with the grader leaving the fill level to the correct grade. Vibrating rollers shall now compact the fill layer in a logical sequence that compacts the fill layer uniformly. Testing of the layer shall be conducted according to specification requirements. Equipment Dozers & Graders, Vibrating drum rollers, Dumper trucks, Excavators & Loaders, Water tankers Attachment None. Refer to indicative google photos as incuded as a facility. Assume there was nothing prior to construction & whole site was filled for preparationworks. #2 Protection of existing services Top Index Scope - Reference documents – Definitions – Responsibilities – Safety – Method – Equipment - Attachment Scope The purpose of this method statement is to define the procedure that can be implemented, for the identification, protection and / or removal / relocation of existing services upon the site. Reference documents Specifications: Site preparation…, Fill…, Grading and Paving...(certain sections re to record services within the specifications) Definitions GE PSM SE SO QM/QE IS ST PPE Geotechnical Engineer Project Site Manager Site Engineer Safety Officer Quaity Manager/Quality Engineer Infrastructure Superintendent Survey Team Personal Protective Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 11 of Responsibilities It is the overall responsibility of the PSM to ensure that the identification, protection and / or removal / rerouting to existing services are conducted in a safe methodical sequence as defined by this method statement as well as directed by the relevant authorities. The IS shall coordinate investigation of existing services with the Plant authorities. The ST shall accurately plot and record all existing services upon the site. The SE shall ensure that the excavation is rightly carried out. The SO shall ensure that excavations are safely carried out. Safety Prior to the commencement of any activities, the workforce shall receive a safety induction talk on the project site safety requirements. The necessary permits that may be required to work near these services shall be obtained. Any special conditions imposed upon these permits shall be implemented. The use or restriction of specific mechanical equipment whilst locating these services shall be implemented. Generally, where appropriate, only manual excavation shall be carried out. Method From the existing record drawings provided by the relevant authorities controlling Plant, existing services shall be located and exposed by hand excavation. The ST shall check and accurately record these services. A line of pegs shall be positioned to indicate the route of the existing services. The warning tape and / or nylon cord to indicate and protect the route of the service shall be provided. The ST shall inform the IS about the exact location of the services relative to the warning flags. Should an existing service be disbanded or made redundant, that shall be exposed to allow for the inspection as well as confirmation of its status by the authorities. The IS through the EPC Contractor representative shall request the relevant authority to review the excavated service to confirm the status as well as instruct for necessary action required for removal or diversion. The redundant service shall be removed under the supervision of the IS according to the agreed criteria of that relevant authority. Where an existing live service remains working or serving during the site preparation activity such as the 33KVA electric cable, that existing live service shall be protected in compliance with the regulations. Upon location of the live service, the ST shall mark that location upon the ground using spray paint or small pegs. At necessary locations along the route of the existing live service indicated by the ST, small hand dug pits shall be excavated to expose live service to ensure its location. On ten meters (10m) either side of the route of the existing live service shall be erected posts at suitable centres. A nylon cord with warning tape streamers shall be strung between the posts to clearly indicate the service and its route. Signboards that indicate what exactly the live service within the marked corridor is, shall also be displayed at sufficient locations conveniently within the view along the route. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 12 of Where temporary roads cross existing cables, sufficient suitable fill material shall be placed on top of the cables to afford adequate protection by distributing the axle loadings safely. The Safety Officer shall periodically check the condition of the barriers where necessary refurbishment is conducted. Equipment Excavation Tools, Survey Equipment, Pegs, Nylon cord, Warning tape. Attachment None. Attachments depends on the available record drawings. #3 Re-routing of 33kv cables Top Index Scope- Reference documents- Definitions- Responsibilities- Safety- Method- Equipment- Attachment Scope The purpose of this method statement is to define the procedure that can be implemented for re-routing of the existing 33KV electric cable that crosses the project site. This method statement includes the location, excavation, isolation, re-routing, jointing, testing and backfill. Reference documents Site drawing, Record Drawings Definitions GE PSM SE SO QM/QE IS ST PPE Geotechnical Engineer Project Site Manager Site Engineer Safety Officer Quaity Manager/Quality Engineer Infrastructure Superintendent Survey Team Personal Protective Equipment Responsibilities The EPC Contractor PSM shall ensure the required permits from Operating Authority are obtained prior to the commencement of this activity. It is the overall responsibility of the PSM to ensure that the identification, protection and / or removal / rerouting to existing services are conducted in a safe methodical sequence as defined by this method statement as well as directed by the relevant authorities. The IS shall coordinate investigation of existing services with the Plant authorities. The ST shall accurately plot and record all existing services upon the site. The SE shall ensure that the excavation is rightly carried out. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 13 of The SO shall ensure that excavations are safely carried out & ensure that all safety issues are addressed as defined upon the work permits. Safety Prior to the commencement of any activities, the workforce shall receive a safety induction talk on the project site safety requirements. The necessary permits that may be required to work near these services shall be obtained. Any special conditions imposed upon these permits shall be implemented. Only specifically approved mechanical equipment whilst locating these services shall be used. Generally, where appropriate, only manual excavation shall be carried out. Method The existing route of the 33KV cable shall be identified, marked & a barrier erected on either side clearly defining the route across the site. The route proposed for the new 33KV cable on the AFC drawing shall be identified & marked with pegs by the ST. Excavation shall commence to the line and required level. The appropriate sand bed shall be placed within the trench. The new cable supplied by EPC Contractor shall be laid into the trench according to established methods and standards that would include placing of the cable drum on a cable trolley and rollers. The cable shall be unwound from the cable drum by pulling. If required, a cable tugger fitted with load cell control may be utilized. The new cable shall be correctly placed to line and level upon the sand bed. Wherever joints occur, sufficient cable overlap to allow for the jointing shall be provided. The insulation value of the new cable shall be tested by 5KV motorized megger. Upon the EPC Contractor Electrical Engineers approval, the cable shall be covered with dune sand to the required thickness evenly. Cable tiles shall be placed on top of the sand above the new cable. The trench shall be backfilled with approved material. The backfill activity shall continue until the trench is completely filled. Route markers shall be placed with the splice joints surveyed and recorded. Where joints occur to the cable either at the two termination points with the old cable or along the length of the new cable, the same technique shall be adopted. An experienced cable jointer under the supervision of an electrical engineer shall conduct all the jointing. Approved jointing kits shall be utilized. The manufacturers recommendations relating to the installation of these jointing kits shall be followed. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 14 of Upon completion of the jointing of the new cable length, the entire length of the new cable shall be tested. The cable shall be subjected to a pressure test of 67KV DC for 15 minutes on the cable between each core and earth. The remaining cores shall be connected to earth. The engineer shall measure the leakage current. All readings shall be recorded upon the appropriate form. The testing shall be witnessed by the EPC Contractor engineer. Prior to the excavation at the points where the new cable is to be connected to existing 33KV cable, the necessary permits shall be obtained. EPC Contractor method statement for conducting cable Diversion shall be complied with. The old cable shall be hand dug. An area sufficient to conduct the jointing of the cable shall be excavated. Electrical engineer in coordination with the EPC Contractor engineer shall ensure that the old cables are identified and isolated under the supervision of the Refinery Supervisor within the appropriate substation. The necessary earthing and isolation to the cables shall be conducted prior to the commencement of jointing the old cable to the new. The cables shall be jointed in the same manner as described previously. Once the cables have been jointed, these shall be tested by mega test at 5KV and HV test at 53KVDC to establish its integrity and insulation. The disbanded cable shall be removed from the new jointed cable by excavating and rolling the cable to allow the new cable route corridor to be covered with sand, cable tiles and backfill material. Upon completion of the cable testing activities, the Refinery Electrical engineer shall authorize the energizing of the new cable route. The disbanded cable route shall be excavated to expose the old cable. The old cable shall be removed onto the surplus cable drums from which the new cable was coiled. These drums shall be stored on site for EPC Contractor disposal. A program to be developed by all parties of power outage windows shall be produced for the tie-in activities of the cables. Equipment Excavator,Dump trucks,Cable drum trolley,Cable rollers,Cable tugger with load cell Attachment EPC Contractor standard method statement for cable diversion. (Since this statement may be submitted by the Civil Works subcontractor on behalf of the EPC contractor, the EPC standard method statement is required to be attached) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 15 of Top Concrete Pipe Culverts Index Scope-Reference documents-Definitions-Responsibilities-Safety-Method-Equipment-Attachment Scope The purpose of this Statement is to define the sequence and methodology for the laying, jointing and testing of the concrete pipe culverts. Reference documents Specification….,Drawing No…. Definitions GE PSM SE SO QM/QE IS ST PPE Geotechnical Engineer Project Site Manager Site Engineer Safety Officer Quaity Manager/Quality Engineer Infrastructure Superintendent Survey Team Personal Protective Equipment Responsibilities The CS shall Plan and Resource the concrete culvert laying activities to ensure that these are Carried out complying with the contract documents. The Construction Foreman shall actually execute the works controlling the workforce as necessary all according to the directions by the site engineer or the superintendant. Safety Prior to the commencement of any activities, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any adopted process that may have a particular Safety risk, shall be assessed, shortcomings analysed and addressed accordingly meeting the operational requirement. Method Setting Out The edge co-ordinates of the concrete pipe shall be calculated from the information on IFC drawing. Allowing for the 1:1.5 slope, the edges shall be fixed in such a way that full length of pipes are used avoiding unnecessary cutting. The center line and the actual trench width shall be set out by marking on ground. Excavation The trench shall be excavated to the correct width, length and formation by using a Hydraulic backhoe. Once the bulk excavation is completed, wooden pegs with elevation marked on them shall be used for indication to complete the remaining excavation to accurate formation levels. The formation shall be watered and compacted with a plate compactor to achieve compaction Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 16 of of 90% of MDD in accordance with specification documents. The compacted formation shall be inspected and field tested prior to the commencement of the Bedding activity. Bedding Once the excavation is approved, Bedding material shall be placed to a thickness of 150mm, watered and compacted in accordance with the specification. The compacted surface shall be inspected & field samples tested for approval. Pipe Work The socket positions shall be marked on the Bedding and Hand excavated to ensure that the barrel of the pipe rests firmly on the bedding with spigot ends remaining clean for installing the gaskets. The concrete pipes shall be transported from the store to the location of the trench and gently lowered keeping the socket end upstream into the trenches with a crane using belt slings only. The pipes shall be laid back to back to the correct orientation. The spigot end of the pipes shall be cleaned using a cloth with special care taken to clean the recess which shall be lubricated with liquid soap following gasket placement in position. Supports shall be placed at one end. The spigot shall be so placed that the gasket is in contact with the entry taper at the socket evenly all around. The spigot shall then be drawn into the socket using a 5 tonTirfor. Jointing shall be carried out. Upon completion of the Jointing operation, the Bedding material shall be packed below the pipes so that the barrel rests firmly on the bedding keeping the pipe intact. The top elevation of the pipe shall be checked to ensure that the pipe lebvel is accurate. The operation shall be repeated until all the pipes are laid. The completed pipework shall be inspected and approved. Each joint shall be visually inspected from inside the pipe. Backfill Once the pipes are laid to the True gradient and alignment as described above, Bedding Material shall be carefully placed along the sides and in between the pipes by means of a backhoe. The bedding and surround material shall be placed in layers and watered and compacted until the bedding and surround material reaches 300mm above the top of the pipe. Excavated suitable material shall then be placed in 200mm layer, compacted, inspected and tested. A list of Do’s and Don’t’s provided by the manufacturer is attached herewith. Equipment Crane 20Ton 1 No / Flat Bed TrailorPart time / Excavator Backhoe1 No / Trifor 5 To 2Nos / Fork liftParttime / Plate Compactor1 No / Water Tanker Part time Labour ForemanNo. 1 / PipefitterNos. 2 / LabourersNos. 4 Attachment Manufacture’s datasheet. Top Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 17 of #5 Concreting to walls of Central control building / laboratory Super – structure activities Top Index Scope / Reference documents / Definitions / Formwork Design / Method Scope The purpose of this method statement is to define the procedure that shall be adopted for the erection of formwork and placement of structural concrete to the wall sections of the CCB. Reference documents Specification Concrete Construction, Formwork and Coating. Specification Concrete Buildings. Drawing No. Definitions E PSM CM Engineer Project Site Manager. Construction Manager. Formwork system The basic formwork supporting system shall be as designed and supplied by M / s. Giffin Scaffco. The supplier of formwork shall provide all design drawings for approval as well as for implementation. Additional bracing and support props shall be added by Civil Contractor in compliance with the formwork design provided by the supplier. Surface forming materials such as plies & timber scantlings etc. shall be added by the civil contractor. Upon completion of the suspended slab formwork system particularly, Civil Contractor Site Engineer shall check and confirm the adequacy of the system. If so required, the whole form work shall then be checked by the supplier’s expert & the adequacy certified in as by third party. Method The surveyor shall set out, check the line and levels to establish the correct positions. The wall starter bars shall be installed in place in accordance with the IFC drawings for the foundations. The kicker to the base of the wall sections shall be planned to be cast along with the foundation. The vertical and horizontal reinforcement to the wall shall be installed according to the IFC drawings. Where service inserts (ducts pipes etc) are shown on IFC drawings, these shall be securely located,installed as well as checked. The continuity testing of the reinforcement for the cathodic protection requirement shall be conducted and witnessed by the QC department. The results shall be recorded. Connection bosses shall be fixed as detailed on the approved drawings. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 18 of One side of the formwork shall be erected and braced. A safe means of access to a working platform as well as working platform shall be erected for this formwork. This access shall allow the steel fixers, carpenters and concrete crew a safe working area. All service openings shall be boxed for block outs / ducted onto the formwork. The height and width of the wall section shall be agreed with EPC Contractor/ Engineer. The wall height shall terminate near the underside of the roof slab, where the remaining top part of the wall can be cast along with the roof slab. The walls shall be prepared and cast in sections not exceeding 6.0m length where a construction and or contraction joint shall be formed using plywood. After all the inspections of the preparatory works, the concrete pouring activity shall be carried out in lifts not more than 450 mm layers. This concrete surface at joint location shall be scabbled prior to the next section is formed formed. Where applicable, the laboratory portion outer wall form shall be erected with the profile strips prefixed to the formwork. The remaining wall form shall be erected and braced. A safe means of access to a working platform as well as working platform shall be erected for this formwork. This access shall allow the steel fixers, carpenters and concrete crew a safe working area. The surveyor shall check the alignment of the wall. The preparatory works shall be checked by the site engineer who then request the QC. The finished reinforcement and formwork configuration shall be inspected on an ongoing basis by the Civil Contractor QC department who in turn obtain concrete pouring permission from EPC Contractor. Having obtained approval, the structural concrete shall be poured by pumping. Curing shall be carried out according to the specification requirements. Equipment Crane. Concrete Pump. Vibrators Hand Tools. Attachment None. #6 Concrete pipe culverts Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 19 of Scope The purpose of this Method Statement is to define the sequence and methodology for the laying, jointing and testing of the concrete pipe culverts. Reference documents Specification Specification Drawing No. Definitions E PSM CS Engineer Project Site Manager. Construction Superintendent Responsibilities The CS shall Plan and Resource the concrete lining activities, to ensure that they are Constructed according to the Drawings and Specification. The Construction Foreman shall actually execute the works, directing the workforce as necessary. Safety Prior to the commencement of any activities, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that may have a particular Safety risk, shall be assessed and addressed as required in consultation with the safety engineer. Method Setting Out The edge co-ordinates of the pipe shall be calculated from the information on the drawing as well as allowing for the 1:1.5 slope & fixed in such a way that full length of pipes are used without pipe cutting. The center line and the actual width shall be marked on ground. Excavation The trench shall be excavated to the correct width, length and formation by using a Hydraulic backhoe. Once the bulk excavation is completed, wooden pegs shall be used showing the elevations marked on them to guide & complete the excavation to required formation levels. The formation shall be watered and compacted using a plate compactor to achieve compaction of 90% of MDD in accordance with specification. The compacted formation shall be inspected and field compaction tested prior to the commencement of the Bedding activity. Bedding Once the excavation is completed & approved, Bedding material shall be placed to a thickness of 150mm, watered and compacted in compliance with the specifications. The compacted surface shall be inspected, tested and approved. Pipe Work The socket positions shall be setout on the Bedding. Manual excavation shall be carried out for socket portion to ensure that the barrel of the pipe rests firmly on the bedding. It shall also be ensured that spigot ends remain clean to the same standard as were while installing the gaskets. The concrete pipes shall be transported from the store to the location of the trench and gently lowered into the trenches with a crane using belt slings only. The socket end shall be placed upstream. The pipes shall be laid back to back to the correct orientation. The spigot Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 20 of end of the pipes shall be cleaned using a cloth with special care taken to clean the recess which be lubricated with liquid soap following which the gasket placed in position. Supports shall be placed at one end. The spigot shall be so placed that the gasket is in contact with the entry taper/bevel at the socket evenly on circumference. The spigot shall then be drawn into the socket using a 5 tonTirfor. Upon completion of the Jointing operation, the Bedding material shall be packed below the pipes so that the barrel rests firmly on the bedding and the pipe doesn’t move. The top elevation of the pipe shall be checked to ensure that the laid pipe is accurately placed to the correct alignment and elevations. The operation shall be repeated until all the pipes are laid. The completed pipework shall be inspected and approved. Each joint shall be visually inspected from inside the pipe if accessible. Backfill Once the pipes have been laid to the True gradient and alignment as described above, Bedding Material shall be carefully placed along the sides and in between the pipes by means of a backhoe. The bedding and surround material shall be placed in layers, watered and compacted until the surround material reaches 300mm above the top of the pipe. Excavated suitable material shall then be used in compacted layers of 200mm inspected and tested until the backfilling operations are completed. A list of Do’s and Don’t’s provided by the manufacturer is attached herewith. Equipment Crane 20Ton Flat Bed Trailor Excavator Backhoe Trifor 5 Ton Fork lift Plate Compactor Water Tanker Labour Foreman Pipefitter Labourers 1 No. Part time 1 No. 2 Nos. Part time 1 No. Part time No. 1 Nos. 2 Nos. 4 Attachment Manufacture’s datasheet. #7 Culvert crossings to avenue e and main highway. Top Index Scope Reference documents Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 21 of Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this statement is to define the sequence and methodology for the excavation, placement of culvert pipes, backfill and reinstatement to the culvert crossings on avenue E and the main highway next to the retention pond. Reference documents Drawing No: Drawing No: Definitions E PSM CM Engineer Project Site Manager. Construction Manager. Responsibilities The CM shall plan and resource the culvert construction operation, including the permissions required from all authorities concerned. The Construction Foreman shall control and monitor these activities, directing the workforce as necessary. Safety Prior to the commencement of any activities, the labour force shall receive a tool box talk on the project site safety requirements. Any process that may have a particular safety risk, shall be assessed and addressed as required. Method The route of the culvert trench shall be set-out by the surveyor. The existing services such as the fibre optic cable shall be located and protected. The cable shall be supported across the excavation, placed within a PVC duct, wrapped with polythene & tied to the support. The traffic diversion scheme wilth all signs installed shall be implemented according to the attachment and monitored regularly by the safety department to ensure a smooth traffic management. Concrete barriers shall be placed at the head of the diversion. The ditch along the side of the diversion shall be barricaded with nylon rope bearing warning tape. The initial excavation shall commence at the drainage ditch to the west side of avenue E and extend across avenue E up to the fibre optic cable location. The trench shall be excavated using appropriate equipment while dump trucks collect the surplus excavated earth to be removed from site to the spoil area. Material that is to be reused shall be stockpiled. The excavated asphalt shall be deposited at the tip area in the pre-agreed location. Any damage to the existing asphalt shall be repaired during the reinstatement operation. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 22 of The sides of the excavation shall be sloped where the excavation depth exceeds 1.2 m. A ladder shall be provided for ingress and egress of the excavation. Ladder shall be located every 8 m if so required depending on length of excavation. A banksman shall be provided to monitor the excavation machine operations. The bottom of the excavated trench shall be inspected by the EPC Contractor engineer prior to the compaction activity commences. All unsuitable material shall be removed. Inspection and testing of the compaction shall be conducted by the site test laboratory. The field density test results shall be submitted for approval. The surveyor shall monitor the line and level of the excavation regularly & provide level pins for the pipe bedding. Approved bedding material shall be placed and compacted to the required levels and density values. The site test laboratory shall conduct the field density tests & reported accordingly. The concrete culvert pipes shall be placed correctly to the line and level as shown on the IFC drawing. The pipes shall be inspected for damage prior to placement. No damaged pipes shall be placed. The spigot head on the culvert pipe shall be on the up stream end of the pipe. A pair of nylon strap shall be used to lift the pipes using a 50 ton crane and place the pipes correctly in to the trench. Backfill material shall be placed around the pipes in layers of 150mm thickness duly compacted & tested by the laboratory. Backfill operations shall continue up to the existing road formation level. When the backfill activity is completed, asphalt repair to the existing highway shall be conducted & avenue E road construction shall be reinstated. The traffic management scheme shall be removed to allow the re-use of avenue E. A temporary security fence outside the existing RRD area shall be erected to allow the culvert construction to continue east towards the retention pond. The temporary security fence shall be erected to the agreement and requirements of the security police. When this activity is completed and approved by the security police, the existing security fence can be cut and rolled back sufficiently to allow the construction activities to be conducted. The next section for the culvert trench shall be excavated taking care of where existing services have been exposed to be well protected. The trench formation shall be inspected, compacted and tested as previously described. Pipe bedding shall be placed, compacted and tested as previously described. The pipes shall be installed within the trench after inspection for transit damage is completed. Backfill around the pipes shall be placed, compacted and tested. The backfill shall be reinstated above the pipe surround up to existing ground level. Reinstatement of any existing services shall be done. The fibre optic cable shall be left protected by the PVC duct and polythene sheet, then surrounded with concrete. The existing security fence shall be replaced. The existing fabric shall be re-erected onto the existing poles which shall be re concreted in position. The barbed wire shall be re placed using new material where required. The temporary security fence shall be removed. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 23 of The final section of the culvert trench shall be set-out and excavated in the same sequence as the previous sections. The compaction and testing of the pipe bedding shall be carried out. The placement of the pipes to the correct line and level shall be carried out. The backfilling of the pipe surround shall be conducted. The reinstatement of the backfill above the pipe surround material shall be conducted. The site test laboratory shall conduct the field density testing. The inlet and outlet chambers of the crossing shall be constructed. Refer to the method statement for chambers. This procedure shall be similarly followed in principle for any other culvert crossings on avenue E. Equipment Excavators. Dump trucks. Compactors. Attachment None. #8 Placing concrete on service Water tank 58-tk-205 foundations Top Index Scope Safety Method Equipment Attachment Scope The purpose of this method statement is to define the sequence and methodology for the placing of concrete on service water tank foundations. Reference documents Specification Definitions E PSM CM Engineer Project Site Manager. Construction Manager. Responsibilities The CM shall plan and resource the concrete repair activities, to ensure that they are implemented according to this method statement. The Construction Foreman shall monitor the concrete repair activities, directing the workforce as necessary. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 24 of Safety Prior to the commencement of the concrete pour, the labour force shall receive a tool box talk on safety requirements with special care taken to ensure adequate lighting arrangements are made. We propose to use 2 Nos. Tower lights each with 4 X 1000 Watts bulbs. Accers platforms shall be provided all around the ground beam on the outside formwork, 2 Nos. Aluminium ladders shall be placed at opposite ends to reach the Accers platforms from the ground levels. The accers platform shall be provided with Hand Rails all around. Method Preparatory works shall be carried out for the form works in circular profile for which due provisions shall be made for the specialist form. This form shall be well supported & anchored to resist ecpected forces during the our. As parallel activity, rebars shall be placed & fixed in the correct positions duly inspected. It is proposed to cast the Ring beam in two pours. Stopend forms shall be placed at opposite locations across the full width and depth to establish construction joints. The concrete shall be poured onto the section in one go 300 to 450 mm high around and compacted with suitable vibrators. Care shall be taken to ensure that concrete is placed and compacted in its final position within the time permissible form the time of batching to the time it should be compacted in accordance with the concrete production specification that may be generally 1 to 2 hours. Concrete delivery shall be planned accordingly to quantity & duration of pour to enable a smooth concreting operation. Concrete shall be continually poured from the start to the concrete por finish. No cold jointshall be allowed to form. All flash setting shall be avoided by keeping the rebars lower than the air temperature. Proper vibration shall be effected. After the concrete is completed, proper method of curing shall be carried out & continued for specified number of days. All tests for on site concreting shall be conducted by the RMC laboratory staff duly recorded. Equipment Concrete pump, concrete trucks, vibrators, Attachment None. #9 Concrete repair Top Index Scope Reference documents Definitions Responsibilities Safety +Method Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 25 of Scope The purpose of this method statement, is to define the criteria for the concrete repair to all structures. Reference documents Specification Definitions E PSM CM Engineer Project Site Manager. Construction Manager. Responsibilities The CM shall plan and resource the concrete repair activities, to ensure that they are implemented according to this method statement. The Construction Foreman shall monitor the concrete repair activities, directing the workforce as necessary. Safety Prior to the commencement of any activities, the labour force shall receive a tool box talk on the project site safety requirements. Any process that is adopted that may have a particular safety risk, shall be assessed and addressed as required. Method Upon removal of the formwork, the concrete surface shall be inspected by the Site engineer & foreman to check surface defects. Where no surface imperfections have occurred, the concrete surface shall be cured according to the relevant procedure. Minor defects as described in A – D below shall be repaired as soon as practical. More significant defects as described in E – H shall be subject to joint inspection / agreement between Civil Contractor, EPC Contractor and Company. A. Pin holes / blow holes Where small defects to the concrete surface has occurred such as pin holes or holes smaller than 3mm in diameter or depth, the surface shall be repaired using Nitomortar FC with an approved bonding agent. This surface repair shall be conducted as soon as the formwork is removed whilst the concrete is still green. The repair shall then be cured in accordance with manufacturer’s instructions or agreed procedures using water or curing agent as appropriate. B. Sand runs / scouring Water movement inside the shutter can result in a streaky appearance giving loose sandy finish. Where this occurs, any loose material shall be removed by stiff brushing and then repaired as described in A above. C. Plastic shrinkage cracks Cracking caused by plastic shrinkage due to inadequate curing and protection of horizontal surfaces usually results in a series of diagonal cracks. These should be repaired by brushing dry cement powder directly into the cracks while the concrete is less than 3 days old and covering with damp hessian. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 26 of D. Minor misalignments (Typically Less than 2cm) Misalignments due to shutter movements etc, should be ground back to provide a smooth transition between areas. Where occurring at joints between panels, the ground profile length should be 2-3 times the size of the maximum misalignment. Following grinding, the surface should be reinstated as in A above. Care should be taken to ensure that concrete cover is maintained per specifications at all times. E. Honey combing / segregation / minor voids The repair shall be conducted as soon as the formwork is removed and the repair method agreed with EPC Contractor / Engineer. It shall require chipping the repair area free of laitance and exposing any voids. The repair area shall then be soaked, an approved bonding agent applied followed by working on with an approved mortar such as Master Flow 544 before the area dries out.. The materials shall be mixed using the bonding agent and not water. The mixed material shall be trowelled firmly into the repair area. Incase, the depth of the repair exceed 15mm, the repair shall be conducted in two layers providing a scratch coat on the first layer. The repair shall then be cured in accordance with the agreed procedure using water or curing compound as appropriate. F. Major voids (Typically Deeper than 5cm) This repair shall consist of chipping the affected area to remove any laitance and voids. Where reinforcement is exposed in a void, the surrounding concrete shall be chipped away to provide adequate space to place fresh concrete around the reinforcement including removal of all soft concrete. (Note- a distance of one and a half times the stone size must be allowed around all exposed reinforcement). Formwork shall be provided to retain the fresh concrete. The chipped area shall be soaked in and primed with a bonding agent. The bonding agent shall not be allowed to dry. Fresh concrete of the same grade as the surrounding concrete shall be used to fill in the void. The repair shall be water cured along with the parent concrete. The surface finishes to the repair shall be as the same standard as the surrounding concrete. G. Plastic settlement cracks Cracking caused by settlement of concrete usually in deep lifts or at changes in section can result in a series of cracks which mirror the reinforcement pattern in horizontal surfaces or appear to arch on vertical surfaces. Any such cracks should be chased out to a depth of 1015mm and filled with an epoxy mortar such as Nitomortar FC as in A above. H. Pourous / spongy surface Where inadequate vibration and poor finishing techniques have caused excessive bleeding, horizontal surfaces can appear spongy and pourous. In this case all affected surfaces should be ground back to good concrete usually only 2-3mm below the surface. The surface should then be reinstated using Nitomortar as in A above. This type of defect often occurs with plastic settlement cracks which should be treated as In G above. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 27 of All repairs noted above shall be recorded on the post-pour inspection form (QCF). It is not necessary to raise a non-conformance report provided the repairs are carried out as indicated above and agreed with EPC Contractor where necessary. Any repairs not covered by the above procedure shall be dealt with on a case-by-case basis and agreed with EPC Contractor and Company before commencing repairs. Equipment Hand Tools. Attachment None. #10 Construction of pipe rack bases Top Index Scope Reference Documents Definition Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement is to define the sequence and methodology for the Construction of the pipes rack bare foundations . Documents Specifications Drawing No: Definitions E PSM CM CS Engineer Project Site Manager Construction Manager Construction Superintendent Responsibilties The CS shall plan and resource the Construction of Pipe Rack Bases activities, to ensure that they are Constructed according to the Drawings and Specification . The Construction Foreman shall actually execute the works, directing the workforce as necessary. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 28 of Safety Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed as required. Method It is proposed to cast the pipe rack bases and the columns at actual locations at site. The method of Construction of the pipe rack bases can be summarized in the following activities. Setting Out Excavation Blinding Concrete Formwork Steel Reinforcement Concrete Construction Concrete Protection Construction of Columns with Anchor Bolts Backfilling Grouting Setting Out- Pipe Rack Bases The center lines of the Anchor bolt group shall be set out and offset provided 2m on either side of the foundation as reference line for blinding using manual methods of setting out. Excavation The bases shall be excavated with excavator, sides trimmed to avoid caving in. The formation shall be compacted, inspected, field tested and approved prior to the commencement of the blinding. Blinding Concrete The formation area to receive the blinding shal be prepared to the design levels & profiles. C20 PBFC grade concrete shall be placed to a minimum thickness of 50mm and the top surface smoothened by steel trowel. Curing shall be carried out for the blinding concrete for at least two days. Prior to the placement of the precast pipe rack base on it, mass concrete infill shall be placed as required in accordance with the drawings as necessary. Site Precast Yard for foundations A precast yard shall be constructed on site at the location indicated in the attached sketch. A wind shield fence 2m high shall be erected on the Northern boundary as indicated in the proposed location in accordance with clause ………………… of the specification. Steel Formwork Steel Forms as shown in the attached sketch shall be used for casting the pipe rack base foundations. The forms should be easily struck as well placed in position. Separate forms shall be used for the bases and columns . The base slab formwork shall have 100mm high suspended kicker. Fosroc reebol mould release oil shall be used. The template for anchor bolts for piperack base type1, 3 & 5 shall be a 100mm wide strip of steel plate across the width of the column steel Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 29 of formwork at the top. The template for piperack type 2, 4, 6, & 7 shall be similar in Construction type with 2 plates and a connecting piece. Anchor Bolts & Steel Reinforcement Steel Reinforcement cut and bent to the required shape and size shall be available on site. Reinforcement shall be timely fixed in place on the casting beds. Lifting Hooks Lifting hooks shall be inserted into the correct location & properly fastened so as not to be dislocated during concrete pouring. Casting Concrete Formwork applied with a fresh coat of mould release oil shall be placed in position around the already assembled steel reinforcement. Lifting recess plugs shall be installed in position with a Template. All supports shall be fixed in position. Inspection shall be conducted to the ITP requirement. The Base shall be poured and compacted with vibrators. The surfaces shall be smoothened with steel trowel. Curing shall ne carried out. Formwork for the column shall be installed the following day. The plumb and alignment shall be checked and the anchor bolts with sleeves installed and held in position by the template . The widths of the template shall be kept to the minimum to allow room for concrete vibrators. Once the column is cast, the formwork shall be stripped after 36hrs and the concrete cured for a minimum period of 7 days . Protective Coatings Once the curing is completed as stated above, the polythene sheets and hessian shall be removed and the concrete faces allowed to dry for atleast 24hrs during which time minor repairs such as filling up of blow holes etc. shall be carried out. The faces shall be wiped clean with a wet sponge and surface prepared to receive the first coat of protective painting. Fosroc Nitocote ET 402 shall be mixed with a slow speed electric drill and spray applied with an airless sprayer equipment to the required thickness of 1mm as a single high build coat in accordance with the manufacture’s instructions. The column and the top sides of the boxes, vertical faces shall be painted as described above. The bottom of the base slab shall be left without painting. Traceability The pipe rack bases shall be numbered and the date & time of casting marked on the concrete. Lifting, Transportation and Installation After completion of the curing, certified cranes of required capacity shall be used to lift the pipe rack base from the casting bed to the flat low bed trailor. The bases shall be transported to the actual location of installation. On location preparatory pf preceeding activities shall be completed prior to the transportation of the bases. The screed shall be cast accurately to the actual dimension of the bone of the pipe rack foundation. Using a jack of adequate capacity, the unit shall be moved to the correct position accurately. The crane shall be used to lift the pipe rack base from the Trailor down onto the screed surface. The position of Anchor bolts shall be rechecked with a Theodalite and accuracy of the installation certified by a surveyor. Back filling Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 30 of Once the pipe rack base is installed, Backfilling with selected suitable fill material shall commence. The fill material shall be pre mixed with water 3% more than the optimum moisture content for the daily requirement. Layers of premixed fill material shall be placed to a thickness of 200 mm and compacted properly. The compacted surface shall be inspected, field tested and these operations repeated until the Backfilling operations are completed. Anchor Bolts shall remain protected with PVC sleeves until completion of the Backfilling operations and only exposed at the time of installation / erection of steel works. Equipment Crane 50Ton Flat Bed Trailor 40 Ton Excavator Backhoe Plate Compactor Water Tanker 2 No. 1 No. 1 No. 1 No. 1 No. Labour Casting Engineer Placing Engineer Casting Foreman Placing Foreman Carpenters Steel fixers Masons Laborers 1 No. 1 No. 1 No. 1 No. 20 Nos. 30 Nos. 20 Nos. 40 Nos. Attachment Manufacture’s datasheet. #11 Excavation in Operating Authority controlled areas Top Index Scope Reference Documents Definition Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement is to define the methodology that shall be implemented, for construction activities that shall be conducted in areas under Operating Authority control. These areas shall primarily be the easement areas. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 31 of Documents All applicable Operating Authority easement drawings. All applicable EPC Contractor project Drawings. All applicable EPC Contractor project specifications. Definitions E PSM CM CF Engineer Project Site Manager Construction Manager Construction Foreman. Responsibilities The CM shall plan and resource the construction activities, to reflect the conditions imposed upon the “Permit to Work” system. The CF shall actually execute the construction activities, directing the workforce as necessary. Safety Prior to the commencement of any of the construction activities, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any activity that is conducted that may have a particular Safety risk, shall be assessed as required . Method The Construction Manager shall assign an Engineer and Construction Foreman to be responsible for the relevant activities. The Engineer shall be responsible for producing a method statement for the activities to be carried out. This method statement shall contain the procedure defined below. When the method statement has been agreed with EPC Contractor, a work permit covering the work activities within area of work shall be obtained from Operating Authority & duly registered into the work permit log. The Work area shall be surveyed to establish existing services location using the Operating Authority easement drawings and the cable detector. These services shall be exposed by hand dug trenches along the route. Where the existing service may cross the route of the proposed work activity, adequate protection and warning of that existing service shall be provided. The method of excavation for the work activity shall be defined upon the work permit. Where mechanical methods are accepted, a banksman shall be deployed with all mechanical excavation equipment to check for any existing service and advise the operator of the excavation machine. The excavated material where possible shall be stockpiled in a controlled area location. Any unsuitable material shall be removed from site to the spoil area immediately. Where soil conditions dictate, the sides of the trench shall be sloped. During the duration of the work activities, the site shall be kept clean.& tidy The Civil Contractor QC department shall conduct the required inspection and test regime required under the ITP. Upon completion of the work activity, all rubbish shall be removed from the work site. The easement area shall be left graded. Equipment Cable scanner. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 32 of Dump trucks Excavators as applicable. Compactors. Attachment Checklist MS #12 Construction of main substation Top Index Scope Reference Documents Definition Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement is to define the sequence and methodology for the Construction of the Main Substation. Documents Specifications Definitions E PSM CM CS Engineer Project Site Manager Construction Manager Construction Superintendent Responsibilities The CS shall plan and resource the Construction of Main Substation activities, to ensure that they are Constructed according to the Drawings and Specification . The Construction Foreman shall actually execute the works, directing the workforce as necessary. Safety Prior to the commencement of any activities, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that is adopted that may have a particular Safety risk shall be assessed as required. Method This method statement details only the Structural Concrete works. Finishes, Steel Sheet Roofs, Ladders, Access Platforms, Internal and External Insulation, Galvanised Steel Mesh etc are not Included in this Method Statement. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 33 of The Main Substation structure is to be constructed in the following stages. Stage 1: Earthworks, blinding, waterproofing, screed protection up to defined Elevation Stage 2. Footing pad construction including kicker up to 100mm above top of footing. Stage 3. Stub columns / walls including anchor bolts for galvanised screen mesh up to underside of floor slab / ground beam – defined Elevation. Stage 4. Ground slab of HVAC room including anchor bolts for ladder / access platforms TOC Stage 5. Floor slab for Main Building TOC (Top of Concrete) Stage 6. Wall construction up to bottom of roof slab / roof beam elevation Stage 7. Roof slab construction including kicker for parapet wall. Stage 8. Parapet wall construction. The Transformer Bays and the Foundation are to be constructed in the following sequence: Stage 1 Earthworks, blinding, waterproofing, screed protection. Stage 2. Footing pad construction and kicker 100mm above the top of footing including water stop bar for transformer bay partition wall and boundary wall footings. Stage 3. Transformer bay partition walls full height of 10m including cast in anchor plates for Roof truss. Stage 4 Transformer bay boundary wall including cast in sleeves for Fence Posts. Stage 5. Transformer foundation bases including bases for Sump and Valve Pit. Stage 6. Gravel Fill between foundations and walls. Stage 7. Steel Roof Trusses and Roof. Setting Out Grid line (1) to (13) and (A) to (D) shall be offset 3m away from the edge of the walls. The points shall be marked by a nail driven on top of wooden pegs driven into the ground and set in concrete. STAGE I Excavate whole area to Formation Level. Further excavate for transformer bay partition wall. Foundations to required elevations. Create Access ramp at either short ends to allow Heavy equipment to get in and out. Using grader and 12T Formation roller, Scarify and compact formation to elevation + 20mm. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 34 of Test for degree of Compaction and get approved. Set out grid lines (1) – (13) and (A) to (D). Use steel pins to be 2m away at outer edge of Concrete face. Mark Grid lines with chalk powder. Use Timber reapers to construct edge forms and place blinding Concrete to Elevation 98.50 200mm wider than required. Cure the concrete according to specifications requirements. Apply waterproofing membranes in sections one day prior to fixing formwork for base pads. STAGE II Place Formwork directly on Waterproof membrane. Formwork height shall be the height of Footing Pad + 30mm for protection screed. Timber shall be placed on top of the base formwork to act as kicker for Columns / Walls. Place Steel Reinforcement with Starter bars for Columns / Walls. Place timber reapers on bothfaces of the formwork for Contraction Joint at location indicated in the attached sketch No. 1. Care would be taken to ensure that contraction joints in west wall would be hidden behind GRC Facia Care to be taken to ensure that waterbars are placed at the right position on the edge of Pad Concrete for Transformer Bay partition walls and East wall. Isolated footing bases shall be cast. Bases for wall foundations shall be cast as per sequence shown in attached sketch no. 2. STAGE III Place Reinforcement for Stub Columns and Walls up to Floor Level. Place Formwork for Stub Columns and walls up to Floor Level. Vertical Construction Joints shall be located at same positions as indicated in the attached sketch No. 1. The distance from the corner shall not exceed 4.5m and the distance between intermediate ones shall not exceed 6m. Horizontal Construction Joints shall be at locations shown in Drawing No. as described in this Method Statement. Cast Stub Columns and Walls up to underside of Floor Slab. STAGE IV & V Install Formwork for floor beams and floor slab including 100mm Kicker for main walls. Construction Joints for floor slab shall be as shown in attached sketch No. 3. Install Reinforcement for floor beam and Floor slab. Place steel channels and Box outs for openings in floor slab for switchgear control panels. Penetration sleeves / ducts shall be boxed out for cables and utility services Cast Floor slab in alternate panels. Construction Joints shall be located within the middle third point of slabs and beams as shown in the attached sketch No. 2. STAGE VI External Formwork for vertical walls shall be placed in position, aligned and supported. Box outs for Bus duct penetration, rebates for Personnel and Equipment, Blast door frames, Air Conditioner openings and others shall be Boxed out. Cast in items such as Anchor plates for Roof truss shall be fixed in position. Timber reapers for Contraction Joints shall be fixed to the outer formwork face. Steel Reinforcement shall be installed as required. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 35 of Inner Formwork not exceeding 6m lengths shall then be placed after inspection approval of rebars up to the bottom of Roof slab level. Design calculations included as attached. The wall section shall be cast. Formwork design is similar to the ones used at Seawater surge basin. The rate of pour shall not exceed 2m vertical height / hr. STAGE VII Roof Slab scaffolding shall commence even as the wall construction activity is in progress on completed sections of walls. Roof Slab Construction Joints are shown in the attached sketch. Suspended kickers shall be placed for parapet wall. The Roof slab shall be cast. A set of four cubes shall be taken for each pour. Scaffolding shall not be removed for 14days and until the full design strength of concrete is reached. Cubes shall be crushed for 7,14 and 28 day strength. STAGE VIII Rainwater chutes shall be boxed out on parapet wall formwork. Reinforcement shall be placed and concrete cast in the same manner as for main wall. CURING Every pour be it a footing, stub column, wall, floor or roof, shall be wet cured with Hessian, covered with polythene sheet and kept wet for a minimum period 14 days in accordance with the specification. 2nos, 5000ltrs. Capacity water tanks in elevated platforms shall be provided for round the clock curing operations. Approved Curing Compound shall be used in Roof Soffits. Equipment Excavator / JCB Transit Mixer Crane 20 T Attachment Sketch No. 1: Showing locations of Contraction Joints. Sketch No. 4. Showing Concrete Pouring Sequence. Sketch No. 2. Showing Construction Joints for floor slab. Sketch No. 3. Showing Construction Joints for Roof slab. #13 Removal of hazardous materials Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 36 of Attachment Scope The purpose of this method statement, is to define the procedure that shall be implemented, for the investigation, quantification and disposal of the hazardous material upon the site. Reference documents Operating Authority regulations. Bechtel HSE Manual. Definitions PSM GE IS ST Project Site Manager Geotechnical Engineer. Infrastructure Superintendent. Survey team. Responsibilities EPC Contractor shall coordinate with all concerned authorities, for their approval of the hazardous material disposal. The PSM shall plan, resource and control the activities required for the orderly execution of the hazardous material disposal. The IS shall monitor the activities, in compliance with this procedure. The GE shall ensure accurate reporting of the materials. Safety Prior to the commencement of any activities, the workforce shall receive a Tool Box Talk on the project site safety requirements. PPE where appropriate shall be provided to those persons who shall come into contact with any hazardous materials. Method The hazardous material shall be located and identified upon the site. The ST shall record these details upon a site sketch. The GE and IS shall inspect the hazardous material visually and complete an inspection report. An accurate description of the material shall be provided. Where elements such as barrels are part of the hazardous material, the identifying marks upon the barrel shall be checked. Where appropriate, samples shall be taken to verify the content. Where such liquids have leaked into the soil, samples of the soil shall be taken to verify the amount of contamination. The ST shall assist the GE and IS to establish the extent of contamination. Trial pits may be dug to visually gauge the penetration of contamination. Samples of soil from these pits shall verify the content and absorption if any of the contaminant. The ST shall record the details. Upon receipt of the laboratory results that verify the analysis of the contaminant, a specific safety plan if required, shall be prepared for the safe handling of suspect material or soil. Any precautions that are not defined within this method statement but essential shall be taken up. The solid items of contaminated material shall be lifted by loader shovel into the rear of a tipper truck. An inventory of the items loaded into the truck shall be produced. A permission shall be obtained from the operating authority for the purpose of disposal of hazardous material waste into a designated area. The truck covered with a dust preventive sheet shall transport the Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 37 of material to the approved Operating Authority waste disposal site in the industrial area. The contents shall be offloaded in accordance with the facility rules and regulations monitored by the EPC Contractor representative. This process shall continue until all items of waste are removed from the site. The existing soil material that is contaminated shall be clearly marked with pegs. Using a loader shovel, the material shall be excavated and loaded into a tipper truck. The truck shall be covered whilst transporting the soil to the mixing area where the soil be stockpiled. This process shall continue until all contaminated soil is removed to the satisfaction of the GE. The stockpile of contaminated soil shall be lightly spread across the disposal area at levels above the water table. This shall be achieved by using loader shovel and grader. The layer thickness shall not exceed 150mm. A grader shall now mix this layer with the layer of uncontaminated material below. This shall have the affect of dispersing the material. A normal layer of uncontaminated material shall be placed upon the top of this mixed material. If required, a further layer of contaminated material shall be spread over this layer of material until the stockpile is depleted. This layer shall be mixed with the layer below as described previously. A topping layer of uncontaminated material shall be placed on top of all mixed material. The GE shall satisfy himself that the layer thickness is minimal and the material is adequately mixed with the layer below. Upon completion of the removal of the hazardous material, the GE shall prepare a report that identifies the material disposed as well as the areas of disposal. Equipment Excavator. Grader. Dump trucks. Attachment ITP No: QCF, Visual inspection Report. #14 Construction of control building floor slab central Top Index Scope Reference Documents Definition Responsibilities Safety Method Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 38 of Scope The purpose of this method statement is to define the sequence and methodology for the Construction of the floor slab to the Central Control Building. Documents Grade Slab General Arrangement Grade Slab Sections Foundation Details Penetration Definitions PSM Project Site Manager CM Construction Manager CS Construction Superintendent Responsibilties The CS shall plan and resource the Structrual Backfill activity to achieve the required compaction as per the specification. The site test laboratory shall conduct and verify the compaction crireria. The surveyors shall be responsible for setting out the exact levels of fill and concrete up to designated drawings. The construction Foreman shall actually lead the execution operations by directing all Foreman and workforce as necessary. Safety Prior to the commencement of any of the required activities, the Labour force shall receive a tool box talk on the Project Site Safety requirements. Method The slab on grade level shall be casted over compacted fill by using a separation Polyethylene Membrane. The slab is divided into two main portions. The low level portion at EL shall have a smooth level finish in order to receive the bases of the access panel system. This portion is to be cast in panels to give the required joints as specified on the drawing. The high Level portion at EL shall be cast in panels according to the required joints shown on the drawings. The surface finish for this section shall be rough since Tiling and flooring systems are to be applied. In Electro-Mechanical rooms the surface finish shall be smooth to receive the epoxy coating finish as specified. General Curing shall be carried out to the norms of the Project Specifications. All cable trenches and separating Wall shall be cast up to levels and dimensions specified on related drawings. Equipment Crane 50Ton 2 No. Flat Bed Trailor 40 Ton 1 No. Excavator Backhoe 1 No. Plate Compactor 1 No. Water Tanker 1 No. Labour Casting Engineer 1 No. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Placing Engineer Casting Foreman Placing Foreman Carpenters Steel fixers Masons Laborers Attachment None. Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 39 of 1 No. 1 No. 1 No. 20 Nos. 30 Nos. 20 Nos. 40 Nos. #15 Mortar for blockwork Top Index Scope Reference Documents Definition Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement is to define the sequence and methodology for the production of mortar for use with the blockwork activities. Documents Masonary Definitions PSM Project Site Manager CM Construction Manager CS Construction Superintendent Responsibilties The CS shall plan and resource the blockwork activity, to achieve the required combination of workmanship and material quality. The construction Foreman shall actually lead the execution operations by directing all the workforce as necessary. Safety Prior to the commencement of any of the required activities, the Labour force shall receive a tool box talk on the Project Site Safety requirements. Method Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 40 of The block supplier shall be submitted for approval to EPC Contractor. The sand aggregate for the mortar shall be submitted and approved by EPC Contractor. Potable water from the Operating Authority source shall be used for mixing sand and cement. Storage of materials shall be on appropriate seggregated suitable areas adjacent to the work place with no possibility of contamination or deterioration of the materials. Mortar shall be mixed mechanically on site using standard boxes for measuring sand for each batch. The amount of water required shall also be defined depending on water cement ratio. The ingredients shall be mixed thouoghly until a uniform mix is achieved. Mix production quantiry in one batch shall be limited to a volume which can be consumed within the initial setting time of cement. The remixing of martar by adding additional water shall not be permitted. Once the mortar is produced, it shall be taken to the workplace and used within specified setting time that is generally 2 hours of adding into the mixer. Equipment Cement mixer Gauge boxes Hand tools. Attachment None. #16 Control of camp sewage system Top Index Scope Reference Documents Definition Responsibilities Safety Method Attachment Scope The purpose of this method statement is to actions that shall be implemented to monitor and control the sewage holding tank status, so that overflow is avoided. Documents Method statement Waste Management. Definitions PSM Project Site Manager CB Camp Boss TM Transport Manager. Responsibilities The PSM shall be responsible for the implementation of the preventative measures. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 41 of The CB shall execute the required monitoring and record keeping of the investigation. The TM shall ensure the provision of the disposal tankers as and when required. Safety All relevant safety issues including hygiene precautions shall be implemented, monitored and maintained for this activity. The site safety department shall monitor the sewage disposal areas. Method A new water meter to record water usage shall be installed prior to the water storage tanks. For the next one month, regular readings at specific times shall be recorded to establish water requirement trends. The information collected from this exercise shall help to understand the peak demand periods which also define the sewage disposal requirements. In parallel to this water input recording, a survey of the sewage holding tanks filling trends shall be established. A tank volume indicator system shall be installed at every sewage holding tank. This indicator system shall consist of a visible indicator rod. Based on a float system, the rod shall raise up as the holding tank fills. This visual system shall remind the CM to organise the emptying of the tank. Data obtained from the tanker drivers on number of loads discharged, shall help verify the water meter quantity to establish leakage’s. The existing provision for the trucking of the sewage waste shall be monitored. The fleet capacity shall be increased as required based upon the results of the survey. A review of the collected data shall be conducted after one month to supplement existing operational criteria as required. The responsibility for compiling the information shall be with the camp boss who ensure that water consumption is regularly monitored, that areas of water abuse are identified, that holding tank emptying schedule established as well as formulating measures to conserve and re-cycle water wherever possible. Initial trucking capacity that is dedicated to the sewage disposal activity is ‘two trucks’. These trucks operate on both suction fill and pump fill systems. The survey shall review and confirm the required trucking levels needed to service the holding tanks. Attachment. N / A #17 Structural steel-piperacks Top Index Scope Reference documents Definitions Responsibilities Safety Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 42 of Method Equipment Scope The purpose of this Method Statement is to define the sequence and methodology that shall be implemented for the Erection of the steel structure piperacks. Reference Documents Specification Grouting Specification Steel Structure Fabrication Specification Painting Specification Galvanizing Specification Project Preservation and Export Packing Relevant IFC drawings. Definitions CM CS EF Construction Manager. Construction Superintendent . Erection Foreman. Responsibilities The CM shall plan and resource the steel structure erection activities, to ensure that they are implemented according to this procedure, with the correct equipment resources. The CS shall ensure that all safety requirements are implemented and explained to the erection workforce. The CS shall control the day to day activities The EF shall control the workforce ensuring the full implementation of this method statement including all safety measures. Safety Prior to the commencement of any activity, the labour force shall receive a Toolbox Talk on the Project Site Safety Requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed and addressed as required. The use of cranes shall be assessed and all safety regulations enforced. Men working at height shall be equiped with the required personal safety equipment Method Materials Receivables. All Structural steel material to be used for permanent works shall be received on site in the appropriate laydown area. All tems shall be inspected to conduct a check of the delivery against necessary shipping documents. All structural steel members shall be checked for quantity, quality and identification. Then all materials shall be properly stored and protected. Concrete Foundations. The surface of the concrete foundation shall be prepared in accordance with the specification, to receive grout. All concrete foundations on which the steel structures are to be erected shall be released by the QC department upon completion of the civil activity.\\\\ Fasteners (Bolts, Nuts & Washers). Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 43 of Upon receipt on site of the fasteners, a minimum of one sample (1bolt, 1 nut,& 1 washer) shall be selected and tested by an independent laboratory to confirm specification conformance. Assembly Of Grid Frames Material for the necessary grids shall be placed near to the area of erection. This shall be carried out using a suitable trailer & a 50 ton crane.The grid frames for both rows (A&B) shall be assembled. All bolts, washers and nuts shall be fitted, fastened and tightened. Erection Of Columns \ Grid Frames. Stainless steel shim plates to the correct thickness of approx. 25mm shall be placed at the center of the foundation column between the holding down bolts. The shim plates shall be retained in position permanently by surrounding with mortar to avoid shim displacement during the erection of the columns. The shim placed on the foundation shall be embedded in mortar bed such that the top of the shim is level in all planes. The grid frames shall be installed leveled and plumbed on the foundation bases. Stay ropes shall be provided to maintain stability until such time when the horizontal members are connected. The stays shall be secured to purpose made anchor plates attached to adjacent foundations. Foundation bolts shall be only hand tightened. (Necessary tightening or torquing shall be done later after grouting). Horizontal members and the bracings that interconnect these grid frames shall be assembled and erected. The assembly of Verticals and Horizontal members shall be in sections. On completion of each section with all bolts and nuts in place and tightened, the final level and alignment shall be checked and inspected. Grouting After the structural steel frame assemblies have been inspected by the QC department, the application of grouting shall be carried out according to the Specifications & manufacturer’s instructions. Equipment Crane 30Ton\ 50 Ton Flat Bed Trailor to transport fabricated members to the location at site Fork lift – for minor movement of steel members Guy ropes and tensioning equipment Man baskets whenever required Scaffolding (Movable & Non-movable Types) Air Compressor Impact Wrench Welding Generator( if required) Gas Cutting Equipment (if required) Portable Grinding Machines Portable Drilling Machines Exclusively written by PEng Suraj Singh Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 44 of #18 Compressors’ structures RCC column plate inserts Top Index Scope Reference Documents Definition Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement is to define the sequence and methodology that shall be implemented for the inclusion of RCC column plate inserts. Documents Specification Drawing No: Definitions PSM Project Site Manager CM Construction Manager CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource the required materials ensuring that these are implemented according to this procedure. CM shall ensure that all the Safety requirements are implemented and explained to the relevant work force and control the day to day activities. CS shall ensure the implementation of technicalities involved. FM shall control the work force ensuring the full implementation of the procedure. Safety Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed as required. Method 1. Place & fix the column reinforcement be in design locations. 2. Make the fabricated forms ready. 3. Drill the holes on the marked locations on the forms ’2’ sides according to the attached sketch to receive inserts holding bolts. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 45 of 4. Fix the column inserts plates assembly on the fabricated forms and the bolts fastened as per sketch. 5. Erect the forms, support, well secure and concrete pour be carried out. 6. Having the pour been over, before striking the forms, the threaded bolts be taken out. 7. Later the holes left shall be filled with Galvanised threaded rod 15mm long. Equipment Fabricated Plates with Threaded holes, Pins and Bolts. Attachment Sketches #19 Excavation for 132kv cable interconnection Top Comments incorporated Duct bank construction added Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to carry out the excavation in preparation for laying of the 132 KV electric cable from the GUP power station through to the Company project site substation. Reference documents Specification , Excavation & Backfilling for Underground structures. Definitions PSM CM Project Site Manager Construction Manager Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge CS FM Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 46 of Construction Superintendant Foreman Responsibilities The CM shall plan and resource the trench excavation and backfilling activity, in accordance with this method statement. The CS shall control, coordinate and supervise all the activities directing the Construction Foreman The Construction Foreman shall practically execute these activities, direct the workforce as necessary and report to the CS for all day to day operational matters. EPC Contractor shall control all the activities. Safety Prior to the commencement of any activities, the labour force shall receive a tool box talk every day on the project site safety requirements. Any process to be adopted having a particular safety risk shall be assessed and addressed as required. Method Permits for the involved area excavation shall be obtained from the relevant authorities. The surveyor shall set out the proposed route of the electric cable trench per IFC drawings. Any existing services shown on these drawings or on the record drawings shall be located and identified by an EPC Contractor approved method (i.e. catscan). Wherever necessary, trial pits shall be manually excavated to expose the existing services. Wherever, the protection of the existing services are required, adequate protection and warning shall be installed. Cables or pipes that span the excavation shall be supported. Rigid ducts and trays shall be provided to protect and support these cables. All existing services encountered, shall be plotted by the surveyor on an as-built drawing. The trench shall be excavated by a track excavator to the correct lines and levels. Wherever necessary or as defined on the work permit, manual hand excavation shall be carried out. The sides of the excavation shall be sloped. Barriers shall be placed to indicate an open excavation. The excavated material shall be stockpiled along the trench areas for re-use. Surplus material shall be removed to the tip area by dump trucks. The surveyor shall monitor the lines and levels of the excavation activity. Upon EPC Contractor inspection, the excavated trench shall be released for the next operation as indicated upon the activity ITP following which, compaction of the formation level be carried out to the specified density. The field compaction test report shall be submitted. The surveyor shall provide suitable level pins that indicate the correct elevation of the sand bedding required for the cables. The sand bedding shall be laid and compacted in accordance with the specification. The cables shall be placed correctly within the trench in line with the IFC drawings. Cables shall be laid by the electrical department upon completion of which, EPC Contractor release the trench for the backfill and subsequent activities. Suitable approved backfill material shall be placed in layers, compacted around the cable & field tested. Cable tiles and warning tape shall be placed on top of the sand fill per approved drawing. This backfill activity shall continue up to existing ground level & the site left tidy Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 47 of For the construction of the duct banks, the duct pipes shall be laid according to the sectional design details with fixing arrangements, forms erected to the required profiles. The concrete shall be poured at various intermediate locations in the first instance to create temporary downward anchor to counteract any possible duct uplift by the underducts fluid concrete upward pressure. When the arrangement is completed, the whole section be concreted to the defined level & finished accordingly. Major Equipment Cable Markers. Excavation equipment. Dump trucks. Compactors. Attachment None #20 Road crossing for 132 kv route Top Index Scope Reference documents Definitions Responsibilities Safety Method including traffic management scheme Equipment Attachment Scope The purpose of this method statement, is to define the sequence and methodology for the excavation and laying of PVC ducts , that shall cross existing roads at locations identified on the attached drawing part . Reference documents Specification. Excavation & Backfilling for Underground structures. (INTERCONNECTS UNDERGROUND LAYOUT DRAWING SHEET ‘ 5 ‘) Definitions PSM CM CS FM Project Site Manager. Construction Manager. Construction Superintendant Foreman Responsibilities CM shall plan and resource the trench excavation and backfilling activity, in accordance with this method statement. The Construction Foreman shall monitor these activities, directing the workforce as necessary. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 48 of EPC Contractor shall control the service laying activities. Safety Prior to the commencement of any activity, the labour force shall receive a tool box talk on the project site safety requirements. Any process that is adopted having a particular safety risk shall be assessed and addressed as required. A competent inspector shall inspect the trench daily to assess the safety measures adopted as well as after every rainstorm. If required , the shoring shall be provided to prevent the caving in . In case of the trench depth being more than 1200 mm , adequate means of exit such as ladder or steps shall be provided and located no more than 8 m of lateral travel. Barricades , markers and the night lights etc., shall be arranged as required. Method The required permit to work shall be obtained from the Plant Refinery Division. A traffic management scheme that has been presented herein as detailed on the attached sketch for this road crossing which includes, reduced speed sign, temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety barriers,night lighting and road cleaning activities shall be implemented on site after review & approval by EPC Contractor prior to commencing the work.The aforesaid traffic management scheme is described below Traffic Scheme Road Crossing Inter Connects Underground Layout Drg This proposed crossing is located on the road avenue C as shown on the attached sketch This is a 2 way road with a central verge and carrying 2 lanes on either way The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side of the carriage way In the first instance the work shall be carried out on part L1 diverting the traffic to the road portion on the part L2 as shown on the sketch In the second instance the work shall be carried out on part L2 diverting the traffic to the road portion on the completed road portion on the part L1 as shown on the sketch The first reduce speed for traffic diversion informatory board depicting shall be located at 300 m from the point of the proposed crossing, the second depicting diversion sign be located at 200 m and the third depicting men at work sign be located at 100 m on either way in the opposite directions. The first section of road crossing as per the attached sketch shall be marked by the surveyor on the actual road location. Any existing services shall be identified and protected. The asphalt shall be cut using a mechanical cutter machine. The road section shall be excavated to the correct level using mechanical means and removed from the site to stock pile area. The excavated material shall be removed to a stockpile area. Appropriate bedding material shall be placed within the excavated trench to the correct service level. Wherever required, this bedding shall be compacted and tested for field density. The cable ducts or service pipes shall be laid at the required levels and profile according to the drawings as well as the specifications and approved by the EPC Contractor’s Engineer. Backfill around the service pipes shall be carried out with the appropriate approved material. This service pipe surround material shall be compacted complying with the project specifications. Test results shall be reported. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 49 of General fill up to the underside of road formation shall be placed in 150mm layers compacted mechanically complying with the specifications. A concrete slab shall be cast up to the bottom of the finished asphalt level and the finishing done by using approved asphalt mix . The traffic management system shall be removed after the road crossing has been cleaned of any debris or obstructions. Either side of the road shall be provided with cable markers to indicate the services Equipment Excavator . Dump trucks. Compactors. Attachment Sketch showing the traffic diversion. Sketch showing the location of the proposed crossing. #21 Night shift working - earthworks Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement, is to define the procedure that shall be adopted for the earthworks activity during Night Shift. Reference documents Specification Definitions EPC Contractor Civil Contractor IS Infrastructure Superintendent. PSM Project Site Manager SO Safety Officer Responsibilities The PSM shall ensure that adequate site management and supervision is available for night shift working. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 50 of A dedicated SO shall patrol the site during the night shift activities, and where necessary, stopping the work if an unsafe situation arises. The necessary work permits shall be obtained prior to the start of the night shift activities. Safety The SO shall ensure all those persons who shall work on the night shift activities, are fully aware of the safety obligations expected from them. The emergency procedure for first aid shall be explained to every body. (Refer to the safety plan for night shift working). All equipment that shall operate on the site shall be in full working order with appropriate lighting. Method The activities that are schedules to be carried out during night shift comprise of excavation, hauling, stockpiling, spreading, leveling, watering and compaction. These activities do not require any specific QC inspection coverage other than the supervisor surveillance. The IS shall prepare the schedule define the work faces of the night shift activity prior to beginning. The work faces shall be illuminated by using tower-mounted easily repositionable floodlights. The routes which the construction equipment shall use for hauling ‘the excavated materia’, shall be made safe prior to work commencing. The area for stockpiling the material shall also be illuminated. A banksman wearing a high visibility vest shall direct the stockpile area. Similarly, a banksman shall direct the excavation area. The two banksmen shall be in communication with each other by two way communication facilities (mobile phones). The earthwork supervisor and the SO shall patrol the entire site overseeing all activities. Emergency Procedure. The Safety Officer shall be responsible for coordinating the night shift emergency procedure. Upon an emergency arising, the Safety Officer shall be notified. The Safety Officer shall immediately alert the relevant emergency services if so required. 997 for Fire or civil defence 998 for an Ambulance. 999 for Police. The Safety Officer shall notify the Safety Manager of the emergency occurence. Should the camp doctor be required, he shall be notified. The Safety Manager shall attend the emergency and take control of the situation. The required notification, investigation and reporting of the emergency shall be conducted in accordance with the site HSE plan. First Aid. First aid facilities shall be made available for night shift operations at the camp clinic. The Safety Officer shall have the telephone number of the camp doctor who be summoned in the event of first aid requirements and emergencies. Equipment Excavators. Dump trucks. Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 51 of None. (Revised) Additional manufacturer’s instructions for mixing incorporated Form details amended Manufacturer’s method statement attached #22 Grouting to pipe rack foundation bases Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Scope The purpose of this Method Statement is to grout the annular space between the foundation top and the structural steel base plates. Reference Documents Specification Definitions PSM CM CS FM Project Site Manager Construction Manager. Construction Superintendent . Foreman. Responsibilities The CM shall plan and resource the Cementitious grout activities, to ensure that they are implemented according to this procedure, with the correct equipment resources. The CS shall ensure that all safety requirements are implemented and explained to the erection workforce. The CS shall control the day to day activities The FM shall control the workforce ensuring the full implementation of this method statement including all safety measures. Safety Prior to the commencement of any activity, the suitably qualified labour force shall receive a Toolbox Talk on the Project Site Safety Requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed and addressed as required. About the Chemical effect, Masks to be worn, Safety glasses and gloves to be used Areas of Activity to be Barriered Off / No Unauthorized Entry, Sufficient Lighting to be provided where necessary. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 52 of Method The surface to be grouted shall be chipped / scabbled without using mechanical bush hammer to expose the aggregate and remove the laitance. The finished surface shall be free from oil, dust , dirt, paint, curing compounds etc and be soaked in with water for 24 hours prior to grouting to minimize the localized absorption as well as to assist the free flow of the grout. The bolt holes / pockets shall be waterfree prior to placement of grout. The baseplates / bolts shall be clean and free of oil, grease and paint and correctly aligned according to the approved drawings. The stainless steel shims 50x50x10 mm thick shall be in correct locations covered with mortar so as to allow at least 50 mm grout cover on shim sides. The forms as shown on the attached sketch shall be erected on the defined locations provided with chamfers. An electric drill fitted with a paddle shall be used for the grout mixing purpose using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928 according to product datasheet. The mixer shall be clean with no standing water. Let 90 % of the applicable quantity of water required to achieve the desired consistency to meet the batch volume per manufacturer’s datasheet be added to the mixer before adding the grout and the Masterflow be added gradually while simultaneously, pouring in to the mixer the remaining 10 % water quantity during mixing which has to be kept on for at least 3 to 5 minutes until a uniform lump free consistency is achieved. The grout shall be poured continuously using the grout pour cone with a constant hydrostatic head of at least 15 cm Having poured the grout Masterflow 928 in place, cover all exposed grout material with clean damp Hessian and be kept moist until grout is firm enough to accept a curing membrane The temperature range 4 to 32 degree C shall be maintained for the 3 post pour continuous days. The grout thickness varies between 25 to 50 mm. Equipment Peddle Mixer Grout Flow Cone Attachment Sketch Masterflow Catalogue Masterflow Method Statement #23 Cementitious grouting to foundation bases Top Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 53 of Index Scope Reference documents Safety Method Equipment Scope This statement is aimed to propose the procedures to be adopted to grout the base plates of the stationary equipment / vessels foundation bases. Reference Documents Specification Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Method The surface to be grouted shall be chipped / scabbled without using mechanical bush hammer to expose the aggregate and remove the laitance. The finished surface shall be free from oil, dust , dirt, paint, curing compounds etc and soaked with water for 24 hours prior to grouting to minimize the localized absorption as well as to assist the free flow of the grout. The pockets shall be waterfree prior to placement of grout. The baseplates shall be clean and free of oil, grease and paint and correctly aligned in line with the approved drawings. The stainless steel shims 50x50x10 mm thick shall be in correct locations covered with mortar so as to allow at least 50 mm grout cover on shim sides. The forms as shown on the attached sketch shall be erected on the required locations with chamfers. An electric drill fitted with a paddle shall be used for the grout mixing purpose using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928 according to requirement. The mixer shall be clean with no standing water. Let 90 % of the measured quantity of water required to achieve the desired consistency according to the batch volume be added to the mixer before adding the grout and the Masterflow be added gradually ,simultaneously pouring in the remaining 10 % water quantity during mixing , which has to be kept on for at least 3 to 5 minutes until a uniform lump free consistency is achieved. Let the grout be poured continuously using the grout pour cone with a constant hydrostatic head of at least 15 cm Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 54 of Having poured the grout Masterflow 928 in place , cover all exposed grout with clean dampen Hessian and be kept moist until grout is firm enough to accept a curing membrane The temperature range 4 to 32 degree C shall be maintained for the 3 post pour continuous days The grout thickness varies between 25 to 50 mm. Major Equipment Peddle Mixer Grout Flow Cone Attachment Sketch Masterflow Catalogue Masterflow Method Statement #24 Etylene compressor Massive foundation (concrete pour) Top Index Scope Reference Documents Definition Responsibilities Safety Method Attachment Scope The purpose of this method statement is to define the sequence and methodology that shall be implemented for the Concrete pour of the Ethylene Compressor Foundation. Documents Specification Drawing No: Definitions CM Construction Manager CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource the required materials ensuring that these are implemented according to this procedure. CM shall ensure that all the Safety requirements are implemented and explained to the relevant work force and control the day to day activities. CS shall ensure the implementation of technicalities involved. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 55 of FM shall control the work force ensuring the full implementation of the procedure. Safety Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed as required. Method 1. Pour Size = (14.86 x 11.24 – 2.56 x 0.84) 1.7 = 280.2892 approximately 2. Pour Plan = In Strips Courses of each 11.24m x 2m x 0.4m i.e. width wise (8.992 each). 3. Sequence of strips shown in attached details in numbers. 4. Time of Pour commencement 7.30 / 8.00 Hrs. 5. Plants - Concrete Pumps 1No. Batching Plant 1No. Full Time. / Stand by 1No. Transit mixer 7 Nos. 7m³ each Delivery continuous @ 7minutes intervals. 6. Pour Duration 6 to 7 hrs. 7. Equipment:  Vibrator – Pneumatic / Diesel Operated 3 Nos. (2Nos.in use and 1 Stand by) and 3 Nos. on other sites. 8. Curing-Thermal  Immediate Post Pour: By Curing Compound covered by Polythene membrane.  Post Pour Set concrete: By removing Polythene, adding saturated Hessian, recovering with Polythene membrane and filling clean sand 150mm except the column portion which shall be surrounded by small sand embarkments. The sand shall be kept sprayed with water. 9. Water Supply: By tank, full tank ready on site with 50m water hose pipe. 10. Manpower: Concrete Crew  Foreman - 1 No.  Steel fixers – 2 Nos.  Carpenters – 2 Nos.  Masons - 12 Nos.  Helper - 12 Nos. 11. Specifications High Slag blast furnace cement to BS 4246 with 70% replacement utilising 30% ASTM C150 Type II cement for use in massive concrete. 12. Concrete Temperature 30°C. Slump 150 – 175mm Attachment 1 Sketches 2 Plan of Pour 3 Sectional Sequence details of pour layers. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 56 of #25 Propane compressor Massive foundation (concrete pour) Top Index Scope Reference Documents Definition Responsibilities Safety Method Attachment Scope The purpose of this method statement is to define the sequence and methodology that shall be implemented for the Concrete pour of the Ethylene Compressor Foundation. Documents Specification Drawing No: Definitions PSM Project Site Manager CM Construction Manager CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource the required materials ensuring that these are implemented according to this procedure. CM shall ensure that all the Safety requirements are implemented and explained to the relevant work force and control the day to day activities. CS shall ensure the implementation of technicalities involved. FM shall control the work force ensuring the full implementation of the procedure. Safety Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed as required. Method: 1 Pour Size = (12.0 x 7.5 – 2 x 0.44 x 0.78) 1.7 = 151.833 approximately 2 Pour Plan = In Strips Courses of each 7.5 x 2 x 0.4m i.e. width wise (6.0m³ each). 3 Sequence of strips shown in attached details in numbers. 4 Time of Pour commencement 7.30 / 8.00 Hrs. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 57 of 5 Plants - Concrete Pumps 1No. Batching Plant 1No. Full Time. / Stand by 1No. Transit mixer 7 Nos. 7m³ each Delivery continuous @ 7minutes intervals. 6 Pour Duration 5 to 6 hrs. 7 Equipment: a. Vibrator – Pneumatic / Diesel Operated 3 Nos. (2Nos.in use and 1 Stand by) and 3 Nos. on other sites. 8 Curing-Thermal a. Immediate Post Pour: By Curing Compound covered by Polythene membrane. b. Post Pour Set concrete: By removing Polythene, adding saturated Hessian, recovering with Polythene membrane and filling clean sand 150mm except the column portion which shall be surrounded by small sand embarkments. The sand shall be kept sprayed with water. 9 Water Supply: By tank, full tank ready on site with 50m water hose pipe. 10 Manpower: Concrete Crew i. Foreman - 1 No. ii. Steel fixers – 2 Nos. iii. Carpenters – 2 Nos. iv. Masons - 12 Nos. v. Helper - 12 Nos. 11 Specifications 12 High Slag blast furnace cement to BS 4246 with 70% replacement utilising 30% ASTM C150 Type II cement for use in massive concrete. 13 Concrete Temperature 30°C. Slump 150 – 175mm Attachment 1 Sketches 2 Plan of Pour 3 Sectional Sequence details of pour layers. #26 SeaWater Basin Baffle Walls (concrete pour) Top Index Scope Reference Documents Definition Responsibilities Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 58 of Safety Method Attachment Scope For pouring the baffle walls 9 #s located on the deeper end slope of section AA between the PCJ and the commencement of the falls as the width of the slope being 5.35m. Since no provision of the starter rebars has been made for the slope portion at the ‘slab base level’ for the baffle walls to be connected with then to ensure the structural stability, we propose the following operational descriptions for the construction execution of these elements. Documents Drawing No: Definitions PSM Project Site Manager CM Construction Manager CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource the required materials ensuring that these are implemented according to this procedure. CM shall ensure that all the Safety requirements are implemented and explained to the relevant work force and control the day to day activities. CS shall ensure the implementation of technicalities involved. FM shall control the work force ensuring the full implementation of the procedure. Safety Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed as required. Method Stage 1: Pouring the walls in full heights between the wall designated ‘M’ and the construction joints locations. Stage 2: Pouring the portion of the baffle walls between the construction joint and the wall end upto a level of 7.14m from the slab base. Stage 3: Pouring the remaining portion of the baffle walls from the level 7.14 upto the level 13.5 with a simple construction joint at the level of 7.14m. Attachment None. #27 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 59 of SeaWater Basin Minor Concrete Repair at Kicker Face Top Index Scope Definition Responsibilities Safety Equipment Material Method Attachment Scope For minor concrete repair specially at kicker face Filling of Tie rod holes. Reformation of grooves for sealant on floor slabs and walls. Definitions PSM Project Site Manager CM Construction Manager CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource the required materials ensuring that these are implemented according to this procedure. CM shall ensure that all the Safety requirements are implemented and explained to the relevant work force and control the day to day activities. CS shall ensure the implementation of technicalities involved. FM shall control the work force ensuring the full implementation of the procedure. Safety Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Any process that is adopted that may have a particular Safety risk, shall be assessed as required. Use of safety glasses, gloves, mask, etc., shall be made. Equipment ROADCRAFT model #. 5615 NEEDLE Scaler (Light version for removal of rust, welding slag, old paint etc.) Material Material Epoxy bonding agent MBT Concresive 1414 (permanent epoxy adhesive for internal or external bonding for renderings, concrete repairs, bonding concrete to concrete, steel and granolithic toppings) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 60 of MBT Masterflow 544 (High strength, non shrink cementitious mortar ready to use product in powder form requiring only on site addition of water to produce a non–shrink mortar of predictable performance formulated for use at plastic consistency for bedding, repairing, grouting and void filling such as concrete repairs, void filling between old and new concrete, filling tie bar holes etc.) Method 1 The existing surface shall be scabbled, all loose concrete and mortar drippings removed by using a single head scabbler and / or RODCRAFT model # 5615 NEEDLE scaler. 2 Epoxy bonding agent MBT Concresive 1414 shall be applied by brush and allowed to cure. 3 MBT Master flow 544 shall be mixed with water in small pails by hand complying with manufacturer’s data sheet and trowelled onto the surface. 4. Approved curing compound shall be applied immediately 5 A wooden strip 25mm wide X 20 mm deep shall be placed at the centre of the joint on the existing rebates in the floor slabs as well as walls and the space on either side be filled with MBT Master flow 544 to obtain a clear rebate of X-size 25mm x 20 mm followed by removal of the wooden strip within an hour of fill and the reformed surfaces be sprayed with approved curing compound. Attachment Manufacturers Catalogue #28 Seawater basin (water tightness BS 8007: 1987) Top Index Scope Definition Responsibilities Safety Method / Procedures Equipment Attachment Scope To transport the Sea Water to the Sea Water Basin and Testing the basin Definitions PSM Project Site Manager CM Construction Manager CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource the required materials and plants ensuring that these are implemented according to this procedure. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 61 of CM shall ensure that all the Safety requirements are implemented and explained to the relevant work force and control the day to day activities. CS shall ensure the implementation of technicalities involved. FM shall control the work force ensuring the full implementation of the procedure. Safety Prior to the commencement of any activites, the labour force shall receive a toolbox talk on the Project Site Safety requirements. Traffic directory signs for the ramp breakers on 3 nos road crossings shall be installed. On the exposed pipe route the safety tags shall be installed with cones. A protection arrangement shall be made for the plants at the intake. A full time attendant shall keep the watch and ward on the route. Procedures involved Laying a 100 mm dia hose from the sea to the sea water approximately1800 m. Refer to sketch point # 1 to # 8 i.e. intake at sea and discharge to the basin respectively. Constructing a concrete anchor at the sea to fix the intake pipe spout horizontally and vertically as well as to fix 2 # heavy duty centrifugal pumps at point #1 There are 3 nos road crossings en-route at points 2, 5 and 6 on which temporary 150 mm dia pipe sleeves are to be inserted in the form of the ramped speed breakers.Ref to the sketch. Otherwise, sleeves shall be inserted by road cutting, filling and making good when the job is over Install a ‘round the clock’ generator to supply electricity to the pumps with the Distribution Board at point # 1 or to have electric connection through an alternative source. Install a timber clamping platform on the ditch at point # 4 Water Heads calculations indicative only At intake suction 1m At intake disposal 1m Vertical head loss 25 m At point Nos. 8 loss 10 m Total vertical head loss 37 m Length of Pipe for friction loss 1800 m 4 f l v v / 2 g d = 4x.015x1800x1.5x1.5 / 2x 9.81x.1=123.9m Total head loss = static loss + dynamic loss = 37 +123.9 = 160.90 m Work done= 42000x160.9 kgm, bhp = 42000x160.9 / 270000= 25 units, ihp = 35 units The water flow velocity has been assumed to be 1.5 m / sec giving a discharge of 42 cum per hour. It shall take 20 days to reach 20000 cum of water to the basin keeping round the clock pumping. SEA WATER BASIN PLANNED PUMPING DAY # QTYPUMPED IN CUM 1 1008 2 1008 3 1008 4 1008 QTY CUMM CUM 1008 2016 3024 4032 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 62 of 5 1008 5040 6 1008 6048 7 1008 7056 8 1008 8064 9 1008 9072 10 1008 10080 11 1008 11088 12 1008 12096 13 1008 13104 14 1008 14112 15 1008 15120 16 1008 16128 17 1008 17136 18 1008 18144 19 1008 19152 20 1008 20160 21 1008 21168 First phase Testing The tank completed with Protective Coatings as specified and sealant applied shall be cleaned and filled to the normal maximum level to meet the requirement of clause 9.2 BS 8007 : 1987 Testing of structures i.e. upto 11.5 m which should take 14 days and then be retained for a stabilising period of 7 days for a maximum design crack width of 0.1 mm, allowing absorption and the autogenous healing. Test period starts now for 7 days and the drop in level recording be made every 24 hours during this 7 days period. Total permissible drop in level allowing evaporation etc. should not be more than 1 / 500 of the average water depth of the full tank which limits to 10 mm or another specified or calculated amount. Having the test been successful, the backfill shall be carried out Second phase Testing Let the tank be further filled upto 13 m level i.e another 7 days Stabilisation period Another 7 days (for absorption and autogeneous healing) Test period Another 7 days (level drop recording at an interval of 24 hours) Basin Filling and Testing Schedule S# Description of the operation Duration in Remark days 1 Ist phase water pumping 14 Pumping from sea 2 Retained water stabilisation to 7 allow absorption and autogeneous healing 3 Testing at 24 hour intervals and 7 Loss should not be more monitoring than 1 / 500 of average fullwater depth or 10 mm or other specified value Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 63 of but excluding evaporation. 4 Backfilling testing after successful 14 5 II phase water pumping 7 6 Retained water stabilisation and autogeneus healing 7 Testing at 24 hours intervals 7 Pumping from sea 7 8 Water loss monitoring Loss should not be more than 1 / 500 of average fullwater depth or 10 mm or other specified value but excluding evaporation The code provides that notwithstanding the satisfactory completion of the test, any evidence of seepage of the liquid to the outside faces of the liquid retaining walls should be assessed against the requirement of the specification. Any necessary remedial treatment of the concrete, cracks or joints should, where practicable, be carried out from the liquid face. When a remedial lining is applied to inhibit leakage at a crack, it should have adequate flexibility and have no reaction with the stored liquid. Should the structure not satisfy the 7 days test then after the completion of the remedial work, it should be refilled and if necessary, left for a further stabilising period followed by a further test of 7 days’ duration should then be undertaken in accordance with this clause. Equipment. Pumps IHP 35, 2 Nos. Other General Arrangements Attachment Sketch showing the Hose Route #29 Road Crossing for 132 kV route Top Index Scope Reference documents Definitions Responsibilities Safety Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 64 of Method including traffic management scheme Equipment Attachment Scope The purpose of this method statement, is to define the sequence and methodology for the excavation and laying of PVC ducts, that shall cross existing roads at locations identified on the attached drawing part. Reference documents Specification. Excavation & Backfilling for Underground structures. Drawing No. (INTERCONNECTS UNDERGROUND LAYOUT ‘) Definitions PSM CM CS FM Project Site Manager. Construction Manager. Construction Superintendant Foreman Responsibilities CM shall plan and resource the trench excavation and backfilling activity, in accordance with this method statement. The Construction Foreman shall monitor these activities, directing the workforce as necessary. EPC Contractor shall control the service laying activities. Safety Prior to the commencement of any activity, the labour force shall receive a tool box talk on the project site safety requirements. Any process that is adopted having a particular safety risk shall be assessed and addressed as required. A competent inspector shall inspect the trench daily to assess the safety measures adopted as well as after every rainstorm. If required, the shoring shall be provided to prevent the caving in. In case of the trench depth being more than 1200 mm, adequate means of exit such as ladder or steps shall be provided and located no more than 8 m of lateral travel. Barricades, markers and the night-lights etc., shall be arranged as required. Method The required permit to work shall be obtained from the Plant Refinery Division. A traffic management scheme which includes, reduced speed sign, temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety barriers, night lighting and road cleaning activities has been presented herein that shall be produced on site as detailed on the attached sketch for this road crossing. The traffic management scheme shall be reviewed and approved by EPC Contractor prior to commencing the work. The aforesaid traffic management scheme shall be implemented as described below: Traffic Scheme Road Crossing Drawing reference Inter Connects Underground Layout Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 65 of This proposed crossing is located on the road avenue C as shown on the attached sketch. This is a 2 way road with a central verge and carrying 2 lanes on either way The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side of the carriage way. In the first instance the work shall be carried out on part L1 diverting the traffic to the road portion on the part L2 as shown on the sketch. In the second instance the work shall be carried out on part L2 diverting the traffic to the road portion on the completed road portion on the part L1 as shown on the sketch. The first reduce speed for traffic diversion informatory board depicting shall be located at 300 m from the point of the proposed crossing, the second depicting diversion signs be located at 200 m and the third depicting men at work sign be located at 100 m on either way in the opposite directions. The first section of road crossing as per the attached sketch shall be marked by the surveyor on the actual road location. Any existing services shall be identified and protected. The asphalt shall be cut using a mechanical cutter machine. The road section shall be excavated to the correct level using mechanical means and the excavated material removed from the site to stock pile area. Appropriate bedding material shall be placed within the excavated trench to the correct service level. Where required, this bedding shall be compacted and tested. The cable ducts or pipes service shall be laid at the required levels and profile complying with the drawings, the specifications and approved by the EPC Contractor Engineer. Backfill around the service shall be conducted using the appropriate material. This service surround material shall be compacted as per the project specification requirements. Test results shall be provided for the specification conformance verification. General fill up to the underside of road formation shall be placed in 200mm layers and compacted to 150mm using mechanical methods complying with the specification requirements. A concrete slab shall be cast up to the bottom of the finished asphalt level and the finishing shall be done by using approved asphalt mix. The traffic management system shall be removed after the road crossing has been cleared of any debris or obstructions. Either side of the road shall be provided with cable markers to indicate the services Equipment Excavator. Dump trucks. Compactors. Attachment Sketch showing the traffic diversion. Sketch showing the location of the proposed crossing. #30 Administration building Stair landing extension at grid 4 j Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 66 of Top Index Scope Reference documents Definitions Responsibilities Safety Method including traffic management scheme Equipment Attachment Scope The aim of this statement is to define the methodology how the extension to the existing part of the stair first flight landing at grid 4 J shall be effected to and connected to the existing RCC column as well as the correction to the proposed rebars to be placed in the portion of the first flight. Reference documents Definitions PSM CM CS FM Project Site Manager. Construction Manager. Construction Superintendant Foreman Responsibilities CM shall plan and resource the trench excavation and backfilling activity, in accordance with this method statement. The Construction Foreman shall monitor these activities, directing the workforce as necessary. EPC Contractor shall control the service laying activities. Safety Particular safety shall be taken to cover the drilling in concrete activity and the pouring in the resin into the holes. The person grinding the concrete, drilling and filling in wear safety glass, gloves, masks etc. Method The proposed method involves the following procedures: Extend the RCC landing from its existing line to the outside face of the column at grid 4 J. Provide a shear key at the connection as shown for the extension as well as at column face Maintain the flight width 1450 mm as designed keeping the column face flush with the waist line of the first flight. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 67 of Arrange the rebars in the manner to be placed within the above dimensions according to the details on drawing no…... To accomplish the above operations, preparatory works shall be carried out as usual for the form fixing and reinforcement placement. A ground cut for the shear key shall be provided in the middle 1/3 portion 25 mm deep for the bondage according to the sketch shown on the revised drawing ……. which continue across the column face also. Hilti HIT - HY 150 resin anchor system shall be used to dowel in the rebars for the extension portion into the existing RC landing using 16 T dia bars into 22 mm dia. drilled hole 240 mm long according to the manufacturer’s instructions (System already approved). Hilti drill machine TE 75 with 22 mm dia drill bits and the Hilti pouring gun kit 2000 shall be used. The dowels shall be approved by the EPC Contractor engineer. The remaining procedures shall be the usual operations regarding the RCC. Equipment Grinder, Hilti drill TE 75, Drill bits 22 mm dia, Kit 2000, Material HIT HY 150 In Cartridges according to the requirement. Attachment Extract of Drawing #31 SeaWater Basin Minor Concrete Repair at Kicker Face Top Comments incorporated Material already approved Repairable depth shown on the sketch Preparation & application modified Curing method specified MINOR COMMENTS INCORPORATED Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 68 of This statement is aimed to describe the procedures to be used to carry out making good the existing concrete surfaces by rectifying the undulations formed during the slope pour through cut outs on the top side slope shutters by the application of a shrinkage compensated , high strength repair mortar reinforced with acrylic fibres on the broken and the prepared surface. The repairable thickness is only 10 mm. Definitions PSM CM CS FM Project Site Manager Construction Manager Construction Superintendent Foreman Responsibilities CM shall plan and resource all the activities in accordance with this method statement. The Construction Foreman shall monitor these activities, direct the workforce as necessary. EPC Contractor shall control the activities. Safety The work personnel shall be given a Tool Box talk every day before the commencement of any activity relevant to the operational requirements according to the Project Safety Needs. In addition to the general safety measures to use personal safety Equipment, all persons to work on the demolition breaker, and the proprietary products application shall wear gloves, masks safety glasses etc Equipment Hilti Demolition Breaker TE 905 complete Pointed mechanical chisel ( Bushing tool TP-SKHM 60 ) Material EMACO S88C T in bags 25 kg each Sodapcure WH curing compound METHOD A shrinkage compensated , high strength repair mortar reinforced with acrylic fibres The area to be repaired shall be marked on site A depth of 10 mm from the proposed top level of concrete surface on the effected areas shall be broken out to remove all substandard concrete using Hilti demolition breaker. The vertical edges shall be cut with a grinder. The substrata shall be prepared to a rough surface having at least 5-mm amplitude at 20-mm frequency The prepared surface shall be sound, dense, free of all oil, grease, loose and fractured aggregate or other contaminants that could impair adhesion between the repair mortar and the prepared concrete surface. Thoroughly the repairable surface shall be wetted in to provide a ‘saturated surface dry condition’. Any standing water shall be removed prior to application of the mortar is commenced Priming of concrete Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 69 of Prior to the application of EMACO S 88 CT , the concrete shall be wetted out with potable water to give a saturated surface dry condition. No further bonding agent is required as per manufacturer’s instructions. TEMPERATURE CONDITIONS EMACO S 88 CT shall be used when the ambient temperature is between +5 degree Celsius and 50 degree C, otherwise chilled water be utilised to prevent the mix temperature exceeding 32 degree C Substrata temperature should not be less than 5 degree C. In hot weather, areas to be repaired shall be shaded to prevent from direct sunlight MIXING Hand mixing with trowel or similar of EMACO S 88 C T is not permitted according to the manufacturer’s instructions, therefore, a low speed electric drill with paddle attachment with a forced action mixer shall be used. Water addition shall be between 3.5 to 4 litres of potable water per 25-kg bag. The required quantity of water shall be poured into the pre- wetted mixing drum, and mixer started followed by the addition of EMACO S 88 C T powder rapidly and continuously,The mixing shall continue for 3 to 4 minutes after all the powder has been added until the mortar is homogeneous and lump free More water shall be added within the limits given, if necessary,until the required consistency is achieved and mixed for a further 1-minute. APPLICATION After mixing, EMACO S 88 C T , the material shall be trowel applied by forcing into the prepared substrate ensuring intimate contact and good compaction The surface of the placed mortar shall be levelled using a wooden float. Final finishing mat is done with a steel trowel. CURING Curing shall be done by spraying the approved compound SODAPCURE WH A polythene membrane shall be used to protect the finished surface from the wind blown sand. Attachment Manufacturer’s method statement Sketch showing section #32 Fencing Top Index Scope Reference documents Definitions Responsibilities Safety Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 70 of Method Equipment Attachment Scope The purpose of this method statement, is to define the sequence and methodology for the construction and erection of the site security fencing. Reference documents Specification Standard Drawing Standard Drawing Site Fence Location drawing Definitions PSM CS Project Site Manager. Construction Superintendent. Responsibilities The CS shall plan and resource the fencing activities, to ensure that they are constructed and erected according to the specifications. The Construction Foreman shall monitor the precasting and erection activities, directing the workforce as necessary. Safety Prior to the commencement of any activities, the labour force shall receive a tool box talk on the project site safety requirements. Any process that is adopted that may have a particular safety risk, shall be assessed and addressed as required. Method Precast elements. A precast yard shall be established as shown on the attached sketch. The casting beds shall be such that pouring, stripping, curing and coating can be achieved easily. A casting cycle of 4 days is anticipated for casting, initial curing and coating, prior to removal to site. Easily assembled and stripped steel prefabricated moulds shall be utilized for the fence foundation and ground beam. Fence erection. The final grade level of the area shall be the commencement point for the fence construction. A level survey shall demonstrate the accuracy of the site grading activity. The Survey Team shall set out the line and level of the fence, including post locations for all elements. Using a machine mounted auger, 300 and 450mm diameter holes as appropriate, shall be drilled for the fence post foundations. The drilled holes shall be cleaned and bedded to the correct base level. The fence post foundation shall be placed in the drilled hole to the correct line and level. Dune sand shall be compacted around the foundation. The fence fabric shall be strung and tensioned as per the drawing details and manufacturers recommendations attached items 1.14 through 1.21 Using hand tools, a trench shall be excavated for the ground beam. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 71 of The ground beam shall be placed to the correct line and level. Suitable fill material shall be used to compact around the ground beam. The fence fabric tie staple shall be grouted in position once the fence fabric is tensioned. The gap between the ground beams, at the location of the fence post, shall be concreted to form a continuous beam. QC procedures shall be closed out on an on-going basis. Equipment Concrete Mixer truck. Auger machine. Wagon with hyab. Plate compactor. Attachment Drwg no: Drwg no: Method statement for Link Middle East Ltd, Fence manufacturer. #33 Administration building Ceramic tiles flooring system Top Index Scope Definitions Responsibilities Safety Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to construct the ‘ceramic tiles flooring system’ which involves the laying of the bedding screed as well as the finishing layer with grouting the joints including movement joints. Reference documents Drawing Nos. Specifications UBC & general construction practice Definitions PSM CSM Project Site Manager Construction Manager Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge CS FM QC Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 72 of Construction Superintendent Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety The workers shall receive a Tool Box Talk according to the project requirement relevant to the operation concerned every day prior to commencement of the activity Proper illumination shall be provided in the dark area The area to be tiled shall be closed for the general movement except those working there and be opened only when the tiling has properly been completed with hardboard cover protection spread on the newly laid flooring. Materials Ceramic floor tiles 300 x 300 x 10mm, For General Area ‘RAK GP 21 G’ and for wet areas Johnson ‘Athena’ Joint filling grout – Approved proprietary material with matching shade. Method (Laying ceramic floor tiles by SEMI DRY method) The areas of concrete sub strata to be tiled shall be brush cleaned and dampened until absorption ceases followed by the finished floor level establishment by means of dots and rules. The total thickness of the ceramic tile flooring is 100 mm which includes 90 mm bedding screed (1 cement: 4 mortar sand) by weight and shall be applied as described below. The finishing layer shall be ceramic tiles 10 mm thick and be laid as described below. The mortar for bedding the tiles shall be 1 part cement to 4 parts sand by weight, mixed semi dry by a mechanical mixer with only sufficient water added to give a crumbly consistency which retains its shape when squeezed by hand permitting no fluidity The mix shall be placed to a thickness approximately 10 mm greater than that actually required for the bed, thoroughly compacted by tamping and drawing off to the required level with a screed board. Only sufficient mortar shall be mixed and spread as can be covered with tiles before it attains its initial set. Civil Contractor QC visual inspection shall be conducted A slurry of 1 part cement to 1 part sand by volume shall be poured over the surface of the semi – dry mix bedding and spread with a trowel until it is approximately 2 mm thick Dry tiles shall then be laid on the slurry and beaten firmly into position with a wooden beater ensuring a true surface contact between the tiles and bedding is formed. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 73 of The tiles shall be correctly positioned in both directions the time these are placed forming joints using a proprietary tile spacer ( 1.5 mm for wall tiles and 3 mm for floor tiles) The tiles shall neatly and accurately be cut to a close fit where necessary at abutments, around outlets, pipes and the like. Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment and the level profile The tiles shall be laid level or to 1- % falls in ‘wet’ areas as may be required. Localised variations in level for a nominally flat floor shall be a maximum of +- 2-mm under a 3-meter straight edge. Particular care shall be taken in ‘wet’ areas to prevent low spots that may promote water pooling. The tolerance in the overall level shall not be more than 10 mm from required finishes. (Reef STQ ) Grouting of the joints shall be carried out within a period of not less than 24 hours after completion of laying of tiles so as to allow the grout attach itself firmly to the bedding. MOVEMENT JOINTS IN TILED FLOORS Unless otherwise indicated in the documents, a 10 mm movement joint shall be formed at the perimeter of all the tiled floors and where the tiling meets structural features such as columns, machine bases etc., Where a structural movement joint is provided in the base, a movement joint of the same width in the bedded finish shall be positioned immediately above The movement joint cavities shall extend through the combined thickness of the finish and the bedding mortar, completely filled and sealed after grouting of the normal joints takes place. Major Equipment Mechanical Mixer Wheel barrows Mason’s tools in general Attachment None #34 Administration building Ceramic tiles flooring system Top Index Scope Definitions Responsibilities Safety Material Method Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 74 of Attachment Scope This statement is aimed to propose the procedures to be adopted to construct the ‘ceramic tiles flooring system’ which involves the laying of the bedding screed as well as the finishing layer with grouting the joints including movement joints. Reference documents Drawing Nos. Specifications UBC & general construction practice Definitions PSM CSM CS FM QC Project Site Manager Construction Manager Construction Superintendent Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety The workers shall receive a Tool Box Talk according to the project requirement relevant to the operation concerned every day prior to commencement of the activity Proper illumination shall be provided in the dark area The area to be tiled shall be closed for the general movement except those working there and be opened only when the tiling has properly been completed with hardboard cover protection spread on the newly laid flooring. Materials Ceramic floor tiles 300 x 300 x 10mm, For General Area ‘RAK GP 21 G’ and for wet areas Johnson ‘Athena’ Joint filling grout – Approved proprietary material with matching shade. Method (Laying ceramic floor tiles by SEMI DRY method) A continuous procedure to lay tiles over the cement mortar screed The areas of concrete sub strata to be tiled shall be brush cleaned and dampened until absorption ceases followed by the finished floor level establishment by means of dots and rules. The total thickness of the ceramic tile flooring is 100 mm which includes 90 mm bedding screed (1 cement: 4 mortar sand) by weight and shall be applied as described below. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 75 of The finishing layer shall be ceramic tiles 10 mm thick and be laid as described below. The mortar for bedding the tiles shall be 1 part cement to 4 parts sand by weight, mixed semi dry by a mechanical mixer with only sufficient water added to give a crumbly consistency which retains its shape when squeezed by hand permitting no fluidity The mix shall be placed to a thickness approximately 10 mm greater than that actually required for the bed, thoroughly compacted by tamping and drawing off to the required level with a screed board. Only sufficient mortar shall be mixed and spread as can be covered with tiles before it attains its initial set. Civil Contractor QC visual inspection shall be conducted A slurry of 1 part cement to 1 part sand by volume shall be poured over the surface of the semi – dry mix bedding and spread with a trowel until it is approximately 2 mm thick Dry tiles shall then be laid on the slurry and beaten firmly into position with a wooden beater ensuring a true surface contact between the tiles and bedding is formed. The tiles shall be correctly positioned in both directions the time these are placed forming joints using a proprietary tile spacer ( 1.5 mm for wall tiles and 3 mm for floor tiles) The tiles shall neatly and accurately be cut to a close fit where necessary at abutments, around outlets, pipes and the like. Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment and the level profile The tiles shall be laid level or to 1- % falls in ‘wet’ areas as may be required. Localised variations in level for a nominally flat floor shall be a maximum of +- 2-mm under a 3-meter straight edge. Particular care shall be taken in ‘wet’ areas to prevent low spots that may promote water pooling. The tolerance in the overall level shall not be more than 10 mm from required finishes. (Reef STQ Q) Grouting of the joints shall be carried out within a period of not less than 24 hours after completion of laying of tiles so as to allow the grout attach itself firmly to the bedding. Movement joints in tiled floors Unless otherwise indicated in the documents, a 10 mm movement joint shall be formed at the perimeter of all the tiled floors and where the tiling meets structural features such as columns, machine bases etc., Where a structural movement joint is provided in the base, a movement joint of the same width in the bedded finish shall be positioned immediately above The movement joint cavities shall extend through the combined thickness of the finish and the bedding mortar, completely filled and sealed after grouting of the normal joints takes place. Major Equipment Mechanical Mixer Wheel barrows Mason’s tools in general Attachment None #35 Administration building Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 76 of Plastering and rendering Top Index Scope Definitions Responsibilities Safety Material Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be implemented for carrying out the plastering and rendering operations. The term ‘plastering’ herein is meant for the internal surfaces while ‘rendering’ for the external. Reference documents Drawing Nos. Project specifications Nos. (For Sand) BS Code 1199, Table 1, (for Hydrated Lime) BS Code 890 Class B, (for cement) ASTM C150, (for galvanized metal lath, stops and beads) BS 1369, (for preparation and application) UBC Definitions PSM CM CS FM Project Site Manager. Construction Manager. Construction Superintendant Foreman Responsibilities CM shall plan and organise the Plastering and Rendering works in accordance with this Method Statement. The Construction Foreman shall monitor these activities, directing the workforce as per Site requirements. Safety Prior to the commencement of work, the labour force shall receive the tool box talk on the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be assessed as required as per Site conditions and shall be taken care of. In addition to that proper mason’s scaffolding arrangements shall be made for providing access to the required heights adopting all relevant safety measures. Method Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 77 of Preparation of backgrounds to be plastered or rendered All surfaces to be plastered and rendered shall be thoroughly cleaned of all dust and loose particles. Concrete surfaces shall be scabbled by mechanical means to remove all laitance exposing the aggregates to 3 mm depth Civil Contractor / EPC Contractor inspections shall be conducted for the approval of the prepared surfaces. A slurry coat consisting of 400 kg Cement (white) to 1 cum of sand (No. 1 White Silica) as specified shall be applied on the surface by trowel and 1-day allowance given for the succeeding coat to commence with. Block work surfaces shall have the joints raked out as specified (Ref) during construction. Junctions of different background and the chases for the electrical conduits as well as other service pipes shall be treated by fixing 200mm wide metal lath. Plastering shall not commence until all the mechanical and electrical services, conduits, pipes and Ist stage fixtures have been installed and approved. Where a rendering or plaster is to be continuous across backgrounds of different types, a strip of metal lath minimum 300 mm wide with an isolating membrane of polythene sheet or building paper behind, shall be fixed across the junction. Where small widths of one material less than 300 mm wide are involved e.g. a concrete column, beam or slab dividing block panels, the width shall be bridged completely for a distance of 150 mm on both sides. The metal lath shall be stretched out and fixed along each edge at 100 mm centres using stainless steel fasteners such as washers and shot fired pins, nails or screws and lapped joints tied with galvanized wire, the screws fixed into plugs in predrilled holes if so required. Metal lath shall not be provided where drawing shows a groove in the rendering or the plaster. Fixing beads and stops Beads, stops and the like shall be fixed plumb, square and true to line with clout nails or plaster dabs at not more than 600 mm centres to each mesh wing. Corner / angle beads at all openings as well as plaster ground stops at terminals shall be installed by using stainless steel fasteners. Profile dots shall be formed on the surfaces. Civil Contractor / EPC Contractor inspection shall be conducted for the proposed profile approval. Preparation of mixes for plastering or rendering Slurry coat 400 kg cement: 1 cum sand Second and third coats 300 kg cement: 50 kg lime: 1 cum sand Plaster thickness 19 mm walls and 14 mm ceilings The hydrated lime shall first be thoroughly mixed with sand and then cement added keeping mixer on until the material is uniform in appearance, suitable to receive water which at this stage be added in sufficient quantity to produce the mix stuff workable, uniform in colour and consistency. To improve the workability of the mix, the hydrated lime, sand and water may first be mixed in the required proportion with allowance to stand undisturbed for at least 16 hours before mixing Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 78 of with cement. If allowed to stand for a longer period, the ingredients mix must be protected from drying out. The whole of the batch shall be used within an hour of being mixed Application of the various plaster or render coats The work shall not start until the background has been prepared and all the services have been finished according to requirement and the relevant specifications as described earlier. Slurry coat shall be trowel applied allowing at least one day to start the succeeding coat Two render coat applications shall be carried out. Before applying any coat, the background or the preceding coat shall be brushed down to remove any loose particles and dampened sufficiently to ensure uniform absorption. First coat shall be trowel applied and scored to form a key for the second coat allowing at least one day before the start of the next coat. The undercoat shall be applied either by laying on with or throwing from a trowel or float, as uniformly thick as possible and not less than 8 mm or more than 13 mm thick in any part. The undercoat shall be left rough and open by the edge of the trowel after it has been long enough to set firm, be combed with evenly spaced wavy horizontal lines approximately 20 mm apart and 5 mm deep (less in case of first coat on metal lathing). The surface shall not be scratched, however, when it is to receive a Tyrolean finish. First undercoat applied to metal lathing shall be well worked into the lath to ensure that the material is completely embedded. The finishing coat shall be steel trowel applied The finishing coat shall not be less than 5 mm or more than 10 mm thick and shall be laid on with a trowel and finished with a steel float, taking care not to over work the surface. All coats shall be applied with firm pressure to exclude air and to ensure a good bond. Plaster shall be rodded and straightened to uniform surfaces in true planes. Laps of one coat shall not occur over laps of preceding coat. Each coat shall finish free from cracks, checks or other structural defects. Finish surfaces shall be flush with grounds / stop beads, corner beads, outlet boxes and similar details, free from trowel marks, other blemishes displaying straight arises and true angles. All coats shall be prevented from drying out too quickly and the work be carried out in shade during hot period. All renderings shall be protected by properly constructed hessian or similar screen during hot period Each coat shall be kept damp by means of a fog spray of water for a minimum of 3 days to allow before a subsequent coat is applied or in the case of a finish coat, before the protective screens are removed The surface of the finish coat shall be smooth, true and free from waviness, irregularities or blemishes with straight, level or plumb angles. External angles shall be pencil rounded Care shall be taken when rendering up to beads or stops to avoid excessive polishing at the arris and damage to the galvanizing. Inspections for the approval shall be conducted. Equipment Mixer Attachment. None #36 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 79 of Administration building Roofing system Top Index Scope Definitions Responsibilities Safety Material Method Equipment Attachment Scope This statement is aimed to present the procedures, sequences of operations and all the other details that shall be worked on the proposed roofing system to be laid over the suspended roof slabs. Reference documents Drawings Nos. Specifications, Construction practice Definitions PSM CM CS FM Project Site Manager. Construction Manager. Construction Superintendant Foreman Responsibilities CM shall plan and organise the works to be carried out by the specialist contractor in accordance with this Method Statement. The Construction superintendent shall control , monitor and direct the Foreman regarding the operations as required The Construction Foreman and the supervisor of the specialist contractor shall execute the work according to the CS direction and direct the work personnel to carry out the operations as per Site requirements. Safety Prior to the commencement of work, the labour force shall receive the tool box talk on the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be assessed as required as per Site conditions and shall be taken care of. In Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 80 of addition the work shall not be carried out during fast winds and dust storms. All workers shall use masks and safety glasses in addition to other PPE. The insulation boards shall be protected from the excessive exposure to sunlight. Specialist Contractor Materials DERBIT PASTA, DERBIGUM UNIGUM, MGP, ROOF MASTER, TERRAM 700, PRECAST CONCRETE TILES 500 X500 X50 MM form part of MAR 046 were approved subject to the comments . The clarification on the DERBIGUM MGP – This is the membrane flashing from the same manufacturer of horizontal membrane and is a product finished with mineral granules to make it solar reflective as well as UV resistant, shall be used for the reason that: It is not recommended to mix a self adhesive membrane with a torch applied membrane as both are not compatible From the experience in this climate it has been observed that the textured Aluminium faced membrane tends to delaminate after a few months if left exposed (due to the different co –efficient of expansion between the metal and the bitumen) For the aforesaid reasons the manufacturer recommend a mineral granules faced membrane as these special solar reflective granules are spread over the bitumen while still hot and form part of the roof membrane.This flashing membrane complements the main roof membrane and with this combination on vertical exposed areas the performance is guaranteed for the specified period. Aluminium Flashing- MAR 113 Dated 8.2.2000 It is confirmed that the proposed Aluminium Flashing for the roof upstands is a plain mill finish manufactured to BS 1470 / ASTM B 209 Alloy, H 14 mill finish Method The roofing system shall be carried out to the following operational sequences. Construction of all large foundation pads if any, prior to the commencement of the system laying. Preparing the proposed area over RCC slab, parapet walls and upstands ready by fixing in positions all roof drains, cleaning the roof etc., Laying the Light Weight screed using foam concrete Constructing an angle fillet around Priming with DERBIT PASTA and applying DERBIGUM UNIGUM the water proofing membrane over the screed. Applying flashing membrane MGP over the vertical exposed part of water proofing layer Water test for 72 hours Laying ROOF MASTER insulation boards 75 mm thick Laying in TERRAM 700 membrane Laying loose the precast concrete tiles 500 x 500 x 50 mm Installing Aluminium flashing as specified and approved On the existing RCC suspended slab all large foundations if any, shall be constructed prior to commencing any roofing system operation. A groove shall be formed around the periphery of the area, pad foundations and other upstands at a specified height from the slab level for tugging the water proofing membrane into the parapet with sealant applied over. All services drains or other necessary items required to be in place prior to the roofing starts shall be completed in all respects including grouting. The area shall be cleared and made dry. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 81 of Inspection shall be conducted. The lightweight screed using special foam concrete shall be laid in to the following mix design to produce a density of 650 to 750 Kgs / cum Sand / Cement: 1 / 1 Cement: 350 Kg / cum Sand: 350 Kg / cum Water: 210 Lit / cum Foaming agent: 1.2 Lit / cum The ingredients shall be mixed using a mechanical mixer, an aerator and a pump. The surfaces to be laid with screed shall be formed using mortar dabs to the specified profiles to 1 % slope. The foam concrete screed shall be laid in two layers to avoid settlement. The second layer shall be laid when the first has dried out followed by forming smooth finish to the required falls and cross-falls Inspection shall be conducted The completed screed shall be cured with fresh water for two days and thereafter, left for one day to dry out. A cement sand angle fillet of 50 x 50 mm triangular cross section shall be formed at all directional changes. Before laying in water proofing membrane, a coat of DERBIT PASTA bituminous primer shall be applied to all the proposed surfaces. Once dried, laying in 4 mm DERBIGUM UNIGUM membrane shall be commenced with by full torching over the primed screed allowing 100 mm wide side and end overlaps. The dressing shall be carried out over the angle fillet and upstands properly terminating into the preformed grooves by tugging the membrane into the groove as well as rainwater outlets and around penetrations. The exposed vertical surface of the membrane shall be protected by applying 4 mm thick MGP flashing membrane 300 mm girth, mineral surface finished, UV resistant, torched over main membrane and tugged into groove as aforesaid. Inspection shall be conducted The surface shall be flooded with water for a period of 72 hours after plugging in all the roof drains After successful completion of the test, water shall be drained out and the membrane left for being dried out. The ROOF MASTER insulation boards with rebated edges 75 mm thick shall be laid over the dry membrane ensuring all areas are properly covered. The TERRAM 700-filter membrane with 100 mm overlaps shall be laid over top of the insulation boards. All small and light precast pedestals / foundations for the cable trays, pipe supports etc., if any, shall be loosely laid over the filter membrane. Inspection shall be conducted by the manufacturer’s representative and all coordinations made. A warranty for the specified period of 10 years shall be issued by the specialist contractor and the Civil Contractor according to the contract requirement The concrete paviors in the form of pre cast concrete tiles 500mm x 500 mm x 50 mm shall be laid loose over the ITALPROFILI PVC TILE PADS to be provided at all the intersections and Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 82 of at the corners as shown on the sketch. At the borders where cut tiles may be required, gravels of nominal size 15 – 30 mm filling shall be carried out to create a good aesthetic. The membrane shall be tugged into the groove and sealed with JOINT SEAL bituminous Mastic. Plain mill Aluminium flashing 0.90mm thick, 80 mm girth, cut and bent to the required profile shape shall be fixed with stainless steel screws above the groove covering and protecting the sealant all according to details. Major Equipment Mixer Aerator Pump Attachment #37 Buildings Roofing system Top Index Scope Safety Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the operations on the proposed roofing system over the suspended slabs on buildings. Reference documents Drawings Nos. Specifications, Construction practice Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 83 of A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Specialist Contractor M / S Al Nahda Contracting and Trading Company Limited PO Box # 1053, Sharjah Materials DERBIT PASTA, DERBIGUM UNIGUM, MGP, ROOF MASTER, TERRAM 700, PRECAST CONCRETE TILES 500 X500 X50 MM form part of MAR were approved subject to the comments. The clarification on the DERBIGUM MGP – This is the membrane flashing from the same manufacturer of horizontal membrane and is a product finished with mineral granules to make it solar reflective as well as UV resistant, shall be used for the reason that: It is not recommended to mix a self-adhesive membrane with a torch-applied membrane, as both are not compatible From the experience in this climate it has been observed that the textured Aluminium faced membrane tends to delaminate after a few months if left exposed (due to the different co – efficient of expansion between the metal and the bitumen) For the aforesaid reasons the manufacturer recommend a mineral granules faced membrane as these special solar reflective granules are spread over the bitumen while still hot and form part of the roof membrane. This flashing membrane complements the main roof membrane and with this combination on vertical exposed areas, the performance is guaranteed for the specified period. Aluminium Flashing- MAR It is confirmed that the proposed Aluminium Flashing for the roof upstands is a plain mill finish manufactured to BS 1470 / ASTM B 209 Alloy, H 14 mill finish Method The roofing system shall be carried out to the following operational sequences. On the existing RCC suspended slab all large foundations if any, shall be constructed prior to commence any roofing system operation. A groove shall be formed around the periphery of the area, on the pad foundations and other upstands at a specified height from the slab level for tugging waterproofing membrane into the parapet with sealant applied over. All services drains or other necessary items required to be in place prior to the roofing commences, shall be completed in all respects including grouting. The area shall be cleared and made dry. An Civil Contractor QC Inspection shall be conducted. The lightweight screed using special foam concrete shall be laid in to the following mix design to produce a density of 650 to 750 Kgs / cum Sand / Cement: 1 / 1 Cement: 350 Kg / cum Sand: 350 Kg / cum Water: 210 Lit / cum Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 84 of Foaming agent: 1.2 Lit / cum The ingredients shall be mixed using a mechanical mixer, an aerator and a pump. The surfaces to be laid with screed shall be formed using mortar dabs to the specified profiles to 1 % slope. The ‘foam concrete screed’ shall be laid in two layers to avoid settlement. The second layer shall be laid when the first has dried out followed by forming smooth finish to the required falls and cross-falls An Civil Contractor QC Inspection shall be conducted The completed screed shall be cured with fresh water for two days and thereafter, left for one day to dry out. A cement sand angle fillet of 50 x 50 mm triangular cross section shall be formed at all directional changes. Before laying water proofing membrane, a coat of DERBIT PASTA bituminous primer shall be applied to all the proposed surfaces. Once dried, laying in 4 mm DERBIGUM UNIGUM membrane shall be commenced with by full torching over the primed screed allowing 100mm wide side and end overlaps. The dressing shall be carried out over the angle fillet and upstands properly terminating into pre formed grooves by tugging the membrane into the groove as well as rainwater outlets and around penetrations. Exposed vertical surface of the membrane shall be protected by applying 4 mm thick MGP flashing membrane 300 mm girth, mineral surface finished, UV resistant, torched over main membrane and tugged into groove as aforesaid. Application on the AC foundation & upstands shall be carried out according to the details shown on the sketch A Civil Contractor QC Inspection shall be conducted & ITP signed off Whole surface shall be flooded with water for a period of 72 hours after plugging in all roof drains After successful completion of the test, water shall be drained out and the membrane left to dry out. ROOF MASTER insulation boards with rebated edges 75 mm thick shall be laid over the dry membrane ensuring all areas are properly covered. TERRAM 700-filter membrane with 100-mm overlaps shall be laid over top of the insulation boards. All small and light pre cast pedestals / foundations for the cable trays, pipe supports etc., if any, shall be loosely laid over the filter membrane. An inspection shall be conducted by the manufacturer’s representative and all coordination made. A warranty for the specified period of 10 years shall be issued by the specialist contractor and the Civil Contractor according to the contract requirement Concrete paviors in the form of pre cast concrete tiles 500mm x 500 mm x 50 mm shall be laid loose over ITALPROFILI PVC TILE PADS to be provided at all the intersections and at the corners as shown on the sketch. At the borders where cut tiles may be required, gravel(nominal size 15 – 30 mm) filling shall be carried out to create a good aesthetic. The membrane shall be tugged into the groove and sealed with JOINT SEAL bituminous Mastic. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 85 of Plain mill Aluminium flashing 1 mm thick, 80 mm girth, cut and bent to the required profile, shall be fastened with stainless steel screws above the groove, covering and protecting the sealant all according to details. Major Equipment Mixer, Aerator, Pump Attachment Sketch (Typical upstands and at AC Foundation) Sub Contractor’s method Statement Clarification regarding DERBIGUM MGP Clarification regarding Aluminium Flashing Clarification regarding 10 years guarantee Clarification regarding 72 hours water test #38 Buildings Roofing system Top Index Scope Safety Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the operations on the proposed roofing system over the suspended slabs on buildings. Reference documents Drawings Nos. Specifications, Construction practice Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 86 of A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Specialist Contractor M / S Al Nahda Contracting and Trading Company Limited PO Box # 1053, Sharjah Materials DERBIT PASTA, DERBIGUM UNIGUM, MGP, ROOF MASTER, TERRAM 700, PRECAST CONCRETE TILES 500 X500 X50 MM form part of MAR 046 were approved subject to the comments. The clarification on the DERBIGUM MGP – This is the membrane flashing from the same manufacturer of horizontal membrane and is a product finished with mineral granules to make it solar reflective as well as UV resistant, shall be used for the reason that: It is not recommended to mix a self-adhesive membrane with a torch-applied membrane, as both are not compatible From the experience in this climate it has been observed that the textured Aluminium faced membrane tends to delaminate after a few months if left exposed (due to the different co – efficient of expansion between the metal and the bitumen) For the aforesaid reasons the manufacturer recommend a mineral granules faced membrane as these special solar reflective granules are spread over the bitumen while still hot and form part of the roof membrane. This flashing membrane complements the main roof membrane and with this combination on vertical exposed areas, the performance is guaranteed for the specified period. Aluminium Flashing- MAR It is confirmed that the proposed Aluminium Flashing for the roof upstands is a plain mill finish manufactured to BS 1470 / ASTM B 209 Alloy, H 14 mill finish Method The roofing system shall be carried out to the following operational sequences. On the existing RCC suspended slab all large foundations if any, shall be constructed prior to commence any roofing system operation. A groove shall be formed around the periphery of the area, on the pad foundations and other upstands at a specified height from the slab level for tugging waterproofing membrane into the parapet with sealant applied over. All services drains or other necessary items required to be in place prior to the roofing commences, shall be completed in all respects including grouting. The area shall be cleared and made dry. A Civil Contractor QC Inspection shall be conducted. The lightweight screed using special foam concrete shall be laid in to the following mix design to produce a density of 650 to 750 Kgs / cum Sand / Cement: 1 / 1 Cement: 350 Kg / cum Sand: 350 Kg / cum Water: 210 Lit / cum Foaming agent: 1.2 Lit / cum Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 87 of The ingredients shall be mixed using a mechanical mixer, an aerator and a pump. The surfaces to be laid with screed shall be formed using mortar dabs to the specified profiles to 1 % slope. The ‘foam concrete screed’ shall be laid in two layers to avoid settlement. The second layer shall be laid when the first has dried out followed by forming smooth finish to the required falls and cross-falls A Civil Contractor QC Inspection shall be conducted The completed screed shall be cured with fresh water for two days and thereafter, left for one day to dry out. A cement sand angle fillet of 50 x 50 mm triangular cross section shall be formed at all directional changes. Before laying water proofing membrane, a coat of DERBIT PASTA bituminous primer shall be applied to all the proposed surfaces. Once dried, laying in 4 mm DERBIGUM UNIGUM membrane shall be commenced with by full torching over the primed screed allowing 100mm wide side and end overlaps. The dressing shall be carried out over the angle fillet and upstands properly terminating into pre formed grooves by tugging the membrane into the groove as well as rainwater outlets and around penetrations. Exposed vertical surface of the membrane shall be protected by applying 4 mm thick MGP flashing membrane 300 mm girth, mineral surface finished, UV resistant, torched over main membrane and tugged into groove as aforesaid. Application on the AC foundation & upstands shall be carried out according to the details shown on the sketch A Civil Contractor QC Inspection shall be conducted & ITP signed off Whole surface shall be flooded with water for a period of 72 hours after plugging in all roof drains After successful completion of the test, water shall be drained out and the membrane left to dry out. ROOF MASTER insulation boards with rebated edges 75 mm thick shall be laid over the dry membrane ensuring all areas are properly covered. TERRAM 700-filter membrane with 100-mm overlaps shall be laid over top of the insulation boards. All small and light pre cast pedestals / foundations for the cable trays, pipe supports etc., if any, shall be loosely laid over the filter membrane. An inspection shall be conducted by the manufacturer’s representative and all coordination made. A warranty for the specified period of 10 years shall be issued by the specialist contractor and the Civil Contractor according to the contract requirement Concrete paviors in the form of pre cast concrete tiles 500mm x 500 mm x 50 mm shall be laid loose over ITALPROFILI PVC TILE PADS to be provided at all the intersections and at the corners as shown on the sketch. At the borders where cut tiles may be required, gravel(nominal size 15 – 30 mm) filling shall be carried out to create a good aesthetic. The membrane shall be tugged into the groove and sealed with JOINT SEAL bituminous Mastic. Plain mill Aluminium flashing 1 mm thick, 80 mm girth, cut and bent to the required profile, shall be fastened with stainless steel screws above the groove, covering and protecting the sealant all according to details. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 88 of Major Equipment Mixer, Aerator, Pump Attachment Sketch (Typical upstands and at AC Foundation) Sub Contractor’s method Statement Clarification regarding DERBIGUM MGP Clarification regarding Aluminium Flashing Clarification regarding 10 years guarantee Clarification regarding 72 hours water test #39 Cracked gas compressor table top concrete pour Top Index Scope Reference documents Definitions Responsibilities Safety Method including traffic management scheme Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to pour the Table Top of the framed beam structure. References Drawing nos. Specifications and Rev D Safety Prior to the commencement of work, the labour force shall receive the tool box talk on the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be assessed as required as per Site conditions and shall be taken care of. In addition proper scaffolding according to the project requirements shall be erected around the area to be poured along with providing complete access system such as stepped stairs and the working platforms with top and the bottom guardrails. The area shall be cleared on ground allowing free access to the concrete pumps, transit mixers water tank etc., and the provision of the night lights shall be made for curing Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 89 of Materials The gross volume of the pour is 173 cum The volume of the steel plates inserts is 1.08 cum The applicable volume of the pour is 170 cum approximately. (Details of the calculations attached). According to the specification the pour pertains to the definition of massive structure, hence C 30 high slag blast furnace cement to BS 4246 with 70 % replacement utilising 30 % ASTM C 150 Type II cement shall be utilised for the batching according to the specified design mix with the placing temperature not more than 24 degree Celcius Curing materials such as curing compound, polythene sheets, bur lap sheets / hessians and water shall be available according to the requirement Plants and Equipment Batching plant 1 # and 1 standby Concrete pump 1 # and 1 stand by Transit mixers 6# Vibrator 2 # and 2 standby Water tanker 1# Manpower Masons 6# Carpenters 3# Steel fixers 3# Scaffolder 3# Helpers 7# Method The drawing shows the above pour to be carried out into 13 sections by forming 16 construction joints. Pour sequences are described as Pour ‘A’ and Pour’B’. A total of 5 pours ‘A’ sections, all shown to be concreted prior to Pour ‘B’. Remaining 16 Pours ‘ B’ sections shown to be concreted after 14 days of the Pour ‘A’ completion. But according to the decision vide STQ , the Table Top shall be poured one time monolithically without formation of any construction joint. The quantitities involved have been detailed in the attachment. The overall procedures that shall be carried out have been given as follows Erection for the preparatory works horizontal forms for the complete pour based on the properitory details from SGB drawings Placing the insert plates on the horizontal forms and if required some tangs be welded or tied by binding wires to the rebars by link rebars Placing the holding down bolts sleeves in the proper locations as shown on the drawings Placing and binding all the design rebars to the drawings’ details. Placing and fixing the vertical and the top plates on the vertical forms. Erecting preparatory works vertical forms in positions Aligning all forms, the insert plates and the bolt sleeves from the shown ’ centre line of Turbine Exhaust axis’ to be used as a reference line. Inspection and approvals. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 90 of Pouring details The pour shall commence from East End and be accomplished in 4 layers according to the attached sequences details proportioned in 12 sections. The concrete temperature shall not be more than 24 degree Celcius as specified for the massive structures. Immediately after pouring is finished, curing compound shall be sprayed and the surface be covered with polythene membrane. Lator within 2 hours polythene shall temporarily be lifted, the saturated hessian spread and the polythene relaid. A layer of insulation material 100 mm thick shall be laid over the polythene, covered with ply sheets to keep the insulation material intact / in place for 72 hours for thermal curing, and thereafter, the routine curing shall continue for the specified period. The differential thermometers shall be used to record the temperature variations. Attachment Q.A. Procedures Pour sequence plan Pour quantities Insert plates volume #40 Water tightness tests for the collection sumps according to BS 8007:1987 section 9 Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures(Typical) that shall be adopted to conduct the water tightness tests for the following water retaining structures. Collection sump Utilities East Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 91 of Collection sump Ethylene Collection sump Utilities East Collection sump Utilities South References Definitions PSM CSM CS FM QC Project Site Manager Construction Manager Construction Superintendent Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive the toolbox talk on the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be assessed to the requirement for Site conditions and be taken care of. The safety barricades shall be erected around the sumps. Night hazard indicator light illuminaries shall be installed on the necessary locations. No unauthorised persons shall be allowed to enter the test area. Materials Water requirements For 70-TB-201 For 70-TB-202 For 70-TB-203 For 70-TB-205 370 cum and 5 237cum and 5 166cum and 5 191cum and 5 % for stabilisation period % for stabilisation period % for stabilisation period % for stabilisation period Method This test requires the following operational sequences to be completed prior to conductance such as Complete RCC construction of the structure Complete filling of the tie rod holes with MBT Master Flow 544 External Protection to the concrete surfaces with Bitustick XL, Polybit- Corrotech Civil Contractor QC Inspection and the approval of the membrane Structural Backfilling around the tank to the required level with compaction tests Cleaning the surface of the structure by using waterjetting Application of the floor screed as specified The following operations shall be required to conduct the water tightness test A graduated stick shall be provided on wall top to show the water levels to a’ mm’ count Filling the structure with potable water to the maximum supply level Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 92 of After water filling, 7 days allowance to stabilise for absorption and autogeneous healing. Test to be conducted for 7 days for a design crack width of 0.1 mm. Recording the water losses at 24 hours intervals by simple measurements or by float indicator. Monitoring the seepage and marking the locations.Recording level losses After the test completion, pumping the water out and transporting off the site. Post water tightness test MBT shall produce a representative sample for approval prior to the coating is applied Approval of the sample by EPC Contractor / Client Applying the concrete protection approved coating material according to the representative sample on the internal surfaces of the structure as specified. Inspection of the applied coating by Civil Contractor QC followed by EPC Contractor approval Details 70-TB-201 / 202 / 203 Inlet pipes 600 mm dia and for 205 inlet pipes 450 and 400 mm dia to be in place according to the levels shown on the drawings as reflected on the schedule as the Inverted level for maximum supply level. The structure to be tested shall be completed of all RCC constructions according to the specified and agreed procedures. The tie rod holes shall be filled with Master Builder Technology MBT Masterflow 544 according to the instructions The external surfaces of the structure shall be prepared for the specified application Inspection of the prepared surface by Civil Contractor QC followed by EPC Contractor approval The external surfaces of the concrete around shall be applied with the specified protective system Bitustick XL, Polybit Inspection of the applied membrane by Civil Contractor QC followed by EPC Contractor approval Structural backfilling shall be carried out according to the project specifications Necessary fileld density tests shall be conducted by Civil Contractor and laboratory All the aforesaid operations shall be completed prior to the commencement of the water tightness test The structure to be tested shall be cleaned to the requirement by using waterjetting on the entire surface of concrete removing all loose spalls, dust dirt etc., The internal surfaces shall be inspected by Civil Contractor QC followed by EPC Contractor approval Civil Contractor QC Inspection shall be conducted before the test commences EPC Contractor approval shall be obtained. Water tightness test shall be conducted according to the BS 8007 : 1987 Section 9.1 applicable to liquid retaining structures Potable water shall be filled into the respective sump pit structures at a rate 2 m per 24 hours for which the attached filling scheduled quantities shall apply. The records of the test shall be documented on the attached sample form QCF 61 STRUCTURE LEAK TEST form and the judgement on the test shall be made accordingly SCHEDULE PLANNED FOR THE PROPOSED TEST Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge S # 1 2 3 4 5 6 7 Engineering Construction Method Statements 93 of DESCRIPTION OF OPERATION NUMBER OF DAYS Filling potable water in sump pit 1m 1 deep below the base level of the catch pit and 1 m depth above the base slab to make a total depth 2 m Filling potable water another 2 m depth 1 to make 4 m Filling potable water the remaining 1 depth to maximum supply level Stabilisation period to allow for 7 absorption and autogenous healing Testing period to record the water loss 7 by seepage and by evaporation every 24 hours Pumping the filled water out offsite Total period of water Test Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 1 18 Days REMARK By tankers filled at a uniform Rate not greater than 2 m in 24 hours By tankers By tankers Additional water to be filled if required Monitoring regarding seepage loss and the provision of 1 / 500 of average depth or 10mm. (Visual inspection) To the other structure for test The potable water shall be filled by the water tankers to the above schedule upto the maximum level. A 7 days stabilisation period shall be allowed for water absorption and autogenous healing for the requirement for a maximum design crack width 0.1 mm .The water level shall be maintained by filling in further water for stabilisation. After the stabilisation period, monitoring for the water loss excluding the evaporation shall be conducted every 24 hours either employing the level floats or manometers or by simple daily measurements. The observations shall be recorded on the form QCF 61 Structure Leak Test for documentation During this 7 days period the total permissible loss in level shall not exceed 1 / 500 of the average water depth of the full tank or 10 mm. After the test is successfully completed, the water shall be pumped out either to the other structure for testing should that be ready to receive it or if not, the other construction areas for curing or any other purpose as agreed leaving the pit empty. The application of the internal protective specified coating shall be carried out to the manufacturer’s instructions Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval Remedial Work if required In case of unsatisfactory performance of the water tightness test and upon the agreement with EPC Contractor, injection grouting method shall be adopted to seal the seepage routes. Should the structure not satisfy the 7 days test then after the completion of the remedial work it should be refilled and if necessary left for a further stabilising period; a further test of 7 days’ duration should then be undertaken in accordance with this clause. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 94 of Equipment Water Tanker Pump, sweep blasting package etc., Graduated stick Attachment Water quantity schedule Documentation form QCF for structural leak test Sketch Sub Contractor’s method Statement Clarification regarding DERBIGUM MGP Clarification regarding Aluminium Flashing Clarification regarding 10 years guarantee Clarification regarding 72 hours water test #41 Water tightness tests for the collection sumps according to BS 8007:1987 section 9 Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures (Typical) that shall be adopted to conduct the water tightness tests for the following water retaining structures. Collection sump 70-TB-201 Utilities East Collection sump 70-TB-202 Ethylene Collection sump 70-TB-203 Utilities East Collection sump 70-TB-205 Utilities South References Specification, Clause 7.0, Crack Control Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 95 of Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Water requirements For 70-TB-201 370 cum and 5 % for stabilisation period For 70-TB-202 237cum and 5 % for stabilisation period For 70-TB-203 166cum and 5 % for stabilisation period For 70-TB-205 191cum and 5 % for stabilisation period Method The structure to be tested shall be completed of all RCC constructions according to the specified and agreed procedures. Complete filling of the tie rod holes with MBT Master Flow 544 shall be carried out according to the manufacturer’s instructions 70-TB-201 / 202 / 203 Inlet pipes 600 mm dia and for 70-TB-205 inlet pipes 450 and 400 mm dia shall be laid in place to the levels shown on the drawings as reflected on the water quantity schedule i.e the Invert levels at maximum supply elevations. The external surfaces of the structure shall be prepared & applied with the specified protective system Bitustick XL, Polybit Civil Contractor QC Inspection shall be conducted for the approval of the membrane Structural backfilling shall be carried out externally to the project specifications & necessary field density tests conducted to the requirement Application of the floor screed as specified shall be carried out The entire surfaces of structure to be tested shall be sweep blasted removing all loose spalls, dust dirt etc., The prepared internal surfaces shall be inspected by Civil Contractor QC for approval The following operations shall be involved to conduct the water tightness test according to the BS 8007 : 1987 Section 9.1 applicable to liquid retaining structures A graduated stick shall be provided on wall top to show the water levels to a’ mm’ count Potable water shall be filled into the respective sump pit structure at a rate 2 m per 24 hours for which the attached ‘filling scheduled quantities ‘shall apply. After water is filled in to the required level, it shall be allowed to stay for a period of 7 days for stabilisation, absorption and autogeneous healing. If so required, water shall be added to maintain the maximum test level in case it is lost during this period. Test shall commence from 8th day and continue for 7 days for a design crack width of 0.1 mm according to specification requirement. Observations regarding water level drops shall be recorded every 24 hours by visual measurements on mm scale Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 96 of The test records shall be documented on the attached form QCF ‘ STRUCTURE LEAK TEST ‘and the judgement on the test made accordingly During this 7 days period the total permissible loss in level shall not exceed 1 / 500 of the average water depth of the full tank or 10 mm. After the test is successfully completed, water shall be pumped out either to the other structure for testing should that be ready to receive it or if not, to the other construction areas for curing or any other purpose as agreed leaving the pit empty. Remedial Work if required In case of unsatisfactory performance of the water tightness test and upon the agreement with EPC Contractor, injection grouting method may be adopted to seal the seepage routes. Should the structure not satisfy the 7 days test then after the completion of the remedial work it should be refilled and if necessary left for a further stabilising period; a further test of 7 days’ duration should then be undertaken in accordance with this clause. SCHEDULE PLANNED FOR THE PROPOSED TEST S DESCRIPTION OF OPERATION NUMBER # OF DAYS 1 Filling potable water in sump pit 1m 1 deep below the base level of the catch pit and 1 m depth above the base slab to make a total depth 2 m 2 Filling potable water another 2 m depth 1 to make 4 m 3 Filling potable water the remaining 1 depth to maximum supply level 4 Stabilisation period to allow for 7 absorption and autogenous healing 5 Testing period to record the water loss 7 by seepage and by evaporation every 24 hours 6 7 Pumping the filled water out offsite Total period of water Test 1 18 Days REMARK By tankers filled at a uniform Rate not greater than 2 m in 24 hours By tankers By tankers Additional water to be filled if required Monitoring regarding seepage loss and the provision of 1 / 500 of average depth or 10mm. (Visual inspection) To the other structure for test Post water tightness test MBT shall produce a representative Masterseal 550 coating sample for approval by EPC Contractor and the client. The internal surfaces shall be coated according to the approved sample Civil Contractor QC inspection shall be conducted to approve the applied coating Equipment Water Tanker, Pump, sweep blasting package etc., Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 97 of Graduated stick Attachment Water quantity schedule #42 Administration building Marble flooring Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out marble flooring on the various room areas, FF Reception, Lobby, the stair case steps & landing References Drawing EPC Contractor UBC & General Construction Practice, STQ MAR Dated 2.4.2000 Approved 4.4.2000 Perlato Royal marble for Administration Building Reception, FF lobby & stairs MAR Dated 12.3.2000 Approved 30.3.2000 Blue Pearl marble for Worktop and Toilet Counters Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 98 of language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety The workers shall receive a ToolBox Talk according to the project requirement relevant to the operation concerned every day prior to commencement of the activity Proper illumination shall be provided in the dark area The area to be laid with marble flooring system shall be closed for the general movement except those working there and be opened only when the work has properly been completed with hardboard cover protection spread on the newly laid finishes. Only industrial cable / wires shall be used for the grinding machine with earthing arrangement to avoid any shock or mishap The personnel working around the grinding machine shall use eyeglasses and all other Personal Protective Equipment Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during the inspection shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Marble tiles 300x600x20mm (Directly placeable) and also Kitchen Work tops & toilet Counters, Reception Area + Lobby First Floor- Perlato Royal (Placeable according to the supplier’s details) (Al Ain Cement and Marble Product Co) Proprietary Grout Method (Laying Marble Floor Tiles by SEMI DRY method) The following activities are involved to carry out the marble flooring system The areas of the concrete sub strata to be laid with marble shall be brush cleaned and dampened until absorption ceases followed by the finished floor level establishment by means of dots and rules Total thickness for the marble flooring is 100 mm including 80 mm bedding screed (1 cement: 4 mortar sand) by weight and shall be applied as described below The finishing layer shall be marble tiles 20 mm thick and be laid as described below Details The mortar for bedding the tiles shall be 1 part cement to 4 parts sand by weight, mixed semidry by a mechanical mixer with only sufficient water added to give a crumbly consistency which retains its shape when squeezed by hand permitting no fluidity The mix shall be placed to a thickness approximately 10 mm greater than that actually required for the bed, thoroughly compacted by tamping and drawing off to the required level with a screed board. Only sufficient mortar shall be mixed and spread as can be covered with tiles before it attains its initial set. Civil Contractor QC visual inspection shall be conducted Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 99 of A slurry of 1 part cement to 1 part sand by volume shall be poured over the surface of the semi – dry mix bedding and spread with a trowel until it is approximately 2 mm thick Dry marble tiles / flags shall then be laid on the slurry and beaten firmly into position with a wooden beater ensuring a true surface contact between the tiles and bedding is formed. The marble tiles / flags shall be correctly positioned in both directions the time these are placed The tiles shall neatly and accurately be cut to a close fit where necessary at abutments, around outlets, pipes and the like. Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment and the level profile followed by EPC Contractor approval The tiles shall be laid level or tops to 1- % falls in ‘wet’ areas as may be required. The floor finishing shall be carried out using an electrically operated rotary grinding machine fixed with a carborundum stone of varying grades for the uneven edges or the protrusions as well as the fine range for the even areas to attain a smooth surface texture allowing water lubrication. The grinding runs shall depend on the finishing profile formed. More varying profile shall be applied with additional grinding rotation till the acceptable one is achieved. Plenty of water shall be used for this purpose. All the water shall be washed away after the grinding is completed. Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment and the level profile followed by EPC Contractor approval During grinding any portion damaged or effected badly shall be replaced to the specification requirement. Minor blown up or damaged tile shall be grouted with the proprietary compatible colour to match the marble texture A seal coat shall be applied on the ground surface with an approved proprietary polishing material according to the manufacturer’s instructions after which the finished surface be cleaned, the arrangement to protect the finished areas be made by overlaying hardboards and closing the entry in general. MOVEMENT JOINTS IN TILED FLOORS Unless otherwise indicated in the documents, a 10-mm movement joint shall be formed at the perimeter of all the tiled floors and where the tiling meets structural features such as columns, machine bases etc. Where a structural movement joint is provided in the base, a movement joint of the same width in the bedded finish shall be positioned immediately above The movement joint cavities shall extend through the combined thickness of the finish and the bedding mortar, completely filled and sealed after grouting of the normal joints takes place. Other standard items such as treads, risers, worktops and the counters shall be cut to the exact site dimensions with the wash basins and the sink blocks taken out. These preformed items shall be supplied completed in all respects and fixed to the supplier’s details Major Equipment Mechanical Mixer Wheel barrows Mason’s tools in general Grinding Machine with varying carborundum stone grades attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 100 of Attachment #43 Ethylene gas compressor Table top pour Top Index Scope Reference documents Definitions Responsibilities Safety Material Method Equipment Manpower Attachment Scope This statement is aimed to present the proposed procedures to be adopted to pour the Table Top of the framed beam structure. References Drawing No.. Specifications Safety Prior to the commencement of work, the labour force shall receive the tool box talk on the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be assessed to the requirement for Site conditions and be taken care of. Proper scaffolding according to the project requirements shall be erected around the area to be poured along with providing complete access system such as stepped stairs and the working platforms with top and the bottom guard rails. The area shall be cleared on ground allowing free access to the concrete pumps, transit mixers water tank etc., and the provision of the night lights shall be made for curing Materials The gross volume of the pour is 81 cum The volume of the steel plates inserts is 0.35 cum The applicable volume of the pour is 80 cum apprx. (Details of the calculations attached). According to the specification the pour pertains to the definition of massive structure , hence, C 30 high slag blast furnace cement to BS 4246 with 70 % replacement utilising 30 % ASTM C 150 Type II cement shall be utilised for the batching according to the specified design mix with the placing temperature not more than 24 degree Celcius. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 101 of Curing materials such as curing compound, polythene sheets, bur lap sheets / hessians and water shall be available according to the requirement Method The drawing shows the above pour to be carried out into 7 sections by forming 8 construction joints. Pour sequences are described as Pour ‘A’ and Pour’B’. A total of 3 pours ‘A’ sections, all shown to be concreted prior to Pour ‘B’. Remaining 4 Pours ‘ B’ sections shown to be concreted after 14 days of the Pour ‘A’ completion. But according to the decision vide STQ, the Table Top shall be poured one time monolithically without formation of any construction joint. The quantitities involved have been detailed in the attachment. The overall procedures that shall be carried out have been given as follows; Erection for the preparatory works horizontal forms for the complete pour based on the properitory details from SGB drawings Placing the insert plates on the horizontal forms and if required some tangs be welded or tied by binding wires to the rebars by link rebars Placing the holding down bolts sleeves in the proper locations as shown on the drawings Placing and binding all the design rebars to the drawings’ details. Placing and fixing the vertical and the top plates on the vertical forms. Erecting preparatory works vertical forms in positions Aligning all forms, the insert plates and the bolt sleeves from the shown ’ centre line of Turbine Exhaust axis’ to be used as a reference line. Inspection and approvals. Pouring details The pour shall commence from East End and be accomplished in 4 layers according to the attached sequences details proportioned in 7 sections. The concrete temperature shall not be more than 24 degree Celcius as specified for the massive structures. Immediately after pouring is finished, curing compound shall be sprayed and the surface be covered with polythene membrane. Lator within 2 hours polythene shall temporarily be lifted, the saturated hessian spread and the polythene relaid. A layer of insulation material 100 mm thick shall be laid over the polythene, covered with ply sheets to keep the insulation material intact / in place for 72 hours for thermal curing, and thereafter, the routine curing shall continue for the specified period. The differential thermometers shall be used to record the temperature variations. Plants and Equipment Batching plant 1 and 1 No. stand by Concrete pump 1 and 1 No. stand by Transit mixers 6 Nos. Vibrator 2 and 2 Nos. standby Water tanker 1 No. Manpower Masons 6 Nos. Carpenters 3 Nos. Steel fixers 3 Nos. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 102 of Scaffolder 3 Nos. Helpers 7 Nos. Attachment QA Procedures Pour sequence plan Pour quantities Insert plates volume #44 Propane gas compressor table top pour Top Index Scope Reference documents Definitions Responsibilities Safety Material Method Equipment Manpower Attachment Scope This statement is aimed to present the proposed procedures to be adopted to pour the Table Top of the framed beam structure. References Drawing nos Specifications Safety Prior to the commencement of work, the labour force shall receive the tool box talk on the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be assessed to the requirement for Site conditions and be taken care of. Proper scaffolding according to the project requirements shall be erected around the area to be poured along with providing complete access system such as stepped stairs and the working platforms with top and the bottom guard rails. The area shall be cleared on ground allowing free access to the concrete pumps, transit mixers water tank etc., and the provision of the night lights shall be made for curing. Materials The gross volume of the pour is 60 cum The volume of the steel plates inserts is 0.75 cum The applicable volume of the pour is 58 cum apprx. (Details of the calculations attached). Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 103 of According to the specification the pour pertains to the definition of massive structure , hence, C 30 high slag blast furnace cement to BS 4246 with 70 % replacement utilising 30 % ASTM C 150 Type II cement shall be utilised for the batching according to the specified design mix with the placing temperature not more than 24 degree Celcius Curing materials such as curing compound, polythene sheets, bur lap sheets / hessians and water shall be available according to the requirement. Method The drawing shows the above pour to be carried out into 7 sections by forming 8 construction joints. Pour sequences are described as Pour ‘A’ and Pour’B’. A total of 3 pours ‘A’ sections, all shown to be concreted prior to Pour ‘B’. Remaining 4 Pours ‘ B’ sections shown to be concreted after 14 days of the Pour ‘A’ completion. But according to the decision vide STQ, the Table Top shall be poured one time monolithically without formation of any construction joint. The quantitities involved have been detailed in the attachment. The overall procedures that shall be carried out have been given as follows Erection for the preparatory works horizontal forms for the complete pour based on the properitory details from SGB drawings Placing the insert plates on the horizontal forms and if required some tangs be welded or tied by binding wires to the rebars by link rebars Placing the holding down bolts sleeves in the proper locations as shown on the drawings Placing and binding all the design rebars to the drawings’ details . Placing and fixing the vertical and the top plates on the vertical forms. Erecting preparatory works vertical forms in positions Aligning all forms ,the insert plates and the bolt sleeves from the shown ’ centre line of Turbine Exhaust axis’ to be used as a reference line. Inspection and approvals. Pouring details The pour shall commence from East End and be accomplished in 4 layers according to the attached sequences details proportioned in 5 sections. The concrete temperature shall not be more than 24 degree Celcius as specified for the massive structures. Immediately after pouring is finished , curing compound shall be sprayed and the surface be covered with polythene membrane. Lator within 2 hours polythene shall temporarily be lifted, the saturated hessian spread and the polythene relaid. A layer of insulation material 100 mm thick shall be laid over the polythene, covered with ply sheets to keep the insulation material intact / in place for 72 hours for thermal curing, and thereafter, the routine curing shall continue for the specified period. The differential thermometers shall be used to record the temperature variations. Plants and Equipment Batching plant 1 and 1 No. stand by Concrete pump 1 and 1 No. stand by Transit mixers 6 Nos. Vibrator 2 and 2 Nos. standby Water tanker 1 No. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Manpower Masons Carpenters Steel fixers Scaffolder Helpers Attachment Q.A. Procedures Pour sequence plan Pour quantities Insert plates volume #45 Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 104 of 6 Nos. 3 Nos. 3 Nos. 3 Nos. 7 Nos. Expansion joints in ditches Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to seal the Expansion joints in the ditches. References Drawing nos Safety Prior to the commencement of work, the labour force shall receive the tool box talk on the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be assessed to the requirement for Site conditions and be taken care of. The personnel working on this activity shall wear masks, safety glasses, gloves, etc., Method To seal the expansion joints the following operations shall be carried out. Cleaning of the joint surfaces. Preparing and filling the joints with Bitumastic Details The size of the proposed joints to be filled / sealed is 15 mm wide x 15 mm deep Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 105 of Application procedure The surface shall be cleaned of all dirt, dust and loosely adhering materials. All grease and oil contamination shall be removed using hard small brushes, compressed air etc. The fibre board shall be removed to the required depth. Masking tape shall be used to confine the joint borders keeping the adjoining concrete surfaces clean. The contents of the Can shall be removed by a Trowel or a Spatula. The Bitumastic shall be applied to the prepared and masked portions. In case of the vertical joints, bottom to top application sequence shall be followed ensuring that the entire volume of the joint is filled in using a spatula or a trowel to effect a total contact with joint surfaces. After application, the sealant shall be smoothened and compressed into the joint using a spatula or a putty knife moistened with cleaning solvent. Masking tape shall be removed immediately after the application has been over to keep the concrete surface clean. It shall take 4-6 weeks post application normally to a full cure at a stage when the solvent evaporation is completed. Over painting if so required, shall be carried out only after the full cure has taken place. Coverage Coverage for joint depth 10 mm and width 15mm 6.5 kg of Bitumastic per linear metre Equipment Trowel Spatula Knife etc., Attachment None #46 Expansion joints in ditches Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to seal the Expansion Joints in the ditches. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 106 of References Drawing nos. Specs: BITUMASTIC, Manufacturer - Polybit Safety Prior to the commencement of work, the labour force shall receive a Toolbox talk on the Project Site Safety requirements. Necessary measures shall be applied for any process involving particular safety risk Personnel working on this activity shall wear masks, Eye protection, gloves, etc., Method Size of the proposed joints to be filled / sealed is 15 mm wide x 15 mm deep The surface shall be cleaned of all dirt, dust and loosely adhering materials. All grease and oil contamination shall be removed using hard small brushes, compressed air etc. The fibreboard shall be removed to the required depth. Under normal circumstances priming is not required Masking tape shall be used to confine the joint borders keeping the adjoining concrete surfaces clean. The contents of the Can shall be removed by a Trowel or a Spatula. The Bitumastic shall be applied to the prepared and masked portions. In case of the vertical joints, bottom to top application sequence using a spatula or a trowel, shall be followed ensuring that the entire volume of the joint is filled in to effect a total contact with joint surfaces. After application, the sealant shall be smoothened and compressed into the joint using a spatula or a putty knife moistened with cleaning solvent. Masking tape shall be removed immediately after the application is completed to keep the concrete surface clean. A full cure (a stage when the solvent evaporation is completed) shall normally consume 4 to 6 weeks post application of the sealant Painting over concrete surface if so required, shall be carried out only after full cure has taken place. Equipment Trowel Spatula Knife etc., Attachment Manufacturer Datasheet #47 Concrete coating Using master seal 550 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 107 of Top Index Scope Reference documents Definitions Responsibilities Safety Material Method Equipment Attachment Scope This statement is aimed to present the proposed procedures that shall be adopted to apply the specialist material for concrete protection on the internal surfaces as specified. References Collection sump 70-TB-201 Collection sump 70-TB-202 Collection sump 70-TB-203 Collection sump 70-TB-205 Utilities East Ethylene Utilities East Utilities South Drawings Specifications Master seal 550-product data sheet Definitions PSM CSM CS FM QC Project Site Manager Construction Manager Construction Superintendent Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive the tool box talk on the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk, shall be assessed to the requirement for Site conditions and be taken care of. Scaffolding shall be erected to afford access to the working personnel according to the project requirements. Hand rails ladders and the toe boards shall be fitted and inspected prior to use. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 108 of During mixing and application of master seal 550, personnel protective equipment shall be used i.e. overalls, goggles, gloves (to avoid material contact to eyes, mouth and skin) Material storage / disposal of used containers / waste material Materials shall be stored out of direct sunlight clear of ground and protected from rainfall. Used containers shall be collected and disposed off as per project requirements. Materials Coating, Masterseal 550 Master seal 550 is a two component acrylic modified cementitious coating that requires only site mixing to form an ideal product to waterproof and resurface concrete, masonry and most other construction materials. Simply applied by stiff brush, roller or trowel it forms a waterproof, flexible coating providing an effective barrier to waterborne salts and atmospheric gases. Method The method involves the following sequences in general. Surface preparation Mixing Application Details All grease, oil, dust, residual curing compound, mould release agent or other contaminants, which could impair adhesion, shall be removed from the surface by degreasing and washing. The whole surface to be coated shall be cleaned using water jetting and visually inspected to ensure that the roughness does not exceed grade 80 sandpaper. All the holes, voids, depressions, spalls etc., shall be filled with Masterseal 550 mixed to a trowel consistency ,scraped lightly into the surface, allowed to dry and later roughened by hand wire brush on the small areas and gently water jetted on the larger areas. The filled areas shall be visually inspected to ensure that the correct mechanical key is achieved. Mixing Master seal is supplied in the pre measured units and shall be mixed on site using clean containers. The powder shall be slowly added to the liquid component and agitated / mixed for 2 minutes by using a slow speed hand power drill fitted with a suitable paddle attachment, until a homogeneous lump free consistency is obtained. The mix quantity shall be such that it could be consumed in one hour during application without allowing any retempering with water. Application Coverage 1.8 Kg / sqm at 1 mm thickness The coating shall be 1 mm thick applied in one coat In hot weather the surface to be coated shall be shaded from direct sunlight. The areas to be coated shall be saturated with fresh and clean water. The prepared and the saturated surface shall be inspected by Civil Contractor QC followed by EPC Contractor approval The mixed material shall be applied while the surface is visibly damp without standing water using short stiff brush or roller. (Roller shall be used in major / large areas) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 109 of The evenness and the thickness of the applied coating shall be regularly checked during application while the material is still wet. The materials shall be allowed to dry and visually inspected Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval Any missed areas shall be saturated and then touched up. Equipment Water tanker with water jetting arrangement Hard brushes for minor areas Clean container Slow speed drill with paddle attachment Stiff brush / Roller Attachment Masterseal 550 Data sheet and statement #48 Dewatering for the 84” GRE parallel to Corniche road east west pair line Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The statement is aimed to present the proposed procedures to be adopted to keep the proceeding excavations, for the route respecting pair of 84 “ GRE pipe lines to be laid in, dry and free of inflowing water References Specifications Water Control / Dewatering Plan , Dewatering and Drainage Excavation Safety Plan Excavation & Backfilling for Underground structures. Definitions PSM CM CS Project Site Manager. Construction Manager. Construction Superintendent Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge FM Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 110 of Foreman Responsibilities CM shall plan and resource the trench excavation and backfilling activity, in accordance with this method statement. The Construction Foreman shall monitor these activities directing the workforce as necessary. EPC Contractor shall control the activities. Safety Appropriate means regarding safety shall be provided to the requirements . Round the clock watch and ward shall be maintained for the plants and the Equipment Safety standard barriers posted with warning tags shall be installed on both the sides of the excavations covering the well point systems also Night indicator lights shall be provided according to the provisions of safety Access ladders shall be provided every 8 m intervals The safety inspector shall visit the site every day in the morning and the after noon to check whether the safety systems work to the requirement or else the corrective measures be applied. The water logged area shall not be allowed for the workers in general to acceed crossing the existing fence except, if so required , for the purpose of laying out hoses over used plies to be routed in to reach the proposed sumps for the pumped water disposal. METHOD Ref Attached Drawing and Sketches The North South excavation has already been carried out to the intersection of the proposed line and the Corniche Road as indicated by point at ‘S’ On the proposed route of the lines i.e on the North of the road exist various services at a distance 4 m to 8 m at a depth of 2 to 3 m from the existing road level running along eitherside of the intersection i.e East and West as shown on the attached sketch as locations marked A to H for the exposed inspection pits The existing uneven ground level on the proposed area is 1.8 m average lower than the road level and the water is available at 2 m from the road level but fluctuates rapidly depending on the tides. The GRE pipe 2200 mm dia pair shall be laid at a bedding of not less than 4000 mm to 4500 mm from the road surface .Since the drawing shows the natural ground level 3.4 m , a 2.4 m depth is required to be excavated , while water level is shown at 2.15m level, water has to be bailed out upto 0-0 level requiring a 2m massive dewatering along the entire route commencing from the intersection at point ‘S‘ to the terminal point at ‘T’. The existing services shall be protected by the necessary measures according to the statutory regulations and the specifications prior to the excavation commencement for which an inquiry be conducted with the relevant Statutory Organizations / Client Since this massive earth work is to be carried out in full to cover a length of 1200 m or more , dewatering shall be carried out accordingly by the standard Well Point System to be installed on both sides of the proposed route at a depth of minimum 3 m from the existing ground levels at the locations shown on the sketch / drawing and disposed off through the hoses into the proposed sumps to be located at varying distances from 100 to 200 m off Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 111 of the road berm by the use of booster pumps installed next to the intermediate water tanks, so as not to allow the disposed water to flow back into the well point systems. For the route part besides the box culvert (under construction) leading to the pipelines West end after running beneath the overhead conveyors, the disposal may be made into the culvert manholes as being done by M / S ARCHIRODIN CONSTRUCTION OVERSEAS for that the matter was casually discussed with the supervisor on site Mr BADRI who expressed no concern should the water be discharged that way. Anyway should this option does not work, the disposal shall be carried on to the proposed sumps as shown since in the vicinity of the Sulpha Plant Building area further sumps to form may not be allowed. The sumps shall be located as shown on the drawing / sketch near the embankment north / south side , for south after jumping over the bund, whatever course be feasible. On the south of the embankment side the existing levels are low lying. A total of 8 to 10 sumps shall be needed be formed. The sump pits to receive the disposed water shall be filled with 75 mm clean aggregate prior to the disposal is commenced The Well Points on both sides shall be installed in sections of 100 m average for each Sykes Pump catchment and the disposal be effected to as shown by boosting. It shall take a duration of around 60 days to carry out the excavation,bedding, laying pipes and the backfill,the system / s have to be kept working till these operations are over . Equipment / plants Well point system Plants and equipment requirement S# 1 2 3 4 5 6 7 8 9 10 ITEM DESCRIPTION Length of the proposed route Length of the well point system 150mm dia Headers average 5 m or so long 50 mm dia Well points 3 m long 50 mm dia Well points / Headers Flexible connections Sykes / Miller pumps with suction and delivery heads Intermediate water tanks (open top) 3 cum capacity Booster pumps 5 bhp with compatible fittings for tanks connections 150 mm dia hose pipe to suit the pump inlets and outlets with suction and disposal / delivery heads 75 mm dia disposal hose to suit the water tank outlets UNIT m m each QUANTITY 2400 2400 480 REMARK 2 x 1200 m 2 x 1200 m 6 points in each each each 2880 2880 each 24 each 6 each 6 m 500 Filterable 6 connections each header 1 pump / 100 well points 1 tank for 4 Sykes pumps 1 booster pump for 4 Sykes pumps Delivery upto the open water tanks m 1500 Disposal from open water tanks to the proposed sumps Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge 11 12 13 Engineering Construction Method Statements 150 mm steel sleeve pipe for under m ground use Drilling Rig with adjustable Auger each attachment for 50 mm dia Well Points All other compatible fittings and miscellaneous items for the whole assembly not covered in above Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 112 of 50 1 To be installed for the incoming crossings For drilling well point bores ATTACHMENT Drawing showing the well point system installation layouts and section Typical details of the system indicative only #49 Ceramic wall tiles fixing Top (INTERNAL) Administration building Index Scope Reference documents Definitions Responsibilities Safety Method Equipment SCOPE This statement is aimed to present the proposed procedures to be adopted to fix the Ceramic wall tiles by bedding with an approved adhesive on one coat plaster applied according to the specification with the pre spatterdash treatment except on metal lathing where 2 coats are permitted with wood float finish, uniformly as thick as possible and not less than 8 mm or more than 13 mm References Specification Safety The work force shall receive every day prior to the commencement of any activity a Tool Box talk regarding operational safety according to the project requirements in addition to the use of personal protective equipment.. Specifically the personnel engaged on the tiling items shall use masks to prevent inhale the grout or the adhesive smell. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 113 of In the rooms where proper ventilation or the sunlight is not available, electric lights shall be provided with due care regarding protection from the electric wires ,the distribution board and the other fixtures etc., In hot weather standing upright fans shall be provided at the work areas. The work area shall be closed to general workers on other parts and opened only after the tiles have been finally cleaned as well the space cleared of electrical fittings. Definitions PSM CSM CS FM QC Project Site Manager Construction Manager Construction Superintendent Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Material Glazed Tile size specified 108 x 108 mm Setting material (ultra set polyurethane adhesive ) recommended by manufacturer Cushion edges Rounded external corners Head Jamb and Cill trim shapes Wain scot cap Surface bullnose or bull nose cap External corners Bullnose shapes or as specified Internal corners Field butted square Grouting material Water proof epoxy tiling grout with antifungicide additive (Commercial white sanded latex portland cement type) Method Mesh reinforcement shall be incorporated in the plaster where 1 The structure is out of line and the thickness of the plaster exceeds 13 mm 2 The plaster is to be applied over different structural materials 3 The surfaces of the structural wall shall be subject to excessive movement .e.g., light weight concrete block of all types Examination The strata to receive the tiles shall be examined closely to ascertain that the moisture content are within limits to allow the fixing operation Where the tiling is to be bedded in a thin bed adhesive, the trueness of the plaster shall be such that when tested with a 3 m straight edge no gap exceeds 3 mm Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 114 of Where the gap lies between 3 and 6 mm, if the walls are out of plumb by not more than 6 mm, a thick bed adhesive shall be applied in preferance to cutting the defective areas and making good Deviation from true vertical or plumb in the surface of plastering exceeding 6 mm shall be made good Thin bed adhesive shall not be used for fixing tiles with backs incorporating deep keys or frogs for which thick - bed adhesives must be used Civil Contractor inspection followed by EPC Contractor approval The tiles shall be set out before the work commences so that cut tiles be kept to a minimum and where they do occur be as large as possible Joints shall be horizontal and vertical, with horizontal joints aligning in walls that adjoin or be adjacent The tiles shall be neatly and accurately cut to close fit where necessary at abutments and around outlets, pipes and the like The tiles shall be extended into recesses, under equipment and fixtures to form a complete covering without interruptions as well as terminated neatly at obstructions, edges or / and corners keeping the on going pattern or joint alignment. The tiles shall fit closely to the electrical outlets and fixtures allowing plates, collars, covers etc., overlap the tiles. Movement joints not less than 6 mm shall be provided: At all internal vertical corners At all angles with structural walls and ceilings To form bays not greater than 3000x4500 mm Over all structural movement joints: The joints shall be carried through the plastering to the structural wall, partially filled with an approved joint filler and finished flush with an approved sealant recommended by the manufacturer for the relevant situations. Glazed edge tiles shall be used at the exposed edges. The tiles shall be fixed in position prior to the adhesive gets dried for that it shall be prepared and applied on a small area not exceeding 1m x 1m at a time with a trowel to dry plaster surface in a manner recommended by the manufacturer followed by the tiles pressed firmly into with a twisting / sliding action tapping firmly and cleaned as soon as the bedding be completed. The finished surface of the tile shall be firm and true such that when checked with a 3 m straight edge, no gap exceeds 3 mm Civil Contractor inspection followed by EPC Contractor approval The joints shall be grouted well to completely fill in as well as appear flush after the adhesive has set and not less than 48 hours post fixing. Surplus grout shall be cleaned off from the tiles surfaces as neatly as possible as the work proceeds using a damp cloth and the joints tooled smooth. The grout haze shall be removed according to the manufacturer’s instructions for the use of acid and chemical cleaners The tile work shall be rinsed thoroughly with clean water prior to and post using chemical cleaners followed by polishing with soft cloth. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 115 of Civil Contractor inspection followed by EPC Contractor approval Equipment Tile cutter Attachment Approved ITP Form #50 Bedding and gravel filling beneath 60 “ dia pipe cooling water pipe Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted for the execution of bedding and the sub strata gravel filling with the provision to prohibit the fine soil particles to migrate to the bedding beneath the pipe where the water table is met at the bedding level making the compaction and the density test unsustainable Reference documents Drawing Specification. Excavation & Backfilling for Underground structures. Definitions PSM CM CS FM Project Site Manager. Construction Manager. Construction Superintendent Foreman Responsibilities CM shall plan and resource the trench excavation and backfilling activity, in accordance with this method statement. The Construction Foreman shall monitor these activities, directing the workforce as necessary. EPC Contractor shall control the service laying activities. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 116 of Safety Prior to the commencement of any activity, the labour force shall receive a tool box talk on the project site safety requirements. Any process that is adopted having a particular safety risk shall be assessed and addressed as required. A competent inspector shall inspect the trench daily to assess the safety measures adopted as well as after every rainstorm. If required, the shoring shall be provided to prevent the caving in. In case of the trench depth being more than 1200 mm, adequate means of exit such as ladders or steps shall be provided and located no more than 8 m of lateral travel. Barricades, markers and the night lights etc., shall be arranged as required. Safety Method COOLING WATER PIPE LINE 60 “ DIA PIPE BEDDING AND GRAVEL FILLING The attached sketch shows the proposed bedding and sub strata gravel filling wrapped by Geotextile. The excavation shall be carried out upto the formation level plus another 200 mm for crushed gravel filling as shown . The Geotextile TERRAM membrane shall be laid on the prepared substrata as shown. A well packed 200 mm thick crushed gravel filling shall be carried out on apprx.3000 mm wide base. The Geotextile TERRAM membrane shall be continued over the prepared crushed gravel filled formation level surface making gravels wrapped fully allowing no fine soil particles enter the strata. Over this wrapped strata a 150 mm thick sand bedding shall be carried out duly compacted according to the requirement of the specifications. After these operations are over and the inspection done, 60 “ dia pipe shall be laid according to the requirement Equipment Excavator Compactor Attachment Sketch #51 External concrete protection Administration building Top Index Scope Reference documents Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 117 of Definitions Responsibilities Safety Storage Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to form a protection coating on the external concrete surface to be cladded with the Glass Reinforced Concrete elements. References Drawing Specification above ground concrete protection. Definitions PSM CSM CS FM QC Project Site Manager Construction Manager Construction Superintendent Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of any activity, the labour force shall receive a toolbox talk relevant to the operation concerned on the project site safety requirements. Any process that is adopted having a particular safety risk shall be assessed and addressed as required. Only tagged scaffolding comprising all the guard rails foot rails etc.,shall be used for the work at heights according to safety requirements. The use shall be made in well-ventilated area and avoid inhalation. The personnel shall use protective clothing, gloves eye protection glasses, masks etc., for to avoid skin contact. Plenty of clean water shall be available all the time. Medical attention shall be available all time to treat the adverse effects. Transportation shall be available to move the effected personnel to the hospital should the circumstances so require. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 118 of Storage The material shall be stored under cover out of direct sunlight and protected from temperature extremes. Product shelf life is 12 months subject to proper storage Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and foodstuffs. The containers shall be resealed after use. Immediate medical attention shall be called for in case of any adverse effect to the personnel handling the product Damaged tins shall be disposed off according to the state regulations. Material Master Builder Technology Product Masterseal 300H - an acrylic based, elastomeric decorative, flexible, anti-carbonation and waterproof protective coating designed for the protection of concrete structures against carbonation and chloride ingress. Masterseal 181S- primer system Masterseal 300 H filler Method This application involves the following sequences Cleaning and making up the surface Priming the surface Coating the surface Details Preparation All surfaces shall be free from oil, grease, friable matters and curing compound. The surfaces shall be cleaned from dust / sand using compressed air. Arrises shall be rounded off and the protrusions ground so that the resulting surfaces appear smooth. The surfaces shall be brush primed with Masterkure 181S and subsequently Masterseal 300H mixed with Masterseal 300 H filler applied as a scrape coat over blow holes and depressions. The primed surface shall be allowed to dry tack free for a minimum duration of 2 hours before applying Masterseal 300H coating. Application Masterseal 300 H shall be applied directly from the containers using a brush or roller @ 0.8 litre per sqm surface coverage to achieve a continuous coating The continuous coating may be achieved in 1 or 2 coats of application The coating shall be protected from the rain and humidity for 24 hours / until it dries out using polythene sheets keeping off the area. The coating shall be applied when the humidity is less than 90 % The coating shall not be applied in the dusty weather conditions No post application curing is required The areas to be coated shall be protected from direct sunlight by shading in the hot weather conditions and the ambient temperature be more than 5 degree Celsius. Equipment Brush Roller Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 119 of Attachment MBT Statement #52 Above ground concrete protection Using masterseal 300 h Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to apply protection coating on above ground concrete surfaces. References Specification above ground concrete protection. MAR -Material Approval for 181 S and 300H Safety Prior to the commencement of any activity, the labour force shall receive a toolbox talk relevant to the operation concerned on the project site safety requirements. STARRT Card shall be used. Necessary measures shall be applied to any activity involving safety risk. Only tagged scaffolding with guardrails, foot rails etc., shall be used to afford access to high locations. Material shall be used in well-ventilated area and inhalation avoided. Personnel shall use protective clothing, gloves, eye protection, masks etc .to avoid skin contact. Plenty of clean water shall be made available. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit, shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Master Builder Technology Product Masterseal 300H - an acrylic based, elastomeric decorative, flexible, anti-carbonation and waterproof protective coating designed for the protection of concrete structures against carbonation and chloride ingress. Masterseal 181S- primer system Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 120 of Masterseal 300 H filler Storage The material shall be stored under cover out of direct sunlight and protected from temperature extremes. The containers shall be resealed after use. Damaged tins shall be disposed off according to the state regulations. Method Surface Preparation All surfaces shall be free from oil, grease, friable matters and curing compound. Sweep blasting shall be used when necessary to obtain an acceptable surface for coating otherwise the surfaces shall be cleaned from dust / sand using compressed air. Arrises shall be rounded off and the protrusions ground so that the resulting surfaces appear smooth. Primer The surfaces shall be brush primed with Masterkure 181S and allowed to dry for 2 hours Subsequently Masterseal 300H mixed with Masterseal 300 H filler applied as a scrape coat over blowholes and depressions and allowed to dry. Application Masterseal 300 H shall be applied directly from the containers using a brush or roller @ a minimum of 0.8 litre per sqm surface coverage to achieve a continuous coating Continuous coating may be achieved in 1 or 2 coats of application The coating shall not be applied in the dusty weather conditions No post application curing is required Equipment Brush Roller Attachment MBT Statement #53 Above ground concrete protection Using masterseal 300 h Top Index Scope Reference documents Safety Method Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 121 of Scope This statement is aimed to propose the procedures to be adopted to apply protection coating on above ground concrete surfaces. References Specification above ground concrete protection. MAR -Material Approval for 181 S and 300H Safety Prior to the commencement of any activity, the labour force shall receive a toolbox talk relevant to the operation concerned on the project site safety requirements. STARRT Card shall be used. Necessary measures shall be applied to any activity involving safety risk. Only tagged scaffolding with guardrails, foot rails etc., shall be used to afford access to high locations. Material shall be used in well-ventilated area and inhalation avoided. Personnel shall use protective clothing, gloves, eye protection, masks etc .to avoid skin contact. Plenty of clean water shall be made available. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit, shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Master Builder Technology Product Masterseal 300H - an acrylic based, elastomeric decorative, flexible, anti-carbonation and waterproof protective coating designed for the protection of concrete structures against carbonation and chloride ingress. Masterseal 181S- primer system Masterseal 300 H filler Storage The material shall be stored under cover out of direct sunlight and protected from temperature extremes. The containers shall be resealed after use. Damaged tins shall be disposed off according to the state regulations. Method The system shall only be applied to surfaces that have been passed as being ready to receive them. All necessary repairs to the concrete surface shall have been carried out and relevant QC documentation completed. All surfaces shall be free from oil, grease, friable matters and curing compound. Sweep blasting shall be used to obtain an acceptable surface for coating and the surfaces shall be cleaned from dust / sand using compressed air. Primer The surfaces shall be brush primed with Masterkure 181S and allowed to dry for 2 hours Subsequently Masterseal 300H mixed with Masterseal 300 H filler applied as a scrape coat and allowed to dry. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 122 of Application Masterseal 300 H shall be applied directly from the containers using a brush or roller @ a minimum of 0.8 litre per sqm surface coverage to achieve a continuous coating Continuous coating may be achieved in 2 coats of application (minimum) The coating shall not be applied in the dusty weather conditions No post application curing is required Equipment Brush Roller Attachment MBT Statement #54 Hand excavation to install Telephone ducts between box no. 20 to telecom centre Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the laying in 2 No. 4 “ dia PVC ducts for telecommunication cables over the existing ducts between box No. 20 to telecom centre. References Drawing Nos. Specification. Excavation & Backfilling for Underground structures. Definitions PSM CM CS FM Project Site Manager. Construction Manager. Construction Superintendent Foreman Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 123 of Responsibilities CM shall plan and resource the trench excavation and backfilling activity, in accordance with this method statement. The Construction superintendent shall control and monitor the operations directing the construction Foreman The Construction Foreman shall execute these activities directing the workforce as necessary. EPC Contractor shall control the activities. Safety Prior to the commencement of any activity, the labour force shall receive a toolbox talk on the project site safety requirements. Any process that is adopted having a particular safety risk shall be assessed and addressed as required. A competent inspector shall inspect the trench daily to assess the safety measures adopted as well as after every rainstorm. If required, the shoring shall be provided to prevent the caving in. In case of the trench depth being more than 1200 mm, adequate means of exit such as ladders or steps shall be provided and located no more than 8 m of lateral travel. Barricades, markers and the night-lights etc., shall be arranged as required. Status The site is located at the police station where 2 no. manholes MH2 and MH3 exist The manholes centre-to-centre distance is 141 m. The proposed section to be excavated is 500mm wide and 1000 mm deep. Additional / spare 2 nos. PVC ducts 4 “ dia are to be provided above the existing ducts The access road to the police station is wearing asphalt course From manhole no. 3 to no. 2 i.e. 141 m is running under the police station car park and the access road. The main portion of the line in the middle as shown is access road and the parking facility for the police station The internal portion of the line from man hole no. 2 to the internal Telecom Vault is also running beneath the interlocking blocks paving after crossing under the fence wall Method The work shall involve the following operational procedures. Between man hole No. 3 and No. 2. Remove the interlocking blocks Road cutting at the police station entrance across 500 mm wide or as required Bridge the gap at the road cut using steel plates to facilitate the smooth traffic plying Manual excavation of the trench in the entire 141 m length Sand bedding 75 mm Install 2 nos. 100 mm dia pipe ducts Sand filling over the ducts 75 mm Backfilling as specified Refixing the interlocking tiles Making good the access road Removing the steel plates Between the manhole No. 2 and the internal telecom vault Removing the interlocking blocks Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 124 of Manual excavation of the trench to the existing ducts from the manhole No.2 to the internal vault crossing below the fence wall Sand filling 75 mm thick below the proposed duct Laying ducts Filling 75 mm thick sand over the laid ducts Entering cable way Making good the entry Backfilling as specified Refixing the interlocking blocks to the pattern Clearing the site Details External The existing interlocking paving tiles shall be removed to a safer location from the required work area and stacked properly The access road shall be cut across to the required level exposing the existing ducts and the bridging steel plates be laid over completely to facilitate the car access The manual excavation shall be carried out in the entire length of 141 m to the given sectional dimensions upto the existing ducts as shown After the excavation to the required depth is completed, a 75 mm thick layer of sand shall be filled in on the existing ducts to receive 2 nos. 4 “ dia new ducts which be placed and further covered with another 75 mm thick sand layer After the sand is filled in, the backfilling shall be carried out according to the project specifications upto the bottom of the interlocking blocks to be refixed After the backfilling is completed, the interlocking blocks shall be refixed to the same location or the pattern, which existed before these were removed. The backfilling shall be done in the road cut part upto the concrete bottom and asphalt laid over After the whole backfilling is over, the effected access road shall be made good by asphalt laying on concrete base Internal The interlocking blocks shall be removed from the proposed marked route and stacked well and safe to be reused The excavation shall be carried out on the entire length from the fence to the existing vault The excavation shall be carried out from the manhole nos. 2 to the inside of the wall penetrating beneath The whole route of the existing ducts shall be exposed Sand shall be filled in 75 mm thickness over the existing ducts Spare ducts 2 nos shall be laid over the sand filling over the existing ducts Further sand filling 75 mm thick shall be carried out to cover the new ducts and the backfilling be commenced to the bottom of the existing interlocking pavement according to the specifications After the backfilling is over, the interlocking blocks shall be refixed to the existing pattern and the effected wall portion be repaired to the extent of damage if any Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 125 of The external portion from the wall to the manhole shall also be sand filled and backfilled according to the details The whole work shall be approved Equipment Jackhammer Compressor Attachment Sketch #55 Backfilling of the west side of the quench tower foundation – (rib) Top Index Scope Reference documents Existing Windows Section as per drawing Reasons for Proposal Details of New proposal and Location change in Placement Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted for the construction of west direction extended part of the design foundation / Cantilever rib. References Drawing The revised IFC drawing was received after the completion of the blinding concrete and Rebar binding works. Definitions PSM Project Site Manager. CM Construction Manager. CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource the activities in accordance with this method statement. The Construction Superintendent shall control and monitor the operations directing construction Foreman. Foreman shall execute and assist monitor these activities directing the workforce necessary. EPC Contractor shall control the activities. the the the as Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 126 of Safety The workforce shall receive every day before the commencement of any activity a Tool Box talk relevant to the operation according to the project requirements. All the safety measures shall be arranged according to the operational requirement. Method The extended part shall be constructed to the following sequences. The concrete shall be poured to the preparatory works carried out on site. The deshuttering shall be done after 14 days. Application of the membrane to the underside / soffit of the slab. Backfilling the underside space by the lean mix PBFC 20 grade concrete. Details Since all the preparatory works such as the bending and binding of the reinforcement, centering and shuttering of form work, propping etc., and all the relevant activities have been carried out to the design requirement per previous revision and according to the project specifications, the concrete shall be poured to the works done. After the completion of the pour and the sequential curing and a lapse of 14 days, the forms shall be struck from the underside of the slab / soffit The formed surface shall be applied with the protective concrete membrane as specified and shown on the sketch The space left between the soffit and the prepared ground shall be prepared for the concrete filling by erecting the formwork in the letter box style The forms shall be fabricated according to the following descriptions Bottom panel of 600 mm height shall be erected around Top panel of 200 mm shall be prepared in letter box style to allow the pour of the concrete The top panel post pour shutters shall be made ready before the commencement of the concrete Immediately after the pour reaches to the brims / soffit level The top panels shall be placed in position to close all the external surface and supported to the requirement The forms shall be struck as per the project specification Equipment Concrete Pump Concrete Transit Mixers Attachment Sketch #56 Excavation Cooling water outfall chamber Top Index Scope Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 127 of Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to carry out the excavation for the foundation in respect of the Cooling Water Outfall Chamber. References Drawing Specification Excavation & Backfilling for Underground structures. Definitions PSM Project Site Manager. CM Construction Manager. CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource the excavation activity in accordance with this method statement. The Construction Superintendent shall control and superintend and monitor the operations directing the Foreman as required. The Construction Foreman shall execute these activities, deploying the workforce on the job as necessary. EPC Contractor shall do surveillance on the operations. Safety Prior to the commencement of any activity, the labour force shall receive a tool box talk on the project site safety requirements. Any process that is adopted having a particular safety risk shall be assessed and addressed according to the project safety requirements. A competent inspector shall inspect the excavated area daily as well as after every rainstorm to assess the safety measures adopted. If required, the shoring shall be provided to prevent the caving in. In case of the trench depth being more than 1200 mm, adequate means of exit such as ladders or steps shall be provided and located no more than 8 m of lateral travel. Barricades, markers and the night-lights etc., shall be arranged as required. Design Status The centre lines of the proposed structure and the coordinates meet at N (Typ) and E (Typ) The plan size of the chamber is 10.025 m x 7.2 m The excavation has to be carried out to the +2.3 m level from RGL +10.500 i.e a depth of 7.8 m shall be excavated Method The excavation shall be carried out to the following sequences Setting out the lines Barricading the area Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 128 of Excavation in stages as shown on sketch Details Attached sketch To start with, a surveyor shall set out the site for the excavation to the exact lines and coordinates references. After the setting out, the excavation lines shall be marked 4750 mm away from the proposed external faces of the structure as shown on the sketch. The excavation shall be carried out to the details shown on the sketch in 5 steps of size 750 mm tread and 1500mm riser and the bottom step of 675 mm riser. The size of the lowest level excavation shall be 120025 x 9200 mm and that of the top 19525 x 16700 mm. The excavation shall be started from one end and the top 750 mm deep be completed The access shall be ramped for the equipment to enter. The excavation shall be carried out in strips of 750 mm depth until the whole earth mass is taken out. The excavated earth shall be transported to the stockpiles immediately keeping the site tidy. Equipment Excavator Dumper Attachment Sketch #57 Drilling of holes on Pipe rack & structures on site Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Scope The purpose of this Method Statement is to define the sequence and methodology that shall be implemented for the drilling of holes on structural steel members that have been erected and which requires the drilling of holes due to manufacturing error in location or design change after the beams have been primed or finished coated. Reference Documents Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 129 of Specification Steel Structure Fabrication Specification Painting Specification Galvanizing Specification Structural Steel Erection ANSI A 10.13 Safety Requirements for Steel Erection Relevant Drawings Definitions CM CS FM Construction Manager. Construction Superintendent Foreman Responsibilities CM shall plan and resource the drilling of holes, in accordance with this method statement. The Construction Supertindent shall monitor these activities, directing the workforce as necessary. The Erection Foreman shall control the workforce ensuring the full implementation of this method statement including safety measures. Safety Prior to the commencement of any activity, the labour force shall receive a tool box talk on the project site safety requirements. Any process that is adopted having a particular safety risk shall be assessed and addressed as required. The use of cranes or man lifts shall be assessed and all safety regulations enforced. Men working at heights shall be equipped with the required personal safety equipment. Method The new location of the hole centres on the specific member item shall be marked as per the details on the drawing or drawing revision. Using a drilling machine, preferably a magnetic base drilling machine, a pilot hole of size 8mm or 10mm diameter shall be initially drilled. These holes shall be subsequently drilled to the specified diameter. The area around the holes shall be cleaned, burrs removed and edges rounded off. This shall be effected by either using emery paper or grinding wheel. The bare surfaces is made dust free and cold galvanizing applied as a coat with ‘Jotun Barrier 86” , a two pack zinc-rich epoxy primer . Allow about 4 Hours for drying. Make necessary touch-ups using the same grade, colour which were used to paint the structure-prime coat and the top coat if necessary. Equipment Drilling machine Man lift Scaffolding if required Grinding machine #58 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 130 of Site office establishment Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement, is to define the procedure that shall be adopted for the establishment of the site office. Reference documents Approved Site office layout and details drawings. Definitions EPC Contractor Civil Contractor . PSM Project Site Manager. CS Construction Superintendent. IS Infrastructure Superintendent. ST Survey team. Responsibilities The PSM shall ensure the establishment of the site office complex is in accordance with the drawings and agreed specifications. The Construction Superintendent shall coordinate and supervise the day to day activities, along with the Foremen and Survey Team. Safety The Safety Officer shall monitor the daily activities, advising and implementing all safety procedures. Method The site shall be graded and compacted to the levels indicated upon the approved grading drawings. The ST shall check the final grades. A record drawing of the final grades shall be produced. The ST, using approved drawings, shall set out the relevant issues such as service trenches and foundations. Services: Service trenches relating to the site office complex, for the drainage, water, electric and fire water, shall be set out. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 131 of Working to levels, a mechanical excavator shall excavate the trenches. Excavated material shall be re-used for backfilling when the services have been installed. Surplus material shall be removed from site. The services may share common trenches where appropriate. The drainage pipes shall be installed to grade. Manholes shall be placed at locations indicated upon the site office complex drainage drawings. Sewage holding tanks shall be located as per drawing. A steel tank shall be utilized for water storage. The tank shall be backfilled as appropriate. Draw pits and chambers for cabling shall be located in a similar manner. All service trenches shall receive appropriate sand bedding and surround, plus warning tape for cabling shall be provided. Where any services shall cross an area that shall be trafficked, the service shall be ducted or / and protected with concrete surround as appropriate. Foundations: For the pre-engineered office units, the foundation layout drawing that indicates the precast concrete block foundation locations, shall be utilized for the setting out. The precast concrete foundation blocks, shall be placed upon the pre graded ground. The pre-engineered office units, shall be off loaded from the delivery wagon, direct onto these blocks. Shim plates shall be used between the precast concrete block and the unit chassis where necessary. Power Supply: The relevant pre-engineered sections shall be sealed. The relevant utilities that require connection shall be connected. The appropriate electrical power supply and distribution network shall be provided and commissioned as per approved drawings and schematics. The appropriate checklist shall be utilized. Telephone Service. Etisalet shall provide the service to the designate locations within the building. The internal distribution system shall be installed as per approved scheme. Infra structure: Access roads to the site office shall be constructed according to the layout drawing. Footpaths around the site office shall be constructed as per drawing. Drainage ditches for stormwater shall be graded according to the site office layout drawing. Parking areas as indicated on the site office layout drawing, shall be constructed including covered shelters where appropriate. Equipment Excavator. Dump trucks. Crane. Attachment ITP No: Temporary Building Checklist QCF08. #59 Welding of Earthing Lugs on Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 132 of East West Piperack (SR0099A &B) Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this Method Statement is to define the sequence and methodology that shall be implemented for the welding of Earthing Lugs on the columns of the East West Piperack steel structure. Reference Documents Specification Steel Structure Fabrication Specification Painting Specification Galvanizing Specification Structural Steel Erection Drawing No. (Also Refer E-Mail of 6\11\99) - Attached for Reference Definitions PSM Project Site Manager CM Construction Manager. CS Construction Superintendent FM Foreman Responsibilities CM shall plan and resource this activity, in accordance with this method statement. The Construction Foreman shall monitor these activities, directing the workforce as necessary. The QC inspector shall ensure that the necessary visual inspection is carried out. Safety Any process that is adopted having a particular safety risk shall be assessed and addressed as required. Method The location of the Earthing Lugs on the respective columns shall be marked off. Approximate 30mm of the surrounding area shall be cleaned to remove the primer and galvanising. The Lug shall be initially tack welded to the column and then fully welded to the required fillet size. The fillet weld shall be cleaned and free of defects. Welding shall be done according to the approved WPS using duly qualified welders. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 133 of Visual inspection to be done prior to surface finish. The surface shall be inspected prior to cold galvanizing and painting. The bare surfaces is made dust free and cold galvanizing applied as a coat with ‘Jotun Barrier 86”, a two pack zinc-rich epoxy primer. Allow about 4 Hours for drying. Make necessary touch-ups using the same grade, colour which were used to paint the structure-prime coat and the top coat if necessary. Equipment Welding Machine Grinding Machine Attachment Drawing N0. Copy of E-Mail (indicating location of Earthing Lug) PQR No. QP-009 PQR No. QP-010 WPS No. QW-009 WPS No. QW-010 #60 Filling around all the pipes within the plant area Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted for the filling around the GRP pipes within the Plant Area. Reference Documents Specification PSM Project Site Manager CM Construction Manager. CS Construction Superintendent Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge FM QC Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 134 of Foreman Quality Control Responsibilities CM shall plan and resource this activity in accordance with this method statement. CS shall control, monitor and direct these activities. The Construction Foreman shall execute these activities deploying the workforce as necessary. The QC inspector shall ensure that the necessary inspection and test are carried out. Safety Any process that is adopted having a particular safety risk shall be assessed and addressed according to Project requirement. Method The following activities shall be involved to fill around the pipes laid within the plant area To fill the sand in 150 mm thickness around the laid pipes To fill the approved Red fill material in layers in the remaining trench space 150 mm compacted Details The first layer shall be filled 200 mm apprx. compacted to 150 mm. The field density test shall be conducted for 95 % compaction. A portion of the compacted material 150 mm radially shall be removed to replace with sand circumferentially . The sand shall be placed in the first layer portion to replace the filled material circumferencially. The structural fill material for the second layer shall be placed in 200 mm thick compacted to 150 mm for 95 % field density and tested according to the specifications. Again a portion of the compacted material 150 mm radially shall be removed to replace with sand circumferentially. The sand shall be placed in the second layer portion to replace the filled material circumferentially. Similarly the succeeding layers of fill material shall be placed in 200mm thickness approximately compacted to 150 mm according to the specifications and replaced by the sand filling as aforesaid until the apex level of the pipe is covered with sand. The remaining strata upto the ground level / required level shall be filled in with fill material in 200 mm approximately compacted to 150 mm thick layers according to specifications. Equipment Compactor Attachment Sketch showing various stages of filling #61 Precasting man holes Catch basin and Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 135 of Valve chambers Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to precast the manholes, catch basins and fire water main valve box (wherever so required to be used precast) chambers and install in specified prepared locations. Reference Documents Drg Drg Drg Drg Drg Drg Drg Drg Man Holes Man Holes Man Holes Man Holes Catch Basins Catch Basins Catch Basins Typical Details Specifications Definitions PSM Project Site Manager CM Construction Manager. CS Construction Superintendent FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 136 of Safety Every day prior to the commencement of any activity, the work personnel shall receive a Tool Box talk relevant to the operation according to the project safety requirements. A safety inspector shall inspect the operation daily and direct the Foreman and superintendent address the snags if any Method The following activities shall be involved: To prepare a precasting yard on site To fabricate the form works according to design details To fabricate the box outs to be used in forms To fabricate the reinforcement To place the rebars and the non critical cathodic protection To cast bases with a kicker and shear key as shown in the first stage and cure To scabble the kicker to roughen the construction joint surface To cast walls with pipes inlet and outlet boxes formed in the second stage with the lifting hooks To cure the cast units To cast the cover slabs in the third stage and cure Excavation of the relevant area / s Blinding and membrane Transportation of the completed open units to the locations Installation of the units on the correct alignment and levels Inspections by Civil Contractor QC and EPC Contractor approval To prepare the cover slab bearing mortar bed as specified To provide the box out sleeves for steps insertion Pipe laying by others To install the seals around the pipes and the box out concrete To cast the surrounding concrete 150 mm thick as specified To apply 1 mm thick coal tar epoxy on the external surfaces as specified To bench the invert levels between the pipe flows where specified Inspections by Civil Contractor QC and EPC Contractor approval To plug the pipe spigot ends To place the covers Details A precast yard having a capacity of about 20 units as shown on the attached sketch shall be used for the precasting operations The yard shall have convenience for the vehicles to freely move for various activities Strong platforms of 100 mm thick concrete shall be used as the casting bases / floors In one go about 10 units shall be made ready for the bottom slab pouring The overlap shall be provided from the top of the kicker as specified and if so convenient the rebars shall be fabricated continuously The formwork for the base slabs with kickers to be cast monolithically shall be prepared according to the typical sketch attached Required rebars shall be placed in the correct locations with 75 mm covers / spacers Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 137 of Shear key forms shall be erected according to the details and well clamped in Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval The concrete shall be poured through a chute The curing shall be carried out by spraying compound and later by saturated hessian and polythene cover The wall formwork shall be fabricated on site using marine ply The internal forms shall be fixed first to the correct dimensions The box outs shall be fixed to the required locations on the fixed forms The rebars for the walls as well as the trimming around box outs shall be placed in position The external forms shall be fixed around well supported, in plumb and correct dimensions The lifting lugs shall be placed in the required locations in the walls using 16 mm dia rebar according to the detailed sketch attached A binding wire length shall be tied to the horizontal rebars in continuity connected to the boss fixed near wall top for the cathodic non critical arrangement / connection Civil Contractor QC inspection followed by EPC Contractor approval Pouring concrete into wall forms with wood float top surface finish and curing by compound and later by hessian and polythene cover for the specified period Forming cover slab shutters according to the specified details Forming the cover box out shutters into the required position Placing the rebars into the correct positions Fixing the cover lifting hooks according to details attached Civil Contractor QC inspection followed by EPC Contractor approval Pouring concrete and curing as aforesaid Inserting the steps shall be carried out by fixing the pieces into the preformed holes in the concrete walls as created by box sleeves with approved grout at a stage when the concrete has gained sufficient strength The excavation shall be carried out to the specified level and alignment followed by blinding and water proofing The open precast chambers shall be crane lifted and transported by a trailor to the relevant locations followed by offloading into the correct alignment The pipes shall be laid by others After the pipes are laid, specified seals shall be placed in with the surrounding concrete as well as the box out void forms erected followed by concrete pouring into the box out voids and the plug(concrete surround) The benching wherever specified shall be formed according to the channel flows and the details The bedding of the joint 20 mm thick shall be carried out on site as specified After the levels and the alignment are ensured, the cover slab shall be correctly placed in followed by the formation of the concrete block work pad to suit the cover elevation The cover shall be set in on the block work pad using cement sand mortar The mass concrete shall be laid around the cover as specified The external surfaces shall be applied with 1 mm dry film thickness non solvented coal tar epoxy in accordance with project specifications Civil Contractor QC inspection followed by EPC Contractor approval Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 138 of The whole levels and the alignment details shall be documented according to requirement Equipment Crane Concrete Transit mixer Trailer Vibrator Attachment Yard layout Kicker details Sketch showing lifting hooks for unit walls and base Sketch showing lifting hooks for cover slab #62 Termination detail to protective membrane around rcc columns supporting the structural steel Columns for pipe racks CASE (1) WITH ALUMINIUM BEAD CASE (2) WITH REBATE CASE (3) GRAVEL FILL CASE (4) PAVING Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures that shall be adopted to clampin the waterproofing membrane termination using Aluminium Beads around the column sides to substitute the formation of the conventional rebate partly for the pipe racks foundations and for the other areas such as hard / soft landscapes. References STQ , MAR Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Definitions PSM CSM CS SE FM QC Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 139 of Project Site Manager Construction Manager Construction Superintendent Site Engineer Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the toolbox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a toolbox talk on the Project Site Safety requirements relevant to the activity involved Any process adopted which may involve a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. The personnel shall use the PPE, gloves, masks, eyeglasses etc. To avoid skin contact, use of barrier cream to protect from the adverse effect of sealant application shall also be made. Industrial cleaner shall be used followed by washing with soap and water. Material safety data shall be referred to for disposal and any further information. A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who shall immediately implement the instructions accordingly. Storage The material including the sealant shall be stored under cover out of direct sunlight and protected from extreme temperatures. All the manufacturer’s instructions shall be followed for the purpose. Materials Aluminium Bead lengths to the Sectional dimensions 30 mm x 2 mm Drilling and fixing screws 3 mm dia Sealant- Polyurethane-Gun Grade Cold seal 200PF for horizontal usage on Aluminium strip (Manufacturer BCR) (Emirates Specialities) or equivalent Method The following operational sequences shall be involved Case 1 To cut the Aluminium beads to the exact dimensions according to the column size requirement. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 140 of To provide every column 4 # beads by drilling and fixing using Hilty equipment To connect the bead to the column side keeping the membrane tacked in by drilling and fixing screws 3 # each side To apply sealant a few mm above on the top of the bead covering the bead / column surface junction and a portion few mm downwards well finished to a smooth profile Case 2 Where the grooves have already been chased, the waterproofing membrane shall be tacked in with the sealant applied according to the specifications and the manufacturer’s instructions. No Aluminium bead shall be used for this case. Case 3 Where the area comprises soft landscape such as gravel or soil fill Case 4 Where the area comprises hard landscape such as paving Details Case 1 Application of the waterproofing membrane according to the specifications to the defined levels keeping the top 200 mm or variable dimension according to the drawing above the finished ground level Marking shall be made to the exact line and level to obtain the profile as per drawing Required lengths to the exact site dimensions shall be cut to suit a close fit between the bead ends Every bead shall be provided 3 # minimum screws to be drilled and fixed into the bead and the concrete penetrating the membrane The screws shall be fixed using an electrical operated Drill and Screw After the screws have been fixed into and the beads are in proper alignment / the location, approved sealant shall be applied to the top of the bead keeping about 5 mm above the bead with an overlap on the down ward on the bead as follows Application of sealant The material shall be applied using a sealant gun fitted with conical nozzles adjustable to suit the width The sealant shall be gunned into the junction using an even trigger pressure, cleaning the nozzle occasionally to avoid contamination. A smaller timber spatula soaked in soapy water shall be used to compact the sealant into the joint for a smooth polish finish formation. The mixing and application equipment shall be cured immediately Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval Case 2 Where the conventional groove is to be provided, the sealant shall be applied on to the space left in the groove after the application of the water proofing membrane termination has been trimmed .The sealant shall be applied around and formed continuous according to the manufacturer’s instructions Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 141 of Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval Case 3 In gravel or soil area the membrane shall be terminated at a level 150mm plus below the footing top keeping the Aluminium bead strip details typical. All other details shall remain Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval as in case 1 if no rebate be chased Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval Case 4 In the paved area the membrane shall continue upto the termination level but the protection board cease at 20 mm below the paving level filled with mastic on top keeping all other details as in case 1 if not chased for rebate Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval Equipment Electrical operated drill Sealant applying gun Attachment Sketches as in STQ Case wise description #63 Termination detail to protective membrane around rcc columns supporting the structural steel Columns for pipe racks CASE (1) WITH ALUMINIUM BEAD CASE (2) WITH REBATE CASE (3) GRAVEL FILL CASE (4) PAVING Top Index Scope Reference documents Safety Method Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 142 of Scope This statement is aimed to propose the procedures to be adopted to clampin the waterproofing membrane termination using Aluminium Beads around the column sides to substitute the formation of the conventional rebate partly for the pipe racks foundations, other structures and for the other areas such as hard / soft landscapes. References MAR (Site fixed sample approved) Safety Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox talk on the relevant activity to the Project Site Safety requirements Necessary measures shall be applied to address any risk involved on any process The personnel shall use the PPE (gloves, masks, eyeglasses etc.) Use of barrier cream to protect skin from the adverse effect of sealant shall also be made. Material safety data shall be referred to for disposal and any further information. A safety inspector shall visit the site every day and instruct the supervisor in case any snag is noticed who must immediately implement the instructions Materials Aluminium Bead lengths to the Sectional dimensions 30 mm x 2 mm Screws 3 mm dia Sealant- Polyurethane-Gun Grade Cold seal 200PF for horizontal usage on Aluminium strip (Manufacturer BCR) (Emirates Specialities) or equivalent Method The following operational sequences shall be involved Case 1 Concrete surface shall be cleaned of all dirt & dust using a brush Application of the waterproofing membrane according to the specifications to the defined levels keeping the top 200 mm or variable dimension according to the drawing above the finished ground level Lines shall be marked on all sides to correct level as per drawing Bead Lengths to exact site dimensions shall be cut to suit a close fit between the ends Every bead shall be provided with a minimum 3 # screws to be drilled and fastened into the concrete penetrating the membrane using an electrical operated Drill After the screws have been fastened and the beads are in proper alignment, approved sealant shall be applied to top of the bead keeping about 5 mm above the bead with a down ward lap as follows Sealant shall be applied using a gun fitted with conical nozzles adjustable to suit the width into the corner using an even trigger pressure & cleaning the nozzle occasionally to avoid contamination. A smaller timber spatula soaked in soapy water shall be used to compact the sealant into the joint / junction for a smooth polish finish formation. The mixing and application equipment shall be cleaned immediately after use Civil Contractor QC inspection shall be conducted & the relevant ITP signed off Case 2 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 143 of Where grooves have already been chased, the waterproofing membrane shall be tacked in & sealant applied to the space left in the groove according to specifications and the manufacturer’s instructions. No Aluminium bead shall be used in this case. Sealant shall be applied around bead continuously Civil Contractor QC inspection shall be conducted & the relevant ITP signed off Case 3 In gravel or soil area, membrane shall be terminated at a level ‘150mm plus’ below the footing top level keeping Aluminium bead details typical. All other details shall remain as in ‘case 1’ if no rebate has been chased Civil Contractor QC inspection shall be conducted & the relevant ITP signed off Case 4 In the paved area, membrane shall continue upto the termination level but the protection board cease at 20 mm below the paving level filled with mastic on top keeping all other details as in case 1 if not chased for rebate Civil Contractor QC inspection shall be conducted & the relevant ITP signed off Equipment Electrical operated drill Sealant applying gun Attachment Sketches Case wise description #64 Road crossing for laying 2 pipes 1 for 20” raw ethane & 1 for 6” propane First street Operating Authority entry Top Index Scope Reference documents Definitions Responsibilities Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road crossing to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at location identified on the attached drawing to the following references Reference documents Specification. Excavation & Backfilling for Underground structures. Drawing No. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 144 of Easement Systems 1 ST Street Piping Interconnection Drawings, First Street Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly and be overall responsible for the excavation operation CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS Any mishap on the excavation operation shall immediately be notified to the CS and the CM for the immediate action if so required for any possible remedy or record or the authority review whatsoever,the case may be FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process is adopted having a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. In the present case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be resorted to effect a full safety standard. ToolBox TalksWhile conducting ToolBox Talks, a representative from the authority shall be involved to witness and sign the instruction imparted with the workers prior to the commencement of the operations to make a record. Only English literate Foreman shall be employed to work on the excavation execution. Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all the relevant persons involved on the crossing Traffic Management-Sign boards keep up-All the personnel shall be briefed about the safe keep up of the boards Barricades,cones, markers and the night-lights, flood lights etc. shall be arranged as required for a complete safety. No oil spillage shall be allowed. The sides of the excavation shall be sloped with the barriers placed to indicate the excavation work in progress Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 145 of Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be engaged to operate full time to direct the traffic about the excavation work in progress by waving the flag for all the vehicles passing by Hand Excavation- Excavation required to be by hand shall only be carried out manually. In case certain services not shown on the record drawings such as fibre optics cable is discovered, the excavation shall be ceased to be continued until the decision to hydrojetting is taken up and the authority are involved. Jack Hammer- The worker engaged on operating this equipment shall use protective glass and work in phases with pause intervals. The compressor air pressure shall be monitored from time to time so that the hammer works smoothly. The compressor shall be place within the barricade limits Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out. No jumping shall be allowed Machine Excavation The operators shall be explicitly explained and instructed about the requirement of the reverse signal and sound when operating reverse. The truck driver shall also be instructed similarly. Banksman shall be engaged while the equipment operate. No violation of the traffic rules shall be allowed Deep Trenches If required, the shoring shall be provided to prevent the caving in. In case of the trench depth being more than 1200 mm. Adequate means of exit such as Aluminium ladder or steps shall be provided and located no more than 8 m of lateral travel. Plants preservation The live plants and the trees arboricultured shall be deplanted integrally with the roots and preserved to the specialist requirement so that these remain live till the replantation is carried out all to the satisfaction of the specialist Safety Supervision A competent inspector shall inspect the trench daily to assess the safety measures adopted. Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme has been presented herein and shall be produced on site as detailed on the attached sketch for this road crossing which includes, reduced speed sign, temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety barriers, night lighting and road cleaning activities. The traffic management scheme shall be reviewed and approved by EPC Contractor prior to commencing the work. The aforesaid traffic management scheme shall be implemented as described below: TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street Drawing reference – This proposed crossing is located on the road 1 st Street between the following co-ordinates as shown on the referred drawing. This is a 2-way road with a central verge and carrying 1 lane on either way Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 146 of Both ends of the crossing are existing earthen ramp. On the central verge 4 minor irrigation pipes are in service. On the West Side, one irrigation pipe is in service. On the East Side one irrigation pipe is disconnected. On the central verge one electric pole is in service. In addition to the aforesaid tiny plants are arboricultured. The proposed crossing is just situated at the access road to Operating Authority gate. The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side of the carriageway In the first instance the work shall be carried out on L1 diverting the traffic to the road portion on L2 as shown on the sketch. In the second instance the work shall be carried out on L2 diverting the traffic to the road portion on L1 as shown on the sketch. The road x-ing lies on the branch road hence one directory sign shall be fixed on both east and west side of the 1st street road at 200m from the location to indicate the work ahead .on the left and right directions respectively. The first board depicting ‘reduce speed’ for traffic diversion informatory shall be located at 100 m from the point of the proposed crossing and the second depicting ‘men at work’ sign be located at 100 m on either way in the opposite directions. A Flagman shall be engaged full time on both the directions to guide the traffic about the ongoing excavation operations in addition to the conventional signboards The following activities are involved. Reference to the marked note ‘B’ on the Easement Systems Drawing To produce the Traffic Management Scheme To divert the minor irrigation, electric pole, plants etc. temporarily as required. To excavate by hand and expose all the underground facilities (5.5KV / 0.24KV cables are available) Trial pit to be excavated in size (5mx2mx1.5m) deep by hand tools To seam the area with the detectors to ascertain the existing cables. To expose the cable fully and to be inspected by the authorities / Operating Authority After the exposure & diversion, the cables to be covered with split PVC pipes by others To continue the excavation mechanically according to the authority directions / and as agreed To excavate the remaining portion by the excavator machine To have authority inspection The pipes to be laid by others To fill the bedding material according to the specification requirement To reinstate the diverted services To reinstate the central verge to the existing state Details The Traffic Management Scheme shall be executed as explained in the foregoing and to the traffic manual directions. The first section of road crossing on both sides as per the attached sketch shall be marked by the surveyor on the actual location. The asphalt shall be cut using jack hammers. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 147 of The road section shall be excavated to expose the existing cables manually for which the trial pit may be made prior the full manual excavation is proceeded with. The existing electrical pole shall be diverted accordingly. The minor irrigation lines shall be diverted according to the Officials instructions. The plants shall be taken off the site for preservation After the exposure of the cables, the Operating Authority authorities shall inspect and the cables be diverted accordingly following which the remaining machine excavation be carried out to the specified levels The excavated material shall be removed from the site to stockpile area. Appropriate bedding material shall be placed within the excavated trench to the correct service level. Where required, this bedding shall be compacted and tested. The excavated trench shall be inspected by the authorities as required. The potable and the Desalinated water pipes shall be laid by others. Backfill around the service pipes shall be carried using the appropriate material. The service pipes surrounding material shall be compacted as per the project specification requirements. Test results shall be provided for the specification conformance verification. The existing services shall be reinstated accordingly. The plants or trees if removed and so required, shall be reinstated accordingly. General fill up to the underside of road formation shall be placed in 150mm compacted layers using mechanical methods to the specification requirements. A concrete slab shall be cast up to the bottom of the finished asphalt level. The finishing shall be carried out using approved asphalt mix. The traffic management system shall be removed after the road crossing has been cleaned of any debris or obstructions. Either side of the road shall be provided with cable markers to indicate the services Major Equipment Excavator.Dump trucks.Compactors. Jack Hammer, Compressor, Attachment Sketch showing the traffic management scheme Drawings including the traffic diversion #65 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 148 of Road crossing for laying 2 pipes 1 for 20” raw ethane & 1 for 6” propane First street Operating Authority entry Top Index Scope Reference documents Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road crossing to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at location identified on the attached drawing to the following references Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect a full safety standard. Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all the persons involved on the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On both directions, in addition to the traffic sign boards, a flagman shall be engaged full time to direct the traffic about the excavation work in progress by flag signal Hand Excavation- Excavation to expose the services be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased and hydrojetting applied. Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out. No jumping shall be allowed Machine Excavation Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 149 of The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged while the equipment operates. No violation of the traffic rules shall be allowed Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced as detailed on the attached sketch Drawing reference Piping Interconnections First Street’: Existing Services One lighting pole is located on the central verge adjacent to the proposed excavation The minor irrigation / hoses exist to irrigate the central verge plantation Some minor trees and plants are also growing on the central verge. The road shall be divided in 2 parts as shown on the sketch as L1 and L 2 In the first instance the work shall be carried out on part L1 diverting the traffic to the road portion on the part L2 In the second instance the work shall be carried out on part L2 diverting the traffic to the road portion on the completed road portion on the part L1 Instance 1 The asphalt shall be removed Hand excavation shall be carried out to expose the cables & other services by seaming the area with detectors After the exposure, all the cables shall be covered with split PVC pipe to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine Preparation of the trench to lay RCC pipe sleeves shall be carried out Bedding material shall be laid to receive the pipe sleeves Pipe sleeves with dia 8 “ more than the specified respective pipes dia shall be laid to the design alignment and levels Filling over the pipe sleeves shall be carried out to specifications The diverted services shall be reinstated Backfilling up to the road formation shall be carried out to specifications The above operations shall be repeated for Instance 2 The central verge shall be made good & the diverted services reinstated A 70 mm thick layer of concrete shall be laid in place of the asphalt concrete. This shall be subsequently broken out and replaced by asphalt when the asphalt plant is next in operation The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. Either side of the road shall be provided with cable markers to indicate the services Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Attachment Sketch showing the traffic management scheme #66 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 150 of Directional boring For laying sleeves for 2 pipes 1 # 20” raw ethane & 1 # 6” propane Operating Authority Plant refinery entry Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the directional boring under the road to facilitate to lay the sleeves for pipe lines 1 # each 20” Raw Ethane and 6” Propane at location identified on the attached drawing to the following reference Drawing reference –Piping Interconnections First Street: Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect a full safety standard. Excavation Work PermitA copy of the work permit shall be posted on a mini board installed on site at the location shown on the sketch to be noticeable to all the persons involved A copy shall also be transmitted to EPC Contractor Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required at the pits for a complete safety. Method The necessary permit to work shall be obtained from the Plant Refinery Division. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 151 of The record drawings regarding the existing services shall be obtained 2 # trial pits shall be made manually on both ends of the proposed boring to ascertain the availability of the existing services and protect these from any damage and shall also be used for the bentonite trial at the receiving end On site, sufficient excavated space is available to lower the sleeve in to pull into the bore On Eastern end, some electric cable is existing 2 # 24” pipe lines are also existing adjacent to the proposed route Minor trees on both ends may be effected in the roots The excavated trench does not show any sign of water therefore, no de watering shall be carried out Excavation shall be carried out according to the requirement On East End missing the berm, boring machine shall be positioned in the trench at about 3 m from the berm The boring shall be carried out in stages. First stageThe sleeve is in the trench on the West end and the reamer fully underground. Second stageThe sleeve is partly pulled in and the reamer partly withdrawn Third stageThe sleeve further pulled and the reamer withdrawn accordingly Fourth stageFull portion of the sleeve is underground in the bore and the reamer out The excavated trenches on both ends shall be backfilled by Civil Contractor according to the specification requirement and the required tests carried out The reinstatement of the effected services shall be carried out after the directional boring is completed Directional Boring – A non- excavation Method which does not allow collapsing of the ground surface M / S Ditch Witch shall carry out the Directional Boring employing Jet Trac Directional Boring equipment according to their method statement attached. Refer to the attached sketches based on the Ditch Witch guidelines Bentonite is pure clay to be used as a fluid / slurry formed by mixing water. It shall be used to cool the drill bit and to lubricate the drill area The material displaced by the head / sleeves shall be discharged at the receiving end in the receiving pit and removed from the site All fully trained operators shall be used on the job Major Equipment Jet Track Unit (complete package), Crane, Compactor Attachment Plan of the area indicating trial pits etc Ditch Witch Method Statement Cross-Section Sketches showing the indicative procedures #67 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 152 of Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the thrust boring under the road to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at location identified on the attached drawing to the following reference Drawing reference –Piping Interconnections First Street Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect a full safety standard. Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all the persons involved Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required at the pits for a complete safety. Traffic Signs- Necessary traffic signs at the pits shall be provided Hand Excavation- Excavation to ascertain the routes of the existing services encountered during Thrust Boring in case not shown on the record drawings shall be carried out manually. Method The necessary permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. Non Excavation Method Necessary drive and receiving pits shall be excavated by Civil Contractor according the approved procedures M / S Ditch Witch shall carry out the Thrust Boring employing Jet Trac Directional Boring according to the brief procedures given below The Jet Track unit shall be anchored to the ground surface using hydraulically operated anchor stakes The directional boring / Angled bit shall be drilled into the ground using fluid assistance to operate. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 153 of Bentonite and water shall be used to form a fluid to be sprayed at low pressure ejected out of the drill head to lubricate the drill procedure as well as to cool electronic tracking components in the drill head An electronic receiver shall be used to track the head from the ground surface and when the directional control is required, the head shall be pushed by the drill unit without rotation until the drill head angle is reached Head shall be steered to the ground surface when it reaches the destination end Then Drill head shall be removed from the drill pipe and a backreamer with a pipe puller attached alongwith the pipe / s to be installed underground During backreaming, the drill fluid shall assist the backreamer lubricate and form slurried area for the installable pipe Backreaming and pipe pulling simultaneously shall allow the pipe to be installed underground without excavation and continue until the backreamer and pipe reach the launch end of the Directional bore accomplishing boring complete Necessary tests shall be carried out by EPC Contractor Major Equipment Jet Track Unit complete package Attachment Ditch Witch Method Statement Sketches showing the indicative procedures #68 2 #s road crossings For laying 1 for 14” desalinated water 1 for 8”potable water & 1 for 20” raw ethane 1 for 8” natural gas 1 for 6” propane Avenue ‘c’ At fire station Top Index Scope Safety Method including traffic management scheme Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 154 of Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road crossings to construct culverts to facilitate to lay the pipe lines 1 # each 14” Desalinated water, 8” Potable water and 1 # each 20” Raw Ethane, 8” Natural Gas and 6” Propane at locations identified on the attached drawing pertaining to avenue C at existing Fire Station Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed, to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to have ‘ full safety standard’ effect. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the adopted safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On all directions, in addition to the traffic sign boards, flagmen shall be engaged full time to direct the traffic about the ‘excavation work in progress’ by ‘flag signal’ Hand Excavation- Excavation to expose the services shall be carried out manually. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 155 of In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged during equipment operation. No violation of the traffic rules shall be allowed Pre cast members Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising & downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced as detailed on the attached sketch Drawing reference – Piping Interconnections Road Avenue ‘C’: N Existing Services One serving electric pole is located away from the crossing towards North The minor irrigation / hoses exist to irrigate the central verge plantation Street light electric cables exist & Some minor plants also growing on the central verge. The road shall be excavated in one instance by diverting the traffic on both sides as shown Procedures Backfilling shall be carried out to the existing excavated cross trenches on both end of the proposed crossings up to the natural ground level to provide effective traffic ‘divertion routes’ from the road carriageways according to the traffic management scheme attached Traffic management scheme shall be implemented effectively Existing services from the central verge shall be diverted or protected as required and directed by the competent concerned authority The asphalt and the central verge pertaining to the crossings portion shall be removed Hand excavation shall be carried out to expose the cables & the other services by seaming the area with detectors After the exposure, all the cables shall be covered with split PVC pipe & well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culverts shall be carried out The construction pertaining to the pipe carrying culverts including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc.shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members In addition, one access boxout on both ends shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 156 of The central verge shall be made good & the diverted services reinstated The broken asphalt portion shall be made good using new asphalt The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. 75 mm dia holes in the pre cast units meant for lifting shall be filled with concrete Access boxout shall be closed with concrete after the pipes are laid Either side of the road shall be provided with cable markers to indicate the services 8 mm galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic management scheme #69 2 #s road crossings For laying 1 for 14” desalinated water 1 for 8”potable water & 1 for 20” raw ethane 1 for 8” natural gas 1 for 6” propane Avenue ‘c’ At fire station Top Index Scope Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road crossings to construct culverts to facilitate to lay the pipe lines 1 # each 14” Desalinated water, 8” Potable water and Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 157 of 1 # each 20” Raw Ethane, 8” Natural Gas and 6” Propane at locations identified on the attached drawing pertaining to avenue C / First Street Road Crossing at existing Fire Station Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed, to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to have ‘ full safety standard’ effect. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the adopted safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On all directions, in addition to the traffic sign boards, flagmen shall be engaged full time to direct the traffic about the ‘excavation work in progress’ by ‘flag signal’ Hand Excavation- Excavation to expose the services shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- the workers shall clearly be instructed to use only the ladders to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged during equipment operation. No violation of the traffic rules shall be allowed Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 158 of Pre cast members Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising & downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced as detailed on the attached sketch Drawing reference Piping Interconnections Road Avenue ‘C’: Existing Services One serving electric pole is located away from the crossing towards North The minor irrigation / hoses exist to irrigate the central verge plantation Street light electric cables exist & Some minor plants also growing on the central verge. The road shall be excavated in two instances by diverting the traffic on either lane completing one after the other as shown on the traffic management scheme Procedures Traffic management scheme shall be implemented effectively Existing services from the central verge shall be diverted or protected as required and directed by the competent concerned authority Instance 1 The asphalt and the central verge pertaining to the crossing portion Stage-1 shall be removed Hand excavation shall be carried out to expose the cables & the other services employing seaming the area with detectors to detect the existence of cables After the exposure, all the cables shall be covered with split PVC pipe & well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culverts shall be carried out The construction pertaining to the pipe carrying culverts including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc.shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members In addition, one access boxout at the end shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications The broken asphalt portion shall be made good using new asphalt Instance 2 The aforesaid activities shall be repeated for this instance for the crossing portion Stage-2 The central verge shall be made good & the diverted services reinstated The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. 75-mm dia holes in the pre cast units meant for lifting shall be filled with concrete Access boxout shall be closed with concrete after the pipes are laid Either side of the road shall be provided with cable markers to indicate the services Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 159 of 8 mm galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details. Other chequer plates shall be provided to the design details Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic management scheme #70 Administration building GRC Panel fixing Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the fixing of preformed GRC panels to columns, parapet and horizontal bands ( locations where there are no projected beams and also where the projected beams exist). Reference documents Drawings- ELEVATIONS FIBREX Shop Drawings and Statement Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 160 of CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of any activity the work force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process is adopted having a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. Adequate scaffolding shall be provided for the safe access to the work location Safety harness shall be provided for the personnel working at heights Method The work of the GRC manufacturing and fixing shall be carried out by the Fibrex Co. W.L.L PO Box # All the metal hanger sub frames exposed surfaces shall be painted to specifications Fixing Column Panels The floor finish level shall be marked and the bottom defined. The bottom fixing level shall be marked using a template corresponding to the GRC bottom panel situation. 2 #s Stainless Steel bracket 75x75x6 mm shall be fixed with 10 mm S / S Parabolt pins drilled on the wall The bottom panels C1 shall be located to the final true position with slotted holes in GRC panels prefilled with Polyurethane mastic prior to placing Stainless Steel double side pin bracket 75x75x6mm shall be fixed on the top of the bottom panels to have a pin penetration at least 25 mm inside the slot at bottom panel to act as a lateral restraint with 25mm protrusion beyond top( panel top) level. FIBREX Drawing Ref The inverted S / S upper restraint bracket shall be fixed with over sized hole at the C1S panel top cast in sockets and the panel fixed to the bracket with M10 S / S bolt. The upper panel C1S shall be located and aligned to the final level and position The panel shall be fixed to the bracket with M10 S / S bolt The foregoing sequence shall be repeated for the other column panels The panel joints shall be filled with Polyurethane sealant Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval Fixing Parapet Panels The bottom level of the panel and the location of the steel box brackets shall be marked according to the details on the FIBREX shop drawings The steel box brackets shall be fixed to walls according to the details on the drawings The horizontal 70x60x6 mm U channels shall be fixed to the box bracket at 3 levels as marked on the drawing 16 mm holes shall be drilled on U channels corresponding to the panel fixing points using template Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 161 of 75x75x6xmm steel brackets shall be fixed with over sized holes to the wall locations corresponding to the cast in sockets in the GRC panels. (Ref drg) GRC panels shall be located and aligned to the final level and position The panel cast in socket shall be fixed to the bottom bracket with 10 mm S / S bolt with washer 2 # S / S brackets shall be fixed on the concrete parapet corresponding to the cast in socket on the top level of the panel and the panel be fixed with the bracket with M 10 threaded bar, nuts and washers The top GRP cover shall be fixed and screwed in to the GRC panel on one side and parapet on the other as shown on the shop drawing All the slots / exposed fixings locations shall be closed with GRC closing pieces The foregoing sequence shall be repeated for the other panels also The panel joints shall be filled with Polyurethane sealant Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval Fixing Horizontal Bands Fixing at locations where there is no projected beams The level and the fixing locations shall be marked on the wall according to the details on the shop drawings 2 # 75x75x6mm S / S brackets shall be fixed with pin on the marked locations 2 # 75x75x6mm S / S brackets shall be fixed with hole at higher level as shown on the shop drawing The panel shall be located and aligned to final level and position. Slotted holes in GRC panels shall be prefilled with Polyurethane mastic prior to placing The panel shall be fixed to the top brackets with S / S M 10 bolts The top fixing slot shall be closed with GRC closing pieces The foregoing sequence shall be repeated for the other panels also The panel joints shall be filled with Polyurethane sealant Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval Fixing at locations where there is projected beams The level and fixing locations shall be marked on the wall as shown on the shop drawing 12 mm dia holes shall be drilled on the wall fixing locations M10 threaded bars shall be fixed to the panels ‘cast in sockets 4 #’ in the panel 4# holes on the wall shall be filled with chemical (Upat chemical anchors) The panel shall be located and aligned to final level and position The panel shall be held until the chemical dries The foregoing sequence shall be repeated for the other panels also The panel joints shall be filled with Polyurethane sealant Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval Major Equipment Attachment Fibrex Statement Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 162 of #71 Painting Administration building Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures that shall be adopted to apply the Painting System on the above building on various surfaces according to the specifications and the material system approved. References Specifications DG MAR # Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to the operation concerned to the Project Site Safety requirements. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 163 of Any process that is adopted which may have a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. The personnel shall use the PPE, gloves, masks, eyeglasses etc and to avoid skin contact. use of barrier cream shall also be made. Material safety data shall be referred to for disposal and any further information. Adequate arrangement shall be made to provide access to the top of the wall. Adequate scaffolding with proper netshade shall be provided wherever required The personnel shall use the waist safety belt / harness while working on height. Immediate medical care shall be provided in case the eyes of any personnel are effected due to the paint splashes or any other reason Proper ventilation shall be provided to let the workers respirate properly A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Storage The material shall be stored under cover out of direct sunlight and protected from extreme temperatures. Shelf life 12 months between 5 deg and 35 Celsius Materials Berger Paint systems MAR # Table 1 S # Sub Strata 1 2 3 4 5 6 Galvanised steelExterior,Polyurethane Mild steel-Exterior, Polyurethane Concrete SurfaceExterior, Polyurethane textured Galvanised SteelInterior, Alkyd Galvanised SteelInterior, Primed ferrous metal Alkyd Plaster and GypsumGypsum wall board and plaster, Acrylic Surface preparation Mechanical cleaning loose deposits Blasting to Sa 2.5 to Operating temperature remove Upto 100 deg C Upto 100 deg C Cleaning with sand stone to Upto 100 deg C smoothen the surface free from all dirt etc Mechanical cleaning to remove Upto 60 deg C loose deposits Mechanical cleaning to St 2 to Upto 60 deg C remove loose rust, scales Cleaning with fine emery paper to Upto 50 deg C remove dirt etc. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 164 of System # 1, Exterior Surfaces –Galvanised Steel, Polyurethane Table 2 Coats Generic # of Solids DFT Colour Applicat Type coat volume Microns ion s % Primer Surface 1 82 100 Alumini Brush / tolerant um Spray high build epoxy Finish Gloss 1 50 50 White / Brush / Polyurethan Colours Spray e 2 150 Berger Product Epimast ic 5100 Al Robbiat hane System # 2, Exterior Surfaces –Ferrous Metal, Polyurethane Table 3 Coats Primer Interme diate Finish Generic Type # of coat s build 1 High epoxy polyamide primer High build 1 epoxy polyamide Gloss 1 Polyurethan e 3 Solids volume % 57 DFT Colour Applicat Berger ion Product 75 Red Brush / Spray 68 100 Grey 50 50 Microns Brush / Spray White / Brush Colours / Spray Epilux 78 Epilux 218HS Robbiat hane 225 Touch up if required with Epilux 78 after power tool cleaning on spots Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 165 of System # 3, Exterior Surfaces –Concrete Masonry, Polyurethane Textured Table 4 Coats Generic Type # of coat s 1 Primer Epoxy Concrete Interme diate Epoxy 1 spray compound in textured finish Gloss / 1 Semi Gloss Polyurethan e Finish Solids volume % 45 DFT Colour Applicat Berger ion Product 50 White 68 1000 White 50 50 White / Colours Brush / Epilux Spray / Concret Roller e Primer Hopper Luxatile Gun Epoxy Spray Compo und Roller / Robbiat Spray athane Microns 1100 The textured pattern is unpressed and the DFT could vary from 700 to 1000 micron or more as manually applied by hopper gun System # 4, Interior Surfaces –Galvanised Steel, Alkyd Table 5 Coats Etch Primer(T o be used in surface preparati on instead of blasting) Primer Coat Generic Type # of Solids coat volume s % DFT Colour Applicat Berger ion Product Microns Two Pack 1 washer primer 8.5 5 Greenish Yellow Brush Spray / Luxaprim e 1500 Anticorrosive 1 rust inhibitive 55 55 Red Brush Spray / Luxaprim e 1500 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Primer Intermedi Alkyd ate Coat Undercoat Finish Alkyd Enamel Coat Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 166 of 1 55 55 1 48 48 White Brush Spray White / Brush Colours Spray / Luxole 1000 / Luxole 5000 4 155 Luxaprime 1000 has to be applied on the same day of Luxaprime 1500 System # 5, Interior Surfaces –Primed Ferrous Metal, Alkyd Table 6 Coats Primer Coat(If required) Generic Type # of Solids DFT coat volume % Microns s High build 1 alkyd zinc phosphate primer Intermedi Alkyd 1 ate Coat undercoat Finish Alkyd Enamel 1 Coat Note3 Primer need not be applied if already primed Colour 50 50 Red Grey 55 50 White 50 50 Applicat Berger ion Product / Brush Spray Brush Spray White / Brush Colours Spray / Luxaprim e 1400 / Luxol 1000 / Luxol 5000 150 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 167 of System # 6, Interior Surfaces –Gypsum Wallboard and plaster, Acrylic Table 7 Coats Primer Coat Filler Coat Generic Type # of Solids coat volume s % DFT Premium quality alkali resisting primer High quality acrylic based wall filler 1 25 25 81 To White smoothe n the surface 35 50 White / Roller Colours 35 50 White / Roller Colours 1(to seal & smo othe n the surf ace) quality 1 Intermedi High ate Coat acrylic emulsion Finish Semi gloss 1 Coat acrylic emulsion 3 Colour Applicat Berger ion Product White Brush Roller Microns / Brolac Acrylic AR Primer Spatula Berger Super Wall Filler Bergerco at Acrylic Emulsion Brolac Semi Gloss Emulsion >100 Method GENERAL Marking of containers Materials shall be delivered in sealed containers clearly labelled with the following information. Manufacturer’s name, initials or recognised trade mark Title and specification number Whether primer or undercoat, finishing coat Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 168 of Whether for internal or external use where appropriate Colour reference from BS 4800 Method of application Batch number and date of manufacture and re – test No paint shall be used after 18 months of manufacture or re test Coating materials other than spray paints, bituminous pants and fine textured masonry paint shall be in containers not exceeding 5 litres capacity Samples Sample panel of 1 sqm in area shall be prepared for each type and colour of coating material to be used in the work for the approval Sample material of each paper / fibre material minimum size 500 x 500 mm showing at least the pattern repeat where applicable shall be submitted for approval Part 2 Materials Preparatory Materials Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping, knotting, fillers and other commodities shall be of the types recommended by the manufacturer of the coating to be applied White spirit shall comply with BS 245 Knotting shall comply with BS 1336 Stopping and filler for woodwork shall be approved proprietary Leadless oil based type recommended for internal or external work as appropriate. Stopping for woodwork to receive a coat finish shall be tinted to match with the surrounding work Filler for plaster or rendering shall be approved proprietary type The following operational sequences shall be involved Priming Coat Filler Coat to the requirement Intermediate Coat Finishing Coat All according to the approved system as aforesaid detailed for reference. Application PREPARATION OF THE GALVANIZED SURFACES Dirt and other adherent contaminating matter / loose deposits shall be removed from galvanised surfaces by mechanical means using Berger tool cleaner. Cleaning shall not damage the galvanising. Oil or grease shall be removed from galvanised surfaces by the application of an emulsion cleaner. Any zinc corrosion products remaining shall be removed by washing with sweet water and scrubbing with hard bristle brushes After being cleaned and degreased, all galvanised surfaces shall be etched with T-wash as described in BS 5493. If any surface fails to turn black as cleaning, greasing and etching processes shall be repeated. APPLICATION OF PAINT GENERALLY All paints shall be prepared and applied in strict accordance with the manufacturer’s instructions. Priming paints shall be applied by brush. Spray application shall only be used for painting of epoxy resin base Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 169 of Exposure of intermediate coats of paint for periods in excess of a few days shall not be permitted except in case of work delivered to site in a primed condition The dried films shall be free from bloom, shrinkage, sheeringness, wrinkling, sagging, curtailing, discoloration and extraneous matter No exterior or exposed paint work shall be carried out under adverse weather conditions, during rain, mist, sandstorms nor when the relative humidity exceeds 80% Painting shall insofar as is practicable be shaded from direct sunlight by netting to prevent wrinkling and bristling. Whenever possible exterior painting shall be so programmed during the day so as to be carried out in shadow Painting of surfaces shall not be carried out when condensation is present on such surfaces or the application and / or drying of the paints is likely to be affected Surfaces to be painted shall receive as first coat of paint as quickly as possible after the e preparation has been completed In case of metal surfaces this shall preferably be within one hour but always before the metal temperature drops to less than 3 deg C above dew point and before any rusting METHOD OF COATING Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall be avoided. When these occur they shall be brushed out immediately or the materials removed and the surface recoated. On beams and irregular surfaces, edges shall be strip coated first and at extra pass made later. Each coat shall be allowed to dry for the time specified by the manufacturer before application of any succeeding coat Any primer coat exposed to freezing, excess humidity, rain, dust etc., before drying, shall be removed, surface again prepared and primed The time interval between application of coats shall not exceed that specified for optimum results by the manufacturer All coatings shall be cleaned as specified by the manufacturer before the next coat is applied All areas not specifically mentioned in the painting specification shall be finished to conform to the adjacent comparable areas All fixtures and surfaces not to be painted shall be properly protected during application and upon completion of the work all paint and varnish removed from glass, fixtures, covering, etc., Moveable parts shall not to be painted. All parts such as pipe supports, seatings and cleats, back to back sections which shall become inaccessible after fabrication shall be treated on both surfaces with the full paint system prior to final assembly, thus ensuring adequate protection. SPRAY APPLICATION All equipment for spray application shall be inspected and approved before any application begins. Spray guns, hoses and pumps shall be cleaned before new material is added. An adequate moisture and oil trap shall be installed between the air supply to each application unit. Suitable pressure regulators and gauges shall be provided for the air supply to the application units. Spray equipment and operating pressures shall comply with the manufacturer’s recommendations. Coating materials containing heavy pigments that have a tendency to settle shall be kept in suspension during the application by the power driven, continuous agitator Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 170 of The spray gun shall be held at right angles to the surface and each pass overlap the previous one by approximately 50%. All materials contained herein may be applied by airless spray. BRUSH APPLICATION Brushes shall be of a style and quality that permit proper application of the material Flat brushes shall not be more than 100 mm wide. No extending handles shall be used on brushes. Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is obtained without any deep or detrimental marks Paints shall be worked into all corners and crevices. When applying solvent type coating, care shall be taken to prevent lifting of previous coats. FILM THICKNESS Specified film thickness for coating materials shall be strictly observed which be checked with an appropriate film thickness gauge. Calibration for the thickness range to be checked at least twice a day When dry film thickness are less than those specified, additional coats shall be applied as required. Particular attention shall be paid to full film thickness on edges In hot weather such additional precautions as are necessary shall be taken to ensure that the specified dry film thickness on priming or finish coats is obtained COATING QUALITY Coatings shall be free from pinholes, voids, bubbles, dust, foreign inclusions and other holidays and any such defect shall be repaired. Prior to the application of a coating, any damage to the previous coating shall be repaired with the specified material. Upon completion of the fabrication any damage to the coating system shall be repaired TEST EQUIPMENT Svensk photographic standard SIS 05 59 00 Coating thickness meter such as Elcometer ‘Minitector” Model 150 Wet fill thickness combs Hygrometer Maximum and minimum thermometer Flow cup type B # 4 and timer Surface profile meter such as Elcometer’Roughness detector’ Bolted site connections other than faying surfaces of Grip Bolt connections shall be brought together ‘wet’ EPOXY COATING WORK GENERALLY In addition to the general requirements the following conditions shall apply wherever epoxycoating work is being carried out Forced draught ventilation shall be used wherever required for the needs of the personnel or for drying out surfaces Operatives shall work in pairs Samples areas on substrate shall be prepared and coated for approval There shall be strict control of surface cleanliness between primer and epoxy coating / and between coats of the same. Vacuum removal of dust and sand shall be employed and contamination removed. Where dirt or dust has been trapped in the painted surface it shall be Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 171 of removed with suitable abrasive paper. The surface being painted shall be free of visible moisture throughout these operations The paint shall be applied only to the clean dry primed or previously coated surfaces. Any thick runs or collections of paint shall be removed before these harden Not less than 2 coats shall be applied over the primer by airless spray, less than 3 by brush Each coat shall be distinctly different in colour from the primer or previous coat. The colour of the final coat shall be as approved. Each coat shall be seen to have completely covered the proceeding without ‘ misses’ or pinholes or any areas visibly low in thickness. A high voltage pinhole detector shall also be used to determine the integrity of the coats The manufacturer of the coating shall stipulate primer and epoxy recoat interval for all curing temperatures likely to be encountered and these be adopted with a maximum tolerance of +4 hours. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to remove gloss and provide a key Wet thickness gauges shall be used by the coating operators continually to check that sufficient paint is being applied to achieve the desired dry film thickness EPOXY COATING FOR CONCRETE AND RENDERED SURFACES No priming shall commence until the moisture content of the cementitious surface is less than 5% measured by Wetcheck Moisture meter or other instrument Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 % on the concrete scale of the instrument when the probe tips are held against such painted surfaces just prior to recoating The priming shall be applied by suitable Nylon bristle brush or spray over the whole area to be coated at such thickness that it may then be squeezed into the pores of the concrete. Any excess shall be removed by the most suitable means before application of the high build epoxy The total DFT of the paint layer shall have a minimum specified value Whenever the paint inspection gauge has been used and wherever the coating has been otherwise damaged for 50 mm around such damage, the surfaces shall be abraded followed by the area touched in with not less than 2 # thick applications to restore the coating integrity to the specified thickness. Adhesion tests shall be carried out on the cured coating surface using the test equipment supplied in accordance with the best practice. The resulting test specimens shall show no indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness. The following instrument shall be used 1 Adhesion Tester 0 to 35 kg / cm2 1 DC high voltage holiday detector # 105 One paint inspection gauge PIG 1 wet check moisture meter #72 Painting Administration building Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 172 of Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures that shall be adopted to apply the Painting System on the above building on various surfaces according to the specifications and the material system approved. References Specifications MAR # Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the FM and workforce for the operations FM shall execute the operations deploying the workforce QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to the operation concerned to the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. The personnel shall use the PPE, gloves, masks, eyeglasses etc and to avoid skin contact. use of barrier cream shall also be made. Material safety data shall be referred to for disposal and any further information. Adequate arrangement shall be made to provide access to the top of the wall. Adequate scaffolding with proper netshade shall be provided wherever required The personnel shall use the waist safety belt / harness while working on height. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 173 of Immediate medical care shall be provided in case the eyes of any personnel are effected due to the paint splashes or any other reason Proper ventilation shall be provided to let the workers respirate properly A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Storage The material shall be stored under cover out of direct sunlight and protected from extreme temperatures. Shelf life 12 months between 5 deg and 35 Celsius Materials Berger Paint systems MAR # Table 8 S # Sub Strata 1 2 3 4 5 6 Galvanised steelExterior,Polyurethane Mild steel-Exterior, Polyurethane Concrete SurfaceExterior, Polyurethane textured Galvanised SteelInterior, Alkyd Galvanised SteelInterior, Primed ferrous metal Alkyd Plaster and GypsumGypsum wall board and plaster, Acrylic Surface preparation Mechanical cleaning loose deposits Blasting to Sa 2.5 to Operating temperature remove Upto 100 deg C Upto 100 deg C Cleaning with sand stone to Upto 100 deg C smoothen the surface free from all dirt etc Mechanical cleaning to remove Upto 60 deg C loose deposits Mechanical cleaning to St 2 to Upto 60 deg C remove loose rust, scales Cleaning with fine emery paper to Upto 50 deg C remove dirt etc. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 174 of System # 1, Exterior Surfaces –Galvanised Steel, Polyurethane Table 9 Coats Generic # of Solids DFT Colour Applicat Type coat volume Microns ion s % Primer Surface 1 82 100 Alumini Brush / tolerant um Spray high build epoxy Finish Gloss 1 50 50 White / Brush / Polyurethan Colours Spray e 2 150 Berger Product Epimast ic 5100 Al Robbiat hane System # 2, Exterior Surfaces –Ferrous Metal, Polyurethane Table 10 Coats Primer Interme diate Finish Generic Type # of coat s build 1 High epoxy polyamide primer High build 1 epoxy polyamide Gloss 1 Polyurethan e 3 Solids volume % 57 DFT Colour Applicat Berger ion Product 75 Red Brush / Spray 68 100 Grey 50 50 Microns Brush / Spray White / Brush Colours / Spray Epilux 78 Epilux 218HS Robbiat hane 225 Touch up if required with Epilux 78 after power tool cleaning on spots Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 175 of System # 3, Exterior Surfaces –Concrete Masonry, Polyurethane Textured Table 11 Coats Generic Type # of coat s 1 Primer Epoxy Concrete Interme diate Epoxy 1 spray compound in textured finish Gloss / 1 Semi Gloss Polyurethan e Finish Solids volume % 45 DFT Colour Applicat Berger ion Product 50 White 68 1000 White 50 50 White / Colours Brush / Epilux Spray / Concret Roller e Primer Hopper Luxatile Gun Epoxy Spray Compo und Roller / Robbiat Spray athane Microns 1100 The textured pattern is unpressed and the DFT could vary from 700 to 1000 micron or more as manually applied by hopper gun System # 4, Interior Surfaces –Galvanised Steel, Alkyd Table 12 Coats Etch Primer(T o be used in surface preparati on instead of blasting) Primer Generic Type # of Solids coat volume s % DFT Colour Applicat Berger ion Product Microns Two Pack 1 washer primer 8.5 5 Greenish Yellow Brush Spray / Luxaprim e 1500 Anticorrosive 55 55 Red Brush / Luxaprim 1 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 176 of Coat rust inhibitive Primer Intermedi Alkyd 1 ate Coat Undercoat Finish Alkyd Enamel 1 Coat 4 55 55 48 48 Spray e 1500 Brush Spray White / Brush Colours Spray / Luxole 1000 / Luxole 5000 White 155 Luxaprime 1000 has to be applied on the same day of Luxaprime 1500 System # 5, Interior Surfaces –Primed Ferrous Metal, Alkyd Table 13 Coats Primer Coat(If required) Generic Type # of Solids DFT coat volume % Microns s High build 1 alkyd zinc phosphate primer Intermedi Alkyd 1 ate Coat undercoat Finish Alkyd Enamel 1 Coat Note3 Primer need not be applied if already primed Colour 50 50 Red Grey 55 50 White 50 50 Applicat Berger ion Product / Brush Spray Brush Spray White / Brush Colours Spray / Luxaprim e 1400 / Luxol 1000 / Luxol 5000 150 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 177 of System # 6, Interior Surfaces –Gypsum Wallboard and plaster, Acrylic Table 14 Coats Primer Coat Filler Coat Generic Type # of Solids coat volume s % DFT Premium quality alkali resisting primer High quality acrylic based wall filler 1 25 25 81 To White smoothe n the surface 35 50 White / Roller Colours 35 50 White / Roller Colours 1(to seal & smo othe n the surf ace) quality 1 Intermedi High ate Coat acrylic emulsion Finish Semi gloss 1 Coat acrylic emulsion 3 Colour Applicat Berger ion Product White Brush Roller Microns / Brolac Acrylic AR Primer Spatula Berger Super Wall Filler Bergerco at Acrylic Emulsion Brolac Semi Gloss Emulsion >100 Method GENERAL Marking of containers Materials shall be delivered in sealed containers clearly labelled with the following information. Manufacturer’s name, initials or recognised trade mark Title and specification number Whether primer or undercoat, finishing coat Whether for internal or external use where appropriate Colour reference from BS 4800 Method of application Batch number and date of manufacture and re – test No paint shall be used after 18 months of manufacture or re test Coating materials other than spray paints, bituminous pants and fine textured masonry paint shall be in containers not exceeding 5 litres capacity Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 178 of Samples Sample panel of 1 sqm in area shall be prepared for each type and colour of coating material to be used in the work for the approval Sample material of each paper / fibre material minimum size 500 x 500 mm showing at least the pattern repeat where applicable shall be submitted for approval Part 2 Materials Preparatory Materials Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping, knotting, fillers and other commodities shall be of the types recommended by the manufacturer of the coating to be applied White spirit shall comply with BS 245 Knotting shall comply with BS 1336 Stopping and filler for woodwork shall be approved proprietary Leadless oil based type recommended for internal or external work as appropriate. Stopping for woodwork to receive a coat finish shall be tinted to match with the surrounding work Filler for plaster or rendering shall be approved proprietary type The following operational sequences shall be involved Priming Coat Filler Coat to the requirement Intermediate Coat Finishing Coat All according to the approved system as aforesaid detailed for reference. Application PREPARATION OF THE GALVANIZED SURFACES Dirt and other adherent contaminating matter / loose deposits shall be removed from galvanised surfaces by mechanical means using Berger tool cleaner. Cleaning shall not damage the galvanising. Oil or grease shall be removed from galvanised surfaces by the application of an emulsion cleaner. Any zinc corrosion products remaining shall be removed by washing with sweet water and scrubbing with hard bristle brushes After being cleaned and degreased, all galvanised surfaces shall be etched with T-wash as described in BS 5493. If any surface fails to turn black as cleaning, greasing and etching processes shall be repeated. APPLICATION OF PAINT GENERALLY All paints shall be prepared and applied in strict accordance with the manufacturer’s instructions. Priming paints shall be applied by brush. Spray application shall only be used for painting of epoxy resin base Exposure of intermediate coats of paint for periods in excess of a few days shall not be permitted except in case of work delivered to site in a primed condition The dried films shall be free from bloom, shrinkage, sheeringness, wrinkling, sagging, curtailing, discoloration and extraneous matter No exterior or exposed paint work shall be carried out under adverse weather conditions, during rain, mist, sandstorms nor when the relative humidity exceeds 80% Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 179 of Painting shall insofar as is practicable be shaded from direct sunlight by netting to prevent wrinkling and bristling. Whenever possible exterior painting shall be so programmed during the day so as to be carried out in shadow Painting of surfaces shall not be carried out when condensation is present on such surfaces or the application and / or drying of the paints is likely to be affected Surfaces to be painted shall receive as first coat of paint as quickly as possible after the e preparation has been completed In case of metal surfaces this shall preferably be within one hour but always before the metal temperature drops to less than 3 deg C above dew point and before any rusting METHOD OF COATING Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall be avoided. When these occur they shall be brushed out immediately or the materials removed and the surface recoated. On beams and irregular surfaces, edges shall be strip coated first and at extra pass made later. Each coat shall be allowed to dry for the time specified by the manufacturer before application of any succeeding coat Any primer coat exposed to freezing, excess humidity, rain, dust etc., before drying, shall be removed, surface again prepared and primed The time interval between application of coats shall not exceed that specified for optimum results by the manufacturer All coatings shall be cleaned as specified by the manufacturer before the next coat is applied All areas not specifically mentioned in the painting specification shall be finished to conform to the adjacent comparable areas All fixtures and surfaces not to be painted shall be properly protected during application and upon completion of the work all paint and varnish removed from glass, fixtures, covering, etc., Moveable parts shall not to be painted. All parts such as pipe supports, seatings and cleats, back to back sections which shall become inaccessible after fabrication shall be treated on both surfaces with the full paint system prior to final assembly, thus ensuring adequate protection. SPRAY APPLICATION All equipment for spray application shall be inspected and approved before any application begins. Spray guns, hoses and pumps shall be cleaned before new material is added. An adequate moisture and oil trap shall be installed between the air supply to each application unit. Suitable pressure regulators and gauges shall be provided for the air supply to the application units. Spray equipment and operating pressures shall comply with the manufacturer’s recommendations. Coating materials containing heavy pigments that have a tendency to settle shall be kept in suspension during the application by the power driven, continuous agitator The spray gun shall be held at right angles to the surface and each pass overlap the previous one by approximately 50%. All materials contained herein may be applied by airless spray. BRUSH APPLICATION Brushes shall be of a style and quality that permit proper application of the material Flat brushes shall not be more than 100 mm wide. No extending handles shall be used on brushes. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 180 of Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is obtained without any deep or detrimental marks Paints shall be worked into all corners and crevices. When applying solvent type coating, care shall be taken to prevent lifting of previous coats. FILM THICKNESS Specified film thickness for coating materials shall be strictly observed which be checked with an appropriate film thickness gauge. Calibration for the thickness range to be checked at least twice a day When dry film thickness are less than those specified, additional coats shall be applied as required. Particular attention shall be paid to full film thickness on edges In hot weather such additional precautions as are necessary shall be taken to ensure that the specified dry film thickness on priming or finish coats is obtained COATING QUALITY Coatings shall be free from pinholes, voids, bubbles, dust, foreign inclusions and other holidays and any such defect shall be repaired. Prior to the application of a coating, any damage to the previous coating shall be repaired with the specified material. Upon completion of the fabrication any damage to the coating system shall be repaired TEST EQUIPMENT Svensk photographic standard SIS 05 59 00 Coating thickness meter such as Elcometer ‘Minitector” Model 150 Wet fill thickness combs Hygrometer Maximum and minimum thermometer Flow cup type B # 4 and timer Surface profile meter such as Elcometer’Roughness detector’ Bolted site connections other than faying surfaces of Grip Bolt connections shall be brought together ‘wet’ EPOXY COATING WORK GENERALLY In addition to the general requirements the following conditions shall apply wherever epoxycoating work is being carried out Forced draught ventilation shall be used wherever required for the needs of the personnel or for drying out surfaces Operatives shall work in pairs Samples areas on substrate shall be prepared and coated for approval There shall be strict control of surface cleanliness between primer and epoxy coating / and between coats of the same. Vacuum removal of dust and sand shall be employed and contamination removed. Where dirt or dust has been trapped in the painted surface it shall be removed with suitable abrasive paper. The surface being painted shall be free of visible moisture throughout these operations The paint shall be applied only to the clean dry primed or previously coated surfaces. Any thick runs or collections of paint shall be removed before these harden Not less than 2 coats shall be applied over the primer by airless spray, less than 3 by brush Each coat shall be distinctly different in colour from the primer or previous coat. The colour of the final coat shall be as approved. Each coat shall be seen to have completely covered the Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 181 of proceeding without ‘ misses’ or pinholes or any areas visibly low in thickness. A high voltage pinhole detector shall also be used to determine the integrity of the coats The manufacturer of the coating shall stipulate primer and epoxy recoat interval for all curing temperatures likely to be encountered and these be adopted with a maximum tolerance of +4 hours. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to remove gloss and provide a key Wet thickness gauges shall be used by the coating operators continually to check that sufficient paint is being applied to achieve the desired dry film thickness EPOXY COATING FOR CONCRETE AND RENDERED SURFACES No priming shall commence until the moisture content of the cementitious surface is less than 5% measured by Wetcheck Moisture meter or other instrument Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 % on the concrete scale of the instrument when the probe tips are held against such painted surfaces just prior to recoating The priming shall be applied by suitable Nylon bristle brush or spray over the whole area to be coated at such thickness that it may then be squeezed into the pores of the concrete. Any excess shall be removed by the most suitable means before application of the high build epoxy The total DFT of the paint layer shall have a minimum specified value Whenever the paint inspection gauge has been used and wherever the coating has been otherwise damaged for 50 mm around such damage, the surfaces shall be abraded followed by the area touched in with not less than 2 # thick applications to restore the coating integrity to the specified thickness. Adhesion tests shall be carried out on the cured coating surface using the test equipment supplied in accordance with the best practice. The resulting test specimens shall show no indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness. The following instrument shall be used 1 Adhesion Tester 0 to 35 kg / cm2 1 DC high voltage holiday detector # 105 One paint inspection gauge PIG 1 wet check moisture meter #73 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 182 of Road crossing for laying 2 pipes 1 for 20” raw ethane & 1 for 6”propane Avenue ‘c’ Top Index Scope Reference documents Definitions Responsibilities Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road crossing to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at locations identified on the attached drawing to the following references Reference documents Specification Excavation & Backfilling for Underground structures. Drawing No. Easement Systems Avenue “C” Piping Interconnection Drawings, Avenue ‘C’ Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly and be overall responsible for the excavation operation CS shall control, monitor and direct the SE, FM and workforce for the operations Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 183 of SE shall be responsible for all the site operations and follow the instructions of the CS Any mishap on the excavation operation shall immediately be notified to the CS and the CM for the immediate action if so required for any possible remedy or record or the authority review whatsoever,the case may be FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process is adopted having a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. In the present case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be resorted to effect a full safety standard. ToolBox TalksWhile conducting ToolBox Talks, a representative from the authority shall be involved to witness and sign the instruction imparted with the workers prior to the commencement of the operations to make a record. Only English literate Foreman shall be employed to work on the excavation execution. Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all the relevant persons involved on the crossing Traffic Management-Sign boards keep up-All the personnel shall be briefed about the safe keep up of the boards Barricades,cones, markers and the night-lights, flood lights etc. shall be arranged as required for a complete safety. No oil spillage shall be allowed. The sides of the excavation shall be sloped with the barriers placed to indicate the excavation work in progress Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be engaged to operate full time to direct the traffic about the excavation work in progress by waving the flag for all the vehicles passing by Hand Excavation- Excavation required to be by hand shall only be carried out manually. In case certain services not shown on the record drawings such as fibre optics cable is discovered, the excavation shall be ceased to be continued until the decision to hydrojetting is taken up and the authority are involved. Jack Hammer- The worker engaged on operating this equipment shall use protective glass and work in phases with pause intervals. The compressor air pressure shall be monitored from time to time so that the hammer works smoothly. The compressor shall be place within the barricade limits Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out. No jumping shall be allowed Machine Excavation Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 184 of The operators shall be explicitly explained and instructed about the requirement of the reverse signal and sound when operating reverse. The truck driver shall also be instructed similarly. Banksman shall be engaged while the equipment operate. No violation of the traffic rules shall be allowed Deep Trenches If required, the shoring shall be provided to prevent the caving in. In case of the trench depth being more than 1200 mm. Adequate means of exit such as Aluminium ladder or steps shall be provided and located no more than 8 m of lateral travel. Plants preservation The live plants and the trees arboricultured shall be deplanted integrally with the roots and preserved to the specialist requirement so that these remain live till the replantation is carried out all to the satisfaction of the specialist Safety Supervision A competent inspector shall inspect the trench daily to assess the safety measures adopted. Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme has been presented herein and shall be produced on site as detailed on the attached sketch for this road crossing which includes, reduced speed sign, temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety barriers, night lighting and road cleaning activities etc. The traffic management scheme shall be reviewed and approved by EPC Contractor prior to commencing the work. The aforesaid traffic management scheme shall be implemented as described below: TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street / Avenue ‘C’ Drawing reference –24168-P40-310-00005 Rev O This proposed crossing is located on the Road Avenue ‘C’ between the following Co-ordinates as shown on the referred drawing. This is a 2-way road with a central verge and carrying 2 lanes on either way The proposed crossing is located about 160 m from 1 st street road towards North One serving electric pole is located away from the x-ing The minor irrigation / hoses are serving on the central verge Some minor trees and plants are arboricultured on the central verge. The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side of the carriageway. In the first instance the work shall be carried out on part L1 diverting the traffic to the road portion on the part L2 as shown on the sketch. In the second instance the work shall be carried out on part L2 diverting the traffic to the road portion on the completed road portion on the part L1 as shown on the sketch. The directory signboards shall also be placed on the 1 st street road East West on both ways to indicate the work at the crossing For the traffic North to South the first reduce speed for traffic diversion informatory board depicting shall be located at 300 m from the point of the proposed crossing, the second Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 185 of depicting diversion signs be located at 200 m and the third depicting men at work sign be located at 100 m on either way in the opposite directions. For the traffic South to North past crossing, one sign shall be placed to direct for the diversion, to slow down and the men at work ahead A Flagman shall be engaged full time on both the directions to guide the traffic about the ongoing excavation operations in addition to the conventional signboards The following activities are involved. Reference to the marked note ‘B’ on the Easement Systems Drawing To produce the Traffic Diversion Management Scheme To excavate by hand and expose all the underground facilities 5.5KV / 0.24KV cables are available Trial pits to be excavated in size 5mx2mx1.5m deep by hand tools To seam the area with the detectors to ascertain the access to the cable To expose the cable fully and to be inspected by the authorities / Operating Authority After the exposure, all the cables to be covered with split PVC pipe to continue the excavation mechanically according to the authority directions and as agreed To excavate the remaining portion by the excavator machine To have authority inspection The pipes to be laid by others To fill the bedding material according to the specification requirement To reinstate the diverted services To reinstate the central verge to the existing state Details The Traffic Management Scheme shall be executed as explained in the foregoing and to the traffic manual directions. The first section of the proposed road crossing as per the attached sketch shall be marked by the surveyor on the actual location. Any existing services shall be identified from the Record drawings and measures to protect resorted to according to the regulations. The asphalt shall be cut using jackhammers The road section shall be excavated to the existing cables manually for which the trial pit may be made prior to the full manual excavation is proceeded and after ascertaining the safe procedures the exposures be completed. After the exposure of the cables, the Operating Authority authorities shall inspect and the cables be diverted accordingly following which the remaining machine excavation be carried out to the specified levels The excavated material shall be removed from the site to stockpile area. Appropriate bedding material shall be placed within the excavated trench to the correct service level. Where required, this bedding shall be compacted and tested. The excavated trench shall be inspected by the authorities as required. The potable and the Desalinated water pipes shall be laid by others. Backfill around the service pipes shall be carried using the appropriate material. The service pipes surrounding material shall be compacted as per the project specification requirements. Test results shall be provided for the specification conformance verification. The existing services shall be reinstated accordingly. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 186 of The plants or trees if removed and so required, shall be reinstated accordingly. General fill up to the underside of road formation shall be placed in 150mm compacted layers using mechanical methods to the specification requirements. A concrete slab shall be cast up to the bottom of the finished asphalt level. The finishing shall be carried out using approved asphalt mix. The traffic management system shall be removed after the road crossing has been cleaned of any debris or obstructions. Either side of the road shall be provided with cable markers to indicate the services Major Equipment Excavator.Dump trucks.Compactors. Jack Hammer, Compressor, Attachment Sketch showing the traffic management scheme Drawings including the traffic diversion #74 Earthworks survey system Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement, is to define the procedure that shall be adopted for the control of the site earthwork activities. Reference documents Method statement. Site Preparation & Earthworks. Specification Site Preparation. Definitions EPC Contractor Civil Contractor . PSM Project Site Manager. IS Infrastructure Superintendent. ST Survey team. QM Quality Manager. RFI Request for Inspection. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 187 of Responsibilities The PSM shall ensure the implementation of this method statement upon the earthworks activities. The IS shall coordinate and supervise the implementation of this method statement by the ST on a day to day basis. Safety The Safety Officer shall monitor the daily earthworks activities, advising and implementing all safety procedures. Method Where areas are to be grubbed, the IS shall direct the ST to establish grid stakes, at 50m centers, within the area to be grubbed. The ST, prior to the commencement of the machine activities shall provide a sketch of the area defining the outer Northings and Eastings of the area. Upon completion of the establishment of the survey grid stakes and the site sketch, the IS shall inform the QM. The QM shall inspect the area to verify the correct establishment of the survey grid stakes. The QM shall notify the EPC Contractor Engineer of the proposed grubbing activity by using the RFI notification system. The EPC Contractor Engineer shall review the proposed grubbing area. Should the EPC Contractor Engineer have any comments or observations about the area, he shall inform the QM and / or IS of these observations. The appropriate actions shall be conducted. Upon completion of the grubbing activity, the IS shall notify the QM, who shall inspect the area and complete the appropriate RFI. The EPC Contractor Engineer shall review the area with the QM and Geotechnical Engineer, and comment if appropriate. Where the area requires to be “cut”’ the ST shall establish pegs to indicate the correct cut level. The cut activity shall be conducted. Upon completion of the “cut” activity, the ST shall produce a ground level survey of the cut area. This survey shall be forwarded to the QM for record purposes. The QM shall transmit a copy of the survey report to the EPC Contractor Engineer. Where the area requires a “fill” activity, the formation level shall be moisturized and compacted as defined within the earthworks method statement. The IS shall coordinate with the ST to establish fill stakes, that shall indicate the layer levels. Each fill layer shall be placed, moisturized and compacted according to the earthworks method statement. Upon completion of all the fill layers to the area, the ST shall produce a survey of finished ground levels. This survey shall be forwarded to the QM for record. A copy of this survey shall be transmitted to the EPC Contractor Engineer. Should a grubbing level stake or fill stake be damaged or moved, the ST shall re establish the stake correctly. The RFI system shall document the comments and observations of an activity by the EPC Contractor engineer. Equipment Total station distomat. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 188 of Stakes. Marker tape. Attachment None. #75 Road crossing for laying 84”GRE pair seawater Cooling lines At Avenue ‘d’ / corniche Junction Top Index Scope Reference documents Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road to facilitate to lay the pipe lines 1 # pair 84” GRE Sea Water Cooling supply lines at Avenue’D’ and ‘Cornice Road’ junction identified on the attached drawing to the following references Reference documents Specification. Excavation & Backfilling for Underground structures. Drawing No. Piping Interconnection Drawings- SeaWater Cooling Supply Lines Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect ‘ full safety standard’. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 189 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On all directions, in addition to the traffic sign boards, a flagmen shall be engaged full time to direct the traffic about the ‘excavation work in progress’ by ‘flag signal’ Hand Excavation- Excavation to expose the services shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged equipment operation. No violation of the traffic rules shall be allowed Method Corniche Road / Avenue ‘D Junction’ Avenue ‘D’ is a 2-way road carrying single lane on either way Corniche Street is a 2-way road with a central verge, carrying 2 lanes on either way on the West direction and without a central verge but single lane on the Eastern direction. The essential permit to work shall be obtained from the Refinery Division. The record drawings pertaining to the existing services shall be obtained. A traffic management scheme has been presented herein and shall be produced on site as detailed on the attached sketch for this road crossing Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 190 of Pumping out water shall be carried out continuously in case it is necessary Existing Services 2 # serving electric poles are located one at the curve and the other in the Northern central verge which shall be effected by the proposed trench as the excavation line is expected to pass through the verge and the general impacts shall be to the extent of, “The central verge partly, the island partly, guard rail fully about 30 m with channels, Corniche street sign board, Kerb stones” The road shall be divided in 2 parts on either side of the carriageway. First Instance The first section covering the length of one pipe to be connected to the existing pipeline at South of the proposed road crossing shall be marked on the actual location. The work shall be carried out on part 1 diverting the traffic to the road portion on part 2 and on the existing natural ground at South as shown on the sketch. The asphalt shall be cut using jackhammers The road section shall be excavated to the existing cables manually and the existence of the cables confirmed by the use of seaming. After the exposure of the cables, the Operating Authority authorities shall be invited to inspect and the cables diverted accordingly The cables shall be protected by PVC split pipe and covered, supported well temporarily. The machine excavation shall be carried out to the final levels. The excavated material shall be removed from the site to stockpile area. Appropriate bedding material shall be placed within the excavated trench to the correct service level, compacted and tested. The excavated trench shall be inspected by EPC Contractor The GRE pipes shall be laid & the line tested by EPC Contractor. Backfill around the service pipes shall be carried out using the appropriate material. and compacted to the project specification requirement with the test results provided confirming the conformance The existing services shall be reinstated accordingly. General fill up to the underside of road formation shall be carried out in 150mm compacted layers using mechanical methods to the specification conformance. The finishing shall be carried out using approved asphalt mix. Second Instance In the second instance the work shall be carried out on part 2 diverting the traffic to the road portion on the completed part 1.The second instance shall commence only when the first is completed allowing the traffic to ply. All the aforesaid operations shall be repeated for the 2 nd instance allowing the traffic on the completed Instance 1 The traffic management system shall be removed after the road crossing is cleared of all debris or obstructions. Either side of the road X-ing shall be provided with relevant markers to indicate the services Major Equipment Excavator.Dump trucks.Compactors. Jack Hammer, Compressor, hydro jetting (depending on necessity) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 191 of Attachment Sketch showing the traffic management scheme #76 Road crossing for laying 84”GRE pair seawater Cooling lines At Avenue ‘d’ / corniche Junction Top Index Scope Reference documents Definitions Responsibilities Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road to facilitate to lay the pipe lines 1 # PAIR 84” GRE SEA WATER COOLING SUPPLY LINES at Avenue’D’ and ‘Corniche Road’ junction identified on the attached drawing to the following references Reference documents Specification Excavation & Backfilling for Underground structures. Drawing No. Piping Interconnection Drawings- SeaWater Cooling Supply Lines Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge FM QC Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 192 of Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly and be overall responsible for the excavation operation CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS Any mishap on the excavation operation shall immediately be notified to the CS and the CM for the immediate action if so required for any possible remedy or record or the authority review whatsoever,the case may be FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process is adopted having a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. In the present case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be resorted to effect a full safety standard. ToolBox Talks While conducting ToolBox Talks, a representative from the authority shall be involved to witness and sign the instruction imparted with the workers prior to the commencement of the operations to make a record. Only English literate Foreman shall be employed to work on the excavation execution. Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all the relevant persons involved on the crossing Traffic Management-Sign boards keep up-All the personnel shall be briefed about the safe keep up of the boards Barricades,cones, markers and the night-lights, flood lights etc. shall be arranged as required for a complete safety. No oil spillage shall be allowed. The sides of the excavation shall be sloped with the barriers placed to indicate the excavation work in progress Flagman-On all the direction, in addition to the traffic sign boards, a flagman shall be engaged to operate full time to direct the traffic about the excavation work in progress by waving the flag for all the vehicles passing by Hand Excavation- Excavation required to be by hand shall only be carried out manually. In case certain services not shown on the record drawings such as fibre optics cable is discovered, the excavation shall be ceased to be continued until the decision to hydrojetting is taken up and the authority are involved. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 193 of Jack Hammer- The worker engaged on operating this equipment shall use protective glass and work in phases with pause intervals. The compressor air pressure shall be monitored from time to time so that the hammer works smoothly. The compressor shall be place within the barricade limits Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out. No jumping shall be allowed Machine Excavation The operators shall be explicitly explained and instructed about the requirement of the reverse signal and sound when operating reverse. The truck driver shall also be instructed similarly. Banksman shall be engaged while the equipment operate. No violation of the traffic rules shall be allowed Deep Trenches Since the proposed excavation is wide and deep all the safety measures shall be resorted to and If required, the shoring shall be provided to prevent the caving in. The trench depth being more than 1200 mm.adequate means of exit such as Aluminium ladder or steps shall be provided and located no more than 8 m of lateral travel. Existing Services 2 # electric poles and the other various categories of about 8 to 10 # running services ducts and the cables etc shall be properly diverted according to the regulatory requirement and preserved until reinstated Safety Supervision A competent inspector shall inspect the trench daily to assess the safety measures adopted. Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme has been presented herein and shall be produced on site as detailed on the attached sketch for this road crossing which includes, reduced speed sign, temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety barriers, night lighting and road cleaning activities etc. The traffic management scheme shall be reviewed and approved by EPC Contractor prior to commencing the work. The aforesaid traffic management scheme shall be implemented as described below: TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – Corniche Road / Avenue ‘D Junction’ Drawing reference This proposed crossing is located on the Road Avenue ‘D’ between the following Co-ordinates as shown on the referred drawing. Avenue ‘D’ is a 2-way road carrying single lane on either way Corniche Road is a 2-way road with a central verge, carrying 2 lanes on either way on the West direction and without a central verge but single lane on the Eastern direction. 2 # serving electric pole are located 1 at the curve and the other in the Northern central verge which shall be effected by the proposed excavation because of encroachment on the verge. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 194 of The central verge partly, the island partly, guard rail fully about 30 m with channels, Corniche street sign board, Kerb stones shall all be effected by the construction of the proposed road crossing The road shall be divided in 2 parts as shown on the sketch as L1 and L 2 on either side of the carriageway. In the first instance the work shall be carried out on part L1 diverting the traffic to the road portion on the part L2 as shown on the sketch. In the second instance the work shall be carried out on part L2 diverting the traffic to the road portion on the completed road portion on the part L1 as shown on the sketch. The second instant shall be commenced only when the first has been completed and the traffic can ply. The directory signboards shall also be placed on the 1 st street road East West on both ways to indicate the work at the crossing For the traffic on both roads at’ 3’ locations bothways, the first reduce speed for traffic diversion informatory board depicting shall be located at 300 m from the point of the proposed crossing, the second depicting diversion signs be located at 200 m and the third depicting men at work sign be located at 100 m on either way in the opposite directions. A Flagman shall be engaged full time on both the directions to guide the traffic about the ongoing excavation operations in addition to the conventional signboards The following activities are involved to produce the Traffic Diversion Management Scheme To excavate by hand and expose all the underground facilities Various types of electrical, telecom and other services are running below and near the proposed crossing Trial pits to be excavated in size 5mx2mx1.5m deep by hand tools To seam the area with the detectors to ascertain the access to the cable To expose the cable fully and to be inspected by the authorities / Operating Authority After the exposure, all the cables to be covered with split PVC pipe to continue the excavation mechanically according to the authority directions and as agreed To excavate the remaining portion by the excavator machine To have authority inspection The pipes to be laid by others To fill the bedding material according to the specification requirement To reinstate the diverted services To reinstate the central verge to the existing state To reinstate the CORNICHE ROAD board and the metallic rail guard Details The Traffic Management Scheme shall be executed as explained in the foregoing and to the traffic manual directions. The first section of the proposed road crossing as per the attached sketch shall be marked by the surveyor on the actual location. All the existing services shall be identified from the Record drawings as well as by digging and measures to protect or divert temporarily resorted to according to the regulations. The asphalt shall be cut using jackhammers Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 195 of The road section shall be excavated to the existing cables manually for which the trial pit may be made prior to the full manual excavation is proceeded and after ascertaining the safe procedures the exposures be completed. After the exposure of the cables, the Operating Authority authorities shall inspect and the cables be diverted accordingly following which the remaining machine excavation be carried out to the specified levels The excavated material shall be removed from the site to stockpile area. Appropriate bedding material shall be placed within the excavated trench to the correct service level. Where required, this bedding shall be compacted and tested. The excavated trench shall be inspected by the authorities as required. The GRE pipes shall be laid by others. Backfill around the service pipes shall be carried using the appropriate material. The service pipes surrounding material shall be compacted as per the project specification requirements. Test results shall be provided for the specification conformance verification. The existing services shall be reinstated accordingly. General fill up to the underside of road formation shall be placed in 150mm compacted layers using mechanical methods to the specification requirements. A concrete slab shall be cast up to the bottom of the finished asphalt level. The finishing shall be carried out using approved asphalt mix. The traffic management system shall be removed after the road crossing has been cleaned of any debris or obstructions. Either side of the road X-ing shall be provided with markers to indicate the services Major Equipment Excavator.Dump trucks.Compactors. Jack Hammer, Compressor, hydro jetting (depending on necessity) Attachment Sketch showing the traffic management scheme Drawings including the traffic diversion #77 Tennis courts surfacing Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 196 of Scope The statement is aimed to propose the procedures to be adopted to carry out the Surfacing on 2 #s Tennis Courts located in the Camp Reference documents Drawing No. Definitions PSM CSM CS SE FM QC Project Site Manager Construction Manager Construction Superintendent Site Engineer Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process adopted having a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. The workers shall take all the precautions to avoid the skin and the eye contacts by using the safety glasses, hand gloves, the uniform, gun shoes all according to the manufacturer’s instructions. Immediate medical attention shall be provide when required Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during the inspection shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Storage The bags shall be stored in a cool shaded area prior to use Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 197 of Material MBT proprietary material Concresive 1414 MasterTop 512 Concresive 1414 is a 2 parts epoxy bonding agent Mastertop 512 is a ready to use non-metallic and non oxidising synthetic mineral aggregate and cementitious product applied as a topping onto the existing new concrete slab as a hard durable wearing course. 10 to 12 mm thick. Total surface area of the Tennis Courts 2 # 930 m2 Method The following operations are involved to carry out the surfacing Substrata preparation Priming and Bonding Mixing and Application Curing Details The area shall be closed to all persons except the workers and other personnel The surface of concrete shall be cleaned of all contamination such as oil, grease or fat which be removed before the preparations are commenced with High pressure water jetting shall be used to prepare the concrete surface to a coarse texture ensuring all weak or friable concrete be removed along with the contaminants The concrete is already more than 28 days Oil free Compressed air shall be used to remove dust making the surface clean & dry The surface shall be primed with Concresive 1414 ensuring total coverage of the surface A forced action Mixall mixer shall be used to mix Mastertop 512 according to the manufacturer’s instructions The content of the bag shall be poured into the mixer followed by blending for about 30 seconds, thereafter slowly adding 2.3 to 2.4 litres of water per 25 kg bag allowing to mix for 3 minutes In hot weather chilled clean water shall be used for mixing The primed surface shall be prepared to be guided for the proposed profile formation by using timber / wooden straightedge battens 10 mm thick The mixed mortar shall have a plastic consistency exhibiting low slump which be evenly spread over the primed surface already prepared as expressed in the foregoing A straightedge shall be used to systematically tampen and level the Mastertop 512. The floating material shall be pressed firmly on the primed surface using a wooden float to produce the material evenly spread and compacted A steel trowel shall be used to carry out the finishing. Curing The curing shall be carried out immediately after the final trowelling operation has been completed by either covering with polythene sheets or by the application of Masterkure 181 applied at a rate of 1 litre per 5 m2 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 198 of All the surfaces shall be protected from traffic until hardened( for light traffic the limit is 24 hours and for heavy 72 to 96 hours ) Major Equipment Compressor, Mixer, Air Blower Jack Hammer, Compressor, hydro jetting (depending on necessity) Attachment MBT Method Statement #78 Precasting lighting poles foundations Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the pre casting, transporting and installing on exact site locations the street lighting poles foundation bases 319 # Reference documents Drawing No. Specification Definitions PSM CSM CS SE FM QC Project Site Manager Construction Manager Construction Superintendent Site Engineer Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 199 of language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process adopted involving a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. All the safety precautions required to be adhered to while working on the excavations, blinding, forms, rebars, concrete pouring, waterproofing etc.all according to the acceptable standards shall be adopted on the operations concerned Adequate safety shall be observed during lifting and offloading the precast foundations to the relevant locations to avoid any mishap BY OBSERVING THE REGULATORY CRANE FITNESS REQUIREMENT AND VALIDITY OF PERMIT. Only competent personnel shall be engaged to carry out the operation The crane and the trailer operators shall adhere to all the traffic rules while carrying out the operations and if so required, a banksman be engaged to direct the movement The crane shall not be operated during the inclement weather conditions with dust storms Immediate medical attention shall be provide as and when required Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during the inspection shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Concrete, Rebars / Lifting Lugs, Anchor Bolts, 100 mm dia 350 internal radius PVC Cable Duct etc. Method Pre casting Area-The existing yard being used for the pre casting of manholes, catch basins etc. shall be employed for this purpose also The following operations are involved to carry out the production of the light poles foundation bases Pre installation operations To fabricate and erect the side forms 4 #s to the specified dimensions To fabricate the rebars according to the specified details To provide the non critical cathodic protection To provide the PVC cable duct To provide the bolt assesmbly to the requirement and location To provide the lifting lugs to carry a gravity load of at least 3 tonnes + handling stresses To pour the concrete To cure the concrete immediately after pouring Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 200 of Post casting operations To cure for the specified period To excavate the location to the required formation level To blind the area to be founded with concrete To waterproof the blinding as specified To keep the area ready in all respects well oriented & aligned to receive the foundation directly to be offloaded To apply the water proofing membrane around as specified To provide the protection board as specified To back fill the surrounding space to the relevant grade level Details The typical size of the foundation is 1000x1000mm in plan and 1100mm deep According to the drawing 319 # are specified to be constructed for a quantity 351 m3 A possible of 10 units shall be produced by pre casting every day on an average The forms to the exact size with the preformed chamfers shall be prepared and erected The steel rebars shall be cut, bent to the required shape, placed and the cage prepared holding 75mm concrete spacers, be positioned into the forms. 1 # 350 mm internal radius 100 mm dia PVC cable duct formed to the dimensions shall be anchored by binding wires to the exact locations shown on the drawing keeping the upper end flush with the concrete top The Lifting lugs as shown on the sketch shall be fixed in to the correct locations The forms for the block outs for the lifting lugs shall be fixed in to the correct locations as shown without clashing with the duct or the rebars allowing a protrusion of the hook The bolt assembly shall be fixed in exact position according to the design details The non-critical cathodic protection shall be arranged using a metallic continuous binding wire connecting all the horizontal rebars terminating into a boss fixed at one location near the top in the middle of the side opposite the duct carrying portion All the supports and the dimensions shall be checked and the plumb monitored Civil Contractor QC inspection shall be conducted followed by the EPC Contractor inspection The concrete shall be poured to all the prepared units in 3 layers in vertical sequence The appropriate vibrator shall be used for the compaction of the concrete During concreting, care shall be taken to keep the anchor bolts’ position undisturbed and the intermittent checks be continuously made to monitor the spacing / centres between the bolts After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel Immediately after the concrete starts setting, approved curing compound shall be sprayed on the surface forming a continuous membrane which be covered over with a polythene sheet according to the specifications After 2 hours, the polythene sheet shall be temporarily removed to spread over the concrete surface the saturated burlap cloth or hessian, and recovered immediately The side forms shall be removed within the specified period The vertical concrete surfaces shall be spread with the curing compound immediately after striking the forms and covered with the polythene sheet according to requirement The curing shall be continued for the specified period Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 201 of The relevant locations shall be made ready to receive the precast units by completing the excavation, blinding, the horizontal waterproofing and forming the correct alignment Civil Contractor QC inspection shall be conducted for the’location to receive followed by EPC Contractor approval The unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the location for offloading on to the prepared ‘location to receive’ the unit The unit shall be installed on the marked location according to the correct orientation to the lighting layout drawing Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval The protruding lifting lug eyes shall be cut to 60 mm inside the block out, the void filled with concrete by first scabbling the internal surface followed by cement slurry grouting and pouring concrete The external surfaces of the foundation shall be applied with the concrete protective membrane according to the specifications Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval The membrane protection board shall be provided covering the surface to the specified details The back filling shall be carried out according to the specification upto the required levels in layers and upto the required ground grade or the pavement The points to locate the cathodic protection shall be provided with a marker to trace the boss The sequence shall be repeated for all the lighting poles foundations Major Equipment Compressor, Mobile Crane, Trailer Concrete Pump, Transit mixer Attachment Lifting arrangement sketch #79 Lighting poles foundations Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the pre casting, transporting and installing on exact site locations the street lighting poles foundation bases 319 # Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 202 of Reference documents Drawing No. Specification Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk All safety precautions necessary during working on excavations, blinding, forms, rebars, concrete pouring, concrete protection etc. shall be applied to acceptable standards Adequate safety measures shall be adhered to during lifting and offloading precast foundations to relevant locations avoiding any mishap BY OBSERVING THE REGULATORY CRANE FITNESS REQUIREMENT AND VALIDITY OF PERMIT. Only competent personnel shall be engaged to carry out the operation Crane and trailer operators shall abide by all traffic rules while carrying out operations and if so required, a banksman shall be engaged to direct the movement The crane shall not be operated during the inclement weather conditions with dust storms Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Concrete, Rebars / Lifting Lugs, Anchor Bolts, 100 mm dia 350 internal radius PVC Cable Duct, Bitustick XL, Masterseal 300H Method Pre casting Area- the existing yard being used to pre cast manholes, catch basins etc. shall be employed for this purpose also The following operations are involved to carry out the production of the lighting poles foundation bases Pre installation operations The typical size of the foundation is 1000x1000mm in plan and 1100mm deep According to drawing 319 # are specified to be constructed (quantity 351 m3) On an average 10 units shall be produced by pre casting every day The forms to the exact size with the preformed chamfers shall be prepared and erected The steel rebars shall be cut, bent to the required shape, placed and the cage prepared holding 75mm concrete spacers, and positioned into the forms. 1 # 350 mm internal radius 100 mm dia PVC cable duct formed to the dimensions shall be anchored by binding wires to the exact locations shown on the drawing keeping the upper end flush with the concrete top The Lifting lugs as shown on the sketch shall be fixed in at the correct locations The forms for the block outs for the lifting lugs shall be fixed in at the correct locations as shown without clashing with the duct or rebars allowing a protrusion of the hook Bolt assembly shall be fixed in at exact position according to the design details Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 203 of Non-critical cathodic protection shall be arranged using a metallic continuous binding wire connecting all the horizontal rebars terminating into a boss fixed at one location near the top in the middle of the side opposite the duct carrying portion All the supports and dimensions shall be checked, corrected if required and the plumb monitored An Civil Contractor QC inspection shall be conducted at regular intervals throughout the operations The concrete shall be poured to all the prepared units in 3 layers in vertical sequence The appropriate vibrator shall be used for the compaction of the concrete During concreting, care shall be taken to keep the anchor bolts’ position undisturbed and the intermittent checks be continuously made to monitor the spacing / centres between the bolts An Civil Contractor QC inspection shall be conducted prior to concrete pour & ITP signed off After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel Curing Immediately after the concrete is finished, the surface shall be covered with polythene sheet with the edge lapped or tied down to exclude air circulation without permitting the membrane to be in touch with concrete surface according to the specifications After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be removed followed by immediate covering the surface with saturated( soaked with mix quality water) hessian and recovered with polythene sheet to prevent evaporation from the hessian. Throughout the curing period, the hessian shall be maintained in a permanent wet condition using mix quality water The side forms shall be removed after the specified period of 24 to 36 hours as agreed The vertical concrete surfaces shall be draped with the saturated hessian immediately after striking the forms and covered with the polythene sheet held firmly in place along all edges & kept continuously wet for duration of curing The curing shall be continued for the specified period An Civil Contractor QC inspection shall be conducted from time to time throughout the operations Installation operations The relevant locations shall be made ready to receive the precast units by completing the excavation, blinding, the concrete protection and forming the correct alignment AN Civil Contractor QC inspection shall be conducted for the'location to receive' & ITP signed off The unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the relevant area to offload on to the prepared ‘location to receive’ The unit shall be installed on the marked location according to the correct orientation to the lighting layout drawing AN Civil Contractor QC inspection shall be conducted The protruding lifting lug eyes shall be cut to 60 mm inside the block out, the void filled with concrete by first scabbling the internal surface followed by cement slurry grouting and pouring concrete Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 204 of The below ground surfaces of the foundation shall be applied with concrete protective membrane according to the specifications AN Civil Contractor QC inspection shall be conducted The membrane protection board shall be provided covering the surface to the specified details. The backfilling shall be carried out in layers according to the specification upto the required levels The points to locate the cathodic protection shall be provided with a marker to trace the boss. Top surface of the foundation shall be applied with above ground concrete protection as specified EPC Contractor surveillance / inspection / approval shall be according to the approved ITPs Major Equipment Compressor, Mobile Crane, Trailer Concrete Pump, Transit mixer Attachment Lifting arrangement sketch #80 Sea water surge basin Concrete protection master seal 550 Top Index Scope Reference documents Definitions Responsibilities Safety Material Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to apply the specialist protection coating material on the internal concrete surfaces (shown on the drawings by cross hatching) of the sea water surge Basin according to the specifications. References Drawings Specifications Master seal 550-product data sheet Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 205 of -Protection to concrete Surfaces Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the toolbox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a tool box talk on the Project Site Safety requirements. Any process adopted which may involve a particular Safety risk, shall be assessed to the requirement for Site conditions and be taken care of. Scaffolding shall be erected to afford access to the working personnel according to the project requirements. Hand rails ladders and the toe boards shall be fitted and inspected prior to use. During mixing and application of master seal 550, personnel protective equipment shall be used i.e. overalls, goggles, gloves (to avoid material contact to eyes, mouth and skin) Material storage / disposal of used containers / waste material Materials shall be stored out of direct sunlight clear of ground and protected from rainfall. Used containers shall be collected and disposed off according to the state regulations. Medical attention shall immediately be made available as and when required Materials Coating, Masterseal 550 Master seal 550 is a two component acrylic modified cementitious coating that requires only site mixing to form an ideal product to waterproof, resurface concrete, masonry and most other construction materials. Simply applied by stiff brush, roller or trowel it forms a waterproof and flexible coating providing an effective barrier to waterborne salts and atmospheric gases. Method The method involves the following sequences in general. Surface preparation Mixing Application To keep up the exact coverage to form 1 mm thick coating an area of 11 m2 shall be marked on the concrete surface. The contents of the bag shall be applied on this area only Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 206 of At Joints The material coating shall terminate at the joints (Refer to the attached sketch) which are to be treated with sealant. The part of the coating that has to be embedded into the joint sealant shall be applied first followed by the major area on the panel be coated thereafter Details All grease, oil, dust, residual curing compound, mould release agent or other contaminants which could impair adhesion shall be removed from the surface by degreasing and washing. Arrises shall be rounded off and the surface protrusions ground down to ensure smooth substrata The whole surface to be coated shall be cleaned using water jetting from a distance of 2 to 3 m from the panel surface and visually inspected to ensure that the required degree of roughness has been achieved which be evident at a stage when the aggregate be exposed on the surface. All the holes, voids, depressions, spalls etc. shall be filled with Masterseal 550 mixed to a trowel consistency, scraped lightly into the surface, allowed to dry and later roughened by hand wire brush on the small areas and gently water jetted on the larger areas. The filled areas shall be visually inspected to ensure that the correct mechanical key is formed. Mixing Master seal supplied in the pre-measured units shall be mixed on site using clean containers. The powder shall be slowly added to the liquid component and agitated / mixed for 2 minutes using a slow speed hand power drill fitted with a suitable paddle attachment until a homogeneous lump free consistency is obtained. The mix quantity shall be such that it could be consumed in one hour during application without allowing any retempering with water. Application Coverage 1.8 Kg / sqm at 1 mm thickness The material shall be 1 mm thick applied in one coat In hot weather the surface to be coated shall be shaded from direct sunlight. The prepared surface area to be coated shall be saturated with fresh and clean water Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval The material shall in no case be applied on the dry surface The mixed material shall be applied while the surface is visibly damp without standing water using short stiff brush or roller with short hair. (Roller shall be used in major / large areas) The evenness and the thickness of the applied coating shall be regularly ascertained by the consumed quantity to the applicable ratio of 11 m2 each container during application while the material is still wet. The coverage of 11-m2 surface shall be the evidence for the actual formation of 1-mm thick coating. The material shall be allowed to dry and visually inspected Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval Any missed areas shall be saturated and then touched up. No curing shall be carried out Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 207 of Equipment Water tanker with water jetting arrangement Hard brushes for minor areas Clean container Slow speed drill with paddle attachment Stiff brush / Roller Attachment Masterseal 550 Data sheet and statement Typical sketch for joint for guidance purpose #81 Concrete coating masterseal 550 of structures using Top Index Scope Reference documents Safety Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to apply the specialist protection coating material on those concrete surfaces requiring special protection e.g. The interior of Sea water Surge basin & Collection Sumps References Specifications Master seal 550-product data sheet Protection to concrete Surfaces Safety Prior to the commencement of work, the labour force shall receive a STARRT card / Tool box talk relevant to the operation concerned on the Project Site Safety requirements. Necessary measures shall be applied to address any risk involved on any process Tagged scaffolding shall be erected to afford access to the working personnel Personnel working on sand blasting & mixing and application of master seal 550, shall wear overalls, gloves, safety glasses and masks Used containers shall be collected and disposed off according to the state regulations. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 208 of Method Joints - The material coating shall terminate at the joints to be treated with sealant. As shown on the attached sketch The part of the coating to be embedded into the joint shall be applied first to permit sealant application followed by the major area on the panel to be coated thereafter Surface preparation Arrises shall be rounded off and protrusions ground down to ensure smooth substrata The whole surface to be coated shall be lightly sand blasted & visually inspected to ensure that the required degree of roughness has been achieved. All holes, voids, depressions, spalls etc. shall be filled with Masterseal 550 mixed to a trowel consistency, scraped lightly into the surface, allowed to dry and later roughened by hand wire brush on small areas and lightly sand blasted on larger areas. The filled areas shall be visually inspected to ensure that the correct mechanical key is formed. Mixing Master seal supplied in the pre-measured units shall be mixed on site using clean containers. The powder shall be slowly added to the liquid component and agitated / mixed for 2 minutes using a slow speed hand power drill fitted with a suitable paddle attachment until a homogeneous lump free consistency is obtained. The mix quantity shall be consumed in one hour during application without allowing any retempering with water. Application Coverage 1.8 Kg / sqm at 1 mm thickness One coat application shall be 1 mm thick In hot weather the surface to be coated shall be shaded from direct sunlight. An area of 11 m2 shall be marked on Concrete surface to consume 1 bag content to produce 1 mm thick coating. Prepared surface area to be coated shall be saturated with fresh and clean water Civil Contractor QC inspection shall be conducted Material shall in no case be applied on the dry surface Mixed material shall be applied on the visibly damp surface without standing water using short stiff brush or roller with short hair. (Roller shall be used in major / large areas) Evenness and the thickness of the applied coating shall be regularly monitored relating the consumed quantity @ 11 sqm / bag during application while the material is still wet. Applied material shall be allowed to dry and visually inspected Civil Contractor QC inspection shall be conducted and the ITP signed off Any missed areas shall be saturated and then touched up. No curing shall be carried out Field samples shall be taken to confirm 1mm thick coating has been applied Equipment Sand blasting package Compressors Clean container Slow speed drill with paddle attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 209 of Hard brushes for minor areas Stiff brush / Roller Attachment Masterseal 550 Data sheet and statement Typical sketch for joint (for guidance) #82 Above ground concrete protection Seawater surge basin Top Index Scope Reference documents Definitions Responsibilities Safety Storage Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to form a protection coating on the above ground RCC walls’ external faces as well as on the internal surface areas other than those where Masterseal 550 shall be applied References Drawing Specifications Master seal 300 H-product data sheet Master seal 181 S-product data sheet Protection to concrete Surfaces MAR for Masterseal300 H MAR for Masterkure 181 Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 210 of Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the toolbox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a tool box talk on the Project Site Safety requirements. Any process adopted which may involve a particular Safety risk, shall be assessed to the requirement for Site conditions and be taken care of. Scaffolding with the hand rails, the ladders and the toe boards fitted and inspected prior to use shall be erected to provide access to the working personnel according to the project requirements. Only tagged scaffolding comprising all the guard rails foot rails etc. shall be used for the work at heights according to safety requirements. The personnel shall use protective clothing, gloves eye protection glasses, masks etc., for to avoid skin contact. Plenty of clean water shall be available all the time. Medical attention shall be available all time to treat the adverse effects. Transportation shall be available to move the effected personnel to the hospital should the circumstances so require. Material storage / disposal of used containers / waste material The material shall be stored under cover out of direct sunlight clear of ground, protected from rainfall as well as temperature extremes. Product shelf life is 12 months subject to proper storage Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and foodstuffs. The containers shall be resealed after use. Immediate medical attention shall be called for in case of any adverse effect to the personnel handling the product Damaged tins shall be disposed off according to the state regulations. Material Master Builder Technology Product Masterseal 300H - an acrylic based, elastomeric decorative, flexible, anti-carbonation and waterproof protective coating designed for the protection of concrete structures against carbonation and chloride ingress. Masterseal 181S- primer system Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 211 of Masterseal 300 H filler Method This application involves the following sequences Cleaning and making up the surface Priming the surface Coating the surface Details Preparation All surfaces shall be free from oil; grease, friable matters and curing compound. The surfaces shall be cleaned from dust / sand using compressed air. Arrises shall be rounded off and the protrusions ground so that the resulting surfaces appear smooth. The surfaces shall be brush primed with Masterkure 181S and subsequently Masterseal 300H mixed with Masterseal 300 H filler applied as a scrape coat over blowholes and depressions. The primed surface shall be allowed to dry tack free for a minimum duration of 2 hours before applying Masterseal 300H coating. Application Masterseal 300 H shall be applied directly from the containers using a brush or roller @ 0.8 litre per sqm surface coverage to achieve a continuous coating The continuous coating may be achieved in 1 or 2 coats of application The coating shall be protected from the rain and humidity for 24 hours / until it dries out using polythene sheets keeping off the area. The coating shall be applied when the humidity is less than 90 % The coating shall not be applied in the dusty weather conditions No post application curing is required The areas to be coated shall be protected from direct sunlight by net shading in the hot weather conditions and the ambient temperature be more than 5 degree Celsius. Equipment Brush Roller Attachment MBT datasheet & Statement #83 Sea water surge basin joint seal Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 212 of Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures that shall be adopted to apply the sealant to fill the joints formed in the walls and the base. This statement shall be construed in conjunction with Method Statement # approved / IFC vide Transmittal site-including an alternative to this document. Any of the 2 methods may be used for the joint treatment according to the convenience on site References Specifications Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the toolbox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a tool box talk on the Project Site Safety requirements. Any process adopted which may involve a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 213 of Scaffolding with the hand rails, the ladders, the toe boards fitted and inspected prior to use shall be erected to provide access to the working personnel according to the project requirements. Only tagged scaffolding comprising all the guard rails foot rails etc. shall be used for the work at heights according to safety requirements. Material storage / disposal of used containers / waste material Materials shall be stored out of direct sunlight clear of ground and protected from rainfall. Used containers shall be collected and disposed off as per project requirements. Medical attention shall immediately be made available as and when required The personnel shall use the PPE, gloves, masks, eyeglasses etc, and to avoid skin contact. use of barrier cream shall also be made. Hands shall be cleaned by Industrial cleaner followed by washing with soap and water. Material safety data shall be referred to for disposal and any further information. A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Storage The material shall be stored under cover out of direct sunlight and protected from extreme temperatures. Shelf life 12 months between 5 deg and 35 Celsius Materials De-bonding tape (to be applied before priming) Sealant Masterflex 700 (High performance, elastomeric joint sealant) Masterflex Primer # 1 Masterflex 700 is a high grade, synthetic rubber sealant possessing outstanding resistance to deterioration due to weathering, ozone, ultra violet light and attack by chemicals present in industrial atmospheres. The product has the capability to withstand repeated cycles of compression and extension over a wide range of tempertaure range and has excellent adhesion properties to all materials employed in buildings Supplied in pouring and gun grade for horizontal and vertical joints respectively Masterflex Primer # 1 is meant for porous surfaces such as concrete and masonry Coverage Joint depth 25 mm, width 25 mm, Filling length 1.6 m per litre Packages 3 litres sealed containers Method This following operational sequences shall be involved Pre application activity The corner area to be embedded into the sealant to be made ready with Master seal 550 Refer to Method Statement # 93 Application Preparation of the surface required to be sealed Taking the filler board to the required depth Cleaning the surface and applying the de-bonding tape Priming the surfaces Application of the sealant up to the profile shown Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 214 of Details The joint area shall be prepared according to the sketch and the site conditions. The filler shall be trimmed the the specified depth All surfaces shall be cleaned of dust and contaminants using wire brush and made dry. Civil Contractor QC inspection shall be conducted The debonding tape shall be fixed as shown on the sketch The surface shall be primed using brush according to the instructions given on the primer tins The primer shall be allowed to dry to a tack free state before Masterflex 700 is applied within 3 hours maximum to avoid repriming Mixing One complete unit shall be mixed at one time without subdivision Mixing shall be carried out for 5 to 10 minutes using a paddle fitted 500 rpm electric drill A palette knife shall be used to scrap the container surface intermittently to ensure that all curing agent be completely blended with the base compound. The material shall immediately be used after mixing Application The material shall be applied using a sealant gun fitted with conical nozzles adjustable to suit the joint width by cutting The sealant shall be gunned into the joint using an even trigger pressure and cleaning the nozzle occasionally to avoid contamination. Deep joints shall be filled in 2 runs to prevent air entrapment A smaller timber spatula soaked in soapy water shall be used to compact the sealant into the joint for a smooth polish finish formation. The mixing and application equipment shall be cured immediately Equipment Paddle mixer Sealant gun Attachment Manufacturer’s statement #84 Painting Sub stations Top Index Scope Reference documents Definitions Responsibilities Safety Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 215 of Method Equipment Attachment Scope This statement is aimed to present the proposed procedures that shall be adopted to apply the Painting System on the above building on RCC surfaces, Galvanised surfaces,Metal surfaces, Dry wall partition and the plastered surfaces according to the specifications and the material system approved. A brief regarding the proposed surfaces has been mentioned below Concrete General Wall Surfaces- Textured Epoxy Coating Equipment Enclosure External Concrete Walls at grade level- Textured Epoxy Coating Column Faces Features –50mm projection from general wall face with central vertical rebateSmooth Epoxy coating & finished Face-horizontal band finish-50mm projection beyond wall face. Top horizontal edge to be splayed at 45 degree-Smooth epoxy coating & finished Vertical ribs fair face concrete face- Smooth epoxy coating & finished Electrical Equipment / HVAC / Battery / Air LockWalls- High Build Washable Acrylic Emulsion Ceilings- High Build Emulsion Steel doors external- Polyurethane Galvanised external- Polyurethane References Notes on the Drawings & the Finishing Schedule Specifications MAR # Berger Paint Systems Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 216 of EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to the operation concerned to the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. The personnel shall use the PPE, gloves, masks, eyeglasses etc and to avoid skin contact. use of barrier cream shall also be made. Material safety data shall be referred to for disposal and any further information. Adequate arrangement shall be made to provide access to the top of the wall. Adequate scaffolding with proper netshade shall be provided wherever required The personnel shall use the waist safety belt / harness while working on height. Immediate medical care shall be provided in case the eyes of any personnel are effected due to the paint splashes or any other reason Proper ventilation shall be provided to let the workers respirate properly A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Storage The material shall be stored under cover out of direct sunlight and protected from extreme temperatures. Shelf life 12 months between 5 deg and 35 Celsius Materials Specified: Texotile from Jotun or Equivalent Approved: Berger Paint systems MAR # dated 27.1 The following table provides the details of the approved systems but the appropriate relevant system shall be followed according to the scope of the work. Appropriate arrangement adjustment shall be made for the Textured and the smooth surface applications to the manufacturer’s specifications / instructions Column head –50-mm epoxy coating shall be separately stated Table 15 S # Sub Strata Surface preparation Operating temperature 1 Galvanised steel- Mechanical cleaning to remove Upto 100 deg C Exterior,Polyurethane loose deposits 2 Mild steel-Exterior, Blasting to Sa 2.5 Upto 100 deg C Polyurethane 3 Concrete Surface- Cleaning with sand stone to Upto 100 deg C Exterior, smoothen the surface free from all Polyurethane dirt etc textured 4 Galvanised Steel- Mechanical cleaning to remove Upto 60 deg C Interior, Alkyd loose deposits Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge 5 6 Engineering Construction Method Statements Galvanised SteelInterior, Primed ferrous metal Alkyd Plaster and GypsumGypsum wall board and plaster, Acrylic Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 217 of Mechanical cleaning to Sa 2 to Upto 60 deg C remove loose rust, scales Cleaning with fine emery paper to Upto 50 deg C remove dirt etc. System # 1, Exterior Surfaces –Galvanised Steel, Polyurethane Table 16 Coats Generic # of Solids DFT Colour Applica Type coa volume Microns tion ts % Primer Surface 1 82 100 Alumini Brush / tolerant um Spray high build epoxy Finish Gloss 1 50 50 White / Brush / Polyurethan Colours Spray e 2 150 Berger Product Epimast ic 5100 Al Robbiat hane Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 218 of System # 2, Exterior Surfaces –Ferrous Metal, Polyurethane Table 17 Coats Primer Interme diate Finish Generic Type # of coa ts build 1 High epoxy polyamide primer High build 1 epoxy polyamide Gloss 1 Polyurethan e 3 Solids volume % 57 DFT Colour Applica tion Berger Product 75 Red Brush / Spray Epilux 78 68 100 Grey 50 50 Microns Brush / Spray White / Brush Colours / Spray Epilux 218HS Robbiat hane 225 Touch up if required with Epilux 78 after power tool cleaning on spots Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 219 of System # 3, Exterior Surfaces –Concrete Masonry, Polyurethane Textured Table 18 Coats Generic Type # of coa ts 1 Primer Epoxy Concrete Interme diate Epoxy 1 spray compound in textured finish Gloss / 1 Semi Gloss Polyurethan e Finish Solids volume % 45 DFT Colour Applica tion 50 White 68 1000 White 50 50 White / Colours Brush / Epilux Spray / Concret Roller e Primer Hopper Luxatile Gun Epoxy Spray Compo und Roller / Robbiat Spray athane Microns Berger Product 1100 The textured pattern is unpressed and the DFT could vary from 700 to 1000 micron or more as manually applied by hopper gun. Appropriate instruction to apply the smooth coat shall be followed according to the manufacturer’s manual System # 4, Interior Surfaces –Galvanised Steel, Alkyd Table 19 Coats Generic Type # of Solids coa volume ts % Etch Two Pack 1 Primer(T washer o be primer used in surface preparati on instead of 8.5 DFT Colour Applica tion Greenish Yellow Brush Spray Microns 5 Berger Product / Luxaprim e 1500 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 220 of blasting) Coats Generic Type # of Solids coa volume ts % Primer Coat Anticorrosive 1 rust inhibitive Primer Intermedi Alkyd 1 ate Coat Undercoat Finish Alkyd Enamel 1 Coat 4 DFT Colour Applica tion Brush Spray Microns 55 55 Red 55 55 White 48 48 Brush Spray White / Brush Colours Spray Berger Product / Luxaprim e 1500 / Luxole 1000 / Luxole 5000 155 Luxaprime 1000 has to be applied on the same day of Luxaprime 1500 System # 5, Interior Surfaces –Primed Ferrous Metal, Alkyd Table 20 Coats Primer Coat(If required) Generic Type # of Solids coa volume ts % High build 1 alkyd zinc phosphate primer Intermedi Alkyd 1 ate Coat undercoat Finish Alkyd Enamel 1 Coat Note3 Primer need not be applied if already primed DFT Colour Microns 50 50 Red Grey 55 50 White 50 50 Applica tion / Brush Spray Brush Spray White / Brush Colours Spray Berger Product / Luxaprim e 1400 / Luxol 1000 / Luxol 5000 150 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 221 of System # 6, Interior Surfaces –Gypsum Wallboard and plaster, Acrylic Table 21 Coats Primer Coat Filler Coat Generic Type # of Solids coa volume ts % DFT Premium quality alkali resisting primer High quality acrylic based wall filler 1 25 25 81 To White smoothe n the surface 35 50 White / Roller Colours 35 50 White / Roller Colours 1(to seal & smo othe n the surf ace) quality 1 Intermedi High ate Coat acrylic emulsion Finish Semi gloss 1 Coat acrylic emulsion 3 Colour Applica tion White Brush Roller Microns Berger Product / Brolac Acrylic AR Primer Spatula Berger Super Wall Filler Bergerco at Acrylic Emulsion Brolac Semi Gloss Emulsion >100 Method GENERAL Marking of containers Materials shall be delivered in sealed containers clearly labelled with the following information. Manufacturer’s name, initials or recognised trade mark Title and specification number Whether primer or undercoat, finishing coat Whether for internal or external use where appropriate Colour reference from BS 4800 Method of application Batch number and date of manufacture and re – test No paint shall be used after 18 months of manufacture or re test Coating materials other than spray paints, bituminous pants and fine textured masonry paint shall be in containers not exceeding 5 litres capacity Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 222 of Samples Sample panel of 1 sqm in area shall be prepared for each type and colour of coating material to be used in the work for the approval Sample material of each paper / fibre material minimum size 500 x 500 mm showing at least the pattern repeat where applicable shall be submitted for approval Part 2 Materials Preparatory Materials Paint removers, abrasive papers and blocks, cleaning agents, etching solutions, stopping, knotting, fillers and other commodities shall be of the types recommended by the manufacturer of the coating to be applied White spirit shall comply with BS 245 Knotting shall comply with BS 1336 Stopping and filler for woodwork shall be approved proprietary Leadless oil based type recommended for internal or external work as appropriate. Stopping for woodwork to receive a coat finish shall be tinted to match with the surrounding work Filler for plaster or rendering shall be approved proprietary type The following operational sequences shall be involved Priming Coat Filler Coat to the requirement Intermediate Coat Finishing Coat All according to the approved system as aforesaid detailed for reference. Application PREPARATION OF THE GALVANIZED SURFACES Dirt and other adherent contaminating matter / loose deposits shall be removed from galvanised surfaces by mechanical means using Berger tool cleaner. Cleaning shall not damage the galvanising. Oil or grease shall be removed from galvanised surfaces by the application of an emulsion cleaner. Any zinc corrosion products remaining shall be removed by washing with sweet water and scrubbing with hard bristle brushes After being cleaned and degreased, all galvanised surfaces shall be etched with T-wash as described in BS 5493. If any surface fails to turn black as cleaning, greasing and etching processes shall be repeated. APPLICATION OF PAINT GENERALLY All paints shall be prepared and applied in strict accordance with the manufacturer’s instructions. Priming paints shall be applied by brush. Spray application shall only be used for painting of epoxy resin base Exposure of intermediate coats of paint for periods in excess of a few days shall not be permitted except in case of work delivered to site in a primed condition The dried films shall be free from bloom, shrinkage, sheeringness, wrinkling, sagging, curtailing, discoloration and extraneous matter No exterior or exposed paint work shall be carried out under adverse weather conditions, during rain, mist, sandstorms nor when the relative humidity exceeds 80% Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 223 of Painting shall insofar as is practicable be shaded from direct sunlight by netting to prevent wrinkling and bristling. Whenever possible exterior painting shall be so programmed during the day so as to be carried out in shadow Painting of surfaces shall not be carried out when condensation is present on such surfaces or the application and / or drying of the paints is likely to be affected Surfaces to be painted shall receive as first coat of paint as quickly as possible after the e preparation has been completed In case of metal surfaces this shall preferably be within one hour but always before the metal temperature drops to less than 3 deg C above dew point and before any rusting Civil Contractor QC inspections shall be conducted at every stage of surface preparation , post application of the coat, prior to the proceeding and at the final coat completion followed by EPC Contractor approval all according to the ITP documents attached METHOD OF COATING Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall be avoided. When these occur they shall be brushed out immediately or the materials removed and the surface recoated. On beams and irregular surfaces, edges shall be strip coated first and at extra pass made later. Each coat shall be allowed to dry for the time specified by the manufacturer before application of any succeeding coat Any primer coat exposed to freezing, excess humidity, rain, dust etc., before drying, shall be removed, surface again prepared and primed The time interval between application of coats shall not exceed that specified for optimum results by the manufacturer All coatings shall be cleaned as specified by the manufacturer before the next coat is applied All areas not specifically mentioned in the painting specification shall be finished to conform to the adjacent comparable areas All fixtures and surfaces not to be painted shall be properly protected during application and upon completion of the work all paint and varnish removed from glass, fixtures, covering, etc., Moveable parts shall not to be painted. All parts such as pipe supports, seatings and cleats, back to back sections which shall become inaccessible after fabrication shall be treated on both surfaces with the full paint system prior to final assembly, thus ensuring adequate protection. SPRAY APPLICATION All equipment for spray application shall be inspected and approved before any application begins. Spray guns, hoses and pumps shall be cleaned before new material is added. An adequate moisture and oil trap shall be installed between the air supply to each application unit. Suitable pressure regulators and gauges shall be provided for the air supply to the application units. Spray equipment and operating pressures shall comply with the manufacturer’s recommendations. Coating materials containing heavy pigments that have a tendency to settle shall be kept in suspension during the application by the power driven, continuous agitator The spray gun shall be held at right angles to the surface and each pass overlap the previous one by approximately 50%. All materials contained herein may be applied by airless spray. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 224 of BRUSH APPLICATION Brushes shall be of a style and quality that permit proper application of the material Flat brushes shall not be more than 100 mm wide. No extending handles shall be used on brushes. Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is obtained without any deep or detrimental marks Paints shall be worked into all corners and crevices. When applying solvent type coating, care shall be taken to prevent lifting of previous coats. FILM THICKNESS Specified film thickness for coating materials shall be strictly observed which be checked with an appropriate film thickness gauge. Calibration for the thickness range to be checked at least twice a day When dry film thickness are less than those specified, additional coats shall be applied as required. Particular attention shall be paid to full film thickness on edges In hot weather such additional precautions as are necessary shall be taken to ensure that the specified dry film thickness on priming or finish coats is obtained COATING QUALITY Coatings shall be free from pinholes, voids, bubbles, dust, foreign inclusions and other holidays and any such defect shall be repaired. Prior to the application of a coating, any damage to the previous coating shall be repaired with the specified material. Upon completion of the fabrication any damage to the coating system shall be repaired TEST EQUIPMENT Svensk photographic standard SIS 05 59 00 Coating thickness meter such as Elcometer ‘Minitector” Model 150 Wet fill thickness combs Hygrometer Maximum and minimum thermometer Flow cup type B # 4 and timer Surface profile meter such as Elcometer’Roughness detector’ Bolted site connections other than faying surfaces of Grip Bolt connections shall be brought together ‘wet’ EPOXY COATING WORK GENERALLY In addition to the general requirements the following conditions shall apply wherever epoxycoating work is being carried out Forced draught ventilation shall be used wherever required for the needs of the personnel or for drying out surfaces Operatives shall work in pairs Samples areas on substrate shall be prepared and coated for approval There shall be strict control of surface cleanliness between primer and epoxy coating / and between coats of the same. Vacuum removal of dust and sand shall be employed and contamination removed. Where dirt or dust has been trapped in the painted surface it shall be removed with suitable abrasive paper. The surface being painted shall be free of visible moisture throughout these operations Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 225 of The paint shall be applied only to the clean dry primed or previously coated surfaces. Any thick runs or collections of paint shall be removed before these harden Not less than 2 coats shall be applied over the primer by airless spray, less than 3 by brush Each coat shall be distinctly different in colour from the primer or previous coat. The colour of the final coat shall be as approved. Each coat shall be seen to have completely covered the proceeding without ‘ misses’ or pinholes or any areas visibly low in thickness. A high voltage pinhole detector shall also be used to determine the integrity of the coats The manufacturer of the coating shall stipulate primer and epoxy recoat interval for all curing temperatures likely to be encountered and these be adopted with a maximum tolerance of +4 hours. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to remove gloss and provide a key Wet thickness gauges shall be used by the coating operators continually to check that sufficient paint is being applied to achieve the desired dry film thickness EPOXY COATING FOR CONCRETE AND RENDERED SURFACES No priming shall commence until the moisture content of the cementitious surface is less than 5% measured by Wetcheck Moisture meter or other instrument Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 % on the concrete scale of the instrument when the probe tips are held against such painted surfaces just prior to recoating The priming shall be applied by suitable Nylon bristle brush or spray over the whole area to be coated at such thickness that it may then be squeezed into the pores of the concrete. Any excess shall be removed by the most suitable means before application of the high build epoxy The total DFT of the paint layer shall have a minimum specified value Whenever the paint inspection gauge has been used and wherever the coating has been otherwise damaged for 50 mm around such damage, the surfaces shall be abraded followed by the area touched in with not less than 2 # thick applications to restore the coating integrity to the specified thickness. Adhesion tests shall be carried out on the cured coating surface using the test equipment supplied in accordance with the best practice. The resulting test specimens shall show no indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness. The following instrument shall be used 1 Adhesion Tester 0 to 35 kg / cm2 1 DC high voltage holiday detector # 105 One paint inspection gauge PIG 1 wet check moisture meter Equipment Spray appliance Brushes Rollers Attachment ITP-Doc: QCF Rev B Concrete paint system checklist ITP-Doc :QCF Rev B Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 226 of Internal painting check list #85 Painting Sub stations Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the procedures to be adopted to apply the Painting System on the various surfaces of all the Sub Station buildings according to the following specifications and the drawing references References Specifications Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications Safety Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox talk regarding the painting system operation concerned to the Project Site Safety requirements. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 227 of Any process involving a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. In this case all the adverse effects of the epoxy paint shall be informed and the safety measures to be adopted instructed. The personnel shall use the PPE, gloves, masks, eyeglasses etc and to avoid skin contact. use of barrier cream shall also be made. Material safety data shall be referred to for disposal and any further information. Adequate arrangement shall be made to provide access up to the top of the wall. Tagged scaffolding with proper netshade shall be provided wherever required The personnel shall use the waist safety belt / harness while working height. Immediate medical care shall be provided in case the eyes of any personnel are effected due to the paint splashes or any other reason Proper ventilation shall be provided to breathe properly A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Storage The material shall be stored under cover out of direct sunlight and protected from extreme temperatures. Materials Specified: Texotile from Jotun or Equivalent Approved: Berger Paint systems MAR dated 27.1. The following table provides the details of the approved systems Table 22 S # Sub Strata Surface preparation Operating temperature 1 Galvanised steel- Mechanical cleaning to remove Upto 100 deg C Exterior,Polyurethane loose deposits –Cleaning with Berger Cleaner-Refer to manufacturer’s recommendations 2 Mild steel-Exterior, Blasting to Sa 2.5 Upto 100 deg C Polyurethane 3 Concrete Surface- Cleaning with sand stone to Upto 100 deg C Exterior, smoothen the surface free from all Polyurethane dirt etc textured 4 Galvanised Steel- Mechanical cleaning to remove Upto 60 deg C Interior, Alkyd loose deposits - Cleaning with Berger Cleaner -Refer to manufacturer’s recommendations 5 MS / Ferrous Metal- Mechanical cleaning to Sa 2 to Upto 60 deg C Interior, remove loose rust, scales Primed ferrous metal Alkyd 6 Plaster and Gypsum- Cleaning with fine emery paper to Upto 50 deg C Gypsum wall board remove dirt etc. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 228 of and plaster, Acrylic System # 1, Exterior Surfaces –Galvanised Steel, Polyurethane Table 23 Coats Generic # of Solids DFT Colour Applica Microns Type coa volume tion ts % Primer Surface 1 82 100 Alumini Brush / tolerant um Spray high build epoxy Finish Gloss 1 50 50 White / Brush / Polyurethan Colours Spray e 2 150 System # 2, Exterior Surfaces –Ferrous Metal, Polyurethane Berger Product Epimast ic 5100 Al Robbiat hane Table 24 Coats Primer Interme diate Finish Generic Type # of coa ts build 1 High epoxy polyamide primer High build 1 epoxy polyamide Gloss 1 Polyurethan e 3 Solids volume % 57 DFT Colour Applica tion Berger Product 75 Red Brush / Spray Epilux 78 68 100 Grey 50 50 Microns Brush / Spray White / Brush Colours / Spray Epilux 218HS Robbiat hane 225 Touch up shall be carried out with ‘Epilux 78’ after cleaning the effected area using power tool Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 229 of System # 3, Exterior Surfaces –Concrete Surface / Masonry, Polyurethane Textured Table 25 Coats Generic Type # of coa ts 1 Primer Epoxy Concrete Interme diate Epoxy 1 spray compound in textured finish Gloss / 1 Semi Gloss Polyurethan e 3 Finish Solids volume % 45 DFT Colour Applica tion 50 White 68 1000 White 50 50 White / Colours Brush / Epilux Spray / Concret Roller e Primer Hopper Luxatile Gun Epoxy Spray Compo und Roller / Robbiat Spray athane Microns Berger Product 1100 Because the textured pattern is unpressed the DFT may vary from 700 to 1000 micron or more as manually applied by hopper gun. The smooth surface shall be produced by following the relevant manufacturer’s instruction System # 4, Interior Surfaces –Galvanised Steel, Alkyd Table 26 Coats Generic Type # of Solids coa volume ts % Etch Two Pack 1 Primer(To wash be used in primer surface preparation instead of blasting) 8.5 DFT Colour Applica tion Greenish Yellow Brush Spray Microns 5 Berger Product / Luxaprim e 1500 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Coats # of Solids coa volume ts % Generic Type Primer Coat Intermediat e Coat Finish Coat Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 230 of Anticorrosi 1 ve rust inhibitive Primer Alkyd 1 Undercoat Alkyd 1 Enamel 4 DFT Colour Applica tion Brush Spray Microns 55 50 Red 55 50 White 48 50 Brush Spray White / Brush Colours Spray Berger Product / Luxaprim e 1500 / Luxole 1000 / Luxole 5000 155 Luxaprime 1000 primer coat shall be applied the same day when the surface is prepared by etching using Luxaprime 1500 System # 5, Interior Surfaces –Primed Ferrous Metal, Alkyd Table 27 Coats Primer Coat(If required) Generic Type # of Solids coa volume ts % High build 1 alkyd zinc phosphate primer Intermedi Alkyd 1 ate Coat undercoat Finish Alkyd Enamel 1 Coat Note3 Primer need not be applied if already shop primed DFT Colour Microns 50 50 Red Grey 55 50 White 50 50 Applica tion / Brush Spray Brush Spray White / Brush Colours Spray Berger Product / Luxaprim e 1400 / Luxol 1000 / Luxol 5000 150 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 231 of System # 6, Interior Surfaces –Gypsum Wallboard and plaster, Acrylic Table 28 Coats Primer Coat Filler Coat Generic Type # of Solids coa volume ts % DFT Premium quality alkali resisting primer High quality acrylic based wall filler 1 25 25 81 To White smoothe n the surface 35 50 White / Roller Colours 35 50 White / Roller Colours 1(to seal & smo othe n the surf ace) quality 1 Intermedi High ate Coat acrylic emulsion Finish Semi gloss 1 Coat acrylic emulsion 3 Colour Applica tion White Brush Roller Microns Berger Product / Brolac Acrylic AR Primer Spatula Berger Super Wall Filler Bergerco at Acrylic Emulsion Brolac Semi Gloss Emulsion >100 Method GENERAL Materials shall be delivered in sealed containers clearly labelled with the following information. Manufacturer’s name or recognised trade mark Title and specification number Whether primer or undercoat, finishing coat Whether for internal or external use where appropriate Colour reference from BS 4800 Method of application Batch number and date of manufacture Samples Sample panel of 1 sqm in area shall be prepared for each type of coating for approval on any of the surfaces to be applied with that paint The following operational sequences shall be involved Priming Coat Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 232 of Filler Coat to the requirement Intermediate Coat Finishing Coat All according to the approved system as aforesaid Application PREPARATION OF THE GALVANIZED SURFACES Dirt and other adherent contaminating matter / loose deposits shall be removed from galvanised surfaces by mechanical means using Berger tool cleaner. Cleaning shall not damage the galvanising. APPLICATION OF PAINT (GENERAL) All paints shall be prepared and applied in strict accordance with the manufacturer’s instructions. Exposure of intermediate coats of paint for periods in excess of specified time shall not be permitted except in case of work delivered to site in a primed condition The dried films shall be free from all defects such as bloom, shrinkage, sheerings, wrinkling, sagging, curtailing, discoloration and extraneous matter No exterior or exposed paintwork shall be carried out under adverse weather conditions i.e., during neither sandstorms nor when the relative humidity exceeds 80% Painting shall insofar as is practicable be shaded from direct sunlight by netting to prevent wrinkling and bristling. Painting of surfaces shall not be carried out when condensation is present on such surfaces or the coating application on drying is likely to be affected Surfaces to be painted shall receive the first coat of paint as quickly as possible after the preparation has been completed In case of metal surfaces, this shall preferably be within one hour but always before the metal temperature drops to less than 3 deg C above dew point and before any rusting Civil Contractor QC inspections shall be conducted at every stage of surface preparation, post application of the coat, prior to the proceeding coat and at the final coat completion, all according to the ITP documents attached METHOD OF COATING Each coat shall be applied uniformly over the entire surface. Skips, runs, sags and drips shall be avoided. When these do occur, they shall be brushed out immediately or the materials removed and the surface recoated. On beams and irregular surfaces, edges shall be strip coated first and an extra pass made later. Each coat shall be allowed to dry for the time specified by the manufacturer before application of any succeeding coat Any primer coat exposed to, excessive humidity, dust etc., before drying, shall be removed, and the surface again prepared and primed All coatings shall be cleaned as specified by the manufacturer before the next coat is applied All fixtures and surfaces not to be painted shall be properly protected during application and upon completion of the work all paint and varnish removed from glass, fixtures, covering, etc., Moveable parts shall not to be painted. All parts such as pipe supports, seatings and cleats, back to back sections which shall become inaccessible after fabrication shall be treated on both surfaces with the full paint system prior to final assembly, thus ensuring adequate protection. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 233 of SPRAY APPLICATION All equipment for spray application shall be inspected and approved before any application begins. Spray guns, hoses and pumps shall be cleaned before new material is added. An adequate moisture and oil trap shall be installed between the air supply to each application unit. Suitable pressure regulators and gauges shall be provided for the air supply to the application units. Spray equipment and operating pressures shall comply with the manufacturer’s recommendations. Coating materials containing heavy pigments that have a tendency to settle shall be kept in suspension during the application by the power driven, continuous agitator The spray gun shall be held at right angles to the surface and each pass overlap the previous one by approximately 50%. All materials contained herein may be applied by airless spray. BRUSH APPLICATION Brushes shall be of a style and quality that permit proper application of the material No extending handles shall be used on brushes. Brushing shall be done so that a smooth coat as nearly uniform in thickness as possible is achieved without any deep or detrimental marks Paints shall be worked into all corners and crevices. FILM THICKNESS Specified film thickness for coating materials shall be strictly observed which is checked with an appropriate ‘film thickness gauge’. When dry film thickness is less than that specified, additional coats shall be applied as required. Particular attention shall be paid to full film thickness on edges In hot weather such additional precautions as are necessary shall be taken to ensure that the specified dry film thickness on priming or finishing coats is achieved by monitoring the wet film thickness using the appropriate gauge. Additional coats shall be applied on the deficient area COATING QUALITY Coatings shall be free from pinholes, voids, bubbles, dust, foreign inclusions and other holidays and all such defects shall be repaired. Prior to the application of a coating, any damage to the previous coating shall be repaired with the specified material. TEST EQUIPMENT Coating thickness meter such as Elcometer ‘Minitector” Model 150 or equivalent Wet fill thickness combs Hygrometer Maximum and minimum thermometer Surface profile meter such as Elcometer’Roughness detector’ EPOXY COATING WORK (GENERAL) In addition to the general requirements the following conditions shall apply wherever epoxycoating work is being carried out Forced draught ventilation shall be used wherever required for the needs of the personnel or for drying out surfaces Operatives shall work in pairs Sample on substrate shall be prepared and coated for approval Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 234 of There shall be strict control of surface cleanliness between primer and epoxy coating / and between coats of the same application. Vacuum removal of dust and sand shall be employed and contamination removed. Where dirt or dust has been trapped in the painted surface, it shall be removed with suitable abrasive paper. The surface being painted shall be free of visible moisture throughout these operations The paint shall be applied only to the clean & dry primed or previously coated surfaces. Any thick runs or collections of paint shall be removed before these harden Each coat shall be distinctly different in colour from the primer or previous coat. The colour of the final coat shall be as approved. Each coat shall be seen to have completely covered the proceeding without ‘ misses’ or pinholes or any areas ‘visibly low’ in thickness. A high voltage pinhole detector shall also be used to determine the integrity of the coats “The manufacturer of the coating shall stipulate primer and epoxy recoat interval for all curing temperatures likely to be encountered and these be adopted with a maximum tolerance of +4 hours”. Where this is exceeded, the surfaces to be recoated shall first be suitably abraded to remove gloss and provide a key Wet thickness gauges shall be used by the coating operators continually to check that sufficient paint is being applied to achieve the desired dry film thickness EPOXY COATING FOR CONCRETE AND RENDERED SURFACES No priming shall commence until the moisture content of the cementitious surface is less than 5% measured by Wetcheck Moisture meter or other instrument Similarly moisture measurements over the primer or any epoxy intercoat shall not exceed 1 % on the concrete scale of the instrument when the probe tips are held against such painted surfaces just prior to recoating The priming shall be applied by suitable Nylon bristle brush or spray over the whole area to be coated at such thickness that it may then be squeezed into the pores of the concrete. Any excess shall be removed by the most suitable means before application of the high build epoxy The total DFT of the paint layer shall have a minimum specified value Whenever the paint inspection gauge has been used and wherever the coating has been otherwise damaged, the surfaces shall be abraded 50 mm around and the area touched in with not less than 2 # thick applications to restore the coating integrity to the specified thickness. Adhesion tests shall be carried out on the cured coating surface using the test equipment supplied in accordance with the best practice. The resulting test specimens shall show no indication of poor adhesion to the substrate, residual laitance or intercoat adhesion weakness. The following instrument shall be used 1 Adhesion Tester 0 to 35 kg / cm2 1 DC high voltage holiday detector # 105 One paint inspection gauge PIG 1 wet check moisture meter Equipment Spray appliance Brushes Rollers Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 235 of Attachment ITP-Doc: QCF Rev B Concrete paint system checklist ITP-Doc :QCF Rev B Internal painting check list #86 Electrical & instrumentation trenches Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to carry out the construction of the proposed Electrical and Instrumentation trenches to the following specified details Cable trench X-ing with U / G pipe Cable trench X-ing with U / G pipe with closed drain pipe trench Pipe X-ing direct buried cables only Typical elctrical layout at pumps Typical corner details for walled trench Direct buried trench X-ing under Dummy Trench Trench with dummy Trench X-ing under direct buried cable trench Dummy + walled trench section References paving & Under Ground services Electrical and Instrumentation Trench and Duct Bank details Specifications Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge FM QC Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 236 of Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to the operation concerned to the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. The personnel shall use the PPE, gloves, masks (for gas leak in area), eyeglasses (during dusty winds) etc Adequate arrangement shall be made to provide access to the top of the wall. A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Materials Mass Concrete for strip foundation beam, Concrete blocks, precast covers, oil resistant sealant Method GENERAL-Dummy and walled trench section The following operational sequences shall be involved To set out the exact alignment of the trenches to the specified co-ordinates To barricade the involved area to the safety requirement To excavate the trenches to the specified levels To dress the formations and compact To prepare the sides for the mass concrete 100mm thick To pour the mass concrete To set out the block walls alignment To carry out 150mm thick block work to the specified levels upto the paving down beam level To carry out the down standing paving portion & extend to the block wall top To fill the trench with the excavated earth back according to specifications To place the precast coloured concrete covers 1m or 3m lengths on the compacted ground To Seal the paving and cover joint Where the dummy trench runs over the duct bank (Typical Trench Duct Bank Detail) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 237 of The duct bank with the uPVC sleeves in for the crossing portion below the underground pipe should be ready formed with the mass concrete the size of which shall vary according to the number of crossing pipes The following operational sequences shall be involved To excavate down to the top of the duct concrete in case backfilling has been completed To clean the concrete surface To set out the trench alignment To set out the block wall alignment keeping maximum 50 mm overhang To construct the block walls to paving down beam level To carry out the down standing paving portion & extend to the block wall top To fill the trench with the excavated earth back according to specifications To place the precast coloured concrete covers 1m or 3m lengths on the compacted ground To Seal the paving and cover joint Additionally, in case the underground pipe runs X-ing the Trench, to lay the specified pipe prior to the block work operation by others To provide a flat crossing size equal (Duct Bank length + 300x2) The formation level of the duct bank and the dummy trench shall be the same at the exact crossing location Where the dummy trench and the direct buried trench run parallel The following operational sequences shall be involved To repeat all the sequences as in general in the aforesaid To follow the profile of the dummy trench while constructing the buried trench for ease To form the down slope profile at the crossings as shown on the drawing The slope grade shall be 1 in 2 Where the cable trench crossing the closed drain pipe trench The following additional operational sequences to the general trench construction for the dummy or the direct buried shall be required To provide the profile of the direct buried trench same as that of the cable duct trench To provide the transition of levels between the dummy trench and the flat below X-ing by a slope grade 1 in 2 as specified on the drawing To provide a duct bank of size depending on the dimension of the closed drain trench to pass above by providing a width (closed drain trench width + 100mmx2) To provide a total flat width below the crossing equal (duct bank length + 300x2). To provide the uPVC sleeves in the duct bank prior to the mass concreting To allow a clear void of 100mm minimum between soffit of closed drain trench base and the duct bank top To provide cable tiles under trench crossing in direct buried cable trenches only(By others) To allow the closed drain trench isolate from the paving Where direct buried trench crossing under dummy trench The following additional operational sequences to the general trench construction for the dummy or the direct buried shall be required To provide a level difference of 350 mm between the dummy trench elevation and the compacted surface below the crossing maintaining a transition slope grade 1 in 2 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 238 of To allow the cables running in dummy trench to be protected by the cable tiles installed at 75 mm above the top of cables where no paving is shown (By others) To allow to provide the cable protection tiles above the cables where these pass in the walled trench to cross under the dummy trench (By others) To form the walled trench corner detail according to the corner splay internal size 8485 mm Where dummy Trench crossing under direct buried cable trench The following additional operational sequences to the general trench construction for the dummy or the direct buried shall be required To provide a flat surface below the X-ing at the bottom of the duct bank of size equal (duct bank length + 300x2) with a slope grade transition 1 in 2 To provide a level difference of 100 mm between soffit of the direct burried cable trench and the duct bank top Where direct buried cable trench crossing under direct buried cable trench The following additional operational sequences to the general trench construction for the dummy or the direct buried shall be required To maintain a level difference 700 mm between direct buried trench and the crossing formation level To provide a transition grade 1 in 2 To provide a cable tiles in unpaved areas only and at trench crossing (By others) To provide the formation crossing width equal (direct buried cable trench width + 400x2) Electric Trench Layout at Pumps The following additional operational sequences to the general trench construction for the dummy or the direct buried shall be required To form the trench termination into an integral chamber of internal dimensions as (Pump base length / 2+trench internal width) x (Pump base width +300+500) Details in general The surveyor shall setout the alignment of the trench concerned according to the details given on the paving and underground services layouts to the reference co-ordinates Civil Contractor QC shall conduct the inspection followed by EPC Contractor approval The required safety arrangement shall be discussed with the safety department and implemented accordingly to control the trench excavation, to provide barricades night-lights etc, to divert the traffic if so required and to adopt any other unforeseen measures. The excavation shall be carried out by an excavator to the lines and the surveyor monitor various stages during the operation to maintain the required profile The excavated material shall be transported immediately after being taken out using a dumper, to the earth stockpiles temporarily The formation levels after the excavation is over shall be well dressed and compacted to the specification requirement The forms of width 350mm and depth 100 mm shall be readily available to be fixed on the prepared compacted formation duly aligned Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval The mass concrete shall be poured to the marked levels and tamped by wooden float The curing shall be carried out according to approved procedures Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 239 of The alignment of the block walls 150 mm thick shall be set out, the block work carried out in courses in a straight line and plumb The whole number of courses shall be laid, the fraction remained to be completed for the wall height shall be covered by pouring during the paving down beam concrete The connecting integrated / pouring area including the down beam shall be carried out to the specified details according to the procedures Civil Contractor QC inspection shall be conducted followed by the EPC Contractor approval The backfilling shall commence and the trench filled according to the specifications The precast covers of 1m or 3 m standard length already precast shall be placed on the formed trench internal surface to the specified levels The concrete shall be coloured to the specification requirement Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval Option If so required and felt convenient for certain standard equal depth reaches, precast concrete members of 100 mm thick sections may be utilised to substitute 150 mm thick walls directly resting on the prepared formation Equipment Excavator Dumper truck Compactor Attachment None #87 Electrical & instrumentation trenches Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the procedures to be adopted to carry out the construction of the Electrical and Instrumentation Trenches to the typical details. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 240 of References Drg Paving & Under Ground services Electrical and Instrumentation Trench and Duct Bank details Specifications Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications Safety Prior to the commencement of work, the labour force shall receive a STARRT card / Toolbox talk relevant to the operation concerned to the Project Site Safety requirements. Any process involving a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. The personnel shall use the PPE, gloves, masks (for gas leak in area), eyeglasses (during dusty winds) etc A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Materials Mass Concrete for strip foundation beam, Concrete blocks, Precast trench covers, oil resistant joint sealant Method GENERAL Dummy / walled trench section (Detail 5 on the reference drawing) The following operational sequences in brief are involved Setting out to the exact alignment the route of the trench to the specified co-ordinates Barricading the involved area to the safety department direction and requirement Excavating the trench to the specified levels and sectional details Preparing the formation to the required levels and dimensions Form work for the sides of the mass concrete strip beams Pouring the mass concrete to the strip beam forms Setting out the alignment for the trench block walls Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 241 of Block work 150mm thick in walls to the specified levels upto the pavement downstand beam soffit level Preparation and concreting the pavement portion monolithic with the downstand beam extended upto the top of the block wall Backfilling the trench with the excavated earth to the specifications Placing the precast coloured concrete covers in 1m or 3m standard lengths on the relevant compacted area Sealing the joint between the pavement and the trench cover Details about the above operations in general The surveyor shall set out the alignment of the trench concerned according to the relevant details given on the paving and underground services location plans to the reference Co-ordinates Civil Contractor QC shall conduct the inspection The safety arrangement shall be discussed with the safety department and implemented accordingly to control the trench excavation, to provide barricades, night-lights, to divert the traffic if so required, and to adopt any other necessary measure. The excavation shall be carried out by an excavator to the lines and the levels. The surveyor shall monitor all stages of excavation to achieve the required profile The excavated material shall be transported immediately by a dump truck to the earth stockpiles temporarily After the excavation is over, the formation levels shall be well dressed and compacted to the specification requirement The forms shall be fabricated for the mass concrete section The fabricated forms of width 350mm and depth 100 mm shall be erected / fixed on the prepared compacted formation duly aligned and levelled Civil Contractor QC shall conduct the inspection throughout the stages of construction The mass concrete shall be poured to the marked levels and tamped by wooden float The forms shall be struck after the specified period The curing of the mass concrete shall be carried out according to approved procedures and for the specified period The alignment of the block walls 150 mm thick shall be set out and the block work carried out in courses in a straight line and plumb The whole number of courses shall be laid. The fractional block course if so remained to make up the required wall height, shall be constructed as a part of the pavement down beam concrete by extending the bottom to the top of the block walls The pavement / down beam monolithic pouring shall be carried out to the specified details according to the procedures Civil Contractor QC shall conduct the inspection throughout the stages of construction The backfilling shall commence and the trench filled according to the specifications The precast covers of 1m or 3 m standard length shall be placed on the filled trench internal surface to the specified levels The concrete shall be coloured to the specification requirement Civil Contractor QC shall conduct the inspection throughout the stages of construction Where the dummy trench runs over the duct bank (Ref drawing Detail 4, Sec A) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 242 of All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities Excavation shall be carried out to the top of the duct concrete only The walls shall be started from the duct top level Additionally, where the underground pipe runs X-ing the Trench, the specified pipe shall be laid prior to the block work is commenced or openings shall be formed in the walls (Pipe laying operation by others) Flat width of the crossing shall be in size equal to the value given by the equation “Duct Bank length + 300x2 “ Where the dummy trench and the direct buried trench run parallel (Ref Drg Detail 4,sec B) All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities While constructing the buried trench, the profile of the dummy trench shall dictate the profile of the buried trench Sloping profile to a grade 1 in 2 shall be formed as shown on the drawing Where the cable trench crossing with the closed drain pipe trench (Ref drg Detail 6 sec C) All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities The profile of the cable duct trench shall dictate the profile of the direct buried trench The transition of the formations between the trenches and the crossing shall be in grade 1 in 2 as shown on the drawing The length of the duct bank shall be equal to the value given by the equation Width of the closed drain trench in mm + 2x100 The crossing flat width shall be the duct bank length + 2x300 A gap of 100mm shall be kept between the duct bank top and the closed drain bottom surfaces The duct bank shall be constructed according to the details Cable tiles under the closed drain trench shall be provided in the direct buried trench only A joint shall be provided between the pavement and the closed drain trench wall Where direct buried trench crossing under dummy trench (Ref Drg Detail) Sec G & H) All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities A level difference of 350mm shall be kept between the elevations of the crossing formation and the dummy trench The level transition shall be established by grading 1 in 2 The cables passing under the dummy trench shall be protected by cable tiles (By others) The trench corner wall shall be constructed to the details showing the corner length on the trench internal face 8485mm Where trench with dummy Trench crossing under direct buried cable trench (Ref Drg Detail 3 Sec E) All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 243 of The profile of the cable duct trench shall dictate the profile of the direct buried trench The transition of the formations between the trenches and the crossing shall be in grade 1 in 2 as shown on the drawing The length of the duct bank shall be equal to the value given by the equation Width of the direct buried cable trench in mm + 2x100 The crossing flat width shall be the duct bank length + 2x300 A gap of 100mm shall be kept between the duct bank top and the closed drain bottom surfaces The duct bank shall be constructed according to the details Cable tiles under the closed drain trench shall be provided in the direct buried trench only Where direct buried trench crossing under direct buried cable trench (Ref Drg Detail 7 Section D) All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities A level difference 700 mm shall be kept between direct buried trench and the crossing formation level The crossing formation width shall be equal to the value from the equation in mm (direct buried cable trench width + 400x2) The transition of the formations between the trenches and the crossing shall be to grade 1 in 2 as shown on the drawing Cable tiles shall be provided in unpaved areas and at trench crossing (By others) Electric Trench Layout at Pumps (Ref Drg Detail 13) All the operations described in general shall be applicable herein as well with the following amendments / additions to certain activities The pump base shall be constructed to the details The trench walls shall be continued to the shape as shown Option If so required and felt convenient for certain uniform section reaches, precast concrete units 100 mm thick may be utilised to substitute 150 mm thick walls directly resting on the prepared formation Equipment Excavator Dumper truck Compactor Attachment None #88 Pull pits Top Index Scope Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 244 of Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to carry out the construction of the Pull Pits References Specifications Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process involving a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. All the safety precautions required to be adhered to while working on the excavations, mass concrete, forms, rebars, concrete pouring etc all according to the acceptable standards, shall be adopted on the operations concerned Adequate safety shall be observed during lifting and offloading the precast concrete covers to the relevant locations to avoid any mishap BY OBSERVING THE REGULATORY CRANE FITNESS REQUIREMENT AND VALIDITY OF PERMIT. Only competent personnel shall be engaged to carry out the operation The crane and the trailer operators shall adhere to all the traffic rules while carrying out the operations and if so required, a banksman be engaged to direct the movement The crane shall not be operated during the inclement weather conditions with dust storms Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 245 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during the inspection shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Mass Concrete of specified grade, Structural concrete of specified grade, Blocks, 16 mm dia GI Lifting Lugs, Rebars all according to requirement Method The following operations are involved (Brief description) ( Details on the following page) Operations in prcasting Yard Form work to the details shown for Pit type 1 and 2 i.e. P1 and P2 Rebars placement to the details shown for Pit type 1 and 2 i.e. P1 and P2 Lifting lugs fixing to the details on the sketches attached Pouring concrete & finishing by a steel float Curing according to specified procedures Lifting & loading by a crane to a trailer for transportation On site operations- post laying of Cable ducts Setting out Excavation of the pit manually in case of the ducts are not encased in concrete Mass concrete base on formation according to the details Concrete protection according to specifications Block work in walls according to specifications Uncompacted sand fill only for pit Type 1 Compacted backfill only for pit Type 1 Placing the precast covers 300 mm deep sand backfill over the laid ducts not encased in concrete As dug compacted backfill above to the specifications Pre casting Area-The existing yard being used for the pre casting of manholes, catch basins and lighting poles foundations etc. shall be employed for this purpose also Details about operations in the pre-casting yard The typical size of the Pit type 1 cover is 1990x500mm in plan and 200mm deep The typical size of the Pit type 2 cover is 2990x500mm in plan and 200mm deep According to the schedule 71 #s for type 1 and 81#s for type 2 are specified to be constructed On an average 5 units shall be produced by pre casting every day The forms to the exact size with the pre -formed chamfers shall be prepared and erected The steel rebars shall be cut, bent to the required shape, placed with 75mm concrete spacers and positioned into the forms. The Lifting lugs as shown on the sketch shall be fixed in to the correct locations All the supports and the dimensions shall be checked and corrected if required Civil Contractor QC inspection shall be conducted from time to time throughout the operations The concrete shall be poured to all the prepared units in 1 layers The appropriate vibrator shall be used for the compaction of the concrete After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 246 of Immediately after the concrete starts setting, saturated hessian shall be spread over the finished surface covered with polythene sheet according to the specifications The side forms shall be removed after the specified period The vertical concrete surfaces shall be draped with the saturated hessian immediately after striking the forms and covered with the polythene sheet according to specifications The curing shall be continued for the specified period Civil Contractor QC inspection shall be conducted from time to time throughout the operations The relevant locations shall be made ready to receive the precast units by completing the excavation, mass concrete, the horizontal concrete protection, block walls, backfill and forming the correct alignment The unit shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the location for offloading on to the prepared ‘location to receive’ the unit The unit shall be installed on the marked location according to the correct orientation to the lighting layout drawing Civil Contractor QC inspection shall be conducted from time to time throughout the operations Details about operations on site The area around the excavation coverage shall be barricaded to the site requirement based on the direction of the safety incharge The setting out shall be carried out by the surveyor to the required coordinates Civil Contractor QC inspection shall be conducted from time to time throughout the operations Excavation shall be carried out (manually if the ducts are not encased in concrete) to the specified formation levels i.e. 1300 mm from the finished grade monitored by surveyor Compaction and the tests if so required, shall be carried out accordingly The form work for the mass concrete 500mm wide and 150mm thick shall be prepared and erected to the settings Civil Contractor QC inspection shall be conducted from time to time throughout the operations Concrete shall be poured to the exact levels, finished properly and cured to the specified procedures Concrete protection shall be applied to the mass concrete top to the details & specifications Block work shall be carried out in 200 mm width as shown on the drawings to the required levels so that the cover placing level is 1050mm from the top of mass concrete including the thickness of the levelling mortar. In case of the ducts are not laid in, opening shall be left in the wall Civil Contractor QC inspection shall be conducted from time to time throughout the operations Uncompacted sand shall be filled as shown on the drawing in case of pit type 1 The remaining portion shall be backfilled and compacted to the specification requirement in case of pit type 1 The top surface shall be well prepared, compacted and levelled to receive the precast covers in case of pit type 1 The top of the block walls shall be given a cement mortar bearing in the form of a levelling course about 20mm thick allowed to be fully set in prior to the precast cover is placed on Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 247 of The covers shall be offloaded by a crane from a trailer as transported from the precasting yard to the relevant locations. The covers shall be properly spaced and levelled to the details shown on the drawing #89 Pull pits Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to carry out the construction of the Pull Pits References Specifications Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the work force & Instruct, through the medium of language they understand, all safety precautions to be strictly adhered to as STARRT Card / ToolBox talks every day and ascertain that these are followed up regularly QC shall inspect all the operations according to the specifications Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 248 of Any process involving a particular safety risk shall be assessed and addressed to raise the measures to a minimum standard / an acceptable mark. The safety precautions required while working on the excavations, mass concrete, forms, rebars, concrete pouring etc all according to the acceptable standards, shall be strictly adhered to on the operations concerned Adequate safety shall be observed during lifting and offloading the precast concrete covers to the relevant locations to avoid any mishap BY OBSERVING THE REGULATORY CRANE FITNESS REQUIREMENT AND VALIDITY OF PERMIT. Only competent personnel shall be engaged to carry out the operation The crane and the trailer operators shall abide by all traffic rules while carrying out the operations and if so required, a banksman be engaged to direct the movement The crane shall not be operated during the inclement weather conditions with dust storms Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during the inspection shall be notified to the supervisor present who must immediately act to bring the safety measures to an acceptable standard Materials Mass Concrete of specified grade, Structural concrete of specified grade, Blocks, 16 mm dia GI Lifting Lugs, Rebars all according to requirement Method The following operations are involved Operations in Precasting Yard Pre casting Area The existing yard being used for the pre casting of manholes, catch basins and lighting poles foundations etc. shall be employed for this purpose also Form work The typical size of the Pit type 1 cover is 1900x500mm in plan and 200mm deep The typical size of the Pit type 2 cover is 2900x500mm in plan and 200mm deep According to the schedule 71x 6 #s each=426 #s Type 1 and 81x 6 #s each=486 #s Type 2 covers are quantified to be constructed On an average, 20 units shall be produced by pre casting every day The wooden forms to the exact dimensions with pre -formed chamfers shall be prepared and erected Rebars placement The steel rebars shall be cut, bent to the required shape, placed with 75mm concrete spacers and positioned into the forms according to the details shown for type P1 & P2 Lifting lugs fixing The Lifting lugs as shown on the attached sketch shall be fixed in to the correct locations All supports and dimensions shall be checked and corrected if required Civil Contractor QC inspection shall be conducted before pouring concrete and signatures appended to ITPs Pouring concrete & finishing The concrete shall be poured into all the approved preparatory works in 1 layer by directly delivering from the concrete truck / transit mixer through the chute Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 249 of 1 # ¾” needle vibrator shall be used to compact the concrete and 1 # reserved standby After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel Curing Immediately after the concrete is finished, the surface shall be covered with polythene sheet with the edge lapped or tied down to exclude air circulation without permitting the membrane to be in touch with concrete surface according to the specifications After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be removed followed by immediate covering the surface with saturated( soaked with mix quality water ) hessian and recovered with polythene sheet to prevent evaporation from the hessian. Throughout the curing period the hessian shall be maintained in a permanent wet condition using mix quality water The side forms shall be removed after the specified period of 24 to 36 hours as agreed The vertical concrete surfaces shall be draped with the saturated hessian immediately after striking the forms and covered with the polythene sheet held firmly in place along all edges & kept continuously wet for duration of curing The curing shall be continued for the specified period of 14 days Civil Contractor QC inspection shall be conducted from time to time throughout the operations Lifting, loading & transportation The covers shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the area concerned to offload on to the prepared ‘location to receive’ On site operations- post laying of Cable ducts The area around the excavation coverage shall be barricaded to the site requirement based on the direction of the Construction Superintendent Setting out The setting out shall be carried out by the surveyor to the required co-ordinates Civil Contractor QC inspection shall be conducted throughout the operation and ITP for the survey check signed off Excavation Excavation shall be carried out (manually if the ducts are not encased in concrete) to the specified formation levels i.e. 1300 mm (varying from area to area) from the finished grade monitored by surveyor Compaction and the tests if so required, shall be carried out accordingly Mass concrete base The form work for the mass concrete 500mm wide and 150mm deep shall be prepared and erected to the settings Civil Contractor QC inspection shall be conducted from time to time throughout the operations and concrete pour ITPs signed off Concrete shall be poured to the exact levels, finished properly and cured to the specified procedures Concrete protection Concrete protection shall be applied to the mass concrete to the details & specifications Block work in walls Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 250 of 200mm Block work shall be carried out as shown on the drawings to the required levels so that the cover top level is 100mm from the finished grade / ground level. In case the ducts are not laid in, opening shall be provided in the wall Civil Contractor QC inspection shall be conducted from time to time throughout the operations Uncompacted sand fill Uncompacted sand shall be filled as shown on the drawing & in accordance with the specifications Compacted backfill The remaining portion shall be backfilled and compacted to the specification requirement The top surface shall be well prepared, compacted and levelled to receive precast covers Placing the precast covers The covers shall be offloaded by a crane from a trailer as transported from the precasting yard to the relevant locations. The covers shall be properly spaced and levelled to the details shown on the drawing Sand fill 300mm deep sand backfill shall be carried out over the laid ducts not encased in concrete Backfill As dug compacted backfill shall be carried out above the sandfill to the specifications Civil Contractor QC inspection shall be conducted from time to time throughout the operations with the relevant ITPs signed off Lugs Fill The sand shall be filled in the lifting lugs recess Concrete Protection The exposed concrete surface is a part of pavement and therefore no protection shall be applied Equipment Transit mixer, Trailor, Vibrator, Crane, Attachment 3 # Sketch -showing the lifting lugs arrangement #89 Pull pits Top Index Scope Reference documents Safety Method Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 251 of Attachment Scope This statement is aimed to present the proposed procedures to be adopted to carry out the construction of the Pull Pits References Specifications Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process involving a particular safety risk shall be assessed and addressed to raise the measures to a minimum standard / an acceptable mark. The safety precautions required while working on the excavations, mass concrete, forms, rebars, concrete pouring etc all according to the acceptable standards, shall be strictly adhered to on the operations concerned Adequate safety shall be observed during lifting and offloading the precast concrete covers to the relevant locations to avoid any mishap BY OBSERVING THE REGULATORY CRANE FITNESS REQUIREMENT AND VALIDITY OF PERMIT. Only competent personnel shall be engaged to carry out the operation The crane and the trailer operators shall abide by all traffic rules while carrying out the operations and if so required, a banksman be engaged to direct the movement The crane shall not be operated during the inclement weather conditions with dust storms Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during the inspection shall be notified to the supervisor present who must immediately act to bring the safety measures to an acceptable standard Materials Mass Concrete of specified grade, Structural concrete of specified grade, Blocks, 16 mm dia GI Lifting Lugs (Exposed portion only), Rebars all according to requirement Method The following operations are involved Operations in Precasting Yard Pre casting Area The existing yard being used for the pre casting of manholes, catch basins and lighting poles foundations etc. shall be employed for this purpose also Form work The typical size of the Pit type 1 cover is 1900x500mm in plan and 200mm deep The typical size of the Pit type 2 cover is 2900x500mm in plan and 200mm deep According to the schedule 71x 6 #s each=426 #s Type 1 and 81x 6 #s each=486 #s Type 2 covers are quantified to be constructed On an average, 20 units shall be produced by pre casting every day The wooden forms to the exact dimensions with pre -formed chamfers shall be prepared and erected Rebars placement Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 252 of The steel rebars shall be cut, bent to the required shape, placed with 75mm concrete spacers and positioned into the forms according to the details shown for type P1 & P2 Lifting lugs fixing The Lifting lugs as shown on the attached sketch shall be fixed in to the correct locations All supports and dimensions shall be checked and corrected if required Civil Contractor QC inspection shall be conducted before pouring concrete and signatures appended to ITPs Pouring concrete & finishing The concrete shall be poured into all the approved preparatory works in 1 layer by directly delivering from the concrete truck / transit mixer through the chute 1 # ¾” needle vibrator shall be used to compact the concrete and 1 # reserved standby After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float followed by light steel trowel Curing Immediately after the concrete is finished, the surface shall be covered with polythene sheet with the edge lapped or tied down to exclude air circulation without permitting the membrane to be in touch with concrete surface according to the specifications After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be removed followed by immediate covering the surface with saturated( soaked with mix quality water ) hessian and recovered with polythene sheet to prevent evaporation from the hessian. Throughout the curing period the hessian shall be maintained in a permanent wet condition using mix quality water The side forms shall be removed after the specified period of 24 to 36 hours as agreed The vertical concrete surfaces shall be draped with the saturated hessian immediately after striking the forms and covered with the polythene sheet held firmly in place along all edges & kept continuously wet for duration of curing The curing shall be continued for the specified period of 14 days Civil Contractor QC inspection shall be conducted from time to time throughout the operations Lifting, loading & transportation The covers shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the area concerned to offload on to the prepared ‘location to receive’ On site operations- post laying of Cable ducts The area around the excavation coverage shall be barricaded to the site requirement based on the direction of the Construction Superintendent Setting out The setting out shall be carried out by the surveyor to the required co-ordinates Civil Contractor QC inspection shall be conducted throughout the operation and ITP for the survey check signed off Excavation Excavation shall be carried out (manually if the ducts are not encased in concrete) to the specified formation levels i.e. 1300 mm (varying from area to area) from the finished grade monitored by surveyor Compaction and the tests if so required, shall be carried out accordingly Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 253 of Mass concrete base The form work for the mass concrete 500mm wide and 150mm deep shall be prepared and erected to the settings Civil Contractor QC inspection shall be conducted from time to time throughout the operations and concrete pour ITPs signed off Concrete shall be poured to the exact levels, finished properly and cured to the specified procedures Concrete protection Concrete protection shall be applied to the mass concrete to the details & specifications Block work in walls 200mm Block work shall be carried out as shown on the drawings to the required levels so that the cover top level is 100mm from the finished grade / ground level. In case the ducts are not laid in, opening shall be provided in the wall Civil Contractor QC inspection shall be conducted from time to time throughout the operations Uncompacted sand fill Uncompacted sand shall be filled as shown on the drawing & in accordance with the specifications Compacted backfill The remaining portion shall be backfilled and compacted to the specification requirement The top surface shall be well prepared, compacted and levelled to receive precast covers Placing the precast covers The covers shall be offloaded by a crane from a trailer as transported from the precasting yard to the relevant locations ready with one layer 0.25mm thick polythene sheet with laps 300mm, spread over. The covers shall be properly spaced and levelled to the details shown on the drawing Sand fill 300mm deep sand backfill shall be carried out over the laid ducts not encased in concrete Backfill As dug compacted backfill shall be carried out above the sandfill to the specifications Civil Contractor QC inspection shall be conducted from time to time throughout the operations with the relevant ITPs signed off Lugs Fill The sand shall be filled in the lifting lugs recess Concrete Protection The exposed concrete surface is a part of pavement and therefore no protection shall be applied Equipment Transit mixer, Trailor, Vibrator, Crane, Attachment 3 # Sketch -showing the lifting lugs arrangement #90 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 254 of Road crossing to make good Wearing course over completed 1# for 14” desalinated water & 1# for 8”potable water Avenue ‘c’ Top Index Scope Reference documents Definitions Responsibilities Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out to make good the wearing course over the completed road crossing to facilitate the smooth traffic plying.The pipe lines 1 # each 14” Desalinated water and 8” Potable water at locations identified on attached drawing for this X-ing were completed to the following references Reference documents Specification. Excavation & Backfilling for Underground structures. Drawing No. -Easement Systems Avenue “C” Piping Interconnection Drawings, Avenue ‘C’ Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 255 of CM shall arrange the resources required accordingly and be overall responsible for the excavation operation CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS Any mishap on the excavation operation shall immediately be notified to the CS and the CM for the immediate action if so required for any possible remedy or record or the authority review whatsoever,the case may be FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of any activity the labour force shall receive a Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process involving a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. In the present case the minor debris removal / excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be resorted to effect a full safety standard. ToolBox TalksWhile conducting ToolBox Talks, every precautionary measure to be adopted shall be explained expressely to all the personnel and translated to the language understood by them Only English literate Foreman shall be employed to work on the critical execution. Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all the relevant persons involved on the crossing Traffic Management-Sign boards keep up- All the personnel shall be briefed about the safe keep up of the boards Barricades,cones, markers and the night-lights, flood lights etc. shall be arranged as required for a complete safety. No oil spillage shall be allowed. The barriers shall be placed to indicate the excavation work in progress Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be engaged to operate full time to direct the traffic about the excavation work in progress by waving the flag for all the vehicles passing by Jack Hammer- The workers if engaged on operating this equipment shall use protective glass and work in phases with pause intervals. The compressor air pressure shall be monitored from time to time so that the hammer works smoothly. The compressor shall be place within the barricade limits Machine Excavation The operators shall be explicitly explained and instructed about the requirement of the reverse signal and sound when operating reverse. The truck driver shall also be instructed similarly. Banksman shall be engaged while the equipment operate. No violation of the traffic rules shall be allowed Safety Supervision Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 256 of A competent inspector shall inspect the trench daily to assess the safety measures adopted. Method The required permit to work shall be obtained from the Plant Refinery Division. A traffic management scheme has been presented herein and shall be produced on site as detailed on the attached sketch for this road crossing which includes, reduced speed sign, temporary diverted roads sign, men at work sign, warning signs, informatory signs, safety barriers, night lighting and road cleaning activities. The traffic management scheme shall be reviewed and approved by EPC Contractor prior to commencing the work. The aforesaid traffic management scheme shall be implemented as described below: TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street / Avenue ‘C’ Drawing reference – This completed crossing is located on the Road Avenue ‘C’ between the following Co-ordinates as shown on the referred drawing. This is a 2-way road with a central verge and carrying 2 lanes on either way The proposed crossing is located about 60 m from 1 st street road towards North One serving electric pole is located away from the x-ing to North The minor irrigation / hoses are lying disconnected Some minor trees and plants are arboricultured on the central verge. The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side of the carriageway. In the first instance the work shall be carried out on part L1 diverting the traffic to the road portion on the part L2 as shown on the sketch. In the second instance the work shall be carried out on part L2 diverting the traffic to the road portion on the completed road portion on the part L1 as shown on the sketch. The directory signboards shall also be placed on the 1 st street road East West on both ways to indicate the work at the crossing For the traffic North to South the first reduce speed for traffic diversion informatory board depicting shall be located at 300 m from the point of the proposed crossing, the second depicting diversion signs be located at 200 m and the third depicting men at work sign be located at 100 m on either way in the opposite directions. For the traffic South to North past crossing, one sign shall be placed to direct for the diversion, to slow down and the men at work ahead A Flagman shall be engaged full time on both the directions to guide the traffic about the ongoing excavation operations in addition to the conventional signboards The following activities are involved. Reference to the marked note ‘B’ on the Easement Systems Drawing To produce the Traffic Diversion Management Scheme To excavate mechaniclly the loose wearing portion to a depth so that a total concrete thickness of 70 mm is poured To have authority inspection To pour the concrete To reinstate the central verge to the existing state Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 257 of Details The Traffic Management Scheme shall be executed as explained in the foregoing and to the traffic manual directions. The first section of the proposed road crossing as per the attached sketch shall be marked by the surveyor on the actual location. The debris / asphalt shall be cut using jackhammers or grader to the require levels so that a final concrete thickness 70mm be poured The excavated material shall be removed from the site to stockpile area. The excavated trench shall be inspected by the authorities as required. A concrete slab shall be cast up to the bottom of the finished asphalt level. The traffic management system shall be removed after the road crossing has been cleaned of any debris or obstructions. Either side of the road shall be provided with cable markers to indicate the services Major Equipment Grader,Excavator,Dump trucks.Compactors. Jack Hammer, Compressor, Attachment Sketch showing the traffic management scheme #91 Road crossing to make good Wearing course over completed 132 kv electric cable Avenue ‘c’ Top Index Scope Reference documents Definitions Responsibilities Safety Method including traffic management scheme Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out to make good the wearing course over the completed road crossing to facilitate smooth traffic plying. Laying of 132 KV electric cable at location identified on the reference drawing for this X-ing has been completed Reference documents Specification. Excavation Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 258 of Drawing No. -Easement Systems Avenue “C” Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly and be overall responsible for the excavation operation CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS Any mishap on the crossing operation shall immediately be notified to the CS and the CM for the immediate action if so required, for any possible remedy or record or the relevant authority review whatsoever the case may be FM shall execute the operations deploying the work force .and instruct in full in the medium of language the work persons understand about all the required measures and the STARRT / ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications & ITP requirement Safety Prior to the commencement of any activity the labour force shall receive a STARRT Card / Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process involving a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. In this case the minor debris removal / excavation has to be carried out on the Operating Authority area, therefore all the regulated precautionary measures shall be strictly adhered to ToolBox Talks While conducting ToolBox Talks, every precautionary measure to be adopted shall be explicitly instructed to all personnel to abide by through the medium of language they understand A Foreman who also understands English shall be employed to work on the critical execution. Excavation Work Permit A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all the relevant persons involved on the crossing Barricades, cones, markers and the night-lights, flood lights etc. shall be arranged as required for a complete safety. The barriers shall be placed to indicate the excavation work in progress Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be engaged full time to direct the traffic about the excavation work in progress by means of flag signal to all vehicles passing by Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 259 of Jack Hammer- The workers if engaged on operating this equipment shall use protective glass and work in phases with pause intervals. The compressor air pressure shall be monitored from time to time so that the hammer works smoothly. The compressor shall be place within the barricade limits Machine Excavation The operators shall be explicitly instructed about the requirement of the reverse signal and sound when operating reverse. The truck driver shall also be instructed similarly. Banksman shall be engaged while the equipment operate. No violation of the traffic rules shall be allowed No oil spillage shall be allowed Safety Supervision A competent inspector shall inspect the area daily to assess the safety measures adopted. Method The required permit to work shall be obtained from the Plant Refinery Division. A traffic management scheme has been presented herein and shall be produced on site as detailed on the attached sketch for this road crossing which includes, reduced speed sign, temporary diverted roads sign, men at work sign, warning signs, safety barriers, night lighting and road cleaning activities. The traffic management scheme shall be reviewed and approved by EPC Contractor prior to commencing the work. The aforesaid traffic management scheme shall be implemented as described below: TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street / Avenue ‘C’ Drawing reference – This completed crossing is located on the Road Avenue ‘C’ between the following Co-ordinates as shown on the referred drawing. This is a 2-lane dual carriageway road with a central verge This crossing is located about 60 m from 1st street road towards North One serving electric pole is located away from the crossing to North The minor irrigation / hoses are lying disconnected Some minor trees and plants are growing on the central verge. The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side of the carriageway. In the first instance the work shall be carried out on part L1 diverting the traffic to the road portion on the part L2 as shown on the sketch. In the second instance the work shall be carried out on part L2 diverting the traffic to the road portion on the completed portion on the part L1 as shown on the sketch. The directory signboards shall also be placed on the 1 st street road East West on both ways to indicate the work at the crossing For the traffic North to South, the first informatory board for traffic depicting ‘reduce speed’ shall be located at 300 m from the point of the proposed crossing, the second depicting ‘diversion’ signs be located at 200 m and the third depicting ‘men at work ‘sign be located at 100 m on either way in the opposite directions. For the traffic South to North past crossing, one signboard shall be located to depict ‘diversion’, ‘slow down’ and ‘the men at work ahead’ Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 260 of A Flagman shall be engaged full time on both the directions to guide the traffic about the ongoing excavation operations in addition to the conventional signboards The following activities are involved. The Traffic Diversion Management Scheme shall be executed as explained in the foregoing and to the traffic manual requirement reflected on the attached sketch The first section of the crossing shall be marked by the surveyor on the actual location. The debris / asphalt shall be cut using jackhammers or grader to the required level so that a final concrete thickness 70mm can be poured The excavated material shall be removed from the site to stockpile area. Concrete wearing slab 70mm thick shall be cast up to the finished asphalt level These activities shall be repeated for the second section after the first is completed The traffic management system shall be removed after the road crossing has been cleared of all debris or obstructions. Civil Contractor QC inspection shall be conducted to the ITP requirement Either side of the road shall be provided with cable markers to indicate the services In future, after the completion of the proposed pipe laying operations (For which the methodology is included separately, ref. method statement # 86), an approved asphalt wearing course shall be laid to the requirement to replace 70mm concrete paving Major Equipment Grader,Excavator,Dump trucks.Compactors. Jack Hammer, Compressor, Attachment Sketch showing the traffic management scheme Civil Contractor QC inspection shall be conducted from time to time throughout the operations The sand shall be filled in the lifting lugs recess The exposed concrete surface is a part of pavement and therefore no protection shall be applied Equipment Transit mixer, Trailor, Vibrator, Crane, Attachment 4 # Sketch -showing the lifting lugs arrangement #92 Road crossing To make good (temporarily) Wearing course over completed Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 261 of 132 kv electric cable Avenue ‘c’ Top Index Scope Reference documents Safety Method including traffic management scheme Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out to make good the wearing course over the completed road crossing to facilitate smooth traffic plying. Laying of 132 KV electric cable at location identified on the reference drawing for this X-ing has been completed Reference documents Specification. Excavation Drawing No. Safety Prior to the commencement of any activity the labour force shall receive a STARRT Card / Toolbox talk relevant to the operation concerned on the project site safety requirements. Any process involving a particular safety risk shall be assessed and addressed as required to raise to a minimum standard / an acceptable mark. In this case the minor debris removal / excavation has to be carried out on the Operating Authority area, therefore all the regulated precautionary measures shall be strictly adhered to ToolBox Talks While conducting ToolBox Talks, every precautionary measure to be adopted shall be explicitly instructed to all personnel to abide by through the medium of language they understand A Foreman who also understands English shall be employed to work on the critical execution. Excavation Work Permit A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all the relevant persons involved on the crossing Barricades, cones, markers and the night-lights, flood lights etc. shall be arranged as required for a complete safety. The barriers shall be placed to indicate the excavation work in progress Flagman-On both the direction, in addition to the traffic sign boards, a flagman shall be engaged full time to direct the traffic about the excavation work in progress by means of flag signal to all vehicles passing by Jack Hammer- The workers if engaged on operating this equipment shall use protective glass and work in phases with pause intervals. The compressor air pressure shall be monitored from time to time so that the hammer works smoothly. The compressor shall be place within the barricade limits Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 262 of Machine Excavation The operators shall be explicitly instructed about the requirement of the reverse signal and sound when operating reverse. The truck driver shall also be instructed similarly. Banksman shall be engaged while the equipment operate. No violation of the traffic rules shall be allowed No oil spillage shall be allowed Safety Supervision A competent inspector shall inspect the area daily to assess the safety measures adopted. Method The required permit to work shall be obtained from the Plant Refinery Division. A traffic management scheme has been presented herein and shall be produced on site as detailed on the attached sketch for this road crossing which includes, reduced speed sign, temporary diverted roads sign, men at work sign, warning signs, safety barriers, night lighting and road cleaning activities. The traffic management scheme shall be reviewed and approved by EPC Contractor prior to commencing the work and agreed with Plant Refinery Division. The aforesaid traffic management scheme shall be implemented as described below: TRAFFIC MANAGEMENT SCHEME ROAD CROSSING – First Street / Avenue C’ This crossing is located about 83 m from center line of 1st street road towards North The road shall be divided in 2 parts as shown on the sketch as lane L1 and L 2 on either side of the carriageway. In the first instance the work shall be carried out on part L1 diverting the traffic to the road portion on the part L2 as shown on the sketch. In the second instance the work shall be carried out on part L2 diverting the traffic to the road portion on the completed portion on the part L1 as shown on the sketch. Signboards shall be positioned as shown on the sketch A Flagman shall be engaged full time on both the directions to guide the traffic about the ongoing excavation operations in addition to the conventional signboards The temporary stone surface on lane L1 shall be excavated to a depth of 70mm and replaced by mass concrete to level with the adjacent asphalt. Traffic shall be allowed on to the concrete after 2 days and the operation shall be repeated for lanes L2 All excavated material shall be removed to an approved tipping area. The concrete surface shall be replaced by asphalt to the same specification as the existing construction at the earliest opportunity Major Equipment Grader,Excavator,Dump trucks.Compactors. Jack Hammer, Compressor, Attachment Sketch showing the traffic management scheme #93 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 263 of Drinking water connection Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement, is to define the procedure that shall be adopted for the connection and laying of the pipeline, from the Operating Authority supply pit No 21, to the Civil Contractor camp. Reference documents Excavation permit. Definitions Operating Authority Abu Dhabi National Oil Company. EPC Contractor Civil Contractor . PSM Project Site Manager. Responsibilities The Civil Contractor PSM shall ensure this method statement is implementation for the connection and laying of the drinking water pipeline. Safety The Safety Officer shall monitor the daily activities, advising and implementing all safety procedures. Method The proposed drinking water connection location and route of the pipeline, shall be defined upon a drawing, which shall be reviewed and approved by Operating Authority. The approved pipeline route drawing shall define the materials and fitting locations. All trenching activities shall be excavated by hand. The excavated material shall be stockpiled for re-use as fill material. The pipe trench shall be excavated to a depth of 500mm. All stones and hard materials from the bottom of the trench shall be removed. The pipe shall be located within the trench. Selected backfill shall be placed around the pipe. The trench shall be backfilled with the excavated material. Any surplus material shall be removed from site. The laying and connection of the pipes shall be conducted by experienced people. Where the pipeline passes beneath a roadway, a sleeve pipe shall be incorporated to protect the water pipe from damage. Testing of the pipes shall be conducted to ensure that leakage does not occur. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 264 of Marker posts to indicate a buried service shall be installed upon completion of backfilling and clearing of the site. Equipment Hand tools. Pipe jointing and cutting tools. Attachment Work permit. Drawing Site Sketch #94 Protection to transformer foundation sides in sub stations with aluminium bead termination for below ground and masterseal 300h for above ground in gravel fill area Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to protect the vertical surfaces of the transformer bases concrete using Aluminium Beads to clampin the waterproofing membrane termination around the foundation sides and apply concrete protection coating on the surfaces above ground References Main Substation Drawing Transformer Foundations Sec A & D and the relevant drawings for all other sub stations SpecificationsDefinitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 265 of Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the toolbox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a toolbox talk on the Project Site Safety requirements relevant to the application of below ground and above ground concrete surface protection operations Any process which may involve a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. The personnel shall use the PPE, gloves, masks, eyeglasses etc. Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and foodstuffs. To avoid skin contact, use of barrier cream to protect from the adverse effect of sealant and other chemicals application shall also be made. Industrial cleaner shall be used followed by washing with soap and water. The containers shall be resealed after use. Immediate medical attention shall be called for in case of any adverse effect to the personnel handling the product Damaged tins shall be disposed off according to the state regulations. Material safety data shall also be referred to for disposal and any further information. A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Materials Bitustick XL Polybit MAR 003 Aluminium Bead lengths to the Sectional dimensions 30 mm x 2 mm Fixing screws 3 mm dia Joint filler Alpex Joint Fill BCR MAR 008 Sealant- Polyurethane-Gun Grade Cold seal 200PF for horizontal usage on Aluminium strip (Manufacturer BCR) (Emirates Specialities) or equivalent MAR Masterseal 300H MBT MAR 059 Masterseal 181S Primer system Masterseal 300H filler Storage The manufacturer’s instructions shall be followed for this purpose. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 266 of The material shall be stored under cover out of direct sunlight and protected from temperature extremes. Method Waterproofing membrane shall be applied according to the specifications to the defined levels keeping the top 50 mm above the gravel fill Marking shall be made to the exact line and level as per drawing Required lengths to the exact site dimensions shall be cut to suit a close fit between the bead ends Every bead shall be fixed with screws @ 400mm centres drilled and tightened to the concrete penetrating the membrane The screws shall be drilled and fixed using an electrical operated equipment After the screws are drilled in with the beads in proper alignment / location, compressed fibre shall be installed as protection over the Bitustick XL membrane as specified Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval The vertical surface above the bead as well as a 50mm wide strip around the top periphery of the foundation shall be prepared for the above ground concrete protection and Master seal 300 H be applied to the manufacturer’s instructions This application involves the following sequences Cleaning and making up the surface Priming the surface Coating the surface Preparation All surfaces shall be free from oil, grease, friable matters and curing compound. The surfaces shall be cleaned from dust / sand using compressed air. Arrises shall be rounded off and the protrusions ground so that the resulting surfaces appear smooth. The surfaces shall be brush primed with Masterkure 181S and subsequently Masterseal 300H mixed with Masterseal 300 H filler applied as a scrape coat over blow holes and depressions. The primed surface shall be allowed to dry tack free for a minimum duration of 2 hours before applying Masterseal 300H coating. Application The areas to be coated shall be protected from direct sunlight by shading in the hot weather conditions. At the time of coating application the ambient temperature shall be more than 5 degree Celsius with humidity less than 90 % and no dusty weather Masterseal 300 H shall be applied directly from the containers using a brush or roller @ 0.8 litre per sqm surface coverage to achieve a continuous coating The continuous coating shall be achieved in 1 or 2 coats of application The coating shall be protected from the humidity for 24 hours / or until it dries out using polythene sheets keeping off the area. No post application curing is required Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 267 of Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval Application of sealant after 24 hours The material shall be applied using a sealant gun fitted with conical nozzles adjustable to suit the width The sealant shall be gunned into the junction using an even trigger pressure, The nozzle shall be cleaned occasionally to avoid contamination. A smaller timber spatula soaked in soapy water shall be used to compact the sealant into the joint for a smooth polish finish formation. The mixing and application equipment shall be cleaned immediately after use Civil Contractor QC inspection shall be conducted followed by EPC Contractor approval Equipment Electrical operated drill Sealant applying gun Brush and roller Attachment None #95 Timber doors fixing Administration building Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope This statement is aimed to present the proposed procedures to be adopted to carry out the fixing of the workshop / factory builtin wooden doors to the exact locations on the prepared openings left in the walls Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 268 of References Specifications MAR Teak Wood Definitions PSM CSM CS SE FM QC Project Site Manager Construction Manager Construction Superintendent Site Engineer Foreman Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the ToolBox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications EPC Contractor shall conduct surveillance Safety Prior to the commencement of work, the labour force shall receive a Toolbox talk relevant to the operation concerned to the Project Site Safety requirements. Any process that is adopted which may have a particular Safety risk shall be assessed to the requirement for Site conditions and be taken care of. The personnel shall use the PPE, gloves, masks (for gas leak in area), eyeglasses (during dusty winds) etc Adequate arrangement shall be made to provide access to the top of the wall. A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Materials Material from Aldiar UAE 1 hour fire rated, ½ hour fire rated Method The following operations are involved Equipment Attachment None #96 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 269 of Grouting to steel tanks bearings on ring beams Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Scope The statement is aimed to propose the procedures to be adopted to grout the space between the top of the ring beams and the steel tank base plate(acting as bearing) according to the following drawings and the specifications. Reference Documents. Drgs Demineralised Water Tank Drgs Spent Caustic Storage Tank Drgs Fire Water Storage Tank Drgs Fire Water Storage Tank Drgs Caustic Storage Tank Drgs Neutralisation Tank Water Tank Specification Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the toolbox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 270 of Safety Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox talk on the Project Site Safety requirements relevant to the application of Masterflow 928T MBT grouthing material according to the manufacturer’ s instruction and the filling the sand into minutely narrow spaces The personnel shall use the PPE, gloves, masks, eyeglasses etc. Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and foodstuffs. To avoid skin contact, use of barrier cream to protect from the adverse effect of grouting material shall also be made. Industrial cleaner shall be used followed by washing with soap and water. The containers shall be resealed after use. Immediate medical attention shall be called for in case of any adverse effect to the personnel handling the product Material safety data shall be referred to for disposal and any further information. A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Method Refer to the sketch attached The space to be grouted shall be cleaned to remove all dirt and loose particles using compressed air The surrounding area shall be shaded to avoid the effects of temperature extremes The grouting operation shall be carried out in pieces on the tank circumference The surface shall be soaked in water for 24 hours prior to conmmence the operations Sandfilling shall be carried out into the spaces leaving a clear portion 200 mm wide for the grouting purpose. A backing rod 25 mm dia shall be provided as shown on the sketch The space to be filled in various locations shall be prepared by form strips of the size equal to the thickness of the grout circumferentially and radially. The pouring end shall be kept open and after the pouring is completed in the prepared area, shall be closed An electric drill fitted with a paddle mixer shall be used for the grout mixing purpose. The mixer shall be cleaned with no standing water. Using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928T according to the requirement, the mixing shall be carried out as follows 90 % of the measured quantity of water required to achieve the desired consistency according to the batch volume shall be added to the mixer followed by the grout material Masterflow 928 T added gradually.The remaining 10 % water quantity shall be poued during mixing, which has to be kept continued for at least 3 to 5 minutes until a uniform lump free consistency is achieved. Civil Contractor QC inspection shall be conducted according to the ITP requirement The grout shall be poured continuously using the pour cone with a constant hydrostatic head of at least 15 cm Civil Contractor QC inspection shall be conducted according to the ITP requirement Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 271 of After pouring the grout Masterflow 928 in place, all the exposed surfaces shall be covered with clean and damp Hessian to keep the applied material moist until it is firm enough to accept a curing membrane The specified temperature range(4 to 32 degree C) shall be maintained for the 3 post pour continuous days The grout thickness varies between 25 to 35 mm. Major Equipment Peddle Mixer Grout Flow Cone Attachment Sketch #97 Grouting to steel tanks bearings on ring beams Top Index Scope Reference documents Safety Method Equipment Scope The statement is aimed to propose the procedures to be adopted to grout the space between the top of the ring beams and the steel tank base plate(acting as bearing) according to the following drawings and the specifications. Reference Documents. Drgs Demineralised Water Tank Drgs Spent Caustic Storage Tank Drgs Fire Water Storage Tank Drgs E Fire Water Storage Tank Drgs Caustic Storage Tank Drgs Neutralisation Tank Water Tank Specification Safety Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox talk on the Project Site Safety requirements relevant to the application of Masterflow 928T MBT grouting material according to the manufacturer’ s instruction and the filling the sand into minutely narrow spaces Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 272 of The personnel shall use the PPE, gloves, masks, eyeprotection etc. Care shall be taken during use and storage to avoid contact with eyes, mouth, skin and foodstuffs. To avoid skin contact, use of barrier cream to protect from the adverse effect of grouting material shall also be made. Industrial cleaner shall be used followed by washing with soap and water where grout comes in contact with skin. Immediate medical attention shall be called for in case of any adverse effect to the personnel handling the product Material safety data shall be referred to for disposal and any further information. A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed who immediately implement the instructions accordingly. Method Refer to the sketch attached The space to be grouted shall be cleaned to remove all dirt and loose particles using compressed air The surrounding area shall be shaded to avoid the effects of temperature extremes The grouting operation shall be carried out in pieces on the tank circumference The surface shall be soaked in water for 24 hours prior to conmmence the operations Sandfilling shall be carried out into the spaces leaving a clear portion 200 mm wide for the grouting purpose. A backing rod 25 mm dia shall be provided as shown on the sketch The space to be filled in various locations shall be prepared by form strips of the size equal to the thickness of the grout circumferentially and radially. The pouring end shall be kept open and after the pouring is completed in the prepared area, shall be closed An electric drill fitted with a paddle mixer shall be used for the grout mixing purpose. The mixer shall be clean with no standing water. Using water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928T according to the requirement, the mixing shall be carried out as follows 90 % of the measured quantity of water required to achieve the desired consistency according to the batch volume shall be added to the mixer followed by the grout material Masterflow 928 T added gradually.The remaining 10 % water quantity shall be poued during mixing, which has to be kept continued for at least 3 to 5 minutes until a uniform lump free consistency is achieved. Civil Contractor QC inspection shall be conducted according to the ITP requirement The grout shall be poured continuously using the pour cone with a constant hydrostatic head of at least 15 cm Civil Contractor QC inspection shall be conducted according to the ITP requirement After pouring the grout Masterflow 928 in place, all the exposed surfaces shall be covered with clean and damp Hessian to keep the applied material moist until it is firm enough to accept a curing membrane The grout thickness varies between 25 to 35 mm. Major Equipment Paddle Mixer Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 273 of Grout Flow Cone Attachment Sketch #98 Excavation water tank for ccb underground Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Scope The statement is aimed to propose the procedures to be adopted to excavate the area for the underground water tank foundation where one cable trench is passing 1400 mm apart from one of the longitudnal (East) walls Reference Documents. Drgs Underground WaterTank Structural Details Specification Definitions PSM Project Site Manager CSM Construction Manager CS Construction Superintendent SE Site Engineer FM Foreman QC Quality Control Responsibilities PSM shall control the overall operations CM shall arrange the resources required accordingly CS shall control, monitor and direct the SE, FM and workforce for the operations SE shall be responsible for all the site operations and follow the instructions of the CS FM shall execute the operations deploying the workforce. FM shall explain in full in the language the work persons understand about all the instruction and the toolbox talks every day and check that the same are followed up regularly QC shall inspect all the operations according to the specifications Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 274 of Safety Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox talk on the Project Site Safety requirements relevant to the deep excavation. Required safety arrangements shall be made by installing barricades and night lights A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed, who immediately implement the instructions accordingly to get the measures to an acceptable standard Method Refer to the sketch attached The setting out of the tank area shall be carried out to the relevant co-ordinates Civil Contractor QC inspection shall be conducted to the ITP requirement Safety barricades shall be provided according to the requirment Since the work is also in progress on the chiller area, the access to the formation shall be provided from the two shorter sides by benching The location of the longitudnal walls shall be marked adding 50 mm margin for the backblinding Longitudnally the excavation line shall be kept to vertical profile that is feasible for the soil is sufficiently stiff Necessary forms shall be erected in stages for the vertical / back blinding and the concrete poured to form a soil protective surface After the blinding is over, further activities of the tank construction shall be followed according to the relevant drawings and the specifications Major Equipment Excavator Truck Attachment Sketch #99 Excavation water tank for ccb underground Top Index Scope Reference documents Safety Method Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 275 of Scope The statement is aimed to propose the procedures to be adopted to excavate the area for the underground water tank foundation where one cable trench is passing 1400 mm apart from one of the longitudnal (East) walls Reference Documents. Drgs Underground WaterTank Structural Details Specification Safety Prior to the commencement of work, the labour force shall receive a STARRT Card / Toolbox talk on the Project Site Safety requirements relevant to the deep excavation. Required safety arrangements shall be made by installing barricades and night lights A safety inspector shall visit the site every day and instruct the supervisor in case any snag is observed, who immediately implement the instructions accordingly to get the measures to an acceptable standard Method Refer to the sketch attached The setting out of the tank area shall be carried out to the relevant co-ordinates Civil Contractor QC inspection shall be conducted to check the coordinates Safety barricades shall be provided according to the requirment The location of the longitudnal walls shall be marked & the excavation lines demarcated according to the sketch attached Excavation shall commence from the free side and continued to the cable trench line following the section shown on the sketch The existing soil is stiff enough to be excavated to a vertical profile but tempararily,on the cable trench side pre cast concrete cubes 1mx1mx1m shall be used to retain the earth pressure as shown on the sketch After the cubes are placed in, further construction operations shall be carried out to the drawings and specifications Cubes shall be used to act as a support to the forms After the cubes placement, further activities of the tank construction shall be followed according to the relevant drawings and the specifications Major Equipment Excavator Truck Attachment Sketch #99 Soakaway chambers Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 276 of Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the construction of soakaway chambers Reference documents Drawing No Specification Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk All safety precautions necessary during working on excavations, mass concrete, forms, rebars, concrete pouring, etc. shall be applied to acceptable standards Adequate safety measures shall be adhered to during lifting and offloading precast perforated concrete manhole rings & covers to relevant locations avoiding any mishap BY OBSERVING THE REGULATORY CRANE FITNESS REQUIREMENT AND VALIDITY OF PERMIT. Only competent personnel shall be engaged to carry out the operation Crane and trailer operators shall abide by all traffic rules while carrying out operations and if so required, a banksman shall be engaged to direct the movement The crane shall not be operated during the inclement weather conditions with dust storms Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Concrete, Rebars / Lifting Lugs, Steps, Manhole covers Method Pre casting Area- the existing yard being used to pre cast manholes, catch basins, lighting poles etc. shall be employed for this purpose also The following operations are involved to carry out the production of the soakaway chambers Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 277 of The typical size of the precast rings are dia 1800mm and 1200 mm & other details as shown on the sketch The internal forms shall be erected to the exact internal dia and the specified height Drain holes blockout forms dia 75 mm shall be fixed to the internal shutter to suit circular profile at ends 8 #s in each row for 1200 mm dia and 12 #s in each row in 1400 mm dia staggered as shown on the sketch The 8T(not specified) steel rebars shall be cut, bent to the circular shape, placed and the cage prepared holding concrete spacers, and positioned into the forms. The blockout form for the inlet pipe shall be prepared and fixed to the circular form wherever required Polystyrene sleeves shall be inserted for the steps to be grouted after the forms are struck After all the blackouts are fixed in, the dimensions and the plumb shall be checked An Civil Contractor preliminary inspection shall be conducted External forms shall be erected to specified dia and height & correctly supported. All the supports and dimensions shall be checked, corrected if required and the plumb monitored An Civil Contractor QC inspection shall be conducted & ITP for concrete pour signed off Concrete grade 30 shall be poured to the prepared units in 3 layers in vertical sequence The needle vibrator shall be used for the compaction of the concrete After the concrete is poured in full & well compacted, the surface shall be levelled using a wooden float Top circular strip shall be finished with a wooden float and covered with polythene sheet An Civil Contractor QC inspection shall be conducted at regular intervals throughout the operations Immediately after the concrete is finished, the surface shall be covered with polythene sheet with the edge lapped or tied down to exclude air circulation without permitting the membrane to be in touch with concrete surface according to the specifications After the concrete has stiffened but no longer than 2 hours, the polythene sheet shall be removed followed by immediate covering the surface with saturated (soaked with mix quality water) hessian and recovered with polythene sheet to prevent evaporation from the hessian. Throughout the curing period, the hessian shall be maintained in a permanent wet condition using mix quality water The external and the internal forms shall be removed after a specified period of 24 to 36 hours as agreed The vertical concrete surfaces shall be draped with the saturated hessian immediately after striking the forms and covered with the polythene sheet held firmly in place along all edges & kept continuously wet for the duration of curing The curing shall be continued for the specified period An Civil Contractor QC inspection shall be conducted from time to time throughout the operations Similarly RCC covers 250mm thick with circumferential web section 150x450mm shall be precast to specified dia The relevant locations shall be made ready to receive the precast rings by completing the excavation, mass concrete ring footing, and forming the correct alignment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 278 of AN Civil Contractor QC inspection shall be conducted for the'location to receive' & ITP signed off The rings shall be lifted by a mobile crane, loaded gently onto a trailer and transported to the relevant area to offload on to the prepared ‘location to receive’ The rings shall be installed on the marked location according to the correct orientation to the relevant layout drawing keeping one ring above the other in such a way that the steps are formed in vertical alignment and the perforations are staggered but centred vertically AN Civil Contractor QC inspection shall be conducted Space surrounded by the mass concrete ring footing shall be backfilled with 40mm nominal single size stones Another ring shall be placed over the previous and jointed with cement mortar The excavation and laying of inlet pipe shall be carried out to the details and the block out filled with concrete. The surrounding pipe and the rings shall be backfilled with 40 mm nominal single size stones AN Civil Contractor QC inspection shall be conducted Precast covers shall be transported from the precasting yard, offloaded and properly located over the approved rings to the correct alignment Manhole cover bedding / bearing shall be made of concrete by forming to the given profile to suit the cover placing level After the bearing concrete stiffens, the cover frame shall be fixed and levelled using cement mortar 1 : 3 Forms shall be erected for the mass concrete surround with preformed chamfers and concrete poured to a level 50 mm above the grade level EPC Contractor surveillance / inspection / approval shall be according to the approved ITPs Major Equipment Compressor, Mobile Crane, Trailer Transit mixer Attachment Lifting arrangement sketch Drain Holes locations indicative only #100 Epoxy flooring Buildings Top Index Scope Reference documents Safety Method Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 279 of Scope The statement is aimed to propose the procedures to be adopted to carry out the construction of Epoxy Flooring 3 and 5mm thick in buildings Reference documents Drawing No. Specification Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Mastertop 1230i, MBT MAR # Mastertop 1200i Resin Method Surface Preparation The floor base concrete shall be lightly scabbled to remove the laitance Surface shall be cleaned of all dust and dirt by compressed air An Civil Contractor QC inspection shall be conducted Prior to the application of Mastertop1230i the concrete scabbled & cleaned surface shall be sealed by applying Mastertop1200i resin diluted with 5% solvent #2 as follows. Sealer Mixing Base and reactor components shall be poured into a mixing vessel and half a litre of Solvent # 2 added. All these components shall be mixed using a slow speed drill with a paddle attachment for 1 minute Sealer shall be applied at a rate of 5-8 sqm per litre using a medium pile roller Sealed surface shall be allowed to become tack free before the application of Mastertop1230i An Civil Contractor QC inspection shall be conducted Mastertop1230i shall be applied as follows Mixing Reactor base and colour pack components of the Mastertop1230i shall be poured into a vessel of 25 litre capacity The components shall be mixed with a drill with paddle attachment until a uniform colour is achieved. 1230i aggregate shall be slowly added to the mixed components keeping the mixer running until the mixture is of smooth and lumpsfree consistency Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 280 of Laying Mixed material shall be poured on to the primed & sealed surface & spread to 5mm thickness in stores & warehouses and 3 mm thickness in other areas using a pin screed, notched trowel or steel float. Immediately after the spread of the material to the required thickness, rolling shall be carried out by a ‘Spiked Roller’ to release entrapped air and remove the trowel marks Rolling shall be continued until all air is released and a uniform colour is obtained Rolling shall again be carried out after 20 to 30 minutes Operator shall wear the ‘spiked shoes’ when using the ‘spiked roller’ to walk on wet material. Rolling shall cease before Mastertop 1230i begins to gel An Civil Contractor QC inspection shall be conducted & ITP signed off Mastertop1230i shall be removed from the tools and equipment whilst still wet using cleaning solvent # 2 Equipment Slow speed drill with suitable paddle Brushes, Short nap hair rollers Grinder, Spiked roller, Pin screed Attachment MBT 1230 i Data sheet #101 Epoxy flooring Buildings Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the construction of Epoxy Flooring 3 and 5mm thick in buildings Reference documents Drawing No. & like Specification Clause 13 Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 281 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Mastertop 1230i, MBT MAR # Mastertop 1200i Resin Applicators Skilled applicators shall carry out the work Manufacturer’s demonstrator shall train a group of personnel on site for one room and later the remaining work of epoxy coating shall be carried out by this group Method (Surface Preparation) Equipment shall be protected by covering with polythene sheet The floor base concrete shall either be grit blasted or acid etching applied to remove the laitance Surface shall be cleaned of all dust and dirt by compressed air An Civil Contractor QC inspection shall be conducted to accept substrate Prior to the application of Mastertop1230I, the prepared concrete surface shall be sealed by applying Mastertop1200i resin diluted with 5% solvent #2 as follows. (Sealer Mixing) Base and reactor components shall be poured into a mixing vessel and half a litre of Solvent # 2 added. All these components shall be mixed using a slow speed drill with a paddle attachment for 1 minute Sealer shall be applied at a rate of 5-8 sqm per litre using a medium pile roller Sealed surface shall be allowed to become tack free before the application of Mastertop1230i An Civil Contractor QC inspection shall be conducted to approve that the surface is properly sealed with no imperfections. Mastertop1230i shall be applied as follows (Mixing) Reactor base and colour pack components of the Mastertop1230i shall be poured into a vessel of 25 litre capacity The components shall be mixed with a drill with paddle attachment until a uniform colour is achieved. 1230i aggregate shall be slowly added to the mixed components keeping the mixer running until the mixture is of smooth and lumpsfree consistency (Laying) Mixed material shall be poured on to the primed & sealed surface & spread to 5mm thickness in stores & warehouses and 3 mm thickness in other areas using a pin screed, notched trowel or steel float. Immediately after the spread of the material to the required thickness, rolling shall be carried out by a ‘Spiked Roller’ to release entrapped air and remove the trowel marks Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 282 of Rolling shall be continued until all air is released and a uniform colour is obtained Rolling shall again be carried out after 20 to 30 minutes Operator shall wear the ‘spiked shoes’ when using the ‘spiked roller’ to walk on wet material. Rolling shall cease before Mastertop 1230i begins to gel An Civil Contractor QC inspection shall be conducted & ITP signed off Mastertop1230i shall be removed from the tools and equipment whilst still wet using cleaning solvent # 2 Equipment Slow speed drill with suitable paddle Brushes, Short nap hair rollers Grinder, Spiked roller, Pin screed, Spiked shoes Attachment MBT 1230 i Data sheet #102 Epoxy flooring Buildings Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the construction of Epoxy Flooring 3 and 5mm thick in buildings Reference documents Drawing No. & like Specification Clause 13 Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Mastertop 1230i, MBT MAR # Mastertop 1200i Resin Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 283 of Applicators Skilled applicators shall carry out the work Manufacturer’s demonstrator shall train a group of personnel on site for one room and later the remaining work of epoxy coating shall be carried out by this group Method (Surface Preparation) Equipment shall be protected by covering with polythene sheet The floor base concrete shall either be grit blasted or acid etching applied to remove the laitance Surface shall be cleaned of all dust and dirt by brush & vacuum cleaner An Civil Contractor QC inspection shall be conducted to accept substrate Prior to the application of Mastertop1230I, the prepared concrete surface shall be sealed by applying Mastertop1200i resin diluted with 5% solvent #2 as follows. (Sealer Mixing) Base and reactor components shall be poured into a mixing vessel and half a litre of Solvent # 2 added. All these components shall be mixed using a slow speed drill with a paddle attachment for 1 minute Sealer shall be applied at a rate of 5-8 sqm per litre using a medium pile roller Sealed surface shall be allowed to become tack free before the application of Mastertop1230i An Civil Contractor QC inspection shall be conducted to approve that the surface is properly sealed with no imperfections. Mastertop1230i shall be applied as follows (Mixing) Reactor base and colour pack components of the Mastertop1230i shall be poured into a vessel of 25 litre capacity The components shall be mixed with a drill with paddle attachment until a uniform colour is achieved. 1230i aggregate shall be slowly added to the mixed components keeping the mixer running until the mixture is of smooth and lumpsfree consistency (Laying) Mixed material shall be poured on to the primed & sealed surface & spread to 5mm thickness in stores & warehouses and 3 mm thickness in other areas using a pin screed, notched trowel or steel float. Immediately after the spread of the material to the required thickness, rolling shall be carried out by a ‘Spiked Roller’ to release entrapped air and remove the trowel marks Rolling shall be continued until all air is released and a uniform colour is obtained Rolling shall again be carried out after 20 to 30 minutes Operator shall wear the ‘spiked shoes’ when using the ‘spiked roller’ to walk on wet material. Rolling shall cease before Mastertop 1230i begins to gel An Civil Contractor QC inspection shall be conducted & ITP signed off Mastertop1230i shall be removed from the tools and equipment whilst still wet using cleaning solvent # 2 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 284 of Equipment Slow speed drill with suitable paddle Brushes, Short nap hair rollers Grinder, Spiked roller, Pin screed, Spiked shoes Attachment MBT 1230 i Data sheet #103 Vinyl wall covering Buildings Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to apply Fabric Backed Vinyl Wall Covering paper over dry walls in buildings Reference documents Drawing No. and like MAR Ref Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Fabric backed Vinyl wall covering Suwide Scala N 5858 Manufacturer-Swide, Supplier / Sub Contractor-Trade Line Method The surface shall be made dry, firm, smooth & free from grease A vertical line shall be marked at 200 mm from the corner to apply first drop Higher material roll # shall be used first Plenty of adhesive shall be coated on the wall portion for the first piece of material using a lambswool roller or a block brush Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 285 of Pieces shall be cut & numbered using a graphite pencil Strips shall be fixed in reverse alternate Material piece shall be cut to a length equal to wall height plus 40mm (20mm extra at ceiling and 20mm extra at skirting) Edge of the first piece shall be located against the vertical line making sure that there is a small selvedge at top and bottom for subsequent trimming Smoothening shall be carried out using a spatula along the length of the material Second length shall be placed against the adhesive tape and smoothened out with a spatula and if necessary rolled over The uppermost length shall fall off by itself while the lower length shall be removed. A thin coat of adhesive shall be applied to the wall before the joint is closed Rubber roller shall be moved over the material to make sure that no bubble emerges A small vertical cut shall be made in the overlap near the ceiling using a Stanley knife Joint shall be closed and sealed smooth with spatula Before hanging the second piece the marker pins shall be placed at about 4 cm from the edge of the first piece Overlap shall be cut with a suitable cutting knife Slevedge shall be removed from the ceiling and the plinth with Stanley knife Knife shall be kept in cut and spatula moved An Civil Contractor QC inspection shall be conducted and the ITP signed off Equipment Rubber roller, Stanley knife, Spatula, Marker pins Attachment SUWIDE Instruction Sheet ITP- Civil Contractor / ITP / Rev B Check List- QCF Rev B #104 Dry wall linings buildings Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to install dry wall linings in the buildings. Reference documents Specs (Gypsum Wall boards Systems) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 286 of STQ Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material MAR 076 Galvanised Studs, Runners & Furrings (Metal Framing System) Gypsum wall lining & wall partitions Framing System- TMI (Technical Material Industrial Company) UAE External wall lining-Studs & Runners Galvanised Steel Stud depth 63mm-Thickness 1mm, Runner depth 65mm-Thickness 0.7mm Metal Internal wall lining, Furring channels-Galvanised Steel, Material Width 50mm-Thickness 0.7mm, depth 22mm Metal Framing for dry wall partitions, Studs & Runners- Galvanised Steel Stud width 92mm-Thickness 1mm, Runner Width 94mm-Thickness 0.7mm, MAR Gypsum Wall Board system Regular wall board 12.5mm thick 1.2 x 2.4 m panel, tapered edges Moisture Resistant board 15 mm thick, tapered edges, Knauf Australia, Trade line, MAR Acoustical Fibreglass for demountable partitions Accoustical glasswool insulation material 60mm thick for internal partition walls & 50 mm thick for external walls, Kimmco- Isover Fibre Glass, Kimmco Specialist Sub Contractor- Trade Line Method De-mountable panels shall be fixed to flooring / top of tiles while the others to the screed Floors & Ceilings shall be constructed as specified For the levelling purpose, a chalk line shall be marked to be used as a datum Floor and ceiling tracks shall be fixed by shot firing nails as per details Vertical studs shall be placed every 600mm c / c wherever possible Bracing shall be fixed between studs and walls & at all board joints for rigidity & strength to the requirement Gypsum boards shall be fixed using dry walls screws at 300 mm c / c in the middle and 200 mm c / c at the edges of the board For the internal partitions where the insulation is to be provided, shall be installed after one board is fixed Civil Contractor QC inspections shall be conducted The other board shall be fixed after the approval of the insulation Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 287 of On the external walls where the insulation is to be provided, shall be installed prior to Gypsum board is fixed The tapered surface at the board joints shall be pasted from lower to higher level vertically with fibre tape to act as a support for joint compound to be filled in. Joint compound shall be filled in to a suitable & acceptable profile Hole ends posed due to the fasteners shall also be filled in with the compound All external corners shall have stainless steel corner beading fitted Gypsum board shall be sanded to smoothen the surface to receive sequential finishing items Civil Contractor QC inspections shall be conducted throughout the above operations and the ITP signed off Equipment Hilty relevant drills Attachment Trade Line method statement #105 Rubber flooring (buildings) Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to install Rubber Flooring in the buildings. Reference documents Main Sub Station Utility Sub Station Building Sub Station Sub Station MAR Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 288 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material MAR, Norament 926 Manufactured by Nora / Freudenberg-Germany-Colour # 0884 Manufacturer recommended Adhesives from UZIN-Werk German (MAR in process) 1) UZIN KR 430 A+B Two Component Polyurethane Adhesive for fixing 6mm thick Coned Back Rubber Tiles 2) UZIN GN 276 Neoprene adhesive for fixing Cove Skirting and Angles Primer PE 412 PUR KR 410 PUR Levelling Compound (To be used to remove large unevenness if so required) Specialist Applicator The flooring application shall be carried out by M / S JOS HANSEN, the authorised agent Method For installation, the sub floor shall be even, clean, dry, firm, to the correct levels with no major unevenness & free of cracks. Surface shall be free from oil, wax, paint residues with minimum porosity and roughness If required on large uneven areas, KR410 shall be applied to self level the surface Smaller unevenness shall be made up by the adhesive itself Civil Contractor QC inspections shall be conducted to approve that the surface is suitable Priming PE 12 PUR shall be applied in 1 or 2 coats depending on surface porosity Within 24 hours of priming while the surface is still tacky, floor covering operation shall proceed. In case the primed surface has cured, it shall be roughened to provide a satisfactory bond with adhesive Civil Contractor QC inspections shall be conducted to approve that the primed surface is fit to receive the floor covering “Rubber tiled” floor shall be installed fully in accordance with pages 2-6 of the attached installation instructions Civil Contractor QC inspections shall be conducted throughout the above operations to ensure compliance with specifications and ITP requirements Equipment Adhesive spreader, Hooked blade, Smoothing spatula, wax Serrated blade 21 Attachment Adhesive data sheet from UZIN-Werk Manufacturer’s Installation instructions #106 Rubber flooring (buildings) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 289 of Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to install Rubber Flooring in the Sub Station buildings. Reference documents Main Sub Station Utility Sub Station Building Sub Station Sub Station MAR Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material MAR, Norament 926 Manufactured by Nora / Freudenberg-Germany-Colour # 0884 Manufacturer recommended Adhesives from UZIN-Werk German (MAR in process) 1) UZIN KR 430 A+B Two Component Polyurethane Adhesive for fixing 6mm thick Coned Back Rubber Tiles 2) UZIN GN 276 Neoprene adhesive for fixing Cove Skirting and Angles Specialist Applicator The flooring application shall be carried out by an applicator approved and certified by M / S JOS HANSEN, the authorised agent Method For installation, the sub floor shall be even, clean, dry, firm, to the correct levels with no major unevenness & free of cracks. Surface shall be free from oil, wax, paint residues with minimum porosity and roughness Smaller unevenness if any, shall be made up by the adhesive itself The concrete surfaces are more than 28 days old Civil Contractor QC inspections shall be conducted to approve that the surface is suitable Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 290 of “Rubber tiled” floor shall be installed fully in accordance with pages 2-6 of the attached installation instructions Civil Contractor QC inspections shall be conducted throughout the above operations to ensure compliance with specifications and ITP requirements Equipment Adhesive spreader, Hooked blade, Smoothing spatula, wax Serrated blade 21 50 Kg Metal Roller Attachment Adhesive data sheet from UZIN-Werk Manufacturer’s Installation instructions #107 Rubber flooring (buildings) Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to install Rubber Flooring in the buildings. Reference documents Main Sub Station Utility Sub Station Building Sub Station Sub Station MAR Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 291 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material MAR, Norament 926 Manufactured by Nora / Freudenberg-Germany-Colour # 0884 Manufacturer recommended Adhesives from UZIN-Werk German (MAR in process) 1) UZIN KR 430 A+B Two Component Polyurethane Adhesive for fixing 6mm thick Coned Back Rubber Tiles 2) UZIN GN 276 Neoprene adhesive for fixing Cove Skirting and Angles Primer PE 412 PUR KR 410 PUR Levelling Compound (To be used to remove large unevenness if so required) Specialist Applicator The flooring application shall be carried out by M / S JOS HANSEN, the authorised agent Method For installation, the sub floor shall be even, clean, dry, firm, to the correct levels with no major unevenness & free of cracks. Surface shall be free from oil, wax, paint residues with minimum porosity and roughness If required on large uneven areas, KR410 shall be applied to self level the surface Smaller unevenness shall be made up by the adhesive itself Civil Contractor QC inspections shall be conducted to approve that the surface is suitable Priming PE 12 PUR shall be applied in 1 or 2 coats depending on surface porosity Within 24 hours of priming while the surface is still tacky, floor covering operation shall proceed. In case the primed surface has cured, it shall be roughened to provide a satisfactory bond with adhesive Civil Contractor QC inspections shall be conducted to approve that the primed surface is fit to receive the floor covering “Rubber tiled” floor shall be installed fully in accordance with pages 2-6 of the attached installation instructions Civil Contractor QC inspections shall be conducted throughout the above operations to ensure compliance with specifications and ITP requirements Equipment Adhesive spreader, Hooked blade, Smoothing spatula, wax Serrated blade 21 Attachment Adhesive data sheet from UZIN-Werk Manufacturer’s Installation instructions #108 Rubber flooring (buildings) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 292 of Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to install Rubber Flooring in the Sub Station buildings. Reference documents Main Sub Station Utility Sub Station Building Sub Station Sub Station MAR Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material MAR, Norament 926 Manufactured by Nora / Freudenberg-Germany-Colour # 0884 Manufacturer recommended Adhesives from UZIN-Werk German (MAR in process) 1) UZIN KR 430 A+B Two Component Polyurethane Adhesive for fixing 6mm thick Coned Back Rubber Tiles 2) UZIN GN 276 Neoprene adhesive for fixing Cove Skirting and Angles Specialist Applicator The flooring application shall be carried out by an applicator approved and certified by M / S JOS HANSEN, the authorised agent Method For installation, the sub floor shall be even, clean, dry, firm, to the correct levels with no major unevenness & free of cracks. Surface shall be free from oil, wax, paint residues with minimum porosity and roughness Smaller unevenness if any, shall be made up by the adhesive itself The concrete surfaces are more than 28 days old Civil Contractor QC inspections shall be conducted to approve that the surface is suitable Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 293 of “Rubber tiled” floor shall be installed fully in accordance with pages 2-6 of the attached installation instructions Civil Contractor QC inspections shall be conducted throughout the above operations to ensure compliance with specifications and ITP requirements Equipment Adhesive spreader, Hooked blade, Smoothing spatula, wax Serrated blade 21 50 Kg Metal Roller Attachment Adhesive data sheet from UZIN-Werk Manufacturer’s Installation instructions #109 Suspended ceilings All buildings Top Index Scope Reference documents Safety Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to install suspended ceilings in the buildings. Reference documents Specifications : for Acoustical Ceilings MAR MOM MM- Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material MAR - Acoustical Metal Ceiling Fully accessible suspended modular grid type perforated metal ceiling panels with concealed insulation pads- Telecom Room- Administration Building Colour RAL 9010- Ref MAR for fire proof material Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 294 of MOM MMSAS ceiling system 120, manufacturer SAS ceilings UK, MAR Mineral fiber ceiling- Mineral fiber lay in suspended ceiling-Plane Done Plus MOM MM- - Prima, manufactured-Armstrong UK, MAR Humidity resistant tile suspended Ceiling Ceramaguard, Armstrong UK, Trade Line Drg & Drg MAR Plastic Faced Ceiling- VL BIO, Armstrong USA, Drg 2& Drg MAR Metal Panel Suspended Ceiling 600 x 600mm metal panel suspended ceiling in a lay-in-system RAL 9010 (Cleaner’s Room Administration Building) System 130 TrueGrid T24 System, Manufacturer SAS Ceiling UK, Trade Line MAR Aluminium Strip Ceiling- Suspended Ceiling with colour coated Aluminium strip Only one colour RAL 9016 (Toilets)-Matador 100, Manufacturer Matador, UAE MAR Satin Anodised Strip Ceiling with rounded off & closed cleat Product SMSC 100, Manufacturer Saddi Metal, UAE MAR Insulation pads for metal acoustical ceiling Rockwool fill material with non combustible black glass tissue, Man-SAS, UK Method Installation of Lay in suspended ceiling tiles- 600 x 600 mm Acoustic Tiles 600mmx600mm & Aluminium Tiles 600mmx600mm on exposed suspension Chalk line shall be marked around the periphery to form a datum to be used for levelling purpose Suspension hangers shall be shot fired to the slab using Hilty equipment Wall angles shall be fixed to the correct levels using steel nails Main channels shall be fixed at 1200mm c / c to the details shown on shop drawings Cross Tees 1200mm shall be fixed perpendicular to the main channels at 600mm c / c to form cells of grid (600mmx1200mm) Cross Tees 600mm shall further be fixed at the centre of 1200mm Cross Tees to form cells in final grid (600mmx600mm) Full tiles shall be installed in 600mmx600mm cells & the ‘cut tiles’ to suit the site requirement as agreed Openings for AC diffusers, spot lights, smoke detectors, fire alarm etc, all shall be provided to the requirement Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 295 of Civil Contractor QC inspections shall be conducted throughout the above operations and the ITPs signed off. Ceilings shall not be fully closed until QC confirms that all preceding electrical & HVAC installations have been completed. Installation of Aluminium Clip in Tiles Chalk line shall be marked around the periphery to form a datum to be used for levelling purpose Suspension hangers shall be shot fired to the slab at 1000mm c / c using Hilty equipment Wall edge trims shall be fixed to correct levels using steel nails Main channels shall be fixed at 1200mm c / c by holding clamps to the details shown on shop drawings Spring Tees shall be secured every 600mm by wire clips perpendicular to main channels Tiles 600mmx600mm shall be inserted into Spring Tees Openings for AC diffusers, spot lights, smoke detectors, fire alarm etc, shall be provided all to the requirement Civil Contractor QC inspections shall be conducted throughout the above operations and the ITPs signed off. Ceilings shall not be fully closed until QC confirms that all preceding electrical & HVAC installations have been completed. Equipment Shot firing gun Attachment Trade Line method statement #110 Pit 21 water connection Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement, is to define the procedure that shall be adopted for the connection of the water pipeline, from the Operating Authority supply pit No 21, to the Civil Contractor camp. Reference documents Excavation permit. Drawing No: Operating Authority easement Drawing No: Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 296 of Definitions Operating Authority EPC Contractor Civil Contractor PSM Project Site Manager. Responsibilities The Civil Contractor PSM shall ensure this method statement is implementation for the connection to pit 21, the laying of the drinking water pipeline, as well as the reinstatement to pit 21. Safety The Safety Officer shall monitor the daily activities, advising and implementing all safety procedures. Method The position of the proposed pipe location through the wall of pit 21 shall be marked. Using hand tools, a hole shall be made through the concrete pit wall. The size of the hole in the pit wall, shall be adequate to allow the positioning of a purpose made Upvc pipe sleeve. Upon the positioning of the pipe sleeve, the pit wall shall be made good using a mortar mix of 1 part cement to 3 part sand. As the hole is above the local water table, no provision against the ingress of water shall be required. When the water pipe is correctly located through the pipe sleeve, the gap between the water pipe and the pipe sleeve shall receive a mastic seal. The route of the pipe from pit 21 to the pipe sleeve in avenue C, is indicated upon the drawing The pipe shall be located in a hand excavated trench, above the existing services. Where necessary, thrust blocks shall be installed to resist any pressure movements. The relevant pipe fittings required to control and monitor the water flow within the pipe, shall be located inside of pit 21. The area around the pit and along the route of the pipeline shall be left clean of construction material. Upon completion of the project, the water pipe shall be removed in accordance with the instruction of Operating Authority. The fittings within the pit provided by Civil Contractor shall be removed, leaving the existing Operating Authority valve and small vent pipe. The pipe sleeve through the wall of pit 21, shall be capped with purpose made Upvc end caps, that may be removed at a later date for future use if required. Equipment Hand tools. Pipe jointing and cutting tools. Attachment Work permit. Drawing Site Sketch Operating Authority drawing No: #111 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Cement based non shrink foundation bases Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 297 of grouting to Using masterflow 928 t Top Index Scope Reference documents Safety Method Equipment Scope This statement is aimed to propose the procedures to be adopted to grout the base plates of stationary equipment / vessels foundation bases using cement based non shrink grout materia for a grouting thickness of 25 – 50 mm. Reference Documents Specification Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Method The surface of the foundation under the base plate or equipment to be grouted shall be chipped / scabbled & brushed to remove the weak upper layer of the concrete, damaged concrete and any oil soaked concrete areas without using mechanical bush hammer Prior to grouting, loose concrete or dust shall be removed by compressed air. The concrete surface shall be soaked with clean water for 24 hours prior to grouting grouting to minimize the localized absorption as well as to assist the free flow of the grout. Just prior to grouting,all standing water shall be removed leaving only a damp film. Baseplates shall be clean and free of oil, grease, paint and correctly aligned according to the drawings. The levelling plates shall be set to proper elevation. Base plates and equipment bases shall be uniformly supported in order to eliminate sag and distortion. Equipment bases shall be levelled using both anchor bolts and jackscrews. Stainless steel shims 50x50x10 mm thick shall be in correct locations covered with mortar so as to allow at least 50 mm grout cover on shim sides. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 298 of The forms as shown on the attached sketch shall be erected on the required locations with chamfers. An electric drill fitted with a paddle shall be used for the grout mixing purpose. Water @ 3.5 to 4.5 litres per 25 kg bag of Master flow 928 shall be used according to requirement. The mixer shall be clean with no standing water. 90 % of the measured quantity of water required to achieve the desired consistency according to the batch volume, shall be added to the mixer prior to adding Masterflow grout material, which has to be added into the mixer gradually and remaining 10 % water quantity shall be poured during mixing , which has to be kept on for at least 3 to 5 minutes until a uniform lump free consistency is achieved. The grouting material shall be poured continuously using’ grout pour cone’ with a constant hydrostatic head of at least 15 cm Grouting shall extend to the edge of the concrete surface where it is to be finished with a 25 mm chamfer After pouring Masterflow 928 in place, all exposed grout shall be covered with clean dampen / saturated Hessian and kept moist until the applied grout is firm enough to receive a curing membrane Temperature less than 32 degree C shall be maintained for the 3 post pour continuous days Major Equipment Peddle Mixer Grout Flow Cone Attachment Sketch Masterflow Catalogue Masterflow Method Statement #112 Repair of concrete floor screeds Top Index Scope Reference documents Safety Method Equipment Scope This statement outlines the repair procedures to be followed for the repair and reinstatement of defective floor screeds, so as to provide a durable and serviceable levelling layer for the floor covering placed above. Safety Prior to commencement of any activity, the labour force shall receive a STARRT Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 299 of Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Responsibilities All inspection and repair work related to the concrete floor screeds shall be under the sole direction of a dedicated Site Engineer (SE) who shall have full authority and responsibility for ensuring that the works are carried out in accordance with this Method Statement. Procedure 1. Repair activities shall be restricted to a limited number of rooms at any time, and access to the rooms restricted during repair. Before commencing any repair activity, including preparation, the SE shall ensure that previously completed works are suitably protected from damage and dust, using a combination of polythene sheeting and ply boarding as appropriate. 2. Before commencing any repairs in a room, the SE shall agree the scope of the repairs to be undertaken with the Site Quality Manager, with the agreed repair marked on the floor. The scope shall be recorded on a sketch and identify which type of repair is to be used and the approximate area of the repair. The repairs shall be selected from the following: Repair Type A – Removal and Reinstatement with Cement Screed. This repair should be adopted where the existing screed has completely disbonded and broken up, leaving loose isolated sections of screed. Repair Type B – Repair with Epoxy Mortar This repair should be adopted where there are significant isolated cracks in the screed. It is not intended to repair minor hairline cracks by this method, or construction joints between adjacent panels of screed, unless they have become otherwise damaged. Repair Type C – Repair with Resin Injection This repair should be adopted where the screed appears to be disbonded and cracked or lifting but is otherwise intact. This may be carried out in conjunction with repair Type B above. It is not necessary to use resin injection on hollow sounding areas where there is no other sign of failure. Repair Type D – Surface Epoxy Coating This repair shall be applied as a final protective coating to all repaired areas. As well as sealing any un-repaired hairline cracks, this shall also ensure an overall uniform appearance of the repaired areas. 3. The repairs shall be carried out as follows: Repair Type A: Removal and reinstatement with Cement Screed A1. The affected area shall be sawcut to the full depth of the top layer of screed (typically 35mm) and the affected section removed carefully so as to cause minimum disruption to adjacent areas. A2. The removed area shall be fully cleaned of all dust and debris, and any loose material removed. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 300 of A3. The cleared area shall be thoroughly soaked (not just dampened) for at least one hour before reinstatement. A4. Immediately before placing the replacement screed, remove any surplus water (the substrate should still be wet) and apply one coat of NITOBOND PVA bonding agent to all surfaces – horizontal and vertical. A5. Place and compact the replacement screed material. Trowel and immediately cover with polythene sheeting placed flat against the surface. A6. Remove the polythene sheet after 4 hours and replace with wet hessian, covered with polythene sheeting. Ensure that further water is added to the hessian at least twice daily for a minimum of three days. A7. Ensure that no-one walks on the repair for minimum three days. If unavoidable, lay ply sheet over repair, ensuring it remains in place. Repair Type B – Repair with Epoxy Mortar B1. Using a hammer and chisel, carefully chase a ‘V’ notch along the length of any crack and along the edge of any loosened area. This should typically be 5mm from the edge of the crack and 5mm deep. B2. Physically remove all loose material and clean using a using a wire brush or similar. Remove all dust and debris, using a brush and / or vacuum cleaner. B3. Mix the repair material – NITOMORTAR FC-B (or FC) – in accordance with manufacturers recommendations and firmly press the repair mortar into place using a steel trowel. Finish the material flush with the surrounding concrete. It may be necessary to apply a second levelling coat if the material settles. B4. Ensure that the repair area is not walked on for 24 hours. Repair Type C – Repair with Resin Injection C1 Drill three 10mm holes in the area to be repaired, to a depth of approximately 35mm, representing the interface between the two screed layers. This can be determined by the change in sound of the drill. C2. Fix an injection nipple to the drilled holes using an epoxy mortar e.g NitoMortar FC-B, and seal using a trowel. Allow to set for eight hours. Mix the repair resin – NITOFILL EPLV – in accordance with the manufacturers reccomendations, and insert into injection gun. C3. C4. Commence filling the central nipple, and continue until resin is observed at the outer nipples. If neccesary, continue filling the outer nipples. Note that material usage rate should be approximately 1litre per 1m2. Do not attempt to place more than this, or the floor could lift further. C5. Leave for 6 hours, then remove the nipples and fixing mortar, and make the surface good. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 301 of Repair Type D – Surface Epoxy Coating D1. Ensure all repairs have been completed and allowed to cure (24 hours for epoxy repair – 5 days for cement screed repair). D2. Brush the surface thoroughly to remove all dust and debris. Ensure that the surface is not wet or damp. Mix the material – NITOFLOR FC140 - in accordance with the manufacturers instructions. Firstly apply a stripe coat to any untreated minor cracks, taking care to work the paint into the crack. D3. D4. Starting at the furthest corner, apply a single coat to the entire surface using a brush or roller, ensuring that the material fully coats the surface but without ponding. D5. Ensure that the surface is not walked on for 24 hours. 4. Details of all repairs shall be recorded on a Screed Repair Sheet – see QCF 91 attached. Attachment Check list Doc QCF Rev A Location Sketch #113 Repair of concrete floor screeds Top Index Scope Reference documents Safety Method Equipment Scope This statement outlines the repair procedures to be followed for the repair and reinstatement of defective floor screeds, so as to provide a durable and serviceable levelling layer for the floor covering placed above. Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 302 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Responsibilities All inspection and repair work related to the concrete floor screeds shall be under the sole direction of a dedicated Site Engineer (SE) who shall have full authority and responsibility for ensuring that the works are carried out in accordance with this Method Statement. Procedure 5. Repair activities shall be restricted to a limited number of rooms at any time, and access to the rooms restricted during repair. Before commencing any repair activity, including preparation, the SE shall ensure that previously completed works are suitably protected from damage and dust, using a combination of polythene sheeting and ply boarding as appropriate. 6. Before commencing any repairs in a room, the SE shall agree the scope of the repairs to be undertaken with the Site Quality Manager, with the agreed repair marked on the floor. The scope shall be recorded on a sketch and identify which type of repair is to be used and the approximate area of the repair. The repairs shall be selected from the following: Repair Type A – Removal and Reinstatement with Cement Screed. This repair should be adopted where the existing screed has completely disbonded and cracked, leaving loose isolated sections of screed. Repair Type B – Repair with Epoxy Mortar This repair should be adopted where there are significant isolated cracks in the screed. It is not intended to repair minor hairline cracks by this method, or construction joints between adjacent panels of screed, unless they have become otherwise damaged. Repair Type C – Repair with Resin Injection This repair should be adopted where the screed appears to be disbonded and cracked or lifting but is otherwise intact. This may be carried out in conjunction with repair Type B above. It is not necessary to use resin injection on hollow sounding areas where there is no other sign of failure. Repair Type D – Surface Epoxy Coating This repair shall be applied as a final protective coating to all repaired areas. As well as sealing any un-repaired hairline cracks, this shall also ensure an overall uniform appearance of the repaired areas. 7. The repairs shall be carried out as follows: Repair Type A: Removal and reinstatement with Cement Screed A8. The affected area shall be sawcut to the full depth of the screed to be removed and the affected section removed carefully so as to cause minimum disruption to adjacent areas. A9. The removed area shall be fully cleaned of all dust and debris, and any loose material removed. A10. The cleared area shall be thoroughly soaked (not just dampened) for at least one hour before reinstatement. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 303 of A11. Immediately before placing the replacement screed, remove any surplus water (the substrate should still be wet) and apply one coat of NITOBOND PVA bonding agent to all surfaces – horizontal and vertical. A12. Place and compact the replacement screed material. Trowel and immediately cover with polythene sheeting placed flat against the surface. A13. Remove the polythene sheet after 4 hours and replace with wet hessian, covered with polythene sheeting. Ensure that further water is added to the hessian at least twice daily for a minimum of three days. The hessian to be kept damp the whole time A14. Ensure that no-one walks on the repair for minimum three days. If unavoidable, lay ply sheet over repair, ensuring it remains in place. Repair Type B – Repair with Epoxy Mortar B1. Using a hammer and chisel, carefully chase a ‘V’ notch along the length of any crack and along the edge of any loosened area. This should typically be 5mm from the edge of the crack and 5mm deep. B2. Physically remove all loose material and clean using a using a wire brush or similar. Remove all dust and debris, using a brush and / or vacuum cleaner. B3. Mix the repair material – NITOMORTAR FC-B (or FC) – in accordance with manufacturers recommendations and firmly press the repair mortar into place using a steel trowel. Finish the material flush with the surrounding concrete. It may be necessary to apply a second levelling coat if the material settles. B4. Ensure that the repair area is not walked on for 24 hours. Repair Type C – Repair with Resin Injection C1 Drill three 10mm holes in the area to be repaired, to a depth of approximately 35mm, representing the interface between the two screed layers. This can be determined by the change in sound of the drill. C2. Fix an injection nipple to the drilled holes using an epoxy mortar e.g NitoMortar FC-B, and seal using a trowel. Allow to set for eight hours. Mix the repair resin – NITOFILL EPLV – in accordance with the manufacturers reccomendations, and insert into injection gun. C3. C4. Commence filling the central nipple, and continue until resin is observed at the outer nipples. If neccesary, continue filling the outer nipples. Note that material usage rate should be approximately 1litre per 1m2. Do not attempt to place more than this, or the floor could lift further. C5. Leave for 6 hours, then remove the nipples and fixing mortar, and make the surface good using epoxy mortar ( Nitomortar FC-B or FC). Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 304 of Repair Type D – Surface Epoxy Coating D1. Ensure all repairs have been completed and allowed to cure (24 hours for epoxy repair – 5 days for cement screed repair). D2. Brush the surface thoroughly to remove all dust and debris. Ensure that the surface is not wet or damp. Mix the material – NITOFLOR FC140 - in accordance with the manufacturers instructions. Firstly apply a stripe coat to any untreated minor cracks, taking care to work the paint into the crack. D3. D4. Starting at the furthest corner, apply a single coat to the entire surface using a brush or roller, ensuring that the material fully coats the surface but without ponding. D5. Ensure that the surface is not walked on for 24 hours. 8. Details of all repairs shall be recorded on a Screed Repair Sheet – see QCF 91 attached. Attachment Check list Doc QCF Rev A Location Sketch #114 Epoxy grouting to Vibrating installation bases Using masterflow 648 cp General foundations Top Index Scope Reference documents Safety Method Equipment Scope This statement is aimed to propose the procedures to be adopted to grout the base plates of vibratory installations using epoxy grout material for varying grouting thickness for normal thickness range Reference Documents Specification Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 305 of Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Method Thin section- A gap between a base plate and substrate below 25 mm Thick section- A gap between a base plate and substrate above 80mm Normal thickness- In between the thin and the thick sections Refer to MBT clarification attached The following activities are involved for normal thickness Surface preparation Metal parts that should not be bonded to the grout like jack screws of the reciprocating machinery and part of the foundation bolts shall be sealed with tape prior to grouting. Base plates and equipment bases shall be uniformly supported in order to eliminate sag, distortion and levelled using both anchor bolts and jackscrews. Stainless steel shims 50x50x10 mm thick shall be placed in correct locations covered with mortar so as to allow at least 50 mm grout cover on shim sides. Full extent of the foundation surface under the base plate or equipment to be grouted shall be chipped / scabbled & brushed to remove the weak upper layer of concrete and any oil soaked concrete areas prior to the installation of the base plate Base plate surfaces in contact with epoxy grout shall be grit blasted so as to expose white metal All surfaces and bolt pockets to receive grout must be clean & free of rust, oil, dirt, paint and residual curing compound All base plate holding down bolts etc must be free of rust, oil, dirt or contaminants that could impair bond Formwork Unless otherwise shown on design drawing, the entire area under the base plate shall be grouted and the forms fixed around the plate keeping a minimum of 25 mm clearance from the plate edge and at least 50 mm from the edge of the pouring side so that total groutable area is equal to underside of the plate and the clearance around the plate. Before the form work is fixed, it shall be ensured that the foundation area to be grouted and the bolts holes are clean A liquid tight formwork as practicable, shall be fixed around the base plate to prevent the leakage of the resin keeping the top of the forms 25mm above the underside of the base plate A chamfer 25mm x 25mm shall be provided on the sides so that top of the chamfer and the top of grout are in one level in case the whole of the foundation area around the plate is to be grouted, Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 306 of A 45 sloping surface above the form on the pouring side shall be constucted to create a pressure head to enable the grout material flow to cover full width of the pour A coating of an approved release agent shall be applied to the form work Civil Contractor QC inspection shall be conducted to ascertain the form profile and general preparatory works Grouting application All dirt and debris shall be removed from the form work using compressed air Sufficient Grout material to completely fill the prepared area in a continuous process shall be made available Mixing equipment shall be demonstrated to be in a suitable as well as in good working condition A standby equipment shall also be made available Concrete surfaces to be grouted shall be completely dry before grouting Mixing Base and reactor components shall be poured into a suitable mixing vessel and mixing carried out for 1 minute or until successfully blended All required quantity of aggregate shall be added to the mixing vessel which is to be kept turning and mixing continued until a uniform lumpfree consistency is achieved. Overmixing shall be avoided to prevent air entrainment Placing All bolt pockets shall be filled with grout prior to pouring the rest of the underplate space as a separate operation to prevent voids formation Pouring of the grout shall start from one end of the base plate and continued until the material reaches the far side. Mixed grout shall be steadily poured down the form work slope to avoid air entrapment Pouring shall be carried out only from one side of the base plate to avoid creation of voids and any reduction of the effective bearing area When the grout reaches the far side of the formwork which shall be ensured by poured material rising above the bottom of base plate, the pouring location has to move along the length of the base plate keeping the process continued until the whole area is completed. Civil Contractor QC inspection shall be conducted throughout the above operations to ascertain the proper implementation of the procedures according to the manufacturer’s instructions Shoulders- Exposed surfaces shall be brushed with Solvent # 2 just before or as the grout gels Curing No curing is required Major Equipment Peddle Mixer / Mixing Vessel Attachment Sketches Masterflow 648 CP datasheet MBT Method statement Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 307 of #115 Kerbs & interlocking blocks paving around buildings Top Index Scope Reference documents Safety Method Equipment Scope This statement is aimed to propose the procedures to be adopted to lay kerb stones and concrete interlocking blocks in paving around buildings Reference Documents Specification MAR and Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Kerb stones, Interlocking Paving blocks Method All loose soil shall be cleared and formation level made up and well compacted (Laying Kerb stones) Setting out kerb excavation lines according to drawing Excavation upto the formation level i.e 325mm from the kerb top level Form work fixing and pouring grade 20 concrete 200mm wide and 100 mm thick Bedding in cement mortar 1 :4, 25mm thick for kerb stones Fixing kerb on the mortar to the true lines and levels with chamfer facing pavement & jointing with mortar Placing haunch back concrete grade 20, 150 mm high in triangular section Filling above haunch portion with soil An Civil Contractor QC inspection shall be conducted for kerb laying approval and ITP signed off (Laying Paving Interlocking blocks) Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 308 of Thickness of the interlocking blocks 60mm Thickness of the sand bedding 50mm Top level of sand in joint from the kerb top level 50mm Sharp sand to be consumed shall be piled up along the area to be paved and evenly spread with the blocks laid over snugly to the agreed pattern and colour Plank runs shall be used to allow barrows to move on to avoid level disturbance The blocks shall be laid in full but at the edges of the obstacles such as inspection covers where cut blocks may be required, whole blocks shall be laid first wherever possible and the trimmable blocks exactly marked & cut to the required size. After sufficient blocks have been laid, sand bedding shall be carried out using a plate vibrator pressing the blocks to the required level in 2 passes covering entire area with each pass to make the bedding even Sand shall be spread on the surface of the blocks with 2 more vibrator passes applied & brushed under the leading edge of the vibrator to allow the joints vibrated A Civil Contractor QC inspection shall be conducted to approve the paving Major Equipment Plate Compactor Attachment Manufacturer’s Conctruction method #116 Erection of steel structures (for higher levels) Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Scope The purpose of this Method Statement is to define the sequence and methodology that shall be implemented for the erection of the steel structures. Reference Documents Specification Specification Specification Specification Grouting Steel Structure Fabrication Painting Galvanizing Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 309 of Specification Structural Steel Erection ANSI A 10.13 Safety Requirements for Steel Requirements Relevant IFC Drawings Method Statement – Structural Steel Definitions CM CS EF Construction Manager Construction Superintendent Erection Foreman Responsibilities The CM shall plan and resourse the steel structure erection activies, to ensure that they are implemented according to this procedure, with the correct equipment resources. The CS shall ensure that all safety requirements are implemented and explained to the erection work force. The CS shall control the day to day activities. The EF shall control the workforce ensuring the full implementation of this method statement including all safety measures. Safety Before commencement of any task the relevant qualified labour force shall first receive a Safety Task Analysis Risk Reduction Talk about the task to be performed and all safety hazards shall be addressed as required. Main activities to be implemented are: a) Safe access to elevated levels b) Man baskets c) Full body harness d) All P.P. Equipment e) Extra Harness Lanyard f) Stay ropes g) Life Line Method Material Receivables All structural steel material to be used for permanent works shall be received on site and checked against relevant documents. All members shall be checked for quantity and identification and transportation damage. Concrete Foundations The surface of the concrete foundation shall be prepared in accordance with the specification to receive grout. All concrete foundations on which the steel structures shall be erected shall be released by the QC department, upon completion of the civil activity. Method Briefing Structures erected to date were low levels, varying from 6m to 16m and access was easy. Now the structures are at levels from 12m to 33m. These main columns or grid frames shall be assembled on the ground near the foundation. These shall then be installed on the columns using the appropriate capacity crane. Stay ropes Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 310 of shall be used to secure these till the connecting horizontal member beams are installed. All splice plates shall be installed and bolted down before the horizontal members are connected. Steel Catcher crew with the necessary full body harness & lanyard shall be placed in position on the beams using either a man lift or man basket. The full body harness shall secure the steel catcher to the steel. Steel Catcher shall move around on the steel by the “Slip & Slide” method to get in position for the next member. Life lines shall also be pulled between columns, so that the steel catchers can walk on the beams below with their Safety Harnesses hooked onto the life line. Access ladders shall be installed as soon as possible for safe access. The other option shall be to install step ladders. All fasteners shall be installed and then the line & levels checked. When the first level of steel with the majority of the horizontal members are installed, line & levels checked, the grouting of the column base plates shall then be grouted as per the approved procedure. Platform\Handrails\Gratings: After completion of the main steel erection, the platform\handrails shall be installed as required as per drawings. Major Equipment Mobile cranes Man lift Man basket Guy ropes and tensioning equipment Flat bed trailers and forklifts\other mobile shifting equipment Air compressor Impact wrench Welding generators Grinding machines Drilling machines #117 Vinyl flooring buildings Top Index Scope Reference documents Safety Method Equipment Scope This statement is aimed to propose the procedures to be adopted to lay Vinyl tiles floor finish on cement sand screed in buildings Reference Documents Specification Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 311 of MAR Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Vinyle Tiles, Adhesive- Laybond Multibond Gold (Multi Purpose Acrylic ) Method Surface shall be broomed followed by vacuum cleaning. The sub floor shall be dry and free from contaminants, hardening compound , dust and other deleterious matter immediately prior to floor installation Adhesive shall be spread evenly over the surface with a triangular notched trowel 1.5mm deep cut at 5mm centres with a sweeping motion at about 60 degree angle to horizontal & allowed to reach a tacky consistency Vinyl covering shall be placed into position and rolled using 68 kg roller to ensure overall contact A Civil Contractor QC inspection shall be conducted for approval and ITP signed off Major Equipment Roller 68 Kg, Notched Trowel Attachment Adhesive Manufacturer’s Conctruction method #118 Concrete paving Top Index Scope Reference documents Safety Method Equipment Scope This statement is aimed to propose the procedures to be adopted to construct the concrete paving Reference Documents Drawing Road & Paving Details Sheet 1 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 312 of Specification Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Fibre Concrete grade 30, Joint filler board, Crack Inducer, Welded Wire Fabric, Oil resistant joint sealant Method All the relevant underground services shall be laid in all respects prior to the commencement of the pavement work The area to be paved shall be made ready by clearing all weak soil & by scarifying Approved sub base material 150mm thick shall be filled up to the bottom of the concrete slab following the profile given on the drawing and compacted to 95 % dry proctor density Weed killer chemical shall be applied to the soil to prevent the organic growth The whole area shall be divided into parts to suit the services and the contraction joints formations & as shown on drawings On the’ compacted filled area’ to be paved, polythene sheet 0.25mm shall be placed with end overlaps at least 150mm at all joints and intersections End forms shall be fixed on sides allowing a provision to place 20MS dowel bars 650mm long & 300mm centres half painted with 2 coats bitumastic paint with 100mm long cardboard cap containing compressible material such as cotton waste at the expansionjoint to the details shown on the drawing. The thickness of the expansion joint shall be 20mm Refer to detail 9 At contraction joints 25x25 mm plastic crack inducer shall be provided as shown in the detail 10 & the joints cut for a depth of 20mm with a concrete cutting machine Welded wire fabric mesh dia 7mm –200# shall be placed in the bay centrally located with concrete spacers below Forms shall be set to correct levels so that the total thickness of the concrete is as specied on the drawings Civil Contractor QC inspection shall be conducted for the pour approval Concrete shall be poured in one layer and compacted using parker vibrator to brush finish & to correct levels. Curing compound shall be spread on the surface for immediate curing covered with polythene sheet and later within 2 hours damp hessian added by removing polythene sheet temporarily and recovered thereafter The expansion joints between the two adjacent slabs shall be filled with an elastic joint filler and sealed with a chemical resistant sealant complying with the details shown on the drawings Refer to detail 12 – Details A & B Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 313 of Details A shows 20mm x 25 mm joint seal and detail B shows 15mm x 20mm slightly rounded to prevent damage to edges Civil Contractor QC inspection shall be conducted Major Equipment Concrete Pump, Transit Mixer, Parker / Dr Kewande Vibrator, Concrete cutting machine Attachment None #119 Central control building Ceramic tiles flooring system Top Index Scope Definitions Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to construct the ‘ceramic tiles flooring system’ which involves the laying of the bedding screed as well as the finishing layer with grouting the joints including movement joints. Reference documents Drawing Nos. Specifications page STQ Qand UBC & general construction practice Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Proper illumination shall be provided in the dark area Safety Supervision The area to be tiled shall be closed for the general movement except those working there and be opened only when the tiling has properly been completed with hardboard cover protection spread on the newly laid flooring. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 314 of A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Ceramic floor tiles 300 x 300 x 10mm, For General Area ‘RAK GP 21 G’ and for wet areas Johnson ‘Athena’ Cementitious adhesive- Nitotile GP Joint filling grout – Approved proprietary material with matching shade. Method (Laying ceramic floor tiles by SEMI DRY method) The areas of concrete sub strata to be tiled shall be brush cleaned and dampened until absorption ceases followed by the finished floor level establishment by means of dots and rules. The total thickness of the ceramic tile flooring is 100 mm which includes 90 mm bedding screed (1 cement: 4 mortar sand) to be mixed by weight and 10 mm thick ceramic tiles, shall be applied as described below. The mortar for bedding the tiles shall be 1 part cement to 4 parts sand by weight, mixed semi dry by a mechanical mixer with only sufficient water added to give a crumbly consistency which retains its shape when squeezed by hand permitting no fluidity The mix shall be placed to a thickness approximately 10 mm greater than that actually required for the bed, thoroughly compacted by tamping and drawing off to the required level with a screed board and given a smooth trowel finish. Civil Contractor QC visual inspection shall be conducted to ascertain proper compaction and levels. The surface of the screed shall be cleaned by brush prior to the application of the adhesive. The adhesive shall be mixed with water using a slow speed drill to the water adhesive ratio per manufacturer’s data sheet. Adhesive Nitotile GP mix shall be applied in uniform thickness of 2 to 3 mm over the surface of the cement sand screed bedding and then combed horizontally. Tiles shall then be laid on the adhesive layer with a twisting motion ensuring good contact between the tile and the adhesive bed. For this purpose the adhesive manufacturer’s instruction shall be adhered to. The tiles shall be correctly positioned in both directions the time these are placed forming joints using a proprietary tile spacer ( 1.5 mm for wall tiles and 3 mm for floor tiles) The tiles shall neatly and accurately be cut to a close fit where necessary at abutments, around outlets, pipes and the like. Civil Contractor QC Inspection shall be conducted for the correct formation of joint alignment and the level profile The tiles shall be laid level or to 1- % falls in ‘wet’ areas as may be required. Localised variations in level for a nominally flat floor shall be a maximum of +- 2-mm under a 3-meter straight edge. Particular care shall be taken in ‘wet’ areas to prevent low spots that may Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 315 of promote water pooling. The tolerance in the overall level shall not be more than 10 mm from required finishes. (Reef STQ Q) Excessive adhesive shall be removed with a damp cloth before the material has set. Grouting of the joints shall be carried out after a period of 24 hours after completion of laying of tiles. MOVEMENT JOINTS IN TILED FLOORS Unless otherwise indicated in the documents, a 10 mm movement joint shall be formed at the perimeter of all the tiled floors and where the tiling meets structural features such as columns, machine bases etc., Where a structural movement joint is provided in the base, a movement joint of the same width in the bedded finish shall be positioned immediately above The movement joint cavities shall extend through the combined thickness of the finish and the bedding mortar, completely filled and sealed after grouting of the normal joints takes place. Major Equipment Mechanical Mixer Wheel barrows Mason’s tools in general Slow speed drill Attachment Adhesive manufacturer’s Datasheet #120 Concrete placement Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement, is to define the procedure that shall be adopted for the placement of structural concrete upon the project. Reference documents Project Specification Project Specification ACI 301 chapter 8. Definitions EPC Contractor Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 316 of Civil Contractor PSM Project Site Manager. Responsibilities The Construction Superintendent shall ensure that the concrete Foreman implements this procedure. The Concrete Foreman shall ensure that the concrete crew is fully aware of this procedure and the correct methods of working. Safety The Safety Officer shall monitor the concrete activities, advising and implementing all safety procedures. Method The structure that is to be concreted, shall be inspected and approved as correct, by both Civil Contractor and EPC Contractor. The permission to place concrete shall be authorized by EPC Contractor The concrete Foreman shall ensure that he has adequate equipment resources (vibrating pokers, compressors, hoses, steelfixer, carpenter, water etc), at the location of concrete placement. When the site laboratory concrete technician, has approved the concrete delivery, the concrete placement activity can commence. Refer to Method statement, Testing of Fresh Concrete. The concrete shall be discharged by one of two methods. For pours greater than two cubic meters in volume, the concrete shall be discharged through a concrete pump. For pours less than two cubic meters, the concrete can be discharged direct from the truck mixer. Regardless of the method of discharge, no concrete shall be dropped from a height greater than two meters, or in a manner that shall cause the segregation of the aggregates. Immediately prior to placement activities commencing, the reinforcement within the concrete pour, shall be sprayed with clean water. The placement of the fresh concrete within the shutters, shall be in a logical sequence. Concrete shall be placed at locations that do not exceed 1.5 meters from the final location of the concrete. The maximum concrete layer thickness of 450 mm shall be observed. The fresh concrete shall be compacted with pokers of sufficient size and number. Consolidation of the fresh concrete, shall commence when the placement of the concrete is adequate, so that uncontrolled segregation does not occur. Concrete shall be placed in a sequence that ensures that cold joints are eliminated. Each subsequent layer of concrete shall be adequately compacted into the concrete layer below. Where encast plates, holding down bolts, or any other critical embedded item is included within the pour, the surveyor shall check the location and elevation of that item, when concrete placement has been completed. Immediately the concrete finishing has been completed, the concrete shall be covered with white polythene sheeting, ensuring that the edges are sealed to prevent the circulation of air. Upon adequate setting of the concrete, the white polythene sheeting shall be removed. Hessian which has been soaked in water, shall be placed over the set concrete. The white polythene sheeting shall be replaced and sealed at the edges. The hessian shall be kept moist for a period of 14 days. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 317 of (Note: it is proposed to apply for a specification concession to use a water based curing compound, in leu of water curing.) When shuttering is removed from a pour, the resultant concrete surface shall be inspected. Where a defect is observed, the defect shall be classified as minor or major. A minor defect is one which does not impair the strength of the structure or is greater than 10mm by 10mm. This minor defect shall be repaired using a patching mortar. A major defect shall be brought to the attention of the QA department. A major defect shall be any other surface defect that is larger than 10mm by 10mm. The method of repair of such defects shall be discussed and agreed with EPC Contractor. The repairs to the concrete surfaces shall be cured according to the requirement for fresh concrete. Equipment Truck Mixer. Concrete Pump. Vibrating Pokers. Compressors. Attachment ITP No: Concrete Placement. #121 Precast rcc covers Cable & instrumentation trenches Top Index Scope Definitions Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the construction of the covers for the Instrumentation and the electrical cable trenches. Reference documents Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 318 of Drawing Nos Specifications Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Coloured concrete Grade 30 Red colour concrete for the covers to be used on Electric cable trenches Green colour concrete for the covers to be used on Instrumentation cable trenches Red or Green oxides to be added to the concrete @ 9 kg per cum Lifting Lugs, 16mm dia with exposed portion galvanised, to be flush with concrete Pre fabricated mesh, 7 dia at 200 / 200 Method Since various dimensions are involved for these typical pre cast concrete covers, the details of the lifting lugs with the exposed steel portion of the lug to be galvanised, have been given on the Attachment. Relevant details 5 L & 5 H on the above drawing indicate transverse joints to be formed at a spacing of 3m in case of 150mm thick covers and 1 m in case of 50 mm (proposed to be substituted by 100 mm) covers The pre casting shall be carried out in the pre cast yard to the approved procedures using coloured concrete All other procedures pertaining to the concreting & transporting the members to the site locations shall be similar to as being adopted Prior to placing the covers, the filled compacted base in the trench shall be prepared and polythene sheet spread to receive the covers. The covers shall be offloaded to the locations at the specified spacing leaving a gap of 25 mm between the ends to allow for the oil resistant joint sealant Civil Contractor QC inspection shall be conducted to ascertain the correct alignment and level Major Equipment Transit mixer Wheel barrows Mason’s tools in general Trailor Crane Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 319 of Sketching showing lifting lugs #122 Black top repair Ist street between Avenue c & b Top Index Scope Definitions Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the repair to the road-wearing course damaged superficially to a portion on Ist Street between Avenue ‘’ and Avenue ‘’. Reference documents None Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Tack coat bituminous material 60 / 100 penetration to be applied @ 2.5 litres per sqm of road surface Asphalt for 40mm thick course according to requirement Water Method Traffic diversion if so required shall be effected to the requirement Damaged portion of the ‘wearing course’ shall be removed using ‘Asphalt Remover’ and the surface cleaned using a ‘Mechanical Cleaner’ Tack coat shall be applied to the clean surface according to the specified rate of application as above Asphalt shall be applied to a required thickness (minimum 40 mm) finished to full extent of the damaged area making up the level to the existing wearing course Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 320 of Laid material shall be spread and finished to the required level using Asphalt Finisher First rolling shall be carried out using pneumatic roller ‘6’ tonne capacity giving required number of passes Then second rolling shall be carried out using Tandem roller 8 / 10 tonnes capacity according to the requirement giving required number of passes Water shall be used during rolling according to the requirement Civil Contractor QC inspection shall be conducted to ascertain the correct finished level Major Equipment Asphalt Remover Asphalt Finisher Pneumatic Roller Tandem Roller Water Tank Attachment None #123 Repair of Single leaf swing gates Top Index Scope Definitions Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the repair to the emergency gates to be installed in the sub station fence for transformers. A lock usable from outside is to be added to the gate. Reference documents Attached sketch Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 321 of Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials New post Self levelling grout to specification Epoxy paint system or galvafroid Method Vendor – Link Middle East Ltd Existing gate post shall be cut using gas cutting equipment to a level as shown on the sketch and discarded A new post dia 88.9mm including a locking lug shall be added with a sleeve- slot by welding at the vendor’s shop with 70 mm out to out PVC coated per specification. A circumferencial overlap shall be made in such a way that a minimum of 100mm overlapping length lies below finished concrete level in addition to projection above A portion of the concrete necessary to allow working area (150 mm deep apprx) to weld the circumference on site shall be removed prior to the new post is erected for installation The new assembled post shall be properly aligned to the requirement Welding shall be carried out to the circumference After welding galvafroid or epoxy paint system shall be applied according to manufacturer’s instructions An Civil Contractor QC inspection shall be carried out for the approval of the welding and the paint system The surface of the broken concrete shall be cleaned and approved, forms if necessary, prepared and self-levelling grout shall then be applied to the manufacturer’s instructions and finished accordingly Major Equipment Oxy Acetylene Gas cutting system Welding set Attachment Sketch showing proposed arrangement #124 Repair to Floor screed levels Top Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 322 of Index Scope Definitions Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the repair to eliminate the uneveness from the floor screed surface, prior to applying the Rubber flooring Reference documents None Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Fosroc Nitoflor Leveltop This is a self-levelling, cementitious underlay for a wide variety of floors finishes requiring a smooth level substrate Method Preparation The sub strata shall be clean, sound and free from loose material and contamination such as plaster oil and grease Excessive laitance shall be removed by light scabbling or acid etching followed by washing and debris removed using vacuum cleaner Large cracks and holes shall be filled with a mix of Nitoflor leveltop and clean sharp sand made to a trowel consistency by adding small quantity of water. Substrate shall be primed with 1:1 water Nito bond PVA mixture prior to the repair is done Mixing Material shall be mixed using a heavy-duty drill fitted with a purpose made paddle. Clean water @ 6.5 liters per bag of 25 kg material shall be used as per manufacturer’s instructions First 2 / 3 rd required quantity of water shall be added to the mixing vessel followed by gradually and slowly adding the material from the bag and mixed for 3 minutes minimum Remaining 1 / 3 rd required quantity of water shall be slowly added throughout to the mix and mixing continued until a smooth, self levelling & pourable mix consistency is obtained Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 323 of Material shall be poured onto the primed substrate, spread with trowel or squeegee and allowed to self level The material shall be rolled with a Fosroc spiked roller to achieve air release with final level. Rolling shall be carried out immediately after material is placed. High spots or splashes shall be scraped off with the edge of a trowel after initial set Required thicknesss shall be achieved in one application only with maintaining continuous process of pouring and levelling until the designated area is completed Curing is generally not required An Civil Contractor QC inspection shall be carried out throughout during the above operations Major Equipment Heavy duty drill Mixing Vessel Squeegee and other tools Attachment Fosroc Data Sheet #125 Resin injection to leaking joint Sea water surge basin Top Index Scope Definitions Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the injection to the leaking joints at the sea water surge basin observed during water tightness test according to the BS code 8007. Reference documents BS code 8007 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 324 of Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Master Building Technology, Masterseal 505 Concresive 1335 and 1320 Method Leakage Control Technology The’ leaking joints’ shall be reinstated by injecting resin using MBT material according to the MBT proposed statement and the material data sheet attached Preparation and application of a ‘Low Viscosity Polyurethane Injection Resin’ used for reinstating the structural integrity of cracked concrete accommodating slight movement The following operations are involved Preparation The location of the leakage shall be marked Leaking water shall be plugged with Masterseal 505 Once the water running is temporarily stopped, holes shall be drilled on both sides of the expansion joint at an angle and at 200 to 500 mm spacing Metal screw packers shall be installed in the drilled holes and tightened so that the injected material does not leak Application First stage injection Concresive 1335 shall be injected into the packers to further stop the water as it foams and cures within 30 seconds stopping any flow of water Second stage injection Concresive 1320 shall be injected using a high pressure (up to 240 bars) an electrically operated injection machine at a suitable pressure. This injection shall react with water as well as bubble up to a fine foam and seal the leaking crack / joints permanently Leak shall be checked again after 24 hours and re-injection applied if required Packers shall be removed the next day and holes re-profiled using non shrink grout During the complete operations Civil Contractor QC inspection shall be carried out to record that the leakage has been controlled to the code requirement Major Equipment High pressure electric Injection system Metallic Packers Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 325 of MBT Method Statement Material Datasheet #126 Resin injection to leaking joint Sea water surge basin Top Index Scope Definitions Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the injection to the leaking joints at the sea water surge basin observed during water tightness test according to the BS code 8007. Reference documents BS code 8007 Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Master Building Technology , Concresive 2200 / Masterseal 505 Concresive 1335 and 1320 Method The leaking joints shall be reinstated by injecting resin using the MBT material according to the MBT proposed statement and the material datasheet attached Preparation and application of a low viscosity Polyurethane injection resin used for reinstating the structural integrity of cracked concrete accommodating slight movement The following operations are involved The location of the leakage shall be marked The water shall be pumped out from the basin Laitance and contaminants shall be removed from the surface from a band 50mm wide centered on crack using light grit blasting Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 326 of Holes shall be drilled along the center of the crack for packers at not more than 300 mm apart Compressed air shall be used to remove dust and debris Mixed concresive 2200 shall be applied to the bottom of the flange at perimeter ensuring the paste does not block the port Ports shall be located over the crack center Concresive 2200 shall be applied in a strip 20mm wide and 2-3 mm thick between the ports and the crack center after all the ports have been placed Forcing the paste into the substrate to ensure intimate contact and seal around the port and allowed to cure Application In case of flowing water Concresive 1335 shall be injected into the crack / joint befire using concresive 1320 and when the water ingress stops, the concresive 1320 shall be injected into the joint / crack Injection process shall be started from one end of the crack moving bottom upwards in the case of a vertical joint Both the components of concresive 1320 shall be mixed for at least 1 minute Injection gun shall be filled with mixed resin And connected to the port and injection started Resin shall continue to be injected until it starts flowing from the next port. The port under injectin shall be closed at this stage and the other started being injected All ports shall be injected similarly Resin shall be allowed to cure. Injection ports shall be removed and the paste ground ver the cracks if so required An Civil Contractor QC inspection shall be carried out for the approval of the welding and the paint system Water shall be filled to the specified test levl and test reconducted according to the code requirement Major Equipment Injection system / Hand gun Compressor Grit blasting unit Port flanges Grinder Attachment MBT Method Statement Material Datasheet #127 resin injection to leaking joint sea water surge basin Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 327 of Top Index Scope Definitions Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the injection to the leaking joints at the sea water surge basin observed during water tightness test according to the BS code 8007. Reference documents BS code 8007 Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Master Building Technology, Masterseal 505 Concresive 1335 and 1320 Master Builders Technologies confirms that Concressive 1335 is a flexible / compressible material once set. No materials are to be introduced into the expansion joint that interfere with the function of the joint (ref the attachment) Applicator- Track record for appraisal respecting Dicotech, the applicator attached Measurement of injection quantity Since the material is supplied in small packing of 1 or 5 lts, the used quantity can be measured by counting the number of cans used According to Dicotech the most effective means of injection is from outside as point of crack or leakage can be seen which is almost impossible from inside Method Leakage Control Technology The’ leaking joints’ shall be reinstated by injecting resin using MBT material according to the MBT proposed statement and the material data sheet attached Preparation and application of a ‘Low Viscosity Polyurethane Injection Resin’ used for reinstating the structural integrity of cracked concrete accommodating slight movement The following operations are involved Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 328 of Preparation The location of the leakage shall be marked Leaking water shall be plugged with Masterseal 505 Once the water running is temporarily stopped, holes shall be drilled on both sides of the expansion joint at an angle and at 200 to 500 mm spacing Metal screw packers shall be installed in the drilled holes and tightened so that the injected material does not leak Application First stage injection Concresive 1335 shall be injected into the packers to further stop the water as it foams and cures within 30 seconds stopping any flow of water Second stage injection Concresive 1320 shall be injected using a high pressure (up to 240 bars) an electrically operated injection machine at a suitable pressure. This injection shall react with water as well as bubble up to a fine foam and seal the leaking crack / joints permanently Leak shall be checked again after 24 hours and re-injection applied if required Packers shall be removed the next day and holes re-profiled using non shrink grout During the complete operations Civil Contractor QC inspection shall be carried out to record that the leakage has been controlled to the code requirement Major Equipment High pressure electric Injection system Metallic Packers Attachment MBT Method Statement Material Datasheet Dicotech ref containing all details giving clarifications #128 Fire water line excavation around consumer receipt station Top Index Scope Definitions Material Method Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 329 of Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the excavation for Fire Water Lines to be laid by EPC Contractor around Consumer Receipt Station. Method Statement for the part of road crossing shall be submitted separately Reference documents Specification Excavation & Backfilling for Underground installations Interconnects underground layout drainage Sheet 16 Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Method Permit pertaining to the relevant excavation area shall be obtained from Plant Refinery division. Existing services drawings shall also be obtained to ascertain safety Supervision at the workface must have a copy of the permit, drawing and the method statement Attached sketch shows the location of the proposed Fire Water Line and existing Natural Gas pipe. Any existing services shown on the record drawings shall be located, identified & protected adequately with warning as required Cables or pipes that span the excavation shall be supported using split ducts and trays All existing services encountered shall be plotted by the surveyor on as built drawing The surveyor shall set out the routes of the proposed 8”dia fire water line trenches conforming to the IFC drawings and to the sections shown on the attached sketch keeping a clear level Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 330 of difference between existing natural gas and proposed firewater line 1000mm. which shall also be applicable between the existing 132 kv cable and the proposed fire water line Where necessary or as defined on the work permit, hand excavation shall be carried out When cable markers have been exposed, work shall be temporarily suspended and an evaluation made about the soil conditions. This evaluation shall be conducted by EPC Contractor Superintendent and Operator operations representative. Where necessary, a revised method of work may be necessary and in this instance, all personnel shall be briefed Cables shall be protected by fitting split sleeves after exposure The trench shall be excavated by an excavator to correct lines and levels to the specification requirement providing benching where necessary and employing all safety means. Barriers (including warning tape) shall be placed to indicate an open excavation The excavated material shall be stockpiled in agreed areas for reuse. Surplus material shall be removed to the tip area in dump trucks. The surveyor shall monitor the lines and levels of the excavation operation Exposed (Existing) cables and pipelines shall be checked for damage by EPC Contractor supervision and combined inspection shall be held by EPC Contractor and Civil Contractor. Operation department shall be invited to attend EPC Contractor engineer shall approve the suitability of the formation material by inspecting the trench bottom and after the approval, compaction of the formation level shall be carried out , the specified tests conducted and the results reported accordingly The surveyor shall provide level pins to indicate the correct elevation of the bedding required for 8” Fire Water line. The bedding shall be laid, compacted, tested and the results reported accordingly. The fire water pipes shall be placed correctly within the trench by EPC Contractor (not Civil Contractor) in accordance with EPC Contractor own method statements (noting that Al Jaber equipment is under the Direct Control of EPC Contractor). Upon acceptance of the pipe installation, the laid pipes shall be surrounded with further bedding material that shall be compacted using suitable equipment, tested and reported The approved backfill material shall be spread uniformly in layers of 150 mm up to the existing ground level, compacted to the specification requirement, tested & reported accordingly The site shall be left tidy of excavated and backfill material Major Equipment Excavator Dump Truck Compactor Attachment Sketch and the drawing extract depicting proposed excavation route #129 Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 331 of Road crossing For laying 1 for 20” raw ethane 1 for 6” propane First street Top Index Scope Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road crossings to construct culverts to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at location identified on the attached drawing pertaining to First Street Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect ‘ full safety standard’. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 332 of EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On both directions, in addition to the traffic sign boards, a flagmen shall be engaged full time to direct the traffic about the ‘excavation work in progress’ by ‘flag signal’ Hand Excavation- Excavation to expose the services shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged equipment operation. No violation of the traffic rules shall be allowed Pre cast members Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising and downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced on site as detailed on the attached sketch Drawing reference –Piping Interconnections F Street Culvert XTH Existing Services 3 # cables exist north side of the proposed crossing already exposed The road shall be excavated in two instances by diverting the traffic on either lane completing one after the other as shown on the traffic management scheme Procedures Traffic management scheme shall be implemented effectively Instance 1 The asphalt pertaining to the crossing portion Stage-1 shall be removed Hand excavation shall be carried out to expose the cables & the other services employing seaming the area with detectors to detect the existence of cables After the exposure, all the cables shall be covered with split PVC pipe & well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culverts shall be carried out Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 333 of The construction pertaining to the pipe carrying culverts including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc.shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members In addition, one access boxout at the end shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications The broken asphalt portion shall be made good using new asphalt Instance 2 The aforesaid activities shall be repeated for this instance for the crossing portion Stage-2 The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. 75-mm dia holes in the pre cast units meant for lifting shall be filled with concrete Access boxout shall be closed with concrete after the pipes are laid Either side of the road shall be provided with cable markers to indicate the services 8 mm galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details. Other chequer plates shall be provided to the design details Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic management scheme #130 Road crossing For laying 1 for 20” raw ethane 1 for 6” propane First street Top Index Scope Safety Method including traffic management scheme Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 334 of Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road crossings to construct culverts to facilitate to lay the pipe lines 1 # each 20” Raw Ethane and 6” Propane at location identified on the attached drawing pertaining to First Street Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect ‘ full safety standard’. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Plant Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On both directions, in addition to the traffic sign boards, a flagmen shall be engaged full time to direct the traffic about the ‘excavation work in progress’ by ‘flag signal’ Hand Excavation- Excavation to expose the services shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out of the trench. No jumping shall be allowed Machine Excavation Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 335 of The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged equipment operation. No violation of the traffic rules shall be allowed Pre cast members Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising and downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced on site as detailed on the attached sketch Drawing reference –Piping Interconnections F Street Existing Services 3 # cables exist north side of the proposed crossing already exposed The road shall be excavated in one instance by diverting the traffic on north side as shown Procedures Backfilling shall be carried out to the existing excavated cross trench on north end of the proposed crossing up to the natural ground level to provide effective traffic ‘divertion routes’ from the road carriageway according to the traffic management scheme attached Traffic management scheme shall be implemented effectively The asphalt pertaining to the crossing portion shall be removed Hand excavation shall be carried out to expose the cables & the other services employing seaming the area with detectors to detect the existence of cables After the exposure, all the cables shall be covered with split PVC pipe and well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culvert shall be carried out The construction pertaining to the pipe carrying culvert including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc. shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members In addition, one access boxout on both ends shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications The broken asphalt portion shall be made good using new asphalt The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. 75 mm dia Holes in the pre cast units meant for lifting be filled in with concrete Access box out shall be closed with concrete after the pipe are laid Either side of the road shall be provided with cable markers to indicate the services 8 mm galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details. Other chequer plates shall be provided to the design details Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 336 of Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic management scheme #131 2 #s road crossings For laying 1 for 20” raw ethane 1 for 8” natural gas 1 for 6” propane & 1 for 14”desalinated water 1for 8” potable water Avenue -d Top Index Scope Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation at the road crossings to construct culverts to facilitate to lay the pipe lines 1 # each 20” Raw Ethane, 6” Propane & 8”Natural Gas 1# each 14” Desalinated Water and 8” Potable water at locations identified on the attached drawing pertaining to Avenue -D Safety Prior to the commencement of any activity, the labour force shall receive a STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case, the excavation has to be carried out on the Operating Authority area, therefore, all the regulated precautions shall be strictly adhered to have ‘ full safety standard’ effect. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 337 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On all directions, in addition to the traffic sign boards, flagmen shall be engaged full time to direct the traffic about the ‘excavation work in progress’ by ‘flag signal’ Hand Excavation- Excavation to expose the services if any, shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- the workers shall clearly be instructed to use only the ladders to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged equipment operation. No violation of the traffic rules shall be allowed Pre cast members Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising and downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced on site as detailed on the attached sketch Drawing reference –Piping Interconnections Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 338 of Avenue D , Culvert Procedures Traffic management scheme shall be implemented effectively Both the crossings shall be excavated in one instance together The asphalt pertaining to the crossing portion shall be removed Hand excavation shall be carried out to expose the cables & the other services if any, employing seaming the area with detectors to detect the existence of cables After the exposure, all the cables shall be covered with split PVC pipe and well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culvert shall be carried out The construction pertaining to the pipe carrying culvert including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc. shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members In addition, one access boxout on both ends shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications The broken asphalt portion shall be made good using new asphalt The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. 75 mm dia Holes in the pre cast units meant for lifting be filled in with concrete Access box out shall be closed with concrete after the pipe are laid Either side of the road shall be provided with cable markers to indicate the services 8 mm-galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details. Other chequer plates shall be provided to the design details Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic management scheme #132 Treatment to moved expansion joints Sea water surge basin Top Index Scope Definitions Material Method Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 339 of Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to carry out the injection to the moved expansion joints in the roof and the base at Sea Water Surge Basin observed during water tightness test Reference documents BS code 8007 Safety Prior to commence any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Master Building Technology, Concresive 1320 Epoxy putty Concressive 2200 Hypaton / Combiflex Tape Colma Cleaner Applicator- Dicotech Method Roof Expansion Joint Preparation The joint shall be plugged with a rapid setting cement plug at top and soffit Application When the cement is set, drilling shall be carried out and screw packers fixed to inject polyurethane in the joint Concresive 1320, a two component, low viscosity flexible polyurethane resin shall be injected into the prepared joint using an electric injection machine affecting the joint sealed after polyurethane cures Next day, cement plugs shall be removed from the top and sofit of the slab and the joint cleaned to a depth 100mm to get a uniform depth A suitable dia Backup rod shall be provided and the surface reprofiled using 2 part Polysulphide sealant “Arbokol AG2” and allow that to cure Base slab expansion Joint This joint shall be treated if the leakage is observed Preparation The adjacent area of the joint shall be groind , cleaned and plugged by rapid setting mortar Screw packers shall be drilled and fixed for injection Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 340 of Application Concressive 1320 shall be injected into the prepared space using an electric injection machine so as to seal the joint permanently after the polyurethane resin comes in contact with water The cement plugs & the old sealant from the joint shall be removed the next day Sides of the joint shall be ground using an angle grinder to remove any deleterious material to avoid debonding of the new sealant Backup rod shall be installed followed by priming the sides by “Arbo Primer” Joint shall be reprofiles using “Arbokol AG2” joint sealant and allowed to cure Adjacent area of the joint shall be ground to remove the coating from the surface An Aluminium foil shall be provided on top of the joint sealant 1mm or 2 mm thick “Hypaton Tape / Combiflex Tape” 200 mm wide shall be fixed using “Concressive 2200” (a 2 parts epoxy putty) after activating the tape with “Colma Cleaner” The top surface of the tpe shall be closed with the putty leaving a neat band of 50 mm joint in between The system shall be allowed to cure for 3 days prior to the basin is put to use Major Equipment High pressure electric Injection system Metallic Packers Attachment MBT Method Statement Material Datasheet #133 Testing of fresh concrete on site Top Index Scope Reference documents Definitions Responsibilities Safety Method Equipment Attachment Scope The purpose of this method statement, is to define the procedure that shall be adopted for the on site testing of fresh concrete delivered from the Batch plant. Reference documents Project Specification Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 341 of Project Specification Definitions EPC Contractor Civil Contractor PSM Project Site Manager. Responsibilities The Construction Superintendent shall ensure that the laboratory technician is aware of the concrete program. The laboratory technician shall ensure that he implements this procedure. Safety The Safety Officer shall monitor the concrete activities, advising and implementing all safety procedures. Method The Site Laboratory shall be informed of the concreting program. Each delivery of concrete to the site, shall report to the concrete Foreman. The concrete Foreman shall assist the laboratory technician is testing the fresh concrete delivery. The delivery ticket shall first be checked for the correct grade and type of concrete. The truck mixer shall discharge his delivery into the concrete pump. Upon commencement of a pour, the concrete pump operator shall flush his line with the fresh concrete. The initial discharge from the concrete pump line shall be discarded. A sample of concrete circulated through the concrete pump, shall be taken from the end of the concrete pump line. The pumping operation shall then cease until the laboratory technician has completed his testing. The temperature of the concrete sample shall be determined according to ASTM C1064. A slump of the concrete sample shall be conducted according to ASTM C143. These details shall be recorded upon the test record format QC. Once these test results have been established as conforming to the specification requirements, the pumping operation can proceed. Subsequent deliveries of fresh concrete shall follow a similar procedure. The exemption being that the initial discharge of the subsequent truck mixers shall not be discarded. The laboratory technician shall take concrete samples from random truck mixers, for the purpose of concrete test cubes. The frequency of these concrete test cubes shall be three cubes per 100 cubic meters of delivered concrete. Additional concrete cubes shall be taken as directed by the laboratory manager, for conducting further tests upon hardened cubes as defined within the specifications. Equipment Truck Mixer. Concrete Pump. Slump Cone. Thermometer. Cube molds. Attachment ITP No: Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 342 of #134 Road crossing To install culvert for 1# 14” desalinated water Corniche road / road c At gup gate noth Top Index Scope Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation and installation of 1 # pre cast culvert at the road crossing as shown on the attached sketch Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect ‘ full safety standard’. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 343 of followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On both directions, in addition to the traffic sign boards, a flagmen shall be engaged full time to direct the traffic about the ‘excavation work in progress’ by ‘flag signal’ Hand Excavation- Excavation to expose the services shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged equipment operation. No violation of the traffic rules shall be allowed Pre cast members Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising and downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced on site as detailed on the attached sketch Drawing reference –Piping Interconnections Corniche Road Culvert Existing Services On East End of the crossing exist banks of electrical cables & also exist some utility pipes. On West End exist certain services An electric pole exists on the West of the gate but out of culvert reach On the South adjacent to road exists sea water pipe in the trench Procedures Backfilling shall be carried out to the existing excavated sea water trench on south of the Corniche road crossing up to the natural ground level to provide effective traffic access to the working area from the road carriageway according to the traffic management scheme attached Traffic management scheme shall be implemented effectively subject to RRD approval Hand excavation shall be carried out to expose the cables & the other services employing seaming the area with detectors to detect the existence of cables After the exposure, all the cables shall be covered with split PVC pipe and well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culvert shall be carried out Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 344 of The construction pertaining to the pipe carrying culvert including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc. shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members In addition, one access boxout on both ends shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications The broken asphalt portion shall be made good using new asphalt The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. 75 mm dia Holes in the pre cast units meant for lifting be filled in with concrete Access box out shall be closed with concrete after the pipe are laid Either side of the road shall be provided with cable markers to indicate the services 8 mm-galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details. Other chequer plates shall be provided to the design details Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic management scheme #135 Road crossing To install culvert For 1 # 14” desalinated water Avenue ‘c’ road gup gate east Main entrance Top Index Scope Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation and installation of 1 # pre cast culvert at the road crossing as shown on the attached sketch Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 345 of Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect ‘ full safety standard’. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Flagman-On both directions, in addition to the traffic sign boards, a flagmen shall be engaged full time to direct the traffic about the ‘excavation work in progress’ by ‘flag signal’ Hand Excavation- Excavation to expose the services shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- The workers shall clearly be instructed to use only the ladders to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged equipment operation. No violation of the traffic rules shall be allowed Pre cast members Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 346 of Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising and downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced on site as detailed on the attached sketch Drawing reference –Piping Interconnections Avenue C Culvert Existing Services On North and South end of the crossing exist many electrical cables, minor irrigation cables & also exist some utility pipes. Two trees on either end shall be effected and need preservation On the side terrace a small portion of interlocking block paviors shall be effected Procedures Traffic management scheme shall be implemented effectively subject to RRD approval Trees under effect shall be removed and preserved The crossing shall be carried out in two instances Instance 1 Hand excavation shall be carried out to expose the cables & the other services employing seaming the area with detectors to detect the existence of cables After the exposure, all the cables shall be covered with split PVC pipe and well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culvert shall be carried out The construction pertaining to the pipe carrying culvert including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc. shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members In addition, one access boxout on both ends shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications The broken asphalt portion shall be made good using new asphalt The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. 75 mm dia Holes in the pre cast units meant for lifting be filled in with concrete Access box out shall be closed with concrete after the pipe are laid Removed trees shall be replanted Instance 2 All the activities shall be repeated for this instance Either side of the road shall be provided with cable markers to indicate the services 8 mm-galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details. Other chequer plates shall be provided to the design details Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 347 of Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic management scheme #136 ROAD CROSSING TO INSTALL CULVERT FOR 1 # 14” desalinated water Avenue ‘c’ road gup gate east Main entrance Top Index Scope Safety Method including traffic management scheme Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation and installation of 1 # pre cast culvert at the road crossing as shown on the attached sketch Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect ‘ full safety standard’. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 348 of Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Hand Excavation- Excavation to expose the services shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- The workers shall clearly be instructed to use only the ladders whether to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged equipment operation. No violation of the traffic rules shall be allowed Pre cast members Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising and installing / downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced on site as detailed on the attached sketch Drawing reference –Piping Interconnections Avenue C Culvert Existing Services On North and South end of the crossing exist many electrical cables, minor irrigation cables & also exist some utility pipes. Two trees on either end shall be effected and need preservation On the side terrace a small portion of interlocking block paviors shall be effected Procedures Traffic management scheme shall be implemented effectively subject to RRD approval Trees under effect shall be removed and preserved The crossing shall be carried out in one instance Hand excavation shall be carried out to expose the cables & the other services employing seaming the area with detectors to detect the existence of cables Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 349 of After the exposure, all the cables shall be covered with split PVC pipe and well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culvert shall be carried out The construction pertaining to the pipe carrying culvert including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc. shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members In addition, one access boxout on both ends shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications The broken asphalt portion shall be made good using new asphalt The traffic management scheme shall be removed after the road crossing is cleared of all debris and obstructions. 75 mm dia Holes in the pre cast units meant for lifting shall be filled in with concrete Access box out shall be closed with concrete after the pipes are laid Removed / Preserved trees shall be replanted Either side of the road shall be provided with cable markers to indicate the services 8 mm-galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details. Other chequer plates shall be provided to the design details Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic management scheme #137 Road crossing To install culvert For 1 # 14” desalinated water Avenue ‘c’ road gup gate east Main entrance Top Index Scope Safety Method including traffic management scheme Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 350 of Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the excavation and installation of 1 # pre cast culvert at the road crossing as shown on the attached sketch Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect ‘ full safety standard’. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard In case of incident where utilities not identified are discovered or damaged, all work shall stop in the area and the Operator Shift Controller and HSE department immediately notified Phone number : Shift Controller Emergency Number HSE Direct number Employees working in easement area shall have a daily pre-task briefing that includes; Reporting of incidents Methods of work and tools to be used Potential hazards found in the Easement areas The approved work method statement EPC Contractor and Civil Contractor HSE department shall participate in presenting the STARRT card briefing and monitor the activities to ensure that the work methods are being followed and all personnel have an understanding of the hazards associated with working adjacent to live process areas Excavation Work Permit- A copy of the work permit shall be posted on a mini board installed on site to be noticeable to all persons involved with the crossing Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required for a complete safety. No oil spillage shall be allowed. Hand Excavation- Excavation to expose the services shall be carried out manually. In case certain services not shown on the record drawings such as fibre optics but it is discovered, further excavation shall be ceased until a decision is taken for the method to be adopted for further excavation Access to trench- The workers shall clearly be instructed to use only the ladders whether to enter in or come out of the trench. No jumping shall be allowed Machine Excavation The operators / drivers shall be explicitly instructed to abide by the requirement of the reverse signal and sound when operating reverse. Banksman shall be engaged equipment operation. No violation of the traffic rules shall be allowed Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 351 of Pre cast members Since pre cast culvert units, covers and sleepers are heavy in load, proper care has to be exercised during raising and installing / downing (handling) to the exact locations strictly adhering to the relevant safety measures Method The required permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained. A traffic management scheme shall be produced on site as detailed on the attached sketch Drawing reference –Piping Interconnections Avenue C Culvert Existing Services On North and South end of the crossing exist many electrical cables, minor irrigation cables & also exist some utility pipes. Two trees on either end shall be effected and need preservation On the side terrace a small portion of interlocking block paviors shall be effected Procedures The entrance road shall be closed to all traffic. The traffic shall be diverted to use the North gate Trees under effect shall be removed and preserved The crossing shall be carried out in one instance Hand excavation shall be carried out to expose the cables & the other services employing seaming the area with detectors to detect the existence of cables After the exposure, all the cables shall be covered with split PVC pipe and well supported temporarily to continue the excavation mechanically Remaining portion of the trench shall be excavated by machine to the defined levels Preparation of the trench to construct RCC culvert shall be carried out The construction pertaining to the pipe carrying culvert including the laying of pipe sleepers anchored with standard dowels, covers, fixing steps etc. shall be carried out according to the drawings and the approved procedures using pre cast RCC units / members 75 mm dia Holes in the pre cast units meant for lifting shall be filled in with concrete In addition, one access boxout on both ends shall be provided to design details The diverted services shall be reinstated Inspections shall be conducted to the requirement Backfilling up to the road formation shall be carried out according to specifications The broken asphalt portion shall be made good using new asphalt The traffic diversion shall be removed after the road crossing is cleared of all debris and obstructions. Access box out shall be closed with concrete after the pipes are laid Removed / Preserved trees shall be replanted & all landscaping reinstated to RRD / GUP satisfaction 8 mm-galvanised removable chequer plate covers with 2 lifting handles shall be provided to design details. Other chequer plates shall be provided to the design details Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 352 of Major Equipment Excavator, Dumper trucks, Compactors. Jack Hammer, Compressor, Asphalt finisher, Road Rollers Attachment Sketch showing the traffic diversion #138 Replacement of misaligned anchor bolts in Foundation 55-vv-906 Using renderoc lax tra Top Index Scope Reference documents Safety Method Equipment Scope This statement is aimed to propose the procedures to be adopted to carry out the replacement to the foundation damaged anchor bolts. Reference Documents Method Statement 36 approved for concrete repairs Item F (Renderoc Lax Tra FOSROC) Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Method 3 # Anchor bolts installed for this foundation were damaged post pouring The following operations are invloved to reinstate the bolts into the foundation The effected concrete portion shall be removed in a triangular form from the foundation corners in an approximate prismatic shape of base 250mmx200mm and height of the prism 600mm approximately. During breaking the concrete, care shall be taken to not to damage the rebars. The exposed rebars shall be properly cleaned using hard brush so that no loose particles remain intact to the rebar surface Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 353 of The surface of the broken concrete shall be cleared of all debris and new bolts installed in correct locations Forms shall be erected to the correct profile, alignment , properly leveled and plumbed. Chamfer shall be aligned properly. The form and the concrete surface shall be properly sealed using silicon seal to avoid any leakage of the material Civil Contractor QC inspection shall be conducted to ascertain the correct alignment of the anchor bolts and the forms Then the prepared surface shall be soaked in water for 24 hours prior to grouting The material shall be mixed with specified quantity of clean water according to the manufacturer’s instruction and poured in layers 200 mm thick Civil Contractor QC inspection shall be conducted throughout the pouring operation After the approval of the repair works and giving allowance of specified number of days, further operations shall be carried out Major Equipment Peddle Mixer Attachment None #139 Replacement of misaligned anchor bolts in Foundation 55-vv-906 Using renderoc lax tra Top Index Scope Reference documents Safety Method Equipment Scope This statement is aimed to propose the procedures to be adopted to carry out the replacement to the foundation damaged anchor bolts. Reference Documents Method Statement 36 approved for concrete repairs Item F (Renderoc Lax Tra FOSROC) Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 354 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Method 3 # Anchor bolts installed for this foundation were damaged post pouring The following operations are invloved to reinstate the bolts into the foundation The effected concrete portion shall be removed in a triangular form from the foundation corners in an approximate prismatic shape of base 250mmx200mm and height of the prism 600mm approximately. During breaking the concrete, care shall be taken to not to damage the rebars. The exposed rebars shall be properly cleaned using hard brush so that no loose particles remain intact to the rebar surface The surface of the broken concrete shall be cleared of all debris and new bolts installed in correct locations Forms shall be erected to the correct profile, alignment , properly leveled and plumbed. Chamfer shall be aligned properly. The form and the concrete surface shall be properly sealed using silicon seal to avoid any leakage of the material Civil Contractor QC inspection shall be conducted to ascertain the correct alignment of the anchor bolts and the forms Then the prepared surface shall be soaked in water for 24 hours prior to grouting The material shall be mixed with specified quantity of clean water according to the manufacturer’s instruction and poured in layers 200 mm thick Civil Contractor QC inspection shall be conducted throughout the pouring operation After the approval of the repair works and giving allowance of specified number of days, further operations shall be carried out Major Equipment Peddle Mixer Attachment None #140 Buildings screeds for vinyl and epoxy floor finishes Top Index Scope Safety Material Method Equipment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 355 of Attachment Scope This statement is aimed to propose the procedures to be adopted to lay the floor screed For the vinyl tile and the epoxy floor finishes Reference documents None Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Cement, washed sand, screened sand, bonding agent, water Method (Laying floor screed by SEMI DRY method) The floor area to be laid with screed shall be divided in equal or as considered convenient strips / bays, not more than1500mm wide so that alternatively screed could be laid in. The concrete surface shall be cleared of all loose particles and cleaned using hard wire brush to ensure enough roughness on the concrete surface The levels up to which the floor screed is to be laid, shall be profiled by using Mechanical levelling points with steel pipes to maintain levels so that complete compartment is given a proper level The cleaned area shall be soaked with water 24 hours prior to the application of screed. Civil Contractor QC inspection shall be conducted for the examination pertaining to the preparatory works for the ready to pour compartments Application After the preparation for the alternate bays or strips of 1500 mm width or as sized on site is ready with all levels, cleaned, duly soaked in water for 24 hours and ready for pouring, the prepared surface shall be spread with cement slurry ratio 1:1 (1 part cement and 1 part sand) mixed with mix quality water The mortar for screed shall be mixed semi dry by a mechanical mixer with only sufficient water added to give a crumbly consistency which retains its shape when squeezed by hand permitting no fluidity One layer application with 1:2.5 cement –screened sand mortar The mix shall be placed to a thickness approximately 10 mm greater than that actually required, thoroughly compacted by tamping and drawing off to the required level with a screed board. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 356 of After compacting the layer of mortar, the compacted surface shall be finished by a steel float to achieve a smooth surface ready to receive the vinyl tiles or the epoxy painting floor finishes and then covered with polythene membrane for immediate curing The finished surface shall be permanently cured by adding water soaked hessian after a few hours of finishing and recovered with polythene. The surface shall be kept wet for a period of 3 days and then protected till the floor finishes are laid over the surface Throughout the above operations Civil Contractor QC visual inspection shall be conducted Major Equipment Mechanical Mixer Wheel barrows Mason’s tools in general Attachment None #141 Buildings Screeds for vinyl and epoxy Floor finishes Top Index Scope Safety Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to lay the floor screed For the vinyl tile and the epoxy floor finishes Reference documents None Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 357 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Cement, washed sand, screened sand, bonding agent, water Method (Laying floor screed by SEMI DRY method) The floor area to be laid with screed shall be divided in equal or as considered convenient strips / bays, not more than1500mm wide so that alternatively screed could be laid in. The concrete surface shall be cleared of all loose particles and cleaned using hard wire brush to ensure enough roughness on the concrete surface The levels up to which the floor screed is to be laid, shall be profiled by using Mechanical levelling points with steel pipes to maintain levels so that complete compartment is given a proper level The cleaned area shall be soaked with water 24 hours prior to the application of screed. Civil Contractor QC inspection shall be conducted for the examination pertaining to the preparatory works for the ready to pour compartments Application After the preparation for the alternate bays or strips of 1500 mm width or as sized on site is ready with all levels, cleaned, duly soaked in water for 24 hours and ready for pouring, the prepared surface shall be spread with cement slurry ratio 1:1 (1 part cement and 1 part sand) mixed with mix quality water The mortar for screed shall be mixed semi dry by a mechanical mixer with only sufficient water added to give a crumbly consistency which retains its shape when squeezed by hand permitting no fluidity One layer application with 1:2.5 cement –screened sand mortar The mix shall be placed to a thickness approximately 10 mm greater than that actually required, thoroughly compacted by tamping and drawing off to the required level with a screed board. After compacting the layer of mortar, the compacted surface shall be finished by a steel float to achieve a smooth surface ready to receive the vinyl tiles or the epoxy painting floor finishes and then covered with polythene membrane for immediate curing The finished surface shall be permanently cured by adding water soaked hessian after a few hours of finishing and recovered with polythene. The surface shall be kept wet for a period of 3 days and then protected till the floor finishes are laid over the surface Throughout the above operations Civil Contractor QC visual inspection shall be conducted Major Equipment Mechanical Mixer Wheel barrows Mason’s tools in general Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 358 of None #142 Buildings Screeds for vinyl and epoxy Floor finishes Top Index Scope Safety Material Method Equipment Attachment Scope This statement is aimed to propose the procedures to be adopted to lay the floor screed For the vinyl tile and the epoxy floor finishes Reference documents None Safety Prior to commencement of any activity, the labour force shall receive a STARRT Card / Toolbox Talk relevant to the operation concerned on the project site safety requirements. Necessary measures shall be applied to any process involving a safety risk Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Materials Cement, washed sand, screened sand, bonding agent, water Method (Laying floor screed by SEMI DRY method) The floor area to be laid with screed shall be divided in equal or as considered practicable strips / bays, not more than1500mm wide (may be wider if convenient), so that alternatively screed could be laid in. Scabbling of the concrete surface shall be carried out if so required The concrete surface shall be cleared of all loose particles and cleaned using hard wire brush to ensure sufficient roughness to receive the screed The levels up to which the floor screed is to be laid, shall be profiled by using Mechanical levelling points with steel pipes to maintain levels so that complete compartment is given a proper level The cleaned area shall be soaked with water 24 hours prior to the application of screed. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 359 of Civil Contractor QC inspection shall be conducted for the examination pertaining to the preparatory works for the ‘ready to pour’ compartments Application After the preparation for the alternate bays or strips of 1500 mm width or as sized on site is ready with all levels, cleaned, duly soaked in water for 24 hours and ready for pouring, the pourable surface shall be spread with cement slurry ratio 1:1 (1 part cement and 1 part sand) mixed with mix quality water The mortar for screed shall be mixed semi dry by a mechanical mixer with only sufficient water added to give a crumbly consistency which retains its shape when squeezed by hand permitting no fluidity One layer application with 1:2.5 cement –screened sand mortar The mix shall be placed in one layer progressively to a thickness approximately 10 mm greater than that actually required, thoroughly compacted by tamping and drawn off to the marked level with a screed board. After compacting the layer of mortar, the compacted surface shall be finished by a steel float to achieve a smooth surface ready to receive the vinyl tiles or the epoxy painting floor finishes and then covered with polythene membrane for immediate curing The finished surface shall be permanently cured by adding water soaked hessian after a few hours of finishing and recovered with polythene sheet. The surface shall be kept wet for a period of 3 days and then protected with hard boards spread over till the floor finishes are applied over the surface Throughout the above operations Civil Contractor QC visual inspection shall be conducted Prior to full-scale commencement of the screeding operation, a sample shall be produced on site in the presence of EPC Contractor representative so that an agreement pertaining to the stated procedures to carry out the screeding and about the Quality could reach Major Equipment Mechanical Mixer Wheel barrows Mason’s tools in general Attachment None #143 Directional boring at 3# locations for 14”desalinated water pipe corniche road North of Operating Authority Top Index Scope Reference documents Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 360 of Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the directional boring under the existing culverts to facilitate to lay the sleeves for pipe lines 1 # 14” Desalinated Water at 3 # locations Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect a full safety standard. Excavation Work PermitA copy of the work permit shall be posted on a mini board installed on site at the location shown on the sketch to be noticeable to all the persons involved A copy shall also be transmitted to EPC Contractor Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required at the pits for a complete safety. Method The necessary permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained Trial pits shall be made manually on both ends of the proposed boring to ascertain the availability of the existing services and protect these from any damage and shall also be used for the bentonite trial at the receiving end Case 1 Existing 1 box culvert and a 14” dia pipe about 1 m from culvert A sleeve 5 m long of required material dia 20 “is to be laid beneath the box culvert (about 3m x 3m in section), 1 m below the base by directional boring so that 1 m projection remains on both sides of the culvert. The laying pertaining to the remaining portion of the pipes other than the sleeve shall be carried out by ordinary approved procedures by excavation to the required level, bedding, compaction and the filling above the portion over the pipe and tested accordingly Case 2 Existing 1 box culvert and 1 pipe 1.5 m dia 2 m from the culvert and 1 pipe 1 m dia about 3.3 m below ground. 4 # existing services also have been exposed A sleeve 7.3 m long has to pass beneath the box culvert (about 3m x 3m in section) ,1 m below the base by directional boring so that 1 m projection remains on both sides of the culvert & the existing 1.5 m GRP pipe approximately 2.5 m below the existing ground. . The laying pertaining to the remaining portion of the pipes other than the sleeve shall be carried out by ordinary approved procedures by excavation to the required level, bedding, compaction and the filling above the portion over the pipe and tested accordingly after the pipes are laid Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 361 of Case 3 Existing 1 box culvert and 2 # 60” dia ABB Cooling water pipe laying at about 10 m from the culvert is in progress. Proposed 14 “ Desalinated water pipe has to cross over ABB pipes keeping 1 m apart vertically A sleeve 5 m long has to pass beneath the box culvert (about 3m x 3m in section) below the base by directional boring so that 1 m projection remains on both sides of the culvert. The pipes shall then be raised over the existing 2 #s 6” dia ABB cooling water lines at about 2. 3 m from the existing ground level so that the top of the pipes is 1.2 m from the ground level. The laying pertaining to the remaining portion of the pipes other than the sleeve shall be carried out by ordinary approved procedures by excavation to the required level, bedding, compaction and the filling above the portion over the pipe and tested accordingly. The work for the portion to cross over ABB pipes shall be carried out after the ABB pipes are laid and backfilled On site, sufficient excavated space is available to lower the sleeve in to pull into the bore The excavated trench does not show any sign of water therefore, no de watering shall be carried out Excavation shall be carried out according to the requirement The boring shall be carried out in stages. First stageThe sleeve is in the trench on one end and the reamer fully underground. Second stageThe sleeve is partly pulled in and the reamer partly withdrawn Third stageThe sleeve further pulled and the reamer withdrawn accordingly Fourth stageFull portion of the sleeve is underground in the bore and the reamer out The excavated trenches on both ends shall be backfilled by Civil Contractor according to the specification requirement and the required tests carried out The reinstatement of the effected services shall be carried out after the directional boring is completed Directional Boring – A non- excavation Method which does not allow collapsing of the ground surface M / S Ditch Witch shall carry out the Directional Boring employing Jet Trac Directional Boring equipment according to their approved method statement Refer to the attached sketches based on the Ditch Witch guidelines Bentonite is pure clay to be used as a fluid / slurry formed by mixing water. It shall be used to cool the drill bit and to lubricate the drill area The material displaced by the head / sleeves shall be discharged at the receiving end in the receiving pit and removed from the site All fully trained operators shall be used on the job Equipment Jet Track Unit (complete package), Crane, Compactor Attachment Cross-Section Sketches showing 3 # cases Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 362 of #144 Directional boring at 3# locations for 14”desalinated water pipe corniche road North of Operating Authority Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the directional boring under the existing culverts to facilitate to lay the sleeves for pipe lines 1 # 14” Desalinated Water at 3 # locations Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect a full safety standard. Excavation Work PermitA copy of the work permit shall be posted on a mini board installed on site at the location shown on the sketch to be noticeable to all the persons involved A copy shall also be transmitted to EPC Contractor Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required at the pits for a complete safety. Method The necessary permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained Trial pits shall be made manually on both ends of the proposed boring to ascertain the availability of the existing services and protect these from any damage and shall also be used for the bentonite trial at the receiving end Case 1 Existing 1 box culvert and a 14” dia pipe about 1 m from culvert A sleeve 5 m long of required material dia 20 “is to be laid beneath the box culvert (about 3m x 3m in section), 1 m below the base by directional boring so that 1 m projection remains on both sides of the culvert. The laying pertaining to the remaining portion of the pipes other than the Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 363 of sleeve shall be carried out by ordinary approved procedures by excavation to the required level, bedding, compaction and the filling above the portion over the pipe and tested accordingly Case 2 Existing 1 box culvert and 1 pipe 1.5 m dia 2 m from the culvert and 1 pipe 1 m dia about 3.3 m below ground. 4 # existing services also have been exposed A sleeve 7.3 m long has to pass beneath the box culvert (about 3m x 3m in section) ,1 m below the base by directional boring so that 1 m projection remains on both sides of the culvert & the existing 1.5 m GRP pipe approximately 2.5 m below the existing ground. . The laying pertaining to the remaining portion of the pipes other than the sleeve shall be carried out by ordinary approved procedures by excavation to the required level, bedding, compaction and the filling above the portion over the pipe and tested accordingly after the pipes are laid Case 3 Existing 1 box culvert and 2 # 60” dia ABB Cooling water pipe laying at about 10 m from the culvert is in progress. Proposed 14 “ Desalinated water pipe has to cross over ABB pipes keeping 1 m apart vertically A sleeve 5 m long has to pass beneath the box culvert (about 3m x 3m in section) below the base by directional boring so that 1 m projection remains on both sides of the culvert. The pipes shall then be raised over the existing 2 #s 60” dia ABB cooling water lines at about 2. 3 m from the existing ground level so that the top of the pipes is 1.2 m from the ground level. The laying pertaining to the remaining portion of the pipes other than the sleeve shall be carried out by ordinary approved procedures by excavation to the required level, bedding, compaction and the filling above the portion over the pipe and tested accordingly. The work for the portion to cross over ABB pipes shall be carried out after the ABB pipes are laid and backfilled On site, sufficient excavated space is available to lower the sleeve in to pull into the bore De watering shall be carried out as per specification if necessary Excavation shall be carried out according to the requirement The boring shall be carried out in stages. First stageThe sleeve is in the trench on one end and the reamer fully underground. Second stageThe sleeve is partly pulled in and the reamer partly withdrawn Third stageThe sleeve further pulled and the reamer withdrawn accordingly Fourth stageFull portion of the sleeve is underground in the bore and the reamer out The excavated trenches on both ends shall be backfilled by Civil Contractor according to the specification requirement and the required tests carried out The reinstatement of the effected services shall be carried out after the directional boring is completed Directional Boring – A non- excavation Method which does not allow collapsing of the ground surface M / S Ditch Witch shall carry out the Directional Boring employing Jet Trac Directional Boring equipment according to their approved method statement Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 364 of Refer to the attached sketches based on the Ditch Witch guidelines Bentonite is pure clay to be used as a fluid / slurry formed by mixing water. It shall be used to cool the drill bit and to lubricate the drill area The material displaced by the head / sleeves shall be discharged at the receiving end in the receiving pit and removed from the site All fully trained operators shall be used on the job Equipment Jet Track Unit (complete package), Crane, Compactor Attachment Cross-Section Sketches showing 3 # cases #145 Directional boring at 3# locations for 14”desalinated water pipe corniche road North of gup Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the directional boring under the existing culverts to facilitate to lay the sleeves for pipe lines 1 # 14” Desalinated Water at 3 # locations. The concrete culverts are not in good condition and directional drilling or thrust bore is the method preferred by Operator (RRD) for carrying out this work Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect a full safety standard. Excavation Work PermitA copy of the work permit shall be posted on a mini board installed on site at the location shown on the sketch to be noticeable to all the persons involved A copy shall also be transmitted to EPC Contractor Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 365 of Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required at the works for complete safety. Method The necessary permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained Trial pits shall be made manually on both ends of the proposed boring to check for existing services and protect these from any damage and shall also be used for the bentonite trial at the receiving end Case 1 Existing 1 box culvert and a 14” dia pipe about 1 m from culvert A carbon steel sleeve 5 m long of dia 20 “is to be installed beneath the box culvert (about 3m x 3m in section), 1 m below the base by directional boring so that 1 m projection remains on both sides of the culvert. The 14” dia GRE pipe shall then pass through the installed sleeve Case 2 Existing 1 box culvert and 1 pipe 1.5 m dia 2 m from the culvert and 1 pipe 1 m dia about 3.3 m below ground. 4 # existing services A sleeve 7.3 m long shall be installed beneath the box culvert (about 3m x 3m in section), 1 m below the base by directional boring so that 1 m projection remains on both sides of the obstructions approximately 2.5 m below the existing ground. The 14” dia GRE pipe shall then pass through the installed sleeve Case 3 Existing 1 box culvert A sleeve 5 m long shall be installed beneath the box culvert (about 3m x 3m in section) below the base by directional boring so that 1 m projection remains on both sides of the culvert. On site, sufficient excavated space is available to lower the sleeve in to pull into the bore The excavated trench does not show any sign of water therefore, no de watering shall be carried out Excavation shall be carried out according to the requirement The boring shall be carried out in stages. First stageThe sleeve is in the trench on one end and the reamer fully underground. Second stageThe sleeve is partly pulled in and the reamer partly withdrawn Third stageThe sleeve further pulled and the reamer withdrawn accordingly Fourth stageFull portion of the sleeve is underground in the bore and the reamer out The excavated trenches on both ends shall be backfilled by Civil Contractor according to the specification requirement and the required tests carried out The reinstatement of the effected services shall be carried out after the directional boring is completed Directional Boring – A non- excavation Method which does not allow collapsing of the ground surface Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 366 of M / S Ditch Witch shall carry out the Directional Boring employing Jet Trac Directional Boring equipment according to their approved method statement Refer to the attached sketches based on the Ditch Witch guidelines Bentonite is pure clay to be used as a fluid / slurry formed by mixing water. It shall be used to cool the drill bit and to lubricate the drill area The material displaced by the head / sleeves shall be discharged at the receiving end in the receiving pit and removed from the site All fully trained operators shall be used on the job Major Equipment Jet Track Unit (complete package), Crane, Compactor Attachment Cross-Section Sketches showing 3 # cases #146 Directional boring at 3# locations for 14”desalinated water pipe corniche road North of gup Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the directional boring under the existing culverts to facilitate to lay the sleeves for pipe lines 1 # 14” Desalinated Water at 3 # locations. The concrete culverts are not in good condition and directional drilling or thrust bore is the method preferred by Operator (RRD) for carrying out this work Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard In this case the excavation has to be carried out on the Operating Authority area, therefore all the regulated precautions shall be strictly adhered to effect a full safety standard. Excavation Work PermitA copy of the work permit shall be posted on a mini board installed on site at the location shown on the sketch to be noticeable to all the persons involved Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 367 of A copy shall also be transmitted to EPC Contractor Barricades, cones, markers, the night-lights, and floodlights etc. shall be installed as required at the works for complete safety. Method The necessary permit to work shall be obtained from the Plant Refinery Division. The record drawings regarding the existing services shall be obtained Trial pits shall be made manually on both ends of the proposed boring to check for existing services and protect these from any damage and shall also be used for the bentonite trial at the receiving end Case 1 Existing 1 box culvert and a 14” dia pipe about 1 m from culvert A carbon steel sleeve 5 m long of dia 20 “is to be installed beneath the box culvert (about 3m x 3m in section), 1 m below the base by directional boring so that 1 m projection remains on both sides of the culvert. The 14” dia GRE pipe shall then pass through the installed sleeve Case 2 Existing 1 box culvert and 1 pipe 1.5 m dia 2 m from the culvert and 1 pipe 1 m dia about 3.3 m below ground. 4 # existing services A sleeve 7.3 m long shall be installed beneath the box culvert (about 3m x 3m in section), 1 m below the base by directional boring so that 1 m projection remains on both sides of the obstructions approximately 2.5 m below the existing ground. The 14” dia GRE pipe shall then pass through the installed sleeve Case 3 Existing 1 box culvert A sleeve 5 m long shall be installed beneath the box culvert (about 3m x 3m in section) below the base by directional boring so that 1 m projection remains on both sides of the culvert. On site, sufficient excavated space is available to lower the sleeve in to pull into the bore Dewatering shall be carried out as per specification if necessary Excavation shall be carried out according to the requirement The boring shall be carried out in stages. First stageThe sleeve is in the trench on one end and the reamer fully underground. Second stageThe sleeve is partly pulled in and the reamer partly withdrawn Third stageThe sleeve further pulled and the reamer withdrawn accordingly Fourth stageFull portion of the sleeve is underground in the bore and the reamer out The excavated trenches on both ends shall be backfilled by Civil Contractor according to the specification requirement and the required tests carried out The reinstatement of the effected services shall be carried out after the directional boring is completed Directional Boring – A non- excavation Method which does not allow collapsing of the ground surface Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 368 of M / S Ditch Witch shall carry out the Directional Boring employing Jet Trac Directional Boring equipment according to their approved method statement Refer to the attached sketches based on the Ditch Witch guidelines Bentonite is pure clay to be used as a fluid / slurry formed by mixing water. It shall be used to cool the drill bit and to lubricate the drill area The material displaced by the head / sleeves shall be discharged at the receiving end in the receiving pit and removed from the site All fully trained operators shall be used on the job Major Equipment Jet Track Unit (complete package), Crane, Compactor Attachment Cross-Section Sketches showing 3 # cases #147 Epoxy skirting in Central control building & sub stations on dry lining Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out epoxy skirting on dry lining in areas not exposed to impact or abuse Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Master Builders Technologies Concresive 1020 primer Concresive 2020 Epoxy Mortar Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 369 of Method Surface Preparation Surface shall be cleaned of all dust and dirt and other contaminants A 5 mm groove shall be formed on the dry lining to cove in the skirting Civil Contractor QC inspection shall be conducted to ensure that the surface is clean and contaminants free Primer Coat Mixing of the base and reactor components shall be carried out in a vessel using an electric operated slow speed drill with a suitable paddle attachment making sure that the paddle reaches to the bottom and sides of the vessel and mixing carried out for 1 to 2minutes until a uniform consistency and colour is achieved Application The mixed material shall be applied to the surface using a stiff brush according to the stated coverage on the manufacturer’s datasheet High Build Epoxy Resin Mortar It is essential to apply the mortar while the primer being tacky otherwise a second priming coat shall be applied Thorough mixed mortar according to the manufacturer’s instruction shall be applied in a 3 mm layer to the primed surface with steel trowel pressed well into the surface compacting to ensure positive and permanent adhesion. Finishing shall be carried out by a steel trowel to bring the resin to the surface Mastertop Resin as suggested by the manufacturer is not applicable in this case Civil Contractor QC inspection shall be conducted throughout the above operations Equipment Mixing Vessel Electric drill with paddle attachment Stiff brush Steel trowel Attachment MBT method statement #148 Epoxy skirting on dry lining Top Index Scope Reference documents Safety Method Equipment Attachment Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 370 of Scope The statement is aimed to propose the procedures to be adopted to carry out epoxy skirting on dry lining in areas not exposed to impact or abuse Ref Specs Outline building specification Page Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard . MBT instructions shall be adhered strictly Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Master Builders Technologies Concresive 2200 Epoxy Mortar 3mm thick ‘Mastertop 1230 is’ resin without aggregate component Method A sample was prepared on site in Central Control Building Battery Room approved by EPC Contractor Surface Preparation Sandpaper shall be rubbed lightly on the acrylic wall coating followed by wiping with a clean cloth to remove any residual dust & laitance Civil Contractor QC inspection shall be conducted to ensure that the surface is clean and contaminants free High Build Epoxy Resin Mortar Concresive 2200 Base and the reactor components shall be mixed together using a trowel The mixed material shall be applied in 3mm thickness on the surface to the required level forming cove using the minimum of solvent on the trowel to aid workability Surface shall be finished smooth using a paint brush dipped in cleaning solvent # 2 Civil Contractor QC inspection shall be conducted throughout the above operations An allowance of 24 hours for curing shall be given prior to overcoating with ‘Mastertop 1230 is’ flooring compound using only resin without aggregate component Overcoating with Mastertop ‘1230is’ Resin (500 microns) The surface of the cured Concresive shall be rubbed lightly with sandpaper to remove any rough edges Areas prone to splashing with wet resin shall be protected and the free edges masked with 50mm wide tape The surface shall be sealed with Mastertop 1200 resin diluted with 5 % volume of solvent # 2 prior to applying ‘Mastertop 1230 is’ resin as follows Reactor shall be poured into base and mixed together for 1-2 minutes using a slow speed drill fitted with a spiral mixer, then solvent added and mixed for 1 minute Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 371 of The mixed material shall be applied on the surface ensuring total coverage using a spiked roller. Sealer coat shall be allowed to cure to a tackfree state prior to applying ‘Mastercoat 1230 is’ resin coating Reactor B and Base A shall be poured into a suitable mixer and mixed together using a slow speed drill fitted with a suitable mixing paddle and mixed for about half a minute before ‘Mastertop 1230 is’ filler is added keeping the mixing on until a uniform colour is obtained free of streaks or lumps of unmixed filler Smooth Finish For the base coat ‘Mastertop 1230 is’ shall be applied @ 1.1 liter per m2. For the second coat ‘Mastertop 1230 is’ shall be mixed and applied @ 0.4 liter per m2 48 hours curing allowance shall be given Civil Contractor QC inspection shall be conducted throughout the above operations Equipment Mixing Vessel, Electric drill with paddle attachment, Notched trowel, Soft brush, Attachment MBT method statement ref #149 Epoxy skirting on dry lining Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out epoxy skirting on dry lining in areas not exposed to impact or abuse Ref Specs Outline building specification Page Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard. MBT instructions shall be adhered strictly Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 372 of Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Master Builders Technologies Concresive 2200 Epoxy Mortar 3mm thick ‘Mastertop 1230 is’ resin without aggregate component Method A sample was prepared on site in Central Control Building Battery Room for inspection and acceptance by EPC Contractor Civil Contractor shall co-ordinate with EPC Contractor regarding moving of any UPS batteries that may be required prior to carrying out any skirting Surface Preparation Sandpaper shall be rubbed lightly on the acrylic wall coating followed by wiping with a clean cloth to remove any residual dust & laitance Civil Contractor QC inspection shall be conducted to ensure that the surface is clean and contaminants free High Build Epoxy Resin Mortar Concresive 2200 Base and the reactor components shall be mixed together using a trowel The mixed material shall be applied in 3mm thickness on the surface to the required level forming cove using the minimum of solvent on the trowel to aid workability Surface shall be finished smooth using a paint brush dipped in cleaning solvent # 2 Civil Contractor QC inspection shall be conducted throughout the above operations An allowance of 24 hours for curing shall be given prior to overcoating with ‘Mastertop 1230 is’ flooring compound using only resin without aggregate component Overcoating with Mastertop ‘1230is’ Resin (500 microns) The surface of the cured Concresive shall be rubbed lightly with sandpaper to remove any rough edges Areas prone to splashing with wet resin shall be protected and the free edges masked with 50mm wide tape The surface shall be sealed with Mastertop 1200 resin diluted with 5 % volume of solvent # 2 prior to applying ‘Mastertop 1230 is’ resin as follows Reactor shall be poured into base and mixed together for 1-2 minutes using a slow speed drill fitted with a spiral mixer, then solvent added and mixed for 1 minute The mixed material shall be applied on the surface ensuring total coverage using a spiked roller. Sealer coat shall be allowed to cure to a tackfree state prior to applying ‘Mastercoat 1230 is’ resin coating Reactor B and Base A shall be poured into a suitable mixer and mixed together using a slow speed drill fitted with a suitable mixing paddle and mixed for about half a minute before ‘Mastertop 1230 is’ filler is added keeping the mixing on until a uniform colour is obtained free of streaks or lumps of unmixed filler Smooth Finish For the base coat ‘Mastertop 1230 is’ shall be applied @ 1.1 liter per m2. Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 373 of For the second coat ‘Mastertop 1230 is’ shall be mixed and applied @ 0.4 liter per m2 48 hours curing allowance shall be given Civil Contractor QC inspection shall be conducted throughout the above operations Equipment Mixing Vessel, Electric drill with paddle attachment, Notched trowel, Soft brush, Attachment MBT method statement ref RF / 2833 / 2000 / SRH / NH / 30.10.2000 #150 Road surface Reinstatement over box culvert crossings Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to carry out the reinstatement to the existing road surfaces removed from the crossings effected portions pertaining to Roads Avenue C, D, First Street, GUP Entrance etc. Reference: Specification Section Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum standard. Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material Bitumen MC1 Asphalt Concrete for Base / Under Course Tack Coat SS1h Asphalt Concrete for Wearing Course Method Traffic Management Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 374 of RRD Approved Traffic Management Scheme shall be implemented to the requirement Surface Preparation Civil Contractor QC inspection shall be conducted for the backfill clearance Primer The portion of the backfilled earth 120mm deep shall be excavated from the existing road surface level followed by compaction, testing and preparation for the primer The approved compacted surface shall be made ready for applying MC1 primer Civil Contractor QC inspection shall be conducted to ascertain the suitability of the surface to receive the primer Primer shall be sprayed by tanker on the complete surface @ 0.8 to 1.4 litres / sqm The surface shall be left for such time until the material dries out usually 24 hours post application otherwise, sand shall be used to blot the excessive bitumen prior to commence to lay the Base / Under course asphalt concrete 60 mm Thick Base / Under Course Asphalt Concrete Civil Contractor QC inspection shall be conducted to ascertain the suitability of the primed surface to receive asphalt concrete Asphalt concrete shall be laid on the approved surface to the prepared profile so that a uniform 60 mm compacted thickness is obtained after compaction by rolling After spreading the material, the rolling shall be carried out by one 3 wheel roller, one Pneumatic Tyre roller and one 2-axle Tandem rollers 8 to 10 tonnes capacity according to the specified procedures giving 6 passes overlapping the previous pass by 300mm of the previous trip using sufficient oil or water to moisten the wheels and fully compacted before asphalt concrete reaches 80 C An allowance for one hour shall be given to commence to lay the Wearing course after the base course is compacted by rolling Civil Contractor QC inspection shall be conducted throughout the above operations Tack / Seal Coat using SS1h An application of the tack coat @ 0.4 to 0.7 litres / sqm shall be carried out on the rolled surface of the Base / Under Course Civil Contractor QC inspection shall be conducted to ascertain the correct Base Course surface profile and the Tack Coat acceptability 60mm Wearing Surface Course Asphalt Concrete shall be laid for the Wearing coat also in a similar manner ensuring that the top of the compacted material is at the same level as the top of the existing road surface on both sides of the culvert Civil Contractor QC inspection shall be conducted to ensure that the surface is to the acceptable profile and compaction is carried out to the standards The area shall be fully cleared to the normal requirement The Traffic management scheme shall be removed and normal traffic restored Equipment Bitumen Tanker, Pressure boom, Asphalt Concrete Spreader and paver, Road Rollers Attachment None Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 375 of #151 Repair to lift Cladding panel Administration building Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to rectify the stainless cladding lift panel in the Administration Building Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum acceptable standard Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material New stainless steel lift panel from OTIS Method New panel to be fixed over the damaged one shall be supplied by the factory Civil Contractor QC inspection shall be conducted to ensure that the new panel adheres to the requirement This panel shall be placed over the existing damaged panel to check the compatibility to fixing Then the new panel shall be removed & glue applied on both surfaces to be adhered Glue shall be allowed to dry for a few minutes and then both surfaces shall be bonded together The protection film shall then be removed from the panel and surface cleaned using soft cotton cloth Civil Contractor QC inspection shall be conducted to ensure that the new panel has been fixed properly to the damaged one Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 376 of Equipment Attachment OTIS method statement #152 Fixing sheeting panels Wall & roof cladding Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to fix the roof and the wall panels for various structures to be cladded Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum acceptable standard Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Material MAR 120- Formawall for wall panels, Trisomet for Roof Panels, Profile EP3-Corrugated steel sheet (Single Skin)- by European Profiles (BS / HHR) Three types of panels shall be used as follows Maintenance Building-Roof Panels- Trisomet, Wall Panels- Formawall Flat Car Parks- Corrugated Cladding Work shall be carried out by M / S Khalidiya Intersystems Method Preparation Prior to the commencement of the sheeting operations, the structural items including the door posts and parapet etc shall be lined and levelled properly to the requirement within acceptable tolerances Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 377 of Wind brace clips shall be removed and the building cleaned Civil Contractor QC inspection shall be conducted to ensure that the structural elements are aligned, levelled and fixed to the specified requirement Fixing Roof Panels Valley gutters shall be fixed and aligned Internal ridge flashing shall be fixed in position Insulated Trisomet panels shall be fixed starting from the valley and rising to the ridge and all fixings fastened on the crown All end laps shall be sealed with mastic to prevent capillary humidity rise Procedure shall be repeated for the parapet wall by fixing and aligning the gutter External ridge flashing shall be fixed The entire roof shall be brush cleaned and colour caps fixed Civil Contractor QC inspection shall be conducted throughout the above operations Fixing Formawall Flat Panels First Tier Drip flashing shall be fixed at the base of the wall to be used as a straight datum line The first formawall vertical panel shall be fixed to true plumb and fastened by steel screws throughout the joints and the next panel fixed along side of the first panel by providing a tight vertical joint & the process repeated till the end is reached Special flashing shall be fixed to the entire length of the first tier of vertical panels Second Tier The second tier of the blue panels shall be fixed in the same manner as the lower panel The procedure shall continue till all the sides are completed Special corner flashing shall be used internally and externally to provide an aesthetic finish at the corner joints Civil Contractor QC inspection shall be conducted throughout the above operations Car Park Corrugated cladding Single long panel shall be fixed fastened to the straight end of the structure through the crown with one and a half profile overlapped on sides and mastic inserted between the sheets The procedure shall be continued to the curve where sheets are to be racked and cut to provide roof curvature The entire roof shall be brush cleaned and colour caps inserted Civil Contractor QC inspection shall be conducted throughout the above operations Equipment Attachment Khalidiya method statement ref MAR approval reference #153 Fixing sheeting panels Statements were written by Professional Eng Suraj Singh Project Manager as well as Senior Project Engineer. Most of these were approved by EPC Contractor & Company (no sketches have been included with these for AUTO CAD ) References too have been eliminated from the statements for secrecy requirement of the contract These presents to be used only for acedemical / knowledge exchange purpose. The works were executed for major oil companies. All these statements constitute management documents. A work based on personal experience for improving young engineers / students knowledge Engineering Construction Method Statements Revision No: Original Work by P Eng Suraj Singh April 11, 2006 Page 378 of Wall & roof cladding Top Index Scope Reference documents Safety Method Equipment Attachment Scope The statement is aimed to propose the procedures to be adopted to fix the roof and the wall metal panels for various structures to be cladded Safety Prior to the commencement of any activity the labour force shall receive a / STARRT card / Toolbox talk. Any process involving a particular safety risk shall be assessed and adopted measures addressed to raise to a minimum acceptable standard Safety Supervision A competent inspector shall visit the area daily to assess the safety measures adopted. Any snag observed during his visit shall be notified to the supervisor present who immediately act to bring the safety measures to an acceptable standard Reference Specification (Metals) for fasteners, Material MAR Formawall for wall panels, Trisomet for Roof Panels, Profile EP3-Corrugated steel sheet (Single Skin)- by European Profiles (BS / HHR) Three types of panels shall be used as follows Maintenance Building-Roof Panels- Trisomet, Wall Panels- Formawall Flat Car Parks- Corrugated Cladding Work shall be carried out by